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Buell Forum » Old School Buell » Archives OSB 001 » Archive through July 14, 2004 » Installing XB Rocker covers on an S2 « Previous Next »

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Bluzm2
Posted on Sunday, April 25, 2004 - 01:06 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

OK folks as promised, here's pictures of the XB rocker box cover install on a 1995 S2.
The whole job is very straight forward.
The only "special" tool needed is the ususal shortened allen wrench for the right rear bolt.

The parts list used is as follows:

Quan Part# Desc
1 17605-00YB Cover Front
1 17642-02Y Covor Rear
2 17606-00YA Grommet
2 17607-00Y PCV Valve
2 868A Hex Socket Button Bolt
2 17353-89 Gasket , Rocker Cover
2 17358-84A Gasket, Lower Rocker Cover
8 63858-49 Bolt gaskets

3/8" ID heater hose
3/8" Nylon hose barb type "T"

Yes, the bugger needs washing! I rode in the rain last week, I haven't had time to do a proper cleaning yet...

Here's the before top shot of the stock rocker box covers.
RB-Top Before


Here's the before shot of the carb side and stock breather bolts.
RB-Carb Before


This one is the carb side after install of the hex button head bolts. I used lots of Locktite Blue to hold and seal them.
This would also be a good time to check the condition of your carb boot seal.
RB-Carb After



On to the top. This is a shot of the rear rocker stripped down to the lower rocker assembly.
Just the top and center cover section are removed.
No need to remove the lower rocker cover.
I replaced both the outer and inner gaskets.
RB-Top Cover Off


Before I installed the new XB covers, I installed the PCV valve grommet.
I installed the PCV valve after the covers were in place.
I used standard 3/8" fuel type hose to connect everything together.
The "T" by the rear head is a standard 3/8" nylon barbed hose "T". About $1 at the local hardware store.
The hose fit quite tight, I didn't feel hose clamps were needed.
The rear section of hose is currently routed down to the left rear of the motor and dumps on the ground as far from the rear tire as space allowed.
RB-Top After


In the picture above, the fuel line is routed above the breather hose.
I had to move it under after mounting the tank.
Gas doesn't flow up hill very well..

If you haven't seen a set of stock XB covers, they are pretty rough.
I did a quick cleanup and polish on the ones above.
They come with a rough sand blast type finish.
Lots of sanding needed to get them ready to polish.

Note: The procedure for an S1, X1 or M2 would be very simular.
Clearances however will vary model to model. some grinding may need to be done on the covers to get the necessary clearance.
No grinding was needed on my M2. YMMV

Good luck!

Brad


edited by bluzm2 on April 26, 2004
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Henrik
Posted on Sunday, April 25, 2004 - 06:24 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Brad; thanks, excellent write-up.

Another thing to do while you're in there: safety-wire the throttle cables in place in the carb receiving barrels. Prevents them from jumping up/out and locking the throttle.

Henrik
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Bluzm2
Posted on Monday, April 26, 2004 - 12:48 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Your right Henrik.
I forgot about that.
My M2 has the clamps, I should pick up a set and be done with it.
Wire is cheaper though!
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Henrik
Posted on Monday, April 26, 2004 - 08:57 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

The clamp is probably gentler on the cables though. How much do they go for?

Henrik
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Steveford
Posted on Monday, April 26, 2004 - 07:08 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Henrik,
The clamps are under three bucks last time I looked.
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Henrik
Posted on Monday, April 26, 2004 - 10:29 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Steve; thanks. I have one on order now : )

Henrik
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Court
Posted on Tuesday, April 27, 2004 - 05:13 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Henrik:

P/N and where did you order from?

I am getting ready to start a Buell project and might as well get one.

Court
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Court
Posted on Tuesday, April 27, 2004 - 05:13 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Henrik:

P/N and where did you order from?

I am getting ready to start a Buell project and might as well get one.

Court
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Steveford
Posted on Tuesday, April 27, 2004 - 06:44 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Court,
The part number is C0126.K which retails for $2.65.
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Bluzm2
Posted on Tuesday, April 27, 2004 - 10:16 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Thanks Steve, I'm ordering a set tomorrow.
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Henrik
Posted on Tuesday, April 27, 2004 - 10:57 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Court; I called DaveS at Appleton - a few parts are now on order. Although most (read: all) of my time goes into the house, I like to keep the "I'll be riding soon" illusion alive : )

Henrik
(termites in the basement, squirrels in the garage, wasps in the attic and bats in the belfry : ))
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Firemanjim
Posted on Tuesday, April 27, 2004 - 11:48 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Welcome to the wonderful world of home ownership.After 12 years in this one I think I have most of the big stuff done.(Wait til you add kids into the mix)And I used to think I had alot of time off--it just means more time to get all those honey-do's done.
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Court
Posted on Wednesday, April 28, 2004 - 05:04 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

>>>I like to keep the "I'll be riding soon" illusion alive

If that XB needs "exercised" some weekend, I'd be willing to help.

: )
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Henrik
Posted on Wednesday, April 28, 2004 - 08:54 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Yeah, thanks Fireman - that's the feeling I'm getting; once I get all this done, it'll be time to start over from the beginning : )

Court; I'm still looking for "less unreasonable" insurance, but once there you're welcome to take it out for a weekend.

Henrik
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Bomber
Posted on Wednesday, April 28, 2004 - 05:05 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Henrik

ownership of a dwelling is a great deal like painting the Golden Gate Bridge . . . . .. .

edited by bomber on April 28, 2004
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Mikej
Posted on Wednesday, April 28, 2004 - 05:13 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

And owning one that's 100 years old is like painting the part of the bridge that's underwater.
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Henrik
Posted on Wednesday, April 28, 2004 - 09:33 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Well, our house is only 75 ... so I guess I still have my head above water : )

Henrik
(Golden Gate indeed)
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Bomber
Posted on Thursday, April 29, 2004 - 08:51 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Henrik -- if your house is 75 years old, be aware that the 2 X 4 lumber used to frame walls and stuff are very likely measure 2 inches by 4 inches

this will create some interesting shimming activities should to add/move/repair walls with present day 2 X 4 dimensional lumber

not a big deal, but aggrivating at 6pm on a Sunday evening when you want to button up the project you've been working on all weekend
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Mikej
Posted on Thursday, April 29, 2004 - 09:10 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Yep, and the stud spacing is not always what it is today. Helps to know this when you are searching for a stud to bolt/nail something to.
Our basement has mortis and tenon (sp?) joints on the beams. The wiring would give Sherlock Holmes a good workout trying to figure out what goes where and why and what to fix first. And you should see the setup we have for running the water out to the outside faucet, I should post a pic of that someday as an example of creative plumbing. Imagine a blend of cast iron, pvc, and rubber hose, not in any particular order, all linked up via a convoluted multiple spigot assembly conflaguration.

Somehow this all relates to working on an S2. Probably via the needs for open mind thinking and a patient sense of acceptive humor.
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Henrik
Posted on Thursday, April 29, 2004 - 09:34 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Bomber; thanks - I know : ) I took down a couple of walls, and made sure to keep the old studs, since I'd be adding a bit to another existing wall. The 2x4 dimensions along with the lath/plaster wall covering in varying thichnesses does indeed make it interesting.

Henrik
(way off topic - sorry ; ))
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Loki
Posted on Thursday, April 29, 2004 - 10:53 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I grew up in one of those 100 year old houses.....well at least one section of it was. You could read its history by walking room to room. The original section with its limestone basement walls. The first addition with its slab on grade. The final section with the block wall basement section. Doing projects was always interesting. The coolest part was the front door was the original one.

I miss that old farmhouse. One of my dreams in life is to own it someday.

this is one very convoluted buell topic now.....

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Reepicheep
Posted on Thursday, April 29, 2004 - 11:04 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Ditto... my parents house (they still own it, I grew up there) is something like 180 years old now. Lots of cool stuff, including solid oak wall studs in places, and solid single pieces of either cherry or walnut that are 6 foot by 3 foot square.
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