Buell 2004 XB9S, Service Manual

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3-46 2004 Buell Lightning: Engine
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Rocker Box Assemblies
1. Remove spark plugs.
2. See Figure 3-60. Remove screws with washers and fiber
cover seals. Discard fiber seals.
3. Remove top rocker covers.
4. Remove and discard gaskets.
5. Rotate crankshaft until both valves are closed on head
being removed.
6. See Figure 3-61. Remove hardware holding lower rocker
cover to cylinder head in the following order.
a. Remove two screws and washers (1).
b. Remove three bolts and washers (2).
c. Loosen the four rocker arm fasteners (3) in 1/4-1/2
turn increments using a cross pattern in order to
relieve valve spring pressure on the lower rocker
box.
7. See Figure 3-60. Remove lower rocker cover.
NOTE
Remove lower rocker box as an assembly; then disassemble
as required.
CAUTION
Mark rocker arm shafts for reassembly in their original
positions. Valve train components must be reinstalled in
their original positions to prevent accelerated wear and
increased valve train noise.
8. See Figure 3-62. Remove rocker arm shafts by tapping
them out using a hammer and a soft metal punch.
9. Remove rocker arms; mark them for reassembly in
their original locations.
10. Mark the location and orientation (top/bottom) of each
push rod. Remove push rods.
Figure 3-61. Lower Rocker Box Fasteners
Figure 3-62. Removing Rocker Arm Shafts
1
1
2
2
2
3
3
3
3
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