Ah, now I get it. I went back and re-read your OP. Sometimes, (actually most times) it takes a little time for the light to on.

I think what threw me off was calling the rockers a shaft and the rocker shaft a carrier shaft. Anyway, got it now. Too bad you didn't do a before and after video like the HD one. Would have loved to hear it. I think you should undo and redo your work so you can do the video for us.

All kidding aside, nice investigative work. I'm sure many here will take advantage of it.

SKWEARpeg wrote:


We just don't care about it after awhile. It makes noise. It doesn't break. Ride it. Texasscott has posted about relieving the area that taps on the bolt a few times in the past, when somebody really lets their OCD get the best of them. The most common fix on here, has been to get a louder exhaust. It's also the most recommended.

Yep. Pretty much.

PistonScuffer wrote:
grubsie wrote:
This is the aftermarket solution guys are using on their HD's. Maybe something like it could be used on the Roadies?

https://www.youtube.com/watch?v=jI_KWSz0XWk

I had seen that Video, but THAT fix is not what I did.
I shimmed the rocker shafts, not the carrier shaft, or that bolt that locks the carrier shaft in place.
I can see how that too could be a source of rattling, but in my case it was not.

Think rocker shaft end play, those shafts can move left to right on the carrier shaft by .010" (in my case), and CLACK loudly when they stop their shifting motion from side to side.

Anyway, I'm well pleased OCD or not, I finally have a quiet R*.

Rick


What no pictures

Hey PistonScuffer, don't listen to JD, he's just gettin old and done all this stuff too many times to care anymore. [Much respect JD]

But OCD or not, my 06 has loud clatter on the front cylinder under load and it's annoying as hell and I'd love to fix it. Could you be a little more specific *in laymen terms* and explain how you did it?

Are you saying you slid the rocker arm shaft back, and slipped a washer-like shim in there, the way the guy did in this video at the 3:43 mark??

Here's a direct link if the embedded video doesn't work: https://youtu.be/JQS99wCOWbE?t=3m43s



And if so, where did you get the shim? Are you saying you *machined* the shim yourself??? Trying to figure out how those of us without access to a machine shop can preform this fix.

What about the minimum thickness issue he mentioned in the video and the possibility of the shim disintegrating if it's not thick enough?

Much appreciation and thanks for taking the time to share your experience!

Doc, my 07 does the same thing at the front left! how long has yours been doing it? Is it going to turn into a issue or is it just the nature of the beast? I would like to stop mine also, but being a shade tree mechanic I worry about doing more harm than good. If there is really nothing wrong just the noise I will live with it.

Hey guys....remember this fix was a "known" issue, and somehow it seems I missed it last year when I asked about my top end noise !

So, Doc-V, yes, the video is pretty close to what I did, except I didn't need to remove the entire rocker box.
I pulled the valve covers, did line up the pistons for TDC, and installed a dial indicator to measure the end play on the rocker shafts, like I said mine were pretty much all showing .009" to .010" on the dial indicator.
At first I was going to use some delrin plastic sheet shim stock (.0075", but I thought about the possible effect of friction over time, so I went with SS.
All I had handy was shim stock in .005" (sheet stock)
I machined a center hole .735"
Then cut the outer diameter 1.075", effectively making 4 washers.
Then, like in the video, I removed the locking bolt on the end, and tapped the carrier shaft back far enough so I could slide the shim in place against the support block and the rocker shaft.
Then I tapped the carrier shaft back into place, which is a bit tricky because it has to go through the .005" washer as it goes back into the support block.
I still have a very slight clatter once the engine is good & hot, I guess I should have tried to get some .0075" SS shim stock instead of the .005" that I had.

I did not shim the rocker shaft carrier bolt, that's the 8mm bolt that keeps the carrier from moving, and on the Harley it appears to be part of the noise problem.
In my case, I thought about shimming that 8mm bolt, but I decided to see, or hear what just shimming the shafts alone would do.

So, in my case I would say I managed to reduce the clatter by 90% compared to what it was prior to this mod.
It is so nice to have a near silent engine...

If I am not explaining the procedure well enough, go ahead and ask specific questions, I don't mind "sharing" the info as it is a "known" issue, with a "known" fix....LOL!!


Rick

Rick I commend you on your tenacity to work a solution for this 'known' problem, which has been accepted as the way it is, but may no longer. On behalf of the many others that will be silently rereading this thread and making plans I thank you. If I was only confident enough to tackle this I would, and perhaps I will in time (actually I have a buddy and just maybe we can plan a wrench day!!!). Today I'll just imagine running quieter. I'll continue to follow this as others delve into it and hopefully post their results about quieting our monsters.

Thank you for sharing your solution and I look forward to reading what other obstacles you cross in the future.


Enjoy and ride safe ~Phil

Thanks PistonScuffer; that's really helpful. And as someone who's been on this site 6 years let me just say that wasn't a "known" issue. At least not to the masses. I've adjusted the rocker clearance on my 99 at least 4 times to lessen the noise and not once did shimming the shaft come up. It's certainly not as well known as SVS or front pulley nut issues, etc.

JD has been here longer though and really does have such an amazing breadth of knowledge, he works on jet engines for Pete sake, that I think sometimes he forgets the rest of us aren't as aware. It may have been discussed at length before I came along, however it's good you're bringing it up now, for all of us who weren't in the know.

For those who are hesitant to mess with their motors, I believe the consensus is, it's not "damaging" to the motor. If you can live with it then don't loose any sleep.

However, for those of us who'd like a less "clanky" motor...

The good news is, if you Google "Harley Rocker Shaft Shims" you'll find lots of sources to purchase them on line. They appear to come in everything from .050 up to .020 thickness, however, I don't know about the inner and outer diameters. I've been constantly amazed by how much on the R* is a direct bolt up to HD parts, that it wouldn't surprise me if they worked out of the "bag" [so to speak] but I'm horrible when it comes to SAE; any chance you could do a quick Google search and take a look at the HD shim specs and see how the inner and outer diameters compare to your solution?

Leaving some play at the ends is the safe way until one knows how much heat expansion takes place. Taking some of the end play out has another advantage also. It will force more oil through the rockers to the tops of the valves. The shaft is kept lubed by what exits from the ends and needs some flow to keep the oil from overheating.

I did the "louder exaust" fix.....