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The benefit of doing this is greatly improving
the engine’s breathing ability and therefore reducing the amount of
oil puking out of the heads, a subject near and dear to every
Sportster/Buell owner. A side benefit is the “cool factor” of having
new XB parts on you old tube frame Buell.
The pictures below helps to explain why this new
cover works better than the old one. First you are getting rid of
the spacer, eliminating one more gasket that could leak, but more
importantly it gets rid of the tiny return hole (2) and replaces it
with a bunch of empty space in the top of the head.. Second, the PCV
valve is much larger than the little flapper valve used previously
so it can handle more volume in each head. Third, the air oil
mixture only has to go up through top of the head through the PCV
valve and never return, where the old design had to go through a
wandering route as shown in this figure from the service manual,
increasing the chances of oil pooling and puking when the engine
decides to push the oil out of the breather bolt. |
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The old way
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The New Way
Here are the
parts that you will need: |
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17605-00YB
17642-02A 17606-00YA 17607-00Y 868A |
Rocker cover, front head $39 Rocker
cover, rear head $39 Grommet, Viton, Black $2.95 each (need
2) PCV Valve, $6.90 each (need 2) Hex Socket Button Head
Screw, $4.75 each (need 2), not
shown |
The only special tool that you really need is a cut
down 3/16” hex wrench. Take a regular hex wrench and cut off about ½
inch of the short side of the wrench. What this allows you to do is
to remove the hex bolts that are obstructed by the frame on the rear
cylinder. |
After removing the fuel tank, you might want to
consider removing the top and the front two tie bars and the front
motor mount to rotate the engine down away from the frame to give
you more space to work in. Don’t forget to put a jack under the
engine so it doesn’t drop on you when you undo the front motor
mount. Slowly lower the engine using the jack until the motor mount
gets close to the front tie bar frame member. I found that the extra
space to work with was helpful. |
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The operation is basically take off the four bolts
holding the covers, remove the cover and the spacer, then install
the new XB cover and bolt it down with the same four screws. The
only two clearance issues that I ran into were the front cover and
the front motor mount and the rear PCV valve and the Fuel
tank. |
Now, what do you do about the old breather holes in
the head? Just use the two button head screws that you have not used
yet to replace the old breather bolts, remembering to use thread
sealant on these bolts. |
For the front cover, I shaved away some material
from the front left corner of the rocker box cover so it would clear
the front motor mount during installation. On my bike a friend of
mine had cut down the edges of the head hex bolt in that corner to
provide further clearance when removing and installing the covers.
You can also completely remove the front motor mount, but I did not
want to mess with it. |
For the rear PCV valve, I found that by pointing it
towards the rear of the bike and some creative filing there is just
enough clearance between the top of the PCV valve and the bottom of
the tank on my S3. I’ll keep an eye on this area to see if further
modifications are needed.
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Finally, you can send the two hoses separately or
tied together like I did into a catch can, or just into the ground
like I did here, next to the tank vent. This will ensure that the
side stand switch and hinge are always properly
lubricated! |
So that’s it! The fun part now will be to see how
long it takes your Buell friends to notice that your bike just looks
“different” somehow. |
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