Installing the Rocker Covers

Install the sparkplugs using anti-seize. Be sure you set the gap first--0.032" to 0.033" for most plugs.

Take picts.

Slip alignment dowels into the rocker-bases.

Note: The next steps, pertaining to the chrome spacer, are for 1999-2003 Road Star engines only. Later models do not have a two-piece, chrome valve cover.

Install the chrome spacers (aka lower valve cover) gaskets.

Cost Saving Tip: If metal gaskets aren't perfectly covered with black sealer, you can 'paint' them with xylene thinned Yamabond.

Bolt up and torque the chrome spacers using six M6x40mm bolts. Use 7.2 ft-lbs.

Take picts.

Slip alignment dowels into the chrome spacers.

Install the valve cover gaskets.

Bolt up and torque the valve covers. Use 7.2 ft-lbs of torque. See graphics below for help putting the right bolts back into the right holes.

Rocker Cover Bolt Placement Chart -- for 1999-2003, 1600cc (98ci) Series Engines

Rocker Cover Bolt Placement Chart -- for 2004-2007, 1700cc (102ci) Series Engines

To access related articles, refer back to the Complete Engine Tear Down, Orientation article in this series to see which additional articles best address your situation.

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DISCLAIMER: This information and procedure is provided as a courtesy and is for informational purposes only.  Neither the publishers nor the authors accept any responsibility for the accuracy, applicability, or suitability of this procedure.  You assume all risks associated with the use of this information.  NEITHER THE PUBLISHERs NOR THE AUTHORs SHALL IN ANY EVENT BE LIABLE FOR ANY DIRECT, INDIRECT, PUNITIVE, SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES, OF ANY NATURE ARISING OUT OF OR IN ANY WAY CONNECTED WITH THE USE OR MISUSE OF THIS INFORMATION OR LACK OF INFORMATION.  Any type of modification or service work on your motorcycle should always be performed by a professional mechanic. If performed incorrectly, this procedure may endanger the safety of you and others on your motorcycle and possibly invalidate your manufacturer’s warranty.

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