The sleeve ID compresses the o-ring. You put the o-ring on the shaft slide it through the ID of the tool, butt it up against the hole on the rocker box and slide it in place.
I was told by a reliable source that there was supposed to be a small 10 to 15 deg. chamfer on the ID of rocker arm shaft holes. According to this guy it was supposedly in a service bulletin but was never incorporated at the factory (could be bullcrap). He said that the sleeves don't work real well either and the chamfer allows you to put the O ring on the shaft and slide it in without shaving the OD of the o-ring. Chances are you could break the sharp edge and accomplish the same thing.
In my past life building aircraft generators we coated the o-rings with “o-ring honey” (STP like stuff) before putting them in. I bought a set of o-rings and thought I'd break the sharp edge of the hole, make the tool, lube up the o-ring and give it a try. Good luck.
Re: Rocker Spindle Guide - How does it work?#77267 02/10/059:38 pm02/10/059:38 pm
hi, never used one but i assume it is a oring guide(bullet)tool probably tapered on the id and put on the spindle and as you slide it over the oring its compressed then you install the spindle..you should first ck to see if you have the correct size o'ring then taper the rockerbox hole slightly at the end with a countersink bit this will help compress the o'ring....
I had a conversation with John Healey, President of the TIOC at the Cachuma Lake rally last year, and he basically told me the method drp listed in the first post, use a file to create a chamfer on the ID of the rocker shaft hole, then use some lube and small screw driver to persuade the O ring into place. I think there was also a recent article in the TIOC newsletter outlining this process.
Will S. BSAs: '66 & '69 Lightning Triumphs: '68 TR6R, '68 Bonneville, '73 TR7, '55 6T '71 Norton Commando
The tool is basically worthless. There are easier and quicker ways to achieve the same result.
If you have the shafts out, you can touch the opening with a single flute 3/4" dia countersink and chamfer the entry. This basically builds the tool into the rocker box.
If the boxes are on the bike, rotate the engine until both rockers have slack and slide the shaft out about 3/4". You can then chamfer the entry with a sharp but small pocket knife.
Then I thoroughly clean the o-ring groove and rocker box. Then fill the groove completely with silicone sealer and pop the new o-ring into the groove. A pile of silicone sealer will pop out of the groove and onto the shaft. Rub this all over the top of the o-ring. This will lube the o-ring for entry. Tap the shaft back into place with a plastic-tipped mallet.
The excess sealer will come off the box as one continuous string after about 20 minutes. Don't wipe the sealer or upset the curing of the sealer during this 20 min period. The end result is an absolutely leak-proof rocker shaft.
Hope this helps.
Don't hide 'em, Ride 'em !!
RF Whatley Cornelia, GA
"Shop Boy" at Rodi British Bikes
Re: Rocker Spindle Guide - How does it work?#77272 02/11/053:35 am02/11/053:35 am
Well, the factory drawing does show a 15 degree chamfer in the rocker shaft hole. For some reason not all rocker boxes have it. Mind you the people who assembled these bikes were pretty handy with their hands when they wanted to be. The next time you are at a flea market check out the rocker boxes.
As far as the tool is concerned, I agree that they are useless!!!
Whatever lube you use, siicone, grease, oil or whatever, it doesn't matter, the key thing is you shouldn't have cut a small section of the "O" ring off during assembly. If you did you HAVE TO DO IT AGAIN or it will leak. RedNeck is right the job can be done without taking the rocker box off the motor. Follow his directions. Although I find it a bit easier to loosen the tappets a half a turn to take all of the pressure off the shaft. I have a small 4" Snap-On screw driver that I annealed and bent to about 80 degrees. I narrowed it a bit. I use this to remove circlips and to push the "O" ring into the groove as I offer the shaft to the box.
Re: Rocker Spindle Guide - How does it work?#77275 04/11/051:30 am04/11/051:30 am
I bought the O rings some time ago and after riding about 80 miles today on my "71" T120 I got tired of the oil leak, pulled off the rocker arm covers (figured I'd replace the gaskets also) removed the shafts, replaced the o'rings and put it back together. It was strange, the exhaust side had the chamfer but the intake didn't. Unless someone replaced o'rings prior to "74" when I bought the bike it must have been like that from the factory. I chamfered the intake rocker and it was easy getting the o'rings in. I had more trouble getting all the springs and washers lined up and next time I'll make a tapered alignment tool for the spring & washers alignment.