'04-07 Sportster issue.

So far switching engine cases and rocker boxes with another guy has been a learning experience. In 06, Harley increased the shifter shaft diameter, making the primary case no longer an easy remove and reinstall. In my latest problem, I have found the parts catalogue shows 07 and later rocker boxes as a different part# than the 06 and down. I know on 07 fuel injection came out, and now there is a CH temp sensor on the head,but what differences in the rocker boxes could there be? Oiling passages look the same and valvetrain geometry is same from what I have read.
I was told by one Harley tech that the difference was the design of the breather system, was this EPA related? Visually all looks like an easy swap, but I think the oil breather in the lower rocker boxes has a lower height than the older '04 rocker boxes. Anybody have any info on this? Internet searched for awhile on the weekend to come up with no more info than I already have.

Do the 07 ' s utilize the external breather bolts?

The 07 uses the breather bolts as does the 04. On the 04 the breather bolts help to center and hold down the air cleaner backing plate. The small plastic breathers themselves look almost the the same, but the 07's may be a hair shorter in height.
Called HammerPerf. Talked to Dan. He says no problems with using the rocker boxes from the 07 on my 04. So I guess much ado about nothing. I still would like to have the part # change explained, but some mysteries are not meant to be solved.
Got a price on the Patriot exhaust. Once I get over the exchange rate shock, I'll have to order it, price was pretty good.

I am waiting on pulling the trigger on that exhaust. I like my Basanni ' s too much.

Well, for the money, how can you not? That is a sweet price at what they offer it for, the D&D Bobcat was almost $600 more!
For their price, it's almost worth it to have it for a spare, and with my local area looking at noise bylaw for next year if I get the Bobcat and it is too loud I'm screwed, at least the Patriot system I may be able to lower the decibels a bit.

If I go Patriot system, my stock crossover pipe needs to come off. The three large bolts that hold it to the engine look like they maybe help hold the cases together? I assume they must go back in even if they no longer have a crossover pipe to hold. They are under the front pulley cover.

Sorry man but you lost me? I think you are asking if that cross over pipe helps keep the case together? The answer is no. Your pipes get mounted to a bracket that is on the frame. It isn't behind the pulley.

There should be an exhaust pipe bracket that attaches to the frame, not the engine.

I'll get some pics up on here, it will be more clear when you see it. Basically it is a bracket that holds the hidden crossover pipe for the stock exhaust, the bracket is mounted behind the pulley cover with three large bolts, and the rear brake master cylinder rod passes through it. The bolts are large and long, and appear to do more than just attach a crossover pipe.

Here's the pics I took, hopefully makes it a bit clearer. The crossover pipe is set up just below where it attaches. It is big, ugly, heavy, and I will not miss it when I remove it for the Patriot pipes.

Did you ask Dan at Hammer Performance what the hell that thing is when you last spoke to him? My bike does not have that so I have no idea what it is.

Oh, I know what it is. A big, heavy, ugly, crossover pipe to take the place of the one on the old Sportys that was underneath the air cleaner. 2-1 exhaust will clean up this kind of stuff.

Or a set of open drag pipes .

Drag pipes aren't my thing, but thanks for the thought. My neighbors and I get along and I'd like to keep it that way.

Yeah, I didn't really want to get the whole drag pipe discussion started on here, kind of like when you guys get all fired up over synthetic over dyno oils...

Oh, come on, I was just joshin' about drag pipes. However, they work, look and sound great on my little 60 HP motor .