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Buell Forum » Knowledge Vault (tech, parts, apparel, & accessories topics) » Troubleshooting (Poor Starting/Running/Handling/Ride Issues) » Developed an oil leak « Previous Next »

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Redbuell1203
Posted on Saturday, July 04, 2015 - 11:01 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Have a leak coming from the rocker box. Is the Harley Davidson sportster the same part number?
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Akbuell
Posted on Saturday, July 04, 2015 - 11:36 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

IIRC, the short answer is Yes. Just go to the parts counter and ask for the appropriate gasket for (in your case) a 2002 1200cc Sportster. Don't tell them what you are going to put it on, and you'll be fine.

BTW, if the leak is the gasket(s) between the rocker box and the head, and it has never been replaced, do yourself a favor and replace them both. The updated part is a one piece metal one, not the leaky 2 piece paper ones that are OE.

Hope this helps, Dave
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Redbuell1203
Posted on Sunday, July 05, 2015 - 07:08 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Thanks a bunch. I am very handy with a wrench, but doesn't look to be a really difficult process
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Reepicheep
Posted on Sunday, July 05, 2015 - 09:25 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

It's not. Bolt the rocker box back down slowly so the lifters can bleed down. And when you start it back up, they will clatter while the lifters bleed back up.

You will likely have to cut down an allen wrench to get one screw out. Keep it, it is handy for a few other places as well (intake on my Ulysses, etc).
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Redbuell1203
Posted on Tuesday, July 07, 2015 - 06:22 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Just called local dealership and all the parts are in stock and going to put in together this weekend.
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Redbuell1203
Posted on Wednesday, July 08, 2015 - 10:18 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Has anyone on here also done there own set? Do the rocker arms have to be removed completely or can they be left assembled? I haven't started yet just have the pictures from Harley.
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Bluzm2
Posted on Wednesday, July 08, 2015 - 10:49 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Red,
Most everyone her who has or had a tuber has done rocker box gaskets.
Download the S1 service manual, the torque specs and such are the same. If you don't have a torque wrench, get one before you start or you will have leaks again.

Be warned the old paper gaskets are a bitch to get off. Take your time and use fresh razor blades. Don't scratch or gouge the gasket surfaces on the rocker box or head. Take your time.

Back in the archives there is a step by step procedure with pictures.
It's not hard, just a pain in the butt.
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Redbuell1203
Posted on Wednesday, July 08, 2015 - 10:56 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Thanks a bunch! Plan on taking the whole weekend to do the job! Tools I have thousands of $ of. Was a Chrysler technician for years.
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Akbuell
Posted on Thursday, July 09, 2015 - 07:40 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Not a bad job. Suspend rear wheel off the ground, pull the plugs, and select 5th gear.

Put the cyl of choice on TDC on the compression stroke, and remove the cover, spacer, and rocker box. Reinstall with new gaskets.

Turn the engine over with the rear wheel, and select TDC on compression on the other cyl. Remove and install.

Hope this helps, Dave
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Bluzm2
Posted on Thursday, July 09, 2015 - 11:31 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

You will need a shortened allan wrench for the r rear cover bolt. 3/16 if memory serves.
You will have to cut the short leg real short.
Might need it on the L front too, I don't remember on the X1, been a while.
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Redbuell1203
Posted on Saturday, July 11, 2015 - 03:49 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

For some reason I can't download the s1 manual! I need to find the torque specs and sequences. Any help please. I have everything ready to go back on the front head.
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Redbuell1203
Posted on Sunday, July 12, 2015 - 03:28 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Please note new thread on oil leak.
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