| Author | Message | ||
     Rlgiv |
I think it started after I put on my leather tank protector. When I first put it on I thought it felt like the front strap may have snagged a little on something as I was tightening it up. I have quite a bit of oil only on the left side of the bike. It seems to be coming from up high on the engine but I can't quite tell exactly where it is coming from because it is spread over so much. I think what I may have done is loosened one of the lines that run along the left side from the oil tank to the oil pump. I just can't visualize the lines because the fuel tank is in the way. Is there an easy way to get the tank out of the way so I can see these lines easier? I have a 99 S3. | ||
| Kilroy |
There shouldn't be anything near the tank that contains oil that you could have snagged with a tank bra. Most likely you are experiencing rocket box gasket leaks that just so happened to show up at the same time that you put the bra on. Kilroy | ||
| Daveswan |
pulled a breather hose???? Oil hoses are on the bottom of the tank aren't they? If it's a rocker box leak -- I just did mine and took a bunch of step-by-step pictures. | ||
| Yo_barry |
Most likely rocker box leak, not related to the tank bra. The paper gaskets that came on your '99 may have already failed and been replaced, but not with the redesigned metal gasket. HD sells a rocker box gasket set for pre-2004 Sportsters that is the same for a Buell. Sometimes the HD dealers refuse to speak "Buell." It's a couple of hours job, not difficult. | ||
| Daveswan |
It took me literally two hours, and I wasn't in a hurry. That bottom paper gasket on mine was like a potato chip - hard and brittle, shrunk and cracked and leaking. I replaced it with a metal compression gasket from Cometic along with new rubber gaskets in the kit. Instead of there being 2 separate paper gaskets it's just one gasket that lines up nicely over the 2 areas and won't shrink out of shape nor become petrified. | ||
| Rlgiv |
I think ya'll are right Rocker box covers. Thanks for the replies. Is this a jb that is fairly easy to do at the house.?? | ||
| Skntpig |
Yeah, not too bad. Search Daves post and look at the pics | ||
| Daveswan |
I think I'll post some pics tonight in a separate entry so people can get a visual if they haven't made the repair. | ||
| Daveswan |
Here's a decent pictorial on the replacement from a harley/Buell forum. Go to the link below for the details. The repair here is being done on a sportster. It gives torque specs and some procedural steps if you don't have a service manual that I highly recommend! http://xlforum.net/vbportal/forums/showthread.php?t=453930 I'm adding a picture or two here from my own repair just to supplement the one above until I create my own step-by-step. This shows a leak in the rear cylinder, front left between the bottom of the rocker box and the head.  Here shows the Pro Motion wrench getting at that corner screw. Note: the front bottom left - the oil leak is shown.  Once you have the cover apart you'll have the umbrella gasket that I unfortunately don't show that was in that hole to the LEFT of my drill bit. That hole actually should get chamfered 60 degrees so that the base of the new umbrella valve sits down better. Now that very tiny hole on the right should be drilled out to 1/8" to let the oil drain back.  Here we have the bottom paper gasket that's shrunk, and is hard and brittle as a potato chip!  New Cometic won't have that problem!  Put back together with stainless Allens from Diamond Engineering-no more leak.  | ||
| Rlgiv |
Thanks. This will come in very handy. | ||
| Akbuell |
Yep, easy job. Put a chunk of rebar through the rear axle to get the rear tire off the floor and stabilize the bike. Remove the fuel tank, and take out the spark plugs. Put the bike in 5th gear,and rotate the crank by turning the rear tire until the cylinder you are working on is at TDC on the compression stroke. Remove the bits shown, put in the new gaskets, torque to specs in FSM as you re-assemble, and done. Take your time, and enjoy a job well done when finished. Dave | ||
| Bluzm2 |
If you are running the stock rocker box covers, drilling out the drain back hole and chamfering the umbrella hole is important. It makes a noticible difference in spooge output. Here's a shot of the chamfering. Sorry it's so small, I couldn't find the original.  Notice the drain back hole has also been enlarged to 1/8". The reason for the chamfer is the bottom of the umbrella valve isn't flat and it doesn't seat properly without the chamfering. Just use a big drill bit and knock off the edges.. Brad | ||
| Akbuell |
And before I forget: Be sure to mark the parts as they come off, so the intake pushrod goes back into the intake hole, ect...... When first starting the bike up after assy, you may hear a great deal of engine noise. What has most likely happened is that the lifters have 'bled down' and you have excess valve/pushrod clearance. A gentle lap or two of the block (something below 3k RPM) will allow the lifters to pump back up and solve the problem. | ||
| Rlgiv |
thanks for all the input. I think this is going to go smooth. | ||
| Calidrew |
Bennett's Performance V Twin installed a full Cometic kit from Al at American Sport Bike last year on my '99 M2. A couple months ago the thing starts spewing oil. Ebear tells me to check the rocker box and sure enough the rear (leaking) one has three loose screws. I cut and ground an allen wrench to get to the corner one, but it won't get snug or screw all the way out. Any body know what might cause that? I gotta message into Ebear, but figured I'd check here while I have some daylight. | ||
| Oldog |
stripped screw | ||
| Calidrew |
Thanks Oldog. Unfortunately the screw is fine. A slight upward pressure with the needlenose got it out. Coated with the aluminium threads. Aargh. Guess I need to pull the rocker box and helicoil it. And I was gonna spend this week off riding... Anyone else tried to helicoil the retaining screw hole of the rocker box? It looks like enough meat to do the trick, but I won't know for sure 'til I get the box off. | ||
| Rlgiv |
OK Had a few things to do on the bike before I could get to the leak. Replaced my rear brake pads, took off rear tire and put n a new one, then had to replace my rear shock before I could get to the oil leak. Thanks to a good friend and his garage I got threw that with no problem. Now have my rocker pro motion wrench, torque wrench, and just got my gaskets in. As soon as the snow is melted from the roads here in va I am going to get started on these Rocker Covers. The front is leaking on mine but I am going to replace both cylinders. I have researched this alot and feel fairly comfortable doing it Just not sure if I can do both cylinders at the same time or do I have to do one then open up the other? | ||
| Pkforbes87 |
Other X1 owners chime in on this if you've had a different experience, but I never needed a special tool for stock rocker box covers (or the XB covers) The small end of an "L" shaped allen worked just fine. The frame tubes under the rear of the tank seem to spread a little wider on the X1 than on other models. Dunno if your S3T is the same way or not though. I've got an S3 frame in the garage but have never had an engine in it. | ||
| Kilroy |
I think the issue is getting a torque wrench on all the bolts. I have had to use my calibrated thumb more than once since a standard torque wrench cannot get to all bolts. Kilroy | ||
| Jayvee |
One cylinder, then the other. You don't want to mix up any parts! | ||
| Thunderbolt3 |
i just cut down a allen wrench for my 1998 s3t to get them out worked fine | ||
| Adsva83 |
Does anyone have links of where to get rocker box gasket kits? Opinions of where and which ones to get? I need to replace mine before it's riding season again. | ||
| Jim2 |
I bought mine from an HD stealer. It wasn't even Buell/HD just HD. It was a complete kit with the upgraded cometic type gaskets. Of course, I see that you want to make a cyber purchase | ||
| Adsva83 |
I have a HD store that sells Buell parts and also one that does not in Indianapolis. If I could get part numbers I could go to either of those. My experience with them in the past, as soon as I say the word "Buell" I become almost invisible, like I'm not even standing in front of them wanting parts anymore. But if I go in with a part number they'll still accept my money. | ||
| Jim2 |
HD Part#: 17036-91A Description: GASKET KIT, ROCKER COVER, XL'S This is a complete Rocker Box gasket set for both cylinders and includes the new style Umbrella Valves. The lower box gaskets are the Cometic type one piece gaskets. The rest are rubber. Also included are new fiber-washers. I have a 2000 M2, I don't know if this works for all Tubers. | ||
| Calidrew |
I got my Cometics kit from Al at American Sport Bike. Torqued all but the bolt under the frame. I used a cut down allen wrench on that one. Don't forget to drill out the drainage holes to 1/8". And carefully clean up the aluminum shavings. They ply havoc with the rubber gaskets. Don't ask how I know. | ||
| Rlgiv |
thanks to everybody who gave me advice. I finished the job. just gotta remember in the future "inchpounds not footpounds" one broke bolt in my lower rocker #2 and a warped one in my lower rocker #1 later The job is done and I no longer have an oil leak. |
