| Author | Message | ||
     Johnod |
S2 with XB rocker covers. The front rocker cover leaks in the front right corner. I've replaced the gasket ( Cometic)3 times, I've checked for burrs, and checked for flatness. I've even replaced the top rocker box. Exchanged with the rear, as they are both the same. The rear doesn't leak with either cover, and the front leaks at the same place with either cover. Only thing I can think of is a problem with the lower rocker box. Ideas? Thoughts? Help? Thanks. | ||
| Jim2 |
I had that problem once. It turned out that the lower rocker cover thread was fatigued and 1 inch/lb. away from completely stripped. This caused one corner of the top rocker to leak because it didn't have sufficient clamping pressure to seal against the gasket for that one bolt only. I drilled it out and heli-coiled it. Another thing to look at is maybe the lower cover threaded hole has excess lock-tight or other debris in the bottom of it preventing it from clamping properly. | ||
| Ebutch |
Try some Lucas oil stop-leak.  | ||
| Hootowl |
That must have taken the whole cow. | ||
| 4speeder |
For stupid sealing problems on clean flat surfaces that seem to seep oil for no apparent reason, I use motoseal. Its the same stuff as hondabond, or yamabond, or any of the other factory sealers used to seal engine cases. Make sure the surfaces are clean with a wipe down of lacquer thinner, then apply a thin coat to both surfaces, and both surfaces of the gasket (if you are using a gasket), and I mean a thin coat. It doesn’t take much, then assemble and let sit for a couple hours. Once assembled you should barely be able to see any of the sealer squeezing out of the joint. If a bunch is visible then you used too much. It is amazing stuff.  | ||
| Two_seasons |
I just did my S2T and my 2000 X1. No problems with the S2, but the rear rocker box lower, next to the head, on the X1 required another gasket set. I've read somewhere about "numbers up" on the bottom gasket. I did not use a torque wrench when I did them, but did when I went back for round 2. Only torque your two long corner screws to less than 10 ft/lbs. Seems too tight at 10. (Message edited by two_seasons on July 16, 2016) | ||
| Johnod |
Today I went in and changed the lower box, with new gasket. Installed the upper (again) with the gasket that was new 16 miles ago, and put a sealant on that gasket this time. So we'll see, letting it sit over night. | ||
| Johnod |
On the plus side , I'm getting really good at removing the upper rocker box.  | ||
| Johnod |
Well it still leaks in exactly the same place. I've been using Cometic sportster gaskets, is the XB gasket any different, that would cause the leak? Any other suggestions? I'm running out of ideas here. | ||
| Jolly |
Just checking here as an idea... But when you mention upper and lower rocker box.... You're not still using the spacer are you? Additionally I chased this on one of my bikes and fount that it was actually leaking from the gasket between the head and the rocker box, not the rocker box cover... If you haven't replaced that gasket between head and rocker box, then you have the paper one and it is a sure leak point. Another problem I had on both of my S2 bikes, the front rocker box cover was imperceptibly binding against the front motor mount and keeping it from seating properly, by the time I worked on my second S2 I knew to check it very carefully, I had to enlarge the bevel that's in the front left face a little bit to clearance the front left of the motor mount. (Message edited by Jolly on July 16, 2016) | ||
| 651lance |
How mush oil is sitting in the pocket next to the leak when you pull the top cover off? Is it up to the base of the gasket? | ||
| Johnod |
Jolly, by lower, I mean the one with the rocker arms. Then just the 1 piece on top of that. I've changed the lower gasket,( head to rocker box) it's new. I've clearance the rocker cover, it just drops into place. Also , when testing it for leaks, I've wedged a piece of paper towel between top rocker box joint and front mount to soak up oil, and see where it's coming from. Right front upper joint is the place. (Message edited by johnod on July 16, 2016) | ||
| Johnod |
Lance I don't know, never really checked, why? I'm going to have to tear it apart again anyway. Am I supposed to be using gaskets like the ones on the left in this pic? The ones I have are like the ones on the right on top with the extra material in the 2 corners? | ||
| 651lance |
If it the front right corner that is a low spot and if the oil is sitting at the level of the gasket and if it a little weak it will leak. make sure you rocket box vent line isn't blocked or kinked. When you have the top cover off run all the bolts back in there threaded holes, bottom them out and measure them and see if they are all going in the same amount. | ||
| Akbuell |
Given what you have tried, might do to check around your area at places like the airport, speed shops, or machine shops and get a dye penetrant inspection. Could be that there is a hairline crack, doesn't really expand and leak until it get hot. Hope this helps, Dave | ||
| Johnod |
Lance what gaskets do I want for these XB covers? Do you have a part number. | ||
| 651lance |
Rocker box lower should be 17353-89C. Rocker box center should be 17358-84B. | ||
| Phelan |
Cometic rocker gaskets are notorious for for being stretched too big, even out of the box. I freeze them before hand and make sure it drops in with no fuss, as they move very easily during installation. Also Two Seasons, the corner bolts are the same shaft size (1/4-20) as the 3 7/16" head bolts, and both have a torque spec of 120 inch/lbs, or 10 ft/lbs. If you are using a FT/LBs torque wrench, you could be at the bottom of its range with the least accuracy, as it could need to be calibrated. Best to use an inch/lbs torque wrench. The 4 main rocker bolts with 1/2" heads are 240 FT/LBS torque spec, in case anyone is curious. | ||
| 651lance |
Check your torque spec. Main rocker box to head 5/16-18 bolt 15-19 ft-lbs Rocker box to head 1/4-20 bolt 130-150 INCH-LBS Allen bolt 1/4-20 10-14 ft-lbs. These torque spec's are per Buell service manual. | ||
| Two_seasons |
...what Lance says. Phelan, you are correct. I do indeed need an in/lbs torque wrench. My small one is 20-80 ft/lbs and the big one is 100-210 ft/lbs IIRC. Take my advice guys...buy the best you can afford. I went cheap and regret it. | ||
| Johnod |
Phelan where did you get 240 ft/lbs figure? | ||
| Johnod |
These are the specs I have from the S2 Manual. Lower box to head 90-120 INCH Pounds 10-13 ft lbs 15-18 ft lbs Top cover 10-13 ft lbs | ||
| Phelan |
whoops, I meant to say inch lbs lol. And bad memory. I meant to say 235 in-lbs, not 240. But the manual gives a range while I simply use a set number that I was taught to use. My numbers are in the factory range though. It's late, and I was up until dawn working on a bike. I should have better worded my respone, sorry. | ||
| Screamer |
Pulled threads are one of the more likely causes, but a breather system that's not working properly can cause repetitive rockerbox sealing issues. | ||
| Johnod |
Redid it all today, chased all threads, checked breather system , and pcv valves, checked for pulled threads, new gaskets HD this time, which seemed to fit better, and some hondabond type stuff. Torqued it all down, let it sit over night , and a new test ride tomorrow. Wish me luck. | ||
| Johnod |
Success finally. I believe the main problem was the Cometic gaskets. | ||
| 4speeder |
Great news! |
