rocker box leak Harley Evo Sportster Discuss rocker box leak in the Harley Sportster & Buell forums; i'm supposed to tear into a 04 1200 today for a friend.the front rocker box is really leaking bad,is there anything i need to look for besides the gaskets ?...it ...

[lowrider01]

i'm supposed to tear into a 04 1200 today for a friend.the front rocker box is really leaking bad,is there anything i need to look for besides the gaskets ?...it seams to be leaking between the top and bottom of the boxes...

[shovelmike]

Make sure the rocker box and associated parts are not warped and that the gasket surfaces are smooth. Other than that, just follow directions in the shop manual paying close attention to torque sequence and values and you'll be fine.

[Wrightturn]

Hey Low,
What Shovelmike said. Be sure to service the breather while you are in there. Will have less oil to leak.

[JCourneyaP]

Lowrider, Lemme know if your Gasket was sucked in. There is a open gap in two places on top of lower rocker cover. Curious if your gaskets pulled in.

Also I believe Harley had a service Notice out there about those 04 covers. Some were just plain bad. And do what Shovel and Wright suggested. The breather was a good call. I almost forgot that the first time I went in.

[lowrider01]

ended up working on the sporty last nite...boy was it a hot one yesterday.......anyway,the front rocker gasket was broken .it looks like someone already replaced the rear box gasket,went ahead and changed it anyway while we were in there.the bike has sat up for about 2 yrs supposedly,the ole boy got a steal on it though,......the open gasket on both rockers were in great shape and where they were supposed to be,the breathers were serviced also,not much room at all on that rear one.the new rocker gaskets looked like they have been modified alot compared to the one that came off the front,moco must of had to update them,the old one was flat with round holes for the breathers,and was black in color,the new ones were tan and had square holes that matched the breather,and had dimples to seat them in the head,the rails also had a raised section in the middle,.....anyways we went for a lil ride ..no leaks.........THANKS ALOT for all the suggestions.....have a good one today....

[shovelmike]

I'm glad it went well, Lowrider. It's very hot here in Missouri as well. Ride safe and God bless, Sincerely: Shovelmike.