rocker box gaskets - Harley Forum

72fl · #1 06-07-2009, 11:17 AM

99 sportster 883 I have a leaking rocker box gasket, is it a issue for someone that has mechanical knowledge to change it? I don't have a manual and was wanting to know by someone who has done it or has online manual access. And could possibly post or refer me. thanks

Hammerhead Pat · #2 06-07-2009, 11:54 AM

If you have even minor mechanical abilities it shouldn't be a major task. From what I've read sometimes it's a pain to get your socket and wrench under the tank because of the tight space, I'm not sure if there is a special one designed for it. If whoever has this bike plans on keeping it, I defenitly suggest getting the service manual for it, it will pay for itself the first time they use it

sportsterpaul · #3 06-08-2009, 10:19 PM

I second hammerhead pat, a service manual is worth it's weight in gold if only that it gives you freedom from reliance on the "stealers", commonly known as your local dealer.
Also, its not real uncommon for the rocker boxes to leak, someone at H.D. designed them in three pieces presumedly to allow changing them out without reposistioning the fuel tank. The key to redoing it successfully is keeping all three pieces perfectly lined up top to bottom, side to side and front to back. Tighten each allenhead bolt a little at a time criss crossing from one to another as you go. The rear bolt on the back head, nearest the battery can be especially difficult, grinding the short end of an allen wrench shorter yet will allow you better access to that one, add it to your new collection of "special tools", it won't be the last one. This is a big step towards bonding with your bike, good luck to you.

72fl · #4 06-09-2009, 05:08 PM

Thanks, tryin to find a used not abused manual online.

JCourneyaP · #5 06-09-2009, 09:18 PM

72- I replaced the Rocker Box gaskets on my 04 sporty more than I care to remember. I know mine only has two pieces and yours three. Same principal.

I found it easier to pull the tank. That only takes a few minutes to do and makes working on the Rocker Boxes a lot easier. Get that manual if you can. Gives you step by step and values on which to tighten.

unclepsycho · #6 06-09-2009, 10:48 PM

Getting the manual is the key. It will pay you back the first time you use it. Even if you gotta go to the steelers to get one
I looked in my normal sources, and the rate plus shipping is approx $60.....same as the steelers charge.... I dont think there are any on-line manuals... I have looked....
besides...that would be too easy!

We all encourage you to get a manual, but that dont mean we dont want you to ask questions. the manual dont always tell ya everything.

I will be doing the rocker box removal on my Twin Cam soon, I gotta get under there to get at a breathers that needs replacement.

Lifting the tank off seems like the first step, like JCP mentioned, then it is just nuts and bolts....

take your time and it should be a reletively easy job.