Dreaded Rocker Cover Gasket Leak

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pdksh

pdksh

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Hello Buell Gurus.

Went out for a ride and noticed oil on my transfer case cover, suspected my transfer case cover had a small leak until I followed the leak up my inner swing arm, fan assembly and rear cylinder. With a flash light all I can tell is the leak is coming from the top of the rear cylinder. Now I have seen numerous posts on every buell form about the rocker cover gasket leak. It looks like it could be one of three different things;
1) Upper Rocker Cover Gasket (inner and outer) (p/n 17362-07 & 17695-07)
2) Grommet for the PCV valve (p/n 17608-004A)
3) Lower Rocker Cover Gasket (16800-84A)

Is it typically the Upper Rocker Cover Gasket (inner/outer).

The reason why I'm asking is, I would rather order and replace all the parts if I have to spend all day Saturday rotating the engine. From the leak I can not tell exactly if the leak is coming from the Rocker Cover Top or the Rocker Cover Inner. BTW who comes up with these confusing names. GOSH!

I'm sure the parts are "reasonable" BUT I want to do this as one-stop shopping. Would it be wise to do the front and rear cylinder or is it only the rear that normally leaks?

Thank You in advance!
 
Do them both at the same time or you will regret it! When I did it I just bought a top end kit by James gaskets from amazon for $66.00 IIRC. Things you will want to do while the engine is rotated are intake seals (can't remember if they are in the box or not) and replace the rocker box check valve/breathers (Harley only I think). You will end up with gaskets you won't use but it's better to have them when tearing into the project and not need them then need them and not have em!
 
excellent point, I did do a fresh oil change this spring. BUT the bike sat in a bike shop for about 2 years without being turned over. I will check the oil level

I have spent the day trolling through HD kits and the James kits

the HD kit is 17036-91A and should cost me about $100cnd

the James kit is JGI-17049-07-X and I dont have a price yet.

The DAMN PVC valves are $30 USD a piece! seems a little stiff to me!

Its unclear to me if I'm suposted to use the TALL ORANGE gaskets that come in the kit or the flat dark gaskets. Suggestions and Ideas.

James kit vs HD, etc, etc
 
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If it was me I would go with the James kit. I have used the H-D stuff before and it didn't last to long it seemed. the James kit is still going strong on my bike.
 
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Yikes, as I put the bike on the wheel stand it leaned and broke the left - stock mirror on the wall! Does anyone have a stock lollipop mirror they want to part with?

When rotating the engine does the throttle cables need to be removed from the throttle body? I'll have to review the guides on the forum.

2+ hours to prep the bike to rotate the motor, being careful but man a lot of "stuff" needs to come off
 
If this was me, and I was going through the trouble to rotate the engine.... I'd also do the cylinder base gaskets. Some of the bikes are known to have leaking problems with the original gaskets.

Of course, at that point, I'd also inspect the cylinders/pistons. Maybe send out the pistons for coatings (sorry, I subscribe to that snake oil) and clean out or replace the lifters, and inspect/replace the oil pump gear.
 
Sounds like 3419 thinks you might as well rebuild the engine while you're at it!
Seriously, there's a lot of preventative stuff you can do while rotating the engine but from my experience I would just replace all the gaskets related to the rocker box leak. And I would only mess with the rear rocker box.
If you don't suspect your intake seals are leaking; don't fix what isn't broken.
My rear rocker box started leaking around 15k. It started leaking because I had a combination of issues causing the rear cylinder to run hot.
If your fan is working properly and your tuning is good you should be able to get away with just replacing the rear gaskets.
Most kits come with both front and rear so it up to you if you want to tear into the front.
At 15k I did my rear and rear alone. It wasn't until 34k that I needed to do anything else with the engine. And this engine work was only done because the crank bearing went out.
It's up to you how deep you want to dive into your project.
Good luck
 
True on the drain plug, but then again who the hell uses a torque wrench on a drain plug!
Speaking of torques... ...stick to the lower torque values for the small hex bolts that are found inside the rocker box. Manual calls for 110inch pounds or some crap like that. Just tighten till you fell a bit of resistance then add another 1/4 to half turn max. You go with the manual torque spec and you'll probably snap em. Don't ask me how I know!
Good luck.
 
Chicknstripn said:
True on the drain plug, but then again who the hell uses a torque wrench on a drain plug!
Speaking of torques... ...stick to the lower torque values for the small hex bolts that are found inside the rocker box. Manual calls for 110inch pounds or some crap like that. Just tighten till you fell a bit of resistance then add another 1/4 to half turn max. You go with the manual torque spec and you'll probably snap em. Don't ask me how I know!
Good luck.
Click to expand...

i also snapped one.... he speaks the truth!!!
 
Heh heh!
null_zps1f006d6f.jpg
 
Thanks for the heads up regarding the three small hex nuts and I'm also assuming the Allen bolts. The four black bolts holdin the rocker assembles down I'm assuming proper torque specs
 
pdksh said:
Thanks for the heads up regarding the three small hex nuts and I'm also assuming the Allen bolts. The four black bolts holdin the rocker assembles down I'm assuming proper torque specs
Click to expand...

yes the black ones can be torqued no worries. The allens in the top cover were the ones i snapped one off... the ones in the rocker box are also easy to snap so yes be carefull with all the small allen head bolts in the area. Fortunately they're a pretty common bolt and mine snapped in a way i could run the remaining bolt out with some pliers no prob:black_eyed:
 
Thanks for all of the pointers, really helped. Rocker Box Cover Gasket changed successfully. Unfortuanly when I was putting her on the wheel stands by myself it started to fall over and I snapped off a lolly pop mirror. Other than that the surgery was a success.

Again thanks to all for all the help!
 

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