How to really fix your rockerbox oil leak (w/ pics)

[Bad Karma]

Do not attempt if you are not capable of or have ever drilled hardware for safety wire. IF DONE WRONG YOU COULD DAMAGE THE STRUCTURAL INTEGRITY OF THE HARDWARE.

This is a diy for the dreaded rear cylinder oil leak. As long as the rockerbox gasket is the issue. This fix was just done and has not been tested.

My leak started @ 17k miles and I kept putting it off till it dripped oil on the ground over night(24k).

So I had the orange soft gaskets that don't work worth a flip. Installing the new black rubber coated metal ones would undoubtedly fix my issue...for a while.

The other issue I found was that the cover bolts loosen up over time.

The Fix: Drill rockerbox cover bolts for safety wire.


What you need:
1/16 (or 3/32)drill bits (several as they dull and do not drill evenly)
.032" T-304 Stainless Steel Wire
safety wire pliers
drill press or cordless and a steady hand


Drilling bolts on press.

Done with the rear

And done with the front

Only time will tell if this is a permanent fix though.

 

[wolfo68]

[up] Good idea, but I don't think it'll help if the gasket goes bad.

 

[Bad Karma]

True it's not a "gasket fix" but when you put the new style on, it'll keep it from failing as fast. The bolts DO loosen over time and will start to leak.

 

[roxxx]

Does stage8 have any thing that might work ?

 

[garyphantom222]

That does look like a good idea,but I have always been notorious for checking all bolts on my bikes for tightness,in particular all engine bolts and fasteners.

 

[thrstrmech]

check your timing plug while you're at it, mine backed off 'til there was only two threads holding it in and lots of oil streaks

 

[Bad Karma]

On the older harleys, safety wire is the only was to keep your bike on the road for more that 200 miles[up] ....unless you just like wrenching all the time you're not riding.


Thanks for the heads up THRTRMECH!