| Author | Message | ||
     Cjmblast |
Hey Guys, I have a small leak and two suggestions what it could be. The first a rocker box gasket and the other is the oil leak overfilled. Is there supposed to be a rubber oil ring on the oil dipstick plug up on the frame where the oil goes in. Someone please help!!!!! | ||
| Ezblast |
No o - ring - must be the dreaded rocker gasket - if yours is a real early 2002 it may have had the paper - GT - JBOTDS! EZ  | ||
| Cjmblast |
What is the procedure ?? Is there enough room to get the rocker box out without dropping the engine ?? CJM | ||
| Blake |
CJ, See the online S1 service manual in the Knowledge Vault. It will give you a good idea of what is involved. Thanks for the poster. Blake | ||
| Ezblast |
Hints: a)Aaron's post half way describes generally what you meed to do http://www.badweatherbikers.com/buell/messages/20164/10044.html b)Fssnoc2501 very specific procedure for what you have to do to get to rocker box (this all assumes you will remove the tank - lol - comments following are insightfull also) http://www.badweatherbikers.com/buell/messages/20164/14967.html Manual picture and comentary on instalation starting with Newfie - http://www.badweatherbikers.com/buell/messages/3842/10583.html SportieEric - 1/2 way down - torque specs http://www.badweatherbikers.com/buell/messages/3842/9388.html c) S-1 service manual http://www.badweatherbikers.com/buell/Manuals/S1_1996-1997_Service/intro.pdf Remember letter side up on the gasket - the Blast service manual should walk you through the rest, however, if you use the S-1 manual remember that they have several parts to their rocker box while ours is one piece - only real difference though. Hope this helps! Got Thump?! Just Blasting on the Dark side! EZ  edited by ezblast on August 25, 2003 | ||
| Blastin |
Chris, I have the service manual if you need it. I also have tools if you need them. Jerry | ||
| Cjmblast |
Thanks for the info guys, and thanks for the offer Blastin. You saw the oil sprayed over the bike at Uke's and I know it's probably a rocker box leak. But I did talk to someone who said it appears to be leaking down from the plug where you fill the oil, and there was oil beaded up there all nasty and down the front of the fairing. He said that oil won't blow upwards from below and you trace the oil leak up and he firmly seemed convinced that if I removed some oil, clean the bike up, it should cure the problem. Of course those that think it's a rocker box leak feel just as strongly. I posted the question above obviously from someone who said it was the rocker box, because that person doesn't post here. So no, I haven't suddenly become knowledgable about wrenching or anything. Bottom line is I DID overfill it, seems when the dipstick says fill between lines that's what it means not above. My brother-in-law removed some oil and said it was for sure too full, and we cleaned it up. However, it's possible I have two issues going on, an overfill but still a rocker box leak too. After draining oil and cleaning the bike I rode it 42 miles and there is still oil that sprayed, but in a smaller area around the shifter peg and not the front or other side and a very small amount. But that could happen as I put on more miles. So at this point, because if I'm bikeless through this next week I will not be a happy camper, I'm going to continue riding it and see if it's still getting worse then park it until I get it fixed. But I'm hoping that possibly it's just some left over oil that we couldn't get washed off that might have sprayed afterwards. Or hey my post could just sound like a dumb girl who doesn't have a clue about wrenching and I don't, but like I said I had two different opinions and really WANT to believe it's not the rocker box !! I've looked forward to riding my bike in the 100th celebration for so long, being from Arkansas my whole life !! But I do have several friends who've offered to let me ride with them, so it's just a matter of like I said, I'll ride it until the oil keeps leaking then just put it up until next week !! I'm frustrated !! CJM | ||
| Blastin |
CJ, If you have time, bring it over tonight or tomorrow and we'll clean it up really well. I have some good bike wash that will help. Also check you air box/air filter. If it was overfilled a good indication would be a bunch of oil sitting in your air/box. What year is your bike 2001 or 2002? As a reference, I keep the oil on my bike at the very bottom of the dipstick(even below it) when it is checked HOT. It is VERY important that the oil be checked HOT. If you fill the oil to the mark when cold, you will get oil coming out of the breather into your airbox and then sprayed/leaked all over. And if you had a bit of trouble putting the oil in the hole when adding oil it WILL drip down the frame as well as everywhere else.(Don't ask me how I know that one  ) Solution: add a bit of hose to a funnel and walla! I can help you out with that one as well.(Just don't tell my wife your coming over for a bit of my hose!! There is something definetely wrong with me today Jerry | ||
| Cjmblast |
There is something definetely wrong with me today Someone has stolen Jerry's username !!! Blastin, e-mail me your address again and I'll do a mapblast search and give you a call, will see if I can get over there. Work is kicking my a--, gotta get caught up to be off again !! CJM | ||
| Ezblast |
A nice shortcut discovered at the group - better than a total disassembly - here goes! PLEASE READ the manual and follow that rather than me but this is what I did... Seat off Tank cover off Tank off. Spark plug out. Get engine at top dead centre on the compression stroke (both valves closed) Take black breather from the top of the rocker box. Undo bottom front engine mount at engine Undo top right engine mount at frame. Look at the top front of the engine and you will see the rubber mount with two bolts either side... WITHOUT taking then right out undo them a bit at a time either side until the engine lowers enough to get the top rocker cover off. You should have the nut off the top of the thread about 2mm to make the cover come out ok. Undo the 4 cap screws holding the top rocker cover on... Remove out to the LEFT of the bike. Note: the three smaller bolts holding the rocker box on have small washers under them MAKE sure you don't drop one down the pushrod tubes when taking the bolt out! Now remove all the bolts and cap screws holding the "rocker box" doing each one a little at first until the pressure is off the box. Lift it off. Clean all the old paper gasket off... without cutting the surfaces. Put new metal gasket on with a little gasket sealant on each side. make sure everything is clean and NO old gasket is in the rockerbox or the top of the head. Fit the rocker box back on MAKING sure the tops of the push rods locate correctly. Slowly "pull" the cover down by keeping the gaps the same and slowly tightening down all the bolts. Do them to the torque settings and sequence in the book... or like me make them tight. Fit new rubber rocker box cover gaskets and refit that. Tighten it down Put the breather back in. slowly, a bit at a time lift the engine back up using the two bolts you undid to lower it.. re fit the two other engine mounts,,, you might have to move the bikes engine a bit to do that. Standing it vertical was enough to locate the top one and my foot pushing the engine across was enough for the lower one, Then put the rest together and ride off leak free!! Simple?? Thanks Gavin - remember letter side up and skip the chemical part of his procedure - more likely to harm than help - unless you really know what your doing - lol GT - JBOTDS! EZ  | ||
| Hogluvr |
Hey Guys, My wife's '01 Blast started experiencing the dreaded rocker box leak last week. I called the dealership & asked them if they had the gaskets to fix it, the guy said yeah, it would be about $15. I went over there after work, the guy I talked to was busy, so he had another guy look up the stuff. The guy came back and said that everything was in a kit. When I went to pay for it, it turned out to be $40 and some change! I looked at the kit, it says rocker cover gasket kit for XL's, so I asked the guy since this was a Sportster kit if this had gaskets to do 2 sets of rocker boxes. He said no, it was just for one. Did I get taken? I find it hard to believe that Harley would sell a gasket set to do just one side of a Sportster. The p/n is 17036-91, can anyone tell me if this is double what I need, and what exactly is in the kit? I'm not gonna open it until I know for sure, and if I have to take it back, it's gonna look kinda brown when I stick it where the sun doesn't shine for having to make another 40 mile round trip to take them back!  Thanks, Mike | ||
| Xgecko |
you can try this number...it's listed in the direction with my proseries cams 17055-00YA and the nomenclature is "Gasket Kit, Top Overhaul" I got the same part number that you have from when I asked here. but since the one above is listed on the instruction sheet I'm gonna use that one | ||
| Gearheaderiko |
Thats the right kit for a Blast as listed in the Official Parts Catalog. Should contain only 1. | ||
| Hogluvr |
Thanks guys, Looks like I have the right one, guess I know what I'm doing this weekend...  If anyone has any tips or suggestions to make this thing go smoother, I'd sure appreciate it, gettin' into something I've never done before. | ||
| Gearheaderiko |
I thought HD/Buell was doing the rocker cover gasket for free? Follow the manual. One of the cover bolts is really a tight fit between it and the frame. To get it in or out (there is a special wrench) you'll probably need to use an allen 'bit' (short allen bit that fits into a socket attachment) and a wrench on it to turn it. Pay attention to how tight the other bolts are when you torque them-I dont think there is a way to get any kind of torque wrench in there. | ||
| Ezblast |
Offset crows-foot socket | ||
| Gearheaderiko |
In 3/16" ? Never seen one that small. | ||
| Hogluvr |
Is this a warranty issue? Hadn't heard anything about it (although I've been off this site awhile), I'd better check into that B4 I start tearing her down!! | ||
| Jackbequick |
I cut several short pieces off of a 3/16" Allen wrench, just tall enough to stick out of the socket 1/4" or so. Then I would use a six point, box end, ignition wrench on that to tighten the hard to get at ones. I torqued those using a pain level calibration instead of inch/pounds. I'd hook the wrench onto the one that was torqued almost right, hook one finger around it, pull, and take note of the pain level when it just budged. Then I'd move over to the unapproachable one and tighten until I experienced the same level of pain. I'll bet they are right on the money, we never fail to find an appropriate level of scientific endeavor in my shop. And it is a little extra work, but I'd ride that a few times and then re-torque the cover bolts again. Mine pulled down a fair amount when I did that on the M2 and also on my FXD but they never leaked again. Retorqueing any and all of the primary cover, cam cover, etc., screws is a worthwhile endeavor. My garage floor has not accumulated its first drop of oil yet this riding season and last year it was several drops after every ride. Jack | ||
| Gearheaderiko |
"Retorqueing any and all of the primary cover, cam cover, etc., screws is a worthwhile endeavor." Excellent advice! I do it as a matter of post race service/check over, definitely beneficial on a street bike. | ||
| Hogluvr |
Thanks guys, I called two dealerships today to ask if this was a warranty issue, the one I bought the gaskets from said "I dunno, call back next week & talk to the service manager", the other said definitely not! So it looks like it's gonna be a long night tonight!! | ||
| Swampy |
For the record, is there a short and a long(intake and exhaust) push rod or are they the same? | ||
| Gearheaderiko |
Yes. They are two different lengths. Intake is shorter. (Message edited by gearheaderiko on June 11, 2007) | ||
| Swampy |
Thanks, thats the rear one right...LOL! | ||
| Gearheaderiko |
Motion Pro makes a special rocker cover wrench that has the fitting to attach a torque wrench (for those so inclined for accuracy on the one bolt thats difficult to get to). http://www.motionpro.com/motorcycle/tools/rocker_b ox_cover_wrench/ (a ratcheting wrench is also available) | ||
| Buellistic |
"i" made up my own special tools for TORQUEING the rocker arm bolts and allen screws ... That tool is "BUELLschitte" !!! In BLASTing LaFayette | ||
| Ezblast |
Show us the tool you made and how you made it - please. GT - JBOTDS! EZ | ||
| Milt |
The manual says to "Rotate crankshaft until piston on head reaches top dead center of compression stroke". It notes (in italics, no less) "Both valves in the cylinder head will be closed when viewed through the spark plug hole". I'm having a difficult time seeing into the spark plug hole. Is there another procedure for insuring that the piston head is at top dead center? | ||
| Gearheaderiko |
Remove the timing plug just below the cylinder and look for the line cut into the flywheel. That is TDC. See the section in the manual under 'timing'. That'll show you the plug and TDC timing mark. That mark will mean your at TDC of the compression stroke or 180 degrees out (or 1 full turn of the crankshaft). If your removing the exhaust, you can see exhaust valve move and you'll know whether you've got TDC on the compression stroke or not. Valves open mean your on the wrong stroke. If the carb is off you can also look through the intake manifold and watch the valve open and close. If the top rocker cover is off you can see the valves open and close. This might be difficult to do with the engine dropped (but not impossible). If you follow the procedure on static timing that will give you TDC on the compression stroke (the LED comes on and off at TDC on the compression stroke). Sorry, at this hour I'm not coming up with any other easy ways. Hope this helps. | ||
| Swampy |
With the back wheel up and the transmission in gear. Timing plug out, spark plug out, rotate the rear tire and with a finger over the spark plug hole you will feel air coming out of the hole and if you put your finger tightly over the hole you will feel pressure, then look for the TDC mark in the timing hole. or... With the rocker cover off, you can follow the movement of the rocker arms up and down, what you are watching for is the upward movement of the intake valve, then watch for the TDC mark aligning in the timing window..... |
