| Author | Message | ||
     Wbrisett |
I noticed my '07 spraying a bit of oil last month. Since I had a 15K service coming up and it wasn't bad, I didn't worry too much about it. Turns out it was the rocker box leaking. Apparently this is a very common thing in Sporties. I'm curious if others have seen this. (At least on the sportster and Dyna you don't have to drop the engine to get to the gaskets). Wayne | ||
| Hughlysses |
Not really common on later Buells but certainly not unknown. The factory changed from paper gaskets to Cometic-type (rubber coated aluminum) gaskets around 2002 and these usually hold up much better. The gaskets may have been improved further since then. I had the rear rocker gasket go out on my Uly but I'm pretty sure it can be blamed on a bad #77 connector. Bad connector resulted in no charging resulted in no fan operation under hot conditions when the battery finally discharged and the bike died. This happened a couple of times before I diagnosed the connector so the engine had a couple of good hot-soaks. The gasket started leaking shortly afterwards and was replaced under warranty. It hasn't given any problems since. Future replacements (if necessary) are something of a PITA but it's not a hard problem to diagnose and the gaskets should be available for years to come since they're available aftermarket. | ||
| Wolfridgerider |
I'm getting ready to rotate my engine...  | ||
| Florida_lime |
I'm on my 3rd rear rockerbox seal.... | ||
| Crackhead |
You don't have to rotate the motor to change the rocker box gaskets on the Blast.  | ||
| Longdog_cymru |
The question is "why"? What's the reason for the rear rocker cover to leak? Is there any difference to those that have modded the breather system to exhaust to atmosphere? I know it's an emissions thing, but putting used gasses back into a motor is just wrong, so I was wondering if motors with modded systems have less tendency to leak. | ||
| Hughlysses |
You don't have to rotate the motor to change the rocker box gaskets on the Blast. Nor on a tuber. It's a good question why some people are having repeat failures. I wouldn't think the breather system would cause the problem. If anything I'd think the breather mod (at least where a filter is used) puts slightly more restriction on gases exiting the engine and therefore would be more likely to cause the gaskets to leak. Scott- any ideas on your bike? | ||
| Florida_lime |
"They all do that "  No idea. No breather mods. FYI - The leak took out the fan each time -- the first time, the fan quitting was my first clue about the leak. The second time, I found the leak, and the fan quit the day I brought it in for the appointment. | ||
| Wbrisett |
Here is what a co-worker of mine who rebuilds sporties for fun, sent me on the WHY... ----------- If it leaks between the lower rocket arm cover and the head then it's usually caused by some warpage in the lower rocket cover. They are 3 piece units on the Sporty, not sure on the Buell. The key is to smooth the lower cover out by sanding on a flat surface like a flat plate or a piece of glass and emery cloth for us garage mechanics. Also the new metal gaskets that HD makes now are pretty good. They used paper ones before. -------------- Of course this may not apply at all to the Thunderstorm engine, but I'm not sure Buell did much to change the rocker box area. Wayne | ||
| Endoagain |
I replaced my rear rocker box cover gasket myself for my second leak. While wiping off the residual oil in the rocker box channel for the gasket, my rag got snagged on some flashing at the back edge of the rocker box right where the leak was coming from. Turns out the inner lip of the rocker box that forms the channel for the flexible rubber gasket was not finished smooth on top. It was only a matter of time before that rough surface let oil past as it would not mate properly with the rocker box cover surface. Sanded it smooth 10K miles ago and all is well. My bet is my rear rocker box was not the only one with a finishing defect like that. You will not notice it unless you run your finger over the surface to see if it is smooth. | ||
| Two_buells |
Of course this may not apply at all to the Thunderstorm engine, but I'm not sure Buell did much to change the rocker box area I changed my 99 S3 Thunderbolt to XB style rocker box covers. only a two piece and better breather system. There was a thread posted about it a few years ago. | ||
| Wolfridgerider |
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| Blasterd |
my 09 with 1054 miles is misting at both rocker covers and at the lifter cover. It also has a left front fork seal leak. | ||
| Wbrisett |
Yep, Wolfridgerider that's pretty much the mess my '07 Uly looked like as well. At least I know I'm not alone in having my bike spring a leak.  | ||
| Hughlysses |
I guess I was lucky when mine failed. I noticed an oil film at the fan outlet and investigated. Had it repaired under warranty shortly afterward. My original fan still going strong ~10,000 miles later. | ||
| Wolfridgerider |
When the service manual say to remove the spark plugs and rotate the motor until the valves are closed on the rocker box you are working on... does that mean do it by bumping the starter? makes sense to me... but I want to be sure. | ||
| Crackhead |
I have never understood why the rocker box was not part of the head with just the rocker box top removable. | ||
| Hughlysses |
Mark- if you've got the plugs out, the easiest way is to put it in 5th gear and turn the engine using the back wheel. There were lots of discussions on this job in the tuber forum. Evidently it's possible to find a position where all four valves are closed so you don't have to move the engine once you start the job. | ||
| Wolfridgerider |
Thats gonna be a hard one to do... not impossible but very difficult I have the motor rotated with the bike secured in a front wheel chock... gonna need to do some head scratching... | ||
| Etennuly |
Take the cover off the front belt pulley, put big socket on it with trans in fifth gear, it should be easy to turn with the plugs out. | ||
| Wolfridgerider |
what about the rear tire sitting on the garage floor?.... didn't think about that now did ya? I'm gonna need another jack.... | ||
| Etennuly |
Duh, take the belt off! | ||
| Hughlysses |
I'd imagine bumping it with the starter will work. It just may take a few tries to get it to stop where you want it. | ||
| Wolfridgerider |
Duh, take the belt off now you are just wanting me to take a bunch of crap apart.... LOL I'm already pissed I had to go to sears and buy a Hex set for 39 bucks just to get the T-45 with the hole in the end of it to take the headlight nacelle off so I could get the cables loose... | ||
| Florida_lime |
If you have any rear lift bike stands, or even jack stands, you can put a bar through the rear axle and lift the rear tire up with that. | ||
| Etennuly |
Mark, so like you didn't have a good pair of vise grips?   I'm sorry.....you are making this too easy!! | ||
| Wolfridgerider |
DUDE!! you know my wife is a lurker here... don't be giving away my excuse to go tool shopping... | ||
| Wolfridgerider |
and while we are on the subject.... why in the hell would they use that type of fastener? | ||
| Etennuly |
To make sure people like you don't mess with it! sorry about the wifey thing  | ||
| Sekalilgai |
Mark Bet it's a good looking set though! FWIW here's another source for that stuff (not that it is any cheaper) http://www.wihatools.com/700seri/701_TRsockets.htm you could've gotten the one T45 for $8 and paid $30 in shipping....  |
