Question about 2004 Harley Davidson XL 1200 C Sportster Custom

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Rear rocker box leak on 2004 sportster XL 1200 C

Rear rocker box is leaking with new gaskets

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  • Harley Davidson Master
  • 448 Answers

It's possible one of the gaskets got pinched, or one of the cover pieces is warped. Either way, it's gonna have to come apart again to fix it.

Posted on Nov 19, 2013

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Posted on Jan 02, 2017

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SOURCE: How to replace stock rocker boxes with new chrome

if you prefer you get a Clymer's Repair manual that will give you exact torque specs

Posted on May 03, 2009

wd4ity
  • 4565 Answers

SOURCE: 2001 h-d sportster 1200 custom--torque specs for

5/16" bolt - 15-18 foot pounds
1/4" bolts - 10-13 foot pounds
Upper rocker cover bolts - 10-13 foot pounds.

Posted on Jun 12, 2010

Testimonial: "Very helpful and Quick---------Thankyou !"

wd4ity
  • 4565 Answers

SOURCE: replace rear rocker box gasket

Replacing the silicone gaskets between the rocker box cover is not that difficult. Simply take the bolts out and lift the cover off, replace the gasket, put the cover back on with the bolts loose and line them up correctly. Then tighten the bolts to about 80 - 100 inch pounds of torque.

If the leak is coming from below the lower rocker plate where it mates with the head, this is a bit more difficult and I'd suggest taking the bike to a repair shop. However, if you'ver mechanically inclined and have the tools, even that is a job that can be done by an amateur mechanic. If this is the case, please ro-post and I'll tell you step by step what you need to do to replace the gaskets beneath the lower rocker plate.

Good Luck
Steve

Posted on May 03, 2011

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1 Answer

Replace rear rocker box gasket on 2001 1200 sportster


Replacing the silicone gaskets between the rocker box cover is not that difficult. Simply take the bolts out and lift the cover off, replace the gasket, put the cover back on with the bolts loose and line them up correctly. Then tighten the bolts to about 80 - 100 inch pounds of torque.

If the leak is coming from below the lower rocker plate where it mates with the head, this is a bit more difficult and I'd suggest taking the bike to a repair shop. However, if you'ver mechanically inclined and have the tools, even that is a job that can be done by an amateur mechanic. If this is the case, please ro-post and I'll tell you step by step what you need to do to replace the gaskets beneath the lower rocker plate.

Good Luck
Steve

May 03, 2011 | 2001 Harley Davidson XL 1200 C Sportster...

1 Answer

Rear rocker cover leaks when sitting in garage . and not when riding.


I would replace rear rocker gaskets, oil is pooling in this area when off. while in there replace umbrella breather & small filter if it has a filter some did .. good luck..

Apr 08, 2011 | 2000 Harley Davidson XL 1200 C Sportster...

1 Answer

Have a oil leak top left side off head on 2008 sporster1200.need to know how to change it and the tork settings. Thank you


I have just finished a reseal on my 2000 XL stage I conversion (883 to 1200) and it sounds like you may have a rocker box gasket leak. Which ever it is I need to tell you that there are helpful postings on the web but without following the procedures in the manual, you can do serious and expensive damage starting with the losening order of the head bolts (I had two broken ones, one in each cylinder when I thought I was only doing the rocker boxes). I am glad I invested in the manual and In hindsight, I wouldn't spend double on the gaskets at the Harley Dealer, you can get a whole upper end set for half on ebay.

Mar 17, 2011 | 2006 Harley Davidson XL 1200 C Sportster...

1 Answer

Rear rocker cover gasket is leaking


No problem except that the a couple of the bolts that hold the rocker cover on are pretty close quarters. Simply take the four bolts out and replace the gaskets. Make sure that you get the middle and top part properly aligned before tightening up the bolts. Torque is 100 inch pounds.

Good Luck
Steve

Feb 28, 2011 | 2002 Harley Davidson XL 1200 S Sportster...

1 Answer

My front rocker box is leaking oil


Simple fix. Take the fuel tank off and remove the four bolts that hold the rocker box covers on. If the rocker box is leaking there, simply put a new gasket in place, carefully align the top plate and put the bolts back in. Torque them to 100 inch pounds.

If the lower rocker is leaking remove the smaller 1/4" bolts and then remove the larger 5/16 inch bolts. Remove the larger bolts a turn at a time until they are completely loose. Lift the lower rocker plate and replace the gaskets. Reposition the lower plate and align the pushrods in the rocker arms. Do not mix up the push rods, mark them if necessary. Tighten the 5/16" bolts down evenly until just seated. Then put the 1/4" bolts in. Torque the 5/16" bolts to 15-18 ft. lbs and 1/4" 10-13 ft. pounds. Reinstall the middle and upper rocker boxes and torque those bolts.

Good Luck
Steve

Aug 24, 2010 | 2000 Harley Davidson XL Sportster 883

1 Answer

2001 h-d sportster 1200 custom--torque specs for rear cyl rocker box assy


5/16" bolt - 15-18 foot pounds
1/4" bolts - 10-13 foot pounds
Upper rocker cover bolts - 10-13 foot pounds.

Jun 12, 2010 | 2001 Harley Davidson XL 1200 C Sportster...

1 Answer

Oil leak out of front cylinder between cyl.head and top


sounds like a blown rocker cover gasket,its quite common,although you may have a warped rocker cover thats quite common on Harleys as well,order a new gasket,which you'll need anyway,while you've got the rocker cover off check for warp with a straight edge.if the cover is warped order a new one, Harley were recalling a few bikes not long ago to replace the same thing,but l think they were around 04-05 sporties cant be sure.

May 14, 2009 | 2000 Harley Davidson XL 1200 C Sportster...

1 Answer

Leaking stroker boxes on 2001 883 hugger


I think you are referring to "rocker boxes" on your Sporty. Replace the rubber gaskets between the lower plate and the upper plate. If the lower plate is leaking, you will have to remove the lower plate with the rocker arms and the push rods.

Apr 24, 2009 | 2001 Harley Davidson XL Sportster 883...

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