Question about 2004 Harley Davidson FLSTC - FLSTCI Heritage Softail Classic

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Small oil leak under front rocker box inner

Husband has a '06 H-D Sportster 883, he just replaced rocker box inners and covers - he has a small leak under the inner on the left front corner... Any ideas would be greatly appreciated. Thanks

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Take the rocker cover back off and check the oil breather and make sure the o ring on the bottem of it is still on there

Posted on May 25, 2009

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My 2009 1200L sportster leaks oil out the air filter every 2000-3000 miles.It blows onto my exhaust and higher up. I've had my rocker boxes replaced(warranty issue) THREE TIMES- could this be rela


The problem is the the air breathers inside the rocker covers. Sad to say,but nearly all of them do this. One solution is to take off the air filter cover. There should be two bolts..(one on each side of the inside of the housing) that SHOULD have hoses hooked to them. If they do not have the hoses hooked to them,then that is your problem. See,these bolts are hollow,and have a nipple on the ends of them. These allow the top end to "breathe",a crankcase pressure relief if you will.Anyway,..these nipples are SUPPOSED to have a small hose on each of them,that re-direct the oil/crankcase pressure, into the carb/throttle body,which eliminates the oil running into your air filter housing.Check to make sure they are in fact there,and let me know what you find.

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Hi Anonymous, how about a cheap ($5.50) service manual? Please the website below:
http://harley.manuals.cc/
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1 Answer

My 2003 Sportster is leaking or pushing oil out air filter, my sportster has chrome rocker box covers but none of the rest of the engine is chrome. My mechanic says he has never seen this before.


Hi Anonymous, if it's leaking from the case seams aside from splitting the cases and resealing them is to check the torque on the case bolts 1/4" bolts/nuts 10 ft lbs. 5/16" bolts/nuts 20 ft lbs. for all other leaks the usual suspects are:
1. Loose parts.
2. Imperfect seal at gaskets, push rod covers, washers ect.
3. Restricted oil return line to oil tank/pan.
4. Restricted breather hose to air cleaner.
5. Restricted oil filter.
6. Oil tank/pan overfilled.
7. Bottom rocker housing gasket installed upside down.
Oil leaking from your air cleaner is caused by oil carryover from the engine. For what ever reason the breather system is not seperating enough oil mist and air from the piston downstroke. There are cheap and quick easy fixes and there are more exspensive ones. Start by trying the following:
1. Run your oil level half way between the add and full mark when hot.
2. Run oil breather lines from head into a TEE fitting below carb/induction module then a single line into a mini filter under frame.
3. Purchase Arlen Ness Super Sucker.
4. Replace umbrella valves and realign oil pump
5. Upgrade oil pump and cam plate
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1 Answer

I would like to ontain or find out correct positioning for spacer on rear axle for 1989 883 sportster


Go to this site http://www.bikebandit.com Choose OEM parts and locate your bike and go to wheels and brakes. The brake caliper bracket acts as the spacer on one side and the axle spacer goes on the other side. There may be two small "spacers" that are actually inner races for the wheel bearing seals to ride on in both sides of the wheel.

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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..

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That depends on which gasket is leaking. If it's just a rocker box gasket, it's just a minor problem and if you fix it yourself, the total costs is less than $20. If it's a head gasket, the cost is a bit more and you'll probably want to have that done in a shop, I'm estimating cost about about $200-$250. As far as I know, there were no recalls. The rocker box gasket leaking is more common than the head gasket leakage but neither are what I call major expenses. If the head gasket is leaking, if you rev the engine just a bit when it's cold, sometimes it will pop and you can see fire jump from beneath the head. More than likely, it's just a rocker box gasket leaking.

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Oct 10, 2010 | 2001 Harley Davidson XL Sportster 883...

1 Answer

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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
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1 Answer

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Chances are, it is the cable or connection. Remove the speedo cable from the front tire. See if it turns; this is tough to do, don't sweat if you can't get it done. Remove from the speedo side. The inner should come out from the outer. I would bet the problem is, it is rusted up inside. Chances are good it is no longer in one piece. If it comes out, clean both sides and oil. Compressed air is about all you can do for the outer, maybe a bit of sand to scrape it. If you chuck the inner on a drill motor and CAREFULLY drive it while in the speedo (it will coil up like a slinky and get ruined), you can see if the speedo works.

They sell inners only, but trust me, if it's that bad, buy the whole thing. You'll only gum up & bust the new piece unless you clean the outer well, and it's cleanable with something like a small gun cleaning rod, but it's just not worth the headache.

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