Question about Harley Davidson FLSTF - FLSTFI Fat Boy Motorcycles

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Rocker Cover leak

I have a 2002 Fat Boy with 18,000 miles. I am noticing some oil spray on the oil tank and after closer inspection, see that the rocker covers have a small amount of oil around where they connect. Would this be a problem with the gaskets? How many gaskets normally need to be changed? Are there also gaskets at the base of the cylinders? If so,should they be changed at the same time? What would be the normal maintenance for this type of problem?

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The fasteners should be checked for correct torque/retorqued every 5k miles. At this mileage you shouldn't have leakage if this maintenance was done, so it likely was not. Start by doing the maint. here is the tech bulletin with instructions: TM1132 . There are gaskets/o-rings, also at the cylinder bases. If your performance is fine and retorquiing doesn't take care of leakage, just do the top end gasketing, not the cylinders. It is not difficult but you will need a tech manual.

Posted on Apr 05, 2014


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Posted on Jan 02, 2017

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SOURCE: Small oil leak under front rocker box inner

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

  • 4565 Answers

SOURCE: replace rocker cover gaskets on 1990 fxr

To replace the upper rocker box gaskets is not too difficult. But, if you're replacing the gaskets between the head and the lower plate, this gets a bit more involved. You must remove the fuel tank as well.

To replace the top gaskets, simply remove the four bolts and lift the top and middle plate off the lower plate. The left rear bolt on the rear cylinder is the toughest bolt to get out. Sometimes there is a hole drilled in the frame to make access to this bolt easier. If not, you'll have to shorten a hex key wrench in order to get it out. With the top and middle plates our, replace the "umbrella valve" in the middle plate making sure you put it in from the correct side. Now place the outer gasket in the lower plate, the outer and middle gasket in the middle plate and set the top plate down on them. Wiggle the plates around a bit until you get them lined up properly with each other and tighten the top four bolts down a little at a time one each bolt until they're all tight. Torque to 80 inch pounds.

If you're going to remove the lower plate, first bring the piston of one cylinder up to top dead center on the compression stroke. Remove the spark plug and rotate the engine until both valves are fully closed. Remove the air filter assembly and backing plate. Remove the large bolts on the right side of the rocker arms Slide the rocker arm shaft out of the rocker arms one at the time and remove the rocker arm and it's pushrod. Notice that the rocker arm shaft have a recess ground into them. This is so the 5/16" acts as a lock to hold the shaft in place. It must be realigned on reassembly of the rocker plate. Once you get all the rocker arms and pushrods removed, you should have the pushrod tubes out as well. Remove the rest of the bolts and lift the lower rocker box plate. Clean the bottom of the rocker box plate and top of the head.

Assembly is the reverse of disassembly. Make sure you don't get the pushrods mixed up as they are all four of different lengths and will only work properly in their correct postitions. They are color coded for their proper positions. There is no adjustment of the pushrods.
Front intake --- YELLOW
Front exhaust -- GREEN
Rear Intake --- BLUE
Rear Exhaust --- PURPLE
Lower rocker box torque values are: 5/16" bolts 15-18 foot pounds
1/4" bolts 10-13 foot pounds

Posted on Feb 14, 2010

  • 632 Answers

SOURCE: Could you please explain exactly how to change the

BOth sides of crank case gets oil in em its normal for the skyjet engine
To change oil Locate the 17MM bolt under the engine near the front of engine, Unscrew and Let the oil drain for about 1 hour
Then Put bolt back and tighten properly, Then Add approx 1.6L of 4 stroke Motorbike oil

Posted on Jun 24, 2010

  • 4565 Answers

SOURCE: how to install rocker cover

To replace the rocker box gaskets, you'll have to remove the bolts on top of the rocker boxes to get them off. You may have to remove the fuel tank(s) and seat. You didn't tell me what year and model bike you're working on. Once you have these bolts off, you can replace the gaskets between the center and the upper parts, the inner gasket and the umbrella if your bike is equipped with them.

To replace the gaskets under the lower plate, work with one plate at the time. Remove the spark plugs and jack the rear wheel off the ground. Put the transmission in high gear and bump the engine over until the piston is at top dead center in the cylinder your working on with both vavles closed. Start by removing the three 1/4" hex head bolts and the two 1/4' socket head bolts. Then, remove the 5/16" bolts on the pushrod side of the engine. Tap the rocker shafts out and remove the rocker arms. Remove the other two 5/16" bolts. Lift the lower plate and replace the gaskets. Do not mix up the pushrods. They are usually color coded as to which position they go in.

To reinstall the lower plate, place the rocker box on top of the cylinder and start all bolts except the two 5/16" bolts on the push rod side of the engine. Put the rocker arms in place and push the shafts through them. Start the remaining two bolts. At this point, your lower rocker box plate is "floating" above the cylinder head. Tighten the four large bolts down until they are all flush with the top of the plate. Then, tighten them down 1/4 turn at the time until they are snug. Then, tighten the six smaller bolts down until they are barely snug. Torque the larger bolt to 15-18 foot pounds and the smaller bolts to 10-13 foot pounds. Wait for the tappest to bleed down to where you can turn them by hand to do the other cylinder. Do it the exact same way as you did the first one.

To install the middle and upper plates, put the center gasket and all other gaskets in place and align the plate. Install the socket head bolts in the top and torque to 100 Inch pounds.

Put the transmission in neutral and lower the bike. Reinstall the spark plugs, the tank(s) and the seat.

Good Luck

Posted on Sep 05, 2010

  • 4565 Answers

SOURCE: I have a 1996 fxdl

If you'll remove your inspection cover and the derby cover as well, look on the backside, you'll probably see that the bolt holes have been "pulled" through on each bolt hole. The raised backside of the bolt holes holds your covers up just slightly allowing oil to creep underneath the gasket.

Now, you can do three things. Replace the covers with new ones or use a large smooth file, lay it flat on the backside of the covers and file the "pulled" through areas down level with the rest of the cover, or apply a generous amount of RTV to both sides of the gasket. On the Derby cover, Harley now offers a solid disc type gasket for this application. I use both the solid disc and the original O-ring on the derby cover.

Good Luck

Posted on Oct 08, 2010

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How to replace umbrella valves 1998 fatboy

This is fairly easy on the Evo engines.

Remove top of rocker box cover.
Ease up old valve (not a good time for gorilla tactics here), being careful not to pull valve off of stem, leaving stem in the hole.
A little spritz of WD-40 down the stem might help.

Position new valve stem into hole, push down on center of valve until stem pops into hole.
If difficult, a dab of oil might help.
After insertion, GENTLY pull up on edges of valve to make sure stem stays in hole.

Replace rocker box top cover, repeat for other rocker box.

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Could just be fair wear and tear, Ticking noises can be worn rocker arms but unusual on TC. If bike is well maintained and proper oil services done then wear should not be the problem. Use a steatascope to pinpoint the noise. If lifters are the problem, then noise will be loudest on lifter covers. Lifter roller bearins do fail on TC's.

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I am switching from syn oil to reg hd oil on a 1992 flstf. Do I need to drain the engine case? If so, where is the plug located? Is there anything else I need to be aware of? THANKS

I would purchase a Harley Davidson repair manual or get one on CD from ebay not as much as a paperback and just as good. The repair manual is a mechanics best friend. Remember buy one it is the best friend you can have when doing maintenance on you harley.

The drain plug can be hard to find. In the 2001 Fat Boy, it is in front of the back motorcycle tire between the Fat Boy's rear shocks.

To do the oil change you need to warm up the oil so it drains better.

Tilt the motorcycle to its right side and position your oil catchment container under the oil plug.

Use your wrench set to unscrew the oil drain plug. In a 2001 Harley Davidson Fat Boy, you need a wrench that will fit a 1/4-inch screw.

Drain the oil. While oil is draining from your Harley Davidson, use the time to clean out the magnet and rubber ring positioned under the oil drain plug.

Remove and replace the oil filter after the oil has drained. Refill with 3 to 4 quarts of engine oil. Replace all parts, including drain plug.

Remember the HD manual will tell you how to check the level of primary fluid needed. Each HD is different and needs different amounts.

You check your primary fluid level through the inspection cover, which is the oval cover in the middle of the primary cover. You'll need a T25 Torx wrench to remove the bolts. Have a new inspection cover gasket in case you need it.

Add the fluid through the inspection cover. You can use any kind of oil petroleum or synthetic as long as it does not contain friction modifiers.

replace the gasket on the inspection cover if needed. Tighten bolts finger tight; then tighten the bolts at 10 foot pounds. Start with the top bolt and then tighten the bottom bolt. The third bolt is the right one, and the left bolt is last.

Mar 02, 2011 | 2001 Harley Davidson FLSTF - FLSTFI Fat...

1 Answer

2002 hd fat boy 1450 kiryakin air filter vince hines 2in1 pipe 16000km my problems is on the left side on both top valve cover theres a clicking noise coming from there more likely when the engine warms up...

What you're hearing is the rocker arm opening the valves. This is normal operating noise.

Your Harley is an older design pushrod operated engine. Unlike most other motorcycles engines, Harley does not use overhead cams in any of their bikes other than the V-Rod. Additionally, there is no sound deadening material inside the rocker box covers. Although the engine is equipped with hydraulic tappets, there is a bit of running clearance in the rocker arms and their shafts they run on.

In short, this is not unusual and your Harley will run for many miles. If you can hear that clicking, it sounds like you need to take the baffles out of that V&H pipe.

To see a diagram of your engine, go to , click on OEM and choose your bike or any Big Twin of that year.

Good Luck

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Normal Maintenance Details
90,000 Miles (144,000 Kilometers) : All Applicable Models


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How do I change the oil on a 2002 fat boy? Where is the drain plugs?

On the fatboy, the oil drain plug should be on the right side, just under the frame, directly below the oil tank. The primary drain is on the left side under the derby cover on the bottom. The tranny drain is on the bottom towards the rear pretty much centered.
And, as our darlin' little miss piglet said, a maual is worth the investment.

Jun 28, 2009 | 2003 Harley Davidson FLSTF Fat boy

1 Answer

How to change oil on 2002 fat boy

The drain plug is a hose that comes down to a sprung clamp on the frame behind the gear box on the right side of your bike. Remove from clamp then undo the screw-ring round the hose to allow the plug in the hose to be removed, take lid off oil tank and turn engine over a coupla times to clear engine oil into drainage tank. Replace plug- etc before refilling with half the oil, turn engine over coupla times then add remaining top up oil. Drainage for your primary oil is at the rear inside near the gasket joint and can be removed with a Hex spanner, taking the large outside cover off your primary with star drive sockets to allow airflow for drainage and then to pour new oil in through after replacing drainage plug in the bottom. Buy a Manual Mate, its worth it eh considering the value of your bike?

Jun 18, 2009 | 2003 Harley Davidson FLSTF Fat boy

1 Answer

Finished about a 300 mile ride was pulling into the garage and noticed that gear oil was pouring out the left side of the bike


Sounds like your gear box is wounded... actually, its possible excessive gear box oil is comming out the vent. Check the gearbox oil level before your next ride and check for leaks.

Cheers, Jay

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