Rear rocker cover gasket is leaking - 2002 Harley Davidson XL 1200 S Sportster Sport

remove the transmission , flywheel or torque converter
not an easy job and will requires expert training for a satisfactory job
are you positive that it is the rear oil seal and not
over full sump
leaking sump gasket at the rear
rocker cover gasket leaking down to the sump rear
transmission oil seal leaking

When you replace the rocker cover gaskets, clean the surfaces where the gasket contacts the heads and the rocker cover with alcohol and a rag. Make sure there is absolutely no oil residue on either surface. Use a silicon sealer and spread it on the side of the gasket that will touch the head. Position it and use the head bolts temporarily as guide pins to hold the gasket in place until the sealant dries COMPLETELY. Remove the bolts. Now put more sealant on the surface of the rocker cover and install the cover on the gasket gently so as not to disturb the gasket. Install the cover bolts and tighten firmly but not so as to squeeze or deform the gasket. If dine correctly, the gasket will not leak.

The rocker cover will leak oil..............

1. If the rocker cover has been damaged due to poor mechanical fitment and is no longer perfectly straight; or
2. The rocker cover bolts are not torqued evenly at the correct ft/lbs specification; or
3. If the rocker cover bolts have been excessively torqued in which event the cover will distort and the gasket will be excessively compressed; or
4. The gasket is in poor condition and needs to be renewed; or

5. The gasket fitting is sloppy done in which event you can assume the cover will not have been properly fitted either.

I would be buying a new rocker cover (or a straight used one) before doing the next repair because your original is probably deformed now and will likely never seal properly.

Bettr fix cover..gut a compression leak..inspect whole vehicle. Ignition tune and leak test on injectors if need

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.

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

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..

The rocker cover gaskets, they shrink up over time and leak, usually the rear drivers side on a V6 or V8 is the first spot. You can try tightening them up and stopping the leak, it is the cheapest route to take, but you will probably have to replace the cover gaskets, they do not come off easily. You have to remove the intake, most of the time. Then pull the covers, replace the spark plug seals, then the rocker cover gaskets, put it all back.Use no sealer to put them back on. No more leak. Hope this helps.

pull the valve cover gaskets, clean them and replace them, there is no cheater way to do this. To pin point leak you'l need to look closely at the covers if oil is running down the sides towards front or back of motor (theres 2 covers, one front, one rear) if it is, you may be able to tighten bolts, but be careful not to strip them. If they are tight, youl need to change the cover gaskets

Use a film of gasket sealant on both sides of the new gasket when you replace it. When installing the cover, make sure there isn't any wiring or anything that could get caught under it.