Rocker box gasket replacment - M2 Cyclone Buell Motorcycles

Rocker arms have to be removed, BUT newer push rods are NOT adjustable, so you just can't loosen the push rods.

On the cylinder you're working on, BOTH valves MUST be closed.
EVENLY loosen rocker arm mounting block bolts, a little at a time.

Also, IF you remove the push rods, they are different lengths, so pay attention which one goes back where!

To change the rocker box gaskets, simply take the bolts out of the top of the rocker boxed. You'll probably have to take the tank off to get to the bolts and there should be a hole in the frame to get the left side rear bolt out of the rear cylinder rocker box. Replace the "umbrella valve" in each center section while you're in there. Bolts torque to 100 inch pounds.

Good Luck

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

You probably haven't done anything wrong, it's just you've got an oil leak from your rocker boxes. Remove the fuel tank and take the top off the rocker boxes. Replace the gaskets between the upper and middle plate and the center gasket. Make sure everything is aligned correctly and tighten the bolts down to 100 INCH pounds.

Good Luck
Steve

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
Steve

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

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