1999 softail leaking rocker box

[THUNDR]

I've had my bike at the Dealer (more than one) for the front
rocker box gasket 'blowing' going on its 5th time.

To make a long story short, Not too soon after I first bought the bike, last august, i had a chrome kit put on, ever since then its leaked. Part of the problem I think was 'bad service'.

The current shop is telling me that the top rocker box piece is warped beyond repair....

Am I the only one thats had this much difficulty ???

[Dave63]

Maybe. Part of a "chrome Kit" is a chrome cam cone cover and if done improperly, breather timing (gear) can be off timing. As well, cheap, chinese parts can be less than true and leak. Sometimes the leaks can be due to cheap gaskets alone. I prefer OEM or James gaskets.

[prodrag1320]

check and see if its warped (most likley is,seen it happen more than once,cant see 5 different shops screwing up a rocker gasket)even though one of them should have noticed a warped cover.
kirby
vee twin racing

[THUNDR]

prodrag1320:

To sort of clarify the story, my bike was in my local Harley shop (they do not have a very good reputation, as i had to dicover the hard way) 4 times. They initially installed the Chrome kit. (Harley parts) about a week and a half latter, leak, at the lower front, shifter side, of the front rocker box. Brought it back, the bike stayed two weeks, they replaced the gasket, couldnt tell me why
the leak happened. About a month and a half latter, another leak.
this time major, same place. (all across the front end. Brought it back, stayed there a month. Ordered the lower piece to the rocker box, said it was warped. it came in, they said that one was warped, ordered a new one. put it on. couple months latter ANOTHER leak.
brought it back,, this time they replaced just gaskets.....month or so latter, another leak....brought it to a different shop. replaced gaksets, this shop discovered that the previous shop left out the umbrella. they fixed it. that was about 3 months ago. Now the
upper rocker box cover is warped. I dont know if it was the initial
problem or not. when they dismantled the covers, one of the middle gaskets was severed. its crazy...i dont know if whoever is fastening these bolts down is not torqueing it right or what...

[gruss]

not sure about your rocker box design, but on mine, the left side of the rocker boxes likes to pinch the OEM gaskets during the torque procedure. i found out the hard way once about this one, as i chunked a brand new gasket after an inspection of the rockers.

the gasket is shaped like this....../\.........and when the rocker top is tightened down, the gasket rolls and pinches. then it leaks like hell.
if they change the gasket with "any" oil residue on the mating surface, it will pinch and leak...also does your rocker box use the barrel style bolt down method? i.e. it bottoms the rocker box cover into the rocker box using cast barrels, that only go so far down?
if so, torque is not the issue, just the rolling gaskets. (IMHO)

the severed center gasket is usually caused by "dragging" the rocker box cover over the rockers during the new install..
just like prodrag suggests, you need to determine if the rocker is warped, just place it on a piece of glass, and check for wobble. you'll see it really quick if it is.also look down the edges for obvious gaps in the mating surface.