My first set was chrome moly and I bent all 4 of those and the second set was S&S easy install and the lock nut backed off on one of those.

It does happen.

 

Now that is interesting!!!!!

 

I've done it on my shovelhead with the cork ones...cut at a 45 degree angle..did not use any glue and they have been leak free and saves a **** load of time.

 

Thank you for your experience!!!
I now have another trick up my sleeve!!!

 

Now that you mention it, I've seen kits to "make your own special size o-rings" which consist of a length of rubber cord and super glue. Usually they also include a cutting jig so you can get the ends square.

 

If you could bend four chrome moly pushrods, I can't imagine the flimsy stock aluminum pushrods would have fared any better.

Are you sure they weren't bent out of the box? I had to sort through two or three sets of SE pushrods to cherry pick four that ran straight. The rest were assembled crooked. Yes, I'm on very good terms with the local dealer.

 

No I'm not.
When I installed them I was new to Harleys and a friend helped me.
I didn't even know you needed to check them back then.

 

I just re-read this post. From your description, I would first look at a leak coming out of your air filter, caused by blow-by, because your Evo is a head breather. If you have a leaking O-ring, you will have a leak at any speed and any distance. Because you said it only happens when you are running long distance, this makes me think you may just have a little bit more oil in the tank. At higher speeds, oil mist return at the head doesn't work fast enough, and with air moving through your air filter, it may pull some out and land on rear intake PR cover, making it look like you have a leak.

So, I would wipe it down. Go on a short ride, and re-check. Might save you some grief and $$. Good luck.

edit: If your 98 Evo is running good, and has enough power for you, I would leave it alone and ride the heck out of it. 98 Evos are the closest thing to perfection for HD. :-)

 

I'd cut and glue the o-ring
or
If your thinking about cam swap in the future,
get a set of them spooky adjustable crooked pushrods that leaves millions of bikes stranded all over the world every day.

 

Option 3 all day long. The factory modified the rocker boxes from the Shovels to the Evolution motors just for this (and some other) kinds of leaks. One day job using the shop manual to get it apart, replace the O rings and put it all back together.

No reason to introduce an adjustable anything, adding to future maintenance.