07 nightster with about 6700 miles on it.

I think this is a decently common issue with these motors, but the rocker cover gasket appears to have failed.

Either that or the one allen key bolt is loose and out of torque? I have a PDF service manual which is a b*tch to navigate and I couldn't find the torque specs on those bolts(part 1 in the attached screenshot), anyone know what it is?

It looks fairly simple to replace the gaskets (# 4 and 5 in the attached), am I over looking anything if that is indeed the issue?

 

My leak was right here, I replaced both the rocker cover and the rocker support gaskets on the rear cylinder and wasted my time doing the rocker support gasket, I only did the rocker cover gasket on the front.

 

I figured it was the gasket. And you don't think I should bother with the inner one? I may do it just bc.

Any idea on the torque specs or does it not really matter? I couldn't find the assebly section in my PDF manual on the disassembly section

 

Good news mine just started leaking from same spot on rear.
I picked up all 3 gaskets at the dealer for $15.
I'm just going to do the rear cover as that's the one that's
Leaking. As far as the front my logic is if it ain't broke don't
Fix it. U can google the torque specs or find them here

Not good news it's leaking , it's the 15 bux

 

mine is leaking, but its so slow that i will just live with it until it gets worse. have always wondered why our gaskets break down so often... is it the air-cooled engine? maybe not warming it enough before riding too hard when its not warm? my cages never do this!

 

It's something to do with the new rocker boxes. The pre-rubbermounts have leaks too (mine did on both, thanks to paper OEM gaskets), however they are a one time fix pretty much. The rubbermount two-piece rockers must be a different manufacturing process or supplier, or both, and have a much harder time staying sealed.

 

Those rocker box gaskets can be a pain to keep in place when installing the covers, they twist and shift out of place easily. Make sure the gasket mating surfaces are clean and smooth and be patient making sure they stay in place while you torque them down. I think the torque is something like 17 inch lbs.on the top cover. (Allen head bolts)

 

The (4) screws #1 in this picture torque to 120 to 168 in. pounds. I can get the rest if needed.

 

G, I sat and studied the rear cylinder for quite a while and made the decision to remove the air cleaner and its back plate to gain maneuvering room, I then place the bike in 5th gear, removed the front sparkplug and ran the rear cylinder up against compression. Removed rear sparkplug, inserted 14 inch long 1/8" dowel and moved the rear piston to TDC using the dowel as a guage. Doing all this allowed me to slide the top cover into place without disturbing the gasket. This took longer to type than to do. Anyway, so far so good. No more leak.

 

Thanks for all the info guys, you are more helpful than my manual!