103 Rocker Box gasket change
103 Rocker Box gasket change
I found a minor leak on the back of my rear cylinder at the connection of the lower rocker box. I had ordered rocker box gaskets and went to work on the bike this weekend.
First thing I discovered is that I ordered upper set of gaskets instead of the lower gaskets, so that basically killed the job.
However, I decided to start taking things apart for when I actually do get the correct parts. I was following the manual but for the most part, the manual really didnt give much in the way of instructions.
What is the order of removing the gas tank? Do I plug anything up or just let it drip?
Second, I couldnt find anything on this forum or on youtube for removing the rocker box in the rear for the 103. Everything was a sportster which didnt help. How do you manage to get to everything in such a tight space? What is the order for removing things in there as well? The only information I found is that I need to rotate the rear tire in gear so the rockers are both in the lower position. Seems to be a lot of work for something that isnt really that detrimental and I could just leave alone.
First thing I discovered is that I ordered upper set of gaskets instead of the lower gaskets, so that basically killed the job.
However, I decided to start taking things apart for when I actually do get the correct parts. I was following the manual but for the most part, the manual really didnt give much in the way of instructions.
What is the order of removing the gas tank? Do I plug anything up or just let it drip?
Second, I couldnt find anything on this forum or on youtube for removing the rocker box in the rear for the 103. Everything was a sportster which didnt help. How do you manage to get to everything in such a tight space? What is the order for removing things in there as well? The only information I found is that I need to rotate the rear tire in gear so the rockers are both in the lower position. Seems to be a lot of work for something that isnt really that detrimental and I could just leave alone.
Road Warrior
Joined: Mar 2014
Posts: 1,623
Likes: 698
From: nowhere
Take out the front and rear tank bolts. Have someone gently lift the tank until some resistance is felt. Stuff a rolled up towel under the tunnel in the tank bottom. Voila! plenty of room to work on your rockers.
I was thinking about that, so I dont necessarily need to completely remove the tank? Also, is there enough room to get to all the bolts under the top rocker cover for the bottom cover right under the frame there>?
Stellar HDF Member
Joined: Mar 2006
Posts: 3,124
Likes: 255
From: From Long Island, now in So. Cal
I found a minor leak on the back of my rear cylinder at the connection of the lower rocker box. I had ordered rocker box gaskets and went to work on the bike this weekend.
First thing I discovered is that I ordered upper set of gaskets instead of the lower gaskets, so that basically killed the job.
However, I decided to start taking things apart for when I actually do get the correct parts. I was following the manual but for the most part, the manual really didnt give much in the way of instructions.
What is the order of removing the gas tank? Do I plug anything up or just let it drip?
Second, I couldnt find anything on this forum or on youtube for removing the rocker box in the rear for the 103. Everything was a sportster which didnt help. How do you manage to get to everything in such a tight space? What is the order for removing things in there as well? The only information I found is that I need to rotate the rear tire in gear so the rockers are both in the lower position. Seems to be a lot of work for something that isnt really that detrimental and I could just leave alone.
First thing I discovered is that I ordered upper set of gaskets instead of the lower gaskets, so that basically killed the job.
However, I decided to start taking things apart for when I actually do get the correct parts. I was following the manual but for the most part, the manual really didnt give much in the way of instructions.
What is the order of removing the gas tank? Do I plug anything up or just let it drip?
Second, I couldnt find anything on this forum or on youtube for removing the rocker box in the rear for the 103. Everything was a sportster which didnt help. How do you manage to get to everything in such a tight space? What is the order for removing things in there as well? The only information I found is that I need to rotate the rear tire in gear so the rockers are both in the lower position. Seems to be a lot of work for something that isnt really that detrimental and I could just leave alone.
Rocker Box Oil Leak
https://www.hdforums.com/forum/dyna-...-oil-leak.html
I didn't remove the gas tank, just undo the quick disconnect fuel line, loosen the front tank mount, remove the bolt from the rear mount and stuff an old towel between the tank and frame. I kept my front wheel straight so the upper triple wouldn't hit the tank while it was tilted up. Remove from top to bottom like in the diagram in the below link (upper cover> oil breather> rockers> lower cover). The rear is tight but everything can come out and go back in, you will have to put the bolts in the rocker assembly and move the bolts up and down while slipping it back into the lower cover, same on the breather.
Rocker Box Oil Leak
https://www.hdforums.com/forum/dyna-...-oil-leak.html
Rocker Box Oil Leak
https://www.hdforums.com/forum/dyna-...-oil-leak.html
Stellar HDF Member
Joined: Mar 2006
Posts: 3,124
Likes: 255
From: From Long Island, now in So. Cal
I replaced everything, didn't want to go back in there again for another leak.
EDIT: While Im in there, what are your thoughts on "rocker lockers"?
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Joined: Jul 2015
Posts: 8,538
Likes: 1,646
From: SF Bay area
Make absolutely sure that before you reassemble everything you blow out the oil that may settle down into the bolt holes. An air hose/nozzle, can of aerosol key board cleaner, Q-tips, anything. Those holes are sealed at the bottom. If oil is in there when you install the bolts it will have nowhere to go... "hydrolocked" and you may blow out the bottom of the hole/head. Take your time! 
__________________________________________________ ____
For ROCKOUT information & purchasing please click HERE For all Twin Cams and Evo Big Twins & Sportsters
__________________________________________________ ____
For ROCKOUT information & purchasing please click HERE For all Twin Cams and Evo Big Twins & Sportsters
__________________
NO, they DON'T all do that!
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Imitated, never equaled... ROCKOUTS!
Ordering & info http://www.rockout.biz On ebay! ... CLICK HERE
Also on amazon.com...
Imitated, never equaled... ROCKOUTS!
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Make absolutely sure that before you reassemble everything you blow out the oil that may settle down into the bolt holes. An air hose/nozzle, can of aerosol key board cleaner, Q-tips, anything. Those holes are sealed at the bottom. If oil is in there when you install the bolts it will have nowhere to go... "hydrolocked" and you may blow out the bottom of the hole/head. Take your time!
__________________________________________________ ____
For ROCKOUT information & purchasing please click HERE For all Twin Cams and Evo Big Twins & Sportsters
__________________________________________________ ____
For ROCKOUT information & purchasing please click HERE For all Twin Cams and Evo Big Twins & Sportsters
