Okay, here's the long version of the short story: 1993 FLHS, upper end rebuilt at 42,000 miles. New pistons/rings/valve job/etc. Had the shop install some chrome rocker boxes, cam cone, lifter block covers, and tranny cover. Took off from MI for FL after breaking in the motor noticed rocker boxes leaking around TN. Rode bike to Orlando and had Orlando HD reseal the boxes. Left bike in storage down there for winter without riding after repair. Returned in March, rode to Fort Lauderdale...Yep boxes leaking again. Returned bike to Orlando HD and told them they were leaking and they again resealed them. Returned to FL in late May and rode bike back to MI. Yep, rocker boxes started leaking before I got to GA. Took bike back to the shop that did the original repair, they resealed the boxes, which promptly started to leak again. Took bike back to the shop where they swapped out the chrome boxes for new ones. Bike leaked again. Took the bike back to the shop again asked if perhaps the breather was put in wrong, was assured that this couldn't happen, but I offered to pay to have them check it anyway. Which they did and said it was okay, but installed an S&S steel breather to replace the plastic HD one. Bike started leaking again. I replaced the gaskets twice after this, and the bike still wants to leak around the rocker boxes. It doesn't happen with fresh seals in regular city type driving, but rather will start as soon as I cruise along at 70-80 mph for a while. Then it just keeps oozing the oil over everything form that point on. I've been dealing with this for almost three years now, and only around 3000 miles have been put on the bike because of all the down time.

I'm at a total loss for ideas. Is it possible that both sets of HD chrome rocker boxes were bad? Or what? The bike runs great other than this darn leak.

Help!

 

Is it possible the tops of the heads are warped? I would be checking the rocker boxes on a surface plate, and if they are flat, ya gotta start wondering about the heads.

 

Define "re-sealed" ??? WTH does that mean ?? ...are you warming that engine up and letting the oil pressure drop before taking off ??...if not...thats your problem..barrel gaskets are next.

 

By re-sealing I mean that all the gaskets have been replaced in the rocker boxes. And yes, I do allow the motor to warm up before taking off. But as you know, HD's don't have excessive oil pressure anyway. Even in 30 degree weather my oil pressure (from a mechanical gauge) is barely above 30 psi and I cruise at a hair over 20 psi. I am very meticulous with this bike (other than the rear base gasket described next paragraph). The bike does run excellant and I can sit on it easily for 800+ miles a day. Unfortunately, it has left me stranded at least half a dozen times.

And the base gaskets....Well that's just a (another?) crappy HD design (among many), there are better aftermarket solutions than what HD offers: Jims has one of them. I bought the bike new (owned it now going on 14 years) and mine lasted about thirteen months before it started to leak. If Harley had engineered the oil return passage with a hollow dowl pin so that the oil wouldn't pool inside the gasket (or used a better gasket design to begin with), there would not have been the thousands of leaking base gaskets the dealers repaired. I rode mine with a 'weeping' rear base gasket for ten years before getting it fixed (it didn't leak a lot so I'd just have a rag with me to wipe it off)...Which started the rocker box leak problem.

Interesting thought about the heads being warped. When the upper was done, they were freshened up. I understand that they heat them in an oven so the valve guides will go in... Is this correct? Could 400-500 degrees cause the head to warp?

So now the bike is sitting at a dealer about an hours drive from my house because something happened to the charging system. The HD battery spent the winter on an automatic trickle charger, but it was two years old...Which seems to be the life span of any battery I've ever put into the bike. When it died (luckily in the motel parking lot), my buddy rode 100 miles round trip to get a new HD battery to put in it, but it only lasted around three hours. I was able to make it to the parking lot of a brew pub, before the motor died. Every dealer I called within a fifty mile radius of my home is booked solid with bikes in service...One dealer told me to wait until fall to have the oil leak looked into...Kind of makes you wonder about the overall quality of their products (or service) when they are that backed up. Kudo's to the dealer (Cunningham HD-Burton, MI) that did send out his truck/trailer to get me off the road.

Perhaps they can get it fixed...As I said, I've run out of ideas. I'm thinking my next ride ought to be a HonDa, not an HarleyDavidson. But I suppose they are plagued with their share of problems also.

 

30 psi in 30*f weather indicates a very weak oil pump to me .Hondas dont break...check em out.

 

OWWWWWWWW!!!!!

HD dealer diagnosed the charging problem as a bad voltage regulator...$300.00 total to get it fixed!!!! That's $99 for the part + 2.5 hours labor ($70 per) + (I really loved this) $10 for two plastic wire ties + 'shop supplies (huh?) + tax. It never ceases to amaze me how they continue to gouge their customers..And get away with it. Sorta like the businesses in Daytona during Bikeweek.

They wouldn't even look at the oil leaking problem. You'll love this, the guy in service told me: "We don't like to work on bikes older than 1995." I think what he really meant was: "No one here has a clue what their doing."

So it's off today to find a local bike shop that can get this bastard to quit leaking oil.

 

2.5 hours to change a voltage regulator ??? LMFAO******************

 

Yeah, 2 1/2 hours to diagnose a charging system and replace a voltage regulator, they told me the stator checked out fine, gee... thanks. You gotta love these 'new' HD dealerships. But when your stuck...They stick it to you. You remember when dealers used to ask: Where did you buy it? Because they wouldn't work on it if you didn't buy it from them. Ah, what goes around, comes around. There were lots of unsold HD's on the floor...Can't imagine why.

The saga continues:

Left this morning to go check out a bike shop and see if they might be willing to tackle the on-going rocker box leak. Got the bike to the shop, but they didn't open for another twenty minutes, sooooo figured I run down the street and get a coffee. Click, Click, Click, Click. Bike no start. $400 in parts/battery/labor, and I'm still stranded. But once again at least in a good place. Sat it out until the owners showed up and told them my stories.

More to follow...I'll post it in the Other forum when this new shop attempt to cure the problems.

 

Yours is a common story, man....do yourself a BIG favor...get a manual...find someone who knows a little..and start doing your own work...Harley Davidson is Yuppie Davidson now...remember, most of these dudes pay HD to change their oil.

 

i had to repair a stripped head bolt on my 1990 fxstc. installed new james gaskets. rocker box started leaking after 800 miles. a harley mech. told me to use permatex, grey. on both sides, with the rubber gasket, let it set for 30 minutes, if you dont let it set it wont work, then install them. so far so good. he told me he learned this trick working at a harley dealer. worked great on rocker boxes and primary covers. if you havent fixed it by now this mught be something to try.