04 1200 XLC Rocker Box Cover Leaks???
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5th Gear
Joined: Feb 2006
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04 1200 XLC Rocker Box Cover Leaks???
Hey folks,
new here and am hoping someone may know of or have had similar experience??
I have an 04 Sportster 1200 XLC that I bought new in April 04 and have 10,000 miles to date...
The problem is that at 2500 miles my rocker box covers started to leak..Dealer put oversize gaskets on and said that should do it...
At 7,500 miles the same thing happened and a new dealer I now go to had to replace the lowers but the upper covers were so warped that they had to grind them down and put back on..Called Harley and they said that they had a bunch of defective covers but that they were working on it...This was last fall before putting my bike up for the winter...Went in yesterday and was told that there is still no fix for warped covers...
My concern is that my warranty is up in April and if this happens again it will be on my dime...I have considered buying extended warranty but the general consensus is that they are really expensive and not that good and the coverage is not that extensive...
The mechanic there is good and I know he has done all that he can but I think Harley is ducking this one..Anyone else haveing these problems with the rocker box covers? Any and all suggestions will be appreciated...
I have the bike in the shop right now having some D & D exhausts put on it and would like to get this resolved before the season starts and I am out of warranty... I am also going to have a pair of Sreamin Eagle slip-ons for this bike available for sale after I get my new exhausts on, They only have one season on them (5,000 Miles) and I would sell at a reasonable price...
Thanks
new here and am hoping someone may know of or have had similar experience??
I have an 04 Sportster 1200 XLC that I bought new in April 04 and have 10,000 miles to date...
The problem is that at 2500 miles my rocker box covers started to leak..Dealer put oversize gaskets on and said that should do it...
At 7,500 miles the same thing happened and a new dealer I now go to had to replace the lowers but the upper covers were so warped that they had to grind them down and put back on..Called Harley and they said that they had a bunch of defective covers but that they were working on it...This was last fall before putting my bike up for the winter...Went in yesterday and was told that there is still no fix for warped covers...
My concern is that my warranty is up in April and if this happens again it will be on my dime...I have considered buying extended warranty but the general consensus is that they are really expensive and not that good and the coverage is not that extensive...
The mechanic there is good and I know he has done all that he can but I think Harley is ducking this one..Anyone else haveing these problems with the rocker box covers? Any and all suggestions will be appreciated...
I have the bike in the shop right now having some D & D exhausts put on it and would like to get this resolved before the season starts and I am out of warranty... I am also going to have a pair of Sreamin Eagle slip-ons for this bike available for sale after I get my new exhausts on, They only have one season on them (5,000 Miles) and I would sell at a reasonable price...
Thanks
Tourer
Joined: Sep 2005
Posts: 382
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From:
RE: 04 1200 XLC Rocker Box Cover Leaks???
These are issues where I have my attorney write a letter for me and that usually gets the results needed. but I have Pre Paid Legal and that is what I do. If you want infor PM me.
Penny
Penny
Intermediate
Joined: Nov 2005
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From:
RE: 04 1200 XLC Rocker Box Cover Leaks???
I had the same problem with my 2004. From what the shop told me, there have been about 4 or 5 changes made to the gaskets the newest one about 4 months ago when I had mine replaced for the third time. So far it has not leaked, but I only have about 200 mile since the change. Before that it leaked by the time I got home from the shop. I would have the shop look into the new gaskets while you have it in the shop. They also replaced my front upper and lower covers. I dont think I would let them put covers on my bike that they had to gind down.
Road Captain
Joined: Aug 2005
Posts: 557
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From:
RE: 04 1200 XLC Rocker Box Cover Leaks???
I read somewhere on this forum that they were under warranty because of a defect and they were replacing the covers with chrome ones. Try the search button in this forum.
Thread Starter
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5th Gear
Joined: Feb 2006
Posts: 9
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RE: 04 1200 XLC Rocker Box Cover Leaks???
ORIGINAL: brohrs
I read somewhere on this forum that they were under warranty because of a defect and they were replacing the covers with chrome ones. Try the search button in this forum.
I read somewhere on this forum that they were under warranty because of a defect and they were replacing the covers with chrome ones. Try the search button in this forum.
I did do a search here but came up with only one other person with a little different problem than mine...
But please keep the input coming...
Thread Starter
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5th Gear
Joined: Feb 2006
Posts: 9
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RE: 04 1200 XLC Rocker Box Cover Leaks???
ORIGINAL: am7010
I had the same problem with my 2004. From what the shop told me, there have been about 4 or 5 changes made to the gaskets the newest one about 4 months ago when I had mine replaced for the third time. So far it has not leaked, but I only have about 200 mile since the change. Before that it leaked by the time I got home from the shop. I would have the shop look into the new gaskets while you have it in the shop. They also replaced my front upper and lower covers. I dont think I would let them put covers on my bike that they had to gind down.
I had the same problem with my 2004. From what the shop told me, there have been about 4 or 5 changes made to the gaskets the newest one about 4 months ago when I had mine replaced for the third time. So far it has not leaked, but I only have about 200 mile since the change. Before that it leaked by the time I got home from the shop. I would have the shop look into the new gaskets while you have it in the shop. They also replaced my front upper and lower covers. I dont think I would let them put covers on my bike that they had to gind down.
http://mysite.wanadoo-members.co.uk/...hog3/M1168.pdf
http://mysite.wanadoo-members.co.uk/...og3/M1168A.pdf
I think I am going to have to take Penny's route posted above to get some results before my warranty is up...
I may even insist they replace with a powder coated one till this is resolved...I jsut don't want my bike down for weeks again with the same problem and getting hosed on the defect that was a problem from the begining...
6th Gear
Joined: May 2005
Posts: 10
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From:
RE: 04 1200 XLC Rocker Box Cover Leaks???
Since I have had the same type of leak since I bought my 2004 XL1200R, I've learned a few things about the situation:
(1) Don't worry about the warranty expiring - any problem that shows up while a bike is in warranty will still be covered if the problem is not corrected by the time the warrant expires. Your dealer will confirm this if you ask him.
(2) Switching from chrome to silver won't solve the problem. H-D now acknowledges that the problem is with all three finishes, and the problem is with the inner (lower) rocker cover, not the outer (upper) rocker cover. The latest revisions of these parts is as follows:
chrome: 17537-96C
silver: 17614-98C
polished: 17532-86E
(3) There has only been one revision (at least so far) to the gasket, and the latest rev. is P/N 17353-89B
(4) In addition to the procedure outlined in Service Bulletin M1168A, H-D is now adding a second breather assembly to each of the rocker boxes - this second breather is non-functional (H-D calls it a "dummy breather") and it's sole porpose is to keep the gasket from shifting, which H-D believes is the main cause of the leaks.
(5) If you have any further problems, call H-D Customer Relations department at 414-343-8718 and Lori Oelhafen will help you.
Let's be sure to let this forum know how each of us fares on this problem!
John
State College, PA
(1) Don't worry about the warranty expiring - any problem that shows up while a bike is in warranty will still be covered if the problem is not corrected by the time the warrant expires. Your dealer will confirm this if you ask him.
(2) Switching from chrome to silver won't solve the problem. H-D now acknowledges that the problem is with all three finishes, and the problem is with the inner (lower) rocker cover, not the outer (upper) rocker cover. The latest revisions of these parts is as follows:
chrome: 17537-96C
silver: 17614-98C
polished: 17532-86E
(3) There has only been one revision (at least so far) to the gasket, and the latest rev. is P/N 17353-89B
(4) In addition to the procedure outlined in Service Bulletin M1168A, H-D is now adding a second breather assembly to each of the rocker boxes - this second breather is non-functional (H-D calls it a "dummy breather") and it's sole porpose is to keep the gasket from shifting, which H-D believes is the main cause of the leaks.
(5) If you have any further problems, call H-D Customer Relations department at 414-343-8718 and Lori Oelhafen will help you.
Let's be sure to let this forum know how each of us fares on this problem!
John
State College, PA
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Thread Starter
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5th Gear
Joined: Feb 2006
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RE: 04 1200 XLC Rocker Box Cover Leaks???
ORIGINAL: jpj2004xl1200r
Since I have had the same type of leak since I bought my 2004 XL1200R, I've learned a few things about the situation:
(1) Don't worry about the warranty expiring - any problem that shows up while a bike is in warranty will still be covered if the problem is not corrected by the time the warrant expires. Your dealer will confirm this if you ask him.
(2) Switching from chrome to silver won't solve the problem. H-D now acknowledges that the problem is with all three finishes, and the problem is with the inner (lower) rocker cover, not the outer (upper) rocker cover. The latest revisions of these parts is as follows:
chrome: 17537-96C
silver: 17614-98C
polished: 17532-86E
(3) There has only been one revision (at least so far) to the gasket, and the latest rev. is P/N 17353-89B
(4) In addition to the procedure outlined in Service Bulletin M1168A, H-D is now adding a second breather assembly to each of the rocker boxes - this second breather is non-functional (H-D calls it a "dummy breather") and it's sole porpose is to keep the gasket from shifting, which H-D believes is the main cause of the leaks.
(5) If you have any further problems, call H-D Customer Relations department at 414-343-8718 and Lori Oelhafen will help you.
Let's be sure to let this forum know how each of us fares on this problem!
John
State College, PA
Since I have had the same type of leak since I bought my 2004 XL1200R, I've learned a few things about the situation:
(1) Don't worry about the warranty expiring - any problem that shows up while a bike is in warranty will still be covered if the problem is not corrected by the time the warrant expires. Your dealer will confirm this if you ask him.
(2) Switching from chrome to silver won't solve the problem. H-D now acknowledges that the problem is with all three finishes, and the problem is with the inner (lower) rocker cover, not the outer (upper) rocker cover. The latest revisions of these parts is as follows:
chrome: 17537-96C
silver: 17614-98C
polished: 17532-86E
(3) There has only been one revision (at least so far) to the gasket, and the latest rev. is P/N 17353-89B
(4) In addition to the procedure outlined in Service Bulletin M1168A, H-D is now adding a second breather assembly to each of the rocker boxes - this second breather is non-functional (H-D calls it a "dummy breather") and it's sole porpose is to keep the gasket from shifting, which H-D believes is the main cause of the leaks.
(5) If you have any further problems, call H-D Customer Relations department at 414-343-8718 and Lori Oelhafen will help you.
Let's be sure to let this forum know how each of us fares on this problem!
John
State College, PA
I joined this forum and found others there that are experiencing the same problem:
http://www.xlforum.net/index.html
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6th Gear
Joined: May 2005
Posts: 10
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RE: 04 1200 XLC Rocker Box Cover Leaks???
ORIGINAL: Builder
John, I just talked to the tech doing the work on my bike and he said that they just got a new batch of Upper Rocker Box covers and that every single one of them is warped...He said he examined each one and that the chrome is pooling on the surface plate where it would mate to the lower making the contact surface warped...He said I am better off leaving the ones on that he hand ground down until HD gets this right...
I joined this forum and found others there that are experiencing the same problem:
http://www.xlforum.net/index.html
John, I just talked to the tech doing the work on my bike and he said that they just got a new batch of Upper Rocker Box covers and that every single one of them is warped...He said he examined each one and that the chrome is pooling on the surface plate where it would mate to the lower making the contact surface warped...He said I am better off leaving the ones on that he hand ground down until HD gets this right...
I joined this forum and found others there that are experiencing the same problem:
http://www.xlforum.net/index.html
John
Thread Starter
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5th Gear
Joined: Feb 2006
Posts: 9
Likes: 0
RE: 04 1200 XLC Rocker Box Cover Leaks???
ORIGINAL: jpj2004xl1200r
Are you telling me that H-D has now officially said that there is a problem with both the upper and lower (outer and inner) rocker box covers? If that is the case, then mine may still turn out to leak since the last fix (but I will have to put at least 300-400 miles on it before I can be sure)
John
ORIGINAL: Builder
John, I just talked to the tech doing the work on my bike and he said that they just got a new batch of Upper Rocker Box covers and that every single one of them is warped...He said he examined each one and that the chrome is pooling on the surface plate where it would mate to the lower making the contact surface warped...He said I am better off leaving the ones on that he hand ground down until HD gets this right...
I joined this forum and found others there that are experiencing the same problem:
http://www.xlforum.net/index.html
John, I just talked to the tech doing the work on my bike and he said that they just got a new batch of Upper Rocker Box covers and that every single one of them is warped...He said he examined each one and that the chrome is pooling on the surface plate where it would mate to the lower making the contact surface warped...He said I am better off leaving the ones on that he hand ground down until HD gets this right...
I joined this forum and found others there that are experiencing the same problem:
http://www.xlforum.net/index.html
John
The tech told me that he had pointed out the problem to the regional HD guy here and that the guy told him that HD was not going to do anything about this unless it became epidemic..
This is disconcerting to say the least. I will be back on the phone on Monday with HD because I am just not going to accept this as the fix...There could be issues with the chrome pitting etc...
I think this is a bigger problem than they want to acknowledge...
If your bike is in the shop now I would suggest you have them pull the covers and lay them on a flat surface and see if the ones that you have are flush if so you may be alright...The last thing I want is to get into yet another season and have this happen again..So far I am not impressed with how HD is handling this...