I have recently bought an 04 883 sportster with 350 miles on it. Had dealer change the rocker box covers to chrome. Looks awsome but the problem is I have had it back to the dealer for the 5th time in 3 weeks for leaks. 1st they said it was a warped rocker box, so they replaced it. 2nd time they said it was a pinched gasket and so on and so on. This latest trip thay said that the tork setting on the bolts is between 120 and 167 ft lbs. and that all the other times they tightened these they did it to the max. This time they were going to split the difference and go somewhere in tje 140 range. They took it out for a test drive and around the 20 mile mark the front rocker leaked again. Now they say they are going to shave the chrome down a millimeter. regasket and try again. Can anyone out there help me with this problem? Is this a common occurance with a sporster. Very embarassing, especially when you go out on a group ride. The whole reason I bought a harley was because I heard that the problems were minimal.
I think I got a lemon.
What is the recourse?

Thanx.

 

My workshop manual gives the following torque settings For a Buell X1 , (which is basically a sportster engine) I cant see where they are getting such high settings from? And would guess that if they did manage to tighten the bolts to such a high setting without stripping the threads, this would put strain on the covers causing possible warping, but from experience I can tell you that if they are not correct, or tightened in the correct order, they will leak.



The only ones that look remotely near are the small srews that are inch/pound settings.
I have been reliably informed that the new style metal lower rocker gaskets are 'fit and forget' items, and should cause no problems once installed. I hope this is of some help

Lev

 

get a new mechanic

 

I just replaced the rocker box gaskets on my '98 sportser 1200. The torque settings on the bolt are either 10-13 ft-lbs or 15-18 ft-lbs. Exept for the small bolts. Pretty much what Lev shows. If you tighten these bolts down too much, they will break, trust me!!! The main thing with the gasket kit for these is that the two bottom gaskets have been replaced with a 1 piece metal gasket which is much better like Lev stated. My old gaskets were brittle and fell apart. If you're mechanically inclined, I'd change the gaskets myself like I did. They're pretty easy to do. If you're not comfortable do it yourself, I'd get a second opinon.

 

I read on another forum (gasp), that Harley is waranteeing the leaking rocker boxes as there is a defect. Supposedly, they will give you an aluminum cover which will stop the leak. Once the chrome covers arrive, you will get that installed, if you desire.