How-To: Leaky Rocker Box Gasket Fix on Harley-Davidson Sportster

[@HeneleWright]

I have a 1999 Sportster that has had a minor but annoying oil leak for YEARS. I knew it was rocker box gasket related somewhere low. I was too scared to attempt the repair myself and wasn't trying to spend shop money, so I rode on and cleaned up (as it got worse). I've been watching this video for years and today I replaced my front base gasket following this video verbatim. THANK YOU! You have given me the courage to address ANY issue on my bike.

[@martinguajardo7588]

Awesome now I know Thanks

[@chazbryner]

I could watch this dude bake a cake and still be entertained. Awesome videos brother, keep up the good work.

[@nizamulkillerdot]

When he says “you do have a workshop manual don’t you” gets me all the time xD

[@jluo]

Bravo to Todd and whoever edited this video. Literally perfect amount of information and no filler and wasted time. I pretty much relied on this video

[@hooligan9693]

Not just the step-by-step, but also the why behind each step. Phenomenal!

[@j.acencc6273]

If you own a sporty... or any Harley really. This guy is a necessity to subscribe to.

[@HomeyB23]

I love the visual demonstration and explanation behind actions. Very helpful Thank You!

[@westcoastliving8570]

Totally love watching Todd doing the “How To” vid’s. Great teacher and definitely full of outstanding knowledge and he even ads some comedy too 🤙🏻

[@branney1]

Used a seperate lowbrow video for my 883 conversion and near end of breakin found I had a leaky gasket. Between replacement gaskets and the bolt kit for rocker boxes from their site I no longer have that pesky leak. UV-Light and dye always confirms 😂 Was a 2013, grabbed the torque specs from manual but the video was super helpful!

[@JohnBoy-Ramone]

Cheers Dude; just did my 1200s and thanx to your walkthrough, it was a piece of pi$$. I was pretty apprehensive about attempting this, but, without a doubt the most difficult part was removing the old crappy OEM gasket residue from the alloy covers.

[@brianiams5032]

Awesome video! This gave me the confidence to finally fix my leaky Harley. Thank you.

[@johnvanbeuren5458]

What a great tutorial , I just discovered a gasket leak and WAS apprehensive about doing it but not anymore , thank you ...

[@dwainroberts3307]

That was great, man! You're a good teacher.

[@johncasor9698]

i just changed out my rocker cover gaskets i got from Harley on my 1997 FXLR and they still leaked??? got thicker JAMES GASKETS.. and torqued them down 34 pounds and no leaking so happy... your video was a great video and really helped me... Thx ...

[@rcanoli99]

Thank you LowBrowCustoms for an excellent walk-through. I had a nasty leak on the front cylinder of my '92 XLH. After watching this I fixed it for the cost of the gaskets *and* I got to see what the problem was: it was missing the little rectangle gasket.

[@crabbycrouton4925]

Thank you, I used this video to do my 2011 Iron. Only difference was to have it in top gear to roll the wheel forward, and there's only 2 parts in the top of the header instead of 3. Very easy to understand and saved me a couple hundred dollars.

[@Abrukudubra]

These how-to series are awesome!

[@jeremybennett3744]

Thanks for the pragmatic video - my youngest son bought a 2009 Sportster 883 and it had the leak on the nearside front lower corner and was starting on the the nearside rear lower corner. [we are in UK so that is the kick-stand side on the left]. Your video helped. Ordered all the parts and set to. The front had clearly been bodged with gasket sealer. We needed to apply some heat with a heat gun to soften the gunk and used an old credit card with a rubber mallet to ease it off gently. A person had used a screwdriver gouging the machined face. So a bit of water and 800 wet n dry wet sorted than on a mirror as a flat surface. WE chose to buy two new brethers as one looked a bit sketchy. Assembly was quick. She started first time after filling with fresh fuel. Awesome. Many thanks ! Ride safe . . .

[@keepontruckinoutlawlife1248]

I just wanted to say first I SUBSCRIBED second I definitely couldn't have done this job without your help. Thanks for being so in depth appreciate it very much my harley gaskets are happy.

[@lovetohunt3613]

This is hands down the best how too video of these gasket changes. It’s going to help me out a bunch.

[@bellmichael]

Just bought a 2000 883 with leaking rocker boxes. Followed your video to put on the new James gaskets. Easy. Thanks.

[@kraptastic333]

Pulling that rear cover off is a bit of a blacksmith's puzzle but it will come out with patience. Don't gouge anything. Thanks for the awesome video, got me riding again

[@edwinherrera-nieto-]

thank you from Colorado, I'm not a motorcycle mechanic, but I enjoy doing small things like this, so, much appreciated.

[@Vic-ng8if]

Brilliant mate. You give us the balls to do this ourselves. I left my chops engine into a certain HD dealer to have a new set of 1200 Wiseco barrels and pistons installed, rode it 100 miles and it's weeping from the exact place. I'll do it myself now. Has anyone ever had this happen I wonder?

[@jimmansi1187]

Victor Lonsdale I had a 2008 1200 Custom, beautiful bike and I had a leaky rear cylinder/rocker box at 12,000 miles, got it fixed, cost me $250, six months later it was leaking again, took it to a different mechanic, another $200. I was told that it was a common issue with Sportsers but I was pissed so I sold the bike. Currently I'm riding a 1995 1200 Sportser & love it. The pre 2003 Sportys are better than the current ones, just my opinion!

[@arongarceau]

6 years later and my son and I are about to dive into this project. Why is it ALWAYS the front one? I don't know, just happy it's not the rear, that looks like a nightmare. I've bookmarked this video and will be following it (probably at 1.25 speed) with him and making a day of it. Thanks for lending your expertise to the world! Can't wait for the day when I no longer have to clean oil up from everywhere...

[@DeltaNineProductions]

My 2011 Super Low it's the rear. Just bought it a couple weeks ago.

[@gclambiii]

TY. TY, TY -- I am a 69 year old man (70 next month) with a 2008 Sportster. You saved me over $600 in shop fees for a simple project. I've purchased Low Brow parts and will continue to purchase as needs arise.

[@NavigatorHomeInspections]

Thanks Todd! You made replacing my front rocker gaskets a pleasure.🌞

[@pauldesmarre]

Thank you for the full tutorial. i changed my back top rocker for the first time and it is a success. Thank you

[@bruble14]

I'm glad you mentioned it's possible so I know I'll be able to get it, but man, the one that's leaking is the back one haha. I still appreciate the info.

[@mark2graves-MC]

This is exactly where my 1999 road king twin cam 88 is leaking, but on the rear box. Thank you for the info!

[@loki66678]

Hi lowbrow customs. i'm bought some part from you (Speedometer Gauge Mount 1") and i'm happy for that :) greetings from Poland

[@michaelcriner1628]

Just blew this gasket yesterday. This video is top knotch on how showing replacement. Subscribed I liked it so much!

[@ericweber1969]

Fantastic video, as always! Really thoroughly explained the solution to the leak.

[@bernardlesperance742]

Really surprised he didn't tighten the four main rocker box bolts in star pattern and with 1/8th turns at a time - something the H-D manual says is critical, as does every other video covering this topic. Not doing so can result in real damage to the rocker box. Lowbrowcustoms has definitely raised my eyebrows ! Moral of the story: always get your info from several sources ! . . . and especially the H-D Manual when wrenching on your H-D.

[@skoodlemoose]

this channel is so well done these videos are a life saver thank you guys

[@lowbrowcustoms]

Stoked you dig it! and glad we can help!

[@robjohnson212]

I run a 2007 HD Softail Deuce, and I started noticing the smell of burning oil every time I ride it. I finally took a careful look around my engine and notice that both the front and back rocker covers were leaking oil at the Gasket line. It leaked down into my fins. I was just happy I found the source. Next step, clean up and replace both gaskets.

[@tonymeans]

Hey. .... Thanks for this great video... My wife s bike developed a leak and the Harley dealer wanted a lot of money to replace the gaskets... this video was spot on.... everything you mentioned happened and it took me a Saturday afternoon to do it

[@allenlitherland]

Great instructional video! Now I see how everything fits together but seeing how much room it took to remove everything I'm even more concerned about replacing my rear gaskets - it is very tight back there.

[@mysticapprentice]

Thank you guys and thank you Todd, as always with these videos, very useful and very therapeutic!

[@justsurf3328]

So good! I have to do this for the 93 883. Going to have to get that gasget kit. I've never done this before, but I think I can now. Thanks for the video. I liked and subscribed!

[@unclefuddelmer9224]

🇺🇸Hey guys! Howdy < N.central PA. Recently stumbled onto y’all and grateful I did. My rides an ‘05 XL1200c I found in the fall of ‘16 in cherry condition. Wifey of 44 years talked me into buying it in order to ease my ‘end-of-life crisis’ AND it’s working😎 I do most of my own mechanics Sooo you’ll be hearing from me in the future. Since we’re neighbors I may even ride out to visit this summer. Great job on your channel & hope to see y’all soon! Uncle Fudd

[@lanarkwanderer]

Well done, really enjoy your narrative while doing the work. Keep them coming.

[@revbikerbigd8664]

Let lifters bleed down 30 minutes before removing or installing 4 big bolts on rockers! Removing last! Installing them first! I would also install rocker lockers to stop shaft noise when doing this job. Also use blue stuff on all bolt. Great video 👍👍

[@leroystepp1628]

I'm right in the middle of it. Not to bad so far. Good video, lots of help, big thanks !!!

[@billmeloche4918]

Thanks Todd for your videos...always a pleasure to watch:)

[@azcharlie2009]

Just got my Genuine James gasket kit. Look to do this job very soon. You make it look easy...

[@gregorymarier5210]

You're a stud man I appreciate you so much. Need more bikers like you out there!

[@jeremybanks719]

Rebuilding a 1990 flhs and going with a 94-96 road king looks. Got it wired up with all new harness I made. New wiring and male/female plugs. My first Harley but second bike build. Found I had a front rocker leak. I knew I can change it, but dyslexia can be a challenge for me. So now I know what some people was saying about flat siding the cam. Pfft wish they wouldn't talk like it a top secret shop talk and not explain what they mean. If they even know what they're talking about in the first place. If they knew me they would understand, I know my way with tools, I've built a handful of auto engines, a few race motors, and boat motor as well. It's all the same principle. 4 or 2 stroke. Fuel, air, comp, fire. It's just how the different companies decided how to achieve and direct it. I'll be subscribing, I'm not afraid to learn from someone else's mistakes, saves me from making it myself lol. Also, from someone that's a veteran in the field, I'm sure you know more about this motor then I do and I'm definitely going to be watching for any little tips that you learned the hard way. Age is starting to creep up on me and I'm getting to lazy to learn the hard way now days. Thanks, even if this video is a few years old. New to me.

[@kcav5374]

I've got a leaky rocker box gasket on my 92 sporty 883 that I'd just bought. (It's sat since 2013 I believe and both rocker box covers are aluminum and oxidized so I'll be doing and cleaning both of them. this video took the fear out of attempting it myself, thanx!

[@johntanner848]

You are the man I’m learning by the minute and you’re easy to understand. I got a 49 Panhead matter fact it is an easy Rider 1991 issue. And I have a 2016 fat bob. Learned a lot by watching you

[@justinkeller9187]

I like these videos and dig his style. Gonna do this job very soon. Thanks

[@claudedevault6068]

Very impressed. My dream is a shop like yours. Even more an old school mechanic that can teach me for years to come.

[@mauserwinchester]

I really enjoy watching you work, it's both informative and entertaining.

[@darrellthompson-vr7hv]

Was thinking of getting someone to do mine, because I've never done them. Thanks! I can do that job myself now!

[@craigpennington1251]

Nice Sporty and another great video to keep in the files. Excellent reference.

[@plainoldjason]

Excellent video and instruction. I'm about to do this job on my 2013 XL1200C and I could have done it using just my shop manual but this video is very helpful. Got a fancy digital torque wrench that my family bought me for christmas one year and it does both inch and foot lbs! (my torque elbow is out of calibration)

[@cameronlevy6317]

thanks for the help just picked up my first harley and it needs the same gaskets going to the site now to order a set

[@tobyhaight9595]

Your the best did the gaskets on my softail to day thanks for the help

[@davidderler5924]

Thanks for the demonstration on everything. My 95 front leaks . Going to do in winter .

[@docwatt8881]

Best teaching video I ever watched keep up the good work

[@kcav5374]

Thanks for the video ad tips I just finished 92 rocker box gas on my Sporty 883 yesterday, leak is fixed.

[@knutz7]

Thanks bro, just finished doing my ‘09 1200 with your instructions. Seems to have worked.! Woohoo.

[@HeyNoah]

This is the best tutorial for this!!! Friggin awesome dude, and thank you guys!!! 🤙

[@JBetoRodrigues]

Thanks mate. Great video. Do you have any video about replacement of valve seals. My 1997 Evo Dyna Wide Glide is smoking blue on start up when hot and I think is valve seals. Thanks in advance.

[@kurtfoulke5130]

Gotta love Todd's videos 😆 Good luck installing the rear rocker box with the shafts installed 🤞 If you push a 16 inch .060 dia. length of wire down through the push rods, you can open the check valve in the hyd lifter. 👍 Foot lbs of Tq are 12 in lbs - hence 120 in lbs equals 10 ft lbs 🤔

[@carydavenport1869]

Thank you now I have the confidence to do this on mine and, myself, also purchased the gasket kit. Now if I only had a lift, lol

[@rickdee67]

Excellent video bro! On my 01 883 Sportster i had a hell of a time getting the rear cover off, SHITTY welds! It seems as if I machine down the four rocker bolts and take the crowns off it should go back in no problem though! Thanks for the great video!

[@crosstowntrains]

God I'm so glad the motor can stay in the frame. My Sporty has plumes of smoke coming from the oil burning, guess it's time to tackle it. Thanks for the tutorial.

[@tonyclem1754]

I like that simple straight to the point and informative there's a lot of these videos where they're hey look at this and you know I got this in my shop and you know I painted this yesterday and I did this last week and I got these plants outside your simple you're straight to the point and you get s*** done I like that part

[@Liquormans]

Thank you, I will try to do them on my 08 Xl 12 C Im tempted to put some gasket maker in the corner of the rear. It has leaked before. The bike has 50,000km they were done at about 25k km. Lots of in city riding, nature of the beast. Thanks for the video. "My tools don't make me money they save me money"

[@joirjoja1]

WoW; nicely done, in keeping the lesser known, in a captive state of awe, Mr Teacher if any one don't know now there aint nothing they will ever know...Thanks for the #101 class... I was looking to know and you sure did teach me something... I just got an 06' 883 sportster from a now friend, and this is just what it needs done to it.. So for $2000 i got me a real nice looking and working bike, as soon as i do this job to it. THanks for the video, you now have my attention from here on...So keep it coming... And i hope if i have some questions we can talk on them...Accurate knowledge is life saving....And we all need that.... I see you have done that...Your friend....JRC

[@joirjoja1]

PS. Where do i find that calibrated elbow torque wrench thin-gee thing....JRC

[@lowbrowcustoms]

Give us a call anytime. Todd is an expert technician and can help with (almost) anything and everything. We'll be here!

[@joirjoja1]

@@lowbrowcustoms Am making my list now thanks lol..i just got a bike a small 883' you see am 6' 260lbs my son might want to ride so i got it, i had stopped back in 95'' and i want to see if i can still preform like i once did, am 65' now.. this should be fun if you know what i mean... am going to change the handle bar... might be calling soon...see you soon....JRC

[@agarso]

Love it. Luckily mine is only leaking out the front, looks like quite the chore to do the rear one. Thanks for this!

[@richfrancabandera1363]

Thank you so much..I appreciate the breakdown.. it is actually what i needed

[@witchhunt99]

I just did this job on an early 1984 FXST. Basically the same process I believe. I followed the video step by step & referred to my service manual as well. I did not remove the pushrods. I allowed plenty of time for them to bleed down before tightening any bolts. Please answer this 1 question I have? After all 9 bolts were torqued down there is pressure on the rockers of both cylinders. I have cycled the motor several times by pushing on the kickstarter with my hand. I is easy to do and everything seems to be working smoothly but I am reluctant to hook up the battery and start the bike with electric start. Is it safe to try or have I missed something. Great video by the way!! Thanx

[@unclefuddelmer9224]

...Well did ya start her up?! As long as she turns over Smoothly by hand AND you don’t have any parts left over I’d go right ahead and kick it. What’s the worst thing that could happen?... a leak is about it.

[@lorenzojones3660]

Awesome video...thank you for great instructions!

[@brian4494]

Can the rear rocker come off with the motor on bike still for a 1989 ultra classic electra glide ?

[@bikebuilder8567]

yup

[@skaterson94]

Thank you so much, I was able to change mine out thanks to you!

[@roberttalbot1661]

I have a technical question. I have a 2004 bigdog ridgeback chopper with a -117 ci. S&S mtr. The engine warms up great , no noise, after a few minutes on idle there is a screeching noise in both front and rear valve train. Any ideas? I’m thinking a broken key in the oil pump or worn out plunger and springs in oil pump and during the idle I accelerate and it smokes like crazy bluish color. Please help !

[@jeffdingmann144]

Great video easy to follow and to the point thanks

[@BryanHemedinger]

So if I am going to do this gasket replacement should I also install the Rocker Locker kit while I am at it?

[@bikebuilder8567]

yup

[@rarusl]

Very nicely explained. Thank you.

[@RafiVNYC]

Great video. About to do this repair in a few days. Also, can someone help me figure out what seat is on this bike?!

[@mrbreezeet1]

Great how to. I have the confidence to tackle them again if need be. I had a follow that's a good wrench help me around 2006 we had to take them apart for a noise, but the dealership left the front sprocket loose in the primary as soon as that bike started making noise I said damn that sounds like it's in the primary. But another Harley mechanic said top end of front cylinder so we pulled the rocker boxes, but took a chance and reused the old gaskets and one leaked so we redid it. I have a question, on my cam cover the Chrome is flaking on it I got a pretty good price on a nice used one I have linked to a video below where a gal I think she's in the UK or somewhere she's pretty cool by the way anyways she pulled hers off without touching her rocker boxes at all. But I think hers is a rubber mount mine is a 2002 1200 custom. I guess wishful thinking but there is no way to sneak that can cover on and off without taking my rocker boxes off is there? kzbin.info/www/bejne/ZoOQkHuDZ7KBZrs

[@michelleanais2445]

Hello I have an 1993 HD classic Electra glide. When I cranked it up is leaking oil through the top of the engine where the gasket are. I noticed that the gas is getting into the oil pan. Do you think my engine is blown

[@tomn7829]

Thankyou. It was a big help and I got the job done easy and right. Thanks for your help...

[@mamjack6134]

2019 is a bit different but this video gets you through the technical stuff. 1st need to raise the front (disconnect fuel line) or remove gas tank, so you can move coils and plastic covers that keep wiring harness and throttle cables tucked into place . (save yourself some aggravation and do it to begin with and its as easy as the video) needs to be done for 3/16 Allen drives to fit and box cover to slide out . 2nd There is no middle ring , rocker box is one piece and the top cover

[@knucklebuster8651]

I wish all Harley guys were like this. Versus the overly wanna be tough frown bs guy. Good vid! Cause when I’m riding mine I’m grinning like a champ!!!

[@BeE-v2i]

Does it matter which direction the wittle hole on the roller is pointing?

[@jazzyjuniorlopez388]

Awesome video, looks like I’ll be buying your type of gaskets , keep up the good work.👍

[@robertdouglas7101]

thanks what is best to do back one first or front ?

[@lowbrowcustoms]

It really doesn't matter, if ya gotta get both done, you can start on either one. Just make sure to pay attention to torque sequence when doing front and back in your work shop manual

[@jukeboxheros7021]

on a evo 1340 same deal, except for the torque specs? why didn't u change the pushrod seals? if it ain't broke don't fix it? I'm fixing to do mine, thanks

[@ZipKickGo]

This is great, I'm going to use this video to guide me. My leak is higher up between the first and second plate, but do you think it's worth it to go all the way down and replace all the gaskets since I'm in there anyway?

[@BWGPEI]

Age & experience - I get away with is line being 65++. Man you are good!

[@jerrybigrig9475]

Just curious.. Why is there a square hole in the center of these Evo engines ..??

[@patrickmuraszewski3606]

I heard you're not supposed to re-use the hardware once there torqued is that true ?

[@davedammitt7691]

Great tutorial. Showed everything. Some videos start with the engine on a bench, or cut from a fully assembled bike, then say something like: "Then remove the tank, seat and rocker boxes", then cut to the disassembled engine. Literally useless.

[@cvosburg77]

Great video!!! At this point could I replace the valve seals?

[@humanentity2214]

Very nice and detailed video. Thanks for the attention to detail. On my 2013 HD sportster 1200, I'm seeing some dampness ( no oil spill on floor). Most of my friends said it's normal for an HD, should I be concerned?

[@lowbrowcustoms]

not right away but if it progresses to get worse then yes you'll most likely have to change out that gasket.

[@mikekirwan8809]

why is there any pressure on the valves? in the compression stage top dead there should be no contact?

[@fernando3551]

I have an 08' Nightster, that the wiring harness, running across the bottom of the frame and does not let the rocker box cover, be removed. Do I have to remove the wiring harness too? (alot or extra work, and don't know where to start the removal of the harness, that is very thick.)