Sportster Forty Eight Rocker Box Oil Leak Repair

[@fairbanksjp]

Acquired my first bike this month, a 2007 Sportster 883. Its having this exact issue and this video was spot on what I needed to know. This just may give me the confidence to tackle the job myself.

[@TwoWheelRocco]

If you have any question just ask..You will have no problems. watch the video a few times. Ride Safe and have a great day.

[@WARPED._.VISION]

I don't have a 48 but your knowledge carried me through the entire video

[@TwoWheelRocco]

Happy to help, Any questions just ask. Thank you for watching. Ride Safe and have a great day.

[@dervisdemirovic1553]

I have this problem with my nightster! I ordered the gasket sealers and now I cant wait to start the job! I'm very excited. Thanks for the video.

[@TwoWheelRocco]

Very popular problem with rocker boxes. Happy to Help, , Any questions just ask. Thank you for watching and your Sub Dervis. Let us know how this works out. Ride Safe and have a great day.

[@kingmagdaddy2k]

I Rocco, thanks from the other side of the globe. This video, helps me again and it help me to save money. And learned a bit more about me XL1200 2007. Thank you !!! God bless you

[@TwoWheelRocco]

Happy to Help, Any questions just ask. Thank you for watching and your sub Oliver . Ride safe and have a great day.

[@ChapsShrugged]

I dunno how I haven't subscribed before now- your videos are "Baby Bear": not over-explained, not skipping anything important- JUUSST RIGHT. 😉👌 Thanks man!

[@TwoWheelRocco]

Happy to Help, , Any questions just ask. Thank you for watching and your Sub Joshua. Let us know how this works out. Ride Safe and have a great day.

[@RT-wb5ye]

Great video, I just got a 2010 forty eight and the front one is having this issue. 🤙🏼

[@TwoWheelRocco]

Happy to help just be organized top dead center. Any questions just ask thank you for watching and all your support RT. Let us know how it works out. 48 of great motorcycles. Ride safe and have a great day.

[@johnthomas1919]

I could watch you all day long. Great video. Love the music too.

[@TwoWheelRocco]

Thank you for your kind words. And have a great day.

[@BRUISER1]

Great video. Very good detail. You can undo the plastic wire housing to make it a bit easier to remove the rocker covers.

[@TwoWheelRocco]

Thank you for your support. Ride safe and have a great day.

[@jimmansi1187]

Roc, I had a 2008 1200 Custom that blew the same rocker box gasket twice in 6 months, altogether cost me over $500. I was so pissed I sold it. Now ride a '95 1200 & it blows away the newer models in my opinion. Nice vid!

[@TwoWheelRocco]

Thank you for your support. I agree, Ride Safe and have a great day.

[@redskool8498]

kool rocco thanks for the vid ... now if i can only get done with winter more snow on the way then spring i can work on my bike .. have a good day .. †

[@TwoWheelRocco]

Thank you,

[@jtdundee]

Awesome! Looks like my floor jack will work to raise the rear wheel enough to spin it ;-) Thanks!

[@TwoWheelRocco]

Absolutely. Any questions just ask. Thank you for watching all your support. JT. Ride safe and have a great day.

[@adamak47miller90]

Well if that ever happens to my 48 I will know how thanks for the video.

[@TwoWheelRocco]

Thank you for your support Adem, Ride Safe and have a great day.

[@fredmeyer3063]

Another great video. Thanks for making this, I'm sure it will help on my 1200 Low.

[@TwoWheelRocco]

Happy to Help. Any questions just ask. Thank you for watching and your sub Fred. Ride safe and have a great day.

[@nickpage6931]

thanks for the vid's keep them coming thank you....

[@TwoWheelRocco]

Any questions just ask. Thank you for watching and all your support Nick. Ride safe and have a great day.

[@eguyntx1812]

Excellent job as always rocco!

[@TwoWheelRocco]

Thank you for your support. Ride Safe and have a great day.

[@TwoWheelRocco]

Thank you for your kind words. Have a great day.

[@XenaTheQuadCamBikah]

Hi Rocco I have a 2004 sportster I bought new. I'm doing this job for the second time and don't want to do it again so this go round I'll use the black permatex as you suggest but I have a question about the felt washers on the covers they're stuck and I can't figure out how to remove them without boogering up the cover, any ideas? Tia love your channel!

[@TwoWheelRocco]

I like to use the James gaskets, As for cleaning the old gasket just be careful and use a razor blade. use the black ultra gaskin on the low spots and you won't be fixing this again. Hope this Helps, Thank you for your Sub. Any questions just ask. Ride Safe and have a great day.

[@yayagazab4449]

I bought a 2011 Sporty 48 brand new & within a few months the rear cylinder began to leak. Seems like a common problem with these bikes. Also, you can also use purple Loctite gasket sealer to fortify the new gasket.

[@TwoWheelRocco]

I agree. It's a weak link on the rocker box the low end. Kickstand side. Thank you for watching and your sub Yaya. Ride Safe and have a great day.

[@javoriversen4605]

Hey and thank you for the video.....but I have a question and hope you will be able to answer me: I have adjustable pushrods, do I need to re-adjust them after this?

[@TwoWheelRocco]

Happy to help. No,you do not have to readjust those push rods.Rremove them and putting everything back in the same order.You are just repairing the gaskets. Thank you for watching and all your support javoriversen. Let us know how it works out. Ride safe. Have a great day.

[@thebanditbiker9425]

Thanks for this. It will definitely help guide me with my upcoming projects! I'm replacing the lower rocker boxes, do you think I need to install a new breather cap (that brown plastic on the lower rocker box) on each head? I'm replacing the breather gasket on each but not sure if I also need to replace the breather. The motorcycle has less than 3,500 miles on it and am hoping I need to add those to the parts list if I don't need to.

[@TwoWheelRocco]

I would just replace the gasket it's only has 3500 miles on it. Any questions just ask let us know how it works out. Thank you for your Sub.

[@bernardlesperance742]

Should I assume that this 48 does not have an alarm system? I ask because you made no mention of turning the key ignition to ON so that the bike won't sound the alarm when you are disconnecting various wires and removing the main fuse. For my 2009 XL1200L (LOW) (which has the proximity sensor for the fob but is not keyless), it is necessary to turn the ignition key to ON before disconnecting wires and the main fuse - or else the alarm will go off.

[@TwoWheelRocco]

You would be right. No alarm. Thank you for watching and all your support Bernard. Ride safe and have a great day.

[@dopra26]

Merci pour ce tuto, ça va bien m'aider😎

[@TwoWheelRocco]

Happy to help. Any questions just ask. Thank you for watching all your support Dopra, Ride safe and have a great day

[@mandizzle0517]

i have 10k miles on my 48 and want to replace my rocker box covers. Would you recommend changing my gasket and putting some gasket sealer on the weak spot of the rocker box?

[@TwoWheelRocco]

Yes I would use gasket sealer on the low side that always fail causing the oil leak. I would recommend a new gasket, It is a lot of work not to use a new gasket. Let us know how this works out. Thank you for your Sub. Any questions just ask.

[@drkshad0w89]

Did you just replace the one gasket? Alot of the kits I’m seeing come with a few different gaskets for that second plate you removed.

[@TwoWheelRocco]

It depends on the kit that you buy Jim's gasket kit that will be one piece that main gasket and it does make the job easier. Then you'll have your rubber seals. Not that bad at all. Just take your time. Top dead center and you're good to go. Let me know if you have any questions. Thank you for watching all your support.D A. Ride safe and have a great day.

[@moursymansour7848]

Good job, made me feel confident to do it myself, But what is the black material you used over the gasket?

[@TwoWheelRocco]

ultra Bk. hi temp. gasket maker, by permatex I use it on the low spots where oil will sit when your bike is on its kick stand. Let us know who this works out. Thank you for your Sub Moursy. Ride Safe and have a great day.

[@moursymansour7848]

Two Wheel Rocco is it a must to use while replacing the gasket or I can just replace the gasket without adding it?

[@TwoWheelRocco]

@@moursymansour7848 Use James Gaskets and you should be alright. Let us know how it works out. I like the extra protection with the ultra gasket sealant. These rocker box leak on the low side when sitting on your kick stand, seams to be a weak spot. Dealer love the work or the trade in of your bike. Fails by design.

[@alessandromaio4724]

This is the vide that I was looking for.... Same model of mine, 48 MY '11. I just need to know all the socket and the key that you used for... You know, in Italy the standard isn't the imperial... Many tanx !!

[@TwoWheelRocco]

Tools Needed. 3/8 drive 1/2, 7/16 sockets 3/16 Allen head with swivel 9/16 deep socket. 27 took bit Sportster rocker box gasket kit Torque wrench. torque spec 18 to 22 foot pounds on the four main bolts.#harleydavidsonfix

[@alessandromaio4724]

@@TwoWheelRocco Many tanx !!

[@edgarpena918]

Are you pushing the cylinder with a hose in spark plug?

[@TwoWheelRocco]

Happy to help. The rear wheel is off the ground. I have it in fourth gear or so and I'm rotating the rear wheel which rotates the piston to top dead center. Any questions just ask. Thank you for watching and all your support Ed. Ride safe and have a great day. Any questions just ask, let us know how it works out.

[@9w2zek]

thanks for the guide

[@TwoWheelRocco]

Happy to help. Any questions just ask. It's rewarding to fix your own motorcycle. Thank you for watching and your sub Zek. Ride safe and have a great day.

[@AlessandroMaio82]

Hi Rocco, this is the video that I was looking for.... Same bike of mine... 48 MY 2011...Rocco I just need to know all the size of the key that you Used... 'cause in Italy the standard isn' t imperial.... many tanx ad have a good day

[@TwoWheelRocco]

Tools Needed. 3/8 drive 1/2, 7/16 sockets 3/16 Allen head with swivel 9/16 deep socket. 27 took bit Sportster rocker box gasket kit Torque wrench. torque spec 18 to 22 foot pounds on the four main bolts. Hope this helps, Any questions just ask. Thank you for your Sub Alessandro. Let us know how this works out. Ride Safe and have a great day.

[@AlessandroMaio82]

@@TwoWheelRocco Rocco, are you Italian ? anyway, in Italy, I can't find the 3/16 allen with the ball head....

[@TwoWheelRocco]

Order it on Ebay...

[@TwoWheelRocco]

Hope this helps. www.ebay.com/sch/i.html?_from=R40&_trksid=p2334524.m570.l1313&_nkw=3%2F16+ball+end+allen+head+sooket&_sacat=0&LH_TitleDesc=0&_osacat=0&_odkw=3%2F16+ball+end+allen+head

[@firebug432]

Could you please tell me the part number for the gasket? Or if there is a kit I should buy?

[@TwoWheelRocco]

I like Jims Gaskets. www.ebay.com/sch/i.html?_from=R40&_trksid=m570.l1313&_nkw=harley+sportster+forty+eight+rockor+box+gasket&_sacat=0 Little more money. But well worth it. Hope this helps, Let us know if you have any questions.

[@davidhernandez1986]

My 2011 harley sportster is leaking oil from top of oil tank any thoughts? I tried removing tank but struggling to get it out.

[@TwoWheelRocco]

Happy to help. The first thing I would do is check that the oil level is between the two lines on your oil dipstick. And that will minimize pressure, now if it's coming out of the line on the tank which I doubt it is a 2011 they're pretty good bikes I believe you just got too much oil in there, check your air filter if there's oil on that air filter that means it's too much oil in the system creating pressure. Thank you for watching all your support David. Ride safe and have a great day. Let us know how it works out

[@watcherone142]

What do you use to clean off the old gasket? My bottom rocker gasket is pretty baked on there.

[@TwoWheelRocco]

I like to use a razor blade and gasoline and try not to score it scraping slowly. And clean with gas. That's how I do it. hope this helps.

[@erikortiz3875]

Do you have or own a shop near southeastern California, would definitely trust you to work on my harley 883 sportster...

[@TwoWheelRocco]

Sorry, I do not. I'm located in South Florida. California is beautiful, Thank you for watching and all your support Erik. Ride safe and have a great day.

[@jassierc.8621]

Went through my bike step by step with you and I have smoke coming out the engine area. Figured I fucked up somewhere so redid the whole thing and same issue, any advice? Great video

[@TwoWheelRocco]

Oil will get on the exhaust get inside to jog it's residual oil you'll have to burn it up. keep an eye on it. you probably had to leak fixed the first time. Thank you for watching and all your support Jessierc.. Let us know how it works out. Take it for a few rides, The oil should dissipate. Ride safe and have a great day.

[@jassierc.8621]

⁠@@TwoWheelRoccoended up being the lower gasket haha. Awesome video though thank you

[@TwoWheelRocco]

Happy you figured it out and all is well. Have a great holiday.@@jassierc.8621

[@ronbuccelli8486]

Another great video rocco, my 2008 1200 low just started leaking from same spot.when you took out the push rods, how exactly do they come out and go back in? Do they just pull right out?

[@TwoWheelRocco]

They come right out. It is pretty strieght forward. Thank you for your support. Ride Safe and have a great day.

[@baltazar9865]

Can I use blue Loctite on any other screws?

[@TwoWheelRocco]

Happy to help. Yes you can use blue Loctite. Let us know how everything works out. Thank you for watching and you sub Baltazar.. Ride safe and have a great day.

[@baltazar9865]

I got this done maybe like 2 years ago but the dude that did it did not torque all the screws now it leaks again....question is if I torque them it might stop leak?

[@TwoWheelRocco]

Happy to help. They are notorious for leaking. It's a Harley Davidson moneymaker. Use Jims gaskets with ultra gasket sealer and you won't have this problem again. Thank you for watching and your sub. Ride safe and have a great day. Let us know how it works out.

[@baltazar9865]

Ultra gasket sealer? What brand canseem to find it

[@TwoWheelRocco]

@@baltazar9865 www.google.com/search?client=safari&rls=en&q=ultra+gasket+maker&ie=UTF-8&oe=UTF-8. Black. auto zone

[@bobknight33]

My 1992 Sportster has the same issue. Just shows that HD would rather sell you parts than actually fix their design flaw.

[@TwoWheelRocco]

I agree. Any questions just ask. Thank you for watching and all your support bobbnight33.. Ride safe and have a great day.

[@bernardlesperance742]

Maybe a dumb question but how did you change to 5th gear without using the clutch (as far as I could tell)?

[@TwoWheelRocco]

Happy to help. When the motor is not running, you don't need a clutch. All you need to do is rotate the rear wheel as you're switching the gear lever. When you pull in the clutch that's like disengaging the motor from the transmission so if a motor is not running, it's not engage to the transmission so you don't hear no grinding when you switch gears. Thank you for watching and your sub Bernard. Ride safe and have a great day. I hope that helped.

[@bernardlesperance742]

@@TwoWheelRocco Thank you very much. Very helpful. Gotta change my gaskets as soon as it warms up a bit here in igloo land !

[@TwoWheelRocco]

@@bernardlesperance742 not too big of a problem. You just gotta take your time and stick to the procedure. I hate that design because it's designed to fail. Thank you for all your support, Ride safe and have a great day.

[@BarbarosYurttagul]

Great video Rocco. What is the black creamy thing that you put on the gasket? I couldn't understand.

[@TwoWheelRocco]

Black Pirma Tex ultra gasket sealer. To help out on their weak design. I did it a few times never last long. I said this is a joke ul black ultra gasket sealer AutoZone. Let us know how it works out. Thank you.

[@BarbarosYurttagul]

@@TwoWheelRocco thanks for reply. It is very sad that permatex didn´t work out.

[@TwoWheelRocco]

@@BarbarosYurttagul clean and reapply it will work, oil free.

[@ronaldwaddell3135]

Well done.

[@TwoWheelRocco]

Thank you.Ride Safe and have a great day.

[@PauloMatias]

Do you drain the oil first?

[@TwoWheelRocco]

Happy to help. No need to drain the oil.. Any other questions just ask. Thank you for watching and all your support Paul. Ride safe and have a great day.

[@travellerexplorer1930]

Thanks

[@TwoWheelRocco]

Happy to Help. Thank you for you watching and your Sub Traveller. Ride Safe and have a great day.

[@mackstesses8847]

Thank you 👍

[@TwoWheelRocco]

Happy to help. Any questions just ask... Thank you for watching and your sub Mack. Ride safe and have a great day.

[@mackstesses8847]

@@TwoWheelRocco Thank you very much. We keep in touch 👍

[@TwoWheelRocco]

@@mackstesses8847 my pleasure

[@caduhoffmann]

Good afternoon. Do you use ultra only on the upper side of the gasket?

[@TwoWheelRocco]

Both sides, Hope this helped. Thank you for your Sub Ed. Any questions just ask. Ride Safe and have a great day.

[@caduhoffmann]

@@TwoWheelRocco thanks for your both answers on the same subject on different videos :)

[@TwoWheelRocco]

Happy to help, Let us know how this works out. Thank you for your Support.

[@theone9564]

How you doing Rocco? Do this steps apply to the 2003 883 sportster?

[@TwoWheelRocco]

Yes it does..

[@brucehamman4201]

Is there not any butterfly gaskets?

[@TwoWheelRocco]

I don’t understand what gasket you’re talking about. Butterfly gasket? Are you talking about carburetor base gasket off the air breather. And yes there is one it’s on the back of the plate. Thank you for watching any questions just ask Bruce. And thank you for your sub

[@brucehamman4201]

@@TwoWheelRocco I have a question for you sir I have bought James rocker gaskets for my 2011 nightster they are metal with the red rubber bead around do you think I need any extra black ultra on the lower ends of the heads?

[@TwoWheelRocco]

@@brucehamman4201 Happy to Help, I would use the ultra. those low spots on the Sportster motors are the weak spots for oil sealing. They always leak in time.. Thank you for watching and your sub Bruce. Ride Safe and have a great day

[@brucehamman4201]

@@TwoWheelRocco alright so I did everything as I was suppose to but I did have a horrible tick/clunk sound I let it run for awhile shut it off and started it back up still had the bad noise again but it eventually went away sounds normal again and I don’t see any signs of leaks! I still have to do the front cylinder I’d like to know what I did wrong to get that nasty ticking sound any ideas? Maybe I can save it from happening when I go do the front rocker.

[@TwoWheelRocco]

@@brucehamman4201 Happy to help. You did not have that piston at top dead center. And that collapsed your lifter. So when you restarted the motorcycle, You had to pump up that hydraulic lift with oil and then the noise disappeared. Top dead center will make your two rockers on your top a little loose. Then you can disassemble the piston will be at the top and the two rockers will be loose that's top that center. The piston can be at the top and your two rocker one rocker will be tight that's not where you want to be. The dead giveaway, TDC and the two rockers are loose. I hope that helps. Other than that not too bad.

[@dwaynemadsen964]

I'm new to this, isn't 5,000 miles really low for an oil leak like this? I know lower rocker boxes are a known leak problem, there are a bunch of videos on how to fix them. It just seems to me that 5K miles is very low for this problem?

[@TwoWheelRocco]

I agree...It is terrible. But it is way to common. It is a great source of revenue for Harley Davidson.

[@jasonsilvers825]

Thank u watch I has same one bike 1200 cc

[@TwoWheelRocco]

Happy to help. Any questions just ask. Great motorcycle. Thank you for watching. And all your support Jason. Ride safe and have a great day.

[@edwinmartinez261]

Do the road king

[@TwoWheelRocco]

Happy to help. The Road King would be the same thing but a little different. Any questions just ask. Thank you for watching and all your support Ed. Let us know how it works out. Ride safe and have a great day. Very common problem.

[@darrellbarnes9594]

Do you have a email I have a question about my sportster

[@TwoWheelRocco]

You can use this site. Any questions just ask. Thank you for your Sub Darrell, Ride Safe and have a great day.

[@darrellbarnes9594]

Thanks brother. So my question is I have a 1999 sporty and I’m getting carburetor blow back and coughing also my rocker box gasket’s are leaking which I know I need to fix that but I feel air coming from the rocker box is that normal or is that due to the gaskets being bad

[@TwoWheelRocco]

Heres where I would start, Check for vacuum leak on your petcock diaphragm. A bad diaphragm will cause a rich condition. This is your coughing. Remove air filter and let me know how this changes things. How many miles? Fix the rocker box last, it has no affect on the running of your bike. Take a look at this video. kzbin.info/www/bejne/bXfSaoRvaLR9jqs. Any questions just ask, Ride Safe and have a great day.