Oil leaking from below lower rocker cover

[ChopperJeff]

I've just noticed a VERY slow leak located behind the rear cylinder, just below the lower rocker cover. Pardon my ignorance if I have the terminology incorrect.

It appears to be oil, and after riding about 20 miles there is a small drop of oil located on about the top fin of the motor, rear side and opposite side of the exhaust. I pulled the upper rocker cover and all looked OK with everything tight.

Is this a sign of a bad gasket? If so, can I do this myself?

Thanks.

 

[rwill20]

Had what sounds like the same issue, on my 04 chopper ,turned out to be the head gasket,just a thought.

 

[narow37]

Check out this thread ChopperJeff. I think this is what you are describing, not the actual head gasket but the rocker box gasket.
http://www.bigdogbiker.com/forums/how/4603-how-replacing-your-rocker-boxes-gaskets.html

 

[ChopperJeff]

Thanks narow37!

I checked out that "How To" and it looked very promising, but then step 14 states "Adjust push rods...". That sounds a bit scary to me. Guess I'm at a loss as to why the push rods would need any adjusting just because the rocker box was removed.

I'll keep looking.

 

[narow37]

Because you have to remove the rockers and to do that you have to relieve the tension on the rockers. especially for the reassembly in order to get an accurate torque value.

 

[V]

Chopper Jeff. Doing the rocker box gasket replacement is pretty simple even with the push rod adjustment. If you do this you might want to check the rocker box itself for some chrome build up from the manufacturing process. This has happened to others before causing a leak and is not hard to repair. Narrow's got you on the path. Follow the Big Dog brick road. (Sorry to many rum and cokes tonight)

How many miles on the bike? Did you buy it new?

Over and out V.:2thumbs:

 

[Gas Man]

Thanks narow37!

I checked out that "How To" and it looked very promising, but then step 14 states "Adjust push rods...". That sounds a bit scary to me. Guess I'm at a loss as to why the push rods would need any adjusting just because the rocker box was removed.

I'll keep looking.

Just do as Narow says in his post then to adjust the pushrods... use this
http://www.bigdogbiker.com/forums/how/463-pushrod-adjustment-how-pics.html

 

[ChopperJeff]

OK, thanks guys for all the input!

I have a friend who's willing to help me do this task, and then he has a friend who's an ace mechanic that we figure we can call if we run into a bit of confusion.

And yes, I bought the bike new. It's a 2005 Chopper and it just turned 43,000 miles!

Thanks again guys for all your help!!! I'll let you know how it all turns out once I get to it.

 

[BBChopper]

Check out this thread ChopperJeff. I think this is what you are describing, not the actual head gasket but the rocker box gasket.
http://www.bigdogbiker.com/forums/how/4603-how-replacing-your-rocker-boxes-gaskets.html

Good call bro!! :2thumbs:

 

[barhopper]

It's a 2005 Chopper and it just turned 43,000 miles!

My Idol. I wish I had the time to ride that much. :2thumbs:

 

[mcgroom]

And yes, I bought the bike new. It's a 2005 Chopper and it just turned 43,000 miles!

Raywood would be proud!

 

[ChopperJeff]

OK, with the help of a buddy I got the rocker box off and the gasket replaced. However, while trying to tighten the one bolt that's located toward the back corner of the rocker box, at the same spot the oil was leaking, it wouldn't tighten as if it was stripped. We removed the bolt and it had helicoil on it, and did not appear stripped at all. Apparently helicoils are used not only for repairing a stripped bolt, but also as OEM as it helps create a stronger thread in weak materials. At least that's what a mechanic friend told us and a google search yielded.

So bottom line is this:
Is there a way to just replace the existing helicoil, or is some sort of re-tapping in order? If replacing the helicoil, what size or type do I get?