Mike Roen installs the Harley rocker box cover gasket in the correct location. You will need a little blue Loctite on the cover bolts to help keep them in place.

harley davidson rocker box covers

Make sure the gasket stays in place, run the bolts down snug and then torque to spec. Be careful not to damage the chrome surfaces. Mike walks through the same process for the rear Harley rocker box cover. He goes through the torque sequence using the dog bone.

This is a tight area and you will need to take care as you move around the cover. With both Harley rocker box covers in place with gaskets, bolts and torqued to spec, Mike moves to the throttle body installation.

Use the new intake seals provided in the kit. Make sure to have the front and rear brackets going to the right position, they are labeled. Mike updates the bolts to hex head for ease of service in the future.

You do not want an air leak. Make sure everything goes in place.

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Do not cross your bolts. Finger tight first. Mike uses an angle finder to make sure the throttle body is level. If you do not have an angle finder, put your backing plate on and mock the assembly up.

Check your level then snug up the bolts.

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He will reinstall the fuel injector wires and the rest of the electrical components. You will have good access with the backing plate back off and the tank off.Leaking rocker box gaskets were a particular problem with Harley Evolution engines.

Harley went through four generations of lower rocker covers and four versions of the middle cover, or D-Ring, as the motor company tried to solve the problem. The earliest gaskets, from towere made of cork. The next versions, which lasted untilwere made of zinc and leaked the most. Subsequent versions were rubber. Removing rocker box covers to replace the gaskets is a straightforward process.

Very experienced mechanics can do the job without removing the gas tank but less experienced mechanics should probably begin this job by remove the tank. Remove the seat bolt and washer from the tab on the rear of your seat. Remove the seat to access the battery. Loosen the negative battery cable from the terminal with a box wrench and remove the cable from the battery. Remove the center console. Typically, the center console is attached to the center console bracket with three Allen head screws.

Remove the fuel line from the petcock. Typically the petcock and fuel supply are joined by a hose clamp. Loosen the hose clamp with a flat head screwdrivers. Drain the gasoline in your tank into an adequately sized, sealable, gas can. On models with dual gas caps, disconnect the crossover and fuel venting hoses in the front, middle bottom of the tank. Remove the front mounting bolt, flat washers and acorn nut with a box wrench and socket wrench.

Remove the rear mounting bolt, flat washers and acorn nut.

How to Replace Harley Rocker Box Gaskets

Disconnect the fuel gauge connector on recent models. The fuel gauge connector is under the left side of the fuel tank. Remove the gas tank from the motorcycle. Set the tank on a flat stable surface in a well vented place. Remove the six Allen bolts and washers that connect the rocker cover to the rocker assembly.

Begin with the front rocker box and work on one cylinder at a time. Remove the metal D-ring if your motorcycle is equipped with an Evolution engine.

Note the top, bottom and orientation of the D-ring. Completely remove the old gasket. Use a gasket scraper if necessary. Examine your rocker arm housing. Rocker arm housings with only a partial inner lip require you to use an adhesive like high temperature rubber cement to properly install the new gasket. Rocker arm housings with a full inner lip do not require adhesive. Apply adhesive if needed and properly place the gasket on the rocker arm.

Replace the D-Ring on Evolution engines. Replace the rocker arm cover. Tighten the Allen bolts in a cross pattern to 10 to 12 foot pounds of torque. Refer to the shop manual for your motorcycle and use the exact torque sequence and specifications described there.

Re-bolt the gas tank to your motorcycle. Reconnect the fuel gauge connector. Reinstall the fuel line to the petcock.The item selected will only fit the motorcycles listed. Please select your bike here to see all the parts that fit your motorcycle. In Stock. Free Shipping. Design: Gauge E. By subscribing you agree to our Privacy Policy.

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Free Shipping. Usually ships in business days. This item is temporarily unavailable. We also have all your necessary screws, gaskets, and Harley Sportster Rocker Box Components for proper installation. If you need more than just the covers, you can also find a new set of Harley Sportster Rocker Boxes. By subscribing you agree to our Privacy Policy. Shop Motorcycle Gear Shop All.

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Automotive Format see all Format. All Listings filter applied. Buy It Now. Brand see all Brand. Arlen Ness 3. Covingtons 2. Drag Specialties 1. Harley-Davidson 7. Unbranded Warranty see all Warranty. No Warranty The item selected will only fit the motorcycles listed. Please select your bike here to see all the parts that fit your motorcycle. In Stock. Free Shipping. From anodized aluminum to stainless steel or chrome, you'll benefit from added features in these rocker boxes like increased cooling surface and clear windows to watch the rocker in action.

Harley-Davidson rocker box bolt cover models also come with all necessary mounting hardware so you're ready to install right away. By subscribing you agree to our Privacy Policy. Shop Motorcycle Gear Shop All.

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harley davidson rocker box covers

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