Leaking rocker box - 2001 Buell Blast

On most vehicles rocker covers are not normally bolted down that hard. Install the bolts by hand until finger tight then tighten in sequence a Quarter turn at a time until you get to 20 Ft/lbs and NOT tighter. Rocker covers are not normally exposed to full oil pressure so don't need to be a high torque setting. I often go to 15 Ft/lbs first and run the vehicle for one or two miles to check for leaks. That gives me that extra 5 Ft/lbs to avoid over tightening bolts.

Rocker arms have to be removed, BUT newer push rods are NOT adjustable, so you just can't loosen the push rods.

On the cylinder you're working on, BOTH valves MUST be closed.
EVENLY loosen rocker arm mounting block bolts, a little at a time.

Also, IF you remove the push rods, they are different lengths, so pay attention which one goes back where!

It's possible one of the gaskets got pinched, or one of the cover pieces is warped. Either way, it's gonna have to come apart again to fix it.

The problem is the the air breathers inside the rocker covers. Sad to say,but nearly all of them do this. One solution is to take off the air filter cover. There should be two bolts..(one on each side of the inside of the housing) that SHOULD have hoses hooked to them. If they do not have the hoses hooked to them,then that is your problem. See,these bolts are hollow,and have a nipple on the ends of them. These allow the top end to "breathe",a crankcase pressure relief if you will.Anyway,..these nipples are SUPPOSED to have a small hose on each of them,that re-direct the oil/crankcase pressure, into the carb/throttle body,which eliminates the oil running into your air filter housing.Check to make sure they are in fact there,and let me know what you find.

That depends on which gasket is leaking. If it's just a rocker box gasket, it's just a minor problem and if you fix it yourself, the total costs is less than $20. If it's a head gasket, the cost is a bit more and you'll probably want to have that done in a shop, I'm estimating cost about about $200-$250. As far as I know, there were no recalls. The rocker box gasket leaking is more common than the head gasket leakage but neither are what I call major expenses. If the head gasket is leaking, if you rev the engine just a bit when it's cold, sometimes it will pop and you can see fire jump from beneath the head. More than likely, it's just a rocker box gasket leaking.

Good Luck
Steve

Simple fix. Take the fuel tank off and remove the four bolts that hold the rocker box covers on. If the rocker box is leaking there, simply put a new gasket in place, carefully align the top plate and put the bolts back in. Torque them to 100 inch pounds.

If the lower rocker is leaking remove the smaller 1/4" bolts and then remove the larger 5/16 inch bolts. Remove the larger bolts a turn at a time until they are completely loose. Lift the lower rocker plate and replace the gaskets. Reposition the lower plate and align the pushrods in the rocker arms. Do not mix up the push rods, mark them if necessary. Tighten the 5/16" bolts down evenly until just seated. Then put the 1/4" bolts in. Torque the 5/16" bolts to 15-18 ft. lbs and 1/4" 10-13 ft. pounds. Reinstall the middle and upper rocker boxes and torque those bolts.

Good Luck
Steve

take the rocker cover back off and check the oil breather and make sure the o ring on the bottem of it is still on there

I think you are referring to "rocker boxes" on your Sporty. Replace the rubber gaskets between the lower plate and the upper plate. If the lower plate is leaking, you will have to remove the lower plate with the rocker arms and the push rods.