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Technical Forums => EVO 1340 => Topic started by: JW113 on August 14, 2019, 07:32:33 PM

Title: #!$%&* Softail rocker boxes
Post by: JW113 on August 14, 2019, 07:32:33 PM
OK me brethern, I need some advice.

The original rocker boxes on this '92 softail of mine were totally blistered chrome, looked like hell. So I bought some (what looked good in the ad) used ones from ebay. And now, especially the front one, leaks like a sumbuvabitch. (can I say that?) I've replaced the gaskets three time now, last time just this past weekend. And still, leaking. My conclusion is that these fricken rocker boxes are bad, warped, came from some unethical unclean filthy basterd's bike who sold them on ebay, and now.. here we are.

So my question to all'a y'alls: Are any of the aftermarket rocker boxes worth a crap? Or do they all come warped from the ~ factory they were made in, and are bound to leak as well? As in, Drag Spec, Bikers Choice, etc. Worth it? Not? Does anybody make stuff worth paying for? Please advise!

:banghead:

Muchas gracias,
JW
Title: Re: #!$%&* Softail rocker boxes
Post by: turboprop on August 14, 2019, 07:40:19 PM
Is your question specific to softail rocker boxes, I was not aware the EVO softails had model specific rocker boxes. 
Title: Re: #!$%&* Softail rocker boxes
Post by: rageglide on August 14, 2019, 08:20:01 PM
Over tightening the tops sqoushes the d-rings out of position.   Pretty sure there is not a single year that's vulnerable outside of hamfisting.  Maybe a billet top can handle a bit more, but I'm sure it force the d-ring to move/

IMO replace with OEM gaskets (not jamessucksshit) and go easy AF with the torque... as in little to none. 


Title: Re: #!$%&* Softail rocker boxes
Post by: JW113 on August 14, 2019, 08:38:40 PM
EVO sotfails are not specific. Any Evo rocker box is likely to have similar issues.

Bob: your response is certainly valid. Over-torque can be the source of this issue. Just not sure what to do at this point. Try yet another set of gaskets and try not to over-torqued them (not that you can get a torque wrench in there), or assume the boxes are no good and start fresh? I would love to have a set of virgin rocker boxes and try to start anew, but is that really the solution? I just don't trust this 25+ year old crap.  Is there a new production rocker box that's worth a try?

-JW
Title: Re: #!$%&* Softail rocker boxes
Post by: koko3052 on August 14, 2019, 08:57:40 PM
How about trying to touch them up on a flat plate, a sheet of fine emery cloth & some cooking oil? I do that to heads every time they are removed.
Title: Re: #!$%&* Softail rocker boxes
Post by: Buglet on August 15, 2019, 05:25:29 AM
  Are they OEM boxes or aftermarket, if aftermarket some they take thicker gaskets as the original won't seal right.
Title: Re: #!$%&* Softail rocker boxes
Post by: SixShooter14 on August 15, 2019, 06:02:24 AM
Quote from: koko3052 on August 14, 2019, 08:57:40 PM
How about trying to touch them up on a flat plate, a sheet of fine emery cloth & some cooking oil? I do that to heads every time they are removed.
I'd go with this. I bet they just aren't as flat as they oughta be.
Title: Re: #!$%&* Softail rocker boxes
Post by: Ohio HD on August 15, 2019, 06:48:16 AM
ahhh, pry open that wallet and buy some OEM covers. Only $281.97 for one set (one head).       :smilep:

17528-92 ROCKER COVER, OUTER (CHROME)  $87.99

17529-92 SPACER, ROCKER COVERS (CHROME)  $70.49

17530-92 ROCKER COVER, INNER (CHROME)  $123.49


Title: Re: #!$%&* Softail rocker boxes
Post by: wfolarry on August 15, 2019, 06:56:07 AM
I put S&S 2 piece covers on mine. never leaked again.
Title: Re: #!$%&* Softail rocker boxes
Post by: turboprop on August 15, 2019, 11:58:41 AM
Quote from: JW113 on August 14, 2019, 08:38:40 PM
EVO sotfails are not specific. Any Evo rocker box is likely to have similar issues.


Not sure why you titled the thread softail rocker boxes. I was hoping to learn about some unique softail parts.

Not all evo rocker boxes are the same. The early ones used cork seals between the various layers. The later ones used rubber seals. Components between the two types can physically be interchanged but will not seal. Same with the seals, rubber seals cannot be used in covers designed for cork.

Lapping them will only work on the bottom sides as the upper side has channels for the seals.

Alignment can also be an issue as the middle layer sort of floats and is really only held in position by the clamping force between the base and top covers. With the tolerance in the mounting holes, it is possible to have the top, middle and base layers in just the right position that the seals are barely touching their mating surfaces. Some assemblers will use tapered alignment pins in a couple of the holes to center the top piece, etc.

I have billet and cast EVO rocker boxes from S&S. They each have their good and bad points. The billet ones are a major pain in the ass to work on. Especially with a tall engine in a little FXR frame. The top bolts on the rear left side are the worse. On the positive side, their internal supports are two pieces which makes getting everything in and out easy as everything can go in one piece at a time. The cast S&S boxes are a bit easier as the top bolts are accessible from the outer edge vs being in the middle of the cover. Their internal supports are similar to the TC design and a little harder to get in and out of the rear cylinder.
Title: Re: #!$%&* Softail rocker boxes
Post by: cheech on August 15, 2019, 02:56:51 PM
Get your originals replated?  :scratch:
Title: Re: #!$%&* Softail rocker boxes
Post by: rageglide on August 15, 2019, 09:18:53 PM
JW you have a set of bare covers, you could have em chromed... but I would think there's a good chance that might not work out so good.  Probably better off polishing them on your buffer.

As far as the interchange comments go, grab an evo engine out of any chassis from 1984+ and the f'er will bolt right up in any chassis.  Period.

Remove .050-070" off the heads and it makes rear rocker box easier to remove on a softail.

I put updated H-D rubber gaskets in my '86 with zero issues. It had cork/rubber gaskets when I swapped em out.  IMO the trick and key to leak free rocker box is zero oil on the gasket.  Wash em with brake clean when you could buy the chit, otherwise remove ALL oil and you're going to be ok.  Any oil on the rubbers cause them to move around.
Title: Re: #!$%&* Softail rocker boxes
Post by: Ironheadmike on August 16, 2019, 08:02:37 AM
Quote from: Ohio HD on August 15, 2019, 06:48:16 AM
ahhh, pry open that wallet and buy some OEM covers. Only $281.97 for one set (one head).       :smilep:

17528-92 ROCKER COVER, OUTER (CHROME)  $87.99

17529-92 SPACER, ROCKER COVERS (CHROME)  $70.49

17530-92 ROCKER COVER, INNER (CHROME)  $123.49
Can you still get them from HD ?
Title: Re: #!$%&* Softail rocker boxes
Post by: Ohio HD on August 16, 2019, 08:00:50 PM
Well, the pricing comes from HD online, so I'd say yes.


[attach=0,msg1311641]
Title: Re: #!$%&* Softail rocker boxes
Post by: JW113 on August 16, 2019, 08:46:31 PM
Yes, absolutely, Softail rocker box gaskets are different from all the other Evo rocker box gaskets. Softails are poser bikes, all show and no go. Therefore, the gaskets used in Softails are color coordinated to the bike's paint scheme. Blue bikes get blue gaskets, red bikes get red gaskets, and so on. And not just the rocker boxes, but ALL the gaskets used in the engine and transmission. It's a style thing. Why else ride a Softail if not because it's stylish?

And here I thought this was common knowledge.

-JW
Title: Re: #!$%&* Softail rocker boxes
Post by: astropi on March 09, 2023, 11:41:18 AM
The surfaces must be meticulously cleaned, put a piece of cellophane in between to keep them clean, tighten slowly, evenly, and don't over torque. I got to do these 4 or 5 times until I figured this out. The MOCO gaskets are fine.
Title: Re: #!$%&* Softail rocker boxes
Post by: Tacocaster on March 09, 2023, 04:26:24 PM
OR....similar to what rageglide suggests...but different, how about relieving the blistered chrome off the originals and spray 'em with a nice flat (or gloss, to your taste) wrinkle black paint? I did a set for the same reason and they came out quite nice - or so I thought.
Like this:
Sporster Eng Rgt side.jpg
Title: Re: #!$%&* Softail rocker boxes
Post by: turboprop on March 10, 2023, 07:59:05 AM
Amazing.
Title: Re: #!$%&* Softail rocker boxes
Post by: guido4198 on March 12, 2023, 04:08:31 AM
WHATEVER solution you decide to go with...use a big piece of glass to verify that the rocker box pieces are FLAT, not already warped before you try to get them to seal up. When I went through a similar effort to stop "seeping" in mine, James gaskets and very careful tightening/torqueing solved the problem for me. Others may work just as good but James were what I went with.
Title: Re: #!$%&* Softail rocker boxes
Post by: Deye76 on March 12, 2023, 05:50:52 AM
Cometic gaskets worked well when I had my stock (1992) rocker covers off for powder coating a couple years ago.
Title: Re: #!$%&* Softail rocker boxes
Post by: Ironheadmike on March 21, 2023, 12:32:33 PM
I've owned Evo softail bikes for well over 30 years and never had a problem with the covers . As long as you torque them down properly and the middle piece is aligned correctly. I've found that the Hd gaskets lay the best for the rocker covers.
Title: Re: #!$%&* Softail rocker boxes
Post by: SixShooter14 on March 21, 2023, 01:09:55 PM
I know this is an old discussion... But, I've fixed the box weeping on a Softail and a Road King. proper installation/torqueing and getting the engine up to temp have always kept the leaks from returning for me.
Title: Re: #!$%&* Softail rocker boxes
Post by: Ironheadmike on March 23, 2023, 10:18:14 AM
Quote from: JW113 on August 16, 2019, 08:46:31 PMYes, absolutely, Softail rocker box gaskets are different from all the other Evo rocker box gaskets. Softails are poser bikes, all show and no go. Therefore, the gaskets used in Softails are color coordinated to the bike's paint scheme. Blue bikes get blue gaskets, red bikes get red gaskets, and so on. And not just the rocker boxes, but ALL the gaskets used in the engine and transmission. It's a style thing. Why else ride a Softail if not because it's stylish?

And here I thought this was common knowledge.

-JW
I have never seen color coordinated gaskets all gaskets from 84-99 will work fine if you do proper torque
Title: Re: #!$%&* Softail rocker boxes
Post by: xlfan on March 23, 2023, 10:57:34 PM
Quoteall gaskets from 84-99 will work fine if you do proper torque
There was a time that only OEM rubber rocker box gasket was your only sure way to a leakfree EVO rocker box. I have since stayed with that. Maybe aftermarket gasket have improved? Would be interesting to hear from up to date real world experience.
Title: Re: #!$%&* Softail rocker boxes
Post by: Reddog74usa on March 24, 2023, 07:41:24 AM
Never had an issue using the OEM rubber gaskets.
Title: Re: #!$%&* Softail rocker boxes
Post by: JW113 on March 24, 2023, 12:54:21 PM
Quote from: Ironheadmike on March 23, 2023, 10:18:14 AMI have never seen color coordinated gaskets all gaskets from 84-99 will work fine if you do proper torque

 :fish:

Somebody grab the net, I hooked a big one!

Technical content: Just to clarify, you can't use ANY gasket from 84-99 on ANY model from 84-99. Head breathers use a different gasket set than the case breathers. Maybe you meant that?

-JW
Title: Re: #!$%&* Softail rocker boxes
Post by: Dan89flstc on April 01, 2023, 05:14:20 AM
OEM rocker boxes are no longer available.
Two years ago I was going to replace the boxes on one cylinder on my `89 Softail, when the parts guy got on the computer he said they were still available but had the notation "Pending Obsolete".

I bought 2 sets instead of one, cost about 800 bucks.

The original rockerboxes on my `89 were junk when they were new, they got so soft that the center spacer would bulge so much you could see inside.
Title: Re: #!$%&* Softail rocker boxes
Post by: Dogbone45ACP on April 02, 2023, 07:55:12 AM
My '89 also had problems with the center section getting out of shape. They were made from zinc or some similar crappy material.
Title: Re: #!$%&* Softail rocker boxes
Post by: xlfan on April 07, 2023, 01:16:58 AM
I haven't experienced the same out of shape center section with the Sportster rocker box. Maybe they still are available OEM?
Title: Re: #!$%&* Softail rocker boxes
Post by: Deye76 on April 07, 2023, 06:57:53 AM
Quote from: xlfan on April 07, 2023, 01:16:58 AMI haven't experienced the same out of shape center section with the Sportster rocker box. Maybe they still are available OEM?

I think they look great on a big twin. :up: