Genuine James Gaskets Vs Cometic Sportster Forums
Modern Harleys are pretty leak-tight, but occasionally something will start leaking. Here is how to replace the most common gaskets.
This article applies to the Harley Davidson Touring (1999-2016).
The two most common leaks on a modern Harley are the exhaust gaskets and rocker box gaskets. This article will give you tips on how to replace them. Having the service manual for your bike will be required.
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Materials Needed
- Sockets and ratchets
- Wrenches
- Screwdrivers
- Torque Wrench
- Scotch-Brite pad
- Solvent and lint-free rag
- Blue Loctite
Exhaust Header to Port Gasket
Harleys are typically pretty loud, that's part of the fun, but a leak can affect performance and will sound lousy. If you hear the telltale sound of exhaust from the cylinder heads, specifically where the header bolts to the port, here is how you fix it.
Cometic Head Gasket
- Remove the exhaust system following the shop manual or aftermarket manufacturer's instructions. Gasket should have remained in head.
- Using a pick or bent screwdriver, remove the old gaskets (Figure 1).
- Clean the area where the gasket goes with a Scotch-Brite pad and dish soap or light oil such as 3-in-1 oil. Wipe off with a shop rag (Figure 2).
- Lightly lube the new gaskets with dish soap or light oil such as 3-in-1 oil (Figure 2).
- Gently start the gasket into the head recess beveled side out, and push with your thumbs. Do not force them, and move your thumbs around the gasket so they go in evenly. Jims makes a nice but expensive tool for this (Figure 4).
- Push the gaskets from the inside to make sure they are evenly seated all around (Figure 5).
- Reinstall exhaust system, following the shop manual or manufacturer's instructions.
- The oil you used will burn off and smoke for a few miles, but not do any damage.
Pro Tip
Torque the nuts holding the exhaust to the heads in the correct sequence and value specified in the manual.
Rocker Box Gaskets
Cometic Gasket Review
If you notice oil making a mess of your beautiful big twin motor, the most likely cause is the gasket under the rocker box cover, at the top of the cylinder head. You also should check that the oil isn't just dripping from the breathers plumbed into the air cleaner. SInce the tank has to come off to replace the gaskets, its a good idea to run the bike low on gas before you start.
Genuine James Gaskets Vs Cometic Sportster Forums Engine
- Remove the seat following your owner's manual.
- Remove the dash and gas tank as described in the related article How to Remove Gas Tank.
- Remove the six rocker cover bolts.
- Remove the rocker cover and gaskets.
- Clean the gasket mating surfaces on the head and the rocker cover with solvent and a lint-free rag.
- Lightly oil the gasket and place on head with indent facing forward (Figure 8).
- Place the rocker cover in position, aligning with the gasket.
- Apply a small amount of blue Loctite on the threads and loosely install bolts in the rocker cover.
- Tighten in the sequence shown in Figure 8 to 15-18 ft lbs.
Related Discussions
- 1st Time Exhaust Gasket Replacement - HDForums.com
- Trick to Installing New Exhaust Gasket - HDForums.com
- Changing Rocker Box Gaskets - HDForums.com