I haven't seen this specific issue anywhere and I've checked out a couple different forums, so I thought I'd ask here. Long story short, all the oil came out of my 1996 heritage nostalgia on the way to work one day, towed to the dealer, dealer says my rocker box cover is warped. Just one. My question is, how did this happen? What am I doing wrong? Dealer says it happens, eventually, bike almost 20 years old. Any other theories? Like to avoid this in the future if possible.

 

back in the mid 90s harley had a run of rocker covers pieces - some it was the top some the middle and, even the lower box had too much Zink in the alloy and the covers were heaver than the others on the bike - the expansion rate was different and after a while the up and down heat cycles they would become leakers. the cover normally has a memory being mostly alloy alum and it goes back to its original shape, But those zink ones did not after a while - the mileage if i remember right was around 25 thousand miles - hope that helps - johnjzjz

 

I had to buy new rocker covers this year after no amount of gasket work (tried a couple different ones - rubber, cork etc.) would permanently fix a persistent oil leak. Leak is now history.

 

I have a long, painful, and expensive story in regards to warped EVO rocker boxes.

Cut to the end: They do warp. Normally it is the middle one that warps. Last set of covers I bought from a stealership were pricey. They sell them individually: top, middle, bottom. If you purchase cheap ones from Custom Chrome, or Drag Specalties, you will get cheap. They should be checked on a piece of plate glass for 'wobble' before installation. IMHO: Spend the $$$ and get the Genuine MoCo ones.

 

Many thanks guys, all useful info.