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Thread: DIY Fix: Fan fuses blowing/Rocker Boxes leaking! *BIG*

  1. #11
    Senior Member lowkey's Avatar
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    Great job on the write up!

    Where do the copper washers go that you can see in the background of this picture? There are 8 of them and they were packaged with the 8 fiber washers that go on the top rocker box bolts, are they to be used between the fiber and the built in washer on these same rocker box bolts? I'm at this point before I bolt on the rocker covers and put the motor back in the frame, just want to make sure before I finish up.

    Also I have 2 tips for people that plan to do this first is that the plastic on the wiring clips is very brittle so be very careful when separating them, my main clip on the throttle body has 2 securing clips on ether side and one broke when I released them.

    When you come to the point of dropping the motor down from the frame you will notice the only thing that will snag is the two throttle cables or at least they will have strain on them and prevent a full rotation. I found the best way to release these cables was to take off the 10mm nut at the end of the throttle body that keeps the wheel where the cables are attached to on. Once you have the nut off just pull the wheel off the shaft and you will have the slack needed to remove the cable ends easily from it without destroying them. Make sure to mark the top or bottom cable so you can reassemble easily!

  2. #12
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    Quote Originally Posted by tacklejunkie View Post
    I have about 100 miles on this rebuild so far and will report when I have more.
    How many miles do you have on the motorcycle after replacing the gaskets. Does it leak again?

  3. #13
    Senior Member BuellyBagger's Avatar
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    Just posting so I can find this later.

  4. #14
    Senior Member Silverrider's Avatar
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    great write up.

  5. #15
    Senior Member Simplymichaeljr's Avatar
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    Yes, excellent attention to detail. Anyone on here should have no problem following this write-up. This is inspiring me to finally install the rocker cover gaskets sitting on the work bench in my shop. LOL. Thanks, now I HAVE to rotate the engine

  6. #16
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    Nice write up thanks

  7. #17
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    I've got the James Gaskets set for the top end. As I understand not all of these gaskets will be used? I'm going to rotate the engine, so what would you recommend to replace since I will be there in addition to the rocker box gaskets replacing? I'm going to replace the rocker box gaskets as it was described in this thread, also I'm going to replace intake manifold gaskets and PCV valves gaskets. Anything else I suppose to do? Would it be a good idea to replace the exhaust pipes gaskets since I have them in the kit or just do not touch the pipes since they have no problems? Should I replace the O2 sensor?







    Last edited by TPEHAK; 10-27-2016 at 04:33 AM.

  8. #18
    Senior Member lunaticfringe's Avatar
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    Should I replace the O2 sensor?

    yep. they're cheap

  9. #19
    Would this be the same kit for a 2008 xb9sx? My rear rocker gasket is also leaking and was planning on doing the repair this winter. Thanks.

  10. #20
    Senior Member lunaticfringe's Avatar
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    Quote Originally Posted by GRONX View Post
    Would this be the same kit for a 2008 xb9sx? My rear rocker gasket is also leaking and was planning on doing the repair this winter. Thanks.
    yep. 07-10 XB james kit the same. note that the pushrod cover assy. seals in this kit will not fit buell XB



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