Ok so I have a 2004 Sportsman 600 twin and I have oil coming out above my manifold which i guess would be the rocker cover seal. Anyone know how hard it is to change this seal? can I take the bolts out and lift the cover up and place the new one in?'

thanks

 

I just replaced the valve cover and seal on my 2003 700. The new cover is metal, the old one was plastic. You should also replace the valve in the line that goes back to the airbox from the valve cover, mine was plugged, causing pressure in the valve cover, and blowing the seal. All told, everything came to about $50, the new valve cover came with a new seal. And yes, it was relatively easy to replace.

I must say that I had the gas tank off, so I don't know how easy it would be with it on. Good luck.

 

Did you have to remove plastics and the gas tank or were you able to do it from the side? I really dont wish to spend hours for a little bit of rubber!

 

I'm afraid I can't answer that - I was doing many things on a machine I just purchased, so I had the tank and plastics off to begin with. I was able to change plugs, do compression tests, etc while I was there. Sorry I can't be of more help.

It was a bit of a PITA to remove the plastics and tank.

 

I can get the plastics off in 10 mins, its the front bumper with the winch that I have issues with, I cant seem to find a fast way of taking it off, did you have to remove the winch and then the front bumper?

 

Yes, winch and bumper were removed in order to get the plastics off. But that wasn't that bad, for me the problem was getting the plastics over the handlebars - maybe there's a technique to that, but that was what was toughest for me. And that had to go in order to lift the gas tank.

 

Did the winch come out on its own? I seem to loosen a ton of bolts and I think to myself there must be a better way!

 

If you do get your valve cover off check to make sure the plastic valve cover is not warped, mine was on my 2003 sp600, had to buy a whole new valve cover. I assume this oil leak is what I asked you about in one of your pictures that you had up? Not sure if I pulled the fuel tank or not, or if I just loosened it some to get in there.

 

4 bolts for the winch, plus the two wires. And my plastic valve cover was warped, hence the new (metal) one. And, as I said, the new valve cover came with a new seal (If I recall, the seal was about $25, the new cover + seal was about $45). But don't neglect the PCV valve (or whatever it's called) in the line from the valve cover to the air box - mine was plugged.

 

I checked the cover breather and valve breather and both look good. The seal here is $33.96 and the cover is $54.29. I haven't taken it off yet to see what is going on. I was just going to replace the gasket because our dealer here doesn't keep much stock and it takes a week to get stuff in but he does have the gasket. Should I just get the cover new?