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techtalk:evo:oil06 [2024/01/05 19:51]
– hippysmack |
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techtalk:evo:oil06 [2024/01/06 03:50] (current)
– hippysmack |
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| ====== Diagnosing the Origin of Internal Oil Leaks ====== |
|
| See also in the Sportsterpedia: \\ |
| * [[techtalk:ref:svcproc20|Performing a Compression Test]] |
|
|
| ===== Rocker Box / Gaskets ===== |
|
| * **Installation error**. |
| * **It's easy to get the rocker box gaskets shifted off center if you're not careful when installing them**. |
|
| | Leak with pinched gasket. ((photo by sep69 of the XLFORUM http://xlforum.net/forums/showthread.php?p=3754227)) \\ (can cause crankcase pressure problems) | Leak with non pinched gasket. ((photo by Skuzeee of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-general-discussion-and-problems/196602-the-oil-leak-rabbit-hole/page2?t=2073161&page=2)) \\ (can be caused by crankcase pressure problems) | Worn / leaking HD lower gasket. ((photo by repairguy of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/efi-sportster-motorcycle-talk-2007-and-up/82518-installed-the-lower-rocker-box-gasket?t=612035)) \\ (can be caused by improper torque) | |
| |{{:techtalk:evo:engmech:pinched_rocker_box_gasket_1_by_sep69.jpg?direct&300|}}|{{:techtalk:evo:oil:leaky_rocker_box_by_skuzeee.jpg?direct&300|}}|{{:techtalk:evo:oil:worn_07_rocker_box_gasket_on_883_by_repairguy.jpeg?direct&300|}}| |
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| ==== 2004-2006 Rocker Box Design Change ==== |
|
|
| ===== Pushrod Tubes ===== |
|
| * **Installation error**. |
| * **Upper pushrod tube oil leak**. |
|
| * Officially, the head and cylinder need to come off for a new gasket install. You can pull the cylinders with the pistons still in them. ((ReddTigger of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/190725-suspected-base-gasket-leak?t=2033165)) \\ You only need to replace one wrist pin clip on each piston. There is no need to re-ring or hone the motor if just replacing the base gaskets. |
| * However, some will say that this type of seepage is merely cosmetic if it doesn't leak very much oil and they'll just let it leak. \\ Periodic cleaning is good enough as it keeps you riding instead of wrenching. \\ However, it can affect crankcase pressure (induced air leak) especially if the leak is significant and can indicate a pressure problem. \\ |
|
|
| {{:techtalk:evo:oil:base_gasket_weeping_by_harleydude24.jpg?direct&300|}} ((photo by harleydude24 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-general-discussion-and-problems/163286-am-i-screwed-oil-leaking-from-bottom-of-fins/page4?s=e990bc46dbb9e28925f7d5ca60a40df5&t=1754690&page=4)) \\ |
|
| * The case halves are put together with sealant (not gaskets). \\ It is possible, when mating the left and right case halves, to not spread the sealant evenly and create a future leak. \\ Too thin in some places and too thick in others. If the bolts are not properly torqued, this could leave gaps in the sealing surfaces. |
| * **Motor mount bolts may appear to be leaking oil when the oil is actually coming from the case seam around the bolts**. |
* The bolts don't actually enter the case but rather through bosses on the outside of the case. \\ One practice to seal up old case seam leaks at the bolt holes has been to remove the bolts, add silicone to the threads and reinstall the bolts. ((steelworker of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-general-discussion-and-problems/124905-can-eng-oil-leak-from-eng-mount-bolt-on-evo/page2?t=1250708&page=2)) \\ So if you are leaking out the bolt holes, someone may have smeared sealant on the bolt to make up for the failure of the case seam there. \\ This patch will not in itself cause any harm and may well hold up, but it is not right. \\ The alternative is to completely strip the engine and re-seal the cases. |
| * **Too much crankcase pressure**. See [[techtalk:evo:oil06#crankcase_pressure_problems|Crankcase Pressure Problems]] below. |
| * More often, it seams this is a result of excess crankcase pressure sucking the sealant out of the joints. \\ Excess (vacuum) pressure is generated from failing crankcase breather valve(s) or a kinked/blocked transmission vent hose. \\ 2004-up Sportsters (due to internal changes) seem more susceptible to having crankcase pressure problems. |
|
| * **Repair**. \\ Either repair below may be only temporary unless you check / replace / maintain the crankcase breathing system. \\ See also [[techtalk:evo:engmech07#crankcase_ventilation|Crankcase Ventilation]] in the Evo section of the Sportsterpedia for breather valve replacement. |
| * Officially, the cases need to be split and the joint re-sealed. |
* However, you can try this repair idea from aswracing to apply sealant from the outside of the joint. Depending on which area the seepage is; ((aswracing of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/rubber-mount-sportster-motorcycle-talk-2004-2006/140331-oil-leak-at-cases/page2?s=4c72b9196b3bbb5eba4dd0f61f777757&t=1521789&page=2)) |
| * Drain the primary and/or engine oil. |
| * Hook up a Mightyvac to the transmission breather hose (if sealing joint involving tranny compartment) or crankcase breather (for engine area). |
|
| * The case seam is the lowest part of the engine. \\ Any leaks from above can seep down beside parts you can't see around and end up at the case seam, making you believe the seam is leaking. \\ Clean off the area thoroughly and watch to see where the leak is actually coming from. See [[techtalk:evo:oil06#leaking_with_engine_running_weeping_gaskets|Leaking with Engine Running (weeping gaskets)]] below. |
|
| Case seam mismatched under cylinders causing a leak. ((photos by BlackBikeDave of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/198219-base-gasket-surface-question?s=7717d46f972d38363307890dd86fb953&t=2074954)) ||| |
| |{{:techtalk:evo:oil:case_seam_leak_1_by_blackbikedave.png?direct&300|}}|{{:techtalk:evo:oil:case_seam_leak_2_by_blackbikedave.png?direct&300|}}|{{:techtalk:evo:oil:case_seam_leak_3_by_blackbikedave.png?direct&300|}}| |
|
|This seemingly case seam leak turned out to be a leak at the point where the stator wire grommet comes through the primary case. The oil would pool up on top \\ of the transmission during riding and when parked would run down the back and onto the ground. Every morning, after riding, there would be a 6" oil pool under \\ the bike. These pics are underneath from the rear at the transmission. ((photos by Joe Promedio of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/rubber-mount-sportster-motorcycle-talk-2004-2006/140331-oil-leak-at-cases/page3?s=4c72b9196b3bbb5eba4dd0f61f777757&t=1521789&page=3))||| |
| |{{:techtalk:evo:oil:possible_weeping_case_seam_pic1_by_joe_promedio.jpeg?direct&300|}}|{{:techtalk:evo:oil:possible_weeping_case_seam_pic2_by_joe_promedio.jpeg?direct&300|}}|{{:techtalk:evo:oil:possible_weeping_case_seam_pic3_by_joe_promedio.jpeg?direct&300|}}| |
|
|
| * [[techtalk:ref:engmech01d|Drain Plug Sealing and Temporary Fixes]] |
|
{{:techtalk:evo:oil:timing_hole_plug_leak_on_01_xl1200_by_mds78.jpg?direct&300|}} ((photo by mds78 of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.php?p=4607531sportster-motorcycle-forum/sportster-motorcycle-general-discussion-and-problems/158129-function-of-this-bolt-oil-leak#post3357379)) |
|
| ===== Oil Filter Housing ===== |
|
| * **Check that the oil filter is tight**. |
| * Also check that there no nicks or pits in the oil filter sealing surface of the housing. \\ And that the rubber seal on the filter hasn't separated from the filter itself. |
| * **Check the threads around the oil pressure switch**. |
* They leak a lot and oil blows back when you ride so it may look like it come from someplace else. ((decman of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-general-discussion-and-problems/3173-overfill-oil-leak?t=4841)) |
| * **Tightening the oil pressure switch too much on 91-up motors can crack the aluminum oil filter housing pretty fast and to different degrees**. |
| * [[techtalk:evo:oil01#oil_pressure_switch|Click here]] for more information about function, installing and repair in the Sportsterpedia. |
|
| This filter housing was cracked due to too much torque being applied while tightening the oil pressure switch. (( drawing by Hippysmack, (L and center photos) by vagrant318 of the XLFORUMhttp, drawing (R) by Hippysmack https://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-general-discussion-and-problems/199475-oil-pressure-light/page4?t=2076356&page=4)) ||| |
| |{{:techtalk:evo:oil:2000_1200s_cracked_oil_filter_housing_1_by_vagrant318.jpg?direct&300|}}| {{:techtalk:evo:oil:2000_1200s_cracked_oil_filter_housing_4_by_vagrant318.jpg?direct&300|}}|{{ :techtalk:evo:oil:oil_pressure_switch_threads_by_hippysmack.png?direct&300|}}| |
|
| ===== Oil Pressure Switch ===== |
|
| * Some oil pressure switches leak out their body. |
* On some sending units, the contact comes up through a plastic core that is at the center of the unit. They may leak between the contact and the plastic core. ((thunderpaw of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/rubber-mount-sportster-motorcycle-talk-2004-2006/867-oil-leak-on-the-04-883?t=1076)) |
|
| ===== Oil Tank / Lines and Connections ===== |
|
| * **If you have an oil leak from anywhere, the oil tank is subject to having oil all over it**. |
| * It is an accumulation of spills from filling, blowback from engine gaskets / seals / breathers and road grunge. |
|
| * **Periodically inspect all oil hose connections for leaks or cracks / deteriation, especially before long rides**. |
| * Replace any lines that are cracked. |
* They have been known to have the inner rubber come loose and form a sort of flap valve inside the oil line. ((Hopper of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/153442-breather-spitting-too-much-oil/page2?t=1651226&highlight=slinger&page=2)) |
| * **Restricted oil tank vent line**. |
| * Oil carry over may occur while driving the vehicle at highway speeds. The amount of carry over is directly related to the amount of restriction. ((HD Tech Tips dated November 8, 1985)) \\ More restriction equals more carryover. \\ In most cases the restriction is minor and translates to a small amount of carry over, which if left alone creates a bothersome mess. \\ Start looking for pinched hoses or a restrictive oil filter. \\ Pull the line off at the tank and make sure you can blow through it into the cam gear case. \\ Then blow through the oil tank fitting with the lid off and make sure that path is clear. |
|
| * The plastic clamp breaks from fatigue and the hollow stud will allow your oil to leak out onto the ground without warning while you're riding. \\ See [[techtalk:evo:oil04a#oil_drain_plug_mods|04-05 Oil Drain Plug Mods]] for suggestions on how to fix this problem. |
|
| Oily 06 tank with a bad hose connection repaired with a worm clamp. ((photos by CitySlicker of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-suspension-frame-forks-handlebars-fuel-tank-oil-tank-fenders/174971-oil-bag-leaking?t=1877271)) ((httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-suspension-frame-forks-handlebars-fuel-tank-oil-tank-fenders/174971-oil-bag-leaking/page4?t=1877271&page=4)) || Cracked drain hose on 08 Nightster ((photo by McQueen of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/efi-sportster-motorcycle-talk-2007-and-up/193166-oil-hose-replacement-help?t=2069146)) | |
| |{{:techtalk:evo:oil:leaky_oil_tank_by_cityslicker.jpeg?direct&300|}}|{{:techtalk:evo:oil:leaky_oil_clamp_replaced_by_cityslicker.jpg?direct&300|}}|{{:techtalk:evo:oil:cracked_oil_hose_by_mcqueen.jpg?direct&300|}}| |
|
| ==== Overfilled oil tank ==== |
|
| [[techtalk:ref:oil01#overfilling_the_oil_tank|More on Overfilling the Oil Tank here]] in the REF section of the Sportsterpedia. \\ [[techtalk:ref:oil20|More on Oil Tank Pressure here]]. \\ How about that oil sucking gremlin that steals half a quart every evening? You feel compelled to bring that oil level up to spec the next morning. ((HD Tech Tips dated November 8, 1985)) |
| * **This has been the single most reason for oil puking out the breather vent(s) / air cleaner and popping the oil cap on Evo Sportsters**. |
|
|
| ==== Cracked Oil Tank ==== |
|
* 83-93 oil tanks are prone to cracking and leaking where the oil tank and battery tray are connected. \\ Fractures were due to poorly supporting the weight of the battery. ((Four Speed of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/frame-mount-evo-sportster-talk-1986-2003-models/183021-1986-90-evo-sportsters-what-every-owner-should-know-but-were-afraid-to-ask?t=1971026)) \\ Harley offered 62472-93A and 62482-93A oil tank upgrade kits for replacement (94-96 tank assembly). \\ However, the original oil tank can be reinforced and welded. |
| * 04-06 oil tanks were prone to splitting at the seam. \\ Presumably from either poor quality welds, adding too much oil or excess crankcase pressure. |
|
| ==== Damaged or Flooded Oil Tank Vent / Return Tube ==== |
|
| Vehicles with oil tanks, that have all the fittings on the bottom of the tank, use a stand tube inside the tank for the vent line. ((HD Tech Tips dated November 8, 1985)) \\ |
| * Short, damaged or tilted stand tubes: |
|
| * Start looking for that restriction i.e., a pinched return hose, after market oil filter, oil cooler, plugged fitting or hose. |
| * Friends let's bow our heads and repeat after me. \\ I will never willingly install any fittings, probes or adapters which reduce the oil pump's ability to return oil to the oil tank as this will lead to carry over big time. \\ Amen! |
|
|
| ===== Breather Valves and Vent(s) ===== |
| See [[techtalk:evo:oil06#crankcase_pressure_problems|Crankcase Pressure Problems]] below. \\ |
|
|
| Oil leaking out the breather vents (or oil carry-over) can happen for many reasons. \\ |
|
| - Driving at steady highway speeds? See [[techtalk:ref:oil10|Click here for Wet Sumping]] at high RPM. |
| - After the bike's been sitting for a couple of days and you start it up? See [[techtalk:ref:oil10#sit_sumpimg|Click here for Sit Sumping]]. |
- Is the oil tank cap popping off? See [[techtalk:ref:oil01#overfilling_the_oil_tank|Overfilling the Oil Tank]] and [[techtalk:ref:oil20|Oil Tank Pressure]] in the Sportsterpedia. |
| - **Clean the affected area and ride or run the bike and reproduce the problem with the breather hose in a baby bottle (or other) test catch can** [[techtalk:ref:engmech04?s[]=catch&s[]=can#breather_catch_can_test_for_oil_leaks_out_the_vent|as described here]]. \\ This will help you better understand the amount of carryover you're dealing with. \\ |
| - **Start the diagnostics and separate the systems qualifying each one as you go**. |
|
|
| ===== Primary / Transmission Vent Hose ===== |
|
| * **Check the vent hose for blockage**. |
| * A blocked transmission vent can blow oil out the primary cover and / or ruin the engine sprocket seal. |
| * Oil may leak out the clutch cable, adjuster nuts, primary gasket, stator wire grommet or the starter gasket. |
| * The blocked up and rising pressures in the crankcase can also blow out the sprocket seal between the primary and engine compartments. \\ This can mix engine and primary oils, cause crankcase pressure problems and blow oil out the breather vents. |
* The hose can be blocked from gunked up oil/dirt and in some cases has been known to be blocked by creatures (think Wasps and Dirt Dobbers). ((Gone of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-transmission-clutch-primary-secondary-drive/95798-transmission-vent?t=801718)) |
| * Blow on the hose end to make sure you can push air thru it. Do not used compressed air as that can damage the sprocket shaft seal. \\ Replace the hose if it can't be cleared. Also keep in mind that the walls of the hose can collapse from the inside. \\ So just straightening a kink may not unblock the hose. |
| * **Check the vent hose for kinks**. |
|
| |{{:techtalk:evo:oil:1998_xl1200s_trans_vent_hose_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:1998_xl1200s_trans_vent_hose_2_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:1998_xl1200s_trans_vent_hose_3_by_hippysmack.jpg?direct&300|}}| \\ |
|
| 2000 transmission vent hose. ((photo by BadHabit of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-general-discussion-and-problems/28810-help-need-help-with-primary-vent-hose?t=47744)) || |
| |{{:techtalk:evo:oil:leaky_00_primary_vent_1_by_badhabit.jpg?direct&300|}}|{{:techtalk:evo:oil:leaky_00_primary_vent_2_by_badhabit.jpg?direct&300|}}| |
|
| 2004 transmission vent hose. ((photo by npaisnel of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.php?p=5846932sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-engine-conversions/200486-crank-failure-and-killed-my-1275-hammer-build/page22#post5846932post4433814)) | 2005 transmission vent hose. ((photos by Yuma Rider of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-transmission-clutch-primary-secondary-drive/22759-primary-vent-hose-puking/page2?t=37567&page=2)) || |
| |{{:techtalk:evo:oil:2004_transmission_vent_by_npaisnel.jpg?direct&300|}}|{{:techtalk:evo:oil:leaky_05_primary_vent_2_by_yuma_rider.jpg?direct&300|}}|{{:techtalk:evo:oil:leaky_05_primary_vent_1_by_yuma_rider.jpg?direct&300|}}| |
===== Timing Inspection Plug / Drain Plugs ===== |
|
| ===== Timing Inspection Plug / Drain Plugs ===== |
| * These have been common areas for an oil leaks. |
| * Over-torque during installation and heat / expansion during use seems to be the primary cause of distorting the threads. |
| * [[techtalk:ref:engmech01a#timing_inspection_hole_and_plug_-_sealing_and_thread_repair|Click here]] for Timing Inspection Hole and Plug - Sealing and Thread Repair. |
|
| ===== Clutch Cable or Connection to the Primary Cover ===== |
|
* **The ferrule that connects the cable to the cover has an O-ring**. ((ReddTigger of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-bottom-end/159230-oil-leak-from-clutch-cable?t=1706049)) |
| * If it's leaking here, the ferrule may be broken and you need a new cable. |
| * Or just the O-ring is shot and you need a new one. |
* If you tighten the cable too much, it'll spit / split the O-ring, break the cable threads or the cover threads. \\ All you want to do is seat the connector against the O-ring with a decent nudge. It doesn't have to be tight/tight. \\ If you break the cable threads off in the cover, you may be able to use a small screwdriver wedged in the hole to back out the threads. ((ReddTigger of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/frame-mount-evo-sportster-talk-1986-2003-models/153989-broken-clutch-cable?t=1655011)) |
| * **The connection where the cable meets the ferrule or cable adjuster can be disengaged / broken**. |
* This needs a new cable to fix the problem. ((ReddTigger of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-bottom-end/159230-oil-leak-from-clutch-cable?t=1706049)) |
| * A temporary fix may be to clean the area with alcohol and apply some adhesive (Right Stuff, etc) inside the ferrule to stop the leak. \\ But eventually you'll have to replace the cable. It's best not to use silicone as it can dislodge into the primary compartment. |
| * Another temporary fix may be to use some heat shrink tube over the cable-connector. \\ Home Depot sells a 4:1 shrink tube with sealant made by Raychem in electrical section. \\ Clean the cable with contact cleaner or other means. Remove the cable from the lever. \\ Remove the boot from the adjuster and slide the shrink tube down cable over the crimped connector and shrink the tube. \\ You can use a second smaller piece to cover the whole connector also. |
|
| * You can drill, tap and install a Helicoil in the hole. A Helicoil fix is said to be stronger than the original threads. \\ The cover needs to come off to do this properly and not get shavings in the engine. |
| * If the threads have stripped from too much torque, you can try using a tap with the same thread pitch as the cable end to chase the threads. \\ This restores the original thread pitch (with imperfections now from being stripped). \\ It can be a great fix as long as there is still enough meat left in the hole to straighten back out. \\ The cable doesn't have to be installed very tight against the threads. \\ It is the O-ring that actually seals the connection, not the tightening of the threaded connection. |
* **Make sure it's the primary threads that are stripped before doing any work as it could just be the clutch cable**. ((grimreapers of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/rubber-mount-sportster-motorcycle-talk-2004-2006/123443-possible-stripped-clutch-cable-in-primary?t=1223898)) |
| * Adjust the clutch cable to maximum slack. The adjustment is in the middle of the cable under a rubber boot. \\ Once this is done remove cable from the clutch lever. Next unscrew clutch cable from primary cover. \\ Inspect the cable threads to make sure these are not messed up. \\ If they are not messed up and you can not get the cable to tighten up during reinstalling, it is the primary threads. |
| * **A blocked or kinked transmission hose can bottle up primary pressure using the clutch cable as an escape route**. |
* Sometimes, just blowing out the transmission vent will stop the clutch cable leaks. ((Graywolf of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-transmission-clutch-primary-secondary-drive/166810-quick-fix-for-leaky-clutch-cable?t=1792650)) \\ If the hose stops up (long hose, plus oil and dust) the primary that can't breathe is gonna push oil out somewhere. |
| * Kinks in the line will have the same affect as a blockage. Check where the hose comes up and bends down. |
| * **Too much oil in the primary compartment**. |
|
| * Normally, any oil that could run up into the cable innards should be able to run back down into the primary compartment (engine at rest). |
|
|Clutch cable and O-ring on a 98 S model. ((photo by Hippysmack)) \\ Pipe dope on the threads.| Broken cable threads from tightening too much. ((photo by BeachedSquirrel of the XLFORUM, edited by Hippysmack ((httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/frame-mount-evo-sportster-talk-1986-2003-models/153989-broken-clutch-cable?t=1655011))| |
| |{{:techtalk:evo:engmech:adjusting_-_removing_clutch_cable_13_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:broken_clutch_cable_by_beachedsquirrel.jpeg?direct&300|}}| |
|
| ===== Shifter Shaft ===== |
|
| * **The seal installed in the primary cover sometimes develops an oil seepage**. |
| * This can be due to age of the seal. |
|
| * You may also want to look at the part of the shaft itself that resides in/around the seal. \\ If it's pitted or roughed up, it won't allow the seal to do it's job and may even wear out the next seal. \\ You can clean up surface rust with a slight of hand and a small wire brush. \\ Else you may want to replace the shaft and the bushing together. |
| * They don't all leak. Many leak because they were installed by sliding them over the sharp splines on the shifter shaft. |
* **Slight seepage at the shifter shaft can be helped by adding an O-ring behind the shift lever, adding a little more pressure to the seal itself**. ((sportsterpaul of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-transmission-clutch-primary-secondary-drive/39317-shifter-shaft-seal/page3?t=79795&page=3)) \\ After installing the seal and rubber washer, you might install one or two O-rings to take up the gap between the shift lever and the washer. \\ The O-ring(s) do not seal against leaking oil but, instead, put additional pressure on the oil seal in the primary cover cavity, which does help to seal against leaks. \\ Just make sure the problem is just from age or wear and not other problems mentioned above. |
| * **To remove / install the seal, it can be removed without removing the primary cover**. |
| * Remove the lever, then use a pick or screwdriver to pry the seal out of the cavity. It is simple press fit and the seal is flexible. |
|
| * Remove the tape from the splines, install the spacer, O-ring(s) then the shifter and ride. |
|
| Leaky shifter shaft seal on 09 Sportster. ((photo by manborn of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-transmission-clutch-primary-secondary-drive/39317-shifter-shaft-seal/page3?t=79795&page=3)) | |
| |{{:techtalk:evo:oil:leaky_shifter_shaft_on_09_by_manborn.jpg?direct&300|}}| |
|
| Clean all surface rust on shaft. ((photo by cjburr of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-transmission-clutch-primary-secondary-drive/29955-06-clutch-install?t=49915)) | Make sure you remove the entire seal. ((photo by vagrant318 of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-transmission-clutch-primary-secondary-drive/39317-shifter-shaft-seal/page7?t=79795&page=7)) \\ Or that the entire seal assembly is there. | Tape over shaft to keep from tearing new seal. ((photo by manborn of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-transmission-clutch-primary-secondary-drive/39317-shifter-shaft-seal/page4?t=79795&page=4)) | |
| |{{:techtalk:evo:transfinal:wire_brush_shifter_shaft_by_cjburr.jpeg?direct&335|}}|{{:techtalk:evo:oil:shifter_shaft_oil_seal_stuck_by_vagrant318.jpg?direct&300|}}|{{:techtalk:evo:transfinal:shiftershaft-tapeoversplines-manborn.jpg?335|}}| |
|
|You can push against old seal with a wrench and \\ deep socket to lock in new seal. ((photo by manborn of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-transmission-clutch-primary-secondary-drive/39317-shifter-shaft-seal/page4?t=79795&page=4))|If you have an empty space between the shift lever and the rubber bushing, \\ you can install an O-ring on outside of spacer to increase compression on the shaft seal. ((left photo by cjburr of the XLFORUM, labeled by Hippysmack httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-transmission-clutch-primary-secondary-drive/29955-06-clutch-install?t=49915)) ((right photo by 4-pac of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-intake-and-exhaust/sportster-motorcycle-air-intake-carburetor-efi-fuel-and-exhaust/53895-06-carb-to-07-fuel-injection-conversion/page2?t=254258&page=2)) || |
| |{{:techtalk:evo:oil:shifter_shaft_seal_installation_by_manborn.jpg?direct&300|}}|{{:techtalk:evo:oil:space_between_shifter_and_rubber_spacer_by_cjburr.jpg?direct&300|}}|{{:techtalk:evo:transfinal:shiftershaft-oringmod-4pac.jpg?300|}}| |
|
|
| ===== Cam Cover or Primary Cover ===== |
|
| * **Loose bolts or a worn gasket**. \\ Caution, tightening loose bolts on the cover without using the proper torque sequence can warp the cover. \\ If you find loose bolts, loosen all of them and re-torque the entire set using the correct sequence and torque specs. \\ See also [[techtalk:evo:engmech01f|Removing, Inspecting and Installing the Cam Cover]] in the Sportsterpedia. |
| * **Remove the cover and check it for warpage**. |
|
| * You may be able to file down slight warped areas. If not, you may need to replace the cover. |
| * **Inspect the cover for hairline cracks**. |
* These are notorious for hairline fractures where the bolts go that can produce a leak. ((gunterjaeger of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-general-discussion-and-problems/103214-oil-leak-coming-from-engine-case?t=905055)) \\ Even the primary chain, prior to needing adjustment, can hit those areas and create a leak. \\ If there is a crack evident, you may be able to fill the bolt hole with gasket maker (not silicone) or have it brazed. |
* If it is a top bolt, it is not sitting in oil. ((wedge of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-general-discussion-and-problems/103214-oil-leak-coming-from-engine-case?t=905055)) \\ So it is leaking oil that has been flung on it, which means it's coming from a place that is less likely to leak. \\ Leaks up top are more likely to be seepage rather than dripage. \\ So a crack is good possibility if the bolts up top are tight and the gasket is good. \\ If it's not coming out of the gasket joint, but rather the bolt; \\ The leak is coming through the part of the gasket that wraps around the inside edge of the bolt. \\ (rather than the side that is visible as you look at the edge of the gasket) \\ Or through the bolt threads if that hole is not a blind hole but rather a hole that goes all the way into the primary. \\ Also, check the transmission vent line before doing anything else. A clogged vent can force oil out of places that you wouldn't believe. |
| * **Modifications to the cover**. |
| * If your cam cover has been modified on the bottom, there is a rifling hole there for a drilled oil passage running vertically thru the cover. \\ If the cover was cut / sanded close to this factory welded up hole, it could break thru and leak. \\ If it was cut thru and siliconed / epoxied shut, the sealant could be leaking oil. \\ See also [[techtalk:ref:engmech03e|Chopping the Cam / Gearcase Cover]] in the Sportsterpedia. |
|
|
| ===== Engine Oil Leaking Into Primary Case ===== |
|
| Pull the clutch inspection (derby) cover off the primary, smell the oil and check the primary oil level. \\ |
| It should not be over full and should smell like gear oil (rough smell compared to engine oil). \\ |
| If the oil level is higher than it should be or smell like gas, the engine sprocket seal could have failed or have been compromised. \\ |
| The seal is between the engine and primary oils. If it is bad or has been temporarily compromised, engine oil infiltrates the primary and out the trans vent. \\ |
|
|
| ==== Engine Sprocket Seal ==== |
|
If the primary compartment is filling up with engine oil, then the sprocket shaft seal is leaking. ((chrishajer of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-bottom-end/19169-engine-oil-in-primary?t=31834)) \\ |
| * **There can be a lot of reasons for the leak**. |
| * Worn / torn seal. |
|
|
| === Leaking with Rotor / Sprocket Removed === |
|
| Let's say you've removed the rotor doing some work. The bike sits for a while awaiting time and parts. \\ |
| The seal area was dry or you dried it up the last you pulled the rotor off. \\ |
Later, you notice a small leak coming from the seal area. With the rotor/sprocket removed, this is normal. ((aswracing of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-bottom-end/151040-main-shaft-leak?t=1633371)) \\ |
| The leak is most likely not coming from between the spacer and the seal but rather between the spacer and the sprocket shaft (which would now be removed). \\ |
| Once the rotor/sprocket is bolted back up, it should effectively stop the leak. Oil slowly draining down into the crankcase from the oil tank is not that unusual. \\ |
|
{{:techtalk:evo:oil:crankshaft_sprocket_seal_leak_by_reddtiger.jpg?direct&300|}} ((photo by ReddTigger of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-bottom-end/151040-main-shaft-leak?t=1633371)) \\ |
|
| ==== Test for Excess Primary Compartment Vacuum ==== |
|
| You can test for too much vacuum in the primary with the engine running / transmission in neutral. ((HD Tech Tip #36 dated October 1993)) \\ |
| You can make your own slack tube pretty cheap out of some 2x4 pieces, a 2-3 ft ruler and a clear tube. \\ |
|
|
| ==== Check the Condition and Direction of the Sprocket Shaft Seal ==== |
|
| Beginning on April 1st, 1993, Harley-Davidson began to reverse the direction in which the sprocket shaft seal is installed. ((HD Tech Tip #36 dated October 1993)) \\ |
| The open side of the seal (exposing the spring) now faces towards the engine sprocket and primary/drive compartment. \\ |
|
|
| ==== Primary Oil Smell Like Gas? ==== |
|
| Where did the gas smell come from? \\ |
| See [[techtalk:ref:oil01#why_does_the_oil_smell_like_gas|Why Does the Oil Smell Like Gas]] in the Sportsterpedia. \\ |
|
|
| ===== Crankcase Pressure Problems ===== |
|
| See also in the Sportsterpedia: \\ |
| * [[techtalk:evo:engmech07|Evo Crankcase Ventilation]] |
|
| * You can buy or make your own manometer (slack tube, U-tube) for testing. \\ Once you have the apparatus, bolt it to wall where you normally do maintenance. \\ It only takes a few minutes to hook it up and get a reading and it helps to spot trouble before trouble happens. \\ See [[techtalk:ref:genmsr04|Using / Diagnosing with a Slack Tube (Manometer)]] for testing crankcase pressure. |
|
| L82-90 cap, tube and umbrella ((photo by norseXL of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-bottom-end/36799-installing-the-ultimate-crankcase-vent-%C2%93how-to%C2%94/page25?t=72099&page=25)) | Breather baffle tube installed ((photo by Bryan350 of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/frame-mount-evo-sportster-talk-1986-2003-models/159628-cam-cover-question?t=1712011)) | Compression test. ((photo by MatHormell of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-engine-conversions/183888-hammerperf-90-in-the-works/page71?t=1976997&page=71)) | |
| |{{:techtalk:evo:oil:86_crankcase_vent_3_by_norsexl.jpg?direct&300|}}|{{:techtalk:evo:oil:89_cam_cover_3_by_bryan350.jpg?direct&200|}}|{{techtalk:ref:svcproc:checking_compression_1_by_mathormell.jpg?direct&150|}}| |
|
| 91-03 breather valves ((photo by Hippysmack)) | 04-up breather valves ((photo by chris_b_owens of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-styles/cafe-racer-sportster-motorcycle-talk/170788-my-2013-iron-883-cafe-build/page47?t=1832762&page=47)) |Homemade manometer using a ruler as a scale. ((photo by Hippysmack of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.php?p=5784790sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-bottom-end/197307-sportster-crankcase-pressure-engine-breathing-wetsumping-and-mods/page52#post5784790post4349847))| |
| |{{:techtalk:evo:oil:umbrella_valve_locations_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:2013_crankcase_breather_4_by_chris_b_owens.jpg?direct&300|}}|{{:techtalk:ref:engmech:homemade_slack_tube_5_by_hippysmack.jpg?direct&300|}}| |
|
