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| techtalk:evo:oil06 [2020/09/12 07:48] – [Rocker Box / Gaskets] hippysmack | techtalk:evo:oil06 [2024/01/06 03:50] (current) – hippysmack | ||
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| That is not the case with Sporsters. They should NOT leak oil. \\ | That is not the case with Sporsters. They should NOT leak oil. \\ | ||
| - | **What constitutes an oil leak**? ((Dr Dick of the XLFORUM | + | **What constitutes an oil leak**? ((Dr Dick of the XLFORUM |
| * Leak: Liquid oil on the outside of your rocker box, head etc. | * Leak: Liquid oil on the outside of your rocker box, head etc. | ||
| * Weep: An oily residue that traps road dust leading to a damp, dirty build up. | * Weep: An oily residue that traps road dust leading to a damp, dirty build up. | ||
| Line 26: | Line 26: | ||
| See [[techtalk: | See [[techtalk: | ||
| - | |||
| ====== Do Not Use Silicone In Your Engine ====== | ====== Do Not Use Silicone In Your Engine ====== | ||
| - | |||
| **First and foremost, do not use silicone sealer on any engine, oil pump or related parts or gaskets to stop a leak**. \\ | **First and foremost, do not use silicone sealer on any engine, oil pump or related parts or gaskets to stop a leak**. \\ | ||
| The heat coupled with crankcase pressure pulses can break pieces of it loose and send them through the engine. \\ | The heat coupled with crankcase pressure pulses can break pieces of it loose and send them through the engine. \\ | ||
| Line 48: | Line 46: | ||
| In an instance where used silicone was used to seal the gaskets, pieces of silicone (or sheets) could be sucked in, stretched and broke off into the engine. \\ | In an instance where used silicone was used to seal the gaskets, pieces of silicone (or sheets) could be sucked in, stretched and broke off into the engine. \\ | ||
| This silicone 'gummy bear' sheet was found in the oil pump. \\ | This silicone 'gummy bear' sheet was found in the oil pump. \\ | ||
| - | {{: | + | {{: |
| ====== Diagnosing the Origin of External Leaks ====== | ====== Diagnosing the Origin of External Leaks ====== | ||
| - | \\ | + | |
| - | + | ||
| - | | + | |
| * **Using powder to detect a leak**: | * **Using powder to detect a leak**: | ||
| - | * Degrease the bike until there' | + | * Degrease the bike until there' |
| - | * **Clean the engine, then start it and use a bright light to see where the leak is coming from**. ((Bob F of the XLFORUM | + | * **Clean the engine, then start it and use a bright light to see where the leak is coming from**. ((Bob F of the XLFORUM |
| * **Leaking with Engine Running (weeping gaskets)**. \\ See also [[techtalk: | * **Leaking with Engine Running (weeping gaskets)**. \\ See also [[techtalk: | ||
| * Weeping cylinder base gaskets: \\ Please do not jump the gun. Clean the area and ride the bike. | * Weeping cylinder base gaskets: \\ Please do not jump the gun. Clean the area and ride the bike. | ||
| Line 73: | Line 69: | ||
| * Running the bike hard shouldn' | * Running the bike hard shouldn' | ||
| * **Leaking with Engine Shut Off**. \\ See also [[techtalk: | * **Leaking with Engine Shut Off**. \\ See also [[techtalk: | ||
| - | * Clean the area thoroughly (like with rake cleaner and air blow dry). ((Ferrous Head of the XLFORUM | + | * Clean the area thoroughly (like with rake cleaner and air blow dry). ((Ferrous Head of the XLFORUM |
| - | * Take an old bike tube and cut a piece while retaining the valve stem. ((ezmerf of the XLFORUM | + | * Take an old bike tube and cut a piece while retaining the valve stem. ((ezmerf of the XLFORUM |
| - | |Rocker boxes sprayed with powder antiperspirant to detected oil leaks. ((photos by CitySlicker of the XLFORUM | + | |Rocker boxes sprayed with powder antiperspirant to detected oil leaks. ((photos by CitySlicker of the XLFORUM |
| |{{: | |{{: | ||
| ====== Diagnosing the Origin of Internal Oil Leaks ====== | ====== Diagnosing the Origin of Internal Oil Leaks ====== | ||
| - | |||
| See also in the Sportsterpedia: | See also in the Sportsterpedia: | ||
| * [[techtalk: | * [[techtalk: | ||
| Line 86: | Line 81: | ||
| * [[techtalk: | * [[techtalk: | ||
| - | Obviously you must find exactly what is leaking before you can determine what will be needed to fix it. ((santis5 of the XLFORUM | + | Obviously you must find exactly what is leaking before you can determine what will be needed to fix it. ((santis5 of the XLFORUM |
| Degrease the area in question and run the bike a little and watch the area for the beginning signs of seepage. \\ | Degrease the area in question and run the bike a little and watch the area for the beginning signs of seepage. \\ | ||
| Check torque on the bolts on covers and parts with gasket/ | Check torque on the bolts on covers and parts with gasket/ | ||
| Line 98: | Line 93: | ||
| ====== Oil Consumption Service Bulletin - August 10, 2005 ====== | ====== Oil Consumption Service Bulletin - August 10, 2005 ====== | ||
| - | This Tech Tip reprinted by Krayven Sumhead of the XLFORUM ((http:// | + | This Tech Tip reprinted by Krayven Sumhead of the XLFORUM ((https:// |
| [[techtalk: | [[techtalk: | ||
| Line 142: | Line 137: | ||
| * These additional parts will only be allowed on MC warranty claims filed against your existing inventory of gasket kits used to repair 2005-2006 Big Twins. | * These additional parts will only be allowed on MC warranty claims filed against your existing inventory of gasket kits used to repair 2005-2006 Big Twins. | ||
| * Future kits will have the new valve seals included so additional parts should not be listed on warranty claims. 18094-02A Valve Seal Identification | * Future kits will have the new valve seals included so additional parts should not be listed on warranty claims. 18094-02A Valve Seal Identification | ||
| - | |||
| ====== Visual Inspection ====== | ====== Visual Inspection ====== | ||
| ===== Rocker Box / Gaskets ===== | ===== Rocker Box / Gaskets ===== | ||
| - | |||
| * **Installation error**. | * **Installation error**. | ||
| * **It's easy to get the rocker box gaskets shifted off center if you're not careful when installing them**. | * **It's easy to get the rocker box gaskets shifted off center if you're not careful when installing them**. | ||
| * Once you've got them sitting in place and install the top section, you can make final alignment before installing the screws. \\ This final alignment sometimes shifts the gasket out of the channel it sits in. The screws will pull down and torque properly. \\ But you'll end up with a leak if the gasket doesn' | * Once you've got them sitting in place and install the top section, you can make final alignment before installing the screws. \\ This final alignment sometimes shifts the gasket out of the channel it sits in. The screws will pull down and torque properly. \\ But you'll end up with a leak if the gasket doesn' | ||
| - | * The 3 piece covers are sensitive to alignment and progressive tightening. Patience during installation is a must. ((sportsterpaul of the XLFORUM | + | * The 3 piece covers are sensitive to alignment and progressive tightening. Patience during installation is a must. ((sportsterpaul of the XLFORUM |
| * **Improper torque and / or torque sequence can warp the rocker box**. | * **Improper torque and / or torque sequence can warp the rocker box**. | ||
| * Failure to roll the engine around to where both valves are closed before installing the boxes can result in loose bolts once the valves close. | * Failure to roll the engine around to where both valves are closed before installing the boxes can result in loose bolts once the valves close. | ||
| Line 159: | Line 152: | ||
| * If they curl up on you and make it hard to keep them down for installation; | * If they curl up on you and make it hard to keep them down for installation; | ||
| * **Loose top cover bolts or broken washers will leak air and /or oil**. | * **Loose top cover bolts or broken washers will leak air and /or oil**. | ||
| - | * If using the fiber washers, they harden after installation and do not ride concentric with the bolt or bolt hole. \\ Getting it back exactly the same will be impossible and result in new leaks. So, don't do it twice. ((sportysrock of the XLFORUM | + | * If using the fiber washers, they harden after installation and do not ride concentric with the bolt or bolt hole. \\ Getting it back exactly the same will be impossible and result in new leaks. So, don't do it twice. ((sportysrock of the XLFORUM |
| * Use caution torquing the cover bolts down. \\ They have been known to strip out of the lower threaded holes or crack the cover pulled down too tight. | * Use caution torquing the cover bolts down. \\ They have been known to strip out of the lower threaded holes or crack the cover pulled down too tight. | ||
| * **Too much crankcase pressure**. | * **Too much crankcase pressure**. | ||
| - | * A good amount of rocker box leaks go misdiagnosed as bad gaskets. When in fact, the crankcase venting is not keeping up with the crankcase pressure. ((Deimus of the XLFORUM | + | * A good amount of rocker box leaks go misdiagnosed as bad gaskets. When in fact, the crankcase venting is not keeping up with the crankcase pressure. ((Deimus of the XLFORUM |
| * **Loose rocker box bolts can create in imbalance of crankcase pressure**. | * **Loose rocker box bolts can create in imbalance of crankcase pressure**. | ||
| * Loose top or bottom rocker bolts allows air to be pulled into the engine and muck up crankcase pressure. \\ (which could lead to wetsumping and blowing out of the breather(s) ). | * Loose top or bottom rocker bolts allows air to be pulled into the engine and muck up crankcase pressure. \\ (which could lead to wetsumping and blowing out of the breather(s) ). | ||
| * **Repair**. | * **Repair**. | ||
| * **Check the rocker boxes for war-page** | * **Check the rocker boxes for war-page** | ||
| - | * They are known to warp if the bolts are not removed in the proper sequence or not torqued properly. \\ Put a sheet of Emory cloth down on a flat surface, glass is usually good. ((sportsterpaul of the XLFORUM | + | * They are known to warp if the bolts are not removed in the proper sequence or not torqued properly. \\ Put a sheet of Emory cloth down on a flat surface, glass is usually good. ((sportsterpaul of the XLFORUM |
| * **Also, if the rocker boxes are chromed, the rubber gaskets will slip and slide all over when installing them**. | * **Also, if the rocker boxes are chromed, the rubber gaskets will slip and slide all over when installing them**. | ||
| * Check for pitting around the sealing surfaces. | * Check for pitting around the sealing surfaces. | ||
| Line 185: | Line 178: | ||
| This may be one example of how rocker box bolts get loose by themselves. \\ | This may be one example of how rocker box bolts get loose by themselves. \\ | ||
| - | | Damaged lower rocker box gasket. ((photo by 4-pac of the XLFORUM | + | | Damaged lower rocker box gasket. ((photo by 4-pac of the XLFORUM |
| - | |{{: | + | |{{: |
| - | | | + | | |
| - | |{{: | + | |{{: |
| - | ---- | + | | Leak with pinched gasket. ((photo by sep69 of the XLFORUM http:// |
| + | |{{: | ||
| ==== 2004-2006 Rocker Box Design Change ==== | ==== 2004-2006 Rocker Box Design Change ==== | ||
| Line 206: | Line 200: | ||
| * Part number (17537-96B) has narrow slots. | * Part number (17537-96B) has narrow slots. | ||
| * The newer lower box (17537-96C), | * The newer lower box (17537-96C), | ||
| - | * **Replace the rocker cover gasket with the new style gasket (17353-89B)**. \\ The new style gasket has square edges, whereas the old style gasket has rounded edges. \\ The new replacement rocker box gaskets are different from the originals and have a Teflon or rubberized surface on both top & bottom faces. ((Hoowasat of the XLFORUM | + | * **Replace the rocker cover gasket with the new style gasket (17353-89B)**. \\ The new style gasket has square edges, whereas the old style gasket has rounded edges. \\ The new replacement rocker box gaskets are different from the originals and have a Teflon or rubberized surface on both top & bottom faces. ((Hoowasat of the XLFORUM |
| * **Do not apply silicone for an adhesive for the old style or new style gaskets**. | * **Do not apply silicone for an adhesive for the old style or new style gaskets**. | ||
| - | {{: | + | {{: |
| ===== Air Cleaner / Filter ===== | ===== Air Cleaner / Filter ===== | ||
| - | |||
| * **Oil puking and oil seepage out the air cleaner are different conditions**. | * **Oil puking and oil seepage out the air cleaner are different conditions**. | ||
| * You'll know it if it pukes as there will be a good puddle of oil on the shop floor or gobs of oil running rearward of the A/C all over the bike. \\ This is a sign of too much oil added to the system or wetsumping. | * You'll know it if it pukes as there will be a good puddle of oil on the shop floor or gobs of oil running rearward of the A/C all over the bike. \\ This is a sign of too much oil added to the system or wetsumping. | ||
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| ===== Pushrod Tubes ===== | ===== Pushrod Tubes ===== | ||
| - | |||
| * **Installation error**. | * **Installation error**. | ||
| * **Upper pushrod tube oil leak**. | * **Upper pushrod tube oil leak**. | ||
| * There are O-rings placed in the heads where the upper part of the pushrod tubes connect. \\ The O-rings have to be placed in the head and locked/ | * There are O-rings placed in the heads where the upper part of the pushrod tubes connect. \\ The O-rings have to be placed in the head and locked/ | ||
| * **Lower pushrod tube oil leak**. | * **Lower pushrod tube oil leak**. | ||
| - | * **It is very important to make sure the lower O-rings are installed properly**. \\ Make sure the seal support block(s) are installed flush with the engine case and add a little oil to the O-ring before installing. \\ One trick for installing, use a little bit of super glue to the retainers before you slide the pushrods on and oil the I.D. of the O-rings. ((Scuba10jdl of the XLFORUM | + | * **It is very important to make sure the lower O-rings are installed properly**. \\ Make sure the seal support block(s) are installed flush with the engine case and add a little oil to the O-ring before installing. \\ One trick for installing, use a little bit of super glue to the retainers before you slide the pushrods on and oil the I.D. of the O-rings. ((Scuba10jdl of the XLFORUM |
| - | * **Inspect the case deck where the tubes sit**. If there are any scratches, especially deep ones, the tubes will leak until the scratches are dealt with. \\ Be careful to not scratch the aluminum case when you slide the pushrod tube back in or out especially with stock tubes. \\ If you're using the billet blocks, this won't matter as much. ((chrishajer of the XLFORUM | + | * **Inspect the case deck where the tubes sit**. If there are any scratches, especially deep ones, the tubes will leak until the scratches are dealt with. \\ Be careful to not scratch the aluminum case when you slide the pushrod tube back in or out especially with stock tubes. \\ If you're using the billet blocks, this won't matter as much. ((chrishajer of the XLFORUM |
| - | * **The O-ring base / holder can warp from poor installation or during use**. \\ That pot-metal ring is just flimsy, and even if it doesn' | + | * **The O-ring base / holder can warp from poor installation or during use**. \\ That pot-metal ring is just flimsy, and even if it doesn' |
| * **Non sealing pushrod tubes can contribute to an imbalance of crankcase pressure**. | * **Non sealing pushrod tubes can contribute to an imbalance of crankcase pressure**. | ||
| * See [[techtalk: | * See [[techtalk: | ||
| - | {{: | + | {{: |
| - | ===== Head Gaskets / Bolts ===== | + | |
| + | ===== Head Gaskets / Bolts ===== | ||
| **Head gasket leak**. \\ | **Head gasket leak**. \\ | ||
| Line 247: | Line 239: | ||
| * **A leaking head gasket usually makes some noise (whine and chirping sound like a bird in the intake or carb).** \\ And accompanied by oily or sooty areas around the gasket in the area of the leak. \\ You can confirm a head gasket leak by performing a [[techtalk: | * **A leaking head gasket usually makes some noise (whine and chirping sound like a bird in the intake or carb).** \\ And accompanied by oily or sooty areas around the gasket in the area of the leak. \\ You can confirm a head gasket leak by performing a [[techtalk: | ||
| * **A leaky head gasket usually has little to do with crankcase pressure problem**. | * **A leaky head gasket usually has little to do with crankcase pressure problem**. | ||
| - | * **Check oil smudge marks on the head gaskets when removing the heads**. \\ When dismantling the top end (or to bring parts to your mechanic) and before cleaning the head gaskets / surfaces, check them for oil smears. ((IronMick of the XLFORUM | + | * **Check oil smudge marks on the head gaskets when removing the heads**. \\ When dismantling the top end (or to bring parts to your mechanic) and before cleaning the head gaskets / surfaces, check them for oil smears. ((IronMick of the XLFORUM |
| - | * **Oil around head bolts**. \\ You may have a slight amount of oil sitting around the head bolt(s) after a new build. \\ This is thought to be just assembly lube from when the heads were installed but it could also be that you need to get the head gasket replaced. ((steelworker of the XLFORUM | + | * **Oil around head bolts**. \\ You may have a slight amount of oil sitting around the head bolt(s) after a new build. \\ This is thought to be just assembly lube from when the heads were installed but it could also be that you need to get the head gasket replaced. ((steelworker of the XLFORUM |
| * **Repair**. | * **Repair**. | ||
| * Officially, a leaking head gasket should be replaced. | * Officially, a leaking head gasket should be replaced. | ||
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| * If one or both of the two center cylinder studs on the right side of the engine are loosening, backing out or stripped; \\ The fix is usually a helicoil or other thread repair insert into the case. See [[techtalk: | * If one or both of the two center cylinder studs on the right side of the engine are loosening, backing out or stripped; \\ The fix is usually a helicoil or other thread repair insert into the case. See [[techtalk: | ||
| | | ||
| - | | Oil standing around head bolt. ((photo by pigfoot of the XLFORUM | + | | Oil standing around head bolt. ((photo by pigfoot of the XLFORUM |
| |{{: | |{{: | ||
| - | |Deteriorated O-rings used with MLS gaskets. The MLS gasket is tight around the dowel and has a raised \\ area to seal the dowel. No need for an O-ring. ((photos by Screw Loose Dan of the XLFORUM | + | |Deteriorated O-rings used with MLS gaskets. The MLS gasket is tight around the dowel and has a raised \\ area to seal the dowel. No need for an O-ring. ((photos by Screw Loose Dan of the XLFORUM |
| |{{: | |{{: | ||
| Line 264: | Line 256: | ||
| Check the plugs for wet oil saturation. \\ | Check the plugs for wet oil saturation. \\ | ||
| - | {{: | + | {{: |
| **Check intake and exhaust ports in the heads**. \\ | **Check intake and exhaust ports in the heads**. \\ | ||
| You can pull your exhaust pipes and intake manifold and look at the valves to see if the oil is leaking past the valve stem seals. ((cjburr of the XLFORUM http:// | You can pull your exhaust pipes and intake manifold and look at the valves to see if the oil is leaking past the valve stem seals. ((cjburr of the XLFORUM http:// | ||
| - | {{: | + | {{: |
| ===== Cylinder Base Gaskets ===== | ===== Cylinder Base Gaskets ===== | ||
| - | |||
| **Weeping base gasket leak**. \\ | **Weeping base gasket leak**. \\ | ||
| Line 278: | Line 269: | ||
| * Sometimes the heads were not torqued right to begin with. | * Sometimes the heads were not torqued right to begin with. | ||
| * Paper gaskets can wear out faster than MLS gaskets. | * Paper gaskets can wear out faster than MLS gaskets. | ||
| - | * The sealing surfaces might have been contaminated during installation. \\ If the gaskets get liquid (oil) between them, they won't torque well. The oil won't compress. ((Screw Loose Dan of the XLFORUM | + | * The sealing surfaces might have been contaminated during installation. \\ If the gaskets get liquid (oil) between them, they won't torque well. The oil won't compress. ((Screw Loose Dan of the XLFORUM |
| * Some people don't install a gasket at all or use sealant on the bottom of the cylinders while trying to adjust the [[techtalk: | * Some people don't install a gasket at all or use sealant on the bottom of the cylinders while trying to adjust the [[techtalk: | ||
| * **Too much crankcase pressure**. | * **Too much crankcase pressure**. | ||
| * See [[techtalk: | * See [[techtalk: | ||
| * **Repair**. | * **Repair**. | ||
| - | * 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 | + | * 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 |
| * However, some will say that this type of seepage is merely cosmetic if it doesn' | * However, some will say that this type of seepage is merely cosmetic if it doesn' | ||
| - | + | {{: | |
| - | {{: | + | |
| ===== Engine Case Seam ===== | ===== Engine Case Seam ===== | ||
| - | |||
| * **Installation error**. | * **Installation error**. | ||
| * 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. | * 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**. | * **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 | + | * 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 |
| * **Too much crankcase pressure**. See [[techtalk: | * **Too much crankcase pressure**. See [[techtalk: | ||
| * 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/ | * 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/ | ||
| Line 301: | Line 290: | ||
| * **Repair**. \\ Either repair below may be only temporary unless you check / replace / maintain the crankcase breathing system. \\ See also [[techtalk: | * **Repair**. \\ Either repair below may be only temporary unless you check / replace / maintain the crankcase breathing system. \\ See also [[techtalk: | ||
| * Officially, the cases need to be split and the joint re-sealed. | * 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 | + | * 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 |
| * Drain the primary and/or engine oil. | * 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). | * Hook up a Mightyvac to the transmission breather hose (if sealing joint involving tranny compartment) or crankcase breather (for engine area). | ||
| Line 311: | Line 300: | ||
| * 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: | * 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: | ||
| - | | Case seam mismatched under cylinders causing a leak. ((photos by BlackBikeDave of the XLFORUM | + | | Case seam mismatched under cylinders causing a leak. ((photos by BlackBikeDave of the XLFORUM |
| |{{: | |{{: | ||
| - | |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 | + | |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 |
| |{{: | |{{: | ||
| + | |||
| + | ===== 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. | ||
| + | * **1986-2003 engines (only) have a removable timing inspection plug**. | ||
| + | * Look for stripped threads or fixes by the PO that may not have sealed properly. | ||
| + | * **Repair**. (see these links in the Sportsterpedia) | ||
| + | * [[techtalk: | ||
| + | * [[techtalk: | ||
| + | |||
| + | {{: | ||
| ===== Oil Filter Housing ===== | ===== Oil Filter Housing ===== | ||
| - | |||
| * **Check that the oil filter is tight**. | * **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. | * 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**. | * **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 | + | * 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 |
| * **Tightening the oil pressure switch too much on 91-up motors can crack the aluminum oil filter housing pretty fast and to different degrees**. | * **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: | * [[techtalk: | ||
| - | | This filter housing was cracked due to too much torque being applied while tightening the oil pressure switch. ((drawing by Hippysmack, | + | | This filter housing was cracked due to too much torque being applied while tightening the oil pressure switch. (( (L and center |
| |{{: | |{{: | ||
| ===== Oil Pressure Switch ===== | ===== Oil Pressure Switch ===== | ||
| - | |||
| * Some oil pressure switches leak out their body. | * 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 | + | * 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 |
| ===== Oil Tank / Lines and Connections ===== | ===== Oil Tank / Lines and Connections ===== | ||
| - | |||
| * **If you have an oil leak from anywhere, the oil tank is subject to having oil all over it**. | * **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. | * It is an accumulation of spills from filling, blowback from engine gaskets / seals / breathers and road grunge. | ||
| * **The best way to find out if the oil tank is leaking is to clean it up** (try some blue dawn and a nylon brush). \\ (and use some spray SOFT-N-DRI or talcum powder in the area). | * **The best way to find out if the oil tank is leaking is to clean it up** (try some blue dawn and a nylon brush). \\ (and use some spray SOFT-N-DRI or talcum powder in the area). | ||
| * **Periodically inspect all oil hose connections for leaks or cracks / deteriation, | * **Periodically inspect all oil hose connections for leaks or cracks / deteriation, | ||
| + | * 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 https:// | ||
| * **Restricted oil tank vent line**. | * **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. | + | * 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. |
| * There is a Service Bulletin for 04-later engines discussing proper oil tank vent hose routing with illustrations. \\ You can download the bulletin PDF, M-1143, [[techtalk: | * There is a Service Bulletin for 04-later engines discussing proper oil tank vent hose routing with illustrations. \\ You can download the bulletin PDF, M-1143, [[techtalk: | ||
| * **Oil tank drain lines**. | * **Oil tank drain lines**. | ||
| Line 347: | Line 347: | ||
| * 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: | * 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: | ||
| - | | Oily 06 tank with a bad hose connection repaired with a worm clamp. ((photos by CitySlicker of the XLFORUM | + | | Oily 06 tank with a bad hose connection repaired with a worm clamp. ((photos by CitySlicker of the XLFORUM |
| |{{: | |{{: | ||
| ==== Overfilled oil tank ==== | ==== Overfilled oil tank ==== | ||
| - | + | [[techtalk: | |
| - | [[techtalk: | + | |
| * **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**. | * **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**. | ||
| * Before topping off the oil tank, run the engine if possible for about a 30 min. ride. | * Before topping off the oil tank, run the engine if possible for about a 30 min. ride. | ||
| Line 364: | Line 363: | ||
| * However, that is more like using a band-aid to cover a more important underlying condition of too much total crankcase pressure. \\ This condition doesn' | * However, that is more like using a band-aid to cover a more important underlying condition of too much total crankcase pressure. \\ This condition doesn' | ||
| * Likewise, when you increase your oil level, you decrease your crankcase empty space volume. \\ This may increase the pressure in the crankcase __if__ your vent(s) are not keeping up. \\ This is the reason that running a higher (or proper) level of oil has the effect of contributing to rocker cover leaks or oil puking from the air filter. \\ See also [[techtalk: | * Likewise, when you increase your oil level, you decrease your crankcase empty space volume. \\ This may increase the pressure in the crankcase __if__ your vent(s) are not keeping up. \\ This is the reason that running a higher (or proper) level of oil has the effect of contributing to rocker cover leaks or oil puking from the air filter. \\ See also [[techtalk: | ||
| - | * **Blowing the oil cap off could from too much oil in the tank or (on 04 and later models) it could be from broken internals in the cap itself**. \\ Click here to see [[techtalk: | + | * **Blowing the oil cap off could from too much oil in the tank or (on 04 and later models) it could be from broken internals in the cap itself**. \\ Click here to see [[techtalk: |
| ==== Cracked Oil Tank ==== | ==== Cracked Oil Tank ==== | ||
| - | + | | |
| - | | + | |
| * 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. | * 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 ==== | ==== 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)) \\ | 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: | * Short, damaged or tilted stand tubes: | ||
| Line 409: | Line 406: | ||
| * Start looking for that restriction i.e., a pinched return hose, after market oil filter, oil cooler, plugged fitting or hose. | * 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! | * 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) ===== | ===== Breather Valves and Vent(s) ===== | ||
| See [[techtalk: | See [[techtalk: | ||
| - | |||
| Oil leaking out the breather vents (or oil carry-over) can happen for many reasons. \\ | Oil leaking out the breather vents (or oil carry-over) can happen for many reasons. \\ | ||
| Line 436: | Line 431: | ||
| - Driving at steady highway speeds? See [[techtalk: | - Driving at steady highway speeds? See [[techtalk: | ||
| - After the bike's been sitting for a couple of days and you start it up? See [[techtalk: | - After the bike's been sitting for a couple of days and you start it up? See [[techtalk: | ||
| - | - Is the oil tank cap popping off? See [[techtalk: | + | - Is the oil tank cap popping off? See [[techtalk: |
| - **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: | - **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: | ||
| - **Start the diagnostics and separate the systems qualifying each one as you go**. | - **Start the diagnostics and separate the systems qualifying each one as you go**. | ||
| Line 445: | Line 440: | ||
| ===== Primary / Transmission Vent Hose ===== | ===== Primary / Transmission Vent Hose ===== | ||
| - | |||
| * **Check the vent hose for blockage**. | * **Check the vent hose for blockage**. | ||
| * A blocked transmission vent can blow oil out the primary cover and / or ruin the engine sprocket seal. | * 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. | * 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 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 | + | * 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 |
| * 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. | * 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**. | * **Check the vent hose for kinks**. | ||
| Line 460: | Line 454: | ||
| |{{: | |{{: | ||
| - | | 2000 transmission vent hose. ((photo by BadHabit of the XLFORUM | + | | 2000 transmission vent hose. ((photo by BadHabit of the XLFORUM |
| |{{: | |{{: | ||
| - | | 2004 transmission vent hose. ((photo by npaisnel of the XLFORUM | + | | 2004 transmission vent hose. ((photo by npaisnel of the XLFORUM |
| |{{: | |{{: | ||
| - | ===== Timing Inspection Plug / Drain Plugs ===== | ||
| + | ===== Timing Inspection Plug / Drain Plugs ===== | ||
| * These have been common areas for an oil leaks. | * 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. | * Over-torque during installation and heat / expansion during use seems to be the primary cause of distorting the threads. | ||
| * [[techtalk: | * [[techtalk: | ||
| + | |||
| ===== Clutch Cable or Connection to the Primary Cover ===== | ===== Clutch Cable or Connection to the Primary Cover ===== | ||
| - | + | | |
| - | | + | |
| * If it's leaking here, the ferrule may be broken and you need a new cable. | * 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. | * 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' | + | * 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' |
| * **The connection where the cable meets the ferrule or cable adjuster can be disengaged / broken**. | * **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 | + | * This needs a new cable to fix the problem. ((ReddTigger of the XLFORUM |
| * 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. | * 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. | * 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. | ||
| Line 486: | Line 480: | ||
| * 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. | * 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' | * 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' | ||
| - | * **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 | + | * **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 |
| * 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, | * 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, | ||
| * **A blocked or kinked transmission hose can bottle up primary pressure using the clutch cable as an escape route**. | * **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 | + | * Sometimes, just blowing out the transmission vent will stop the clutch cable leaks. ((Graywolf of the XLFORUM |
| * Kinks in the line will have the same affect as a blockage. Check where the hose comes up and bends down. | * 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**. | * **Too much oil in the primary compartment**. | ||
| Line 499: | Line 493: | ||
| * 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). | * 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.| | + | |Clutch cable and O-ring on a 98 S model. ((photo by Hippysmack)) \\ Pipe dope on the threads.| |
| |{{: | |{{: | ||
| + | |||
| ===== Shifter Shaft ===== | ===== Shifter Shaft ===== | ||
| - | |||
| * **The seal installed in the primary cover sometimes develops an oil seepage**. | * **The seal installed in the primary cover sometimes develops an oil seepage**. | ||
| * This can be due to age of the seal. | * This can be due to age of the seal. | ||
| Line 509: | Line 503: | ||
| * 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. | * 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. | * 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 | + | * **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 |
| * **To remove / install the seal, it can be removed without removing the primary cover**. | * **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 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. | ||
| Line 516: | Line 510: | ||
| * Remove the tape from the splines, install the spacer, O-ring(s) then the shifter and ride. | * 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 | + | | Leaky shifter shaft seal on 09 Sportster. ((photo by manborn of the XLFORUM |
| |{{: | |{{: | ||
| - | | Clean all surface rust on shaft. ((photo by cjburr of the XLFORUM | + | | Clean all surface rust on shaft. ((photo by cjburr of the XLFORUM |
| |{{: | |{{: | ||
| - | |You can push against old seal with a wrench and \\ deep socket to lock in new seal. ((photo by manborn of the XLFORUM | + | |You can push against old seal with a wrench and \\ deep socket to lock in new seal. ((photo by manborn of the XLFORUM |
| |{{: | |{{: | ||
| - | |||
| ===== Cam Cover or Primary Cover ===== | ===== 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: | * **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: | ||
| * **Remove the cover and check it for warpage**. | * **Remove the cover and check it for warpage**. | ||
| Line 534: | Line 526: | ||
| * You may be able to file down slight warped areas. If not, you may need to replace the cover. | * 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**. | * **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 | + | * These are notorious for hairline fractures where the bolts go that can produce a leak. ((gunterjaeger of the XLFORUM |
| - | * If it is a top bolt, it is not sitting in oil. ((wedge of the XLFORUM | + | * If it is a top bolt, it is not sitting in oil. ((wedge of the XLFORUM |
| * **Modifications to the cover**. | * **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: | * 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: | ||
| Line 547: | Line 539: | ||
| ===== Engine Oil Leaking Into Primary Case ===== | ===== Engine Oil Leaking Into Primary Case ===== | ||
| - | |||
| Pull the clutch inspection (derby) cover off the primary, smell the oil and check the primary oil level. \\ | 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). \\ | 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. \\ | 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, | The seal is between the engine and primary oils. If it is bad or has been temporarily compromised, | ||
| - | |||
| ==== Engine Sprocket Seal ==== | ==== Engine Sprocket Seal ==== | ||
| - | + | If the primary compartment is filling up with engine oil, then the sprocket shaft seal is leaking. ((chrishajer of the XLFORUM | |
| - | If the primary compartment is filling up with engine oil, then the sprocket shaft seal is leaking. ((chrishajer of the XLFORUM | + | |
| * **There can be a lot of reasons for the leak**. | * **There can be a lot of reasons for the leak**. | ||
| * Worn / torn seal. | * Worn / torn seal. | ||
| Line 565: | Line 554: | ||
| === Leaking with Rotor / Sprocket Removed === | === 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. \\ | 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. \\ | 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/ | + | Later, you notice a small leak coming from the seal area. With the rotor/ |
| 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). \\ | 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/ | Once the rotor/ | ||
| - | {{: | + | {{: |
| ==== Test for Excess Primary Compartment Vacuum ==== | ==== 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 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. \\ | You can make your own slack tube pretty cheap out of some 2x4 pieces, a 2-3 ft ruler and a clear tube. \\ | ||
| Line 583: | Line 570: | ||
| ==== Check the Condition and Direction of the Sprocket Shaft Seal ==== | ==== 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)) \\ | 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/ | The open side of the seal (exposing the spring) now faces towards the engine sprocket and primary/ | ||
| Line 589: | Line 575: | ||
| ==== Primary Oil Smell Like Gas? ==== | ==== Primary Oil Smell Like Gas? ==== | ||
| - | |||
| Where did the gas smell come from? \\ | Where did the gas smell come from? \\ | ||
| See [[techtalk: | See [[techtalk: | ||
| Line 608: | Line 593: | ||
| ===== Crankcase Pressure Problems ===== | ===== Crankcase Pressure Problems ===== | ||
| - | |||
| See also in the Sportsterpedia: | See also in the Sportsterpedia: | ||
| * [[techtalk: | * [[techtalk: | ||
| Line 663: | Line 647: | ||
| * 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: | * 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: | ||
| - | | L82-90 cap, tube and umbrella ((photo by norseXL of the XLFORUM | + | | L82-90 cap, tube and umbrella ((photo by norseXL of the XLFORUM |
| |{{: | |{{: | ||
| - | | 91-03 breather valves ((photo by Hippysmack)) | + | | 91-03 breather valves ((photo by Hippysmack)) |
| |{{: | |{{: | ||
