Differences

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--- techtalk:evo:engmech01f [2019/11/27 21:39]
hippysmack [Removal]
+++ techtalk:evo:engmech01f [2019/11/27 22:22]
hippysmack [Gaskets / Seals]
@@ Line 66: / Line 66: @@
 |{{:techtalk:evo:engmech:securing_cams_with_the_cover_off_by_travis13.jpg?direct&300|}}|
 |Securing cams with rubber bands ((photo by Travis13 of the XLFORUM http://xlforum.net/forums/showthread.php?t=1692569&page=3))|
+====== Inspection ======
+Before installation, use a straightedge diagonally across the corners to check for warp-age of the cover. \\
+Check the FSM for the 'out of service' spec for warp-age. The thickness of the gasket will compensate for a certain amount of warp-age. \\
+====== Installation ======
+The cover gasket only has a hole for one of the dowel pins so it will slip down if you're trying to place it on the case first. \\
+Put the gasket on the cover and install the screws through the cover and the gasket holes while maneuvering the cover on the case. \\
+Hand start all the screws and leave it loose enough to nudge the gasket, if needed, for a good fit. \\
+This will keep the gasket from sliding down during the process.
+Or you can use a few plastic straws inserted into the case threads and put the gasket on the case over the straws. \\
+You can also buy a short piece of 1/4"x20 all-thread at the local hardware store and use it the same way as the straws. \\
+The cover is app. 1-1/4" plus about 1/4" of threading into the case would be 1-1/2" lengths just to get the shafts flush to the outside cover. \\
+(which won't help you remove them. \\
+So you'd need to cut off about four pieces at least 2" long. 2" bolts with the heads cut off would also work.
+|These are app. 3" long sections of all-thread. ((photos by Hippysmack))||
+|{{:techtalk:evo:engmech:cam_cover_gasket_helper_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:cam_cover_gasket_helper_2_by_hippysmack.jpg?direct&300|}}|
+|Install them into the case, hang the gasket on them and install the cover. \\ The longer length pieces will allow you to center the cover bushings up to the cams easier for a straight push home. ((photos by Hippysmack))|||
+|{{:techtalk:evo:engmech:cam_cover_gasket_helper_3_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:cam_cover_gasket_helper_4_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:cam_cover_gasket_helper_5_by_hippysmack.jpg?direct&300|}}|
+|Once the cover is on, install some 1/4" mounting bolts and pull the all-thread out. \\ Then install the remaining bolts and torque to proper specs using a cross pattern. ((photos by Hippysmack))|||
+|{{:techtalk:evo:engmech:cam_cover_gasket_helper_6_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:cam_cover_gasket_helper_7_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:cam_cover_gasket_helper_8_by_hippysmack.jpg?direct&300|}}|
+|Push the cover on carefully by hand. Do not use the \\ screws to pull the cover flush against the case. ((photo by cjburr of the XLFORUM http://xlforum.net/forums/showthread.php?t=49615))|1/4"x20 bolt lengths and torque. ((photo by Hippysmack))|
+|{{:techtalk:evo:engmech:cam_cover_installation_by_cjburr.jpg?direct&300|}}|{{:techtalk:evo:engmech:98_gearcase_cover_by_hippysmack.jpg?direct&400|}}|
+====== Gaskets / Seals ======
+===== Cover Gasket =====
+and up Sportster engines have an internal rifling hole drilled into the lower left side of the case running past the left side of the oil pump. \\
+That extra hole (in the picture below) is benign and doesn't need a hole in the gasket to match. \\
+That hole is purely an artifact of how they connected two passages for routing crankcase oil up to the oil pump's scavenge section. \\
+They drill that hole to connect the two passages, and then it gets blocked off naturally by the cam box cover and gasket. ((aswracing of the XLFORUM http://xlforum.net/forums/showthread.php?t=2036109&highlight=oil+pump&page=3)) \\
+Also, in 2000, the factory changed the oil routing to the lifters to make manufacturing the cases easier. \\
+The newer cam cover on the left in the pic below and has two extra grooves along the top. \\
+These grooves let oil get to the lifters. \\
+If you have an older style gasket, it will not have cutouts for the grooves and you won't get oil to the lifters. \\
+|  Rubbermount Evo vs Rigid Evo Cam Cover Internals ((photo by Moved On of the XLFORUM http://xlforum.net/forums/showthread.php?t=87313))  |
+|{{:techtalk:evo:oil:rubbermount_vs_rigid_evo_cam_cover_comparison_by_moved_on.jpg?direct&600|}}|
+|  Both have been chopped on the outside but the gearcase perimeter is intact on them for reference.  |
+|  91-99 cam cover gasket ((photo by Hippysmack))  |  91-99 cam cover seals off the extra hole. ((photos by Hippysmack))  ||
+|{{:techtalk:evo:oil:91-99_cam_cover_gasket_2_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:91-99_cam_cover_gasket_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:91-99_cam_cover_gasket_4_by_hippysmack.jpg?direct&300|}}|
+|  2000-up cam cover gasket ((photo by Phillober of the XLFORUM http://xlforum.net/forums/showthread.php?t=1122547&page=7))  |2000 up gasket seals off the extra hole. ((sep69 of the XLFORUM http://xlforum.net/forums/showthread.php?t=2036109&highlight=oil+pump&page=3))|
+|{{:techtalk:evo:oil:2000_up_cam_cover_gasket_by_phillober.jpg?direct&300|}}|{{:techtalk:evo:oil:cam_cover_gasket_on_03_model_by_sep69.jpg?direct&300|}}|
+===== #2 Cam - Cover Seal (86-03) =====
+Seal number (11124): \\
+This surrounds and seals #2 cam when the cover is installed. \\
+|  This side faces out. ((photo by Hippysmack))  |  This side faces #2 cam shaft. ((photo by Hippysmack))  |
+|{{:techtalk:evo:engmech:11124_cam_cover_seal_2_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:11124_cam_cover_seal_1_by_hippysmack.jpg?direct&300|}}|
+Check the #2 cam seal for damage. It's always best to go ahead and replace it while you have the cover off. \\
+Using a screwdriver and hammer, insert the screwdriver inside the lip of the seal from the rear of the cover. \\
+Knock the seal out of the cover. ((photos by Hippysmack)) \\
+|{{:techtalk:evo:engmech:replacing_cam_cover_seal_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:replacing_cam_cover_seal_2_by_hippysmack.jpg?direct&300|}}|
+Clean the recessed area for the new seal thoroughly. \\
+You can use compressed air or brake cleaner (cover the ignition if still installed).
+Set the new seal over the hole aligning it as straight as possible. ((photos by Hippysmack)) \\
+|{{:techtalk:evo:engmech:replacing_cam_cover_seal_3_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:replacing_cam_cover_seal_4_by_hippysmack.jpg?direct&300|}}|
+Use a socket and a hammer to drive in the new seal straight to the cover. \\
+The socket O.D. needs to be just smaller than the seal. \\
+Make sure the seal is flush to the cover when done. ((photos by Hippysmack)) \\
+|{{:techtalk:evo:engmech:replacing_cam_cover_seal_5_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:replacing_cam_cover_seal_6_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:replacing_cam_cover_seal_7_by_hippysmack.jpg?direct&300|}}|

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