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techtalk:evo:engmech01f [2019/11/27 21:55] hippysmack [Gaskets / Seals] |
techtalk:evo:engmech01f [2019/11/27 22:22] hippysmack [Gaskets / Seals] |
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| ====== Inspection ====== | ====== 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. \\ | ||
| - | ====== Gaskets / Seals ====== | ||
| - | ===== Cam Cover Seal (86-03) ===== | ||
| - | Seal number (11124): \\ | ||
| - | This surrounds and seals #2 cam when the cover is installed. \\ | ||
| - | |{{: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|}}| | ||
| ====== Installation ====== | ====== Installation ====== | ||
| Line 117: | Line 98: | ||
| |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))| | |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&300|}}| | + | |{{: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 ===== | ||
| + | |||
| + | 91 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|}}| | ||
