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techtalk:evo:engmech01f [2019/11/27 21:55] hippysmack [Inspection] |
techtalk:evo:engmech01f [2024/01/03 17:13] (current) hippysmack |
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| ====== Removal ====== | ====== Removal ====== | ||
| - | |||
| * **Checklist**: | * **Checklist**: | ||
| * **You'll need to bleed down the lifters and loosen or remove the rocker boxes**: \\ See [[techtalk:evo:engmech04a#removing_the_rocker_boxes|Removing the Rocker Boxes]] in the Sportsterpedia prior to removing the cam cover. | * **You'll need to bleed down the lifters and loosen or remove the rocker boxes**: \\ See [[techtalk:evo:engmech04a#removing_the_rocker_boxes|Removing the Rocker Boxes]] in the Sportsterpedia prior to removing the cam cover. | ||
| - | * Pulling the cover without first loosening the rocker boxes to take the pressure off is generally a bad idea. \\ It's hard on the cam bushings to have valve spring pressure pushing down on them while the cams are only supported on the inboard side. ((aswracing of the XLFORUM http://xlforum.net/forums/showthread.php?page=2&t=1467295)) \\ | + | * Pulling the cover without first loosening the rocker boxes to take the pressure off is generally a bad idea. \\ It's hard on the cam bushings to have valve spring pressure pushing down on them while the cams are only supported on the inboard side. ((aswracing of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-bottom-end/135533-help-cam-timing-confusion/page2?page=2&t=1467295)) \\ |
| * The rocker box puts downward pressure thru the pushrods / lifters to the cams and subsequently the cam bushings. | * The rocker box puts downward pressure thru the pushrods / lifters to the cams and subsequently the cam bushings. | ||
| * The bushings are then pressed hard against the cover in which the bushings reside. Kinda like holding your arm down on a table and let someone push down on your arm. \\ Then try to pull your arm away. It's harder to do. | * The bushings are then pressed hard against the cover in which the bushings reside. Kinda like holding your arm down on a table and let someone push down on your arm. \\ Then try to pull your arm away. It's harder to do. | ||
| Line 33: | Line 32: | ||
| * Now the pressure is off the cam bushings and it's a lot easier and safer to remove the cover. | * Now the pressure is off the cam bushings and it's a lot easier and safer to remove the cover. | ||
| - | * The cam cover has 11 Allen head screws of various lengths. \\ They will need to be replaced back in the same holes from which they were removed. \\ So, their proper location will need to be marked upon removal. \\ You can make a drawing of the cam gear case on a piece of cardboard. \\ Then put them into the cardboard in the proper orientation as removed from the cover. ((Turbota of the XLFORUM http://xlforum.net/forums/showthread.php?t=870)) | + | * The cam cover has 11 Allen head screws of various lengths. \\ They will need to be replaced back in the same holes from which they were removed. \\ So, their proper location will need to be marked upon removal. \\ You can make a drawing of the cam gear case on a piece of cardboard. \\ Then put them into the cardboard in the proper orientation as removed from the cover. ((Turbota of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-bottom-end/763-04-05-cam-install-how-to-complete-with-pics?t=870)) |
| * Although it may not be necessary and depending on your foot control setup; \\ You may have to remove the foot peg / foot brake pedal support or brake rod to fully remove the exhaust or cam cover. | * Although it may not be necessary and depending on your foot control setup; \\ You may have to remove the foot peg / foot brake pedal support or brake rod to fully remove the exhaust or cam cover. | ||
| - | |Remove the exhaust. ((photo by goinsideways136 of the XLFORUM http://xlforum.net/forums/showthread.php?t=385092))|Place a flat drip pan or container under the engine to \\ catch any oil leaking out. It will leak oil when the \\ cover is removed. ((photo by Phillober of the XLFORUM http://xlforum.net/forums/showthread.php?t=1122547&page=2))|Remove the Allen screws holding the cover on and \\ place them in holes cut into a piece of cardboard for \\ safe keeping and sorting of various length screws. ((photo by goinsideways136 of the XLFORUM http://xlforum.net/forums/showthread.php?t=385092))| | + | |Remove the exhaust. ((photo by goinsideways136 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-styles/chopper-bobber-talk/63036-chopped-up-cam-cover-pics?t=385092))|Place a flat drip pan or container under the engine to \\ catch any oil leaking out. It will leak oil when the \\ cover is removed. ((photo by Phillober of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-engine-conversions/116696-phillober-s-1250-conversion-thread-pic-heavy/page2?t=1122547&page=2))|Remove the Allen screws holding the cover on and \\ place them in holes cut into a piece of cardboard for \\ safe keeping and sorting of various length screws. ((photo by goinsideways136 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-styles/chopper-bobber-talk/63036-chopped-up-cam-cover-pics?t=385092))| |
| |{{:techtalk:evo:engmech:removing_cam_cover_1_by_goinsideways136.jpg?direct&300|}}| {{:techtalk:ref:tools:oil_catch_pan_by_phillober.jpg?direct&300|}}|{{:techtalk:ref:tools:removing_cam_cover_3_by_goinsideways136.jpg?direct&300|}}| | |{{:techtalk:evo:engmech:removing_cam_cover_1_by_goinsideways136.jpg?direct&300|}}| {{:techtalk:ref:tools:oil_catch_pan_by_phillober.jpg?direct&300|}}|{{:techtalk:ref:tools:removing_cam_cover_3_by_goinsideways136.jpg?direct&300|}}| | ||
| Line 52: | Line 51: | ||
| * Also, you will need to remove a rubber oil line that attaches to the rear area of the case before the case can be completely removed. \\ Since the clamp holding this oil line cannot be reused, you will need to purchase a new hose clamp when the case is re-installed. | * Also, you will need to remove a rubber oil line that attaches to the rear area of the case before the case can be completely removed. \\ Since the clamp holding this oil line cannot be reused, you will need to purchase a new hose clamp when the case is re-installed. | ||
| * Remove and discard the gasket. Clean the case with brake cleaner. | * Remove and discard the gasket. Clean the case with brake cleaner. | ||
| - | |||
| - | |The cover should come off slow with even pull applied and all cams safely in the case. ((photos by goinsideways136 of the XLFORUM http://xlforum.net/forums/showthread.php?t=385092))||At this point, you can use a screwdriver or putty \\ knife to push the cams back in the case ((photo by sep69 of the XLFORUM http://xlforum.net/forums/showthread.php?t=1332901))| | + | |The cover should come off slow with even pull applied and all cams safely in the case. ((photos by goinsideways136 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-styles/chopper-bobber-talk/63036-chopped-up-cam-cover-pics?t=385092))||At this point, you can use a screwdriver or putty \\ knife to push the cams back in the case ((photo by sep69 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-engine-conversions/128452-mark-s-883-to-1250-conversion?t=1332901))| |
| |{{:techtalk:evo:engmech:removing_cam_cover_4_by_goinsideways136.jpg?direct&300|}}|{{:techtalk:evo:engmech:removing_cam_cover_5_by_goinsideways136.jpg?direct&300|}}|{{:techtalk:evo:engmech:removing_cam_cover_by_sep69.jpg?direct&300|}}| | |{{:techtalk:evo:engmech:removing_cam_cover_4_by_goinsideways136.jpg?direct&300|}}|{{:techtalk:evo:engmech:removing_cam_cover_5_by_goinsideways136.jpg?direct&300|}}|{{:techtalk:evo:engmech:removing_cam_cover_by_sep69.jpg?direct&300|}}| | ||
| - | + | |This is what happens if you don't remove the \\ inspection cover and / or the rotor cup bolt from \\ #2 cam before removing the cam cover. ((photo by Phillober of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-engine-conversions/116696-phillober-s-1250-conversion-thread-pic-heavy/page2?t=1122547&page=2))|This is what can happen to the cams positioning if \\ you try to re-install the cover with the cams still \\ attached to it. ((photo by caseyjones, markups by Shu https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-bottom-end/104387-cam-gear-timing?t=922143))| | |
| - | |This is what happens if you don't remove the \\ inspection cover and / or the rotor cup bolt from \\ #2 cam before removing the cam cover. ((photo by Phillober of the XLFORUM http://xlforum.net/forums/showthread.php?t=1122547&page=2))|This is what can happen to the cams positioning if \\ you try to re-install the cover with the cams still \\ attached to it. ((photo by caseyjones, markups by Shu http://xlforum.net/forums/showthread.php?t=922143))| | + | |
| |{{:techtalk:evo:engmech:cam_cover_removed_with_cams_by_phillober.jpg?direct&300|}}|{{:techtalk:evo:engmech:cams_misaligned_by_caseyjones.jpg?direct&300|}}| | |{{:techtalk:evo:engmech:cam_cover_removed_with_cams_by_phillober.jpg?direct&300|}}|{{:techtalk:evo:engmech:cams_misaligned_by_caseyjones.jpg?direct&300|}}| | ||
| Line 65: | Line 62: | ||
| |{{:techtalk:evo:engmech:securing_cams_with_the_cover_off_by_travis13.jpg?direct&300|}}| | |{{: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))| | + | |Securing cams with rubber bands ((photo by Travis13 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/158199-i-got-very-lucky-gd-autozone-chinese-crap/page3?t=1692569&page=3))| |
| ====== Inspection ====== | ====== Inspection ====== | ||
| - | |||
| Before installation, use a straightedge diagonally across the corners to check for warp-age of the cover. \\ | 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. \\ | 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 ====== | ||
| - | |||
| 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. \\ | 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. \\ | Put the gasket on the cover and install the screws through the cover and the gasket holes while maneuvering the cover on the case. \\ | ||
| Line 117: | Line 90: | ||
| |{{: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|}}| | |{{: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))| | + | |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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-engine-conversions/29770-conversion-tips-tricks-and-warnings?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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-bottom-end/190901-no-oil-pressure-going-to-check-filter-and-pump-what-else/page3?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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-suspension-frame-forks-handlebars-fuel-tank-oil-tank-fenders/40457-whoa-oil-tank-vomits-oil?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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-engine-conversions/116696-phillober-s-1250-conversion-thread-pic-heavy/page7?t=1122547&page=7)) |2000 up gasket seals off the extra hole. ((sep69 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-bottom-end/190901-no-oil-pressure-going-to-check-filter-and-pump-what-else/page3?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|}}| | ||
