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techtalk:evo:oil03h [2018/12/21 05:39] hippysmack [Disassembly] |
techtalk:evo:oil03h [2024/01/05 03:40] (current) hippysmack |
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| ====== EVO: Oiling & Lubrication - Sub-03H ====== | ====== EVO: Oiling & Lubrication - Sub-03H ====== | ||
| ====== 86-90 Oil Pump Removal and Disassembly ====== | ====== 86-90 Oil Pump Removal and Disassembly ====== | ||
| - | |||
| |{{:techtalk:evo:oil:86-90_oil_pump_disassembly_1_by_hippysmack.jpg?direct&300|}}| | |{{:techtalk:evo:oil:86-90_oil_pump_disassembly_1_by_hippysmack.jpg?direct&300|}}| | ||
| | 86-90 Oil Pump ((phoyo by Hippysmack)) | | | 86-90 Oil Pump ((phoyo by Hippysmack)) | | ||
| + | |||
| ====== Removal ====== | ====== Removal ====== | ||
| * The 86-90 gerotor pump can be removed with the engine in the frame and the gearcase cover installed. | * The 86-90 gerotor pump can be removed with the engine in the frame and the gearcase cover installed. | ||
| * Disconnect the oil lines. | * Disconnect the oil lines. | ||
| * Remove the four mounting bolts and the pump should drop down. | * Remove the four mounting bolts and the pump should drop down. | ||
| - | * There is a flat spot on the frame just under the pump. ((IronMick of the XLFORUM http://xlforum.net/forums/showthread.php?t=554323)) | + | * There is a flat spot on the frame just under the pump. ((IronMick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/77330-oil-pump-1977-up?t=554323)) |
| * The complete pump assembly comes out as a unit. | * The complete pump assembly comes out as a unit. | ||
| - | * It´s not possible to take only the cover out because of the of limited space between the cover and frame. ((acb2 of the XLFORUM http://xlforum.net/forums/showthread.php?t=554323)) | + | * It´s not possible to take only the cover out because of the of limited space between the cover and frame. ((acb2 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/77330-oil-pump-1977-up?t=554323)) |
| - | * Its a tight squeeze but you can wriggle the pump out. ((russzx6 of the XLFORUM http://xlforum.net/forums/showthread.php?t=554323)) | + | * Its a tight squeeze but you can wriggle the pump out. ((russzx6 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/77330-oil-pump-1977-up?t=554323)) |
| ===== Pump Stuck to Engine Case ===== | ===== Pump Stuck to Engine Case ===== | ||
| Line 21: | Line 21: | ||
| So the pump may be stuck to the engine case after the bolts come out. \\ | So the pump may be stuck to the engine case after the bolts come out. \\ | ||
| - | There are also times when a gasket could not be found, so RTV or other sealers were used in addition to or instead of a gasket. ((Farmer00-1 of the XLFORUM http://xlforum.net/forums/showthread.php?t=554323)) \\ | + | There are also times when a gasket could not be found, so RTV or other sealers were used in addition to or instead of a gasket. ((Farmer00-1 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/77330-oil-pump-1977-up?t=554323)) \\ |
| Either way, if gasket sealer was applied, expect that to make it more difficult to remove the pump from the engine. \\ | Either way, if gasket sealer was applied, expect that to make it more difficult to remove the pump from the engine. \\ | ||
| * First, be patient with it. | * First, be patient with it. | ||
| - | * Try to turn the motor over by hand. It may push the pump out. ((Jason's Sporty of the XLFORUM http://xlforum.net/forums/showthread.php?t=2071005&highlight=oil+pump)) | + | * Try to turn the motor over by hand. It may push the pump out. ((Jason's Sporty of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/frame-mount-evo-sportster-talk-1986-2003-models/194711-86-883-xlh-oil-pump?t=2071005&highlight=oil+pump)) |
| * Try a rubber mallet. | * Try a rubber mallet. | ||
| * Gently tap down on the pump's rear side so you're not forcing extra pressure against the drive gear on the pinion shaft. | * Gently tap down on the pump's rear side so you're not forcing extra pressure against the drive gear on the pinion shaft. | ||
| * Try a short piece of 2x4 to gently tap on the pump. | * Try a short piece of 2x4 to gently tap on the pump. | ||
| * Try using a crowbar with a "catspaw" on the rear side of the pump. | * Try using a crowbar with a "catspaw" on the rear side of the pump. | ||
| - | * It's a wood working tool for pulling nails. ((123456qwerty of the XLFORUM http://xlforum.net/forums/showthread.php?t=2071005&highlight=oil+pump)) | + | * It's a wood working tool for pulling nails. ((123456qwerty of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/frame-mount-evo-sportster-talk-1986-2003-models/194711-86-883-xlh-oil-pump?t=2071005&highlight=oil+pump)) |
| ===== Gasket Removal ===== | ===== Gasket Removal ===== | ||
| Line 43: | Line 43: | ||
| Below PB Blaster was used with an auto window scraper. ((photos by Hippysmack)) \\ | Below PB Blaster was used with an auto window scraper. ((photos by Hippysmack)) \\ | ||
| |{{:techtalk:ref:tools:removing_gasket_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ref:tools:removing_gasket_2_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ref:tools:removing_gasket_3_by_hippysmack.jpg?direct&300|}}| | |{{:techtalk:ref:tools:removing_gasket_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ref:tools:removing_gasket_2_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ref:tools:removing_gasket_3_by_hippysmack.jpg?direct&300|}}| | ||
| + | |||
| ===== Stuck Cover Gasket ===== | ===== Stuck Cover Gasket ===== | ||
| The spring washer inside the pump puts a lot of tension against the cover. \\ | The spring washer inside the pump puts a lot of tension against the cover. \\ | ||
| Line 49: | Line 50: | ||
| So, it is common for the cover to be stuck to the pump body. \\ | So, it is common for the cover to be stuck to the pump body. \\ | ||
| - | According to the FSM, the pump to case mounting gasket should be coated with gasket sealer before installation. \\ | + | As mentioned above, the pump to case mounting gasket may be coated with gasket sealer. \\ |
| This is a debatable procedure as many have reported that is not necessary. \\ | This is a debatable procedure as many have reported that is not necessary. \\ | ||
| Line 71: | Line 72: | ||
| * However, a 24 hour soak will help to soften the gasket / sealer and make it easier to break free. | * However, a 24 hour soak will help to soften the gasket / sealer and make it easier to break free. | ||
| - | | Carburetor Cleaner ((photo by Hippysmack http://xlforum.net/forums/showthread.php?t=2071153&page=4)) ||| | + | | Carburetor Cleaner ((photo by Hippysmack https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/194881-let-s-study-the-77-85-oil-pump-parts-and-changes-and-when/page4?t=2071153&page=4)) ||| |
| - | |{{:techtalk:ref:tools:parts_cleaner_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ref:tools:parts_cleaner_3_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ih:oil:parts_cleaner_6_by_hippysmack.jpg?direct&300|}}| | + | |{{techtalk:ref:genmsr:parts_cleaner_1_by_hippysmack.jpg?direct&300|}}|{{techtalk:ref:genmsr:parts_cleaner_3_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ih:oil:parts_cleaner_6_by_hippysmack.jpg?direct&300|}}| |
| * After soaking, open the lid, remove the small bucket inside by the handle, set the bucket on the ground and wash the parts cleaner off with a water hose. | * After soaking, open the lid, remove the small bucket inside by the handle, set the bucket on the ground and wash the parts cleaner off with a water hose. | ||
| Line 80: | Line 81: | ||
| This oil pump had to be soaked overnite before the cover would separate from the body. \\ | This oil pump had to be soaked overnite before the cover would separate from the body. \\ | ||
| - | | Cleaning and soaking gaskets for more easy removal ((photos by Hippysmack http://xlforum.net/forums/showthread.php?t=2071153&page=4)) || | + | | Cleaning and soaking gaskets for more easy removal ((photos by Hippysmack https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/194881-let-s-study-the-77-85-oil-pump-parts-and-changes-and-when/page4?t=2071153&page=4)) || |
| - | |{{:techtalk:ref:tools:parts_cleaner_4_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ref:tools:parts_cleaner_2_by_hippysmack.jpg?direct&300|}}| | + | |{{techtalk:ref:genmsr:parts_cleaner_4_by_hippysmack.jpg?direct&300|}}|{{techtalk:ref:genmsr:parts_cleaner_2_by_hippysmack.jpg?direct&300|}}| |
| - | + | ||
| - | |{{:techtalk:ih:oil:77-e83_oil_pump_5.2_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ih:oil:77-e83_oil_pump_5.3_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ih:oil:77-e83_oil_pump_5.1_by_hippysmack.jpg?direct&300|}}| | + | |
| ====== Disassembly ====== | ====== Disassembly ====== | ||
| Line 105: | Line 104: | ||
| * Push in on the outer plate (if needed) to compress the spring and the pin can be removed with pliers or your fingers. | * Push in on the outer plate (if needed) to compress the spring and the pin can be removed with pliers or your fingers. | ||
| - | * Then the outer plate can be removed. | + | * Then the outer plate can be removed. |
| * The notch in the plate mates around the roll pin in the body that keeps it from rotating. | * The notch in the plate mates around the roll pin in the body that keeps it from rotating. | ||
| * It'll have to be lifted straight out or dumped out. | * It'll have to be lifted straight out or dumped out. | ||
| + | * Check the position and condition of the outer plate seal before removing it. | ||
| + | * It is pressed into the outer plate. | ||
| + | * Check the fit around the gearshaft. It should be a snug fit and sitting horizontal to the gearshaft. | ||
| + | * If not, this could easily contributed to wet-sumping in the engine. | ||
| * Then remove the spring washer. | * Then remove the spring washer. | ||
| + | * The inner plate is held in by the retaining ring. | ||
| |{{:techtalk:evo:oil:86-90_oil_pump_disassembly_5_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:86-90_oil_pump_disassembly_6_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:86-90_oil_pump_disassembly_7_by_hippysmack.jpg?direct&300|}}| | |{{:techtalk:evo:oil:86-90_oil_pump_disassembly_5_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:86-90_oil_pump_disassembly_6_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:86-90_oil_pump_disassembly_7_by_hippysmack.jpg?direct&300|}}| | ||
| + | |||
| + | * The outer plate seal will need to be pressed or pried out. | ||
| + | * You can set up a rig as in below (bearing race, a small socket and a rubber hammer). | ||
| + | * Make sure the socket is slightly smaller than the outer plate I.D. | ||
| + | * Gently tap the socket. | ||
| + | * And the seal will fall thru the bearing race (or larger socket etc). | ||
| + | |||
| + | |{{:techtalk:evo:oil:83-90_outer_plate_3_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:83-90_outer_plate_4_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:83-90_outer_plate_5_by_hippysmack.jpg?direct&300|}}| | ||
| + | |||
| + | * Two small drivers were used here (1 to keep the ring from spinning, 1 to raise an end out of the groove in the gearshaft). | ||
| + | * The 1st screwdriver can be pushed into the slot in the gerotor to keep the ring from spinning. | ||
| + | * This will allow you to pick and out on one end and then switch back and forth between the two from there. | ||
| + | * Remove the retainer clip. | ||
| + | * Then pull out the inner plate. | ||
| |{{:techtalk:evo:oil:86-90_oil_pump_disassembly_8_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:86-90_oil_pump_disassembly_9_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:86-90_oil_pump_disassembly_10_by_hippysmack.jpg?direct&300|}}| | |{{:techtalk:evo:oil:86-90_oil_pump_disassembly_8_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:86-90_oil_pump_disassembly_9_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:86-90_oil_pump_disassembly_10_by_hippysmack.jpg?direct&300|}}| | ||
| + | |||
| + | * Inspect the roll pin in the pump body for straightness and damage. | ||
| + | * The return gerotors are also normally 'sandwiched' between the inner plate and the pump body. | ||
| + | * Turn the pump over and dump them out enough to get your fingers on them. \\ (being careful not to loose the second pin in the gearshaft) | ||
| + | * Inspect the area at the pump bore where the pin contacts it for damage. \\ | ||
| + | * Also, make sure the pin is sitting on the outside of the bore surface instead of inside the bore. \\ | ||
| + | * The second pin holds and keeps the gearshaft from coming out. | ||
| + | * Use a pair of needle nose pliers to remove it from the gearshaft. | ||
| + | * Hold the gearshaft with the other hand to keep it from falling when pulling this pin. | ||
| + | * Else, it could fall out and damage the teeth on the gear. | ||
| + | * Inspect the return gerotors and their mating surface in the pump body for scratches / damage. \\ | ||
| |{{:techtalk:evo:oil:86-90_oil_pump_disassembly_11_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:86-90_oil_pump_disassembly_12_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:86-90_oil_pump_disassembly_13_by_hippysmack.jpg?direct&300|}}| | |{{:techtalk:evo:oil:86-90_oil_pump_disassembly_11_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:86-90_oil_pump_disassembly_12_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:86-90_oil_pump_disassembly_13_by_hippysmack.jpg?direct&300|}}| | ||
| + | |||
| + | |||
| + | * Remove the gearshaft and set it in a safe place to protect the gear teeth. | ||
| + | * Clean all parts with solvent (brake cleaner works well). | ||
| + | * With the parts spread out you now can now do further inspection on areas noticed while disassembling. | ||
| |{{:techtalk:evo:oil:86-90_oil_pump_disassembly_16_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:86-90_oil_pump_disassembly_17_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:86-90_oil_pump_disassembly_14_by_hippysmack.jpg?direct&300|}}| | |{{:techtalk:evo:oil:86-90_oil_pump_disassembly_16_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:86-90_oil_pump_disassembly_17_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:86-90_oil_pump_disassembly_14_by_hippysmack.jpg?direct&300|}}| | ||
