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| * [[techtalk:ref:genmsr04|Using / Diagnosing with a Slack Tube (Manometer)]] | * [[techtalk:ref:genmsr04|Using / Diagnosing with a Slack Tube (Manometer)]] | ||
| - | Obviously you must find exactly what is leaking before you can determine what will be needed to fix it. ((santis5 of the XLFORUM http://xlforum.net/forums/showthread.php?t=615245)) \\ | + | Obviously you must find exactly what is leaking before you can determine what will be needed to fix it. ((santis5 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/82747-oil-leaks?t=615245)) \\ |
| 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/seals but do not tighten more than the specs in the FSM to stop a leak. \\ | Check torque on the bolts on covers and parts with gasket/seals but do not tighten more than the specs in the FSM to stop a leak. \\ | ||
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| ====== 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://www.xlforum.net/forums/showthread.php?p=174442#post174442)) \\ | + | This Tech Tip reprinted by Krayven Sumhead of the XLFORUM ((https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-service/sportster-motorcycle-service-bulletins/9056-excessive-oil-comsumption-bulletin/page3#post174442)) \\ |
| [[techtalk:miscres:miscres04|See the original Tech Tip (#59, 8-10-05) PDF here]] in the Sportsterpedia. \\ | [[techtalk:miscres:miscres04|See the original Tech Tip (#59, 8-10-05) PDF here]] in the Sportsterpedia. \\ | ||
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| * 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 ====== | ||
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| * **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't stay in the channel. \\ Check the gasket for leaks all around the rocker box especially between the heads where it's hard to see. | * 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't stay in the channel. \\ Check the gasket for leaks all around the rocker box especially between the heads where it's hard to see. | ||
| - | * The 3 piece covers are sensitive to alignment and progressive tightening. Patience during installation is a must. ((sportsterpaul of the XLFORUM http://xlforum.net/forums/showthread.php?t=2073161&page=2)) ((http://xlforum.net/forums/showthread.php?t=1552827&highlight=rocker+box+bolts)) \\ Keep the valve covers (all 3 pieces) in perfect vertical alignment on all four sides. \\ Tighten down each screw a little at a time crisscrossing as you go. The gaskets are rubber and can be reused if not damaged. \\ You might just try loosening the screws, check alignment and re-tighten before doing a complete dis-assembly. | + | * The 3 piece covers are sensitive to alignment and progressive tightening. Patience during installation is a must. ((sportsterpaul of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-general-discussion-and-problems/196602-the-oil-leak-rabbit-hole/page2?t=2073161&page=2)) ((https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/143289-oil-leak-at-rocker-cover?t=1552827&highlight=rocker+box+bolts)) \\ Keep the valve covers (all 3 pieces) in perfect vertical alignment on all four sides. \\ Tighten down each screw a little at a time crisscrossing as you go. The gaskets are rubber and can be reused if not damaged. \\ You might just try loosening the screws, check alignment and re-tighten before doing a complete dis-assembly. |
| * **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. | ||
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| * If they curl up on you and make it hard to keep them down for installation; \\ Add a little bearing grease in strategic spots to hold the gaskets down. \\ Crankcase pressure can suck the sealer out and send it into your oiling passages and cause loads of damage. | * If they curl up on you and make it hard to keep them down for installation; \\ Add a little bearing grease in strategic spots to hold the gaskets down. \\ Crankcase pressure can suck the sealer out and send it into your oiling passages and cause loads of damage. | ||
| * **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 http://xlforum.net/forums/showthread.php?t=1552827&highlight=rocker+box+bolts&page=2)) | + | * 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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/143289-oil-leak-at-rocker-cover/page2?t=1552827&highlight=rocker+box+bolts&page=2)) |
| * 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 http://xlforum.net/forums/showthread.php?t=1479824&page=3)) \\ It is this increased crankcase pressure inside that causes leaks to occur in the weakest point of the bottom end. \\ In these cases, the weakest point happens to be the rocker box cover seals. Simply replacing the breather valve(s) may leave your leaky boxes behind you. \\ See [[techtalk:evo:oil06#crankcase_pressure_problems|Crankcase Pressure Problems]] below. | + | * 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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/efi-sportster-motorcycle-talk-2007-and-up/136379-leaky-rocker-box-cover/page3?t=1479824&page=3)) \\ It is this increased crankcase pressure inside that causes leaks to occur in the weakest point of the bottom end. \\ In these cases, the weakest point happens to be the rocker box cover seals. Simply replacing the breather valve(s) may leave your leaky boxes behind you. \\ See [[techtalk:evo:oil06#crankcase_pressure_problems|Crankcase Pressure Problems]] below. |
| * **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 http://xlforum.net/forums/showthread.php?s=3e3f3aaa60d056d0d5ab20af30b07751&t=2077619)) \\ Drag the top cover on it a few times and see if you have any markings that would indicate high or low spots. | + | * 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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/200596-front-rocker-top-gasket-keeps-leaking?s=3e3f3aaa60d056d0d5ab20af30b07751&t=2077619)) \\ Drag the top cover on it a few times and see if you have any markings that would indicate high or low spots. |
| * **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. | ||
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| 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 http://xlforum.net/forums/showthread.php?t=254258)) \\ (caused by sandwiching sensor wire with gasket) | | + | | Damaged lower rocker box gasket. ((photo by 4-pac of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-intake-and-exhaust/sportster-motorcycle-air-intake-carburetor-efi-fuel-and-exhaust/53895-06-carb-to-07-fuel-injection-conversion?t=254258)) \\ (caused by sandwiching sensor wire with gasket) | |
| |{{:techtalk:evo:oil:damaged_lower_rocker_box_gasket_by_4-pac.jpg?direct&300|}}| | |{{:techtalk:evo:oil:damaged_lower_rocker_box_gasket_by_4-pac.jpg?direct&300|}}| | ||
| - | | Potential oil leak areas of rocker boxes. ((photo by dagger rider of the XLFORUM )) |Fiber washers will crush in the center and leak \\ around threads due to excess vacuum. ((photo by Hippysmack)) |Replace the washers with new OEM ones. \\ Or consider swapping to copper washers. \\ CHECK BREATHER VALVES ALSO. ((photo by jordan1200 of the XLFORUM))| | + | | Potential oil leak areas of rocker boxes. ((photo by daggar rider of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/68286-bottom-and-top-rocker-gasket-replacement-step-by-step)) |Fiber washers will crush in the center and leak \\ around threads due to excess vacuum. ((photo by Hippysmack)) |Replace the washers with new OEM ones. \\ Or consider swapping to copper washers. \\ CHECK BREATHER VALVES ALSO. ((photo by jordan1200 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/192948-cometic-roc%C4%B7er-box-gasket))| |
| |{{:techtalk:ref:engmech:potential_cc_pressure_leaks_at_the_rocker_box_by_daggar_rider_labeled_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ref:engmech:bad_rocker_box_fiber_washer_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:cometic_rocker_box_washers_by_jordan1200.jpg?direct&300|}}| | |{{:techtalk:ref:engmech:potential_cc_pressure_leaks_at_the_rocker_box_by_daggar_rider_labeled_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ref:engmech:bad_rocker_box_fiber_washer_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:cometic_rocker_box_washers_by_jordan1200.jpg?direct&300|}}| | ||
| - | | Leak with pinched gasket. ((photo by sep69 of the XLFORUM http://xlforum.net/forums/showthread.php?p=3754227)) \\ (can cause crankcase pressure problems) | Leak with non pinched gasket. ((photo by Skuzeee of the XLFORUM http://xlforum.net/forums/showthread.php?t=2073161&page=2)) \\ (can be caused by crankcase pressure problems) | Worn / leaking HD lower gasket. ((photo by repairguy of the XLFORUM http://xlforum.net/forums/showthread.php?t=612035)) \\ (can be caused by improper torque) | | + | | Leak with pinched gasket. ((photo by sep69 of the XLFORUM http://xlforum.net/forums/showthread.php?p=3754227)) \\ (can cause crankcase pressure problems) | Leak with non pinched gasket. ((photo by Skuzeee of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-general-discussion-and-problems/196602-the-oil-leak-rabbit-hole/page2?t=2073161&page=2)) \\ (can be caused by crankcase pressure problems) | Worn / leaking HD lower gasket. ((photo by repairguy of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/efi-sportster-motorcycle-talk-2007-and-up/82518-installed-the-lower-rocker-box-gasket?t=612035)) \\ (can be caused by improper torque) | |
| |{{:techtalk:evo:engmech:pinched_rocker_box_gasket_1_by_sep69.jpg?direct&300|}}|{{:techtalk:evo:oil:leaky_rocker_box_by_skuzeee.jpg?direct&300|}}|{{:techtalk:evo:oil:worn_07_rocker_box_gasket_on_883_by_repairguy.jpeg?direct&300|}}| | |{{:techtalk:evo:engmech:pinched_rocker_box_gasket_1_by_sep69.jpg?direct&300|}}|{{:techtalk:evo:oil:leaky_rocker_box_by_skuzeee.jpg?direct&300|}}|{{:techtalk:evo:oil:worn_07_rocker_box_gasket_on_883_by_repairguy.jpeg?direct&300|}}| | ||
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| * Part number (17537-96B) has narrow slots. | * Part number (17537-96B) has narrow slots. | ||
| * The newer lower box (17537-96C), introduced 9-12-2005, does not have any slots there. | * The newer lower box (17537-96C), introduced 9-12-2005, does not have any slots there. | ||
| - | * **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 http://xlforum.net/forums/showthread.php?t=29799&page=4)) | + | * **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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/rubber-mount-sportster-motorcycle-talk-2004-2006/17882-crap-front-rocker-cover-leak/page4?t=29799&page=4)) |
| * **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**. | ||
| - | {{:techtalk:evo:oil:rocker_box_17537-96b_by_johnk.jpg?direct&400|}} ((photo by JohnK of the XLFORUM http://xlforum.net/forums/showthread.php?p=3944070)) \\ | + | {{:techtalk:evo:oil:rocker_box_17537-96b_by_johnk.jpg?direct&400|}} ((photo by JohnK of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/132786-fixing-a-leaky-top-end-with-pics/page6#post2887799)) \\ |
| ===== 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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| * 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/popped in their corresponding seats/grooves. \\ Installing the O-rings on the tubes first will result in a leak. \\ The O-ring at the top, slipped down the tube, won't compress into the head by the boss on it's own. \\ You can poke a rag on a very small regular screw driver up at the top of the covers to check for a sign of fresh oil. | * 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/popped in their corresponding seats/grooves. \\ Installing the O-rings on the tubes first will result in a leak. \\ The O-ring at the top, slipped down the tube, won't compress into the head by the boss on it's own. \\ You can poke a rag on a very small regular screw driver up at the top of the covers to check for a sign of fresh oil. | ||
| * **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 http://xlforum.net/forums/showthread.php?t=2022009)) \\ This keeps the O-rings from squishing out and leaking. Oil the inner side so it slides easily. | + | * **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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/frame-mount-evo-sportster-talk-1986-2003-models/189600-fixing-bottom-push-rod-tube-leaks?t=2022009)) \\ This keeps the O-rings from squishing out and leaking. Oil the inner side so it slides easily. |
| - | * **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 http://xlforum.net/forums/showthread.php?t=150704)) | + | * **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 https://www.xlforum.net/forum/buell-motorcycle-forum/buell-motorcycle-top-end/44852-getting-to-the-push-rod-tubes-on-a-x1?t=150704)) |
| - | * **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't bend, it also doesn't preload the seal evenly. It can be a real challenge to make it work. ((aswracing of the XLFORUM ((http://xlforum.net/forums/showthread.php?t=1856)) \\ Before installing them, make sure they are still flat across the bottom using a flat surface (glass maybe) and a feeler gauge. \\ If they are warped, do not try to install them with extra torque to pull them in farther. Just replace them. \\ Don't add silicone to them to stop a leak. It'll get loose, work it's way into the engine and stop up the oil system. | + | * **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't bend, it also doesn't preload the seal evenly. It can be a real challenge to make it work. ((aswracing of the XLFORUM ((https://www.xlforum.net/forum/vendors/nrhs-high-performance/1355-billet-aluminum-pushrod-bases?t=1856)) \\ Before installing them, make sure they are still flat across the bottom using a flat surface (glass maybe) and a feeler gauge. \\ If they are warped, do not try to install them with extra torque to pull them in farther. Just replace them. \\ Don't add silicone to them to stop a leak. It'll get loose, work it's way into the engine and stop up the oil system. |
| * **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:evo:oil06#crankcase_pressure_problems|Crankcase Pressure Problems]] below. | * See [[techtalk:evo:oil06#crankcase_pressure_problems|Crankcase Pressure Problems]] below. | ||
| - | {{:techtalk:evo:oil:pushrod_tube_leak_by_t-rexl1200.jpeg?direct&300|}} ((photo by T-reXL1200 of the XLFORUM http://xlforum.net/forums/showthread.php?t=1768811&page=2)) \\ | + | {{:techtalk:evo:oil:pushrod_tube_leak_by_t-rexl1200.jpeg?direct&300|}} ((photo by T-reXL1200 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-general-discussion-and-problems/164511-help-cometic-gasket-oil-leak/page2?t=1768811&page=2)) \\ |
| ===== Head Gaskets / Bolts ===== | ===== Head Gaskets / Bolts ===== | ||
| - | |||
| **Head gasket leak**. \\ | **Head gasket leak**. \\ | ||
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| * **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:ref:svcproc20#cylinder_compression_test|Compression Test]] or [[techtalk:ref:svcproc21#cylinder_leak-down_test|Leakdown Test]] on the cylinder. | * **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:ref:svcproc20#cylinder_compression_test|Compression Test]] or [[techtalk:ref:svcproc21#cylinder_leak-down_test|Leakdown Test]] on the cylinder. | ||
| * **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 http://xlforum.net/forums/showthread.php?t=1940586&page=2)) \\ Smudge marks can be a give away as to where any leaks might occur. \\ Also take a few pics of them (no flash, direct light and a steady hand). \\ The gasket has been known to raise around the head oil drain and only on the inside edge of the gasket. \\ So no outward sign of the leak. With the head removed an experienced eye may be able to spot the problem. \\ If you have a blown gasket and it's near the head oil drain, you may have just found your 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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/180459-oil-leak-on-my-77-sportster/page2?t=1940586&page=2)) \\ Smudge marks can be a give away as to where any leaks might occur. \\ Also take a few pics of them (no flash, direct light and a steady hand). \\ The gasket has been known to raise around the head oil drain and only on the inside edge of the gasket. \\ So no outward sign of the leak. With the head removed an experienced eye may be able to spot the problem. \\ If you have a blown gasket and it's near the head oil drain, you may have just found your problem. |
| - | * **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 http://xlforum.net/forums/showthread.php?t=864390)) \\ Try wiping it off and it may stop leaking after a few months. \\ There should not be a washer under the bolt. \\ There shouldn't be any way for oil to work it's way there unless the head \ gasket wasn't cleaned and torqued down right in the first place. ((Horse of the XLFORUM http://xlforum.net/forums/showthread.php?t=864390)) | + | * **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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/efi-sportster-motorcycle-talk-2007-and-up/100360-cylinder-head-bolt-leaking?t=864390)) \\ Try wiping it off and it may stop leaking after a few months. \\ There should not be a washer under the bolt. \\ There shouldn't be any way for oil to work it's way there unless the head \ gasket wasn't cleaned and torqued down right in the first place. ((Horse of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/efi-sportster-motorcycle-talk-2007-and-up/100360-cylinder-head-bolt-leaking?t=864390)) |
| * **Repair**. | * **Repair**. | ||
| * Officially, a leaking head gasket should be replaced. | * Officially, a leaking head gasket should be replaced. | ||
| Line 253: | Line 251: | ||
| * 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:evo:engmech03a|Cylinder / Head Bolt Issues and Repair]] in the Sportsterpedia. \\ | * 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:evo:engmech03a|Cylinder / Head Bolt Issues and Repair]] in the Sportsterpedia. \\ | ||
| | | ||
| - | | Oil standing around head bolt. ((photo by pigfoot of the XLFORUM http://xlforum.net/forums/showthread.php?t=864390)) | Here are the 2 problematic bolt holes. ((photo by Hippysmack of the XLFORUM http://xlforum.net/forums/showthread.php?t=2074117&highlight=pushrod+leak&page=2)) | | + | | Oil standing around head bolt. ((photo by pigfoot of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/efi-sportster-motorcycle-talk-2007-and-up/100360-cylinder-head-bolt-leaking?t=864390)) | Here are the 2 problematic bolt holes. ((photo by Hippysmack of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/197474-leaking-head-gasket-loose-head-bolts/page2?t=2074117&highlight=pushrod+leak&page=2)) | |
| |{{:techtalk:evo:oil:head_bolt_leak_by_pigfoot.jpg?direct&300|}}|{{:techtalk:evo:engmech:weakest_cylinder_bolt_threads_by_hippysmack.jpg?direct&300|}}| | |{{:techtalk:evo:oil:head_bolt_leak_by_pigfoot.jpg?direct&300|}}|{{:techtalk:evo:engmech:weakest_cylinder_bolt_threads_by_hippysmack.jpg?direct&300|}}| | ||
| - | |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 http://xlforum.net/forums/showthread.php?s=7717d46f972d38363307890dd86fb953&t=1422877&page=3)) || Head gasket leak. ((photo by JohnK of the XLFORUM http://xlforum.net/forums/showthread.php?threadid=1422877)) | | + | |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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/132786-fixing-a-leaky-top-end-with-pics/page3?s=7717d46f972d38363307890dd86fb953&t=1422877&page=3)) || Head gasket leak. ((photo by JohnK of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/132786-fixing-a-leaky-top-end-with-pics?threadid=1422877)) | |
| |{{:techtalk:evo:oil:mls_head_gasket_1_by_screw_loose_dan.jpg?direct&300|}}|{{:techtalk:evo:oil:mls_head_gasket_2_by_screw_loose_dan.jpg?direct&300|}}|{{:techtalk:evo:oil:head_gasket_leak_by_johnk.jpg?direct&300|}}| | |{{:techtalk:evo:oil:mls_head_gasket_1_by_screw_loose_dan.jpg?direct&300|}}|{{:techtalk:evo:oil:mls_head_gasket_2_by_screw_loose_dan.jpg?direct&300|}}|{{:techtalk:evo:oil:head_gasket_leak_by_johnk.jpg?direct&300|}}| | ||
| Line 263: | Line 261: | ||
| Check the plugs for wet oil saturation. \\ | Check the plugs for wet oil saturation. \\ | ||
| - | {{:techtalk:evo:oil:hunting_for_oil_leaks_7_by_cjburr.jpg?direct&300|}} ((photo by cjburr of the XLFORUM http://xlforum.net/forums/showthread.php?t=53769&highlight=valve+guide&page=14)) {{:techtalk:evo:oil:hunting_for_oil_leaks_8_by_cjburr.jpg?direct&300|}} ((photo by cjburr of the XLFORUM http://xlforum.net/forums/showthread.php?t=53769&highlight=valve+guide&page=14)) \\ | + | {{:techtalk:evo:oil:hunting_for_oil_leaks_7_by_cjburr.jpg?direct&300|}} ((photo by cjburr of the XLFORUM https://www.xlforum.net/forum/vendors/nrhs-high-performance/32415-oil-usage-and-timing/page14?t=53769&highlight=valve+guide&page=14)) {{:techtalk:evo:oil:hunting_for_oil_leaks_8_by_cjburr.jpg?direct&300|}} ((photo by cjburr of the XLFORUM https://www.xlforum.net/forum/vendors/nrhs-high-performance/32415-oil-usage-and-timing/page14?t=53769&highlight=valve+guide&page=14)) \\ |
| **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://xlforum.net/forums/showthread.php?t=53769&highlight=valve+guide&page=15)) \\ | 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://xlforum.net/forums/showthread.php?t=53769&highlight=valve+guide&page=15)) \\ | ||
| - | {{:techtalk:evo:oil:hunting_for_oil_leaks_9_by_cjburr.jpg?direct&200|}} ((photo by cjburr of the XLFORUM http://xlforum.net/forums/showthread.php?t=53769&highlight=valve+guide&page=16)) {{:techtalk:evo:oil:hunting_for_oil_leaks_10_by_cjburr.jpg?direct&300|}} ((photo by cjburr of the XLFORUM http://xlforum.net/forums/showthread.php?t=53769&highlight=valve+guide&page=16)) {{:techtalk:evo:oil:hunting_for_oil_leaks_11_by_cjburr.jpg?direct&300|}} ((photo by cjburr of the XLFORUM http://xlforum.net/forums/showthread.php?t=53769&highlight=valve+guide&page=16)) \\ | + | {{:techtalk:evo:oil:hunting_for_oil_leaks_9_by_cjburr.jpg?direct&200|}} ((photo by cjburr of the XLFORUM https://www.xlforum.net/forum/vendors/nrhs-high-performance/32415-oil-usage-and-timing/page16?t=53769&highlight=valve+guide&page=16)) {{:techtalk:evo:oil:hunting_for_oil_leaks_10_by_cjburr.jpg?direct&300|}} ((photo by cjburr of the XLFORUM https://www.xlforum.net/forum/vendors/nrhs-high-performance/32415-oil-usage-and-timing/page16?t=53769&highlight=valve+guide&page=16)) {{:techtalk:evo:oil:hunting_for_oil_leaks_11_by_cjburr.jpg?direct&300|}} ((photo by cjburr of the XLFORUM https://www.xlforum.net/forum/vendors/nrhs-high-performance/32415-oil-usage-and-timing/page16?t=53769&highlight=valve+guide&page=16)) \\ |
| ===== Cylinder Base Gaskets ===== | ===== Cylinder Base Gaskets ===== | ||
| - | |||
| **Weeping base gasket leak**. \\ | **Weeping base gasket leak**. \\ | ||
| Line 277: | Line 274: | ||
| * 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 http://xlforum.net/forums/showthread.php?s=7717d46f972d38363307890dd86fb953&t=2033165)) | + | * 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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/190725-suspected-base-gasket-leak?s=7717d46f972d38363307890dd86fb953&t=2033165)) |
| * Some people don't install a gasket at all or use sealant on the bottom of the cylinders while trying to adjust the [[techtalk:ref:svcproc26?s[]=squish&s[]=band#squish_band|Squish Band]] up top. \\ Depending on what sealant was used, there may be a leak due to a breach in sealant. | * Some people don't install a gasket at all or use sealant on the bottom of the cylinders while trying to adjust the [[techtalk:ref:svcproc26?s[]=squish&s[]=band#squish_band|Squish Band]] up top. \\ Depending on what sealant was used, there may be a leak due to a breach in sealant. | ||
| * **Too much crankcase pressure**. | * **Too much crankcase pressure**. | ||
| * See [[techtalk:evo:oil06#crankcase_pressure_problems|Crankcase Pressure Problems]] below. | * See [[techtalk:evo:oil06#crankcase_pressure_problems|Crankcase Pressure Problems]] below. | ||
| * **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 http://xlforum.net/forums/showthread.php?t=2033165)) \\ You only need to replace one wrist pin clip on each piston. There is no need to re-ring or hone the motor if just replacing the base gaskets. | + | * 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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/190725-suspected-base-gasket-leak?t=2033165)) \\ You only need to replace one wrist pin clip on each piston. There is no need to re-ring or hone the motor if just replacing the base gaskets. |
| * However, some will say that this type of seepage is merely cosmetic if it doesn't leak very much oil and they'll just let it leak. \\ Periodic cleaning is good enough as it keeps you riding instead of wrenching. \\ However, it can affect crankcase pressure (induced air leak) especially if the leak is significant and can indicate a pressure problem. \\ | * However, some will say that this type of seepage is merely cosmetic if it doesn't leak very much oil and they'll just let it leak. \\ Periodic cleaning is good enough as it keeps you riding instead of wrenching. \\ However, it can affect crankcase pressure (induced air leak) especially if the leak is significant and can indicate a pressure problem. \\ | ||
| - | {{:techtalk:evo:oil:base_gasket_weeping_by_harleydude24.jpg?direct&300|}} ((photo by harleydude24 of the XLFORUM http://xlforum.net/forums/showthread.php?s=e990bc46dbb9e28925f7d5ca60a40df5&t=1754690&page=4)) \\ | + | {{:techtalk:evo:oil:base_gasket_weeping_by_harleydude24.jpg?direct&300|}} ((photo by harleydude24 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-general-discussion-and-problems/163286-am-i-screwed-oil-leaking-from-bottom-of-fins/page4?s=e990bc46dbb9e28925f7d5ca60a40df5&t=1754690&page=4)) \\ |
| ===== 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. | ||
