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techtalk:ih:oil03e [2018/12/21 19:15] hippysmack [Stuck Cover Gasket] |
techtalk:ih:oil03e [2024/01/01 18:40] (current) hippysmack |
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| ====== IH: Oiling & Lubrication - Sub-03E ====== | ====== IH: Oiling & Lubrication - Sub-03E ====== | ||
| - | ====== 77-85 Oil Pump Removal and Inspection ====== | + | ====== 77-85 Oil Pump Removal and Disassembly ====== |
| ====== Removal ====== | ====== Removal ====== | ||
| * The 77-85 gerotor pump can be removed with the engine in the frame and the gearcase cover installed. | * The 77-85 gerotor pump can be removed with the engine in the frame and the gearcase cover installed. | ||
| * Disconnect the oil lines and oil pressure switch wire. | * Disconnect the oil lines and oil pressure switch wire. | ||
| * 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 ===== | ||
| The FSM says to apply gasket sealer to the gasket before installation. \\ | The FSM says to apply gasket sealer to the gasket before installation. \\ | ||
| - | 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)) \\ |
| Therefore, expect that to make it more difficult to remove the pump from the engine. \\ | Therefore, 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 35: | Line 35: | ||
| 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 63: | Line 64: | ||
| * 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 72: | Line 73: | ||
| 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|}}| | |{{: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 ====== | ||
| Wiggle the cover off and the feed gerotors are exposed. | Wiggle the cover off and the feed gerotors are exposed. | ||
| Line 92: | Line 94: | ||
| * The outer plate is held in place by a solid pin in the gearshaft. \\ | * The outer plate is held in place by a solid pin in the gearshaft. \\ | ||
| * It's a loose fit in the hole in the gearshaft and it's held in place by tension of the spring washer between the plates. | * It's a loose fit in the hole in the gearshaft and it's held in place by tension of the spring washer between the plates. | ||
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| |{{:techtalk:ih:oil:77-e83_oil_pump_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ih:oil:77-e83_oil_pump_2_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ih:oil:lower_shaft_pin_installed_by_hippysmack.jpg?direct&300|}}| | |{{:techtalk:ih:oil:77-e83_oil_pump_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ih:oil:77-e83_oil_pump_2_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ih:oil:lower_shaft_pin_installed_by_hippysmack.jpg?direct&300|}}| | ||
| Line 124: | Line 125: | ||
| * 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). | * 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. | + | * 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. | + | * 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:ih:oil:77-e83_oil_pump_7_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ih:oil:77-e83_oil_pump_5_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ih:oil:77-e83_oil_pump_6_by_hippysmack.jpg?direct&300|}}| | |{{:techtalk:ih:oil:77-e83_oil_pump_7_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ih:oil:77-e83_oil_pump_5_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ih:oil:77-e83_oil_pump_6_by_hippysmack.jpg?direct&300|}}| | ||
| Line 147: | Line 150: | ||
| |{{:techtalk:ih:oil:77-e83_oil_pump_10_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ih:oil:77-e83_oil_pump_parts_by_hippysmack.jpg?direct&300|}}| | |{{:techtalk:ih:oil:77-e83_oil_pump_10_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ih:oil:77-e83_oil_pump_parts_by_hippysmack.jpg?direct&300|}}| | ||
| - | |||
| - | ====== Gerotors ====== | ||
| - | |||
| - | |{{:techtalk:ih:oil:77-85_oil_pump_feed_gerotors_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ih:oil:77-85_oil_pump_scavenger_gerotors_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:ih:oil:77-e83_gerotors_by_hippysmack.jpg?direct&300|}}| | ||
| - | |||
| - | === Specs and Servicing === | ||
| - | With the replacement of the gear driven oil pump by the new gerotor style pump; \\ | ||
| - | HD issued a recommendation to dealers regarding servicing of the new style oil pumps. ((HD Service Bulletin #M-711 dated June 3, 1977)) | ||
| - | |||
| - | |||
| - | * Zero gerotor (gear) side clearance must be maintained by the flat spring located between the upper and lower gerotor sets in the oil pump to provide adequate oil pressure. For the spring to function properly, the upper face of the lower feed gerotors must extend slightly above the cover to prevent any side clearance which would allow oil to get past the gerotors and reduce oil pressure. ((HD Service Bulletin #M-711 dated June 3, 1977)) | ||
| - | |||
| - | * If you encounter reduced oil, no oil pressure (oil pressure light comes on or stays on) or otherwise need to disassemble the oil pump for any reason, the gerotors should be checked and serviced. ((HD Service Bulletin #M-711 dated June 3, 1977)) | ||
| - | * Using a straightedge across the feed gerotor set (installed) surface, measurement should be taken with a feeler gauge from the gerotor surface to the ridge of the edge of the aluminum cover: | ||
| - | * The thin, feed gerotors (26492-75) are in the oil pump cover (26486-75) and should extend .001" - .005" above the cover's aluminum ridge which surrounds them. ((HD Service Bulletin #M-711 dated June 3, 1977)) | ||
| - | * The later gerotors extend up to .011" above the ridge. If the feed gerotors do not extend above the ridge within the specified range, remove them, lay some sandpaper (#280 grit to start - #400 grit to finish), invert the cover and sand the ridge evenly until the gerotors extend properly when inserted. Check the measurement with a micrometer to see that both the inner and outer gerotors are the same thickness. ((HD Service Bulletin #M-711 dated June 3, 1977)) | ||
| - | * If the widths measure equally but the gerotors are not equal in height when placed into the cover, then the cover surface is not flat and the cover should be replaced. Be sure to check the gerotors in the new cover using a straight edge to assure a level surface and the proper elevation above the ridge. ((HD Service Bulletin #M-711 dated June 3, 1977)) | ||
| - | * Another possible cause of low oil pressure is air leakage into the pump due to a loose hose clamp at the oil pump feed hose fitting (63540-62) and at the oil tank feed hose fitting. If the existing feed hose clamp (10020) cannot be evenly and securely crimped to the fittings, remove the clamp and install a worm drive hose clamp. This will prevent air leakage into the system which could cause loss of oil pressure due to an airlock in the oil pump. ((HD Service Bulletin #M-711 dated June 3, 1977)) | ||
| - | * Oil pump covers found with an uneven gerotor surface should be removed. ((HD Service Bulletin #M-711 dated June 3, 1977)) | ||
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