Differences

This shows you the differences between two versions of the page.

--- techtalk:ih:oil03e [2021/11/07 07:40]
hippysmack [Inspection / Maintenance]
+++ techtalk:ih:oil03e [2024/01/01 18:40] (current)
hippysmack
@@ Line 1: / Line 1: @@
 [[:techtalk:menu|{{  :techtalk:gototechnicalmenu.jpg|}}]]
 ====== IH: Oiling & Lubrication - Sub-03E ======
-====== 77-85 Oil Pump Removal and Inspection ======
+====== 77-85 Oil Pump Removal and Disassembly ======
 ====== Removal ======
   * 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.
     * 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.
-      * 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 =====
 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. \\
     * 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.
         * 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 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 =====
@@ Line 35: / Line 35: @@
 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|}}|
 ===== Stuck Cover Gasket =====
 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.
-|  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: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|}}|
@@ Line 72: / Line 73: @@
 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: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 ======
 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. \\
     * 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.
 |{{: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 149: / 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|}}|
-====== Inspection / Maintenance ======
-**Inspection**: \\ 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 between the upper and lower separator plates for 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) \\ If you have reduced oil, no oil pressure (oil light comes on or stays on) or otherwise need to disassemble the oil pump for any reason, \\ The gerotors and their corresponding operating surface in the housing and the cover should be checked and serviced accordingly.
-  * **Inspect the oil pump cover / body**:
-    * 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) in the oil pump cover (26486-75) should extend .001"-.005" above the cover's aluminum ridge.
-      *  The later feed gerotors extend up to .011" above the ridge. \\ If the feed gerotors do not extend above the ridge within the specified range, \\ Remove and sand the ridge evenly until the gerotors extend properly when inserted. \\ Lay some sandpaper on a flat surface (#280 grit then #400 grit to finish). \\ Invert the cover and sand the ridge then check the measurement with a micrometer. \\ Make sure that both the inner and outer gerotors are the same thickness also.
-    * An oil pump cover found with an uneven gerotor surface should be removed. \\ If the gerotor widths measure equally but they are not equal in height when placed into the cover, the cover surface is not flat. \\ If the gerotors will not sit flat in the cover then the cover should be replaced. \\ Be sure to check the gerotors in the new/replacement cover using a straight edge to assure a level surface and the proper elevation above the ridge.
-    * Check for deep scratches on the machined area where the gerotors sit / rotate. \\
-  * **Inspect both gerotor sets**:
-    * Check inner to outer gerotor clearance. \\ Each gerotor set is made with an inner and outer piece. Mesh the two pieces together (as they normally would sit in operation). \\ Arrange so there is 1 inner tooth facing the center of the wide outer radius. \\ Use a feeler gauge between the inner tooth and outer radius there for a maximum of .004" clearance between them. \\ If the clearance is larger than .004", replace the affected gearotor set. Repeat for the other gerotor set.
-    * Measure the height of each inner and outer gerotor set. \\ Each inner and outer piece (feed side) should be the same height, each inner and outer (return side) should be the same height.
-  * **Inspect the seals and O-rings**:
-    * Inspect the check valve and cover to housing O-rings and make sure they are deformed / out of round and seal tightly when in place.
-    * Inspect the gearshaft seal for deformity and / or wear.
-  * **Inspect the check valve**.
-    *  Make sure it's not clogged and the internal spring closes the cup / disc properly. \\ The spring loaded cup inside the valve should be free to move and should return to it's closed, seated position. \\ It the check valve is damaged in any way, the complete valve assembly should be replaced. \\ There are no replaceable parts to it.
-    * **Inspect the spring washer**:
-      * The spring resides between the separator plates (between the feed and scavenge gerotors). \\ Replace the spring if there are any "fingers" broken.
-  * Other possible causes of low oil pressure;
-      * Air leakage into the pump due to a loose hose clamp at the oil pump and/or oil tank feed hose fitting. \\ If using crimped hose connectors, check them to make sure they are tight. \\ If using worm drive hose clamps, make sure they are tight. \\ Also make sure they haven't been tightened too much (which can cut into the hose under the clamp). \\ This will prevent air leakage into the system which could cause loss of oil pressure due to an airlock in the oil pump.
-|{{: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|}}|
-  * **General Wear Issues**: (things to keep in the back of your head when dealing with oiling issues)
-    * Gerotors can crack but still work to a point. \\ That point may be where it finally wears out the pump housing to gerotor OD clearance thus delivering less oil to the motor. \\ There is no spec for gerotor to housing clearance. \\ But even hairline cracks in a gerotor will allow it to expand when hot. \\ This will eat away at the housing bore, heat up the pump and internals causing damage to other parts as well. \\
-    * The solid pins in the side of the gearshaft are responsible for turning the gerotors. \\ The pins will wear and sometimes they will shear off. Each gerotor set has it's own pin. \\ So it's possible for the pin on the return side to shear with the pin on the feed side staying in tact or vice-versa. \\ So you could have feed oil to the motor but no oil return to the tank or vice-versa. \\ Always check for oil returning to the tank when diagnosing any suspected oiling issues (or any time after checking the oil for that matter). \\ Never check oil level without the motor being up to operating temp. \\ So before you shut the motor down to check the oil, have a look in the tank to verify that oil is returning.

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