IH: Oiling & Lubrication - Sportsterpedia

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====== IH: Oiling & Lubrication ======
====== Oil Tank, Lines and Routing ======

====== Oil Tank Cap ======
===== Sub Documents =====
  * [[techtalk:ih:oil04a|Rebuilding the Kidney Tank Oil Cap]]
\\
There have been negative comments about in-tank oil filters in the past, but these all refer to an old, original "horse hair" filter. ((IronMick of the XLFORUM http://xlforum.net/forums/showthread.php?t=2072162)) \\ 
The modern replacements are very good indeed. \\
But you'll need to shorten your dipstick to use the newer in-tank filters unless you find a "Horsehair" type. ((Popgadget of the XLFORUM http://xlforum.net/forums/showthread.php?t=2072162)) \\
The newer pleated paper ones are a better choice though. \\
See the example below of shortening the dipstick. \\

|  Uncut dipstick. ((IronMick of the XLFORUM http://xlforum.net/forums/showthread.php?t=2072162))  |  After cutting. ((IronMick of the XLFORUM http://xlforum.net/forums/showthread.php?t=2072162))  |  Roll pin goes thru the "top" (smaller) hole. ((IronMick of the XLFORUM http://xlforum.net/forums/showthread.php?t=2072162))  |
|{{:techtalk:ref:oil:dipstick_mod_1_by_ironmick.jpg?direct&300|}}|{{:techtalk:ref:oil:dipstick_mod_2_by_ironmick.jpg?direct&300|}}|{{:techtalk:ref:oil:dipstick_mod_3_by_ironmick.jpg?direct&300|}}|
====== Oil Lines ======
===== Sub Documents =====
  * [[techtalk:ref:oil14|Routing Oil Lines with an Oil Cooler]]
  * [[techtalk:ref:oil17#refoiling_lubrication|Running Copper Oil Lines]]
\\

The OD of the oil & vent lines is as important as the ID. ((IronMick of the XLFORUM http://xlforum.net/forums/showthread.php?t=563241&page=2)) \\
If you buy automotive lines that are larger OD, they will be difficult to run in the limited space and easy to kink. \\
Oil lines for 59 and up: \\

Feed and Return: 3/8" ID X 5/8" OD reinforced rubber. \\
Vent: 1/4" ID, 1/2" OD reinforced rubber. \\
The tank is vented to the cam chest because it applies a slightly negative pressure to the tank. ((ryder rick of the XLFORUM http://xlforum.net/forums/showthread.php?t=600218&page=2)) \\
This promotes the evacuation of condensate from the tank and keeps the tank from being pressurized (by the air that is also returned by the scavenge pump). \\
General oil line routing on AMF Sportsters: \\
The vent and the return lines route under the starter and solenoid. (can't run over them since the exhaust is there) ((74XL of the XLFORUM http://xlforum.net/forums/showthread.php?t=80209)) \\
Use care under the starter as to not kink or flatten the lines (rubber or copper) ((garbiker of the XLFORUM http://xlforum.net/forums/showthread.php?t=80209&page=2)) \\ 
Feed line runs out the bottom of the oil tank, close to the chain, around the swing arm and under. \\
The filter and cooler are (plumbed) in the return line. ((IronMick of the XLFORUM http://xlforum.net/forums/showthread.php?t=783392&page=2)) \\

===== Oil Line Routing =====

There is a steel bracket that holds the oil line in position. ((Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=80209&page=2)) \\
It mounts onto one of the rear engine mount or case bolts and keeps the line away from the chain.\\
The bracket is a piece of .060" sheet metal about 3/4" wide and maybe 3" long with a hole in one end where the bolt passes through it. \\
The other end is bent in a half circle that fits over the oil line and holds it against the frame / engine. \\
|  Feed line behind the chain on 73 XLCH ((photo by Rush of the XLFORUM http://xlforum.net/forums/showthread.php?t=80209))  |  Missing clamp allows the chain to rub the hose. ((photo by Dutch Bobber of the XLFORUM http://xlforum.net/forums/showthread.php?t=2072104&highlight=oil+filter&page=2))  |  A steel line was used to replace the rubber hose. ((photo by Dutch Bobber of the XLFORUM http://xlforum.net/forums/showthread.php?t=2072104&highlight=oil+filter&page=2))  |
|{{:techtalk:ih:oil:73_xlch_chain_and_tank_oil_line_by_rush.jpg?direct&300|}}|{{:techtalk:ih:oil:chain_rubbing_oil_line_by_dutch_bobber.jpg?direct&300|}}|{{:techtalk:ih:oil:steel_oil_line_replacement_by_dutch_bobber.jpg?direct&300|}}|

77-85: \\
The oil return comes off the front of the oil pump, not the top of the case like earlier years. \\
Essentially you have the following lines: ((ericfreeman of the XLFORUM http://xlforum.net/forums/showthread.php?t=600218)) \\
Feed: From the bottom of the oil tank to the rear fitting (inlet) on the oil pump. \\
Return: From the top of the oil tank to the front oil pump fitting close to the pressure switch. \\ (perhaps after going through a cooler) \\
Vent: From the top of the oil tank to the 1/4" hose nipple on the upper backside of the cam cover in front of the sprocket. \\

|  Oil Lines on 77 XLCH. ((photos by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=209347&page=10))  ||
|{{:techtalk:ih:oil:oil_line_routing_2_by_hopper.jpg?direct&300|}}|{{:techtalk:ih:oil:oil_line_routing_4_by_hopper.jpg?direct&300|}}|

  * **1957-1966 XLH and 1958-1969 XLCH**:
    * Oil feed from the tank is on the top of the case behind the rear cylinder (rear fitting).
    * Oil return to the tank is on the top of the case behind the rear cylinder (front fitting).
    * Vent line from the oil tank is on the top of the case behind the rear cylinder (lowest and smallest, 1/4" hose fitting).
    * The primary / transmission vents thru the motor internally via the oil transfer valve.
  * **1967-1976 XLH and 1970-1976 XLCH**:
    * Oil feed from the tank is on the rear of the oil pump (3/8" hose fitting).
    * Oil return to the tank is on the top of the case behind the rear cylinder (3/8" hose fitting).
    * Vent line from the oil tank is on the rear of the cam cover (1/4" hose 90° fitting).
    * The primary / transmission vents thru the motor internally via the oil transfer valve.
  * **1977-1985 (all models)**:
    * Oil feed from the tank is on the lower rear of the oil pump (3/8" hose fitting).
    * Oil return to the tank is on the upper front of the oil pump (3/8" hose fitting).
    * Vent line from the oil tank is on the rear of the cam cover (1/4" hose 90° fitting).
    * The primary / transmission is vented to atmosphere from the top of the transmission near the rear motor mount just in front of the solenoid (1/4" hose fitting).


**Simplified Oil Line Routing Drawings**: ((drawings by Hippysmack)) \\
Click on a drawing to enlarge: \\

{{:techtalk:ih:oil:simplified_oil_routing_57-66_xlh_and_58-69_xlch_by_hippysmack.png?direct&300|}} {{:techtalk:ih:oil:simplified_oil_routing_67-76_xlh_and_70-76_xlch_by_hippysmack.png?direct&300|}} \\

{{:techtalk:ih:oil:simplified_oil_routing_77-78_sportsters_by_hippysmack.png?direct&300|}} {{:techtalk:ih:oil:simplified_oil_routing_79-e84_sportster_by_hippysmack.png?direct&300|}} {{:techtalk:ih:oil:simplified_oil_routing_l84-85_sportster_by_hippysmack.png?direct&300|}} \\

===== Lines and Fittings =====

  * **1957-E1962 XLH**
    * **Return Line**
    * 63525-50 NPT to tube connector fitting (both ends).
    * 63529-57 Rubber sleeve seal for 3/16" pipe (both ends).
    * 63527-50 Oil line nut (both ends).
    * 63507-56A Steel oil return line.


===== Connections at the Oil Tank =====


There are generally 4 holes on all early style oil tanks. ((Ferrous Head of the XLFORUM http://xlforum.net/forums/showthread.php?t=1313106&page=3)) \\
Two near the bottom of the tank and two near the top. \\
The feed line will be near the bottom and the return line near the top. \\
These two lines will be bigger than the other two. \\
The smaller line at the bottom is the chain oiler (often not used and blocked off or just turned off). \\
The smaller line at the top is the vent for the tank. \\
(on early engines it runs to the top of the case just behind the rear cylinder) \\
There are internal drilling to route the vent into the cam chest (which vents to atmosphere). \\
On later engines it runs down to the cam cover which has a 90° fitting to accommodate it. \\

==== XLCH Oil Tank ====


In a horseshoe tank, the return oil should go to the far side so that oil has to migrate from one side of the tank to the other to get picked up again. ((ryder rick of the XLFORUM http://xlforum.net/forums/showthread.php?t=600218&page=2)) \\
Generic XLCH oil tank sketch ((photo by brianbbs67 of the XLFORUM http://xlforum.net/forums/showthread.php?t=1779533&page=2)) \\
{{:techtalk:ih:oil:generic_xlch_oil_tank_sketch_by_brianbbs67.jpg?direct&300|}} \\

Stock XLCH horseshoe tank: (L) ((photo by Dr Dick)), (R) ((photo by fergerburger of the XLFORUM http://xlforum.net/forums/showthread.php?t=1507891)) \\ 
{{:techtalk:ih:oil:horseshoe_tank_by_dr_dick.jpg?direct&350|}} {{:techtalk:ih:oil:58-e63_xlch_horseshoe_tank_by_fergerburger.jpg?direct&350|}} \\

Aftermarket horseshoe tank (no drain): ((photos by CanadianTux of the XLFORUM http://xlforum.net/forums/showthread.php?t=1313106&page=2)) ((http://xlforum.net/forums/showthread.php?t=1313106&page=3)) \\
{{:techtalk:ih:oil:horseshoe_tank_2_by_canadiantux_-_as_annotated.jpg?direct&263|}} {{:techtalk:ih:oil:horseshoe_tank_3_by_canadiantux.jpg?direct&197|}} {{:techtalk:ih:oil:horseshoe_tank_1_by_canadiantux_-_as_annotated.jpg?direct&197|}} \\

The stock lunch box tanks have the vent and return lines on the top of the tank (and feed on the bottom). ((photos by fdny37 of the XLFORUM http://xlforum.net/forums/showthread.php?t=532359)) \\
Return (L), Vent (R) \\
{{:techtalk:ih:oil:68_oil_tank_1_by_fdny37.jpg?direct&300|}} {{:techtalk:ih:oil:68_oil_tank_2_by_fdny37.jpg?direct&300|}}

==== XLH Oil Tank ====

{{:techtalk:ih:oil:oil_line_diagram_by_brianbbs67.jpg?direct&300|}} ((Diagram by brianbbs67 of the XLFORUM http://xlforum.net/forums/showthread.php?t=1779533&page=3)) \\

{{:techtalk:ih:oil:73_oil_tank_4_by_vampkiller.jpg?direct&300|}} ((photo by vampkiller of the XLFORUM http://xlforum.net/forums/showthread.php?t=1779533&page=3)) {{:techtalk:ih:oil:oil_line_routing_1_by_hopper.jpg?direct&300|}} ((photo by Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=209347&page=10)) \\

{{:techtalk:ih:oil:73_oil_tank_1_by_vampkiller.jpg?direct&300|}} ((photo by vampkiller of the XLFORUM http://xlforum.net/forums/showthread.php?t=1779533&page=3)) {{:techtalk:ih:oil:73_oil_tank_2_by_vampkiller.jpg?direct&300|}} ((photo by vampkiller of the XLFORUM http://xlforum.net/forums/showthread.php?t=1779533&page=3))
 {{:techtalk:ih:oil:73_oil_tank_3_by_vampkiller.jpg?direct&300|}} ((photo by vampkiller of the XLFORUM http://xlforum.net/forums/showthread.php?t=1779533&page=3)) \\

==== Custom Oil Tank ====


This tank is pretty straight forward. ((photo by knotwerk of the XLFORUM http://xlforum.net/forums/showthread.php?t=563241)) \\ 
Top (2) fittings are vent and fill. \\ 
Bottom fitting is supply to the engine. \\ 
It also has no drain fitting. \\ 
{{:techtalk:ih:oil:67_oil_routing_2_by_knotwerk.jpg?direct&300|}}

On this one (on a 74 XLH), the vent is higher than the feed and return lines. ((photos by vyper202 of the XLFORUM http://xlforum.net/forums/showthread.php?t=1570042)) \\
{{:techtalk:ih:oil:74_oil_line_routing_2_by_vyper202.jpg?direct&300|}} {{:techtalk:ih:oil:74_oil_line_routing_5_by_vyper202.jpg?direct&300|}}




===== Connections at the Oil Filter =====
[[techtalk:ref:oil13|Click Here]] to reference "**Remote Oil Filters**" in the REF section of the Sportsterpedia for plumbing, connections and custom applications. \\

The oil filter (HD 63782-80T) is the small one that is usually used on custom bikes. Chrome or black can be found. ((IronMick of the XLFORUM http://xlforum.net/forums/showthread.php?t=563241)) \\

On all spin on oil filters, dirty oil goes in the outside of the filter. Clean oil comes out the center. (( ryder rick of the XLFORUM http://xlforum.net/forums/showthread.php?p=5643382&highlight=oil+filter+bracket#post5643382)) \\
If you are not sure, start the motor momentarily with the filter off and if oil is pumped out the center port, you have it backwards. \\

1979 Sportsters didn't initially come stock with an oil filter at all. The MoCo offered an oil filter kit for it. \\


===== Connections at the Engine =====



|Oil line connections on a 61 XLCH ((photo by ironheadjunkie of the XLFORUM http://xlforum.net/forums/showthread.php?threadid=1313106)) \\ Fittings (L) Return, (R) Feed, (hole) Vent|Oil line connections on a 67 XLCH ((photo by knotwerk of the XLFORUM http://xlforum.net/forums/showthread.php?t=563241)) \\ 1- Return to tank, 2- Feed to motor, 3- Vent hose ((Monte03 of the XLFORUM http://xlforum.net/forums/showthread.php?t=563241))|
|{{:techtalk:ih:oil:61_oil_line_routing_by_ironheadjunkie.jpg?direct&300|}}|{{:techtalk:ih:oil:67_oil_routing_1_by_knotwerk.jpg?direct&300|}}|

| Oil lines on a 71 XLH w/ \\ custom mounted oil tank bungs ((photo by JonesL of the XLFORUM http://xlforum.net/forums/showthread.php?t=2071385&highlight=oil+filter))  |  Oil lines on a 72 XLCH (no filter) ((photo by Scuba10jdl of the XLFORUM http://xlforum.net/forums/showthread.php?t=2071385&highlight=oil+filter))  |
|{{:techtalk:ih:oil:71_xlh_oil_lines_by_jonesl.jpg?direct&150|}}|{{:techtalk:ih:oil:72_xlch_oil_line_routing_by_scuba10jdl.jpg?direct&300|}}|

|  Oil lines on a 74 XLH ((photo by vyper202 of the XLFORUM http://xlforum.net/forums/showthread.php?t=1570042))  |  Oil fittings on a 75 custom  ((photo by sifty of the XLFORUM http://xlforum.net/forums/showthread.php?t=1592463&page=29))  |  Oil lines on a 75 XLH ((photo by Dieselox4 of the XLFORUM http://xlforum.net/forums/showthread.php?t=475120))  |
|{{:techtalk:ih:oil:74_oil_line_routing_3_by_vyper202.jpg?direct&300|}}|{{:techtalk:ih:oil:75_oil_routing_by_sifty.jpg?direct&300|}}|{{:techtalk:ih:oil:75_oil_routing_by_dieselox4.jpg?direct&300|}}|

This pic of a 74 model shows the chain oiler fitting (circled in green) which is usually just plugged off. ((ironheadjunkie of the XLFORUM http://xlforum.net/forums/showthread.php?t=1613141)) \\
The one circled in red is the vent return to the tank. \\
|Oil fittings on a 74 model ((photo by whyNot, of the XLFORUM, as labeled by ironheadjunkie  http://xlforum.net/forums/showthread.php?t=1613141&page=2))  |
|{{:techtalk:ih:oil:74_oil_fittings_under_the_cover_by_whynot-_annotated.jpg?direct&200|}}|

===== Connection to Oil Cooler =====
See [[techtalk:ref:oil14|External Oil Coolers]] in the REF section of the Sportsterpedia. \\

====== Oil Lines to the Rockers ======
Installation: \\
The ends are slightly different sizes. ((Ivan RoachCoach of the XLFORUM http://xlforum.net/forums/showthread.php?p=2505289#post2505289)) \\
The larger-sized ends go on the case and the smaller-diameter ones go to the rockers. \\
In other words the closer they are to the oil pump, the bigger they should be. \\
Most people never even notice this. \\
Issues getting oil to the top end: \\
If your pump is primed, and the breather gear is properly timed, then the problem lies in the lines and/or their fittings. \\

If you have a leak here, you may not have to replace any parts. \\
Try to uninstall them, clean, inspect and reinstall them and see what happens. \\
Note for reinstalling the metal oil lines; ((IronMick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1974660)) \\
The line is just long enough to be inserted a small amount at each end at the fittings. \\
So insert at the top, then the bottom ensuring that it is more or less even from top and bottom. \\

You can install the rubbers an inch or more from the line ends. \\
Then, while keeping it from shifting, slide the rubbers into place. \\
 \\
Then slip each line-end in place, and hold it there while sliding the rubbers into final position. \\ 
Tightening the nuts will seat the rubbers. Light grease on the rubbers will help. \\
Tighten them alternately, again keeping it from shifting.

Keep an eye on which style you buy (if any need replaced). ((hcrashsterof the XLFORUM http://xlforum.net/forums/showthread.php?t=1974660)) \\
The OEM is barrel shaped. \\
Some aftermarkets are a barrel with 45° cuts on the top and bottom. \\
The 45° ones are no good. \\
Either a different polymer is used or you really need that full barrel shape to seal the oil line properly.

|  Rocker oil line ((photo by Ironshred of the XLFORUM http://xlforum.net/forums/showthread.php?t=1974660))  |
|{{:techtalk:ih:oil:82_rocker_oil_lines_by_ironshred.jpg?direct&200|}}|

====== Braided Oil Lines ======
Braided lines can flex, leak, and sometimes flatten out. ((Ivan RoachCoach of the XLFORUM http://xlforum.net/forums/showthread.php?t=221093&highlight=split+rocker+box)) \\
Before you try threading any threads into your engine, try threading them on a pipe fitting first. ((MDT of the XLFORUM http://xlforum.net/forums/showthread.php?t=221093&highlight=split+rocker+box)) \\

If the new parts are chromed then you should (must) wire wheel (with light pressure) the chromed threads before installation. ((IronMick of the XLFORUM http://xlforum.net/forums/showthread.php?t=221093&highlight=split+rocker+box)) \\
This is especially important for chromed threaded bolts or bolts that have old Loctite on them. \\
* Always wear a face mask as you can loose hold of the bolt (using a wire wheel on a bench grinder) it will go flying. \\
You can lightly clamp the fastener flats in a vise and use a Dremil or angle grinder wire wheel also. \\
Either way, a mist of metal will get airborne and you don't need that getting into your eyes.

You can also chase the new threads with a die. This will also remove extra bulk on the threads due to the chroming process. \\
See also [[techtalk:ref:tools023#chasing_threads|Chasing Threads]] in the REF section of the Sportsterpedia. \\

===== Copper, Brass and Stainless Tubing =====
These were made with flared fittings and are a positive seat fitting. \\
They do not allow for any growth once the motor gets hot (if that's a concern). ((Monte03 of the XLFORUM http://xlforum.net/forums/showthread.php?t=1793589&page=2)) \\
The OEM style tubing uses slip compression type fittings which will allow expansion. \\
However, the flared fittings have been used on Sportsters. \\

Click on a pic to enlarge: \\

==== Copper ====

|  Copper Oil Lines ((photo by Sadsack of the XLFORUM  http://xlforum.net/forums/showthread.php?t=1793589))  |
|{{:techtalk:ih:oil:copper_oil_lines_by_sadsack.jpg?direct&200|}}|

==== Brass ====
|  Brass oil lines ((photos by Levi Luther of the XLFORUM http://xlforum.net/forums/showthread.php?t=1793589&page=2))  ||  Brass oil lines on a 62 model ((photo by 62 Ironhead of the XLFORUM http://xlforum.net/forums/blog.php?u=57274))  |
|{{:techtalk:ih:oil:brass_oil_lines_1_by_levi_luther.jpg?direct&300|}}|{{:techtalk:ih:oil:brass_oil_lines_2_by_levi_luther.jpg?direct&300|}}|{{:techtalk:ih:oil:brass_oil_lines_by_62_ironhead.jpg?direct&300|}}|

==== Stainless Steel ====
Stainless steel tubing will polish up like chrome and does not rust. \\
You can also use Parker stainless steel fittings and 1/4" tubing. ((Bustert of the XLFORUM http://xlforum.net/forums/showthread.php?t=1793589&page=4)) ((http://xlforum.net/forums/showthread.php?t=1793589&page=5))  \\

They will come with compression fittings, DO NOT USE!!!! \\
On the bottom fitting. \\
On the upper fitting, drill the 1/4" hole to allow the tube to slide up into the rocker box. \\
There will still be a slight taper left. \\
This will allow you to insert the tube into the rocker box and then down into the bottom fitting stop. \\
You can cut pieces of fuel line hose to make the seal rings as it will resist the oil and heat. \\
You can use O-rings here if you have them also. \\

|  Stainless steel oil lines ((photo by Bustert of the XLFORUM http://xlforum.net/forums/showthread.php?t=1793589&page=4))  ||
|{{:techtalk:ih:oil:stainless_oil_lines_by_bustert.jpg?direct&200|}}|{{:techtalk:ih:oil:stainless_oil_lines_2_by_bustert.jpg?direct&300|}}|
 


\\

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