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techtalk:evo:oil02 [2022/09/10 01:16] hippysmack [Engine Oil Routes] |
techtalk:evo:oil02 [2024/01/05 00:20] hippysmack |
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| ====== EVO: Oiling & Lubrication ====== | ====== EVO: Oiling & Lubrication ====== | ||
| ====== Engine Oil Routes ====== | ====== Engine Oil Routes ====== | ||
| - | |||
| - | ====== Oil Passages From The Filter Pad ====== | ||
| - | Below are different cam chest pics showing the oil passages from the filter pad. \\ | ||
| - | |||
| - | |86 Cam Chest ((photo by Mini_blitz of the XLFORUM http://xlforum.net/forums/showthread.php?t=1974615&page=2))| | ||
| - | |{{:techtalk:evo:oil:86_cam_chest_by_mini_blitz.jpg?direct&300|}}| | ||
| - | |||
| - | |1995 Cam Chest ((photo by Johnny Wolf of the XLFORUM http://xlforum.net/forums/showthread.php?t=525868))|1995 Cam Chest ((photo by Narley of the XLFORUM http://xlforum.net/forums/showthread.php?t=190859))| | ||
| - | |{{:techtalk:ref:tools:gearcase_screw_holder_by_johnny_wolf.jpg?direct&300|}}|{{:techtalk:evo:oil:1996_cam_chest_by_narley.jpg?direct&300|}}| | ||
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| - | |1998 Cam Chest ((photo by EvIL sTevE of the XLFORUM http://xlforum.net/forums/showthread.php?t=1637848))|1999 Cam Chest ((photo by vh5150 of the XLFORUM))|2000 Cam Chest ((photo by Shu of the XLFORUM http://xlforum.net/forums/showthread.php?t=922143))| | ||
| - | |{{:techtalk:evo:oil:98_cam_chest_by_evil_steve.jpg?direct&300|}}|{{:techtalk:evo:oil:99_1200_gearcase_by_vh5150.jpg?direct&300|}}|{{:techtalk:evo:oil:2000_cam_chest_by_shu.jpg?direct&300|}}| | ||
| - | |||
| - | |2001 Cam Chest ((photo by hallin222 of the XLFORUM http://xlforum.net/forums/showpost.php?s=d966bf2521b2e6f8506c44fb310c85ac&p=2553030&postcount=26))|2003 Cam Chest ((photo by robo1040 of the XLFORUM http://xlforum.net/forums/showpost.php?s=d966bf2521b2e6f8506c44fb310c85ac&p=2553030&postcount=26))| | ||
| - | |{{:techtalk:evo:oil:2001_cam_chest_by_hallin222.jpg?direct&300|}}|{{:techtalk:evo:oil:2003_cam_chest_by_robo1040.jpg?direct&300|}}| | ||
| - | |||
| - | |2004 Cam Chest ((photo by cowboy770 of the XLFORUM http://xlforum.net/forums/showthread.php?t=989906))|2005 Cam Chest ((photo by Rico 05R of the XLFORUM http://xlforum.net/forums/showthread.php?t=1067220&page=2))|2008 Cam Chest ((photo by Helibee of the XLFORUM http://xlforum.net/forums/showthread.php?threadid=1652078))| | ||
| - | |{{:techtalk:evo:oil:2004_cam_chest_by_cowboy770.jpg?direct&300|}}|{{:techtalk:evo:oil:2005_cam_chest_by_rico_05r.jpg?direct&300|}}|{{:techtalk:evo:oil:08_cam_chest_3_by_helibee.jpg?direct&300|}}| | ||
| - | |||
| - | |2013 Cam Chest ((photo by chris_b_owens of the XLFORUM http://xlforum.net/forums/showthread.php?p=5073119#post5073119))| | ||
| - | |{{:techtalk:evo:oil:2013_cam_chest_by_chris_b_owens.jpg?direct&300|}}| | ||
| - | |||
| - | |XR1200 Cam Chest ((photos by XR1200 Cam Chest 1 by Ralphthe3rd of the XLFORUM http://xlforum.net/forums/showthread.php?page=4&t=218682))|| | ||
| - | |{{:techtalk:evo:oil:xr1200_cam_chest_1_by_ralphthe3rd.jpg?direct&300|}}|{{:techtalk:evo:oil:xr1200_cam_chest_2_by_ralphthe3rd.jpg?direct&300|}}| | ||
| Line 44: | Line 19: | ||
| * The lifters supply oil pressure to the rocker boxes. | * The lifters supply oil pressure to the rocker boxes. | ||
| - | | 86-90 main oil feed path ((photos by Mini_blitz of the XLFORUM, labeled by Hippysmack http://xlforum.net/forums/showthread.php?t=1974615&page=3)) || | + | | 86-90 main oil feed path ((photos by Mini_blitz of the XLFORUM, labeled by Hippysmack https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-bottom-end/183493-1986-evolution-sportster-cam-cover-install-help/page3?t=1974615&page=3)) || |
| |{{:techtalk:evo:oil:86-90_right_case_main_oil_feed_path_by_mini_blitz.jpg?direct&300|}}|{{:techtalk:evo:oil:86_cam_cover_main_oil_feed_path_by_mini_blitz.jpg?direct&300|}}| | |{{:techtalk:evo:oil:86-90_right_case_main_oil_feed_path_by_mini_blitz.jpg?direct&300|}}|{{:techtalk:evo:oil:86_cam_cover_main_oil_feed_path_by_mini_blitz.jpg?direct&300|}}| | ||
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| ====== Bottom End Oiling ====== | ====== Bottom End Oiling ====== | ||
| - | ===== Pinion shaft and Crank Pin ===== | ||
| - | === All === | ||
| - | |||
| - | * Pressurized oil in the pinion bushing is sent through a hole in the (hollow) pinion shaft toward the flywheel. | ||
| - | * Oil travels to and through the right flywheel via an internal passage from the pinion bore and the crank pin bore in the flywheel. \\ Oil enters the crank pin inside the crank pin bore on the flywheel. | ||
| - | * Oil is routed out of the crank pin through a hole under the rod bearings in the middle of the pin and circulates to the rod bearings. | ||
| - | * **This is the end point of static oil pump pressure to the bottom end**. | ||
| - | * Oil leaving the rod bearings flows into the crankcase to be scavenged by the oil pump (or splashed into the gearcase). | ||
| - | * Crankcase pressure moves the oil from this point. | ||
| - | |||
| - | | L81-03 'one hole' crank pin. ((photo by Hippysmack)) ||| | ||
| - | |{{:techtalk:evo:oil:crank_pin_oiling_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:crank_pin_oiling_2_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:crank_pin_oiling_3_by_hippysmack.jpg?direct&300|}}| | ||
| - | ===== Cam Oiling ===== | ||
| - | |||
| - | * Oil flows off the pushrod side of the rocker boxes through the pushrod covers, into vertical holes in the lifter bores and into the gearcase. | ||
| - | * Oil falls on the cam lobes on the way down this hole. | ||
| - | * Some of this oil is transferred between the gear teeth. | ||
| - | * The rear intake (#2) cam gets a little oil spray from the right case oil feed galley through the small orifice underneath the open cavity in the case. | ||
| - | * That oil is transferred between the teeth of the cams. | ||
| - | * Oil flung off the cams lands in the gearcase to be collected into the scavenge (return) side of the oil pump. | ||
| - | |||
| - | Below are pics of the restricted orifice underneath the oil feed galley in the case that shoots a small stream onto #2 cam. \\ | ||
| - | #2 cam rotates counterclockwise and the oil is sprayed on the right side of the cam gear for extra cooling. | ||
| - | | (L) 92-99 ((photo by Hippysmack of the XLFORUM)), (R) 2000 Up ((photo by Bruce of the XLFORUM http://xlforum.net/forums/showthread.php?t=1118529&page=2up)) cam oiling hole from the feed galley || | ||
| - | | {{:techtalk:evo:oil:92-99_cam_oiler_hole_by_hippysmack.jpg?direct&300|}} |{{:techtalk:evo:oil:2000_up_cam_oiler_hole_by_bruce.jpg?direct&300|}}| | ||
| - | |||
| - | ===== Cam Cover Bushings ===== | ||
| - | All cam bushings are fed from splash oil into channeled holes drilled behind the bushing faces. \\ | ||
| - | #1, #3 and #4 cam bores have channels drilled from the top down into the back side of the bores. \\ | ||
| - | The channel for #2 cam bore starts at the bottom and is drilled into the back side of the bore. \\ | ||
| - | The pinion bushing (as well as the hole in the pinion shaft) is fed from a cross drilled hole in the top of the cover. \\ | ||
| - | |||
| - | |{{:techtalk:evo:oil:cam_bushing_oiling_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:cam_bushing_oiling_2_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:cam_bushing_oiling_3_by_hippysmack.jpg?direct&300|}}| | ||
| - | |||
| - | |{{:techtalk:evo:oil:pinion_bushing-shaft_oiling_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:cam_bushing_oiling_4_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:cam_bushing_oiling_5_by_hippysmack.jpg?direct&300|}}| | ||
| - | |||
| - | |{{:techtalk:evo:oil:cam_bushing_oiling_6_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:cam_bushing_oiling_8_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:cam_bushing_oiling_7_by_hippysmack.jpg?direct&300|}}| | ||
| - | |||
| - | ===== Cam Cover \ Gasket ===== | ||
| - | 91 and up Sportster engines have an internal rifling hole drilled into the lower left side of the case running past the left side of the oil pump. \\ | ||
| - | That extra hole (in the picture below) is benign and doesn't need a hole in the gasket to match. \\ | ||
| - | That hole is purely an artifact of how they connected two passages for routing crankcase oil up to the oil pump's scavenge section. \\ | ||
| - | They drill that hole to connect the two passages, and then it gets blocked off naturally by the cam box cover and gasket. ((aswracing of the XLFORUM http://xlforum.net/forums/showthread.php?t=2036109&highlight=oil+pump&page=3)) \\ | ||
| - | |||
| - | Also, in 2000, the factory changed the oil routing to the lifters to make manufacturing the cases easier. \\ | ||
| - | The newer cam cover on the left in the pic below and has two extra grooves along the top. \\ | ||
| - | These grooves let oil get to the lifters. \\ | ||
| - | If you have an older style gasket, it will not have cutouts for the grooves and you won't get oil to the lifters. \\ | ||
| - | |||
| - | | Rubbermount Evo vs Rigid Evo Cam Cover Internals ((photo by Moved On of the XLFORUM http://xlforum.net/forums/showthread.php?t=87313)) | | ||
| - | |{{:techtalk:evo:oil:rubbermount_vs_rigid_evo_cam_cover_comparison_by_moved_on.jpg?direct&600|}}| | ||
| - | | Both have been chopped on the outside but the gearcase perimeter is intact on them for reference. | | ||
| - | |||
| - | | 91-99 cam cover gasket ((photo by Hippysmack)) | 91-99 cam cover seals off the extra hole. ((photos by Hippysmack)) || | ||
| - | |{{:techtalk:evo:oil:91-99_cam_cover_gasket_2_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:91-99_cam_cover_gasket_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:91-99_cam_cover_gasket_4_by_hippysmack.jpg?direct&300|}}| | ||
| - | |||
| - | | 2000-up cam cover gasket ((photo by Phillober of the XLFORUM http://xlforum.net/forums/showthread.php?t=1122547&page=7)) |2000 up gasket seals off the extra hole. ((sep69 of the XLFORUM http://xlforum.net/forums/showthread.php?t=2036109&highlight=oil+pump&page=3))| | ||
| - | |{{:techtalk:evo:oil:2000_up_cam_cover_gasket_by_phillober.jpg?direct&300|}}|{{:techtalk:evo:oil:cam_cover_gasket_on_03_model_by_sep69.jpg?direct&300|}}| | ||
| - | \\ | ||
| - | |||
| - | **DON'T INSTALL a 91-99 CAM COVER GASKET ON A 2000-UP MOTOR!!!!!!!** | ||
| - | |||
| - | The 91-99 cam cover gasket has no business being on a 2000+ motor at all. It will cause you to lose all oil pressure. ((aswracing of the XLFORUM http://xlforum.net/forums/showthread.php?t=2079110&highlight=oil+tank&page=14)) \\ | ||
| - | The 2000+ gasket supersedes the 91-99 gasket. In other words, it can be used all the way back to 1991. \\ | ||
| - | Most companies completely dropped the 91-99 specific gasket and only offer the one that can be used from 1991-present. \\ | ||
| - | Either James Gasket hasn't done that, or they may have some old stock. \\ | ||
| - | The 91-99 lifter feed galley is an internal rifling hole in the case. It's drilled thru the case and only open to the cam cover via the center port to the pinion bushing. \\ | ||
| - | The 2000-up lifter feed galley is external and it takes both the cover and the case mounted together to make up the feed galley. \\ | ||
| - | So 00-up feed galley is split in half between the case and cover. The slots in the 2000-up cam cover gasket mate to both the case and the cover. \\ | ||
| - | If you have the correct gasket on there, oil would be forced (between the cover and case) to all the lifter feed holes and piston squirters. \\ | ||
| - | With the wrong gasket (91-99), oil pressure leaving the filter gets into that (now open) galley. \\ | ||
| - | Then the oil will blow into into the cam chest, therefore bypassing the lifters, piston squirters and rod bearings. \\ | ||
| - | The oil will simply cycle from the oil pump to cam chest to oil pump and back to the oil tank. \\ | ||
| - | The oil light will stay off so you'll get no notice before moving the parts start oil starving and making noises and worse if the noises aren't heeded to quickly. \\ | ||
| - | | 2000-up motor with 91-99 cam cover gasket. ((photo by BestCoastXL of the XLFORUM http://xlforum.net/forums/showthread.php?t=2079110&highlight=oil+tank&page=12)) | Below is a rough cross section of the joint in the \\ feed galley at that first slotted run. ((drawing by Hippysmack)) | | ||
| - | |{{:techtalk:evo:oil:2000-up_sportster_with_wrong_91-99_cam_cover_gasket_by_bestcoastxl.jpg?direct&300|}}|{{:techtalk:evo:oil:2000-up_sportster_with_wrong_91-99_cam_cover_gasket_by_hippysmack.png?direct&300|}}| | ||
| ====== Case Oiling and Drainage ====== | ====== Case Oiling and Drainage ====== | ||
| ===== 86-90 Engines ===== | ===== 86-90 Engines ===== | ||
