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techtalk:ih:oil03g [2024/01/01 19:37] – hippysmacktechtalk:ih:oil03g [2024/09/26 20:39] (current) – [Idler Shaft Removal] hippysmack
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 ====== Leaking Around Oil Pressure Switch Connection====== ====== Leaking Around Oil Pressure Switch Connection======
 +The threading for the pressure switch nipple is not a tapered pipe thread. ((needspeed of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/200460-replacement-oil-pump-year-74)) \\
 +It's a 15/32"-24. An oddball size, but that's what it is. \\
 +Cracked pumps are actually common. It's easy to over tighten the switch fitting. \\
 +You're tightening a steel fitting that has a less than 1/2" thread into aluminum with a large 1" wrench. \\
 +It's not the thread that seals the oil, it's the flat surface of the pump body against the flat surface of the fitting that does that. \\
 +It only needs to be snug.
 +
 If you have a leak from the oil pressure switch nipple area, 99% of the time it is a cracked body. ((Dr Dick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/175074-66-xlch-oil-pump-concerns/page2?t=1878331&page=2)) \\ If you have a leak from the oil pressure switch nipple area, 99% of the time it is a cracked body. ((Dr Dick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/175074-66-xlch-oil-pump-concerns/page2?t=1878331&page=2)) \\
 Pull the 1" hex nut and look for a crack on the flat face of the body at 6:00. \\ Pull the 1" hex nut and look for a crack on the flat face of the body at 6:00. \\
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 But it can also be coming in from the clearances of the gears as well as from the shaft seal between the feed and return gears. \\ But it can also be coming in from the clearances of the gears as well as from the shaft seal between the feed and return gears. \\
  
-==== Testing the oil pump for leaks ====+===== Testing the oil pump for leaks =====
 You could apply oil via the oil tank to the inlet nipple on an installed pump and observe if oil is leaking through the check into the discharge hole to the engine. \\ You could apply oil via the oil tank to the inlet nipple on an installed pump and observe if oil is leaking through the check into the discharge hole to the engine. \\
 There is no reason to take anything but the front fitting of the pump off. \\ There is no reason to take anything but the front fitting of the pump off. \\
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 Now if you have a crappy high clearance pump with a lot of slip, the pump needs replacing. \\ Now if you have a crappy high clearance pump with a lot of slip, the pump needs replacing. \\
  
-===== Shaft Seal Repair =====+===== Breather Gear Shaft Mod =====
 The leaking check ball is the most popular theory out there. ((XLFREAK of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/129161-while-waiting-on-the-paint-to-dry-and-we-thought-it-was-the-ballcheck?t=1347614)) \\ The leaking check ball is the most popular theory out there. ((XLFREAK of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/129161-while-waiting-on-the-paint-to-dry-and-we-thought-it-was-the-ballcheck?t=1347614)) \\
 However, the check ball can be perfectly good and the bike will still wet sump. \\ However, the check ball can be perfectly good and the bike will still wet sump. \\
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 {{:techtalk:ih:oil:oil_pump_mod_1_by_needspeed.jpg?direct&300|}} ((drawing by needspeed of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/191819-took-up-the-challenge#post4147031)) \\ {{:techtalk:ih:oil:oil_pump_mod_1_by_needspeed.jpg?direct&300|}} ((drawing by needspeed of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/191819-took-up-the-challenge#post4147031)) \\
  
 +====== Pump Body Damage ======
 +1952-1976 oil pumps cannot be removed/installed without either removing the engine from the frame or at least leaning the engine over in frame. \\
 +This makes questionable imperfections more to a higher degree of scrutiny than 77-up gerotor pumps that don't require engine uprooting. \\
 +
 +
 +Below is a compilation of just a few oil pumps with various gear well damage. \\
 +
 +{{:techtalk:ih:oil:1952-1976_sportster_oil_pump_gear_wall_damage_compilation_by_hippysmack.jpg?direct&400|}}
 +
 +
 +====== Roll Pin Damage/Removal ======
 +Generally you have 3 lines of action depending on what you're up against. ((Dr Dick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/127032-getting-this-78-back-to-the-way-it-should-be/page30#post2932584)) \\
 +  - Squeeze exposed od of pin so it gets smaller and releases the press fit in the hole.
 +  - Make a "fishhook" tool with an eccentric lip that you can slide thru the center of the pin. \\ Then rotate 180° once the ecentric lip passes the blind end of the pin. \\ Put shank of tool in a vice and tap on part. PIA, but do-able in garage. Doesn't molest part.
 +  - The most extreme but the most effecient and most often the only option. \\ Get a drill bit that fits thru the center hole of the busted pin. \\ Drill clear thru parent part with this bit. Flip part over to get the far end of this thru the hole. \\ Sometimes you can get a drift in this new small hole and catch pin. Tap the pin out. \\ If you can't catch the pin with the drift, from far side enlarge small hole with bit bigger than 1st but smaller than actuall pin hole od. \\ Fit drift thru this hole and tap pin out. Original hole area remains uneffected. New pin will fit normal. 
 +
 +====== Idler Shaft Removal ======
 +If the idler shaft is damaged, you can remove it by applying heat (150°F) to the pump body and the shaft should fall out. \\
 +Heat the pump body to (150°F) to install idler gear shaft. Shaft may not protrude above either oil pump body face. ((1972-2003 XR-750 Service Manual)) \\
  
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