Differences

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

Link to this comparison view

Both sides previous revision Previous revision
Next revision
Previous revision
techtalk:evo:oil03 [2022/09/25 21:09]
hippysmack [Oil Pump Gaskets]
techtalk:evo:oil03 [2024/01/05 03:23] (current)
hippysmack
Line 34: Line 34:
 ====== Oil Pump Function ====== ====== Oil Pump Function ======
 The oil pump is a positive displacement unit. \\ The oil pump is a positive displacement unit. \\
-If you block the discharge flow path, discharge pressure will rise and literally approaches infinity until something fails. ((BuckIRyder of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=730325&​page=2)) \\+If you block the discharge flow path, discharge pressure will rise and literally approaches infinity until something fails. ((BuckIRyder of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​90285-external-oil-filter-micron-age/​page2?​t=730325&​page=2)) \\
 It's non-regulated and delivers its entire volume of oil under pressure to the oil filter mount. \\ It's non-regulated and delivers its entire volume of oil under pressure to the oil filter mount. \\
-However, don't take the term "​positive displacement pump" literally. ((Dr Dick of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1429178&​page=2)) \\+However, don't take the term "​positive displacement pump" literally. ((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/​133153-side-bag-oil-filter/​page2?​t=1429178&​page=2)) \\
 Compared to a centrifigal pump, gear / gerotor type pumps use displacement to function. \\ Compared to a centrifigal pump, gear / gerotor type pumps use displacement to function. \\
 How positive it is depends on what it's pumping. \\ How positive it is depends on what it's pumping. \\
Line 140: Line 140:
 [[techtalk:​evo:​oil04|Click Here]] to reference the Oil Tank, Lines and Routing Page in the Sportsterpedia. \\ [[techtalk:​evo:​oil04|Click Here]] to reference the Oil Tank, Lines and Routing Page in the Sportsterpedia. \\
  
-|  86-90 Oil Pump Oiling Paths. ((photo by Hippysmack)) ​ |  91-97 Oil Pump Oiling Paths  ((photo by Hippysmack)) ​ |  98 and Up Oil Pump Oiling Paths ((photo by bsaman of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=691283&​page=2)) ​ |+|  86-90 Oil Pump Oiling Paths. ((photo by Hippysmack)) ​ |  91-97 Oil Pump Oiling Paths  ((photo by Hippysmack)) ​ |  98 and Up Oil Pump Oiling Paths ((photo by bsaman of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​rubber-mount-sportster-motorcycle-talk-2004-2006/​87615-crank-replacement-documentation/​page2?​t=691283&​page=2)) ​ |
 |{{:​techtalk:​evo:​oil:​86-90_oil_pump_oiling_paths_by_hippysmack.jpg?​direct&​300|}}|{{:​techtalk:​evo:​oil:​91-97_oil_pump_by_hippysmack.jpg?​direct&​300|}}|{{:​techtalk:​evo:​oil:​98-up_oil_pump_oiling_paths_by_bsaman.jpg?​direct&​300|}}| |{{:​techtalk:​evo:​oil:​86-90_oil_pump_oiling_paths_by_hippysmack.jpg?​direct&​300|}}|{{:​techtalk:​evo:​oil:​91-97_oil_pump_by_hippysmack.jpg?​direct&​300|}}|{{:​techtalk:​evo:​oil:​98-up_oil_pump_oiling_paths_by_bsaman.jpg?​direct&​300|}}|
 +
 ====== Priming the Oil Pump ====== ====== Priming the Oil Pump ======
 A dry pump won't pump oil. \\ A dry pump won't pump oil. \\
Line 152: Line 153:
       * Remove the oil pressure switch and rotate the engine until oil comes out the end of the pump and reinstall the switch.       * Remove the oil pressure switch and rotate the engine until oil comes out the end of the pump and reinstall the switch.
     * If you let it sit long enough, oil will gravity drain inside the pump and prime it.     * If you let it sit long enough, oil will gravity drain inside the pump and prime it.
-    * Another way to prime the pump is to use assembly lube on the gerotors and inside of the pump before installing it. ((aswracing of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​p=4805186#post4805186)) \\ Then you have an instant hydraulic seal to help the oil pump suck oil from the hose. +    * Another way to prime the pump is to use assembly lube on the gerotors and inside of the pump before installing it. ((aswracing of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-motor-engine/​sportster-motorcycle-bottom-end/​163867-cam-cover-removal#post3491821)) \\ Then you have an instant hydraulic seal to help the oil pump suck oil from the hose. 
-    * You can also using a large syringe with a tapered tip inserted into the oil supply hose on the bottom of the oil tank. ((ericfreeman of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​p=5751479#post5751479)) \\ Then you can force feed oil the pump and on to the engine using this technique ​and it avoids having to mess with the sending unit.+    * You can also using a large syringe with a tapered tip inserted into the oil supply hose on the bottom of the oil tank. ((ericfreeman of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​196980-vapor-lock-on-77-and-later-oil-pumps#post4303198)) \\ Then you can force feed oil to the pump and on to the engine using this technique.
 \\ \\
 ====== Oil Pump - Complete Unit Part Numbers ====== ====== Oil Pump - Complete Unit Part Numbers ======
Line 207: Line 208:
  
 See these XLForum threads:\\ See these XLForum threads:\\
-http://​xlforum.net/​forums/showthread.php?​t=135265\\ +https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-motor-engine/​sportster-motorcycle-bottom-end/​43858-evo-sportster-engine-oil-pump-up-date?​t=135265\\ 
-http://​xlforum.net/​forums/showthread.php?t=1738158+https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​rubber-mount-sportster-motorcycle-talk-2004-2006/​161897-which-oil-pump-buell-26357-02b-or-xl-2007-26204-91a?t=1738158
  
-====== Oil Pump Gaskets ====== +====== Oil Pump Gaskets ​/ Seals ====== 
-Gasket for mounting the pump to the engine case: \\ +Note: all 1977-present Sportster oil pump to engine ​mounting gaskets have app the same bolt pattern holes. \\
-Note: all 1977-present Sportster oil pump mounting gaskets have app the same bolt pattern holes. \\+
 The main difference is 1977-1990 gaskets are longer to match their longer snout oil pumps (these can be cut down to fit 91-up pumps). \\ The main difference is 1977-1990 gaskets are longer to match their longer snout oil pumps (these can be cut down to fit 91-up pumps). \\
 +All 1991-present pump to engine case gaskets will interchange without alterations. \\
  
-Original gasket part#s; \\ +^{{techtalk:​miscres:​instruction_sheet_header_4.png?​nolink&​700|}}|||| 
-1977-1990 ​Sportsters, gasket (26495-75). \\ +|Year Model|Part#|Notes|Pics| 
-1991-1993 ​Sportsters left the factory with gasket (26495-89) and that part number was replaced by the 1994-up ​gasket\\ +|1977-1990 ​Sportster|26495-75|Oil pump to engine case mounting gasket|{{ :​techtalk:​evo:​oil:​1977-1990_sportster_oil_pump_mounting_gasket_26495-75_by_sum-body1.jpg?​linkonly |Pic}} ((photo courtesy of Ebay seller, Sum-body'​s Harley Parts, [[https://​www.ebay.com/​str/​sumbodysharleyparts|Link to Ebay Store]] ​))  | 
-1994-2003 ​Sportsters, gasket (26495-89A)\\ +|1977-1990 Sportster|26434-76A|Pump cover to body O-ring seal \\ Can also use part #​26434-76|{{ :​techtalk:​ih:​oil:​1977-1990_sportster_oil_pump_cover_o-ring_26434-76_by_morlel32.jpg?​linkonly |Pic}} ((photo courtesy of C & M Sales, [[https://​www.ebay.com/​str/​everythingmotorcycleparts?​_trksid=p2047675.m3561.l2563|Link to Ebay Store]] ))| 
-2004-up Sportster, gasket (26495-89B). \\+|1983-1990 Sportster|12036A|Shaft oil seal between divider plates. \\ Use only with outer plate 26493-75A|{{ :​techtalk:​ih:​oil:​1983-1990_sportster_oil_pump_shaft_seal_12036a_by_boneyard_cycles.jpg?​linkonly |Pic}} ((photos courtesy of Boneyard Cycles in Melbourne, FL))| 
 +|1991-1993 ​Sportster|26495-89|Oil pump to engine case mounting ​gasket \\ All 3 gaskets will interchange in the case of \\ finding a NOS gasket| ​ | 
 +|1994-2003 ​Sportster|26495-89A|:::|{{ :​techtalk:​evo:​oil:​1994-2003_sportster_oil_pump_mounting_gasket_26495-89a_by_sum-body1.jpg?​linkonly |Pic}} ((photo courtesy of Ebay seller, Sum-body'​s Harley Parts, [[https://​www.ebay.com/​str/​sumbodysharleyparts|Link to Ebay Store]] ))| 
 +|2004-Present ​Sportster|26495-89B|:::|  | 
 +|1991-Present Sportster|26434-91|Pump cover to body O-ring seal|{{ :​techtalk:​evo:​oil:​1991-present_sportster_pump_cover_to_body_o-ring_seal_26434-91_by_57harleyrider.jpg?​linkonly |Pic}} ((photos courtesy of Ebay seller, 57harleyrider. [[https://​www.ebay.com/​str/​57harleyrider|Link to Ebay Store]] ))| 
 + 
 +===== Leaky gaskets and hose connections ===== 
 +==== Internal leaks ==== 
 +Generally, oil will leak into the motor on shutdown (especially on extended shutdown periods). \\ 
 +For more information on that, [[techtalk:​ref:​oil10|Click Here]] to view "Sit Sumping"​ in the REF section of the Sportsterpedia. \\ 
 + 
 +Below is concerning an issue with gaskets or seals where either oil / air or both leak into the motor while riding. \\ 
 +  
 +{{:​techtalk:​ih:​oil:​1977-up_sportster_oil_pump_internal_gasket_leak_by_hippysmack.gif?​direct|}}
  
-|  Oil Pump Mounting Gasket (26495-75) ((photo courtesy of Ebay seller, Sum-body'​s Harley Parts, [[https://​www.ebay.com/​str/​sumbodysharleyparts|Link to Ebay Store]] ))  | 
-|{{:​techtalk:​evo:​oil:​1977-1990_sportster_oil_pump_mounting_gasket_26495-75_by_sum-body1.jpg?​direct&​300|}}| 
 ====== Oil Pump Date Code ====== ====== Oil Pump Date Code ======
 ===== 91 and Up Oil Pumps ===== ===== 91 and Up Oil Pumps =====
Line 236: Line 248:
 |  98-03 Pump assembly 26204-98 ((photo by Hippysmack)) ​ |  07-Up Pump assembly 26204-91A ((photo by Hippysmack)) ​ | |  98-03 Pump assembly 26204-98 ((photo by Hippysmack)) ​ |  07-Up Pump assembly 26204-91A ((photo by Hippysmack)) ​ |
 |{{:​techtalk:​evo:​oil:​oil_pump_casting_date_3_by_hippysmack.jpg?​direct&​300|}}|{{:​techtalk:​evo:​oil:​oil_pump_casting_date_5_by_hippysmack.jpg?​direct&​300|}}| |{{:​techtalk:​evo:​oil:​oil_pump_casting_date_3_by_hippysmack.jpg?​direct&​300|}}|{{:​techtalk:​evo:​oil:​oil_pump_casting_date_5_by_hippysmack.jpg?​direct&​300|}}|
 +
 ====== Oil Pump Upgrade 26204-91A ====== ====== Oil Pump Upgrade 26204-91A ======
   * In addition to the upgraded Drive Gear (26391-06), there is also an upgraded entire Oil Pump (first installed on 07-later Sportsters). The new pump reuses the same full unit part number as a previous version, making it difficult & confusing to know to which version someone is referring. The old (& new) part number for the complete oil pump unit is 26204-91A (that P/N first showed up in model year 2000 and used for the older design thru model year 2006).   * In addition to the upgraded Drive Gear (26391-06), there is also an upgraded entire Oil Pump (first installed on 07-later Sportsters). The new pump reuses the same full unit part number as a previous version, making it difficult & confusing to know to which version someone is referring. The old (& new) part number for the complete oil pump unit is 26204-91A (that P/N first showed up in model year 2000 and used for the older design thru model year 2006).
   * The difference between the 1998-2006 version and the 2007-later version relates to the drive shaft, internal Gerotor return & feed gears and the body (which cannot be ordered separately). The internal parts for the new pump design are not backward compatible to the 98-06 pump design.   * The difference between the 1998-2006 version and the 2007-later version relates to the drive shaft, internal Gerotor return & feed gears and the body (which cannot be ordered separately). The internal parts for the new pump design are not backward compatible to the 98-06 pump design.
   * The only known external indicator to identify that the 2007 pump version (using P/N 26204-91A) is currently installed is the cover casting number 26213-07 which is stamped on the bottom of the new version.   * The only known external indicator to identify that the 2007 pump version (using P/N 26204-91A) is currently installed is the cover casting number 26213-07 which is stamped on the bottom of the new version.
-  * The upgraded pump is compatible (and recommended) for use on 1991-later Sportsters.+  * The upgraded pump is compatible (and recommended) for use on 1991-later Sportsters. \\ However, it is not the answer to wetsumping (which involves more than just the pump).
  
 Here are the internal servicing part numbers from 1998-2000 version and 2007-later version: Here are the internal servicing part numbers from 1998-2000 version and 2007-later version:
Line 252: Line 265:
 \\ \\
  
-{{techtalk:​evo:​oil:​26204-91a-2007-oilpumpkit.jpg}} ((photo by aswracing ​http://​xlforum.net/​forums/showthread.php?​t=1589124))+{{techtalk:​evo:​oil:​26204-91a-2007-oilpumpkit.jpg}} ((photo by aswracing ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​lubrication-and-lubricants/​146311-will-buell-oil-pump-pn-26357-02b-work-on-03-xl1200?​t=1589124))
  
 \\ \\
  
 ===== 2007 XL and Buell Oil Pump Comparison ===== ===== 2007 XL and Buell Oil Pump Comparison =====
- +  ​* 2007 XB engines got a new up-dated oil pump which will retro fit to older EVO Sportster Engines, BLAST engines and older XB Engines ... ((BUELListic ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-motor-engine/​sportster-motorcycle-bottom-end/​43858-evo-sportster-engine-oil-pump-up-date?​t=135265)) 
-  ​* 2007 XB engines got a new up-dated oil pump which will retro fit to older EVO Sportster Engines, BLAST engines and older XB Engines ... ((BUELListic ​http://​xlforum.net/​forums/showthread.php?​t=135265)) +  * The -07 XB oil pump is part number 26357-02b. The 07 part number seen on the housing is simply just for the lower housing. ((theM_A_N ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-motor-engine/​sportster-motorcycle-bottom-end/​43858-evo-sportster-engine-oil-pump-up-date/​page3?​t=135265&​page=3)) 
-  * The -07 XB oil pump is part number 26357-02b. The 07 part number seen on the housing is simply just for the lower housing. ((theM_A_N ​http://​xlforum.net/​forums/showthread.php?​t=135265&​page=3)) +  * The part number for a 2006 is 26357-02A. ​ ((aswracing ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​lubrication-and-lubricants/​146311-will-buell-oil-pump-pn-26357-02b-work-on-03-xl1200?​t=1589124))
-  * The part number for a 2006 is 26357-02A. ​ ((aswracing ​http://​xlforum.net/​forums/showthread.php?​t=1589124))+
  
   * The -07 Sportster pump changed at the same time and got the same improvements and the only reason the part number is different from the Buell pump is that the fittings are different. ​ And what's more, just a brief look at some parts books shows that the part number for all Sportster pumps from 2000 to thru 2007 + is the same (26204-91A). So they changed the pump in 2007 as Buell did. However, ​ it doesn'​t appear that they changed the part number. ​ So with the 07-up XL style oil pump, even though the pump’s part number didn’t change from the 2000 model year, the gerotor part numbers did.   * The -07 Sportster pump changed at the same time and got the same improvements and the only reason the part number is different from the Buell pump is that the fittings are different. ​ And what's more, just a brief look at some parts books shows that the part number for all Sportster pumps from 2000 to thru 2007 + is the same (26204-91A). So they changed the pump in 2007 as Buell did. However, ​ it doesn'​t appear that they changed the part number. ​ So with the 07-up XL style oil pump, even though the pump’s part number didn’t change from the 2000 model year, the gerotor part numbers did.
Line 266: Line 278:
     * Feed --- 26503-07 GEROTOR SET     * Feed --- 26503-07 GEROTOR SET
     * Return - 26502-07 GEROTOR SET     * Return - 26502-07 GEROTOR SET
-  * So, it does appear that the Sportster got the same oil pump improvements. Why they changed the Buell pump part number in '07, and yet didn't change the Sportster pump part number at the same time, I have no idea. Just to confuse us I guess. ((aswracing ​http://​xlforum.net/​forums/showthread.php?​t=1589124)) +  * So, it does appear that the Sportster got the same oil pump improvements. Why they changed the Buell pump part number in '07, and yet didn't change the Sportster pump part number at the same time, I have no idea. Just to confuse us I guess. ((aswracing ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​lubrication-and-lubricants/​146311-will-buell-oil-pump-pn-26357-02b-work-on-03-xl1200?​t=1589124)) 
-  * The Sportster pump #26204-91A and the Buell pump # 26357-02B are the same ((Reaction Racing ​http://​xlforum.net/​forums/showthread.php?​t=1589124&​page=3)) +  * The Sportster pump #26204-91A and the Buell pump # 26357-02B are the same ((Reaction Racing ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​lubrication-and-lubricants/​146311-will-buell-oil-pump-pn-26357-02b-work-on-03-xl1200/​page3?​t=1589124&​page=3)) 
-  * The only difference in the pumps are the fittings that come installed on the pump ((rocketmangb of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1589124&​page=3)) which can be removed and replaced with the fittings that you need for your XL.+  * The only difference in the pumps are the fittings that come installed on the pump ((rocketmangb of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​lubrication-and-lubricants/​146311-will-buell-oil-pump-pn-26357-02b-work-on-03-xl1200/​page3?​t=1589124&​page=3)) which can be removed and replaced with the fittings that you need for your XL.
  
 ====== Oil Pump Drive Gear ====== ====== Oil Pump Drive Gear ======
Line 302: Line 314:
 |  1977-1987 Sportster Oil Pump Drive Gear ((photos courtesy of c3cycle.com,​ Link to site: https://​www.c3cycle.com/​)) ​  ||| |  1977-1987 Sportster Oil Pump Drive Gear ((photos courtesy of c3cycle.com,​ Link to site: https://​www.c3cycle.com/​)) ​  |||
 |{{:​techtalk:​ih:​oil:​1977-1987_sportster_oil_pump_drive_gear_26318-75_pic1_by_c3-cycle-tech.jpg?​direct&​300|}}|{{:​techtalk:​ih:​oil:​1977-1987_sportster_oil_pump_drive_gear_26318-75_pic2_by_c3-cycle-tech.jpg?​direct&​300|}}|{{:​techtalk:​ih:​oil:​1977-1987_sportster_oil_pump_drive_gear_26318-75_pic3_by_c3-cycle-tech.jpg?​direct&​300|}}| |{{:​techtalk:​ih:​oil:​1977-1987_sportster_oil_pump_drive_gear_26318-75_pic1_by_c3-cycle-tech.jpg?​direct&​300|}}|{{:​techtalk:​ih:​oil:​1977-1987_sportster_oil_pump_drive_gear_26318-75_pic2_by_c3-cycle-tech.jpg?​direct&​300|}}|{{:​techtalk:​ih:​oil:​1977-1987_sportster_oil_pump_drive_gear_26318-75_pic3_by_c3-cycle-tech.jpg?​direct&​300|}}|
 +
 ===== Drive Gear Removal ===== ===== Drive Gear Removal =====
 The drive gear is inside the gearcase and the cover will need to be removed to access the gear. \\ The drive gear is inside the gearcase and the cover will need to be removed to access the gear. \\
Line 307: Line 320:
 With the cover off, you'll need a [[techtalk:​ref:​tools133#​pinion_gear_tools|tool to lock the pinion gear]] to remove the nut that holds the assembly together. \\  With the cover off, you'll need a [[techtalk:​ref:​tools133#​pinion_gear_tools|tool to lock the pinion gear]] to remove the nut that holds the assembly together. \\ 
 Once the pinion gear is removed, the pump drive gear slides off the pinion shaft. Once the pinion gear is removed, the pump drive gear slides off the pinion shaft.
 +
 ===== Known Drive Gear Failure ===== ===== Known Drive Gear Failure =====
  
 **Inspect your oil pump drive gear** especially if you've gotten your gearcase cover off anyway to hopefully prevent gear failure before it happens. \\ **Inspect your oil pump drive gear** especially if you've gotten your gearcase cover off anyway to hopefully prevent gear failure before it happens. \\
  
-  * Generally speaking, the stock (drive gear) is fine for stock power levels and rpm's. Sure, there are some failures on stock or near stock bikes, but it's pretty rare. ((aswracing of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1920827&​highlight=pinion+gear+locking+tool&​page=2)) \\ Of course, they do eventually wear down and should be replaced with the upgraded version. And if something gets into the pump and locks it up, the teeth get ripped off the gear. ((aswracing of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1974986&​highlight=bronze+drive+gear&​page=3)) +  * Generally speaking, the stock (drive gear) is fine for stock power levels and rpm's. Sure, there are some failures on stock or near stock bikes, but it's pretty rare. ((aswracing of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-general-discussion-and-problems/​178765-oil-pump-drive-gear-question/​page2?​t=1920827&​highlight=pinion+gear+locking+tool&​page=2)) \\ Of course, they do eventually wear down and should be replaced with the upgraded version. And if something gets into the pump and locks it up, the teeth get ripped off the gear. ((aswracing of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-general-discussion-and-problems/​183583-oil-filter-bypass-no-longer-a-question-damage-porn-inside/​page3?​t=1974986&​highlight=bronze+drive+gear&​page=3)) 
-  * The OEM gear is hardened on the surface, but once that is worn through it will wear extremely fast. ((Scuba10jdl ​http://​xlforum.net/​forums/showthread.php?​t=2002257&​highlight=pinion+gear+part+number)) \\ This is a common failure in [high HP or RPM] Sportsters, even when nothing gets into the pump to lock it up first. ((aswracing of the XLFORUM xlforum.net/​forums/showthread.php?​t=1920827&​page=2)) The teeth get sharp and then they break off.  +  * The OEM gear is hardened on the surface, but once that is worn through it will wear extremely fast. ((Scuba10jdl ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-motor-engine/​sportster-motorcycle-bottom-end/​187492-bronze-oil-pump-drive-gear?​t=2002257&​highlight=pinion+gear+part+number)) \\ This is a common failure in [high HP or RPM] Sportsters, even when nothing gets into the pump to lock it up first. ((aswracing of the XLFORUM ​https://​www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-general-discussion-and-problems/​178765-oil-pump-drive-gear-question/​page2?​t=1920827&​page=2)) The teeth get sharp and then they break off.  
-  * The failure happens because of pinion shaft runout (especially when the power level is raised). \\ This causes the engagement depth of the teeth to change as the pinion shaft rotates. \\ This causes the teeth of the steel oil pump drive gear to wear badly on one side. \\ You'll see the teeth getting real sharp there. \\ Generally, 180° from the worn teeth (front of tooth pitch) you'll see almost no wear at all so you have to inspect all the way around the gear (rear tooth pitch). ((aswracing of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1920827&​highlight=pinion+gear+locking+tool&​page=2)) \\ +  * The failure happens because of pinion shaft runout (especially when the power level is raised). \\ This causes the engagement depth of the teeth to change as the pinion shaft rotates. \\ This causes the teeth of the steel oil pump drive gear to wear badly on one side. \\ You'll see the teeth getting real sharp there. \\ Generally, 180° from the worn teeth (front of tooth pitch) you'll see almost no wear at all so you have to inspect all the way around the gear (rear tooth pitch). ((aswracing of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-general-discussion-and-problems/​178765-oil-pump-drive-gear-question/​page2?​t=1920827&​highlight=pinion+gear+locking+tool&​page=2)) \\ 
-   * So lots of people get fooled when they check the gear. They'​ll look at the visible portion from their vantage point only. \\ You have to look all the way around the gear though. The wear will be isolated to one area only. ((aswracing of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1920827&​highlight=pinion+gear+locking+tool&​page=2)) +   * So lots of people get fooled when they check the gear. They'​ll look at the visible portion from their vantage point only. \\ You have to look all the way around the gear though. The wear will be isolated to one area only. ((aswracing of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-general-discussion-and-problems/​178765-oil-pump-drive-gear-question/​page2?​t=1920827&​highlight=pinion+gear+locking+tool&​page=2)) 
-  * With the gearcase on, you may be able to pull the oil pump and look up inside, and inspect the gear while slowly turning the motor. ((aswracing of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1920827&​highlight=pinion+gear+locking+tool&​page=2))+  * With the gearcase on, you may be able to pull the oil pump and look up inside, and inspect the gear while slowly turning the motor. ((aswracing of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-general-discussion-and-problems/​178765-oil-pump-drive-gear-question/​page2?​t=1920827&​highlight=pinion+gear+locking+tool&​page=2))
   * You may still want to remove the cover, pinion nut and gear to get a good prospective on the health of the drive gear. The damage can be easily overlooked. \\ It usually happens on one side of the teeth on the gear due to pinion shaft runout forcing the gear outward while it is moving against the rigid mounted oil pump gear.   * You may still want to remove the cover, pinion nut and gear to get a good prospective on the health of the drive gear. The damage can be easily overlooked. \\ It usually happens on one side of the teeth on the gear due to pinion shaft runout forcing the gear outward while it is moving against the rigid mounted oil pump gear.
   * If you see the teeth sharpening, you're on borrowed time. \\ When one of these steel gears fails, it's really ugly and makes a mess and can damage a lot of other things as well. \\   * If you see the teeth sharpening, you're on borrowed time. \\ When one of these steel gears fails, it's really ugly and makes a mess and can damage a lot of other things as well. \\
Line 328: Line 342:
     * Debris locking up the oil pump.     * Debris locking up the oil pump.
     * Scoring the oil pump cylinder, feed and scavenge gears which opens up the tolerances keeping it from pumping oil correctly in the future.     * Scoring the oil pump cylinder, feed and scavenge gears which opens up the tolerances keeping it from pumping oil correctly in the future.
-    * The debris is also exposed to (everywhere oils travels) as in all the inboard cam bushings ((wedge of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1974986&​highlight=bronze+drive+gear&​page=3)),​ rings, cylinders, rockers etc. so it can be catastrophic failure depending on the severity of the initial damage.+    * The debris is also exposed to (everywhere oils travels) as in all the inboard cam bushings ((wedge of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-general-discussion-and-problems/​183583-oil-filter-bypass-no-longer-a-question-damage-porn-inside/​page3?​t=1974986&​highlight=bronze+drive+gear&​page=3)),​ rings, cylinders, rockers etc. so it can be catastrophic failure depending on the severity of the initial damage.
   * **Cleanup upon discovering broken / exploded metal parts anywhere in the engine**:   * **Cleanup upon discovering broken / exploded metal parts anywhere in the engine**:
     * Simple answer, check and clean everywhere oil can travel. Choosing not to has proven to be destructive to the engine. ​     * Simple answer, check and clean everywhere oil can travel. Choosing not to has proven to be destructive to the engine. ​
     * You can run a magnet along most non-confined areas to check and remove metal particles.  ​     * You can run a magnet along most non-confined areas to check and remove metal particles.  ​
  
-|  Oil pump and drive gear damage. ((photo by xtremer-pxl of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1848987)) ​ ||+|  Oil pump and drive gear damage. ((photo by xtremer-pxl 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/​172631-oil-pump-drive-gear?​t=1848987)) ​ ||
 |{{:​techtalk:​evo:​oil:​oil_pump_drive_gear_failure_1_by_xtremer-pxl.jpg?​direct&​300|}}| ​ {{:​techtalk:​evo:​oil:​oil_pump_failure_from_drive_gear_by_xtremer-pxl.jpg?​direct&​300|}}| |{{:​techtalk:​evo:​oil:​oil_pump_drive_gear_failure_1_by_xtremer-pxl.jpg?​direct&​300|}}| ​ {{:​techtalk:​evo:​oil:​oil_pump_failure_from_drive_gear_by_xtremer-pxl.jpg?​direct&​300|}}|
  
-|  More oil pump and drive gear damage ((photos by lostndallas of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1974986&​highlight=bronze+drive+gear&​page=6)) ​ ||+|  More oil pump and drive gear damage ((photos by lostndallas of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-general-discussion-and-problems/​183583-oil-filter-bypass-no-longer-a-question-damage-porn-inside/​page6?​t=1974986&​highlight=bronze+drive+gear&​page=6)) ​ ||
 |{{:​techtalk:​evo:​engmech:​2010_1200x_cam_inner_bushings_by_lostndallas.jpg?​direct&​300|}}|{{:​techtalk:​evo:​oil:​2010_1200x_oil_pump_gear_damage_2_by_lostndallas.jpg?​direct&​300|}}| |{{:​techtalk:​evo:​engmech:​2010_1200x_cam_inner_bushings_by_lostndallas.jpg?​direct&​300|}}|{{:​techtalk:​evo:​oil:​2010_1200x_oil_pump_gear_damage_2_by_lostndallas.jpg?​direct&​300|}}|
- 
  
 {{:​techtalk:​evo:​oil:​2010_1200x_oil_pump_gear_damage_3_by_lostndallas.jpg?​direct&​300| }} {{:​techtalk:​evo:​oil:​2010_1200x_oil_pump_gear_damage_3_by_lostndallas.jpg?​direct&​300| }}
-A chunk of a tooth from the oil pump gear fell out of the oil pump upon dis-assembly ((photo by lostndallas of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1974986&​highlight=bronze+drive+gear)) ​+A chunk of a tooth from the oil pump gear fell out of the oil pump upon dis-assembly ((photo by lostndallas of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-general-discussion-and-problems/​183583-oil-filter-bypass-no-longer-a-question-damage-porn-inside?​t=1974986&​highlight=bronze+drive+gear)) ​
  
 ===== Bronze Oil Pump Drive Gear Upgrade (26391-06) ===== ===== Bronze Oil Pump Drive Gear Upgrade (26391-06) =====
- 
   * This upgrade is compatible with 1991-later models.   * This upgrade is compatible with 1991-later models.
   * HD finally came out with an upgraded drive gear in 2006 for the Buell models to solve the high-rpm wear problem. Pinion shaft runout was the cause and occurs mostly because of high rpm operation causing flywheel spread. This failure has always been a terrible issue with Buells as they had higher rev limits from the factory - 6800 for most tubers and up to 7500 for the XB9. Even bone stock Buells were having this failure.   * HD finally came out with an upgraded drive gear in 2006 for the Buell models to solve the high-rpm wear problem. Pinion shaft runout was the cause and occurs mostly because of high rpm operation causing flywheel spread. This failure has always been a terrible issue with Buells as they had higher rev limits from the factory - 6800 for most tubers and up to 7500 for the XB9. Even bone stock Buells were having this failure.
-  * But the MoCo never bothered to put it in XL's. It probably costs more than the steel gear, and given that failures are rare at 60hp, it just wasn't needed. But if you're hopping up an XL, it's a good piece of insurance. Especially if you're going into the cam box for a cam swap anyway, then it's a no-brainer in my opinion. It's a really ugly failure that generally requires a full tear down to fix. The gear is an ounce of prevention. ((aswracing ​http://​xlforum.net/​forums/showthread.php?​t=1920827&​highlight=pinion+gear+locking+tool&​page=2)) +  * But the MoCo never bothered to put it in XL's. It probably costs more than the steel gear, and given that failures are rare at 60hp, it just wasn't needed. But if you're hopping up an XL, it's a good piece of insurance. Especially if you're going into the cam box for a cam swap anyway, then it's a no-brainer in my opinion. It's a really ugly failure that generally requires a full tear down to fix. The gear is an ounce of prevention. ((aswracing ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-general-discussion-and-problems/​178765-oil-pump-drive-gear-question/​page2?​t=1920827&​highlight=pinion+gear+locking+tool&​page=2)) 
-  * The bronze gear doesn'​t have this issue because of the different wear characteristics of the metal. The oil pump drive gear sees a lot of sliding friction, which causes the steel on steel to wear quickly. Bronze has much less friction than the OEM gear.  The bronze gear is also uniform throughout, and thus it wears more predictably. So even if bronze is softer than steel, all of the factors in this application end up giving it a longer life than the steel gear. ((Scuba10jdl of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=2002257&​highlight=pinion+locking+tool)) +  * The bronze gear doesn'​t have this issue because of the different wear characteristics of the metal. The oil pump drive gear sees a lot of sliding friction, which causes the steel on steel to wear quickly. Bronze has much less friction than the OEM gear.  The bronze gear is also uniform throughout, and thus it wears more predictably. So even if bronze is softer than steel, all of the factors in this application end up giving it a longer life than the steel gear. ((Scuba10jdl of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-motor-engine/​sportster-motorcycle-bottom-end/​187492-bronze-oil-pump-drive-gear?​t=2002257&​highlight=pinion+locking+tool)) 
-  * It's cheap insurance, even if you only plan to visit 7,000 RPM instead of living there. ((Centennial Sportster ​http://​xlforum.net/​forums/showthread.php?​t=1920827&​highlight=pinion+gear+locking+tool))+  * It's cheap insurance, even if you only plan to visit 7,000 RPM instead of living there. ((Centennial Sportster ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-general-discussion-and-problems/​178765-oil-pump-drive-gear-question?​t=1920827&​highlight=pinion+gear+locking+tool))
  
 \\ \\
Line 357: Line 369:
 {{techtalk:​evo:​oil:​26391-06-bronze-oilpumpdrivegear.jpg}} ​ {{techtalk:​evo:​oil:​26391-06-bronze-oilpumpdrivegear.jpg}} ​
  
-|  **With This** ​ ((photo by Hippysmack)) ​ |  Used steel (L) compared to new bronze (R) oil pump gear ((photo by aswracing of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=501054&​highlight=oil+pump+drive+gear+removal&​page=2)) ​ |+|  **With This** ​ ((photo by Hippysmack)) ​ |  Used steel (L) compared to new bronze (R) oil pump gear ((photo by aswracing of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-motor-engine/​sportster-motorcycle-engine-conversions/​72613-help-needed-pinion-gear-removal/​page2?​t=501054&​highlight=oil+pump+drive+gear+removal&​page=2)) ​ |
 |{{:​techtalk:​evo:​oil:​bronze_oil_pump_gear_upgrade_by_hippysmack.jpg?​direct&​400|}}|{{:​techtalk:​evo:​oil:​oil_pump_gear_comparison_by_aswracing.jpg?​direct&​400|}}| |{{:​techtalk:​evo:​oil:​bronze_oil_pump_gear_upgrade_by_hippysmack.jpg?​direct&​400|}}|{{:​techtalk:​evo:​oil:​oil_pump_gear_comparison_by_aswracing.jpg?​direct&​400|}}|