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Weird air leak
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 Posted: Fri May 16th, 2014 09:55 am
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Dave
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Lots of info out there on which years the cases were better quality than other...

I got into all that when I busted the pinion-shaft on my fresh rebuild. I think that was the second time that my cases were apart (that I know of) Don't remember a lot details now. I do remember that mine weren't the greatest. But, they weren't as bad as some of the later years either...

It's a crap-shoot...

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 Posted: Thu May 15th, 2014 11:02 pm
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jeffy ole boy
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weasle1 wrote:
id forgotten about the early evo cases , they were more of a porus aluminum , than the later ones , they had trouble with them cracking or leaking oil , so what your saying makes sense. glad you got it fixed hope you dont have any more trouble with it .

Met too Weasle. Time to stop wrenching and start riding ;)

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 Posted: Thu May 15th, 2014 01:48 am
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jeffy ole boy
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We concluded that my motor has been apart at least 3 times maybe more in its 23 yr life span. The early Evo's like mine which is a 91 were known to have weak cases... Guess that's why the cyl studs popped up from the apparent somewhat weak case which is of course all aluminum. And yep I owe Ben, food, gas money for going to the dealer today, plus some spending money, :)

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 Posted: Wed May 14th, 2014 11:09 am
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weasle1
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glad you got it fixed jeff , ya better by ben a steak dinner LOL. you ever figure out why they pulled ??

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 Posted: Wed May 14th, 2014 01:50 am
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jeffy ole boy
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Got it fixed. Used helicoils. Drilled out the stripped cyl stud holes with the size required 25/64 drill bit.Used the right size helicoils for the 3/8's new studs, and red locktighted them in. Just so happens my bud Ben had all the stuff to do it with on hand. Cost me virtualy nothing so far. Hate to think whata an Indy or dealer would have charged.... $800. probably... LOL! Steve approved of the helicoil fix. So that makes me feel better. Could of used keenserts or timesert as an alternative, but they are bigger and would of required drilling bigger holes. We shy'd away from using those..... All is well I do believe.

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 Posted: Tue May 13th, 2014 07:49 pm
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weasle1
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damned . did you guys use new studs when you put it back togather ?? probably a dum question but just trying to figure why they pulled, jeff? ive heard of studs pulling , but it usually happens on over 100 hp evo,s . i think their is a way to drill through the casees stud holes. and bolt the studs in , not sure just how they do it.

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 Posted: Tue May 13th, 2014 05:40 pm
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jeffy ole boy
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Found the real culprit.. The metal cometic head gasket was not blown, but venting out the head gasket caused by 2 cyl studs working their way loose from the case :shock:

Now the problem that confronts us trying to find either oversize cyl studs that Harley does not have. They recommended heali coiling or sending in the cases. Not doing the latter.... Gonna ck with Steve. Benny thinks there is a Keihn pin threaded sleeve that may he might have on hand. (Need 2) Or maybe can even be found at NAPA.? Got our work cut out for us now....

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 Posted: Tue May 13th, 2014 11:56 am
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jeffy ole boy
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Your right Dave FXR and FLH Evo frames were about the same I hear. No worrys, Ben has a short allen head wrench just for that hard to reach screw.. I just hope the head is not warped or some shit..

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 Posted: Tue May 13th, 2014 09:46 am
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Dave
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I hope your frame has that hole that Weasle's talking about Jeff. FLH and FXR frames are probably identical in that area. If that hole ain't there, you're gonna learn some new words you won't see in the bible...;)

I had to grind an allen-wrench down (a lot) and extend the handle with a piece of tubing...

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 Posted: Tue May 13th, 2014 02:21 am
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jeffy ole boy
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Yeah were gonna ckeck out both surfaces real good Weas..Have no idea why the head gasket blew at this stage, but will know soon. After work tonight I took off the exhaust and drained the gas. WIll have that head off by noon tomorrow. Tues is my day off. Anxious to find out what went wrong...

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 Posted: Mon May 12th, 2014 12:08 pm
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weasle1
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glad you found the problem i was thinking along the lines of head or exaust gasket . not sure about your bike , but some of the older models evo had a hole in the frame to acess that rocker bolt dave was talking about .i know you and ben know what your doing , but from jan till now is a awful short time for a head gasket to blow .i might sugest laying a strait edge across the jug and bottom of the head just to make sure it isn,t warped . get er up and runnin bud .:D

Last edited on Mon May 12th, 2014 01:37 pm by weasle1

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 Posted: Mon May 12th, 2014 11:41 am
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jeffy ole boy
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Dave wrote:
jeffy ole boy wrote:
jeffy ole boy wrote:
LOL, Dave your forgetting we just did a top end on the bike in Jan. I know how to desemble the motor...;)
The compression check is an excellent idea though.. thanks much!
Forgot about that Jeff...

But, it's a completely different game when the engine is still in the frame. That rear rocker-box is a real PITA...


Its not that bad… Had em both off in Jan. My buddy Ben has all the right tools.. :cool:

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 Posted: Mon May 12th, 2014 09:29 am
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Dave
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jeffy ole boy wrote:
jeffy ole boy wrote:
LOL, Dave your forgetting we just did a top end on the bike in Jan. I know how to desemble the motor...;)
The compression check is an excellent idea though.. thanks much!
Forgot about that Jeff...

But, it's a completely different game when the engine is still in the frame. That rear rocker-box is a real PITA...

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 Posted: Sun May 11th, 2014 10:18 pm
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jeffy ole boy
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Pretty sure now I have a blown rear head gasket.

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 Posted: Sun May 11th, 2014 01:06 pm
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jeffy ole boy
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jeffy ole boy wrote:
LOL, Dave your forgetting we just did a top end on the bike in Jan. I know how to desemble the motor...;)
The compression check is an excellent idea though.. thanks much!

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 Posted: Sun May 11th, 2014 10:12 am
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Dave
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Do the compression check Jeff. If it comes up good, you've got some more detective work to do. Otherwise, you've got some work to do. Removing the rear head is a real PITA...

It's really not what I'd call a "Hard" job, fairly simple really.

But, getting the rocker-box loose is gonna take some creativity on your part. There ain't a lot of room (between the rocker box and the frame) to get a wrench in there. Same thing for puttin' it back together.

Gonna take a bunch of patience...

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 Posted: Sat May 10th, 2014 10:12 pm
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jeffy ole boy
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The intake gaskets seem fine though Weas... Running fine. The popping is coming from head gasket its seems.

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 Posted: Sat May 10th, 2014 10:09 pm
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weasle1
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steve knows his shit , but when my 1 intake gasket went bad i couldnt get the dam thing to idle right , or stop popin on deceleration . i hope steve is right , its not to bad a job to change the intake manafold gaskets.did you do a compression check on the rear cyl , possiable you blew a head gasket or a exaust gasket ??

Last edited on Sat May 10th, 2014 10:15 pm by weasle1

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 Posted: Sat May 10th, 2014 10:09 pm
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jeffy ole boy
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Seems to me like its coming from the rear head gasket...: When I crack the throttle a fairly loud pop occurs and I feel air expell out. No sign of any oil leaks though! No change in the sound of the motor when I spray carb cleaner all around the intake gaskets and head gasket however...

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 Posted: Sat May 10th, 2014 08:33 pm
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jeffy ole boy
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That makes sense Weasle. Steve wrote me and suggested:

Take a little starting fluid or carb cleaner and spray around the area where the sound is coming from and see if the engine speed changes. Make sure the intake gaskets are not leaking to start. Let me know about the rest.

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