Head gasket leak
Thread Starter
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Stellar HDF Member
Joined: Feb 2007
Posts: 2,558
Likes: 280
From: Russellville, Arkansas
Always going to be a problem, since you have a steel sleeve in an aluminum cylinder bodiy, which has two different heat expansion rates against the case.
So the solution to the problem since you have bind channel to bind channel on the cylinder base to engine case for the oil to return down ( with there different expansion rates), is to install pig tails.
This tubes the oil coming done the channel into a tube that seat/seals off above the bottom of cylinder channel, to copper tube that protrudes into the case channel, so you don't have the blind channel against bind channel with different heat expansion rates sealing problem. Also, the tube protruded back down in to the case, stops what is slug back up the channels as well.
http://www.badweatherbikers.com/buel...tml?1491426949
As for when you are installing the rocker bodies, make sure to get the cylinder on TDC, which has the lifter off the cam lobs to being with. Also, big bolts first to draw the push rods down on the lifter to slowly release oil out of them when installing the rocker bodies, then smaller outer bolts in the end since they can strip out pulling down.
As for gasket set, will just state that the James gasket's are not as good as they used to be since the change in ownership, but since the pigtails deals with the base leak problem at the oil return channels, it really just the head gaskets and valve cover gaskets that you have to worry about. As for primary cover gasket, just run with the HD OEM since it tends to last longer with cover removals and reuse.
So the solution to the problem since you have bind channel to bind channel on the cylinder base to engine case for the oil to return down ( with there different expansion rates), is to install pig tails.
This tubes the oil coming done the channel into a tube that seat/seals off above the bottom of cylinder channel, to copper tube that protrudes into the case channel, so you don't have the blind channel against bind channel with different heat expansion rates sealing problem. Also, the tube protruded back down in to the case, stops what is slug back up the channels as well.
http://www.badweatherbikers.com/buel...tml?1491426949
As for when you are installing the rocker bodies, make sure to get the cylinder on TDC, which has the lifter off the cam lobs to being with. Also, big bolts first to draw the push rods down on the lifter to slowly release oil out of them when installing the rocker bodies, then smaller outer bolts in the end since they can strip out pulling down.
As for gasket set, will just state that the James gasket's are not as good as they used to be since the change in ownership, but since the pigtails deals with the base leak problem at the oil return channels, it really just the head gaskets and valve cover gaskets that you have to worry about. As for primary cover gasket, just run with the HD OEM since it tends to last longer with cover removals and reuse.
Anyways.....got pigtails coming.
Thread Starter
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Stellar HDF Member
Joined: Feb 2007
Posts: 2,558
Likes: 280
From: Russellville, Arkansas
Definitely will make sure the bases are trued....before reinstallation.
The front cylinder was never an issue....
Thread Starter
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Stellar HDF Member
Joined: Feb 2007
Posts: 2,558
Likes: 280
From: Russellville, Arkansas
HDF Community Team
Joined: Jan 2020
Posts: 1,434
Likes: 800
From: Colorado
Yep and after lathing the jubs up to square up the bottom/remove the old gasket cleanly on two sets of gaskets dealing with the leak twice, pigtail is what resolved the problem in the end.
Really, had HD just milled, and used a sleeve that was RTV or O rings in place to break up the blind channel to blind channel fit, would have solved the problem since the problem is the entire jug bottom and case not heating up at the same rate, the oil coming down the channel cooling the jug in that location, and the extra membrane on the new gasket not flexible enough long term to keep the gap sealed at heat expansion instead. At least the extra membrane on the new gaskets help at touch longer, since the old type paper gaskets with gasket cinch would just crack their to hemorrhaging oil inside 6 months isntead.
Cruiser
Joined: Jul 2015
Posts: 166
Likes: 13
From: Beaufort, NC
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Thread Starter
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Stellar HDF Member
Joined: Feb 2007
Posts: 2,558
Likes: 280
From: Russellville, Arkansas
Done.....no more leaks!! I let it run long enough for the rocker boxes to be warm.
The cylinder jugs were flat....checked out ok.
I did not use the Pig-Tails after all. I didnt really like the idea of those anyways. Theyre getting shoved in a parts drawer.
Used Cometic metal gaskets.....from base gasket up. The directions stated to leave off the O-rings on the dowels....so I did that. Used new head bolts......probably didnt need to, but as I was disassembling one wasnt as tight as the others.
Gonna go ride today
The cylinder jugs were flat....checked out ok.
I did not use the Pig-Tails after all. I didnt really like the idea of those anyways. Theyre getting shoved in a parts drawer.
Used Cometic metal gaskets.....from base gasket up. The directions stated to leave off the O-rings on the dowels....so I did that. Used new head bolts......probably didnt need to, but as I was disassembling one wasnt as tight as the others.
Gonna go ride today