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May sound really stupid but I had the same damn problem . I put dye in the oil and ran it .Took it apart adn looked with the flo light and found the oil was coming from the 2 tiny *** little screw holes that hold down the regulator wires going to the alt . I'm telling ya I had the bike tore apart more than you want to know . Not a drop since (except for the breather ) .
May sound really stupid but I had the same damn problem . I put dye in the oil and ran it .Took it apart adn looked with the flo light and found the oil was coming from the 2 tiny *** little screw holes that hold down the regulator wires going to the alt . I'm telling ya I had the bike tore apart more than you want to know . Not a drop since (except for the breather ) .
Not stupid at all. When I first tore into the bike to replace the fried alternator I found that some fine shade-tree wrench-thrower had used a sheetmetal screw in one of those holes. I drilled/tapped and replaced using some sealer on the threads. I checked my repair when I tore it back apart to replace the seal and it's holding up fine.
One thing I'm going to try - the bike had one of those high dollar check valves on the breather line. I've taken it apart & cleaned it up 'cause it was sticking. I'm going to remove it completely and run it that way. If it sticks in the closed position it'll pressurize the cases. Maybe I'll get lucky.
Well, it's been apart a couple more times. I found the source ofthe leaks finally. One was around the steel insert as 89FLHT described, and the other is that when the clown used the sheetmetal screw on the alternator leads clamp he caused a hairline crack between the two screw holes. So we traipsed off to the local HD shop in Longview, TX, which is named The Harley Shop, of all things. Plopped the bucks down for a new Evo crate motor, silver & polished version.
Checked on a reman job on my motor, and it's about $2300+. Only $600 more for a new engine, and I get to ride in the meantime. I'm thinking about getting the reman job next year, and maybe start gathering parts to build a rigid. We'll see...
Thanks to 89FLHT and jhnmflr for the hints. Helped pinpoint the problem.
When do you get the crate? Is it stock, or did you do any mod's? Are you doing anything else while the motor's out? Man, that's too bad that you had to spend all those bucks, but I guess it will be fun having a new powerplant in your baby, with a great start for a new ride on the bench.
It's a stock motor straight from HD. It'll be the '99 version of the Evo. I got the go-fast outta my system years ago with my 77" strokerIronhead. I like the 45 - 55 mpg I get better than I like doing the gotta-go-fast thing.
It's s'posed to take about 30 days, so I'll just ride mine in the meantime, and pretend it's a Shovel marking its spot. There won't be anything else done to the bike 'cause I'll try to swap it out over a weekend.
If I can swing the reman on the old engine I'm thinking about building a rigid, no stretch, no rake. Just something as simple as possible; suicide, jockey, open belt primary, Sporty or peanut tank, solo seat, drag bars.
I'd just put some cardboard under it when it was parked, and ride the hell out of it when it wasn't...
but then again, I ride a rat...
You're close!I am riding it now, but I have an old piece of plywood in my shop to park it on, and when I put it on the turbine floor at work I put some oil soak pads, aka diapers, under it.
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