Servicing Oil Tank Cap And Filler Opening

To disassemble, follow order shown in Figure 3-1. Assembly is reverse order of disassembly. Clean and inspect all parts. Replace any that are worn or damaged.

If oil leak should occur between the tank cap and the filler opening, with cap and gasket in serviceable condition, check the lip of the filler opening. A cap drawn too tight will bend the lip of the filler opening resulting in an imperfect seal between gasket and lip.

Drain oil from tank. Using a mallet as a driver and a blockof wood as a cushion, bend the lip down until flush with sealing surface of tank cap. Remove nicks and rough spots with emery cloth. Flush tank before refilling.

Figure 3-1. Oil Tank Filter - Exploded View

Filter clip

Cap seal washer

Filter element

Filter lower retainer

Cup spring

Cup seal

O-Ring

Valve assembly Cap gasket Cap cotter pin Cap screw Cap washer Cap nut Cap top

FL/FLH ENGINE OILING AND BREATHER SYSTEM -1972 AND EARLIER (The following steps are called out on Figure 3-2)

1. Gravity feed from tank to feed pump.

2. Feed (pressure) section of oil pump.

3. Check valve prevents gravity oil drainage from tank to engine.

4. Oil pressure regulating valve limits maximum pressure. Surplus oil is dumped back into gearcase in front of breather valve.

5. Oil is forced through pinion gear shaft to lubricate lower connecting rod bearings from which oil splashes to cylinder walls, piston, piston pin and main bearings.

6. Oil is filtered through oil screen and forced through passages or external oil lines to lubricate rocker arm bushings, shafts, valve stems, valve springs and push rod sockets. A branch passage supplies oil to the hydraulic lifters.

7. Oil is bled from bypass oil for front chain lubrication.

8. Oil drains from cylinder rocker housing through passage in each cylinder, then flows through hole in the base of each cylinder, lubricating cylinder walls, piston, piston rings and main bearings.

9. Some oil drains from the rocker housing through push rod covers into the gearcase compartment, lubricating push rods and tappets.

10. Rotary breather valve is timed to open on the downward stroke of pistons, allowing crankcase exhaust air pressure to expel scavenge oil from flywheel compartment breather valve into gearcase. Breather valve closes on upward stroke of pistons, creating vacuum in flywheel compartment.

During piston upstroke, the small port in breather valve lines up with passage in crankcase and vacuum draws oil from crankcase breather oil trap (see step 17).

11. Oil blown and drained into timing gearcase (steps 6,8 and 9), lubricates timing gears and gear shaft bearings.

12. Gearcase oil settling in gearcase sump flows to scavenge section of pump.

13. Scavenge (return) section of oil pump.

14. Engine oil return to tank.

15. Crankcase exhaust air baffle and transfer passage (in gearcase cover). Air and oil mist is forced into crankcase breather trap.

16. Breather oil trap.

17. Oil transfer passage to breather valve. On piston upstroke, crankcase vacuum draws trapped oil into breather valve.

18. Crankcase exhaust air from breather trap is forced from gearcase into breather hose.

19. Return line from chain housing. On piston upstroke, crankcase vacuum draws oil from chain housing to breather valve. On piston downstroke, oil in breather valve is forced into gearcase.

20. Vent line to oil tank and chain housing.

21. Rear chain oiler.

22. Pressure switch fitting.

FL/FLH/FX ENGINE OILING AND BREATHER SYSTEM -1973 AND LATER (The following steps are called out on Figure 3-2A)

1. Gravity feed from oil tank to feed pump.

2. Feed (pressure) section of pump.

3. Check valve prevents gravity oil drainage from tank to engine.

4. Oil is filtered through oil screen and forced through passages or external oil lines to lubricate rocker arm bushings, shafts, valve stems, valve springs and push rod sockets. A branch passage supplies oil to the hydraulic lifters.

5. Pressure regulating valve maintains correct pressure in system. When oil reaches rocker arms and lifters, regulating valve lifts and allows pressurized oil to flow to pinion gear shaft.

6. Oil is forced through pinion gear shaft to lubricate lower connecting rod bearings from which oil splashes to cylinder walls, piston, piston pin, and main bearings. During cold engine start-up, pressure regulating valve (5) lifts further to allow excess oil to return directly to oil tank.

7. Oil drains from cylinder rocker housing through passage in each cylinder, then flows through hole in the base of each cylinder, lubricating cylinder walls, piston, piston rings and main bearings.

8. Some oil drains from the rocker housing through push rod covers into the gearcase compartment, lubricating push rods and tappets.

9. Rotary breather valve is timed to open on the down-stroke of pistons, allowing crankcase exhaust air pressure to expel scavenge oil from the flywheel compartmenl through the breather valve into gearcase. Breather valve closes on upward stroke of pistons, creating a vacuum ir the flywheel compartment.

During piston upstroke, the small port in breather valve lines up with passage in crankcase and vacuum draws oil from the crankcase breather oil trap.

10. Oil blown and drained into timing gearcase (steps 8 and 9), lubricates timing gears and gear shaft bearings.

11. Front chain oil. Oil is blown into chain case when breather valve is open.

12. Gearcase oil settling in gearcase sump flows to scavenge section of pump.

13. Scavenge (return) section of pump.

14. Engine oil return to tank.

15. Crankcase exhaust air baffle and gearcase cover transfer passage. Air and oil mist is forced into crankcase breather trap.

16. Breather oil trap.

17. Oil transfer to breather valve. On piston upstroke crankcase vacuum draws trapped oil into breather.

18. Crankcase exhaust air escapes from gearcase through outside breather tube.

19. Return line from chain housing. On piston upstroke, crankcase vacuum draws oil from chain housing to breather valve. On piston downstroke, oil in breather valve is forced into gearcase.

20. Vent line to oil tank and chain housing.

21. Rear chain oiler.

22. Pressure switch fitting.

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