oil return lines that run vertically inside cylinder 74 HD Ironhead Sportster 1000cc - Harley Davidson Forums: Harley Davidson Motorcycle Forum
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Old 11-19-2011, 03:46 PM   #1 (permalink)
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Exclamation oil return lines that run vertically inside cylinder 74 HD Ironhead Sportster 1000cc

After boring the 2 new cylinders, for a 1974 Ironhead Sportster 1000cc, we discovered that we must make the oil return lines that run vertically inside the cylinder wall.
How could i know the correct way to do them (long and deep)? and if anybody have some pictures of a correct oil return lines in each cylinder.
Thanks.
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Old 11-19-2011, 06:54 PM   #2 (permalink)
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Old 11-20-2011, 09:46 AM   #3 (permalink)
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If your cylinders got over-bored to the point that the oil return holes got exposed I suspect your cylinders are now junk . The early 1000s were actually over-bored 900s and could only be bored an extra .020" more ! Check your cylinder bores against the service manual spec for your year and model bike .
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Old 11-20-2011, 01:22 PM   #4 (permalink)
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Exclamation They are not over bored, they are new

We instal new cylinders but we dont know how to make the oil return lines, that run vertically inside the cylinder wall.
That our problem now. We dont want to make them wrong.
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Old 11-20-2011, 01:26 PM   #5 (permalink)
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Originally Posted by imorixe View Post
After boring the 2 new cylinders, for a 1974 Ironhead Sportster 1000cc, we discovered that we must make the oil return lines that run vertically inside the cylinder wall.
How could i know the correct way to do them (long and deep)? and if anybody have some pictures of a correct oil return lines in each cylinder.
Thanks.
????
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Old 11-20-2011, 06:10 PM   #6 (permalink)
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????
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Old 11-20-2011, 07:12 PM   #7 (permalink)
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If your cylinders got over-bored to the point that the oil return holes got exposed I suspect your cylinders are now junk ....
Am out of date probably, but;
We used to send deeply gouged or otherwise "ruined" cylinders out to be bored still larger and a sleeve pressed in.
(wonder if LA sleeve co. is still in business)
Welding the old factory oil returns and relocating/drilling new may also be better left to a shop.
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Old 11-21-2011, 07:07 AM   #8 (permalink)
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Exclamation So you recomend me buying somthing new?

Nobody have the measures were i must do the holes, inside the cylinder? Im not going to do them. i going to send them to make the holes, to the same company that bored the new cylinders. Please notice that i am in Uruguay. Thanks.
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Old 11-21-2011, 07:25 AM   #9 (permalink)
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I'm at a loss here.
We've returned the oil from the head to the crankcase via external lines in larger bore applications, but for an OE bore, the internal lines as they come from the manufacturer are absolutely fine.
Scott
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Old 11-21-2011, 07:42 AM   #10 (permalink)
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Racers have been installing outside oil lines and removing fins forever .
I'm wondering why new cylinders would have to be bored out in the first place .
We used to have a place In Plymouth , WI that resleeved cylinders for us untill it got cheaper to just buy new cylinders !
I'm wondering if the PO means sizing the new cylinders to the new pistons ?
Now I'm wondering which company the PO bought the new cylinders from ? OEM ???
Lottsa questions remain on this one ????
Again the early ironhead 1000s were overbored 900s from the factory , that didn't leave much meat for the rebuild overbore , .020" max if I remember correctly . That equates to .010" total metal removal .
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