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Oil System Evaluation & Upgrade (Read 620 times)
DragBikeMike
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Re: Oil System Evaluation & Upgrade
Reply #15 - 09/24/23 at 22:06:32
 
This shows the bypass relief disk.  It doesn’t regulate pressure.  It simply opens when the differential pressure is too high.  When the relief opens, it allows oil to bypass the filter.  The seating area is 11mm.
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Re: Oil System Evaluation & Upgrade
Reply #16 - 09/24/23 at 22:07:07
 
This shows the internal components of the bypass relief.
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Re: Oil System Evaluation & Upgrade
Reply #17 - 09/24/23 at 22:08:06
 
At installed height, the spring exerts about 3.7 lbs of force.  It’s simple to calculate how much differential pressure is required to open the bypass.  It should take about 25 psid.  The keyword here is “differential”.  Remember there is pressure both upstream and downstream of the disk.  The pressure downstream of the disk is working to keep the disk on its seat, the pressure upstream of the disk is trying to lift (open) the disk.  So, if I am reading system pressure downstream of the filter, the lift point for the bypass will be system pressure plus 25.  For instance, if the system pressure is 10 psi, then the pressure at the pump discharge would have to reach 35 psi before the bypass lifts.

58.6 ounces is 3.7 lbs.  An 11mm diameter seating area is 0.15 square inches.  So, 3.7 lbs over 0.15 square inches works out to 24.7 psi.
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Re: Oil System Evaluation & Upgrade
Reply #18 - 09/24/23 at 22:08:40
 
Oil is fed through the right side of the crankshaft to lubricate the bottom end (connecting rod, transmission gear-teeth & bearings, and the cylinder & piston).  The oil seal in the clutch cover mates with the end of the crankshaft.
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Re: Oil System Evaluation & Upgrade
Reply #19 - 09/24/23 at 22:09:17
 
The seal journal on the right side of the crankshaft is critical.  It must be in perfect condition to ensure there are no leaks.  The journal spins upward of 6000 rpm, so the surface finish must be smooth and free of nicks.  I’ve seen a lot of these seal journals damaged from inexperienced mechanics beating on them with a hammer or punch.  Never strike the end of a crankshaft.  It wrecks the crank.

This journal is damaged, but I think it can be salvaged.
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Re: Oil System Evaluation & Upgrade
Reply #20 - 09/24/23 at 22:10:02
 
The oil gets pumped through the crankshaft and into the rod bearing.  There are drain notches in the sides of the rod that permit the oil to escape.  That oil gets thrown all over inside the bottom end, wetting down the cylinder, underside of the piston, wrist pin, and the transmission gear teeth.

This picture shows a five-speed trans.  See how 4th gear (circled in yellow) & 5th gear (circled in red) do not align with the rod drains.   Ride this thing on the freeway and you spend a lot of time in top gear.  The gear will get hot.  It would be nice to have a steady supply of cool oil rather than the random few droplets that find their way into the mesh.   If you make decent power, both of these gears start to pit.
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Re: Oil System Evaluation & Upgrade
Reply #21 - 09/24/23 at 22:10:38
 
The top end circuit runs up through drilled passages in the cylinder, cylinder head, and head cover.  At the very top, you can see my pressure tap for the oil pressure gage.
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Re: Oil System Evaluation & Upgrade
Reply #22 - 09/24/23 at 22:11:16
 
The oil enters the cylinder at the bottom.  This is the drilled passage.  It is located in the right-rear corner of the cylinder.
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Re: Oil System Evaluation & Upgrade
Reply #23 - 09/24/23 at 22:12:04
 
At the top of the cylinder, there is an unusual keyhole shaped passage that allows the oil to flow sideways until it lines up with the drilled passage in the head.  Note there is a threaded hole at the end of the keyhole shaped passage.  That threaded hole is for the long 130mm bolt that secures the head cover.  The bolt runs all the way through the head cover and head.  It runs directly through the oil feed passages.  Those internal threads in the cylinder routinely strip.
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Re: Oil System Evaluation & Upgrade
Reply #24 - 09/24/23 at 22:12:50
 
The top end oil continues upward through the cylinder head.  The green arrow shows the hole in the cylinder head that mates with the unique keyhole passage in the cylinder.  You can see the keyhole impression from the embossed steel head gasket.
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Re: Oil System Evaluation & Upgrade
Reply #25 - 09/24/23 at 22:13:30
 
The oil travels straight up through the cylinder head and exits here.  It hasn’t lubricated anything yet.
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Re: Oil System Evaluation & Upgrade
Reply #26 - 09/24/23 at 22:14:11
 
Then the oil enters the head cover.  There is a network of drilled passages in the head cover.  Those passages direct oil to the upper half of the cam bearings.
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Re: Oil System Evaluation & Upgrade
Reply #27 - 09/24/23 at 22:14:53
 
The upper halves of the cam bearings are incorporated into the head cover.  These are the first items to receive lubrication.
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Re: Oil System Evaluation & Upgrade
Reply #28 - 09/24/23 at 22:15:51
 
Right at the horizontal split, each cam bearing has heavy chamfers.  These chamfers are important parts of the lubrication flow path.  You don’t want the chamfers filled in with sealant or debris.

The chamfers on the left-side (yellow) direct oil into a cavity adjacent to the camshaft.  This cavity is pressurized which forces the oil to run through the hollow camshaft.

The chamfers on the right-side (green) direct oil into a reservoir below the cam lobes.  I call it the trough.  The trough (or reservoir) fills with oil.  As the cam rotates, the lobes dip into the trough (like a paddlewheel), pick up oil, and continue around to the cam followers.  The oil coating the cam lobe lubricates the cam followers and cam lobes.  The followers & lobes are subjected to heavy load as the cam actuates the rocker arm and opens the valves.  Each valve spring requires about 130 lbs of force to fully open, so the rocker arm must overcome about 260 lbs of force.  The rocker arms are about 1.4:1 ratio, so the required force is now increased to about 364 lbs.  Torture.
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Re: Oil System Evaluation & Upgrade
Reply #29 - 09/24/23 at 22:16:40
 
This is the trough (or reservoir).  You can see that the cam lobe is well coated with oil.  This is a picture of a 1995 DR650 cam.  I made the mistake of installing it without drilling holes in the lobes.  More on that later.  I just want to give you an idea of exactly how the oil trough lubricates the cam lobes.
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