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[ultrafxr]

I guess the moco would refer to that as a porous casting, lol.  Good that you caught it before buttoning up the motor.  That' s causing some serious sumping for certain.  But I'd think this is an anomaly albeit a very serious one.  Wouldn't think this is typical of M8 motors that are sumping.

[hrdtail78]

I guess the moco would refer to that as a porous casting, lol.  Good that you caught it before buttoning up the motor.  That' s causing some serious sumping for certain.  But I'd think this is an anomaly albeit a very serious one.  Wouldn't think this is typical of M8 motors that are sumping.

Easy enough to check.  Collapse tubes, take out plugs, and crank engine.  If oil bubbles out of the cover.  You have a problem.  I am inclined to do this before the cost of taking engine apart and do some labor intensive modifications that would turn out just to be a Band-Aid if the supply side was never addressed.

[charles05663]

If it is a systematic casting flaw, HD has some major issues.  It is going to cost HD and/or their suppliers big time.

On the other hand, if someone was to tear down their engine, HD could/would claim that the violated their warranty and it was not their fault.
 

[RivRaptor]

Wow.....interesting find

[J.D.]

This is an absolutely incredible discovery.  Significant volume of hot oil will certainly move through that hole at operating temperature/pressure.

 

[harleytuner]

This is an absolutely incredible discovery.  Significant volume of hot oil will certainly move through that hole at operating temperature/pressure.

 

True that.  I wonder how much oil the top end was robbed.

[98fxstc]

I guess the moco would refer to that as a porous casting, lol.  Good that you caught it before buttoning up the motor.  That' s causing some serious sumping for certain.  But I'd think this is an anomaly albeit a very serious one.  Wouldn't think this is typical of M8 motors that are sumping.

Could be an anomaly in this particular casting or a problem with the mold which would give rise to a problem with all of the castings from that mold.

[mark]

Could be an anomaly in this particular casting or a problem with the mold which would give rise to a problem with all of the castings from that mold.

"They all do that."

[Tn.Heritage]

Can this area be stopped up with something that would eliminate the excessive flow ?

[Phantom309]

Isn't that nice? ... typical quality work/parts from HD. Clean all the oil off real good, slap on some JB Weld and it'll be better than any fix the dealer would do for you ... or put you through.

[Skipper]

OK. What you are saying is, that particular casting flaw is what cause engine to Sump?

Skipper 

[wfolarry]

good catch. Definitely can see how that would be a problem.

[J.D.]

For reference, on the twin cams, there was a design change in 2000 to add an extra oil passage to the camplate.  If you use the later (2000-2006) design camplate on the 1999 models, this extra oil passage, like a 1/4" diameter hole, needs to be plugged.  If not plugged, it blows oil directly into the camchest via this unplugged passage.  I helped a guy diagnose this after he upgraded his camchest and didn't plug this hole.  Just at idle, his engine would completely suck the oil pan dry and fill the camchest in about 40 seconds and sump it.

https://manualzz.com/doc/6336069/instructions---harley

[hrdtail78]

I don't see why someone couldn't stick a 15/64 brass rod covered in Vaseline down the drill oil passage.  Grind out the powder coat and pour some high speed two part epoxy into the casting void.  Something with 3960 psi and could take up to 550 temp.  I have never seen any two part come apart in pieces.  If it failed I think it would come as one piece because it got detached from casting material.  With the location of the anti rotation block covering this void.  I can't see it going any where and the problem would be back to the leak.  The S&S blocks do cover more of the void but the stock blocks would work the same.

[CJ CYCLE]

Not exactly sure how a 2 cylinder 9 valve engine will work

Milwaukee 16 is in the the works!