Isn't gear 25 here the plastic breather gear that a lot of people talk about replacing on these engines? Interesting. Excited to see the stuff I've just been reading about.

 

No, 25 in the diagram is the oil pump shaft driven gear, which is driven by the pinion gear that is on the pinion shaft of the wheels (crank shaft) the breather gear is in the cam chest and is timed with the cam.. Let us know when you pull the cam chest apart and take a lot of pictures but it's starting to sound like cam bearing failure... Don't run it any more.
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Two things on the photos - the cam cover gasket is for a '93-up on a '92 and earlier engine case. Top breather vs bottom breather so don't get the 2 confused. Second, the oil pump diagram is for a '91-up Softail and the cover (15) is different from a '90. Otherwise, except for a very slight bolt pattern change in '92, the oil pump internals are all the same.

But from your recent information, besides correcting whatever fouled the oil pump, I'd say at the very least a top end rebuild, is probably where you need to have your thoughts.

 

Big metal burr on the crankshaft?


Orange washer was just laying there when I popped cover off. Literally sticking right where it is in the photo.

 

Lots of broken metal shrapnel in the bottom of this gear case. I guess I'm going to start stripping down the bike to pull the engine out!

 

The pinion inner race walked out on the shaft, gear caught the lock ring and chewed it. Sorry to say, engine is coming out to split cases and repair the flywheel. There's been a rash of that happening this year it seems.

 

Yup complete R&R sorry bud

 

Right on. Been tearing down the bike this afternoon jamming out to tunes in the garage! This is why I built it!

Been contemplating finding a donor Evo motor or buy a S&S to put in while I do the rebuild and aquire tools.

 

Can anyone give me a rough idea of a parts list to order for this job?

 

Strip it all down before worrying about parts, once you know what’s going on then we can play with a number of options for you. This could vary a lot is why.