I have a 04 sportster (883) which is just rebuilt with these parts from NRHS:

Axtell 1250 kit
NRHS XB style stage 3 ported heads
NRHS 0.40 shorter pushrods for XB heads
NRHS Hurricane oil filter/cooler ( nrhsperformance.com/partslubrication.shtml )

I have just assembled the engine, and I have started it 3-4 times, running it for 10-20 seconds each time only. The engine seems to be ok, except from one detail:

When I turned the ignition on for the first time after assembling the engine, the oil light would not lit. I found out that the oil pressure switch was broken (constantly 2-300 ohms with an ohmmeter), and replaced it with a new one.

Now, the oil light lights up when I switch on the ignition. The oil light goes dark when the engine starts, or even when I turn the engine for some seconds with the starter, with spark plugs disconnected, indicating that oil pump works fine.

The problem is this:
When I STOP the engine, the oil light will not turn on again. It stays off for about 15-20 minutes before it lits up.

I know from the service manual that it could take "some time" before the oil light goes on again due to pressure build-up in the oil filter housing. However, from what I can remember, before rebuilding my engine, the oil lamp turned on as soon as I stopped the engine.

So my question is: What causes this change in oil light behaviour?

Has anyone seen similar oil lamp behaviour? Is this normal, or is it a chance that the lubrication system is clogged somewhere "after" the oil filter/oil light pressure switch? How can I troubleshoot this?

Could it be that the Hurricane oil filter / cooler unit causes this, since it has (or at least, it seems to have) smaller internal volume than a stock oil filter?

Could it be that the new cylinders/heads/pushrods cuases this problem? In case... why?

Could it be that this happens only when the engine is "cold" because the oil is thicker cold than warm?

Anyone have a clue on what I should do? As you all understand, I'm very afraid to blow my "all new" and pretty expensive engine...

Any ideas, hints and tips are welcome!

Thanks,
kib_norway

Forgot to mention this:
After stoping the engine, loosening the oil filter just a little bit created a "fffsssshhhh" sound (like when opening a coke bottle) from releasing the pressure in the filter, causing the oil pressure light to go "red".

Also, when removing the (newly installed) oil filter, I see that there is alot of oil in it, indicating that the oil pump actually works.

That pressure release when you crack open the filter would worry me...that doesn't seem right, but I don't have much experience with these engines as far as internals go - I've just never experienced somethng like that on any engine I've worked on.

As far the light staying off, I know mine (stock 1200) will stay for a good 5 to 10 seconds after i shut down the engine, but 20 minutes seems a bit excessive. It sounds like something isn't flowing like it's supposed to be.

Let's see what someone with a little more know how has to say.

check in the oil tank for circulation while it's running.
you may have a restriction in a passage somewhere

check in the oil tank for circulation while it's running.
you may have a restriction in a passage somewhere

If there's a restriction somewhere in the oil system, how smart is it to start the bike?

What if it's not getting oil out to the engine at all? Running it without lubrication isn't very smart, I've been told...

Being a newbie to HD's, this problem confuses me, and I need every input/help/advice I can get...

Thanks,
kib_norway

well you could pull a rocker cover an see if there is any oil in there

well you could pull a rocker cover an see if there is any oil in there

Ok, so if it's oil in the rocker boxes, we're sure that the engine gets oil, and it is "safe" to run it for a short while for troubleshooting this?

Next step would be checking for circulation in the oil tank, right? Should this be done by looking down the oil tank filler hole, or by disconnecting the return line that goes back into the oil tank, to see if it squirts oil when turning the engine?

The most confusing about this is really what the service manual says about this... it clearly says that it is normal that the pressure builds up in the filter housing (in other words where the oil pressure switch is located) and that this pressure will be there for "a while" after stopping the engine... problem is that it doesn't say how many seconds or minutes one can expect "a while" to be :doh

Anyone seen or heard/read about similar problems?

Harley had problems with the oil pressure switches on the '04 and later Sportsters. I've had mine replaced once under warranty, and I'm sure there's a lot of folks here on the board that have had their's replaced at least once, if not more! The operation of the switches are very erratic, and vary between individual units. They are cheap crap, but that's the cards we're dealt.

If it's not too much trouble, why don't you pick up one more, just to see what kind of indication it gives you. Alternately, you could hook up a temporary mechanical pressure gauge pretty easy to see what's really going on in there. I'd be leaning that way myself, at least until I was satisfied that all was cool. :D

Oh, by the way, sounds like a real nice bike!

That pressure release when you crack open the filter would worry me...that doesn't seem right, but I don't have much experience with these engines as far as internals go - I've just never experienced somethng like that on any engine I've worked on.

As far the light staying off, I know mine (stock 1200) will stay for a good 5 to 10 seconds after i shut down the engine, but 20 minutes seems a bit excessive. It sounds like something isn't flowing like it's supposed to be.

Let's see what someone with a little more know how has to say.

The service manual indicates that pressure build-up in the filter could occur on these engines. When looking on the oil system fold-out diagram in the service manual, this seems logical, since the setup is like this:

Oil pump --> oil filter / oil pressure switch --> pressure valve --> "rest of the engine".

(Anyone know if it is a pressure valve between the oil filter / oil pressure switch and the rest of the engine in pre-04 sportsters?)

So, if the pressure valve between the filter/oil pressure switch and the rest of the engine closes at a higher pressure than what's needed to keep the oil pressure switch to "off" position (in other words: it's enough pressure on the switch to keep indicator lamp switched off), then the lamp will stay "off" until the pressure in this area of the oil system goes down, either by "leak" back thorugh the oil pump or by leak in the pressure valve to the rest of the oil system.

Problem is, my understanding of this is "in theory" only... I don't at all know how these things are supposed to work "in real life"...

Anyone with thoughts about this problem, please post!

Thanks,
kib_norway

You know, since you spent all this money with NRHS, why don't you touch base with Aaron and the bunch, I'm sure they'd be happy to talk you through this.. very knowledgable group of folks, and they are very interested in their customers being happy!

You know, since you spent all this money with NRHS, why don't you touch base with Aaron and the bunch, I'm sure they'd be happy to talk you through this.. very knowledgable group of folks, and they are very interested in their customers being happy!

I sent them (Dan) a mail about this this morning, Norway time... guess they'll reply as soon as they're reading their mail - have received great service from them earlier!

The reason I post this question here is to get everyones view, and also to share the problem/solution with the rest of the sportster community.

Love this site!

Harley had problems with the oil pressure switches on the '04 and later Sportsters. I've had mine replaced once under warranty, and I'm sure there's a lot of folks here on the board that have had their's replaced at least once, if not more! The operation of the switches are very erratic, and vary between individual units. They are cheap crap, but that's the cards we're dealt.

If it's not too much trouble, why don't you pick up one more, just to see what kind of indication it gives you. Alternately, you could hook up a temporary mechanical pressure gauge pretty easy to see what's really going on in there. I'd be leaning that way myself, at least until I was satisfied that all was cool. :D

Oh, by the way, sounds like a real nice bike!

Good idea! I've also heard others complaining about their pressure switches breaking. I'll get another switch (maybe an aftermarket switch?), and also see if I can get ahold of a pressure gauge to check "real" pressure.

FYI, the replacement pressure switch I got is slightly different from the one that originally was on my 04. The new one (still an original HD part) has a shorter "metal housing" than the original one. It may be from a pre-04 production lot? (when google'ing the part number on the package I see that this part number goes for older models as well)

The bike looks like hell because of a little accident last fall (scratches and dents all over it), but that doesn't matter as it will probably GO like hell as well with this NRHS kit :laugh

NRHS response:

Dan at NRHS tells me this:
1. It's propably just residual pressure in the filter housing after stopping engine - nothing to worry about.
2. Problems with the oil supply would cause VERY loud noise from the lifters
3. Removing the rocker box covers and checking for oil there would confirm that everything is ok.

I'll check for oil in the rocker boxes (as also suggested by a45junkie - thanks), and let you all know the result.


Thanks to you all for feedback and help. I'm learning something new every day!

Or rather: It wasn't a problem after all!

I removed the front rockerbox cover, but there was hardly any oil in there at all... allmost completely dry.

I called Dan at NRHS, and he told me that this was quite normal, since I'd ran the engine for 10-20 seconds a few times only.

So what he told me to do was to let the engine run for a minute or two, and let it rev upp a little bit.

I did so, and after a little while, the oil came squirting out from the rocker arms! Also, riny bubbles appeared in the oil tank, indicating that the oil circulated through the entire system.

When shutting the engine off, it still took a while before the oil pressure indicator lamp turned on, but it seemed to turn on quicker now.

I did drop by my local dealer today and got another oil pressure switch... I'll put that in there later to see if it makes any difference - as someone in here mentioned, these switches MAY open/close at at slightly different pressure, and this COULD be the reason why the switch I have in there now takes such a long time to close.

Anyway.... everything seems to be OK, and I've learned more about how my bike works... thanks to everyone in here pointing me in the right direction, and to Dan at NRHS for excellent service once again!

:clap

Problem solved:

After running the bike for a few km's, the oil lamp now turns on as soon as I stop the engine.

Seems like the new oil switch just needed a short break in period to work properly when cutting the oil pressure.

Everything is OK, and the engine runs fine!

Thanks to everyone for helping!

My light wasn't working , so I got a new one from my dealer (£11). I fitted it, switched on the ignition, light was on, I fired her up and ran a minute or so, switched off 15 minutes later, switched on again, light still off, so I phoned the dealer, spoke to the mechanic, who said that when cold they will stay off for 20-25 minutes as the oil pressure stays in that part of the system. You can check if the pump is working, listen to the engine, if there isn't any oil getting to the lifters, they will rattle, stop the engine immediately! You can also see the oil returning if you lift the dipstick out.:tour

When changing oil the other day, the problem occured again.

Oil light would not lit when shutting engine off. Took several minutes for it to get back on.

However, just as the last time, after a few miles of running, everything works like normal again. Light switches off as soon as I shuts off the engine.

Don't know what causes this, but as long as it causes no harm, I really don't care.

By the way: The 1250 / stage III XB heads / 536 cams / SE ignition I bought from NRHS works GREAT!

Haven't dynoed it yet, but it runs like hell! Reminds me of a two stroke engine when the power kicks in at 4500 rpm and above - it gets really wild!!!!

Anyone thinking about getting more horsepower: Go NRHS!!!

The oil pressure switch is on the line between the oil pump and the drainback check valve.

It takes a few lbs of pressure to get past the check valve, so it would take a little bit of time for pressure to go down after shutdown as any residual pressure would have to seep thru the check valve and go backwards thru the oil pump gears.....

A mechanical oil pressure guage would be useful on these bikes IMHO.

Sounds like there's an air bubble in the system (filter?) that needs to be vented out by running with flow for a while. The compressed air bubble with decompress gradually with backflow through the system.

How DOES trapped air leave our partially filled horizontal elements, anyhow??