The thickness of bottom end crankcase on evo engine @

Blow by compression. Severe engine problems. Pull the heads look at cylinder walls

In 1993, Harley went to the "head breathing" crankcase breathing system. The crankcase pressure is vented into the air cleaner to be routed though the engine and burned. This was a requirement mandated by the EPA. Prior to '93, the crank case vent was down behind the oil pump and a pipe directed the crankcase pressure up to the air cleaner. If you have the "head breather" heads, you'll have a large hollow bolt going to each head from the air cleaner assembly. If whoever did the top end job on your engine left the umbrella valves out, installed them upside down, or put the center plates in wrong, it could be causing your problem. If they replaced the head gasket and did not replace the base gaskets, the base gasket are going to leak. Whenever you take the torque off the head bolts, you must replace all gaskets. Additionally, if the cylinder studs on your engine have not been replaced, they are probably stretched and not holding the torque like they should. In 1996, Harley came out with an improved replacement stud for the Evo engine. The large diameter part of the stud is at the lower end of the stud rather than at the top end like the older model was. If you can't get those, Colony Fasteners makes an excellent set of studs that cost about the same as H-D parts. Blue or black smoke out of the exhaust usually indicates a rich fuel mixture.

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Steve

Your crankcase is also known as the oil pan. Technically it's under the hood but is most visible from under the car as it is the bottom of the engine. It's called a crankcase because the crankshaft is inside there. To get a bit more complicated though, the crankcase is also the lower part of the engine where the crankshaft actually is housed in the engine, the oil pan actually serving as a sump for the engine oil and as a cover to keep dirt, mice and zebras from getting into the engine. When someone talks about the "bottom end" of an engine they are referring to the crankshaft, connecting rods and the bearings, all which are contained in the crankcase. Your oil drain plug is always located on the bottom or around the perimeter of the bottom of the oil pan.

Check you oil tank and see if it's nearly empty. If so, you have sheared the key in your oil pump and it's not pumping the oil out of the engine. Your '94 model is what we call a "head breather" in that your crankcase vents are up in the top of the head. If you've got enough oil to "spew" into the air filter, you've got a major problem with the top of the heads filling up with oil. The only way that can happen is they are allowing the oil to drain back down. Unless someone has been working on the engine and done something wrong, it would be because the bottom end is full of oil. For this to happen, a small key that drives the scavenger gears in your oil pump has sheared and it's not pumping the oil out of the engine or you've got an oil filter designed for a Twin Cam on your Evo engine.

Your '94 also has a plastic timing gear in it. I've seen too many of them break a tooth off the gear, the tooth gets caught in the scavenger gears and shears the key. If it's the wrong filter, the mess in the filter is too fine for the Evo style oil pump to push the oil through and it backs up in the engine. Check your oil in the tank to see if it's all in the crankcase.

Good Luck
Steve

White, thick liquid on your oil dipstick is an indicator of engine coolant leaking into your crankcase. It's a major problem that will cause your engine to be destroyed eventually, if you don't have it fixed asap.

The pcv valve (positive crankcase ventilation) will be located somewhere on the top of the engine, with a thick rubber or metal tube to it, that has the pcv valve attached at one end, and the other end will be inserted into the valve cover pan.

This is what we call "oil sumping" around here. On the soft tail line or any other line of Harley where the oil tank is higher than the oil pump, the oil will seep past the check ball in the oil pump and leak into the crankcase of the engine. When the engine is started up, it will "puke" the oil out. Now, up until the introduction of the Evo engine, the engine would puke on the ground under the bike out the breather tube. Now with the Evo engine and the EPA's regulation that crankcase ventilation fumes have to be fed back through the intake, it pukes into the breather. An even bigger mess. So, what we do whenever we think we've got this situation is put a pan under the shovelhead and panhead bikes, On the Evos and Twin Cams, we take the air breater cover and the air filter out before the fire the engine. It's a mess either way you look at it. I don't think the Twin Cams are as bad as the Evo engines due to the different type of oil pump.

Yes the bike has a drain plug at the bottom of the crankcase, however it is a (dry sump) which means there is only about one cup of oil in the crankcase, the rest is in the oil tank, the oil filter should also be in the oil tank.....The oil is likely very old and dirty.......it is very thick to start with SAE 60, and pours like syrup....the primary case (housing the primary chain) has it's own oil,about one half quart........ and the transmission has it's own oil also..about two thirds quart....there are engine flush oils, just follow instructions....