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techtalk:evo:engmech01 [2019/11/27 22:29] hippysmack [Pinion Gear Runout] |
techtalk:evo:engmech01 [2020/08/22 21:13] hippysmack [Pinion Shaft Runout] |
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====== Motor Mounts ====== | ====== Motor Mounts ====== | ||
- | [[techtalk:evo:susp05|Click here for Engine Mounts]] in the Evo Suspension section of the Sportsterpedia. \\ | + | [[techtalk:evo:engmech09|Click here for Engine Mounts]] in the Evo Suspension section of the Sportsterpedia. \\ |
====== Cylinder Mounting Studs ====== | ====== Cylinder Mounting Studs ====== | ||
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* [[techtalk:evo:engmech01k|Removing 91-03 Primary Cover]] | * [[techtalk:evo:engmech01k|Removing 91-03 Primary Cover]] | ||
+ | ===== Shifter shaft Seal ===== | ||
+ | This is a shifter shaft seal on a 1998 1200S primary cover. \\ | ||
+ | {{:techtalk:evo:engmech:98_shifter_shaft_seal_1_by_hippysmack.jpg?direct&300|}} \\ | ||
+ | {{:techtalk:evo:engmech:98_shifter_shaft_seal_2_by_hippysmack.jpg?direct&300|}} {{:techtalk:evo:engmech:98_shifter_shaft_seal_3_by_hippysmack.jpg?direct&300|}} {{:techtalk:evo:engmech:98_shifter_shaft_seal_4_by_hippysmack.jpg?direct&300|}} \\ | ||
+ | |||
+ | {{:techtalk:evo:engmech:98_shifter_shaft_seal_5_by_hippysmack.jpg?direct&300|}} {{:techtalk:evo:engmech:98_shifter_shaft_seal_6_by_hippysmack.jpg?direct&300|}} {{:techtalk:evo:engmech:98_shifter_shaft_seal_7_by_hippysmack.jpg?direct&300|}} \\ | ||
====== Engine Case / Sump Drain Plugs ====== | ====== Engine Case / Sump Drain Plugs ====== | ||
|{{:techtalk:evo:engmech:sump_drain-plug_on_04_by_bored_now.jpg?direct&300|}}| | |{{:techtalk:evo:engmech:sump_drain-plug_on_04_by_bored_now.jpg?direct&300|}}| | ||
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- | ====== Crank Assembly ====== | + | ====== Flywheel Assembly ====== |
+ | |||
+ | |Year Model ((1986-2019 HD Sportster Parts Catalogs))|Flywheel \\ Assembly|Connecting Rod \\ Assembly|Crankpin| | ||
+ | |**Early 1986 Models**| ||| | ||
+ | |E1986 XLH883|23905-86|24275-86|23960-80A| | ||
+ | |E1986 XLH1100|23900-86|24275-86|23960-80A| | ||
+ | |**Late 1986-1990 Models**| ||| | ||
+ | |L1986 XLH883|23905-86A|24275-86A|23960-80A| | ||
+ | |1987 XLH883|23905-87|24275-86A|23960-80A (std) \\ 23948-87 (.001" O.S.) \\ 23949-87 (.002" O.S.)| | ||
+ | |1988 XLH883|23905-88|:::|:::| | ||
+ | |1989-1990 XLH883|23905-88A|:::|:::| | ||
+ | |L1986 XLH1100|23900-86A|24275-86A|23960-80A (std) \\ 23948-87 (.001" O.S.) \\ 23949-87 (.002" O.S.)| | ||
+ | |1987 XLH1100|23900-87|:::|:::| | ||
+ | |1988 XLH1200|23900-88|24275-86A|23960-80A (std) \\ 23948-87 (.001" O.S.) \\ 23949-87 (.002" O.S.)| | ||
+ | |1989-1990 XLH1200|23900-88A|:::|:::| | ||
+ | |**1991-1999 Models**|||| | ||
+ | |1991-1994 XLH883|23905-89|24275-86A|23960-80A (std) \\ 23948-87 (.001" O.S.) \\ 23949-87 (.002" O.S.)| | ||
+ | |1991-1994 XLH1200|23900-90|24275-86A|23960-80A (std) \\ 23948-87 (.001" O.S.) \\ 23949-87 (.002" O.S.)| | ||
+ | |1995-1999 All Models|23905-89A|24275-86A|23960-80A (std) \\ 23948-87 (.001" O.S.) \\ 23949-87 (.002" O.S.)| | ||
+ | |**2000-2003 Models**|||| | ||
+ | |2000-2003 All Models|23905-00 \\ 23905-00A|Not Sold \\ Separate|Not Sold \\ Separate| | ||
+ | |**2004-up Models**|||| | ||
+ | |2004-2005 All Models|23905-04|Not Sold \\ Separate|Not Sold \\ Separate| | ||
+ | |2006-2009 All Models \\ (Except XR1200)|23905-04A|Not Sold \\ Separate|Not Sold \\ Separate| | ||
+ | |2010-2019 All Models \\ (Except XR1200/X)|23905-04B|Not Sold \\ Separate|Not Sold \\ Separate| | ||
+ | |2009-2013 \\ XR1200 / XR1200X|23999-08|Not Sold \\ Separate|Not Sold \\ Separate| | ||
===== 95-99 ===== | ===== 95-99 ===== | ||
The same flywheel set was used in all Sportsters 95-99. \\ | The same flywheel set was used in all Sportsters 95-99. \\ | ||
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Each flywheel casting number (23931-88A) \\ | Each flywheel casting number (23931-88A) \\ | ||
Connecting rod set: part number (24275-86A) \\ | Connecting rod set: part number (24275-86A) \\ | ||
- | Left connecting rod casting number (24320-83) \\ | + | Front connecting rod casting number (24321-83) \\ |
- | Right connecting rod casting number (24321-83) \\ | + | Rear connecting rod casting number (24320-83) \\ |
Rod bearing set (24354-87A) \\ | Rod bearing set (24354-87A) \\ | ||
Rod bearing race - front (2)-(24341-52A) \\ | Rod bearing race - front (2)-(24341-52A) \\ | ||
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===== 00-03 ===== | ===== 00-03 ===== | ||
- | | Flywheel assembly 23905-00 ((photo by AussieGazza of the XLFORUM http://xlforum.net/forums/showthread.php?t=692835&page=7)) | | + | | Flywheel assembly 23905-00 ((photo by AussieGazza of the XLFORUM http://xlforum.net/forums/showthread.php?t=692835&page=7)) | Flywheel assembly 23905-00A ((photo by Wilbur of the XLFORUM http://xlforum.net/forums/showthread.php?t=657090)) | |
- | |{{:techtalk:evo:engmech:flywheel_assembly_23905-00_by_aussiegazza.jpg?direct&300|}}| | + | |{{:techtalk:evo:engmech:flywheel_assembly_23905-00_by_aussiegazza.jpg?direct&300|}}|{{:techtalk:evo:engmech:flywheel_assembly_23905-00a_by_wilbur.jpg?direct&300|}}| |
- | + | ||
- | | Flywheel assembly 23905-00A ((photo by Wilbur of the XLFORUM http://xlforum.net/forums/showthread.php?t=657090)) | | + | |
- | |{{:techtalk:evo:engmech:flywheel_assembly_23905-00a_by_wilbur.jpg?direct&300|}}| | + | |
====== Flywheels ====== | ====== Flywheels ====== | ||
- | 91-99 (all) Flywheels. \\ | + | **Late 1986 flywheels and crankpin bearing changes**. \\ |
- | Flywheel set part number (23905-89A). \\ | + | Information from Technical Service Bulletin #M-927. [[techtalk:miscres:miscres05#tsb_900-949|Click here to see the actual bulletin from this page in the Sportsterpedia]]. \\ |
+ | Beginning with crankcase numbers 883cc (1786 083 003) and 1100cc (1886 090 012), a new (F.A.G.) crank pin bearing set and revised flywheels were installed at the factory. \\ | ||
+ | The new crank pin bearing set (using the existing crankpin P/N) consists of three bearings in a package. Early production engines were assembled without thrust washers. \\ | ||
+ | L1986-later production flywheels had thrust washers staked into a counter-bore in the flywheels. The L86 crank pin bearing set retrofits earlier models. \\ | ||
+ | However, the new bearings require a stepped flywheel thrust washer to provide clearance for the wider bearing cages. \\ | ||
+ | You will select the correct thrust washer for your particular assembly and machine off the raised lip in the area of the flywheel thrust washers' I.D. \\ | ||
+ | This lip must be machined off or you will crush the bearing cage as you assemble and torque the crankpin nuts. \\ | ||
+ | [[techtalk:miscres:miscres04#tech_tips_0-199|See Tech Tip #14]], [[techtalk:miscres:miscres08#bottom_end|Instruction Sheet #J00022]] and [[techtalk:miscres:miscres08#bottom_end|Instruction Sheet #J00025]] in the Sportsterpedia for more information. \\ | ||
+ | |||
+ | The L86 XLH883 flywheel assembly is (23905-86A) and the L86 XLH1100 flywheel assembly is (23900-86A). \\ | ||
+ | There were new crank pin bearing clearances also. \\ | ||
+ | The new crank pin bearing set packages were color coded with either a red or a blue identification. This color coding is used by the bearing manufacturer only. \\ | ||
+ | The color coding DOES NOT indicate size selection for crank pin bearing replacement. \\ | ||
+ | |||
+ | **1989 flywheel changes**. \\ | ||
+ | Information from Technical Service Bulletin #M-971. [[techtalk:miscres:miscres05#tsb_950-999|Click here to see the actual bulletin from this page in the Sportsterpedia]]. \\ | ||
+ | Beginning June 1, 1988, flywheels forged from a micro-alloyed steel went into production. Part numbers and color codes of assemblies with the new material were changed. \\ | ||
+ | |||
+ | **1991-1994 Flywheels**. \\ | ||
+ | From '91 to '94 the Crankshaft/Flywheel was balanced according to the engine size, either for 883 pistons or 1200 pistons. From 1995-later, the flywheels are balanced to be between the weight of the 883 & 1200 pistons. ((http://hammerperf.com/883conversions.shtml)) This is one reason why riders would use Wiseco pistons in early (pre-2004) 883 to 1200 conversions - the Wiseco 1200 piston & pin was closer to the weight of the 883 combination rather than the stock 1200 piston & pin from HD. | ||
+ | |||
+ | **1995-1999 Flywheels**. \\ | ||
+ | Flywheel assembly part number (23905-89A). \\ | ||
Each flywheel casting number (23931-88A). \\ | Each flywheel casting number (23931-88A). \\ | ||
- | | 91-99 Flywheels ((photos by Hippysmack)) || | + | | 95-99 Flywheels ((photos by Hippysmack)) || |
- | |{{:techtalk:evo:engmech:91-99_flywheels_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:91-99_flywheels_2_by_hippysmack.jpg?direct&300|}}| | + | |{{:techtalk:evo:engmech:95-99_flywheels_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:95-99_flywheels_2_by_hippysmack.jpg?direct&300|}}| |
- | | Crank pin boss washer (5608) ((photos by Hippysmack)) || | + | | L1986-up crank pin boss washer (6508) ((photos by Hippysmack)) || |
|{{:techtalk:evo:engmech:crank_pin_boss_washer_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:crank_pin_boss_washer_2_by_hippysmack.jpg?direct&300|}}| | |{{:techtalk:evo:engmech:crank_pin_boss_washer_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:crank_pin_boss_washer_2_by_hippysmack.jpg?direct&300|}}| | ||
- | From '91 to '03 the Crankshaft/Flywheel was balanced according to the engine size, either for 883 pistons or 1200 pistons. From 2004-later, the flywheels are balanced to be between the weight of the 883 & 1200 pistons. ((http://hammerperf.com/883conversions.shtml)) This is one reason why riders would use Wiseco pistons in early (pre-2004) 883 to 1200 conversions - the Wiseco 1200 piston & pin was closer to the weight of the 883 combination rather than the 1200 piston & pin from HD. | + | |
\\ | \\ | ||
====== Crank Pin ====== | ====== Crank Pin ====== | ||
- | Crank pin (23960-80a) used from L81-03. \\ | + | Crank pin (23960-80A) used from L1981-2003. \\ |
| L87-03 crank pin ((photos by Hippysmack)) ||| | | L87-03 crank pin ((photos by Hippysmack)) ||| | ||
|{{:techtalk:evo:engmech:l81-03_crank_pin-1_23960-80a_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:l81-03_crank_pin-2_23960-80a_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:l81-03_crank_pin-3_23960-80a_by_hippysmack.jpg?direct&300|}}| | |{{:techtalk:evo:engmech:l81-03_crank_pin-1_23960-80a_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:l81-03_crank_pin-2_23960-80a_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:l81-03_crank_pin-3_23960-80a_by_hippysmack.jpg?direct&300|}}| | ||
+ | **2004-Later**: \\ | ||
+ | The sprocket shaft nut torque for 2004 & later Sportsters and 2003 & later Buell XB models has been changed. ((HD Tech Tip #211 dated September 16,2005)) \\ | ||
+ | The torque has been increased from 190-210 ft-lbs. to 240-260ft-lbs. \\ | ||
+ | Remember to clean the threads and generously apply LOCTITE Threadlocker 262 (red) onto the threads of engine sprocket shaft and use a sprocket locking tool. \\ | ||
+ | Some examples of sprocket locking tools are [[http://www.sportsterpedia.com/doku.php/techtalk:ref:tools116|here in the tools section]] of the Sportsterpedia. \\ | ||
====== Connecting Rods ====== | ====== Connecting Rods ====== | ||
+ | Rod set (24275-86A) includes bearings, crankpin and nuts. \\ | ||
+ | Below are pics of just the rods off a 1998 1200S model. \\ | ||
+ | The part numbers cast into the rods are front (24321-83) and rear (24320-83). \\ | ||
|{{:techtalk:evo:engmech:connecting_rods_5_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:connecting_rods_3_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:connecting_rods_1_by_hippysmack.jpg?direct&300|}}| | |{{:techtalk:evo:engmech:connecting_rods_5_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:connecting_rods_3_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:connecting_rods_1_by_hippysmack.jpg?direct&300|}}| | ||
- | |||
|{{:techtalk:evo:engmech:connecting_rods_4_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:connecting_rods_6_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:connecting_rods_2_by_hippysmack.jpg?direct&300|}}| | |{{:techtalk:evo:engmech:connecting_rods_4_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:connecting_rods_6_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:connecting_rods_2_by_hippysmack.jpg?direct&300|}}| | ||
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===== Pinion Shaft Runout ===== | ===== Pinion Shaft Runout ===== | ||
+ | Check to see if your crank is out of true. The idea is to measure how much the end of the pinion shaft wobbles. ((aswracing of the XLFORUM http://xlforum.net/forums/showthread.php?t=1578649)) \\ | ||
+ | Up to .005"-.006" out there at the end of the shaft doesn't propose a huge problem. Most motors you measure will show this much. \\ | ||
+ | But above that is not good. Crank spread is a reality of racing these bikes. The flywheels want to spread apart on the side opposite the crankpin. \\ | ||
+ | When they do, the pinion shaft wobbles. You get real bad wear on the oil pump drive gear (this is why Buell went to a bronze drive gear). \\ | ||
+ | Harley never put it in the XL's because they're lower powered and it's less of an issue. But still sometimes they grenade and make a mess. \\ | ||
+ | Pinion shaft wobble also causes teeth to break off the pinion gear, and the pinion bushing to wear, and cam bushings to wear. \\ | ||
+ | To confirm pinion shaft runout dims, make the measurement as in below. \\ | ||
+ | |||
|Attach a scrap piece of metal to the outside of the gearcase and position a gauge holder on it so it won't move while turning over the engine. ((photos by anachris of the XLFORUM ))||| | |Attach a scrap piece of metal to the outside of the gearcase and position a gauge holder on it so it won't move while turning over the engine. ((photos by anachris of the XLFORUM ))||| | ||
|{{:techtalk:ref:tools:checking_pinion_shaft_runout_1_by_anachris.jpg?direct&300|}}|{{:techtalk:ref:tools:checking_pinion_shaft_runout_2_by_anachris.jpg?direct&300|}}|{{:techtalk:ref:tools:checking_pinion_shaft_runout_3_by_anachris.jpg?direct&300|}}| | |{{:techtalk:ref:tools:checking_pinion_shaft_runout_1_by_anachris.jpg?direct&300|}}|{{:techtalk:ref:tools:checking_pinion_shaft_runout_2_by_anachris.jpg?direct&300|}}|{{:techtalk:ref:tools:checking_pinion_shaft_runout_3_by_anachris.jpg?direct&300|}}| | ||
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|{{:techtalk:ref:tools:checking_pinion_shaft_run-out_1_by_dirtycory.jpg?direct&300|}}|{{:techtalk:ref:tools:checking_pinion_shaft_run-out_2_by_dirtycory.jpg?direct&300|}}| | |{{:techtalk:ref:tools:checking_pinion_shaft_run-out_1_by_dirtycory.jpg?direct&300|}}|{{:techtalk:ref:tools:checking_pinion_shaft_run-out_2_by_dirtycory.jpg?direct&300|}}| | ||
+ | ====== Crankshaft Seal ====== | ||
+ | Here is a trick to hold the spring in place to stop it popping off while you are fitting the seal. ((DEEP DIVER of the XLFORUM http://xlforum.net/forums/showthread.php?p=5489312&highlight=main+seal#post5489312)) \\ | ||
+ | Before fitting it, pack some grease around the spring in the seal groove. You only need a small amount. \\ | ||