Differences

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--- techtalk:evo:engmech01 [2022/04/01 03:54]
hippysmack [Cam / Gearcase Cover]
+++ techtalk:evo:engmech01 [2022/10/07 22:19]
hippysmack [Cam Cover Gasket]
@@ Line 24: / Line 24: @@
 Threads: 5/8"-18 x .350" with 3/8" Hex Socket (Allen) Head. \\
-Click on a pic to enlarge: ((photos courtesy of Ebay seller, Sum-body's Harley Parts, [[https://www.ebay.com/str/sumbodysharleyparts|Link to Ebay Store]] )) \\
+{{:techtalk:ref:oil:fitting_720_timing_hole_plug_by_sum-body1_pic1.jpg?direct&300|}} ((photos courtesy of Ebay seller, Sum-body's Harley Parts, [[https://www.ebay.com/str/sumbodysharleyparts|Link to Ebay Store]] )) {{:techtalk:ref:oil:fitting_720_timing_hole_plug_by_sum-body1_pic2.jpg?direct&300|}} ((photos courtesy of Ebay seller, Sum-body's Harley Parts, [[https://www.ebay.com/str/sumbodysharleyparts|Link to Ebay Store]] )) \\
-{{:techtalk:ih:engmech:1972-2003_sportster_timing_hole_plug_720_by_sum-body1_pic1.jpg?direct&300|}} {{:techtalk:ih:engmech:1972-2003_sportster_timing_hole_plug_720_by_sum-body1_pic2.jpg?direct&300|}} \\
 ====== Primary Compartment ======
+===== Primary Cover Gasket =====
+Below is a list of factory gaskets used on Sportster primary covers. \\
+Pics of the different part numbers are listed to the right in the chart. Click on the link to open a picture of the part. \\
+^{{techtalk:miscres:instruction_sheet_header_4.png?nolink&803|}}||||
+|Year Model|Part#|Notes|Pics|
+|1977-1990 Sportster|34955-75|
+|1991-2003 Sportster|34955-89 \\ 34955-89A \\ 34955-89B|-89A replaced original in 1994. ((1994 HD Sportster parts catalog)) \\ -89B shows up in 2013 (-B) series parts catalogs.|{{ :techtalk:evo:engmech:1991-2003_sportster_primary_cover_gasket_34955-89_by_bikersnos_pic1.jpg?linkonly |-89}} ((photo courtesy of BIKERSNOS.com. [[https://www.ebay.com/str/bikersnos?_trksid=p2047675.m3561.l2563|Link to Ebay Store]] ))|
+|2004-Present Sportster|34955-04|
 ===== Shifter Shaft Seal =====
@@ Line 78: / Line 85: @@
 ====== Gearcase / Cam Chest ======
 ===== Cam Cover Gasket =====
-Cam cover gaskets as per the parts manuals are below. \\
+Below is a list of factory gaskets used on Sportster cam covers. \\
--1990 Sportsters used gasket (25263-86). \\
+Pics of the different part numbers are listed to the right in the chart. Click on the link to open a picture of the part. \\
--1993 Sportsters used gasket (25263-90). \\
--1997 Sportsters used gasket (25263-90A). \\
+^{{techtalk:miscres:instruction_sheet_header_4.png?nolink&803|}}||||
--1999 Sportsters used gasket (25263-90B). \\
+|Year Model|Part#|Notes|Pics|
--2003 Sportsters used gasket (25263-90C). \\
+|1986-1990 Sportster|25263-86|  |{{ :techtalk:evo:engmech:1986-1990_sportster_cam_cover_25263-86_by_mg000000.jpg?linkonly |Pic}} ((photo courtesy of Royal Motorworks Citroen Parts Plus, [[https://www.ebay.com/str/royalmotorworkscitroenpartsplus?_trksid=p2047675.m3561.l2563|Link to Ebay Store]]  ))|
+|1991-1993 Sportster|25263-90|
+|1994-1997 Sportster|25263-90A|
+|1998-1999 Sportster|25263-90B|
+|2000-2003 Sportster|25263-90C|
+\\
+-up Sportster engines have an internal rifling hole drilled into the lower left side of the case running past the left side of the oil pump. \\
+That extra hole (in the picture below) is benign and doesn't need a hole in the gasket to match. \\
+That hole is purely an artifact of how they connected two passages for routing crankcase oil up to the oil pump's scavenge section. \\
+They drill that hole to connect the two passages, and then it gets blocked off naturally by the cam box cover and gasket. ((aswracing of the XLFORUM http://xlforum.net/forums/showthread.php?t=2036109&highlight=oil+pump&page=3)) \\
+Also, in 2000, the factory changed the oil routing to the lifters to make manufacturing the cases easier. \\
+The newer cam cover on the left in the pic below and has two extra grooves along the top. These grooves let oil get to the lifters. \\
+If you have an older style gasket, it will not have cutouts for the grooves and you won't get oil to the lifters. \\
+|  Rubbermount Evo vs Rigid Evo Cam Cover Internals ((photo by Moved On of the XLFORUM http://xlforum.net/forums/showthread.php?t=87313))  |
+|{{:techtalk:evo:oil:rubbermount_vs_rigid_evo_cam_cover_comparison_by_moved_on.jpg?direct&600|}}|
+|  Both have been chopped on the outside but the gearcase perimeter is intact on them for reference.  |
+|  1991-1999 cam cover gasket ((photo by Hippysmack))  |  1991-1999 cam cover seals off the extra hole. ((photos by Hippysmack))  ||
+|{{:techtalk:evo:oil:91-99_cam_cover_gasket_2_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:91-99_cam_cover_gasket_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:91-99_cam_cover_gasket_4_by_hippysmack.jpg?direct&300|}}|
+|  2000-up cam cover gasket ((photo by Phillober of the XLFORUM http://xlforum.net/forums/showthread.php?t=1122547&page=7))  |2000-up gasket seals off the extra hole. ((sep69 of the XLFORUM http://xlforum.net/forums/showthread.php?t=2036109&highlight=oil+pump&page=3))|
+|{{:techtalk:evo:oil:2000_up_cam_cover_gasket_by_phillober.jpg?direct&300|}}|{{:techtalk:evo:oil:cam_cover_gasket_on_03_model_by_sep69.jpg?direct&300|}}|
+\\
 ===== #2 Cam - Cover Seal (86-03) =====
 Seal number (11124): \\
@@ Line 145: / Line 178: @@
 |{{: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|}}|
-===== 1995-1999 =====
+===== 1995-1999 Flywheel Assembly =====
 The same flywheel set was used in all Sportsters 95-99. \\
 Sold as a unit: part number (23905-89A) consists of the flywheels, shafts and rods. \\
@@ Line 167: / Line 200: @@
 |{{:techtalk:evo:engmech:flywheels-shafts-rods-23905-89a_pic_10_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:flywheels-shafts-rods-23905-89a_pic_7_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:flywheels-shafts-rods-23905-89a_pic_8_by_hippysmack.jpg?direct&300|}}|
-===== 2000-2002 =====
+===== 2000-2002 Flywheel Assembly =====
 The OEM Flywheel assembly (23905-00) was factory installed in all Sportsters 2000-2003. \\
 That's to say the entire assembly part number is the same from 00-03. \\
@@ Line 183: / Line 216: @@
 |{{:techtalk:evo:engmech:flywheel_assembly_23905-00_by_aussiegazza.jpg?direct&300|}}|{{:techtalk:evo:engmech:flywheel_assembly_23905-00a_by_wilbur.jpg?direct&300|}}|
-===== 2003 =====
+===== 2003 Flywheel Assembly =====
 The original OEM Flywheel assembly (23905-00) was factory installed in all Sportsters 2000-2003. \\
 However, the rods in the 2003 assemblies are reportedly thinner than in the 00-02 assembly and carry -02 casting numbers. ((Randy_rots of the XLFORUM http://xlforum.net/forums/showthread.php?t=1949239&page=34)) \\
@@ Line 203: / Line 236: @@
 |{{:techtalk:evo:engmech:flywheel_assembly_23905-00_pic3_by_randy_rots.jpg?direct&250|}}|{{:techtalk:evo:engmech:flywheel_assembly_23905-00_pic4_by_randy_rots.jpg?direct&250|}}|{{:techtalk:evo:engmech:flywheel_assembly_23905-00_pic5_by_randy_rots.jpg?direct&250|}}|
-===== Crank Pin =====
+===== 2004-Later Flywheel Assembly =====
-Crank pin (23960-80A) used from L1981-2003. \\
-|  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|}}|
-**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. \\
+===== Crank Pin =====
+Crank pin (23960-80A) was used from L1981-2003. \\
+  * Pressurized oil in the pinion bushing is sent through a hole in the (hollow) pinion shaft toward the flywheel. \\ Oil travels to and through the right flywheel via an internal passage from the pinion bore and the crank pin bore in the flywheel. \\ Oil enters the crank pin inside the crank pin bore on the flywheel. \\ Oil is routed out of the crank pin through a hole under the rod bearings in the middle of the pin and circulates to the rod bearings. \\ **This is the end point of static oil pump pressure to the bottom end**.
+  * Oil leaving the rod bearings flows into the crankcase to be scavenged by the oil pump (or splashed into the gearcase). \\ Crankcase pressure moves the oil from this point.
+|   (used) L81-03 'one hole' crank pin. ((photo by Hippysmack))  |||
+|{{:techtalk:evo:oil:crank_pin_oiling_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:crank_pin_oiling_2_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:crank_pin_oiling_3_by_hippysmack.jpg?direct&300|}}|
+|  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|}}|
 ===== Connecting Rods =====

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