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techtalk:evo:engmech01 [2022/09/10 03:40] hippysmack [Crank Pin] |
techtalk:evo:engmech01 [2022/10/07 22:22] hippysmack [Cam Cover Gasket] |
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====== Primary Compartment ====== | ====== 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 ===== | ===== Shifter Shaft Seal ===== | ||
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====== Gearcase / Cam Chest ====== | ====== Gearcase / Cam Chest ====== | ||
===== Cam Cover Gasket ===== | ===== 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. \\ |
- | 1986-1990 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. \\ |
- | 1991-1993 Sportsters used gasket (25263-90). \\ | + | |
- | 1994-1997 Sportsters used gasket (25263-90A). \\ | + | ^{{techtalk:miscres:instruction_sheet_header_4.png?nolink&803|}}|||| |
- | 1998-1999 Sportsters used gasket (25263-90B). \\ | + | |Year Model|Part#|Notes|Pics| |
- | 2000-2003 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|**Note: Do not use a pre-2000 gasket on your cam cover** \\ A 1991-1999 style gasket WILL destroy a 2000-2003 your engine! \\ See below.| \\ | ||
+ | |||
+ | \\ | ||
+ | 1977-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) ===== | ===== #2 Cam - Cover Seal (86-03) ===== | ||
Seal number (11124): \\ | Seal number (11124): \\ | ||
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|{{: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|}}| | ||
- | ===== 1995-1999 ===== | + | ===== 1995-1999 Flywheel Assembly ===== |
The same flywheel set was used in all Sportsters 95-99. \\ | 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. \\ | Sold as a unit: part number (23905-89A) consists of the flywheels, shafts and rods. \\ | ||
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|{{: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|}}| | |{{: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. \\ | 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. \\ | That's to say the entire assembly part number is the same from 00-03. \\ | ||
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|{{:techtalk:evo:engmech:flywheel_assembly_23905-00_by_aussiegazza.jpg?direct&300|}}|{{:techtalk:evo:engmech:flywheel_assembly_23905-00a_by_wilbur.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|}}| | ||
- | ===== 2003 ===== | + | ===== 2003 Flywheel Assembly ===== |
The original OEM Flywheel assembly (23905-00) was factory installed in all Sportsters 2000-2003. \\ | 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)) \\ | 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)) \\ | ||
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| Flywheel assembly 23905-00 ((photos by Randy_rots of the XLFORUM http://xlforum.net/forums/showthread.php?p=5905554#post5905554)) ||| | | Flywheel assembly 23905-00 ((photos by Randy_rots of the XLFORUM http://xlforum.net/forums/showthread.php?p=5905554#post5905554)) ||| | ||
|{{: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|}}| | |{{: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|}}| | ||
+ | |||
+ | ===== 2004-Later Flywheel Assembly ===== | ||
+ | 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 ===== | ||
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| 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 ===== |