Differences

This shows you the differences between two versions of the page.

--- techtalk:evo:engmech01 [2019/11/27 22:07]
hippysmack [#2 Cam Cover Seal (86-03)]
+++ techtalk:evo:engmech01 [2020/08/02 02:54]
hippysmack [Crank Pin]
@@ Line 8: / Line 8: @@
 ====== 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 ======
@@ Line 32: / Line 32: @@
   * [[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 ======
 |{{:techtalk:evo:engmech:sump_drain-plug_on_04_by_bored_now.jpg?direct&300|}}|
@@ Line 38: / Line 44: @@
-====== 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 =====
 The same flywheel set was used in all Sportsters 95-99. \\
@@ Line 44: / Line 75: @@
 Each flywheel casting number (23931-88A) \\
 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 race - front (2)-(24341-52A) \\
@@ Line 63: / Line 94: @@
 ===== 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 ======
--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). \\
-|  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|}}|
-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 (23960-80a) used from L81-03. \\
+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. \\
 ====== 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_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|}}|
@@ Line 142: / Line 198: @@
 {{:techtalk:evo:engmech:removing_the_pinion_gear_by_grind.jpg?direct&300|}} ((photo by ~Grind~' of the XLFORUM http://xlforum.net/forums/showthread.php?t=1448694)) {{:techtalk:evo:engmech:pinion_key_nub_by_aswracing.jpg?direct&250|}} ((photo by aswracing of the XLFORUM http://xlforum.net/forums/showthread.php?t=1666277))
-===== Pinion Gear Runout =====
+===== Pinion Shaft Runout =====
 |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|}}|
@@ Line 154: / Line 210: @@
 |{{: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. \\

Trace:

Differences

Navigation

Search

Toolbox