EVO: Engine Mechanicals - Sportsterpedia

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====== EVO: Engine Mechanicals ======
====== Timing Inspection Hole ======

===== Sub-Documents =====

  * [[techtalk:evo:engmech01a|91-03 Timing inspection hole and plug pics and app. dims]]

====== Motor Mounts ======
[[techtalk:evo:engmech09|Click here for Engine Mounts]] in the Evo Suspension section of the Sportsterpedia. \\
====== Cylinder Mounting Studs ======

|  Weakest cylinder mounting stud holes in the case. ((photo by Hippysmack))  |
|{{:techtalk:evo:engmech:weakest_cylinder_bolt_threads_by_hippysmack.jpg?direct&300|}}|
====== Cam / Gearcase Cover ======
===== Sub Documents =====
  * [[techtalk:evo:engmech04a#removing_the_rocker_boxes|Removing the Rocker Boxes]]
  * [[techtalk:evo:engmech01f|Removing, Inspecting and Installing the Cam Cover]]

===== #2 Cam - Cover Seal (86-03) =====
Seal number (11124): \\
This surrounds and seals #2 cam when the cover is installed. \\
See also [[techtalk:evo:engmech01f#cam_cover_seal_86-03|Removal / Installation of the #2 cam cover seal]] in the Sportsterpedia. \\

|  This side faces out. ((photo by Hippysmack))  |  This side faces #2 cam shaft. ((photo by Hippysmack))  |
|{{:techtalk:evo:engmech:11124_cam_cover_seal_2_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:11124_cam_cover_seal_1_by_hippysmack.jpg?direct&300|}}|


====== Primary Cover ======
===== Sub-Documents =====

  * [[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|}}|
|  Sump drain on 04 model ((photo by Bored now of the XLFORUM http://xlforum.net/forums/showthread.php?p=5718958#post5718958))  |


====== 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. \\
Sold as a unit: part number (23905-89A) consists of the flywheels, shafts and rods. \\
Each flywheel casting number (23931-88A) \\
Connecting rod set: part number (24275-86A) \\
Front 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) \\
Rod bearing race - rear (2)-(24352-52A) \\
Piston pin bushing std (2)-(24331-36), .01" O.S. (24332-36 \\
Crankpin std (23960-80A), .001" O.S. (23948-87), .002" O.S. (23949-87) \\
Crankpin boss washer (2)-(6508) \\

|{{:techtalk:evo:engmech:flywheels-shafts-rods-23905-89a_pic_2_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:flywheels-shafts-rods-23905-89a_pic_1_by_hippysmack.jpg?direct&300|}}|

|{{:techtalk:evo:engmech:flywheels-shafts-rods-23905-89a_pic_3_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:flywheels-shafts-rods-23905-89a_pic_4_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:flywheels-shafts-rods-23905-89a_pic_11_by_hippysmack.jpg?direct&300|}}|

|{{:techtalk:evo:engmech:flywheels-shafts-rods-23905-89a_pic_9_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:flywheels-shafts-rods-23905-89a_pic_6_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:flywheels-shafts-rods-23905-89a_pic_5_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|}}|

===== 00-03 =====

|  Flywheel assembly 23905-00 ((photo by AussieGazza of the XLFORUM http://xlforum.net/forums/showthread.php?t=692835&page=7))  |  Flywheel assembly 23905-00A ((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_23905-00a_by_wilbur.jpg?direct&300|}}|
====== Flywheels ======
**Late 1986 flywheels and crankpin bearing changes**. \\
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). \\ 
|  95-99 Flywheels ((photos by Hippysmack))  ||
|{{:techtalk:evo:engmech:95-99_flywheels_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:95-99_flywheels_2_by_hippysmack.jpg?direct&300|}}|


|  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|}}|



\\

====== Crank Pin ======
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|}}|
====== Pinion Shaft ======

===== Removing / installing the pinion shaft nut =====

To remove or install the pinion gear nut, \\ You'll need to lock the pinion gear from moving while turning it. \\
It's very important to hold the crank on the pinion side with an appropriate pinion locking tool whenever you take the pinion nut off or put it on. \\
If you hold the crank still from the primary side (or by putting the bike in gear and holding the brake), \\
The twisting torque applied to the pinion nut gets transmitted through the crank, from one side to the other. \\
The crank pin is not designed to resist much twisting force. \\
You'll risk scissoring the crankshaft (knocking the crank out of true), which requires a full tear-down to fix. ((Hammer Performance http://www.hammerperf.com/xlvalvetrain.shtml#grindlock)) \\
So this is one of those situations where it's best to use the proper tool. ((aswracing of the XLFORUM http://xlforum.net/forums/showthread.php?t=2002257&highlight=pinion+locking+tool))
The pinion nut takes a 15/16" wrench size. \\

==== 90 and Prior Models (4 Speed) ====
|  {{:techtalk:ref:tools:pinion_gear_tools_buy_bustert.jpg?direct&300|}}|{{:techtalk:ref:tools:homemade_pinion_gear_tool_by_piniongear.jpg?direct&200|}}|{{:techtalk:ref:tools:pinion_gear_puller_by_75bike.jpg?direct&200|}}|
^Homemade Pinion Gear / Removal / Installation Tools ((photo by bustert of the XLFORUM http://xlforum.net/forums/showthread.php?t=395586&page=5))  ^  Homemade pinion gear press ((photo by piniongear of the XLFORUM http://xlforum.net/forums/showthread.php?t=395586&page=12))  ^  Pinion Gear Puller ((photo by 75bike of the XLFORUM http://xlforum.net/forums/showthread.php?t=395586&page=13))  ^

|{{:techtalk:ref:tools:pinion_gear_puller_1_by_sevenyears_of_famine.jpg?direct&200|}}|{{:techtalk:ref:tools:pinion_gear_puller_2_by_sevenyears_of_famine.jpg?direct&200|}}|{{:techtalk:ref:tools:pinion_gear_puller_3_by_sevenyears_of_famine.jpg?direct&200|}}|
|Large fender washer cut into a "C" shape and a gear puller|||
|  Homemade Pinion Gear Puller ((photo by sevenyears of famine of the XLFORUM http://xlforum.net/forums/showthread.php?t=1888378&highlight=pinion+gear+tool&page=10))  |||

|{{:techtalk:ref:tools:pinion_lock_tool_by_big_al.jpg?direct&300|}}|
|3/8" stainless steel plate with 20° spokes (for 18 teeth), \\ sawed initial groove to depth and widened it with files|
|  Homemade pinion gear locking tool for '89 models ((photo by Big Al of the XLFORUM http://xlforum.net/forums/showthread.php?p=5322902#post5322902))  |

==== 91 and Up Models (5 Speed) ====
See also in the Sportsterpedia: \\
[[techtalk:evo:oil03#oil_pump_drive_gear|Oil Pump Drive Gear]] \\
[[techtalk:ref:tools150|Origin of the Grindlock Tool]] \\

  * You can use a 15/16" wrench or deep well socket to remove / install the pinion gear nut.
  * The Grindlock Pinion Shaft Locking Tool engages for the full depth of the pinion gear for max. strength.


{{techtalk:ref:tools:93_and_up_pinion_gear_nut_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)){{:techtalk:ref:tools:grindlock_2000_pic_21_by_aswracing.jpg?direct&300|}} ((aswracing of the XLFORUM http://xlforum.net/forums/showthread.php?t=1618841&page=4)) \\

  * Due to a change in the pinion gear in 2000, there are 2 different versions of this tool: \\ (L) - (91-99) year models & (R) - (2000 to present) year models ((Hammer Performance http://www.hammerperf.com/xlvalvetrain.shtml#grindlock)) ((Grindlock 91-99 & Grindlock 2000, designed by XLFORUM member, "~Grind~" and Built by Hammer Performance ((aswracing of the XLFORUM http://xlforum.net/forums/showthread.php?t=1618841)) \\

{{techtalk:ref:tools:grindlock_tool_2_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{techtalk:ref:tools:grindlock_tool_by_aswracing.jpg?direct&300|}} ((aswracing of the XLFORUM http://xlforum.net/forums/showthread.php?t=1618841&page=4)) ((photo by aswracing of the XLFORUM http://xlforum.net/forums/showthread.php?t=1920827&highlight=pinion+gear+locking+tool))

  * Once the pinion shaft nut is removed, the pinion gear may or may not slide off by itself. \\ You can use a gear puller to remove it if it is stuck on. \\
  * It's very important to hold the crank still from the cam side (not the primary side) when torquing the pinion nut. ((aswracing of the XLFORUM http://xlforum.net/forums/showthread.php?t=1666277)) \\ If you for example put the bike in gear and hold the rear brake and torque on the nut, you run the very real risk of knocking the crank out of true. \\ It's not designed to transmit torque from one side to the other and it tries to twist the crankpin connection.
  * In respect to the key shearing, it's a very common issue particularly when heavy valve springs are used. \\ However, it shouldn't be the one thing that keeps the gear from spinning. The clamp load should do that. \\ The caption in the second pic below describes the fix: \\ Loctite red and 70ft-lbs instead of the factory specified 50ft-lbs. You won't have this issue again. \\ 


{{: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 Shaft Runout =====
Check to see if your crank is out of true. See [[techtalk:ref:svcproc24|Measuring Pinion Shaft Runout]] in the REF section of the Sportsterpedia. \\

====== 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. \\

{{:techtalk:evo:engmech:crank_seal_35151-74a_pic1_by_pearlmoto.jpg?direct&250|}} {{:techtalk:evo:engmech:crank_seal_35151-74a_pic2_by_pearlmoto.jpg?direct&250|}} {{:techtalk:evo:engmech:crank_seal_35151-74a_pic3_by_pearlmoto.jpg?direct&250|}}


\\

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