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techtalk:evo:engmech01 [2019/11/27 22:29]
hippysmack [Pinion Gear Runout]
techtalk:evo:engmech01 [2020/08/02 02:54] (current)
hippysmack [Crank Pin]
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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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 |{{:​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. \\