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techtalk:evo:engmech01 [2020/01/26 01:39]
ixl2relax ↷ Links adapted because of a move operation
techtalk:evo:engmech01 [2020/08/30 18:01] (current)
hippysmack [91 and Up Models (5 Speed)]
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   * [[techtalk:​evo:​engmech01k|Removing 91-03 Primary Cover]]   * [[techtalk:​evo:​engmech01k|Removing 91-03 Primary Cover]]
  
 +===== Shifter shaft Seal =====
 +Navigate to the appropriate year model transmission pages in the Sportsterpedia for removal/​installation. \\ 
 +Part numbers: \\
 +2003 and earlier (37101-84) \\
 +2004-2005 (37101-84A) \\
 +2006-up (37107-06) \\
 +There is a steel bushing pressed into the bore in the cover. The seal installs on the outside of the bushing with a light press fit. \\
 +The seal can be removed/​installed without removing the primary cover.
  
 +Shifter shaft seal on 1998 1200S primary cover. \\
 +{{:​techtalk:​evo:​engmech:​98_shifter_shaft_seal_1_by_hippysmack.jpg?​direct&​300|}} ((photo by Hippysmack)) ​
 +{{:​techtalk:​evo:​engmech:​98_shifter_shaft_seal_5_by_hippysmack.jpg?​direct&​300|}} ((photo by Hippysmack)) \\
 +
 +Shifter shaft seal on 2006 1200R primary cover. \\
 +{{:​techtalk:​evo:​engmech:​2006_1200r_shifter_shaft_seal_1_by_hdmc_ru2.jpeg?​direct&​300|}} ((photo by hdmc_ru2 of the XLFORUM, labeled by Hippysmack http://​xlforum.net/​forums/​showthread.php?​t=49915&​page=7)) {{:​techtalk:​evo:​engmech:​2006_1200r_shifter_shaft_seal_2_by_hdmc_ru2.jpeg?​direct&​300|}} ((photo by hdmc_ru2 of the XLFORUM, labeled by Hippysmack http://​xlforum.net/​forums/​showthread.php?​t=49915&​page=7)) {{:​techtalk:​evo:​engmech:​2006_1200r_shifter_shaft_seal_4_by_hdmc_ru2.jpeg?​direct&​300|}} ((photo by hdmc_ru2 of the XLFORUM, labeled by Hippysmack http://​xlforum.net/​forums/​showthread.php?​t=49915&​page=7)) \\
 ====== 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|}}|
Line 125: Line 189:
 [[techtalk:​ref:​tools150|Origin of the Grindlock Tool]] \\ [[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.+  * You can use a 15/​16" ​6 point 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.   * The Grindlock Pinion Shaft Locking Tool engages for the full depth of the pinion gear for max. strength.
  
Line 140: Line 204:
  
  
-{{:​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))+{{:​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)) ​{{:​techtalk:​evo:​engmech:​oil_pump-pinion_gear_keyways_by_npaisnel.jpg?​direct&​350|}} ((photo by npaisnel of the XLFORUM, labeled by Hippysmack ​ http://​xlforum.net/​forums/​showthread.php?​t=2077485&​page=26)) \\ 
  
 ===== Pinion Shaft 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 ))||| +Check to see if your crank is out of trueSee [[techtalk:​ref:​svcproc24|Measuring Pinion Shaft Runout]] in the REF section of the Sportsterpedia. \\
-|{{: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|}}| +
- +
- +
-|Install a dial gauge on the holder with the pointer on \\ the pinion shaftFind the lowest spot while turning ​\\ the engine over and '​zero'​ the indicator. ((photo by Grind of the XLFORUM))|This setup is made with a piece of angle iron for the magnetic base to stand on ((photos by dezzertrat of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=1860581))|| +
-|{{:​techtalk:​ref:​tools:​checking_pinion_shaft_runout_6_by_grind.jpg?​direct&​300|}}|{{:​techtalk:​ref:​tools:​checking_pinion_shaft_runout_7_by_dezzertrat.jpg?​direct&​300|}}|{{:​techtalk:​ref:​tools:​checking_pinion_shaft_runout_8_by_dezzertrat.jpg?​direct&​300|}}| +
- +
- +
-|This gauge post is threaded into a cover mount hole. ((photos by DirtyCory of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=1297584&​page=8))|| +
-|{{:​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. \\
  
 +|  Crankshaft Seal (35151-74A) ((photos by pearlmoto of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=1815630)) ​ ||| 
 +|{{:​techtalk:​evo:​engmech:​crank_seal_35151-74a_pic1_by_pearlmoto.jpg?​direct&​300|}}|{{:​techtalk:​evo:​engmech:​crank_seal_35151-74a_pic2_by_pearlmoto.jpg?​direct&​300|}}|{{:​techtalk:​evo:​engmech:​crank_seal_35151-74a_pic3_by_pearlmoto.jpg?​direct&​300|}}|
  
 \\ \\
  
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