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EVO: Engine Mechanicals

Timing Inspection Hole

Sub-Documents

Motor Mounts

Click here for Engine Mounts in the Evo Suspension section of the Sportsterpedia.

Cylinder Mounting Studs

Weakest cylinder mounting stud holes in the case. 1)

Timing Hole Plug (1986-2003)

Click Here to go the Timing Inspection Hole and Plug - Sealing and Thread Repair page in the Sportsterpedia.

1972-2003 Sportster Timing Hole Plug (720).
Threads: 5/8“-18 x .350” with 3/8“ Hex Socket (Allen) Head.

2) 3)

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.

Year ModelPart#NotesPics
1977-1990 Sportster34955-75
1991-2003 Sportster34955-89
34955-89A
34955-89B
-89A replaced original in 1994. 4)
-89B shows up in 2013 (-B) series parts catalogs.
-89 5)
2004-Present Sportster34955-04

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.
6) 7)

Shifter shaft seal on 2006 1200R primary cover.
8) 9) 10)

Shifter Shaft Bushing

1977-2003 Sportster Shifter Shaft Bushing 40520-63:

11) 12)

13) 14)

Inspection Covers/Caps

1986-1990

1986-1990 Sportsters use the same threaded cap/plug for the primary oil filler hole and clutch inspection hole on the primary cover.
The tool access hole looks similar to the “Chevy Bowtie” symbol and uses a similar tool to remove and install it.
The plug has no through hole since the primary / transmission breathes out a rubber tube on the top-rear of the transmission.
Each plug is sealed with an O-ring (1139).
1986-1988 models used a polished aluminum plug (34742-86) that was sold through 1990 models.
In 1989, a chrome plug (34745-87) was also available and sold through 1990 for 1986-1990 models.

1986-1990 Sportster Polished Primary Cover Cap Plug (34742-86) 15)
1989-1990 Sportster Chrome Primary Cover Cap Plug (34745-87) 16)

Crankshaft Seal

Here is a trick to hold the spring in place to stop it popping off while you are fitting the seal. 17)
Before fitting it, pack some grease around the spring in the seal groove. You only need a small amount.

Crankshaft Seal (35151-74A) 18)

Gearcase / Cam Chest

Cam Cover Gasket

Below is a list of factory gaskets used on Sportster cam 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.

Year ModelPart#NotesPics
1986-1990 Sportster25263-86 Pic 19)
1991-1993 Sportster25263-90
1994-1997 Sportster25263-90A
1998-1999 Sportster25263-90B
2000-2003 Sportster25263-90CNote: Do not use a pre-2000 gasket on 2000-2003 cam covers
A 1991-1999 style gasket WILL destroy a 2000-2003 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. 20)

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 21)
Both have been chopped on the outside but the gearcase perimeter is intact on them for reference.
1991-1999 cam cover gasket 22) 1991-1999 cam cover seals off the extra hole. 23)
2000-up cam cover gasket 24) 2000-up gasket seals off the extra hole. 25)


DON'T INSTALL a 91-99 CAM COVER GASKET ON A 2000-UP MOTOR!!!!!!!

The 91-99 cam cover gasket has no business being on a 2000+ motor at all. It will cause you to lose all oil pressure. 26)
The 2000+ gasket supersedes the 91-99 gasket. In other words, it can be used all the way back to 1991.
Most companies completely dropped the 91-99 specific gasket and only offer the one that can be used from 1991-present.
Either James Gasket hasn't done that, or they may have some old stock.

The 1991-1999 lifter feed galley is an internal rifling hole in the case. It's drilled thru the case and only open to the cam cover via the center port to the pinion bushing.
The 2000-up lifter feed galley is external and it takes both the cover and the case mounted together to make up the feed galley.
So 2000-up feed galley is split in half between the case and cover. The slots in the 2000-up cam cover gasket mate to both the case and the cover.
If you have the correct gasket on there, oil would be forced (between the cover and case) to all the lifter feed holes and piston squirters.
With the wrong gasket (1991-1999), oil pressure leaving the filter gets into that (now open) galley.
Then the oil will blow into into the cam chest, therefore bypassing the lifters, piston squirters and rod bearings.
The oil will simply cycle from the oil pump to cam chest to oil pump and back to the oil tank.
The oil light will stay off so you'll get no notice before moving the parts start oil starving and making noises and worse if the noises aren't heeded to quickly.

2000-up motor with 1991-1999 cam cover gasket. 27) Below is a rough cross section of the joint in the
feed galley at that first slotted run. 28)

#2 Cam - Cover Seal (86-03)

Seal number (11124):
This surrounds and seals #2 cam when the cover is installed.
See also Removal / Installation of the #2 cam cover seal in the Sportsterpedia.

This side faces out. 29) This side faces #2 cam shaft. 30)

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. 31)
So this is one of those situations where it's best to use the proper tool. 32) The pinion nut takes a 15/16” wrench size.

Pinion Shaft Runout

Check to see if your crank is out of true. See Measuring Pinion Shaft Runout in the REF section of the Sportsterpedia.

Flywheel Related Information

Late 1986 flywheels and crankpin bearing changes.
Information from Technical Service Bulletin #M-927. 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.
See Tech Tip #14, Instruction Sheet #J00022 and 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. 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. 33) 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).

2000 Flywheels:
There are no timing marks on the wheels for any of the rubber mounts. 34)
Nor is there a timing window (on the case) to look through to see the mark that's not there.
And for that matter, there's no way to change the timing, even if you had a window to see the mark that's not there.
The only way to change the timing on a rubber mount is to use an aftermarket ignition that gives you control, through dials and/or a programming kit.
And even doing that, there's no way to measure it, you just have to trust that it's delivering the timing you're telling it to.

95-99 Flywheels 35)
L1986-up crank pin boss washer (6508) 36)

1995-1999 Flywheel Assembly

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)

2000-2002 Flywheel Assembly

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.
However, the rods in the 2000-2002 assemblies are reportedly thicker than the 2003 assembly. 37)

The entire assembly was sold as a unit with no published part numbers for it's individual parts.
To date, we have no pics or casting numbers on the 00-02 rods for comparison.
Rod bearings and races, crankpin and even the shaft nuts were not mentioned in the parts catalogs.

Piston Pin bushing, standard (24331-36), 0.01” O.S (24332-36)
Inner bearing ring (24658-87)
Retaining ring (11177A)

Flywheel assembly 23905-00 38) Flywheel assembly 23905-00A 39)

2003 Flywheel Assembly

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. 40)
So the original 2003 flywheel version appears to be a one year only version.

Entire assembly was sold as a unit with no published part numbers for individual parts for the assembly.
Rod bearings and races, crankpin and shaft nuts were not mentioned in the parts catalogs.

  • The assembly in the pics below came from a 2003 883R:
    • Front connecting rod casting number (24225-02)
    • Rear connecting rod casting number (24224-02)

Piston Pin bushing, standard (24331-36), 0.01“ O.S (24332-36)
Inner bearing ring (24658-87)
Retaining ring (11177A)

Flywheel assembly 23905-00 41)
Flywheel assembly 23905-00 42)

2004-Later Flywheel Assembly

The sprocket shaft nut torque for 2004 & later Sportsters and 2003 & later Buell XB models has been changed. 43)
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 here in the tools section of the Sportsterpedia.

Crank Pin

Crank pin (23960-80A) was used from L1981-2003.

  • Pressurized oil in the pinion bushing is sent through a hole in the (hollow) pinion shaft toward the flywheel.
    Oil travels to and through the right flywheel via an internal passage from the pinion bore and the crank pin bore in the flywheel.
    Oil enters the crank pin inside the crank pin bore on the flywheel.
    Oil is routed out of the crank pin through a hole under the rod bearings in the middle of the pin and circulates to the rod bearings.
    This is the end point of static oil pump pressure to the bottom end.
  • Oil leaving the rod bearings flows into the crankcase to be scavenged by the oil pump (or splashed into the gearcase).
    Crankcase pressure moves the oil from this point.
(used) L81-03 'one hole' crank pin. 44)
L87-03 crank pin 45)

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).


Below is the rod set known to be fitted to at least 2003 model Sportsters.
Front casting number (24225-02)
Rear casting number (24224-02)

46) 47) 48)

Pinion Shaft

Installing 1986-2003 Flywheels

1976 and previous year Sportsters use a one piece dual Timken bearing race on the left (sprocket shaft) side of motor.
These engines also used a press-in outer race on the right (pinion) side.
The right bearing race was able to be line-lapped to the left bearing to fit oversize bearings. You need a line-lapping tool to do this. 49)

1977-E1986 Sportsters use two separate Timken bearing races on the left side.
The right bearing was changed to a single Torrington bearing with an accompanying inner race that presses over the pinion shaft.
This bearing is not rebuildable so you don't lap these engines. You just press the bearing out and install a new one. 50)

L1986-2003 Sportsters still use the two piece Timken bearing races on the left case.
But the right cases are now back to the lap-able race with oversize roller replacements.
(only the rollers are in a cage and the inner race is still pressed onto the pinion shaft)
Pre-1977 cases had loose rollers and post-86 cases have captive rollers in cage with less choices on bearing over-sizes. 51)

The flywheel assembly doesn't really press into the left case half, that's a misconception that a lot of people have.
There are two bearings that get pressed onto the sprocket shaft, and the left case half is sandwiched in between those two bearings.
So it's not the crank itself that's pressed in, it's two bearings that are pressed onto the crank.
(positioned as one inside and one outside of the left case (inner and outer case positions). 52)

Proper assembly of the lower end requires special tools to remove / install the bearing races into the case halves. 53)
Plus you need a puller that can get the inner bearing off to replace it.
And you need to be able to accurately measure the pinion shaft bearing races to a ten-thousandth (.0001”) to select the right replacement size bearing.
(which means snap gauges and a couple different sized .0001“ reading micrometers)
Plus you need to rig up a dial indicator to check your flywheel end play.
And if you've already pressed against the flywheel assembly to remove it, it really ought to be put in a truing stand and make sure it's still straight.
Also, once it's all together, the sprocket shaft seal ought to be put on with the correct tool.
The tool puts it in square and sets the depth correctly.

Left Side Bearing Assembly: 54)

  • The inner bearing goes on the crankshaft before installing it through the bore in the left case.
    And it will remain on the shaft once the shaft is removed from the left case.
    It's corresponding inner race (Timken bearing outer race) is a cone shaped race that's pressed into the inside of the left case.
    It will also remain in it's place when the flywheel assembly is removed.
  • There is a bearing spacer that resides between the inner and outer bearings that separates the bearings and sets the preload between the two.
    It basically controls how much gap is left between the bearings and the case half (actually the races which are pressed into the case half).
    The bearing spacer (shim) is available in sizes from .098” to .114“ in steps of .002”.
    It's thickness is sized (selected) to set the flywheel end play. The end play spec is .001“ to .005”.
  • There is also a bearing race spacer. This spacer is a thick piece of steel that's sandwiched between the inner and outer bearing races.
    It fits into a notch that's machined into the cases. It has a gap that needs to be pointing straight up as there's an oil hole there where crankcase oil bleeds down into the bearing area.
    It will most likely (should) stay in the middle of the cases once the flywheel assembly is removed.
  • The left case outer bearing race, like the inner race, this is a cone shaped race that's pressed into the case.
    It will most likely stay in the case once the flywheel assembly is removed.
  • The outer bearing, same as the inner bearing, is pressed onto the crankshaft and will have to be removed before the flywheel assembly comes out.
    Then it'll have to be pressed back on when the flywheel assembly is installed.
  • There is another spacer that sits directly under the front primary sprocket and holds it away from the outer bearing.
    The seal rides on this spacer. Don't forget it.
  • Even though both bearing outer races are installed into the case half with a press, you really can't put the sprocket shaft bearings on with a press.
    Pressing against the flywheel assembly is a really bad thing to do, it'll knock it out of true.
    There's a special tool for pushing those bearings onto the shaft. It threads onto the end of the shaft, so it never presses against the wheels at all.

Right Side Bearing Assembly: 55)
The pinion shaft just slides into the right case. Oil everything up first though.

  • The pinion bearing is available in four different sizes.
  • The outer race for the pinion bearing is pressed into the right case.
  • You have to precisely measure the I.D. of the outer then measure the O.D. of the race that's on your pinion shaft.
  • Then there's a table in the service manual that shows you which of the four different available pinion bearings to use based on those two measurements.

90 and Prior Models (4 Speed)

Homemade Pinion Gear / Removal / Installation Tools 56) Homemade pinion gear press 57) Pinion Gear Puller 58)
Large fender washer cut into a “C” shape and a gear puller
Homemade Pinion Gear Puller 59)
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 60)

1991-Up Models (5 Speed)

See also in the Sportsterpedia:
Oil Pump Drive Gear
Origin of the Grindlock Tool

  • 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.

61) 62)

  • 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 63) 64)

65) 66) 67)

  • 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. 68)
    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.

69) 70) 71)

Parts Lists

Engine Cases

Year ModelCase Set
Part#
Left Case
Casting# (location)
Right Case
Casting# (location)
1986-E1987 All24527-8624532-86 (outer wall)24552-86 (outer wall)
NotesOne year only case set. Left over 1986 cases used on early 1987 models.
Crank shaft bearings (24729-74) and pinion shaft bearings (24648-77)
1987-1989 All24527-87(E87) 24532-86 (outer wall)
(L87-89) 24534-86 (inner wall)
24558-86 (inner wall)
NotesSome early 1987 models may have leftover cases from 1986.
1987-up crankshaft bearings (24729-74)
1987-up pinion shaft bearings (24647-87 / 24650-87 / 24659-87 / 24660-87)
1990 All24470-8724534-86 (inner wall)24558-86 (inner wall)
NotesCase set supplied with bearings. Replacement set for 1987-1989 Sportsters.
Crankshaft bearings (24729-74)
Pinion shaft bearings (24647-87 / 24650-87 / 24659-87 / 24660-87)
1991 All24470-91
NotesCase set supplied with bearings. Crankshaft bearing complete set (2) (48302-85)
Pinion shaft bearing (24647-87 / 24650-87 / 24659-87 / 24660-87)
1992-1994 All24470-91B24534-89 (outer wall)24558-89 (inner wall)
NotesCase set supplied with bearings.Crankshaft bearing complete set (2) (48302-85)
Pinion shaft bearing (24647-87 / 24650-87 / 24659-87 / 24660-87)
1995-1997 All (except XL1200C)
1996-1997 XL1200C
24470-91C
24466-96
24534-89 (outer wall)24558-92A (inner wall)
NotesCase set supplied with bearings. Crankshaft bearing complete set (2) (48302-85)
Pinion shaft bearing (24647-87 / 24650-87 / 24659-87 / 24660-87)
XL1200C cases are black, all others are silver.
1998-1999 All (except XL1200C)
1998-1999 XL1200C
24470-98
24466-98
24534-98 (outer wall)24558-98 (inner wall)
NotesCase set supplied with bearings. Crankshaft bearing complete set (2) (48302-85)
Pinion shaft bearing (24647-87 / 24650-87 / 24659-87 / 24660-87)
XL1200C cases are black, all others are silver.
2000-2002 All (except XL1200C)
2000-2002 XL1200C
24470-00
24466-00
24534-98A (outer wall)24558-00 (inner wall)
NotesCase set supplied with bearings. Crankshaft bearing complete set (2) (48302-85)
Pinion shaft bearing (24647-87 / 24650-87 / 24659-87 / 24660-87)
XL1200C cases are black, all others are silver.
2003 All (except XL883R/XL1200C)
2003 XL883R/XL1200C
24502-03
24500-03
24555-03 (outer wall)24558-00 (inner wall)
NotesCase set (silver) supplied with bearings. 100th Anniversary restricted sale.
Crankshaft bearing complete set (2) (48302-85)
Pinion shaft bearing (24647-87 / 24650-87 / 24659-87 / 24660-87)
XL883R and XL1200C cases are black, all others are silver.
2004-2005 All (except XL1200C)
2004-2005 XL1200C/XL883R (black)
24470-04
24466-04
24534-04 (outer wall)
NotesCase set (silver) with bearings.
2006-2007
XL883/XL883C/XL883L/XL1200R
24470-06
NotesCase set (silver) with bearings.
2006-2007 XL883R/XL1200C
XL1200L/XL50
24466-0624534-06A (outer wall)24558-06 (inner wall)
NotesCase set (black) with bearings.
2007-2008 XL1200N24745-07
NotesCase set (gray) with bearings.
2008
XL883/XL883C/XL883L/XL1200R
24470-06A
NotesCase set (silver) with bearings.
2008
XL883R/XL1200C XL1200L
24466-06A
NotesCase set (black) with bearings.
2009-2016 XL883/XL883C/XL883L24470-06B
NotesCase set (silver) with bearings.
2009-2016 XL883R/XL883N
XL1200C/XL1200C Anv/XL1200L
XL1200R/XL1200X/XL1200CP
XL1200CA/XL1200CB/XL1200T
2014-2016 XL1200V
24466-06B
NotesCase set (black) with bearings.
2009-2013 XL1200N/XL1200V
2016 XL1200V/XL1200CX
24745-07A
NotesCase set (gray) with bearings.
2009-2013 XR-1200/XR1200X24475-08
NotesCase set (black) with bearings.

Engine Case / Shaft Bearings and Races

Unless coded in parenthesis, all part numbers below are factory part numbers.
Legend for part numbers coded in parenthesis;
(HD) = Harley Davidson (Ti) = Timken (To) = Torrington

1986-2003 Crankshaft Bearings
Year Case
All Models
Crankshaft
Bearing Set
w/ races
Timken Bearing
w/ Outer Race
Timken Bearing
(cone only)
Timken Bearing
Outer Race
Bearing ShimRet Ring
bearing race
spacer
Bearing Seal
198624729-7448302-85(HD) 48348-70
(Ti) L44649
(HD) 48315-60
(Ti) L44610
supplied9119A35151-74
2002 upgrade
(35151-74A)
1987-20039155 (.098“)
9142 (.100”)
9143 (.102“)
9144 (.104”)
9145 (.106“)
9146 (.108”)
9147 (.110“)
9148 (.112”)
9149 (.114“)
2004-Up Crankshaft Bearings
Year Case
All Models
Crankshaft
Bearing
Bearing
Thrust Washer
Inner
Retaining Ring
Outer
Retaining Ring
Sprocket
Shaft Spacer
Bearing Seal
2004-200524604-00C8973 (2)35114-0235118-0340254-0212068
2006-200824604-00D8973 (2)35114-0235118-0340254-0212068
2009-201024605-07897235114-0235118-0340254-0212068
Transmission Bearings
Left Case (trapdoor) Right Case
Year CaseMainshaft
Bearing
includes race
Countershaft
Bearing
includes race
Mainshaft
Bearing
Mainshaft
Bearing Race
Countershaft
Bearing
includes race
Shifter
Shaft/Drum
Bushing / Bearing
1986-1990(HD) 9025A
(NTN) 6207ZZ
(Fafnir) 207KDD
35961-52(HD) 9118
(To) BH2012
35041-84(HD) 35960-54
(To) M-11121
closed end
bushing
40520-63
1991-200335030-89(HD) 8998(HD) 8996 / 8996A
(FAG) 559197
(FAG) 6209 C3
(SKF) 6209 C3
(HD) 8977
(FAG) BK2526
(INA) BK2526
bearing
9151
Pinion Shaft Bearings Inner Cam Bearings or Bushings
Year CasePinion Shaft BearingOuter
Bearing
Race
Inner
Bearing
Race
Bearing
Retainer
Ring
BearingsBushings
E198624648-77 (includes outer race)
(To) HJ-202816
24658-86
(To) IR-162016
n/a(HD) 9057
(To) BH-117
L1986-199024650-87 (red) largest
24647-87 (blue)
24659-87 (white/grey)
24660-87 (green) smallest
bearing locked to pinion shaft
888124658-8711177
11177A (95)
(HD) 9057
(To) BH-117
1991-2003 25598-91

Flywheel Assembly

Year Model 72)Flywheel
Assembly
Connecting Rod
Assembly
Crankpin
Early 1986 Models
E1986 XLH88323905-8624275-8623960-80A
E1986 XLH110023900-8624275-8623960-80A
Late 1986-1990 Models
L1986 XLH88323905-86A24275-86A23960-80A
1987 XLH88323905-8724275-86A23960-80A (std)
23948-87 (.001” O.S.)
23949-87 (.002“ O.S.)
1988 XLH88323905-88
1989-1990 XLH88323905-88A
L1986 XLH110023900-86A24275-86A23960-80A (std)
23948-87 (.001” O.S.)
23949-87 (.002“ O.S.)
1987 XLH110023900-87
1988 XLH120023900-8824275-86A23960-80A (std)
23948-87 (.001” O.S.)
23949-87 (.002“ O.S.)
1989-1990 XLH120023900-88A
1991-1999 Models
1991-1994 XLH88323905-8924275-86A23960-80A (std)
23948-87 (.001” O.S.)
23949-87 (.002“ O.S.)
1991-1994 XLH120023900-9024275-86A23960-80A (std)
23948-87 (.001” O.S.)
23949-87 (.002“ O.S.)
1995-1999 All Models23905-89A24275-86A23960-80A (std)
23948-87 (.001” O.S.)
23949-87 (.002“ O.S.)
2000-2003 Models
2000-2003 All Models23905-00
23905-00A
Not Sold
Separate
Not Sold
Separate
2004-up Models
2004-2005 All Models23905-04Not Sold
Separate
Not Sold
Separate
2006-2009 All Models
(Except XR1200)
23905-04ANot Sold
Separate
Not Sold
Separate
2010-2019 All Models
(Except XR1200/X)
23905-04BNot Sold
Separate
Not Sold
Separate
2009-2013
XR1200 / XR1200X
23999-08Not Sold
Separate
Not Sold
Separate

Primary / Chain Cover

Year
Model
Part
Number
Casting
Number
GasketShifter
Shaft
Bushing
1986-1987 Sportster25430-86Circle
Date Stamp
34955-7540520-63
Notes:Polished. Replaced by 25430-86A (1989)
1988-1990 Sportster25430-88 34955-7540520-63
Notes:Polished
1991-1993 Sportster25430-8935950-8934955-8940520-63
Notes:Polished
1994 Sportster25430-94 34955-89A40520-63
Notes:Polished
1995-2003 Sportster
(except XL1200C)
(except XL1200S)
(except XL883R)
25430-94A34951-9534955-89A40520-63
Notes:Polished
1996-2003 XL1200C25460-9434951-9534955-89A40520-63
Notes:Chrome
1998-2003 XL1200S/XL883C25471-97Y 34955-89A40520-63
Notes:Silver
2002-2003 XL883R25574-99Y 34955-89A40520-63
Notes:Black
2004-2005 XL883/XL883L25430-04 34955-0440520-63
Notes:Polished
2004-2005 XL1200C25460-0434951-0434955-0440520-63
Notes:Chrome
2004-2005 XL883C/XL1200R25471-04 34955-0440520-63
Notes:Silver
2005 XL883R25307-05 34955-0440520-63
Notes:Polished
2006 XL883R/XL1200R25307-06 34955-0440574-06
Notes:Black. New shifter shaft bushing has a flange on one end.
2006 XL883/XL883L25430-06 34955-0440574-06
Notes:Polished
2006 XL1200C/XL1200L25460-06 34955-0440574-06
Notes:Chrome
2006 XL883C25471-06 34955-0440574-06
Notes:Silver
XL1200N60830-07 34955-0440574-06
Notes:Gray

Cam / Gearcase Cover

Year
Model
Part
Number
Casting
Number
Gasket
1986-1990 Sportster25219-8625222-84A25263-86
Polished, cover only. See also circled date stamp.
86-87 cover (25488-86) and 88-90 cover (25488-88) include matched cam gear set.
1991-1993 Sportster25219-9125222-8925263-90
25263-90A (1994)
Polished, includes trans vent fitting/clamp, #2 cam seal and bushings.
1991-1994 cover 25488-89 includes the matched cam gear set.
See also date stamp.
1994 Sportster25219-94 25263-90A
Polished, includes trans vent fitting/clamp, #2 cam seal and bushings.
1995-1997 Sportster
(except XL1200C)
25219-91A25230-9525263-90A
Polished, includes trans vent fitting, #2 cam seal and bushings.
1995-1997 cover 25488-89A includes the matched cam gear set.
1996-1997 XL1200C25213-96 25263-90A
Chrome, includes trans vent fitting, #2 cam seal and bushings.
1996-1997 cover 25483-96 includes the matched cam gear set.
1998-1999 Sportster
(except XL1200C)
(except XL1200S)
25219-91B25230-9825263-90B
Polished, includes trans vent fitting, #2 cam seal and bushings.
98-99 (except 883C) cover 25488-89B includes matching cam gear set.
1999 XL883C cover 25473-97YA (silver) includes matching cam gear set.
1998-1999 XL1200C25213-96A 25263-90B
Chrome, includes trans vent fitting, #2 cam seal and bushings.
98-99 cover 25483-96A includes matching cam gear set.
1998 XL1200S25252-97Y 25263-90B
Silver, includes trans vent fitting, #2 cam seal and bushings.
98-99 cover 25491-98 includes matching cam gear set.
1999 XL1200S25252-97YA 25263-90B
Silver, includes trans vent fitting #2 cam seal and bushings.
2000-2003 XL883/883HUG
XL883C/1200
25219-91C 25263-90C
Polished, includes trans vent fitting, #2 cam seal and bushings.
2000-2003 XL1200C25213-96B 25263-90C
Chrome, includes trans vent fitting, #2 cam seal and bushings.
2000-2003 XL1200S25252-97YB 25263-90C
Silver, includes trans vent fitting, #2 cam seal and bushings.
2002-2003 XL883R25307-99YA 25263-90C
Black, includes trans vent fitting, #2 cam seal and bushings.
2004-2016
XL883/XL883L
25219-0425230-0425263-90D
Polished. Has ignition cover plate (32506-90) labeled “5”.
2004-2016 XL1200C/Anv, XL1200L
XL50/XL1200CP
XL1200V/XL1200T
25213-0425230-0425263-90D
Chrome. Has ignition cover plate (32514-04) with center Bar and Shield.
2004-2010 XL883C
2004-2005 XL1200R
25252-0425230-0425263-90D
Silver. 883C has ignition cover (32514-04), 1200R has ignition cover (32555-04).
2005-2016 XL883R
2006-2009 XL1200R
2009-2016 XL883N
2011-2016 XL1200X
2012-2016 XL1200CP
2013-2016 XL1200CA/XL1200CB
25486-05 25263-90D
Black.
2007-2012 XL1200N25546-07 25263-90D
Gray.
2009-2010
XR1200/XR1200X
25246-0825239-08
Silver.
2010-2013 XR1200/XR1200X HDI25250-10
Black.

Transmission Sprocket Cover

Year
Model
Part
Number
Casting
Number
Notes
1986-1990 Sportster34911-81A 73) Polished
1991-1994 Sportster34911-91
1995-2003 Sportster
(except XL883C)
(except XL1200C)
(except XL1200S)
34911-91A Polished
1996-2003 XL1200C34932-96 Chrome
1998-2003 XL1200S/XL883C34938-98 Silver
2002-2003 XL883R34943-02 Black


1) , 6) , 7) , 22) , 29) , 30) , 44) , 61) , 65)
photo by Hippysmack
2) , 3)
photos courtesy of Ebay seller, Sum-body's Harley Parts, Link to Ebay Store
4)
1994 HD Sportster parts catalog
5)
photo courtesy of BIKERSNOS.com. Link to Ebay Store
8) , 9) , 10)
photo by hdmc_ru2 of the XLFORUM, labeled by Hippysmack http://xlforum.net/forums/showthread.php?t=49915&page=7
11) , 12) , 13) , 14)
photo courtesy of Ebay seller, Robison Motorcycles Link to Ebay Store
15)
photo courtesy of BAD ASS CYCLES ETC, Link to Ebay Store
16)
photos courtesy of Ebay seller, animalhouse2010, Link to Ebay store:
18)
photos by pearlmoto of the XLFORUM http://xlforum.net/forums/showthread.php?t=1815630
19)
photo courtesy of Royal Motorworks Citroen Parts Plus, Link to Ebay Store
21)
photo by Moved On of the XLFORUM http://xlforum.net/forums/showthread.php?t=87313
23) , 35) , 36) , 45)
photos by Hippysmack
28)
drawing by Hippysmack
43)
HD Tech Tip #211 dated September 16,2005
46) , 47) , 48)
Pics courtesy of Ebay seller, house of parts 815. Link to Ebay Store
64)
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
71)
photo by npaisnel of the XLFORUM, labeled by Hippysmack http://xlforum.net/forums/showthread.php?t=2077485&page=26
72)
1986-2019 HD Sportster Parts Catalogs
73)
1986-1990 HD Sportster Parts Catalogs
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