Differences
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techtalk:evo:engmech01c [2022/01/17 21:30] hippysmack [1986-1990 Sportster Cases] |
techtalk:evo:engmech01c [2022/02/08 21:36] hippysmack [Interchangeability] |
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| The engine cases below are grouped by the year span they were installed on. \\ | The engine cases below are grouped by the year span they were installed on. \\ | ||
| Notice the casting numbers follow the same pattern although there may differences in color and minor machining within a group. \\ | Notice the casting numbers follow the same pattern although there may differences in color and minor machining within a group. \\ | ||
| + | |||
| + | ====== Interchangeability ====== | ||
| + | * **Swapping engines and frames**: \\ This is to answer the question of "Will this motor bolt to that frame?". There are other factors not taken into account in this section. \\ This is also in consideration of swapping an entire (complete) engine, not mix matched case halves or other functions/features. | ||
| + | * Any 1986-1990 engine will be a bolt-on to any 1986-1990 frame. | ||
| + | * Any 1991-2003 engine will be a bolt-on to any 1991-2003 frame. | ||
| + | * 1991-2003 engines will bolt to 1986-1990 frames with the consideration of the kickstand mount on the left bottom tube. \\ The casing is larger at the front due to the rotor and stator being moved to the crank in 1991. \\ Otherwise, the motor mounts should all bolt up just fine. | ||
| + | * 1986-1988 frames have the jiffy stand mount welded close to the front motor mounts. \\ The kick stand mount needs to be moved as it interferes with the primary cover on 5 speed cases. | ||
| + | * 1989-1990 frames have the jiffy stand mount welded a little further back, just past the center of the oil pump. \\ You should be able to get the motor in without moving the kickstand mount. ((fcarlos085 of the XLFORUM http://xlforum.net/forums/showthread.php?t=533976&page=2)) | ||
| + | * 1991-2003 frames have the jiffy stand mount welded behind the center of the motor mount. | ||
| + | * 1986-2003 motors will also bolt into 1982-1985 frames. \\ The left bottom tube has the divot to shift the motor as is in 1986-2003 frames. \\ You'll still have to deal with moving the kick stand on those however. | ||
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| + | Welded kickstand mount locations: ((composite of pics used with permission)) \\ | ||
| + | {{:techtalk:evo:body:1986-2003_sportster_frame_kickstand_mount_locations_.jpg?direct&300|}} \\ | ||
| + | |||
| + | * **Swapping engine cases**: \\ Since 1976, the MoCo has not sold left / right case halves individually. They sold replacement cases as a left / right set. \\ So it's up to the owner to decide if swapping out a case half is the right thing to do as opposed to swapping a matched case set. \\ Case sets are factory machined / line bored and the precision is not going to be the exact same by swapping out halves from different cases. \\ Likewise, if you are swapping case halves, make sure to have it done by a competent machinist. \\ | ||
| ====== 1986-1990 Sportster Cases ====== | ====== 1986-1990 Sportster Cases ====== | ||
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| * The oil filter pad for 1991-up models is built into the case and is not removable. | * The oil filter pad for 1991-up models is built into the case and is not removable. | ||
| * Oil is fed to the engine from the top down. Oil is pumped to the oil filter pad by way of an external hose from the oil pump. \\ A drilled passage thru the upper case runs from the filter mount to the upper cam chest feed galley. \\ Then oil is pump thru passages in the cam cover to the pinion shaft to crankpin. | * Oil is fed to the engine from the top down. Oil is pumped to the oil filter pad by way of an external hose from the oil pump. \\ A drilled passage thru the upper case runs from the filter mount to the upper cam chest feed galley. \\ Then oil is pump thru passages in the cam cover to the pinion shaft to crankpin. | ||
| - | * Oil pump information: \\ The oil pump design changed for the new routing system thru the cases. \\ Any 1991-1997 Sportster oil pump is a direct bolt-on for 1991-1997 motors (will bolt up but will not work on 98-up cases). \\ Any 1998-present Sportster oil pump is a direct bolt-on for 91-up cases but has a designed inlet in the top of the pump for cam chest oil scavenge. \\ Will function on 1991-1997 cases. | + | * Oil pump information: \\ The oil pump design changed for the new routing system thru the cases. \\ Any 1991-1997 Sportster oil pump is a direct bolt-on for 1991-1997 motors (will bolt up but will not drain 1998-up cam chests). \\ Any 1998-present Sportster oil pump is a direct bolt-on for 91-up cases but has a designed inlet in the top of the pump for cam chest oil scavenge. \\ Will function on 1991-1997 cases. |
| * The breather holes were redesigned using only two holes thru the cam wall with the middle hole from previous deleted. \\ The two remaining holes were enlarged in a rectangular fashion creating a bigger area for air to escape the crankcase. | * The breather holes were redesigned using only two holes thru the cam wall with the middle hole from previous deleted. \\ The two remaining holes were enlarged in a rectangular fashion creating a bigger area for air to escape the crankcase. | ||
| * 1991 cases (only), the oil pressure bypass was still used but installed thru the case into the back side of the oil filter mount. \\ Still dumping over pressured oil into the cam chest. | * 1991 cases (only), the oil pressure bypass was still used but installed thru the case into the back side of the oil filter mount. \\ Still dumping over pressured oil into the cam chest. | ||
