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techtalk:evo:engmech01c [2022/01/20 02:31] hippysmack [Interchangeability] |
techtalk:evo:engmech01c [2024/01/03 06:37] (current) hippysmack |
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| * 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. | * 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. | * 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)) | + | * 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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/frame-mount-evo-sportster-talk-1986-2003-models/75511-4-to-5-speed-engine-swap-questions/page2?t=533976&page=2)) |
| * 1991-2003 frames have the jiffy stand mount welded behind the center of the motor mount. | * 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 as the left bottom tube is devoted to shift the motor as is in 1986-2003 frames. \\ You'll still have to deal with moving the kick stand on those however. | + | * 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. |
| Welded kickstand mount locations: ((composite of pics used with permission)) \\ | Welded kickstand mount locations: ((composite of pics used with permission)) \\ | ||
| {{:techtalk:evo:body:1986-2003_sportster_frame_kickstand_mount_locations_.jpg?direct&300|}} \\ | {{:techtalk:evo:body:1986-2003_sportster_frame_kickstand_mount_locations_.jpg?direct&300|}} \\ | ||
| - | * **Swapping engine cases**: | + | * **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 ====== | ||
| * 1986-E1987 (all) | * 1986-E1987 (all) | ||
| Line 113: | Line 114: | ||
| ===== Motor Vin Pad / Location ===== | ===== Motor Vin Pad / Location ===== | ||
| - | |||
| Starting in 1970, the bike is titled to the frame only and the same number set is stamped on the motor. \\ | Starting in 1970, the bike is titled to the frame only and the same number set is stamped on the motor. \\ | ||
| Starting in 1981, the motor VIN is only an abbreviation of the frame VIN. \\ | Starting in 1981, the motor VIN is only an abbreviation of the frame VIN. \\ | ||
| Line 122: | Line 122: | ||
| * **1991 to March 1993**: The VIN pad is the case itself not raised, left side in the second rib down from the top with VIN hand stamped there. \\ An off center portion of the second rib was deleted and the Vin was hand stamped into that area. \\ The timing hole plug was moved to the right side of the motor. | * **1991 to March 1993**: The VIN pad is the case itself not raised, left side in the second rib down from the top with VIN hand stamped there. \\ An off center portion of the second rib was deleted and the Vin was hand stamped into that area. \\ The timing hole plug was moved to the right side of the motor. | ||
| * **April 1993-2003**: The VIN is "pin stamped" by machine on the left side of the motor in the same location as 91-E93 and slightly off center. \\ (more toward the front cylinder and with no raised pad) \\ HD issued TSB M-1304/1304A explaining the change was to increase manufacturing efficiency. \\ The pin stamped numbers do not photograph well from afar. \\ In fact, one has to actually focus on the numbers to get a good picture of them. | * **April 1993-2003**: The VIN is "pin stamped" by machine on the left side of the motor in the same location as 91-E93 and slightly off center. \\ (more toward the front cylinder and with no raised pad) \\ HD issued TSB M-1304/1304A explaining the change was to increase manufacturing efficiency. \\ The pin stamped numbers do not photograph well from afar. \\ In fact, one has to actually focus on the numbers to get a good picture of them. | ||
| - | |||
| ===== Various Numbers Found on Cases ===== | ===== Various Numbers Found on Cases ===== | ||
| Line 256: | Line 255: | ||
| | 2000-2003 Sportster Crankcase Number Locations ((photos courtesy of Ebay seller, gnarlydavidson1. [[https://www.ebay.com/sch/gnarlydavidson1/m.html?item=164269655258&rt=nc&nma=true&nordt=true&orig_cvip=true&si=HqcoQgHNj7TAtnE2%252BX5d6I6LD7A%253D&hash=item263f3c04da%3Ag%3AIDEAAOSw4CRe-35v&vxp=mtr&_trksid=p2047675.l2562|Link to Items for Sale page]] )) || | | 2000-2003 Sportster Crankcase Number Locations ((photos courtesy of Ebay seller, gnarlydavidson1. [[https://www.ebay.com/sch/gnarlydavidson1/m.html?item=164269655258&rt=nc&nma=true&nordt=true&orig_cvip=true&si=HqcoQgHNj7TAtnE2%252BX5d6I6LD7A%253D&hash=item263f3c04da%3Ag%3AIDEAAOSw4CRe-35v&vxp=mtr&_trksid=p2047675.l2562|Link to Items for Sale page]] )) || | ||
| |{{:techtalk:evo:engmech:2000-2003_sportster_left_crankcase_number_by_gnarlydavidson1.jpg?direct&300|}}|{{:techtalk:evo:engmech:2000-2003_sportster_right_crankcase_number_by_gnarlydavidson1.jpg?direct&300|}}| | |{{:techtalk:evo:engmech:2000-2003_sportster_left_crankcase_number_by_gnarlydavidson1.jpg?direct&300|}}|{{:techtalk:evo:engmech:2000-2003_sportster_right_crankcase_number_by_gnarlydavidson1.jpg?direct&300|}}| | ||
| + | |||
| ==== Case Match Numbers (1975-Up) ==== | ==== Case Match Numbers (1975-Up) ==== | ||
| In addition to belly numbers, there is a second set of numbers on 75> motors on each case half that should match. \\ | In addition to belly numbers, there is a second set of numbers on 75> motors on each case half that should match. \\ | ||
| Line 269: | Line 269: | ||
| | 1986-1990 Case Match Number Locations ((photo courtesy of c3cycle.com, Link to site: https://www.c3cycle.com/)) | | | 1986-1990 Case Match Number Locations ((photo courtesy of c3cycle.com, Link to site: https://www.c3cycle.com/)) | | ||
| |{{:techtalk:evo:engmech:1986-1990_sportster_case_match_number_locations_-_87_xlh1100_by_c3-cycle-tech.jpg?direct&300|}}| | |{{:techtalk:evo:engmech:1986-1990_sportster_case_match_number_locations_-_87_xlh1100_by_c3-cycle-tech.jpg?direct&300|}}| | ||
| + | |||
| ==== Serial or VIN Numbers ==== | ==== Serial or VIN Numbers ==== | ||
| These numbers pertain to the whole bike, not just the engine. Coding for these numbers changed over the years. \\ | These numbers pertain to the whole bike, not just the engine. Coding for these numbers changed over the years. \\ | ||
| Line 358: | Line 359: | ||
| | 1986-1990 Oil Pump Mounting Boss ((photo courtesy of Robert Evans)) | 1991-2003 Oil Pump Mounting Boss ((photo courtesy of c3cycle.com, Link to site: https://www.c3cycle.com/)) | | | 1986-1990 Oil Pump Mounting Boss ((photo courtesy of Robert Evans)) | 1991-2003 Oil Pump Mounting Boss ((photo courtesy of c3cycle.com, Link to site: https://www.c3cycle.com/)) | | ||
| |{{techtalk:evo:engmech:1986-1990_sportster_oil_pump_mounting_boss_by_robert_evans.jpg?direct&300|}}|{{:techtalk:evo:engmech:1991-2003_sportster_oil_pump_mounting_boss_by_c3-cycle-tech.jpg?direct&300|}}| | |{{techtalk:evo:engmech:1986-1990_sportster_oil_pump_mounting_boss_by_robert_evans.jpg?direct&300|}}|{{:techtalk:evo:engmech:1991-2003_sportster_oil_pump_mounting_boss_by_c3-cycle-tech.jpg?direct&300|}}| | ||
| + | |||
| ==== Right Case Oil Scavenge / Engine Breathing ==== | ==== Right Case Oil Scavenge / Engine Breathing ==== | ||
| 1977-up motors scavenge oil from the crankcase thru an external vertical boss added to the outside of the rear sump area. \\ The boss is rifle drilled from the bottom to connect to the upper horizontal oil passage to the oil pump. \\ A hole is drilled from the inside of the right case to connect sump oil to the return passage. \\ The bottom of the rifled hole in the vertical boss is plugged. \\ | 1977-up motors scavenge oil from the crankcase thru an external vertical boss added to the outside of the rear sump area. \\ The boss is rifle drilled from the bottom to connect to the upper horizontal oil passage to the oil pump. \\ A hole is drilled from the inside of the right case to connect sump oil to the return passage. \\ The bottom of the rifled hole in the vertical boss is plugged. \\ | ||
| Line 370: | Line 372: | ||
| * 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. | ||
| Line 388: | Line 390: | ||
| | 1998-1999 Inner Right Case ((photo courtesy of Ebay seller, Cycle Parts 4U, [[https://www.ebay.com/str/cycleparts4u?_trksid=p2047675.l2563|Link to Ebay Store]] )) | 2000-2003 Inner Right Case ((photo courtesy of Ebay seller, gnarlydavidson1. [[https://www.ebay.com/sch/gnarlydavidson1/m.html?item=164269655258&rt=nc&nma=true&nordt=true&orig_cvip=true&si=HqcoQgHNj7TAtnE2%252BX5d6I6LD7A%253D&hash=item263f3c04da%3Ag%3AIDEAAOSw4CRe-35v&vxp=mtr&_trksid=p2047675.l2562|Link to Items for Sale page]] )) | | | 1998-1999 Inner Right Case ((photo courtesy of Ebay seller, Cycle Parts 4U, [[https://www.ebay.com/str/cycleparts4u?_trksid=p2047675.l2563|Link to Ebay Store]] )) | 2000-2003 Inner Right Case ((photo courtesy of Ebay seller, gnarlydavidson1. [[https://www.ebay.com/sch/gnarlydavidson1/m.html?item=164269655258&rt=nc&nma=true&nordt=true&orig_cvip=true&si=HqcoQgHNj7TAtnE2%252BX5d6I6LD7A%253D&hash=item263f3c04da%3Ag%3AIDEAAOSw4CRe-35v&vxp=mtr&_trksid=p2047675.l2562|Link to Items for Sale page]] )) | | ||
| |{{:techtalk:evo:engmech:1998-1999_sportster_right_case_oil_scavenging_by_88twincam99.jpg?direct&300|}}|{{:techtalk:evo:engmech:2000-2003_sportster_right_case_oil_scavenging_by_gnarlydavidson1.jpg?direct&300|}}| | |{{:techtalk:evo:engmech:1998-1999_sportster_right_case_oil_scavenging_by_88twincam99.jpg?direct&300|}}|{{:techtalk:evo:engmech:2000-2003_sportster_right_case_oil_scavenging_by_gnarlydavidson1.jpg?direct&300|}}| | ||
| + | |||
| ==== High Oil Pressure Bypass ==== | ==== High Oil Pressure Bypass ==== | ||
| - | * 1986-1990 cases do not have provisions for a high oil pressure bypass valve. \\ The bypass is built into the removable oil filter housing that bolts to the front of the right case. \\ There is however a discharge hole in the case from the back of the filter housing into the cam case. \\ Oil released from the bypass valve dumps to the cam chest floor to run the scavenge route back to the oil tank. | + | * 1986-1990 cases do not have provisions for a high oil pressure bypass valve. \\ The bypass valve is built into the removable oil filter housing that bolts to the front of the right case. \\ There is however a discharge hole in the case from the back of the filter housing into the cam case. \\ Oil released from the bypass valve dumps to the cam chest floor to run the scavenge route back to the oil tank. |
| * 1991 cases have the oil filter mount cast into the right case (not removable). \\ The high pressure bypass is incorporated inside the case behind the oil filter mount and very noticeable with the cam cover off. | * 1991 cases have the oil filter mount cast into the right case (not removable). \\ The high pressure bypass is incorporated inside the case behind the oil filter mount and very noticeable with the cam cover off. | ||
| * 1992-Up cases also have a high pressure oil bypass. It's not a valve but rather a tiny hole drilled into the upper right case. \\ The hole is drilled thru the case at the bottom of the upper feed galley above #2 cam gear. It doubles as an added spray of oil onto #2 cam gear. \\ But the hole is app .060" so it won't spray a lot of oil unless the pressure gets to a certain point in the oil feed path. | * 1992-Up cases also have a high pressure oil bypass. It's not a valve but rather a tiny hole drilled into the upper right case. \\ The hole is drilled thru the case at the bottom of the upper feed galley above #2 cam gear. It doubles as an added spray of oil onto #2 cam gear. \\ But the hole is app .060" so it won't spray a lot of oil unless the pressure gets to a certain point in the oil feed path. | ||
| Line 395: | Line 398: | ||
| | 1986-2003 high pressure bypass configurations ((composite using pics from Robert Evans - c3-cycle-tech - gnarlydavidson1)) | | | 1986-2003 high pressure bypass configurations ((composite using pics from Robert Evans - c3-cycle-tech - gnarlydavidson1)) | | ||
| |{{:techtalk:evo:engmech:1986-2003_sportster_right_case_high_pressure_bypass_-_from_robert_evans_-_c3-cycle-tech_-_gnarlydavidson1.jpg?direct&400|}}| | |{{:techtalk:evo:engmech:1986-2003_sportster_right_case_high_pressure_bypass_-_from_robert_evans_-_c3-cycle-tech_-_gnarlydavidson1.jpg?direct&400|}}| | ||
| - | |||
| - | |||
| - | |||
| ==== Primary / Transmission External Vent (1986-Present) ==== | ==== Primary / Transmission External Vent (1986-Present) ==== | ||
| Line 404: | Line 404: | ||
| | 1986-1990 Transmission Vent ((photo courtesy of c3cycle.com, Link to site: https://www.c3cycle.com/)) | 1991-1999 Transmission Vent ((photo courtesy of c3cycle.com, Link to site: https://www.c3cycle.com/)) | 2000-2003 Primary Vent ((photo courtesy of c3cycle.com, Link to site: https://www.c3cycle.com/)) | | | 1986-1990 Transmission Vent ((photo courtesy of c3cycle.com, Link to site: https://www.c3cycle.com/)) | 1991-1999 Transmission Vent ((photo courtesy of c3cycle.com, Link to site: https://www.c3cycle.com/)) | 2000-2003 Primary Vent ((photo courtesy of c3cycle.com, Link to site: https://www.c3cycle.com/)) | | ||
| |{{:techtalk:evo:engmech:1986-1990_sportster_primary-transmission_vent_by_c3-cycle-tech.jpg?direct&300|}}|{{:techtalk:evo:engmech:1991-1999_transmission_-_primary_vent_location_by_c3-cycle-tech.jpg?direct&300|}}|{{:techtalk:evo:engmech:2000-2003_sportster_transmission-primary_vent_by_c3-cycle-tech.jpg?direct&300|}}| | |{{:techtalk:evo:engmech:1986-1990_sportster_primary-transmission_vent_by_c3-cycle-tech.jpg?direct&300|}}|{{:techtalk:evo:engmech:1991-1999_transmission_-_primary_vent_location_by_c3-cycle-tech.jpg?direct&300|}}|{{:techtalk:evo:engmech:2000-2003_sportster_transmission-primary_vent_by_c3-cycle-tech.jpg?direct&300|}}| | ||
| - | ===== Motor mounts ===== | ||
| - | ==== Rear mounts ==== | ||
| \\ | \\ | ||
