Table of Contents
This is an old revision of the document!
EVO: Engine Mechanicals
Camshafts
Removing / Installing Evo Cams
Sub Documents
Cam and Pinion Gear Sets
- 86-99 - Matched cam gear set includes pinion gear and gearcase cover. (not sold separately)
- 00 - Options increased;
- Cam gear sets w/ pinion gear,
- Gear sets w/ #2 cam and pinion gear (only).
- The gearcase cover was now sold separately.
| Year | Model | Cam #1 | Cam #2 Outer (big gear) | Cam #2 Inner (small gear) | Cam #3 | Cam #4 | Pinion Gear |
| 86-87 1) | (25488-86) All cams, pinion gear and cover | 28T | 36T | 28T | 28T | 28T | 18T |
| 88-90 2) | (25488-88) All cams, pinion gear and cover |
||||||
| 91-94 3) | (25488-89) All cams, pinion gear and cover |
||||||
| 95 4) | (25488-89A) All except 1200C cams, pinion gear and cover |
||||||
| 96-97 5) | (25483-96) 1200C chrome cover |
||||||
| 98-99 6) | (25448-89B) Std/Hug/1200 cams, pinion gear and polished cover |
||||||
| (25483-96A) 1200C cams, pinion gear and chrome cover |
|||||||
| (25491-98) 1200S cams, pinion gear and silver cover |
|||||||
| 00 7) | (25193-00) all except 1200S cams and pinion gear only | 28T | 46T | 28T | 28T | 28T | 23T |
| (25194-00) 1200S cams and pinion gear only |
|||||||
| (25190-00) all except 1200S #2 cam and pinion gear only |
|||||||
| (25191-00) 1200S #2 cam and pinion gear only |
|||||||
| 01-03 8) | (25193-00A) all except 1200S cams and pinion gear | 35T | 46T | 35T | 35T | 35T | 23T |
| (25194-00A) 1200S cams and pinion gear |
Cam Gear Changes
- The #2 “W” cam may or may not have a provision for a timing cup after 03. 9)
- If you intend on installing 04-up “W” cams in 03 and prior engines, look at the end of the #2 cam.
- If it does have a provision for a timing cup, they'll work for prior year applications.
- But, you'll have to either update your pinion gear, or use a press to swap your #2 cam's drive gear.
- For 03 and prior year engines, it needs a drilled and tapped hole in the middle of it and the timing cup notch.
- Below (L), you can see the notch on the cam on the right very easily.
- Below (R), shows the (00) #2 cam gear pitch change from the (99) style #2 cam gear.
Pinion Gear
Compatibility 12)
Frame mount Evos 1986-2003 do not list a part number for the pinion gear and it appears the pinion gear is part of the (cam gear set).
| Pinion Gear Part# | Year Models |
| 24047-00 | 2004-2016 All Models |
XL Pinion Gear Color/Size Info here: http://xlforum.net/forums/showthread.php?t=1963918
Timing Cup (Rotor)
Cam Bushings
- The cam bushings get their oil from the fling off of the cam gears and drain back from the top end down the pushrod tubes that puddles in at depressions in the castings where the cam bushing slots are aligned. So basically they are drip fed. Also the cam bushings on the case side are open to the crank behind them, and probably get splash there too. 16)
3)
91,92,93,94 HD Sportster Parts Catalogs
4)
95 HD Sportster Parts Catalog
5)
95-96 HD Sportster Parts Catalog pg 15
6)
98 HD Sportster Parts Catalog pg 15
7)
00 HD Sportster Parts Catalog pg 17
8)
01 HD Sportster Parts Catalog pg 19
9)
aswracing of the XLFORUM http://xlforum.net/forums/showthread.php?page=2&t=1560258
10)
photo by aswracing of the XLFORUM http://xlforum.net/forums/showthread.php?page=2&t=1560258
11)
photo by aswracing of the XLFORUM http://xlforum.net/forums/showthread.php?threadid=1632054
12)
From HD Parts Catalogs 2004 pg 17, 2005 pg 19, 2006 pg 19, 2007 pg 19, 2008 pg 19, 2009 pg 25-27, 2010 pg 25-27, 2011 pg 25-27, 2012 pg 25-27, 2013 pg 29-31, 2014 pg 17, 2015 pg 19, 2016 pg 19
15)
photo by Hippysmack
17)
photo by lostNdallas of the XLFORUM http://xlforum.net/forums/showthread.php?t=1974986&highlight=bronze+drive+gear&page=6
18)
photo by lostNdallas of the XLFORUM http://xlforum.net/forums/showthread.php?t=1974986&highlight=bronze+drive+gear&page=4






