• Installing Evo Cams (91 and Up)

• 86-99 - Matched cam gear set includes pinion gear and gearcase cover.
  • Cam gears are individually matched to each specific gear cover using computer modeling in a controlled environment. ¹⁾
  • Cams are colored coded with a colored dot.
  • Factory gearcase covers were also color coded on the inside with a color dot at each pinion and cam gear location.
  • This allowed for separate colored gears to be factory assembled (and later replaced) using gears optimized for the lowest gear whine and rattle.
    The dealer had to match the cover and gear colors for replacement covers.
• 00-03 - Options increased;
  • Matched cam gear sets w/ pinion gear,
  • Gear sets w/ #2 cam and pinion gear (only).
  • The gearcase cover was now sold separately.
• 04 - Matched cam gear sets were only sold with the pinion gear, pinion gear also sold separately.

Cam Grinds

• 86-87 “T” cams will not work on 88 and up engines.
• 88-90 “C” cams will retrofit to 86-87

• The #2 “W” cam may or may not have a provision for a timing cup after 03. ¹³⁾
  • 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.

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Compatibility ¹⁶⁾

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).

XL Pinion Gear Color/Size Info here: http://xlforum.net/forums/showthread.php?t=1963918

• 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. ²⁰⁾
• Worn bushings can cause excess backlash. ²¹⁾

2010 1200X Inner Cam Bushings (broken teeth on oil pump gear) 22)	2010 1200X Cam Cover and Bushings 23)