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EVO: Oiling & Lubrication


Sub-Documents


Oil Pumps

Oil Pump Part Numbers for 1991-later

1991-1997 XL P/N = 26204-91

1998-1999 XL P/N = 26204-98

2000-2006 XL P/N = 26204-91A

2007-later XL P/N = 26204-91A(new) - is different design w/same P/N - is retrofitable to 1991-2006 - has bottom cover casting P/N 26213-07

Buell P/N - 26357-02B - same pump as XL 26204-91A(new) but different fittings - will bolt up but you need to move other fittings over

See these XLForum threads: http://xlforum.net/vbportal/forums/showthread.php?t=135265 http://xlforum.net/vbportal/forums/showthread.php?t=1738158


Oil Pump Upgrade Kit 26204-91A

  • In addition to the upgraded Drive Gear (26391-06), there is also an upgraded entire Oil Pump (first installed on 07-later Sportsters). The new pump reuses the same kit part number as a previous version, making it difficult & confusing to know to which version someone is referring. The old (& new) part number for the kit is 26204-91A (which first showed up in model year 1998 and installed thru model year 2006).
  • The difference between the 1998 version and the 2007 version relates to the drive shaft, internal Gerotor return & feed gears and the body (which cannot be ordered separately). The internal parts for the new pump design are not backward compatible to the 98-06 pump design.
  • The only known external indicator to identify that the 2007 pump version is currently installed is the number 26213-07 which is stamped on the bottom of the new version.
  • The upgraded pump is compatible for use on 1991-later Sportsters.

Here are the internal servicing part numbers from 1998-2000 version and 2007 and up version:

Part Name 2000 P/N 2007 P/N
Gear Shaft 26488-98 26239-07
Gerotor Return Set 26491-98 26502-07
Gerotor Feed Set 26492-91 26503-07
Separator Plate 26493-91 Unknown?
Bottom Gasket 26495-89A 26495-89B

26204-91a-2007-oilpumpkit.jpg


Oil Pump Comparison Pics

Click on a pic to enlarge.

26204-91A: 1998-2006 Version

1)
Assembly 2)Scavenger (return) Galley 3)Feed Galley 4)
Parts 5)Scavenger Gerotors installed 6)Separator Plate locked in place by pump body tabs 7)
Feed Gerotors Installed 8) Cover only fits in one direction 9)

26204-91A: 2007 and up Version

Click on a pic to enlarge.

Assembly 10)Scavenger Galley 11)Feed Galley 12)
Parts 13)Scavenger Gerotors Installed 14)Separator Plate spins free 15)
Feed Gerotors Installed 16) Pump Cover 17)



1) , 2) , 3) , 4) , 5) , 6) , 7) , 8) , 10) , 11) , 12) , 13) , 14) , 15) , 16)
photo by Hippysmack of the XLFORUM
9) , 17)
photos by Hippysmack of the XLFORUM
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Trace: • EVO: Oiling & Lubrication