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techtalk:ih:engmech01 [2019/06/16 15:42]
hippysmack [Crankcase Oil Strainer]
techtalk:ih:engmech01 [2020/11/06 23:01]
hippysmack [Gearcase / Cam Cover]
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   * [[techtalk:​ih:​engmech01a|Sprocket Cover Dowel Hole (Case) Repair]]   * [[techtalk:​ih:​engmech01a|Sprocket Cover Dowel Hole (Case) Repair]]
   * [[techtalk:​ref:​oil01#​sportster_drain_plugs_explained|Sportster Drain Plugs Explained]]   * [[techtalk:​ref:​oil01#​sportster_drain_plugs_explained|Sportster Drain Plugs Explained]]
-  * [[techtalk:​ref:​engmech01e|Installing a Helicoil on a Drain Plug with the Engine in the Frame]]+  * [[techtalk:​ref:​engmech01e|Tapping or Installing a Helicoil on a Drain Plug with the Engine in the Frame]]
  
 ===== Gearcase / Cam Cover ===== ===== Gearcase / Cam Cover =====
  
-|  Cam Cover (casting 25202-52A((photo by ironheadjunkie of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=1421916&​page=2)) ​ | +|Year Model|Cam / Gearcase Cover \\ Part Number|Gasket| 
-|{{:​techtalk:​ih:​engmech:​cam_cover_1_25202-52a_by_ironheadjunkie.jpg?​direct&​300|}}|+|1952-1956 K Models|25200-52|25224-52 \\ 25244-52A \\ (1977 part #)| 
 +|1954-1956 KH|25200-52A (1963 part #)|:::| 
 +|1957-1962 XL/​XLH/​XLCH|25200-57 \\ 25200-63A (1968 part #)|:::| 
 +|1963-1966 XLH/XLCH \\ 1967-1969 XLCH|25200-63 \\ 25200-63A (1968 part #)|:::| 
 +|1967-1970 XLH|25201-67 \\ 25201-67A (1969 part #)|:::| 
 +|1970 XLCH|25200-70|:::​| 
 +|1971-1972 XLH|25201-71|:::​| 
 +|1971-1972 XLCH|25200-71|:::​| 
 +|1973-1974 XLH|25201-73 \\ black|:::​| 
 +|1973-1974 XLCH|25200-73 \\ black|:::​| 
 +|1975-1976 XLH|25211-75|:::​| 
 +|1975-1976 XLCH|25205-75|:::​| 
 +|1977-1978 XL|25201-75|:::​| 
 +|1977-1978 XLCH|25200-75 \\ 25201-75 (1978 parts sup)|25244-52A| 
 +|1979- XL|25201-79|:::​| 
 +|1979- XLCH|25200-79|:::​| 
 +|1980 XL|25208-80 \\ black|:::​| 
 +|1980 XLS|25209-80 \\ polished|:::​| 
 +|E1981 XL|25227-81 \\ polished|:::​| 
 +|E1981 XLS|25229-81 \\ black|:::​| 
 +|L1981-1982 XLS|25209-81 \\ black|25263-81 \\ '82 part# change| 
 +|L1981-E1984 XL \\ 1983-E1984 XLS/​XLX|25208-81 \\ polished|:::​| 
 +|L1984 XLX|25207-84 \\ alum. finish|:::​| 
 +|L1984 XL/​XLS|25208-84 \\ polished|:::​| 
 +|1985 XLX|25207-84A \\ black|:::​| 
 +|1985 XL/​XLS|25208-84A \\ polished|:::​| 
 + 
 +1957-1967 XLs had the solid bar cam cover. ((Monte03 of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​p=1284165#​post1284165)) \\ 
 +1968-1970 had the finned looking cam cover. \\ 
 +You can interchange the covers if you are not concerned about the look of a stocker for your year bike (better resale trying to stay stock). 
 +Also be aware that some covers had the round cut out for the electric starter XLH that came out in 1967. \\ 
 +You can slap a cover on and wing it, BUT the proper way is to have the cover line reamed when the motor is apart. \\ 
 +(so the cam cover and the right case half are a match in tolerances. \\ 
 + 
 +52-78 cover had only one breather port at 6:00. ((Dr Dick of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=1845601&​page=2)) \\ 
 +79-85 had two. One at 6:00 and one at 10:00. \\ 
 +52-76 uses .625" pinion bushing bore. \\ 
 +77-85 uses .562" pinion bushing bore. \\ 
 + 
 +|  ​1952-1956 ​Cam Cover - casting: 25202-52 ​((photo by Dr Dick of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=1845601&​page=2)) ​ |  1957-1962 Cam Cover - casting25202-52A ((photo by ironheadjunkie of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=1421916&​page=2)) ​ |  1963-1967 Cam Cover - casting: 25202-52A((photo by Dr Dick of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=1845601&​page=2)) ​ |  
 +|{{:​techtalk:​ih:​engmech:​cam_cover_52-56_by_dr_dick.jpg?​direct&​300|}}|{{:​techtalk:​ih:​engmech:​cam_cover_1_25202-52a_by_ironheadjunkie.jpg?​direct&​300|}}|{{:​techtalk:​ih:​engmech:​cam_cover_63-67_by_dr_dick.jpg?​direct&​300|}}| 
 + 
 + 
 +|  1968-1970 Cam Cover - casting: 02-68 ((photo by Dr Dick of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=1845601&​page=2)) ​ |  1971-1976 Cam Cover - casting: 25202-71 ((photo by Dr Dick of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=1845601&​page=2)) ​ |  1977-1978 Cam Cover ((photo by Dr Dick of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=1845601&​page=2)) ​ | 
 +|{{:​techtalk:​ih:​engmech:​cam_cover_68-70_by_dr_dick.jpg?​direct&​300|}}|{{:​techtalk:​ih:​engmech:​cam_cover_71-76_by_dr_dick.jpg?​direct&​300|}}|{{:​techtalk:​ih:​engmech:​cam_cover_77-78_by_dr_dick.jpg?​direct&​300|}}| 
 + 
 +|  1979-1980 Cam Cover - casting: 79-25202 ((photo by Dr Dick of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=1845601&​page=2)) ​ |  1981 Cam Cover - casting: 81-25223 ((photo by Scott of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=2073823)) ​ |  L1984-1985 Cam Cover - casting: 25222-84A ((photo by Dr Dick of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=1845601&​page=2)) \\ (no date code below casting) ​ | 
 +|{{:​techtalk:​ih:​engmech:​cam_cover_79-80_by_dr_dick.jpg?​direct&​300|}}|{{:​techtalk:​ih:​engmech:​1981_cam_cover_by_scott.jpg?​direct&​300|}}|{{:​techtalk:​ih:​engmech:​cam_cover_l84-85_by_dr_dick.jpg?​direct&​300|}}| 
 + 
 +===== Cam Cover Bushings ===== 
 + 
 +**Oil Deflector / Separator Bushing Assembly (57-62)**: (or spring loaded top hat) \\ 
 + 
 +Looking at the brass part, you can see how the spring catches on the inward bent tabs.  There are also unbent tabs on the brass. ((Dr Dick of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=1861965)) \\ 
 +These, when bent outward just a little, fit into slots on the far side of the steel bushing pressed into cam cover. \\ 
 +Here's how the factory assembled this thing. \\ 
 +They had pre-assembled the brass to the steel before the steel was pressed into the cover. \\ 
 +Then dropped the spring into the cover and pressed the brass/steel assembly into the cover as a unit (and manipulated the spring to sit correctly if needed). \\ 
 +However, it is possible to assemble the unit without removing the steel from the cover. ((62 Ironhead of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=1861965&​page=2)) \\ 
 +You can bend the tangs out without having to remove the steel bush with a screwdriver and a hammer to bend the 2 locating tabs out. \\ 
 +Notes: \\ 
 +The tabs must be bent outward enough that the brass stays keyed to the steel at full spring compression. \\ 
 +You don't want the brass hat to '​unkey'​ when the generator compresses spring. 
 +The brass needs to be able to '​plunge'​ in and out under the spring pressure once the tags are bent. \\ 
 +If you get too aggressive, you can cause deformations in the brass that allow it to hang up in it's sliding fit to the steel. \\ 
 +These outward bent tangs do 2 things. \\ 
 +  * They keep the brass hat and spring captive in the cover upon generator removal. 
 +  * More importantly,​ they key the brass to the steel to prevent the brass from rotating with the generator gear. \\ The brass is unable to rotate by the tangs keying into the slots. 
 + 
 +**Inspection**:​ \\ 
 +Check the operation of the oil separator bushing assembly. \\ 
 +The spring should have free action and be fully extended in the gearcase cover. \\ 
 + 
 +{{:​techtalk:​ih:​engmech:​breather_bushing_pic1_by_62_ironhead.jpg?​direct&​300|}} ((photo by 62 Ironhead of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=1861965)) {{:​techtalk:​ih:​engmech:​breather_bushing_pic2_by_62_ironhead.jpg?​direct&​300|}} ((photo by 62 Ironhead of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=1861965)) \\ 
 + 
 +{{:​techtalk:​ih:​engmech:​breather_bushing_pic3_by_62_ironhead.jpg?​direct&​300|}} ((photo by 62 Ironhead of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=1861965)) {{:​techtalk:​ih:​engmech:​breather_bushing_pic4_by_62_ironhead.jpg?​direct&​300|}} ((photo by 62 Ironhead of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=1861965)) {{:​techtalk:​ih:​engmech:​breather_bushing_pic5_by_62_ironhead.jpg?​direct&​300|}} ((photo by 62 Ironhead of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=1861965)) \\
 ====== Flywheel ====== ====== Flywheel ======
 ===== Sub-Documents ===== ===== Sub-Documents =====