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techtalk:ih:engmech01 [2020/11/06 00:13] – [Gearcase / Cam Cover] hippysmacktechtalk:ih:engmech01 [2025/07/28 22:48] (current) – [Breaker Points/Nosecone Ignition Seal] hippysmack
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 ===== Sub-Documents ===== ===== Sub-Documents =====
-  * [[techtalk:ih:engmech01a|Sprocket Cover Dowel Hole (Case) Repair]]+  * [[techtalk:ih:engmech01a|Ironhead Sprocket Cover Dowel Hole (Case) Repair]] 
 +  * [[techtalk:ih:engmech01b|Ironhead Engine Case Numbers]] 
 +  * [[techtalk:ih:engmech01c|Ironhead Engine Case Identification]] 
 +  * [[techtalk:ih:engmech01d|Ironhead Primary/Chain Cover Pics and Information]] 
 +  * [[techtalk:ih:engmech01e|Ironhead Gearcase/Cam Cover Pics and Information]] 
 +  * [[techtalk:ih:engmech01g|Ironhead Gearcase/Cam Cover Removal and Installation]] 
 +  * [[techtalk:ih:engmech01f|Ironhead Transmission Sprocket Cover Pics]] 
 +  * [[techtalk:ih:engmech01t|Catalog of OEM Flywheels]]
   * [[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|Tapping or 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 =====+====== Motor Mounts ====== 
 +[[techtalk:ih:engmech09#engine_mounts|Click here for Engine Mounts]] in the Sportsterpedia. \\
  
-|Year Model|Cam / Gearcase Cover|Gasket| +====== Timing Hole Plug ====== 
-|1952-1956 K Models|25200-52|25224-52| +[[techtalk:ref:engmech01a#timing_inspection_hole_and_plug_-_sealing_and_thread_repair|Click Here]] to go the Timing Inspection Hole and Plug - Sealing and Thread Repair page in the Sportsterpedia. \\
-|1954-1956 KH|25200-52A (1963 part #)|:::| +
-|1957-1962 XL/XLH/XLCH|25200-57 \\ 25200-63A (1968 part #)|:::| +
-|1963-1966 XLH/XLCH \\ 1967 XLH|25200-63 \\ 25200-63A (1968 part #)|:::| +
-|1967-1969 XLH|25201-67 \\ 25201-67A (1969 part #)|:::|+
  
-1957-1967 XLs had the solid bar cam cover. ((Monte03 of the XLFORUM http://xlforum.net/forums/showthread.php?p=1284165#post1284165)) \\ +**1954-1971 KH / Sportster Timing Hole Plug (704)**. \\ 
-1968-1970 had the finned looking cam cover. \\ +This plug was also used as an oil tank drain plug for 1958-1961, 1966-1978 XLCH and 1979-1981 XLH, XLCH, XLS Sportsters. \\ 
-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). +Threads: 5/8"-18 x 3/8" with 3/4" Hex Head. \\
-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)) \\ +Click on a pic to enlarge: \\
-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 - casting ( 25202-52) ((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:ref:oil:fitting_704_timing_hole-oil_drain_plug_704_by_sum-body1_pic1.jpg?direct&300|}} ((photos courtesy of Ebay seller, Sum-body's Harley Parts, [[https://www.ebay.com/str/sumbodysharleyparts|Link to Ebay Store]] )) {{:techtalk:ref:oil:fitting_704_timing_hole-oil_drain_plug_704_by_sum-body1_pic1.jpg?direct&300|}} ((photos courtesy of Ebay seller, Sum-body's Harley Parts, [[https://www.ebay.com/str/sumbodysharleyparts|Link to Ebay Store]] )) \\
-|{{: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|}}|+
  
 +\\
 +**1972-2003 Sportster Timing Hole Plug (720)**. \\
 +Threads: 5/8"-18 x .350" with 3/8" Hex Socket (Allen) Head. \\
 +
 +{{:techtalk:ref:oil:fitting_720_timing_hole_plug_by_sum-body1_pic1.jpg?direct&300|}} ((photos courtesy of Ebay seller, Sum-body's Harley Parts, [[https://www.ebay.com/str/sumbodysharleyparts|Link to Ebay Store]] )) {{:techtalk:ref:oil:fitting_720_timing_hole_plug_by_sum-body1_pic2.jpg?direct&300|}} ((photos courtesy of Ebay seller, Sum-body's Harley Parts, [[https://www.ebay.com/str/sumbodysharleyparts|Link to Ebay Store]] )) \\
 +
 +====== Primary Cover ======
 +===== Primary Cover Gaskets =====
 +Below is a list of factory gaskets used on Sportster primary covers. \\
 +Pics of the different part numbers are listed to the right in the chart. Click on the link to open a picture of the part. \\
 +
 +^{{techtalk:miscres:instruction_sheet_header_4.png?nolink&803|}}||||
 +|Year Model|Part#|Notes|Pics|
 +|1952-1953 K Model \\ 1958-1969 XLC, XLCH|34955-52|XLCH "Tin" cover gasket. Kickstart only. \\ Can also replace XLH gasket 34955-52A.|{{:techtalk:ih:engmech:1958-1969_xlc-xlch_primary_cover_gasket_34952-52_by_jrs_vintage_harley_parts.jpg?linkonly|Pic}} ((photo courtesy of Ebay seller, jrsvintageharley1990. [[https://www.ebay.com/str/jrsvintageharleyparts?_trksid=p2047675.l2563|Link to Ebay Store]]  ))|
 +|1954-1956 K Model \\ 1957-1966 XL/XLH|34955-52A|XLH aluminum cover gasket. Kickstart only.|{{ :techtalk:ih:engmech:1954-1956_k_model_1957-1966_xl-xlh_primary_cover_gasket_34955-52a_by_fox_cycle_works.jpg?linkonly |Pic}} ((photo courtesy of Fox Cycle Works, [[https://www.ebay.com/str/foxcycleworks?_trksid=p2047675.m3561.l2563|Link to Ebay Store]] ))|
 +|1967-1976 XLH \\ 1970-1976 XLCH|34955-67|First electric start XL motor.|{{ :techtalk:ih:engmech:1967-1976_xlh_1970-1976_xlch_primary_cover_gasket_34955-67_by_fox_cycle_works.jpg?linkonly |Pic}} ((photo courtesy of Fox Cycle Works, [[https://www.ebay.com/str/foxcycleworks?_trksid=p2047675.m3561.l2563|Link to Ebay Store]] ))|
 +|1977-1985 XLH \\ 1977-1979 XLCH \\ 1983-1990 Sportster|34955-75|  |  |
 +|1980-1982 XLS|34966-80|Same exact gasket as 1977-1985 version above, just black in color.|  |
 +
 +===== Shifter Shaft Bushing =====
 +=== 1977-2003 Bushing ===
 +1977-2003 Sportster Primary Cover Shifter Shaft Bushing 40520-63. Bushing is open ended. \\
 +Below are approximate (only) dims. ((photos courtesy of Ebay seller, Robison Motorcycles [[https://www.ebay.com/str/robisonmotorcycles?_trksid=p2047675.l2563|Link to Ebay Store]] )) \\
 +
 +{{:techtalk:evo:engmech:1977-2003_sportster_shifter_shaft_bushing_40520-63_by_robisonmotorcycles_pic1.jpg?direct&300|}}  {{:techtalk:evo:engmech:1977-2003_sportster_shifter_shaft_bushing_40520-63_by_robisonmotorcycles_pic2.jpg?direct&300|}}  \\
 +
 +{{:techtalk:evo:engmech:1977-2003_sportster_shifter_shaft_bushing_40520-63_by_robisonmotorcycles_pic3.jpg?direct&300|}} {{:techtalk:evo:engmech:1977-2003_sportster_shifter_shaft_bushing_40520-63_by_robisonmotorcycles_pic4.jpg?direct&300|}} \\
 +
 +===== Primary Cover Dowel Bushing (1977-1985) =====
 +Dowel bushing part# (24754-77). \\
 +1977-1985 covers used 3 dowel bushings to locate the primary cover to the left case. (same bushing used through 1996 covers) \\
 +The mounting bolt hole in the cover is drilled for the OD of the bushing with the ID of the bushing sized for the mounting bolt. \\
 +
 +{{:techtalk:ih:engmech:1977-1996_sportster_primary_cover_dowel_bushing_24754-75_by_robisonmotorcycles.jpg?direct&300|}} ((photo courtesy of Ebay seller, Robison Motorcycles [[ https://www.ebay.com/str/robisonmotorcycles?_trksid=p2047675.l2563 |Link to Ebay Store]] )) \\
 +
 +===== Name Transfer (1971-1980) =====
 +These are used in the "pocket" in the center of the primary cover. \\
 +1971 XLH, XLCH used the transfer labeled "900" (34960-71). \\
 +1972-1976 XLH, XLCH used the transfer labeled "1000" (34960-72). \\
 +1977-1978 XLCR used the transfer labeled "CR1000" (34965-77). \\
 +1977-1980 XLH, XLCH used the transfer labeled "Sportster" (34961-77). \\
 +1979-1980 XLS used the transfer labeled "1000" (34962-79). \\
 +
 +{{:techtalk:ih:engmech:1977-1978_xlcr_name_transfer_34965-77_by_johngoober.jpg?direct&300|}} ((photo by Ebay seller, johngoober, [[https://www.ebay.ca/sch/i.html?item=144998065911&rt=nc&_trksid=p2047675.m3561.l2562&_ssn=johngoober|Link to Ebay Store]] )) {{:techtalk:ih:engmech:1971_xlh-xlch_name_transfer-900_34960-71_by_market406.jpg?direct&300|}} ((photo courtesy of Ebay seller, market406. [[https://www.ebay.com/sch/market406/m.html?_nkw=&_armrs=1&_ipg=&_from=|Link to Items for Sale page]] )) 
 +
 +{{:techtalk:ih:engmech:1977-1980_xlh-xlch_name_transfer-sportster-_34961-77_by_nitrofrankie_go-fast_hd.jpg?direct&300|}} ((photo courtesy of NitroFrankie Go-Fast HD, [[https://www.ebay.com/sch/m.html?item=194837126341&_ssn=ct_kustoms&_ipg=200&rt=nc|Ebay Items for Sale Page]] )) \\
 +
 +===== Access Covers / Cap Plugs =====
 +=== 1957-1970 XL/XLH and 1970 XLCH ===
 +**Oil Filler Hole Plug (34742-52A)**: \\
 +The plug cap is threaded for removal to add oil to the primary case. \\
 +The plug is polished and knurled with a small hole through the center and filter mesh staked in place on the inward side of the plug. \\
 +It screws into the hole in the primary cover with no seal. The small hole with filter mesh serves as primary air intake. \\
 +This hole allows air to come into the primary replacing what's lost to the crankcase from the transfer valve in the left case half. \\
 +It also serves to control the amount of vacuum built up in the primary case by way of intake air from outside the case. \\
 +The plug has a slot milled out across the face as a socket for removal/installation and the tool is similar to and fits into the slot. \\
 +
 +|  1957-1970 XL/XLH and 1970 XLCH Oil Filler Hole Plug (34742-52A) ((photos courtesy of Ebay seller, Sum-body's Harley Parts, [[https://www.ebay.com/str/sumbodysharleyparts|Link to Ebay Store]] ))  ||
 +|{{:techtalk:ih:engmech:1957-1970_xl-xlh_and_1970_xlch_primary_cover_oil_filler_hole_plug_34742-52a_by_sum-body1_pic1.jpg?direct&300|}}|{{:techtalk:ih:engmech:1957-1970_xl-xlh_and_1970_xlch_primary_cover_oil_filler_hole_plug_34742-52a_by_sum-body1_pic2.jpg?direct&300|}}|
 +
 +=== 1971-1976 All Models ===
 +**Oil Filler Hole Plug (34742-71)**: \\
 +Changes made to the 57-70 hole plug include no knurling and now using a sealing O-ring (11106). \\
 +The plug cap is threaded for removal to add oil to the primary case. \\
 +The plug has a small hole through the center and filter mesh staked in place on the inward side of the plug. \\
 +It screws into the hole in the primary cover and seals with the installed O-ring. The small hole with filter mesh serves as primary air intake. \\
 +This hole allows air to come into the primary replacing what's lost to the crankcase from the transfer valve in the left case half. \\
 +It also serves to control the amount of vacuum built up in the primary case from outside air intake. \\
 +The plug has a slot milled out across the face as a socket for removal/installation and the tool is similar to and fits into the slot. \\
 +
 +**Clutch Adjustment Hole Plug (37880-71)**: \\
 +This cap plug was introduced on the primary cover with the redesigned wet clutch models and installs over the clutch adjuster. \\
 +The procedure for clutch cable adjustment (as outlined in 1971-1972 Sportster owner and FSMs require the removal of the chain cover. \\
 +The MoCo revealed an easier way to make clutch adjustments by removing the access plug from the chain cover instead of removing the cover. \\
 +[[techtalk:miscres:miscres05|Click Here]] to go to the service bulletin page and scroll down to TSB #634 to view that PDF bulletin. \\
 +The cap plug is polished, has knurled edges and doesn't install flush with the cover. \\
 +The clutch adjustment hole plug also uses O-ring (11106), has no through-hole vent and has overlapping slots cut into the face in a "cross" pattern. \\
 +No vent is needed in this cap since the oil filler plug has the vent controlling air intake. \\
 +
 +|  1971-1976 Sportster Primary Oil Filler Plug (34742-71)  ((photos courtesy of Ebay seller, 57harleyrider. [[https://www.ebay.com/str/57harleyrider|Link to Ebay Store]] ))  ||
 +|{{:techtalk:ih:engmech:1971-1976_sportster_primary_filler_plug_34742-71_57harleyrider_pic1.jpg?direct&300|}}|{{:techtalk:ih:engmech:1971-1976_sportster_primary_filler_plug_34742-71_57harleyrider_pic2.jpg?direct&300|}}|
 +
 +|  1971-1976 Sportster Clutch Adjustment Hole Plug (37880-71) ((photos courtesy of Ebay seller, Sum-body's Harley Parts, [[https://www.ebay.com/str/sumbodysharleyparts|Link to Ebay Store]] ))  ||
 +|{{:techtalk:ih:engmech:1971-1976_xlh-xlch_clutch_adjustment_hole_plug_37880-71_by_sum-body1_pic1.jpg?direct&300|}}|{{:techtalk:ih:engmech:1971-1976_xlh-xlch_clutch_adjustment_hole_plug_37880-71_by_sum-body1_pic2.jpg?direct&300|}}|
 +
 +=== 1977-1985 All Models ===
 +1977-1985 models use 2 identical hole plugs for the oil filler hole and the clutch adjustment hole. \\
 +It's looks the same as the 1971-1976 oil filler hole plug but it has no vent hole. \\
 +The primary now breathes from a rubber hose on the top rear of the transmission. \\
 +The plug went through a couple revisions but any of these will fit and function on 1977-1985 primary covers. \\
 +1977 models used (34742-77) \\
 +1978-E1985 models used (34742-77A) \\
 +L1984-1985 models used (34742-77B) \\
 +
 +|  L1984-1985 Primary Oil Filler Plug 34742-77B ((photos courtesy of Ebay seller, animalhouse2010, [[https://www.ebay.com/str/animalhouse2010?_trksid=p2047675.l2563|Link to Ebay store:]] ))  |||
 +|{{:techtalk:ih:engmech:1984l-1985_sportster_primary_oil_filler_plug_34742-77b_by_animalhouse2010_pic1.jpg?direct&300|}}|{{:techtalk:ih:engmech:1984l-1985_sportster_primary_oil_filler_plug_34742-77b_by_animalhouse2010_pic2.jpg?direct&300|}}|{{:techtalk:ih:engmech:1984l-1985_sportster_primary_oil_filler_plug_34742-77b_by_animalhouse2010_pic3.jpg?direct&300|}}|
 +
 +====== Gearcase / Cam Chest Cover ======
 +===== Cam Cover Gasket =====
 +**Make sure to use the correct gasket for your engine/cover specifics**. \\
 +There were changes to the upper feed galley that dictate a specific gasket, especially between 1979-1982 models. \\
 +The upper oil feed galley was redesigned during the 1979-1982 and according to the MoCo, the gasket must fit the case design. \\
 +
 +Below is a quick list of factory gaskets used on Sportster gearcase/cam covers. \\
 +Pics of the different part numbers are listed to the right in the chart. Click on the link to open a picture of the part. \\
 +
 +^{{techtalk:miscres:instruction_sheet_header_4.png?nolink&803|}}|||
 +|Year Model|Part#|Notes|
 +|1952-1976 K Models, Sportsters|25224-52|See below|
 +|1977-some E1981 Sportsters|25224-52A|:::|
 +|1982-1985 Sportsters \\ (some 1981 Sportsters)|25263-81|:::|
 +
 +\\
 +More in depth information on the right case changes that affected the cover gasket from 1979-1982; \\
 +[[techtalk:ih:engmech01c#upper_oil_feed_galley|Click Here]] to read more about gearcase changes around the upper feed galley. \\
 +
 +**1957-E1982 right cases with the small boss and __upper oil feed oil slot__:** \\
 +1952-1976 K and Sportster original __gasket__ (25224-52), designed with an upper feed oil hole. Updated gasket (25224-52A). \\
 +1977-L1981 and some E1982 Sportsters original gasket (25224-52A) original had a single for the upper feed galley passage. \\
 +The original gasket was updated in Nov. 1979 with a short slanted slot added to match the gearcase modification in L1979-E1980 models. ((TSB M-778 dated May 13, 1980)) \\
 +And the updated -52A gasket replaced the -52 gasket for 1952-1976 models in the -78B catalog. \\
 +
 +**1982-1985 and some L1981 right cases with the large boss and __upper oil feed hole__:** \\
 +L1981-1985 Sportsters use gasket (25263-81), designed with a long horizontal slot. \\
  
-|  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 ((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))  | +|  1957-E1982 oil feed slot ((photo courtesy of Ebay seller, inlinefabrication. [[https://www.ebay.com/str/inlinefabrication|Link to Ebay Store]] ))   |  L1981-1985 oil feed hole ((photo courtesy of c3cycle.com, Link to site: https://www.c3cycle.com/))  | 
-|{{: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|}}|+|{{:techtalk:ih:engmech:1972_xlch_gearcase_oil_galley_by_inlinefabrication.jpg?direct&300|}}|{{:techtalk:ih:engmech:1984l_xls_gearcase_oil_galley_by_c3-cycle-tech.jpg?direct&300|}}|
  
-|  1979-1980 Cam Cover ((photo by Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1845601&page=2))  |  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)  | +|  Cam Cover Gasket (25224-52A) ((photo courtesy of Ebay seller, jrsvintageharley1990. [[https://www.ebay.com/str/jrsvintageharleyparts?_trksid=p2047675.l2563|Link to Ebay Store]]  ))  |  Cam Cover Gasket (25263-81)  | 
-|{{:techtalk:ih:engmech:cam_cover_79-80_by_dr_dick.jpg?direct&300|}}|{{:techtalk:ih:engmech:cam_cover_l84-85_by_dr_dick.jpg?direct&300|}}|+|{{:techtalk:ih:engmech:1977-l1981_and_some_1982_sportsters_cam_cover_gasket_25224-52a_by_jrsvintageharley1990.jpg?direct&300|}}|{{:techtalk:ih:engmech:1982-1985_and_some_l1981_sportsters_cam_cover_gasket_25263-81_by_jrsvintageharley1990.jpg?direct&300|}}|
  
 ===== Cam Cover Bushings ===== ===== Cam Cover Bushings =====
 +==== Pinion shaft bushings ====
 +1952-1976 bushing (25593-57) uses a .625" pinion bushing bore. ((Dr Dick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/172350-77-breather-please-view-pics/page2?t=1845601&page=2)) \\
 +1977-2020 bushing (25593-74) uses a .562" pinion bushing bore. \\
  
-**Oil Deflector / Separator Bushing Assembly (57-62)**: (or spring loaded top hat) \\+==== Oil Deflector / Separator Bushing Assembly (1957-1962) ==== 
 +AKA, (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)) \\+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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/173424-oil-separator-question-any-help-appreciated?t=1861965)) \\
 These, when bent outward just a little, fit into slots on the far side of the steel bushing pressed into cam cover. \\ 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. \\ 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. \\ 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). \\ 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)) \\+However, it is possible to assemble the unit without removing the steel from the cover. ((62 Ironhead of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/173424-oil-separator-question-any-help-appreciated/page2?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. \\ 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: \\ Notes: \\
Line 63: Line 188:
 The spring should have free action and be fully extended in the gearcase cover. \\ 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:1952-1962_k_model-sportster_breather_oil_separator_bushing_assembly_25265-52_by_jrsvintageharley1990.jpg?direct&300|}} ((photo courtesy of Ebay seller, jrsvintageharley1990. [[https://www.ebay.com/str/jrsvintageharleyparts?_trksid=p2047675.l2563|Link to Ebay Store]]  )) {{:techtalk:ih:engmech:breather_bushing_pic1_by_62_ironhead.jpg?direct&300|}} ((photo by 62 Ironhead of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/173424-oil-separator-question-any-help-appreciated/page2?t=1861965&page=2)) {{:techtalk:ih:engmech:breather_bushing_pic2_by_62_ironhead.jpg?direct&300|}} ((photo by 62 Ironhead of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/173424-oil-separator-question-any-help-appreciated/page2?t=1861965&page=2)) \\
  
-{{: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)) \\ +{{:techtalk:ih:engmech:breather_bushing_pic3_by_62_ironhead.jpg?direct&300|}} ((photo by 62 Ironhead of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/173424-oil-separator-question-any-help-appreciated/page2?t=1861965&page=2)) {{:techtalk:ih:engmech:breather_bushing_pic4_by_62_ironhead.jpg?direct&300|}} ((photo by 62 Ironhead of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/173424-oil-separator-question-any-help-appreciated/page2?t=1861965&page=2)) {{:techtalk:ih:engmech:breather_bushing_pic5_by_62_ironhead.jpg?direct&300|}} ((photo by 62 Ironhead of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/173424-oil-separator-question-any-help-appreciated/page2?t=1861965&page=2)) \\
-====== Flywheel ====== +
-===== Sub-Documents ===== +
-[[techtalk:ih:engmech01c|Catalog of OEM Flywheels]]+
  
-===== Commonized Flywheels ===== 
  
 +==== Shifter Shaft / Brake Shaft Hole Bushings and Plugs ====
 +**1952-1974 Cam Covers**: \\
 +1952-1974 K models and Sportster use shifter shaft bushing (34037-52) in both the right case and the cam cover. \\
 +This bushing is open ended for the long shift shaft to run through it. \\
 +Bushing (34037-52) App. Dims: \\
 +Bushing OD: 5/8" \\
 +Bushing ID: 1/2" \\
 +Bushing Length: 3/4" \\
 +
 +**1975-1976 Cam Covers**: \\
 +1975-1976 Sportsters use shifter shaft bushing (34037-52) in the right case and bushing (34037-75) in the cam cover. \\
 +As result of the Sportster going left side shift in 1975, the shifter shaft got shorter out of the right case. \\
 +The shaft end has linkages back to a crossover arm through the frame. \\
 +This bushing has one closed end which is installed on the outside of the cover. \\
 +Bushing (34037-75) App. Dims: \\
 +Bushing OD: 5/8" \\
 +Bushing ID: 1/2" \\
 +Bushing Length: 3/4" \\
 +
 +**1977-E1981 Cam Covers**: \\
 +1977-E1981 cam covers came with a different bushing (25594-75) for a brake shaft. \\
 +Starting in 1977, the shifter shaft exits out the left case and the old then shifter shaft location in the cam cover became the brake shaft location. \\
 +This was the brake shaft design from 1977-1979 (even though the rear brakes went hydraulic in 1979). \\ 
 +However, in 1980, the MoCo moved the brake operating lever to the trans sprocket cover so the hole in the cam cover was now useless (1980-1985). \\
 +Cam Cover Bushing Bore: .7450" ((Scott of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/197504-cam-cover-swap?t=2074151)) \\
 +Bushing (25594-75) App. Dims: \\
 +Bushing OD (before installing): .752" ((Dims from Robison Motorcycles)) \\
 +Bushing ID (before installing): .6250" ((Scott of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/197504-cam-cover-swap?t=2074151)) \\
 +Bushing Length: .625" ((Dims from Robison Motorcycles)) \\
 +
 +**1980-E1981 Cam Covers**: \\
 +In 1980, the MoCo used a rubber plug (25221-77) in the now unused brake shaft hole in the cam cover. \\
 +The brake shaft bushing was still installed presumably to allow later covers to be used on 1979 models. \\
 +The rubber plug inserts into the bushing. \\
 +The parts books (1980-1985) show the rubber plug sold for 1979-E1981 Sportsters. \\
 +As usual, that means they expected one to upgrade the 1979 system to the 1980 system. \\
 +
 +**L1981-E1984 Cam Covers**: \\
 +Once again a change was made in "how to plug a hole that goes nowhere". \\
 +There may have been some problems with the rubber plug falling out or other. The bushing and plug was deleted from the cover. \\
 +The hole was still there but threaded for metal plug (2506), 7/16"-14 x 1/2" hex socket bolt, which screws into the cam cover. \\
 +L-1984-1985 covers did not use a plug nor did they have a hole for a plug even though the parts books show the plug for L81-85 models. \\
 +
 +**1975-1976 Sportster  cam cover shifter shaft bushing**: ((photos courtesy of Ebay seller, Robison Motorcycles [[ https://www.ebay.com/str/robisonmotorcycles?_trksid=p2047675.l2563 |Link to Ebay Store]] )) \\ 
 +{{:techtalk:ih:engmech:1975-1976_shifter_shaft_bushing_34037-75_by_robisonmotorcycles_pic1.jpg?direct&300|}} {{:techtalk:ih:engmech:1975-1976_shifter_shaft_bushing_34037-75_by_robisonmotorcycles_pic2.jpg?direct&300|}} \\
 +
 +**1977-E1981 Sportster cam cover brake shaft bushing**: ((photos courtesy of Ebay seller, Robison Motorcycles [[ https://www.ebay.com/str/robisonmotorcycles?_trksid=p2047675.l2563 |Link to Ebay Store]] )) \\ 
 +{{:techtalk:ih:engmech:1977-e1981_sportster_brake_shaft_bushing_25594-75_by_robisonmotorcycles_pic1.jpg?direct&300|}} {{:techtalk:ih:engmech:1977-e1981_sportster_brake_shaft_bushing_25594-75_by_robisonmotorcycles_pic2.jpg?direct&300|}} \\
 +
 +**1977-1978 XLCR, 1979-E1981 cam cover brake shaft hole rubber plug**: ((photos courtesy of Ebay seller, Robison Motorcycles [[ https://www.ebay.com/str/robisonmotorcycles?_trksid=p2047675.l2563 |Link to Ebay Store]] )) \\
 +{{:techtalk:ih:engmech:1977-e1981_cam_cover_rubber_plug_25221-77_by_robison_motorcycles.jpg?direct&300|}} \\ 
 +
 +
 +**L1981-E1984 Sportster cam cover screw plug**: ((photo courtesy of C & M Sales, [[https://www.ebay.com/str/everythingmotorcycleparts?_trksid=p2047675.m3561.l2563|Link to Ebay Store]] )) \\
 +{{:techtalk:ih:engmech:1981l-e1984_sportster_cam_cover_shaft_hole_plug_2506_by_morlel32.jpg?direct&300|}} \\
 +
 +===== Ignition Timer Cover =====
 +{{:techtalk:ih:engmech:1991-2002_sportster_ignition_timer_cover_32506-90_by_ebay_cyclewarehouse.jpg?direct&300|}} ((photo courtesy of Ebay seller, cyclewarehouse. [[https://www.ebay.com/sch/cyclewarehouse/m.html?_nkw=&_armrs=1&_ipg=&_from=|Link to Items for Sale]] )) \\
 +===== Breaker Points/Nosecone Ignition Seal =====
 +This is a steel shell radial shaft seal (HD# 11124) installed in the cam cover. \\
 +It surrounds and seals #2 cam when the cover is installed. Also used on 1986-2003 model Sportster cam covers. \\
 +Dims per XLForum member, Fizzle: \\
 +OD 1.570" (39.878mm), ID 1.050" (26.67mm), W 0.248" (6.2992mm) \\
 +
 +Other brands include James (JGI-11124), Cometic (C9355), Athena (51-A210), Custom Chrome (54-043). \\
 +The rubber shell HD Genuine double lip version is part number (11124-DL). \\
 +Other brands include James (JGI-11124-DL). \\
 +**NOTE**: __SKF makes a radial shaft seal with a part number of 11124 but that IS NOT AN HD PART NUMBER__. \\
 +SKF 11124 IS TOO BIG TO FIT THE COVER and they don't show a compatible seal in their catalog for this application. \\
 +
 +HD Seal (11124): \\
 +
 +{{:techtalk:ih:engmech:1971-2003_nosecone_ignition_seal_11124_by_hippysmack.jpg?direct&400|}} ((photo by Hippysmack))
 +====== Parts Lists ======
 +==== Engine Cases ====
 +All part numbers were gathered from period specific Sportster parts catalogs from 1957-1985 including supplement and updated catalogs. \\
 +^{{techtalk:miscres:instruction_sheet_header_4.png?nolink&803|}}||||||
 +|Year Model|Case Set \\ Part#|Left Case \\ Part#|Left Case \\ Casting#|Right Case \\ Part#|Right Case \\ Casting#|
 +|1957-1965 XL/XLH|24511-57|24532-57|24534-57|24556-57|24558-57|
 +|  Notes|"No hump" cases (primary not cast for electric start)|||||
 +|1958-1965 XLC/XLCH|24515-58|24532-58|24534-57|24556-57|24558-57|
 +|  Notes|"No hump" cases  (primary not cast for electric start).|||||
 +|1966 XLH|24511-57 \\ 24511-57A|24532-57|24534-57|24555-57 \\ 24555-57A|24558-57|
 +|  Notes| "No hump" cases  (primary not cast for electric start). \\ E1966 case set (24511-57) replaced by (24511-57A) on 1-13-1966 \\ Factory changes made starting with crankcase# (66 XLCH 6117-up); ((TSB# 537 dated March 22, 1966)) \\  Right case has fillet added to base of countershaft low gear boss. \\ Right case is replacement for all 1957-1965 models. \\ -57A case set is replacement for 57-66 XL/XLH (24511-57) \\ Left case is replacement for 1957-1966 XL/XLH \\ Case set (24511-57A) replaced by 1969 XLCH case set (24515-58A) in 1969 \\ Left case replaced by XLCH (24532-58) in 1969 for 57-66 XL/XLH|||||
 +|1966-1969 XLCH|24515-58 \\ 24515-58A|24532-58|24534-57|24555-57 \\ 24555-57A|24558-57|
 +|  Notes|"No hump" cases  (primary not cast for electric start). \\ E1966 case set (24515-58) replaced by (24515-58A) on 1-13-1966 \\ Factory changes made (66 XLCH 6117-up); ((TSB# 537 dated March 22, 1966)) \\ Right case has fillet added to base of countershaft low gear boss. \\ -57A right case is replacement for all 1957-1965 models \\ -58A case set is replacement for 1966 XLH in 1969|||||
 +|1967-1968 XLH|24512-67|24531-67|34-67|24555-67|24558-67|
 +|  Notes|"Hump" cases (primary cast to accept electric starter)|||||
 +|1969 XLH|24512-67A|24532-58|34-67|24555-67A|24558-67|
 +|  Notes|"Hump" cases (primary cast to accept electric starter). \\ Right case is replacement for 1967-1968 XLH \\ Case set is also replacement for 1967-1969 XLH \\ Right case, lower left of gearcase, drilled and tapped for chain oiler fitting.|||||
 +|L1969-E1971 XLH/XLCH|24512-67A|24531-67|34-67|24555-67A|24558-67|
 +|  Notes|1970 and all future Sportster year cases are "hump" cases for electric start \\ Left case is replacement for 1967-1969 XLH \\ Right case is replacement for 1967-1969 XLH \\ Case set is also replacement for 1967-1969 XLH \\ 1978 parts supplement corrects "used on" models to 70-71 XLCH \\ VIN moved the from the left side case to the right case. \\ A blank Vin pad is still on the left with no number stamped on it. ((Ferrous Head of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/202152-more-stroker-parts/page8?highlight=1970+case#post4499327))|||||
 +|L1971 XLCH|24512-70|24531-67|  |24555-70|24558-67|
 +|  Notes|Case set is also replacement for 1970 XLCH.|||||
 +|1972 XLH/XLCH|24505-72|24535-72|24534-72|24551-72|24558-72|
 +|  Notes|First year for 1000 Sportsters. Last year of the speedometer drive gear in the right case.|||||
 +|1973-1976 XLH/XLCH|24505-73|24535-73|24534-72|24551-73|24558-73A|
 +|  Notes|There was a late 1973 cylinder and head change but the crankcase was left unchanged ((TSB# 652 dated July 30, 1973)) \\ Starting in 1976, case halves not sold separately|||||
 +|1977-1978 XL/XLCH/XLCR|24527-75|  -  |24534-75|  -  |24558-75|
 +|  Notes|Cases redesigned for a minisump, new oil pump mounting boss, left side shifter \\ Crankcase breathes thru holes in gearcase wall, oil trough for timed breather deleted. \\ Vertical oil scavenge passage drilled in sump wall|||||
 +|1979 XL/XLCH|24527-75A|  -  |24534-75|  -  |24558-75|
 +|  Notes|Right case modified to eliminate high pressure oil leakage around the oil passage between the \\ upper crankcase cover and crankcase in November, 1979 ((TSB M-778 dated May 13, 1980))|||||
 +|1979-1980 XLS|24490-79A|  -  |24534-75|  -  |24558-75|
 +|  Notes|Last year cases were cast with hole for kick start.|||||
 +|1980 XL|24527-75B|  -  |24534-75|  -  |24558-75|
 +|  Notes|Case set is also replacement for 1979 XL/XLCH.|||||
 +|1981-1982 XL|24527-81A|  -  |24534-81|  -  |24558-75A|
 +|  Notes|Sold for 1982-E1984 XL/XLS/XLX in 1985 \\ Must use rear motor mount 16203-82A \\ L1981 to E1982 production change on the right case, all XL models. \\ On some cases, the oil galley slot in the top of the gearcase was not machined. \\ Instead, a hole was drilled thru to connect the oil path. \\ Upper left corner of gearcase also received additional threaded hole to mount the gearcase cover. \\ Left case has a new "hump" casting to mount the new Nippon Denso starter.|||||
 +|1981-1982 XLS|24490-81A|  -  |24534-81|  -  |24558-75B|
 +|  Notes|Case set is (painted black). See 1981-1982 XL production change above.|||||
 +|1981-1982 XLS \\ replacement|24490-81C|  -  |  |  -  |  |
 +|  Notes|Replacement (painted black) case for 1981-1982 XLS offered in 1983 \\ Must use rear motor mount 16203-67A on 1981 models \\ Must use rear motor mount 16203-82A on 1982 and 1983 models|||||
 +|1982 XLS \\ replacement|24490-82|  -  |  |  -  |  |
 +|  Notes|Replacement (painted black) case for 1982 XLS offered in 1984 \\ Must use rear motor mount 16203-82A|||||
 +|1983 XL/XLS|24527-81C|  -  |24534-83|  -  |24558-83A|
 +|  Notes|Replacement case for 1981-1982 XL offered in 1983 \\ Must use rear motor mount 16203-67A on 1981 models \\ See TSB M-876A for more details \\ Must use rear motor mount 16203-82A on 1982 and 1983 models \\ L1983 production change: \\ The roll pin for the trans thrust washer in the case was removed. ((TSB m-870 dated April 15, 1983))|||||
 +|L1983 XR-1000|24517-83|  -  |  |  -  |  |
 +|  Notes|  |||||
 +|<del>E1984 XL/XLS/XLX</del>|<del>24480-84</del>|  -  |<del>24534-83A</del>|  -  |<del>24558-83B</del>|
 +|  Notes|Case set 24480-84 is listed in 1984 parts book but number was later given to L1984 case set ((correction noted in Parts and Accessories Bulletin #213 dated January 10, 1984))|||||
 +|E1984 XL/XLS/XLX|24527-82A|  -  |24534-83A|  -  |24558-83B|
 +|  Notes|Late 1984 production change ((TSB M-872 dated August 18, 1983)) \\ Case set is also replacement for 82-E84 models \\ Must use rear motor mount 16203-82A \\ New crankcase set starting with crankcase date code 7 84 174011 (June 22, 1984). \\ Features new mainshaft bearing race (35105-83) and new pressed in mainshaft seal (12049). \\ Trans mainshaft/roller bearing/retaining ring remain unchanged \\ Same channel cast into right side of tranny compartment but hole not drilled for stator grommet|||||
 +|L1984 XL/XLS/XLX|24480-84|  -  |24534-83A|  -  |24558-83B|
 +|  Notes|Production change in 1984 \\ Generator deleted, hole in case there redesigned for oil filter mount \\ Stator mounted to trap door w/ hole in case for wire grommet \\ Channel cast into right side of tranny compartment ending in hole for stator wire grommet|||||
 +|1985 XL/XLS/XLX|24480-85|  -  |  |  -  |  |
 +|  Notes|Originally listed for all 1985 models thru the -85 parts book \\ Sold for Late 1985 thru the -85A parts book \\ Starting with crankcase# (785 303002) a cam gear oiler was installed \\ Right case drilled/tapped between F-R tappets for oiler tube feed oil \\ Gearcase wall tapped to attach oiler tube|||||
 +|E1985 XL/XLS/XLX|24480-85A|  -  |24534-83A|  -  |24558-83B|
 +|  Notes|Sold for Early 1985 thru the -85A parts book|||||
 +
 +==== Flywheels ====
 +All part numbers were gathered from period specific Sportster parts catalogs from 1957-1985 including supplement and updated catalogs. \\
 +
 +^{{techtalk:miscres:instruction_sheet_header_4.png?nolink&815|}}||||||||
 +|Year Model → \\ Parts ↓|1952-1953 \\ K/KK|1954-1956 \\ K Models|1957-1971 \\ XL/XLH \\ XLC/XLCH|1972-1976 \\ XLH/XLCH|1977-1979 \\ XLH/XLCH/XLS \\ full assembly \\ used until \\ depleted →|1980-E1981 \\ XL / XLS \\ full assembly \\ used until \\ depleted →|L1981-1985 \\ XL/XLS/XLX|
 +|Flywheel Assembly \\ w/shafts, w/rods|23900-52|23900-54 \\ 23900-54A|23900-57 \\ 23900-57A (72)|23900-57A|23900-75|23900-75A|23900-75B \\ 23900-75C (83)|
 +|Left \\ Flywheel|23915-52|23916-54 \\ 23916-54A|23916-57 \\ 23916-57A (72)|23916-57A|23916-57A \\ Keyway|23916-57A|23916-80 \\ No keyway|
 +|Right \\ Flywheel|23935-52|23936-54 \\ 23936-54A|23936-57 \\ 23936-57A (72)|23936-57A|23936-57A \\ Compound \\ oil path|23936-57A \\ timing marks \\ changed \\ from case# \\ 780-108-001 ((TSB M-781 dated May 23,1980))|23936-80 \\ Single line \\ oil path|
 +|Connecting Rod \\ Assembly \\ w/bearings \\ w/crankpin|24275-52|24275-54|24275-57|24275-57|24275-57|24275-57|24275-80|
 +|Rear \\ Rod|24290-52|24290-52|24290-57|24290-57|24290-57|24290-57|24290-57|
 +|Front \\ Rod|24294-52|24294-52|24294-52|24294-52|24294-52|24294-52|24294-52|
 +|Crankpin|23960-52|23960-54|23960-54|23960-54|23960-54 \\ Oil hole 110° \\ from keyway|23960-54|23960-80 \\ w/ plug \\ Oil hole 90° \\ from keyway|
 +|Crankpin \\ Roller (std) \\ (1 roller)|9101 (E52) \\ 9381 (L52-53) \\ 9401 (52-53)|9441 \\ 9441A (59) \\ 9150 \\ 9150A (59)|9441 \\ 9441A (59) \\ 9150 \\ 9150A (59)|9441A \\ 9150A|9441A \\ 9150A|9441A \\ 9150A|9441A \\ 9150A|
 +|Crankpin Key|23985-18 \\ 1/8" x 1/2"|23985-18 \\ 1/8" x 1/2"|23985-18 \\ 1/8" x 1/2"|23985-18 \\ 1/8" x 1/2"|23985-18 \\ 1/8" x 1/2"|23985-18 \\ 1/8" x 1/2"|11218 \\ 1/8" x 3/8"|
 +|Crankpin Boss \\ Washer|23972-52|23972-54|23972-57|23972-72|23972-72 (E79) \\ 6506 (L79)|6506|6506|
 +|Crankpin Nut|23967-48|23967-54|23967-54 \\ 23967-54A (71)|23967-54A|23967-54A|
 +|Crankpin Nut \\ Lock Plate|24015-36|24015-36 (E54) \\ 23971-41 (L54)|23971-41|23971-41|23971-41|
 +|Lock Plate \\ Screw|2669|2669|<del>1187 ((1957 parts catalog)) </del> \\ 2669 ((1958 parts catalog supplement)) \\ 2669W (65)|2669W|
 +|Con Rod Rear \\ Roller Retainer|24362-52 \\ 24361-54|24362-54|24362-54|24362-54A|24362-54A|24362-54A|24362-54A|
 +|Con Rod Front \\ Roller Retainer|24364-52 \\ 24361-54|24364-54|24364-54|24364-54A|24364-54A|24364-54A|24364-54A|
 +|Con Rod Rear \\ Bearing Race|   |   |24341-52A (74)|24341-52A (74)|24341-52A|24341-52A|24341-52A|
 +|Con Rod Front \\ Bearing Race|   |24352-52A (74)|24352-52A (74)|24352-52A (74)|24352-52A|24352-52A|24352-52A|
 +|Sprocket Shaft|24000-52|24000-54|24000-57|24000-57|24000-75|24000-75 \\ Large keyway|24000-80 ((1980 parts catalog)) \\ 24000-81 ((TSB M-829 dated 5-19-1981)) \\ common taper \\ No keyway|
 +|Sprocket Shaft Key|23985-12 \\  3/16" x 1/2"|23985-12 \\ E54 KH  \\ 40390-54 \\ L54-56|40390-54|23985-12 \\  3/16" x 1/2"|23985-12 \\  3/16" x 1/2"|23985-12 \\  3/16" x 1/2"|not used|
 +|Gear Shaft|24005-52|24005-54|24005-57|24005-57|24008-75 \\ -77A, -78 \\ 3/16" key|24008-75A \\ 2-piece ((TSB M-829 dated 5-19-1981))|24005-75 ((HD 1979-1982 Parts Catalog pg 11)) \\ 24005-80 ((TSB M-829 dated 5-19-1981)) \\ 1-piece ((TSB M-829 dated 5-19-1981)) \\ common taper \\ 1/8" key|
 +|Gear Shaft Key|23985-18 \\ 1/8" x 1/2"|23985-18 \\ 1/8" x 1/2"|23985-12 \\  3/16" x 1/2" |23985-12 \\  3/16" x 1/2" |23985-12 (E79) \\ 11200 (L79)|11200 ((TSB M-829 dated 5-19-1981))|11218 \\ 1/8" x 3/8"|
 +|Sprocket Shaft \\ or Gear Shaft \\ Lock Plate|  |  |24015-36|24015-36|
 +|Lock Plate \\ Screw|2669|2669|<del>1187 ((1957 parts catalog)) </del> \\ 2669 ((1958 parts catalog supplement)) \\ 2669W (65)|2669W|
 +|Sprocket or Gear \\ Shaft Nut|  |24003-54 \\ (54-E55) \\ 8011 \\ (54-56)|8011|8011|8011|8011|
 +|Pinion Gear Nut \\ Tabbed Washer|  |  |  |  |7913 \\ 7044|7913 \\ 7044|
 +
 +==== L1981-up Commonized Flywheels ====
  
   * In May of 1981, the MoCo issued a bulletin stating that product and quality improvements have brought about a commonized flywheel taper design. \\   * In May of 1981, the MoCo issued a bulletin stating that product and quality improvements have brought about a commonized flywheel taper design. \\
-All tapers were communized at 6° and all keyways were standardized. \\ +All tapers were communized at 6° and all keyways were standardized. In June of 1981, an update to this bulletin was issued to include part numbers. ((HD Service Bulletin #M-829 dated May 19, 1981)) ((HD Service Bulletin #M-829A dated June 12, 1981))
-In June of 1981, an update to this bulletin was issued to include part numbers. ((HD Service Bulletin #M-829 dated May 19, 1981)) ((HD Service Bulletin #M-829A dated June 12, 1981))+
   * A limited number of E1982 XL engines (782216009-782237017) were assembled without the communized flywheel taper design. ((HD Service Bulletin #M-840 dated October 2, 1981))   * A limited number of E1982 XL engines (782216009-782237017) were assembled without the communized flywheel taper design. ((HD Service Bulletin #M-840 dated October 2, 1981))
     * Notable component changes are included in the chart below.      * Notable component changes are included in the chart below. 
     * This was a running change in 1340cc and 1000cc engines but both new and old designs were used in production until the old stock parts ran out.     * This was a running change in 1340cc and 1000cc engines but both new and old designs were used in production until the old stock parts ran out.
-    * Even though the assembly and disassembly was the same for the old and new style flywheels, the torque values did change for the new style assembly. However, new and old style components must not be intermixed. +    * Assembly and disassembly was the same for the old and new style flywheels but the torque values did change for the new style assembly. \\ However, new and old style components must not be intermixed.
-    +
          
 Changes for Sportster 1000 engines include: Changes for Sportster 1000 engines include:
 +^{{techtalk:miscres:instruction_sheet_header_4.png?nolink&803|}}|||
 |**New Flywheel** - \\ Sprocket Side \\ Gear Side| \\ 23916-80 \\ 23936-80| \\ 'Lazy 8' rear cylinder timing mark and no keyway \\ Single hole oil path.| |**New Flywheel** - \\ Sprocket Side \\ Gear Side| \\ 23916-80 \\ 23936-80| \\ 'Lazy 8' rear cylinder timing mark and no keyway \\ Single hole oil path.|
 |The old style flywheel has a keyway on the sprocket side (23916-57A) and a compound (2) hole oil path on the gear side (23936-57A).||| |The old style flywheel has a keyway on the sprocket side (23916-57A) and a compound (2) hole oil path on the gear side (23936-57A).|||
Line 105: Line 385:
 |Old style crank key (23985-18) has a large woodruff key (1/8" x 1/2")||| |Old style crank key (23985-18) has a large woodruff key (1/8" x 1/2")|||
  
- +==== Roller Bearing Inspection (1957-1976) ====
- +
- +
-====== Roller Bearing Inspection (1957-1976) ======+
  
   * In a letter dated May 9, 1977, an HD interoffice memo was sent regarding an inspection of parts stock roller bearings. Some roller bearing part numbers were found to have incorrect diameters. A new micrometer was purchased to remedy this problem.   * In a letter dated May 9, 1977, an HD interoffice memo was sent regarding an inspection of parts stock roller bearings. Some roller bearing part numbers were found to have incorrect diameters. A new micrometer was purchased to remedy this problem.
Line 114: Line 391:
   * In light of this oversight, a listing of part numbers with their correct dims and tolerances was issued as in below:   * In light of this oversight, a listing of part numbers with their correct dims and tolerances was issued as in below:
  
 +^{{techtalk:miscres:instruction_sheet_header_4.png?nolink&803|}}||||
 ^Used for 57-76 Sportster gear shaft roller bearings|Diameter|Size|Length| ^Used for 57-76 Sportster gear shaft roller bearings|Diameter|Size|Length|
 |9421|.1876" - 1974"|Standard|.800" - .796"| |9421|.1876" - 1974"|Standard|.800" - .796"|
Line 130: Line 408:
 |9161|.1873" - .1872"|- .0002"|.480"|  |9161|.1873" - .1872"|- .0002"|.480"| 
  
 +==== Primary / Chain Cover ====
 +All part numbers were gathered from period specific Sportster parts catalogs from 1957-1985 including supplement and updated catalogs. \\
  
-====== Crankcase Oil Strainer ======+^{{techtalk:miscres:instruction_sheet_header_4.png?nolink&803|}}||||||| 
 +|Year \\ Model|Part \\ Number|Casting \\ Number|Gasket|Starter \\ Shaft \\ Bearing|Oil Filler  \\ Plug/Cap|Clutch Adj \\ Hole Plug| 
 +|1952-1953 K Models|34951-52|34950-52|34955-52|N/A|24742-52|N/A| 
 +|1954-1956 K Models|34951-54|34950-52A|34955-52A|N/A|24742-52|N/A| 
 +|1957-1966 XL/XLH|34951-57|34950-57|34955-52A|N/A|34742-52A|N/A| 
 +|  Notes:|Sand cast aluminum. Natural finish|||||| 
 +|1958-1969 XLC/XLCH|34949-58|none  |34952-52|N/A|60569-29|N/A| 
 +|  Notes:|Black, stamped steel|||||| 
 +|1964-1969 XLCH|34949-64|none|34952-52|N/A|60570-64|N/A| 
 +|  Notes:|Chrome, stamped steel|||||| 
 +|1967-1970 XLH|34947-67|34950-67|34955-67|9063|34742-52A|N/A| 
 +|  Notes:|Sand cast aluminum|||||| 
 +|1970 XLCH|34948-70|34950-67|34955-67|N/A|34742-52A|N/A| 
 +|  Notes:|Sand cast aluminum, not drilled for starter shaft bearing. \\ Dowel hole near bearing area not drilled|||||| 
 +|1971 XLCH|34948-71|  |34955-67|9063|34742-71|37880-71| 
 +|  Notes:|Die Cast Aluminum. Name transfer "900" in center. Replaced by 34949-71 (1972). \\ Extra removable plug cap added to cover for wet clutch adjustment.|||||| 
 +|1971-1972 XLH/XLCH \\ 1974-1976 XLH/XLCH ((1974 Sportster Parts Catalog Supplement))|34949-71|  |34955-67|9063|34742-71|37880-71| 
 +|  Notes:|Polished. Name transfer "900" in center (1971). Name transfer "1000" in center (1972-up) \\ Extra removable cap added to cover for wet clutch adjustment.|||||| 
 +|1973 XLH/XLCH|34949-73 ((1974 Sportster Parts Catalog Supplement))|  |34955-67|9063|34742-71|37880-71| 
 +|  Notes:|Black. Name transfer "1000" in center|||||| 
 +|1975-1976 XLH/XLCH|34949-75 ((1975 Sportster Parts Catalog Supplement)) |  |34955-67|9063|34742-71|37880-71| 
 +|  Notes:|Polished. Name transfer "900" in center|||||| 
 +|1977 XLH/XLCH|34949-75 ((1977 Sportster Parts Catalog Supplement))|  |34955-75|9063|34742-77|34742-77| 
 +|  Notes:|Polished. Name transfer "Sportster" in center. \\ Replaced by (34949-75A) in 1978 ((1978 Sportster Parts Catalog Supplement))|||||| 
 +|1978-1979 XLH/XLCH|34949-75A ((1978 Sportster Parts Catalog Supplement)) ((1978 Sportster -78A Parts Catalog)) ((1980 Sportster Parts Catalog))|  |34955-75|9063|34742-77A|34742-77A| 
 +|  Notes:|Polished. Replaced by polished cover from kit (34949-75A). Also replacement for 1977 XLH/XLCH \\ Name transfer "Sportster" in center. Later replacement cover 25430-81.|||||| 
 +|:::|34956-78 ((1980 Sportster Parts Catalog))|  |34955-75|9063|34742-77A|34742-77A| 
 +|  Notes:|Polished. Replaced by polished cover from kit (34949-75A). Also replacement for 1977 XLH/XLCH \\ Name transfer "Sportster" in center. Later replacement cover 25430-81.|||||| 
 +|1979 XLS|34941-79|  |34955-75|9063|34742-77A|34742-77A| 
 +|  Notes:|Gray. Name transfer "1000" in center. Replacement cover 25430-81|||||| 
 +|1980 XLH|34946-78|  |34955-75|9063|34742-77A|34742-77A| 
 +|  Notes:|Polished. Part number for cover assembly. Name transfer "Sportster" in center|||||| 
 +|:::|25423-80|  |34955-75|9063|34742-77A|34742-77A| 
 +|  Notes:|Polished, part number for cover assembly. Name transfer "Sportster" in center|||||| 
 +|1980 XLS|25422-80|  |34966-80|9063|34742-77A|34742-77A| 
 +|  Notes:|Black, cover and gasket. Part# for cover assembly. Name transfer "1000" in center|||||| 
 +|:::|25424-80|  |34966-80|9063|34742-77A|34742-77A| 
 +|  Notes:|Black, cover and gasket. Part# for cover only. Name transfer "1000" in center|||||| 
 +|1981-E1984 XLH \\ 1983-E1984 XLS|25430-81|34950-75B|34955-75|N/A|34742-77A|34742-77A| 
 +|  Notes:|Polished. Starter doesn't require bearing in primary cover. \\ Bearing boss still present with hole milled for 1979-1980 bearing.|||||| 
 +|1981-1982 XLS|25424-81|  |34966-80|N/A|34742-77A|34742-77A| 
 +|  Notes:|Black, cover and gasket. Ribbed across center.|||||| 
 +|1983-E1984 XLX|25433-83|  |34955-75|N/A|34742-77A|34742-77A| 
 +|  Notes:|Aluminum finish.|||||| 
 +|L1984-1985 XLH/XLS|25430-84|  |34955-75|N/A|34742-77B|34742-77B| 
 +|  Notes:|Polished|||||| 
 +|L1984-1985 XLX|25433-84|  |34955-75|N/A|34742-77B|34742-77B| 
 +|  Notes:|Aluminum finish||||||
  
-  * If you've split the cases and the screen is in good shape, you don't have to take it out. Hit it with some compressed air and see if it needs replacing. ((BuckIRyder of the XLFORUM http://xlforum.net/forums/showthread.php?t=357456&highlight=xlch+strainer))  
  
-{{:techtalk:ih:engmech:crankcase_oil_strainer_by_happy_bob.jpg?direct&400|}} ((photo by Happy Bob of the XLFORUM http://xlforum.net/forums/showthread.php?t=357456&highlight=xlch+strainer)) {{:techtalk:ih:engmech:oil_screen_on_75_model_by_betasom.jpg?direct&400|}} ((photo by betasom of the XLFORUM http://xlforum.net/forums/showthread.php?t=1856189)) \\ The strainer is held in place by this pin. It is staked into place with the two horizontal lines radiating from the it. To remove strainer, you must first remove the pin. Tear the screen from the strainer and place pliers on the pin inside (the now destroyed strainer) and wiggle the pin out. Strainers and strainer gaskets are available for replacement. ((Hillclimb68xlch of the XLFORUM http://xlforum.net/forums/showthread.php?t=357456&highlight=xlch+strainer)) 
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