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techtalk:ih:engmech01 [2021/12/24 08:08]
hippysmack [Primary / Chain Cover]
techtalk:ih:engmech01 [2023/12/31 19:30] (current)
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|Engine Case Numbers]]+  * [[techtalk:​ih:​engmech01b|Ironhead ​Engine Case Numbers]]
   * [[techtalk:​ih:​engmech01c|Ironhead Engine Case Identification]]   * [[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]]
  
-====== ​Engine Cases ======+====== ​Motor Mounts ​====== 
 +[[techtalk:​ih:​engmech09#​engine_mounts|Click here for Engine Mounts]] in the Sportsterpedia. \\
  
 +====== Timing Hole Plug ======
 +[[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. \\
 +
 +**1954-1971 KH / Sportster Timing Hole Plug (704)**. \\
 +This plug was also used as an oil tank drain plug for 1958-1961, 1966-1978 XLCH and 1979-1981 XLH, XLCH, XLS Sportsters. \\
 +Threads: 5/​8"​-18 x 3/8" with 3/4" Hex Head. \\
 +
 +Click on a pic to enlarge: \\
 +
 +{{:​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]] )) \\
 +
 +\\
 +**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. \\
 +
 +|  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:​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|}}|
 +
 +|  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:​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 =====
 +==== 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 (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 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. \\
 +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 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. \\
 +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:​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 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)) \\
 +
 +
 +==== 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]] )) \\
 +====== 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|}}|||||| ^{{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#| |Year Model|Case Set \\ Part#|Left Case \\ Part#|Left Case \\ Casting#​|Right Case \\ Part#|Right Case \\ Casting#|
Line 25: Line 267:
 |  Notes|"​Hump"​ cases (primary cast to accept electric starter)||||| |  Notes|"​Hump"​ cases (primary cast to accept electric starter)|||||
 |1969 XLH|24512-67A|24532-58|34-67|24555-67A|24558-67| |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||||| +|  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.||||| 
-|1970-1971 XLH/​XLCH|24512-67A|24531-67|34-67|24555-67A|24558-67| +|L1969-E1971 XLH/​XLCH|24512-67A|24531-67|34-67|24555-67A|24558-67| 
-|  Notes|1970 and all future ​years 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 ​http://​xlforum.net/​forums/showthread.php?p=5894918&​highlight=1970+case#​post5894918))||||| +|  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))||||| 
-|1971 XLCH|24512-70|24531-67| ​ |24555-70| ​ +|L1971 XLCH|24512-70|24531-67| ​ |24555-70|24558-67
-|  Notes|Case set is also replacement for 1970 XLCH. Possible one year only case set (see above)|||||+|  Notes|Case set is also replacement for 1970 XLCH.|||||
 |1972 XLH/​XLCH|24505-72|24535-72|24534-72|24551-72|24558-72| |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.||||| |  Notes|First year for 1000 Sportsters. Last year of the speedometer drive gear in the right case.|||||
Line 65: Line 307:
 |  Notes|Sold for Early 1985 thru the -85A parts book||||| |  Notes|Sold for Early 1985 thru the -85A parts book|||||
  
-====== Flywheel ====== +==== Flywheels ​==== 
-===== Sub-Documents ===== +All part numbers were gathered from period specific Sportster parts catalogs from 1957-1985 including supplement and updated catalogs. \\
-[[techtalk:​ih:​engmech01t|Catalog of OEM Flywheels]]+
  
 ^{{techtalk:​miscres:​instruction_sheet_header_4.png?​nolink&​815|}}|||||||| ^{{techtalk:​miscres:​instruction_sheet_header_4.png?​nolink&​815|}}||||||||
Line 97: Line 338:
 |Pinion Gear Nut \\ Tabbed Washer| ​ |  |  |  |7913 \\ 7044|7913 \\ 7044| |Pinion Gear Nut \\ Tabbed Washer| ​ |  |  |  |7913 \\ 7044|7913 \\ 7044|
  
-===== L1981-up Commonized Flywheels ​=====+==== 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. ​
Line 130: Line 370:
 |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 153: Line 393:
 |9161|.1873"​ - .1872"​|- .0002"​|.480"​| ​ |9161|.1873"​ - .1872"​|- .0002"​|.480"​| ​
  
-====== Primary / Chain Cover ======+==== Primary / Chain Cover ==== 
 +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|}}|||| +^{{techtalk:​miscres:​instruction_sheet_header_4.png?​nolink&​803|}}||||||| 
-|Year Model|Part Number|Gasket|Notes+|Year \\ Model|Part ​\\ Number|Casting \\ Number|Gasket|Starter \\ Shaft \\ Bearing|Oil Filler ​ \\ Plug/​Cap|Clutch Adj \\ Hole Plug| 
-|1957-1966 XL/​XLH|34951-57|34955-52A| +|1952-1953 K Models|34951-52|34950-52|34955-52|N/​A|24742-52|N/​A| 
-|1958-1969 XLC/​XLCH|34949-58|34952-52|black+|1954-1956 K Models|34951-54|34950-52A|34955-52A|N/​A|24742-52|N/​A
-|1964-1969 XLCH|34949-64|34952-52|chrome+|1957-1966 XL/​XLH|34951-57|34950-57|34955-52A|N/​A|34742-52A|N/​A| 
-|1967-1970 XLH|34947-67|34955-67|with needle bearing (9063)+|  Notes:|Sand cast aluminum. Natural finish|||||
-|1970 XLCH|34948-70|34955-67| +|1958-1969 XLC/​XLCH|34949-58|none  ​|34952-52|N/​A|60569-29|N/​A| 
-|1971 XLCH|34948-71|34955-67|cover replaced ​by 34949-71 ​in 1972| +|  Notes:​|Black,​ stamped steel|||||
-|1971-1972 XLH/XLCH \\ 1974-1976 XLH/XLCH ((1974 Sportster Parts Catalog Supplement))|34949-71|34955-67|with needle bearing (9063), polished+|1964-1969 XLCH|34949-64|none|34952-52|N/​A|60570-64|N/​A| 
-|1973 XLH/​XLCH|34949-73 ((1974 Sportster Parts Catalog Supplement))|34955-67|with needle bearing (9063), black+|  Notes:​|Chrome,​ stamped steel|||||
-|1975-1976 XLH/​XLCH|34949-75 ((1975 Sportster Parts Catalog Supplement)) |34955-67| ​ | +|1967-1970 XLH|34947-67|34950-67|34955-67|9063|34742-52A|N/​A| 
-|1977 XLH/​XLCH|34949-75 ((1977 Sportster Parts Catalog Supplement))|34955-75| +|  Notes:|Sand cast aluminum|||||
-|1978-1980 XLH/XLCH|34956-78 ((1978 Sportster Parts Catalog Supplement)) ((1978 Sportster -78A Parts Catalog)) ((1980 Sportster Parts Catalog))|34955-75|with two needle bearings (9063 x 2) \\ polished cover from kit (34949-75A) ​\\ also replacement for 1977 XLH/XLCH| +|1970 XLCH|34948-70|34950-67|34955-67|N/​A|34742-52A|N/​A| 
-|1979 XLS|34941-79|34955-75|gray+|  Notes:|Sand cast aluminum, not drilled for starter shaft bearing. \\ Dowel hole near bearing area not drilled|||||
-|1980 XLS|25424-80|34966-80|cover and gasket ​are both black+|1971 XLCH|34948-71|  ​|34955-67|9063|34742-71|37880-71| 
-|1981-E1984 XLH \\ 1983-E1984 XLS|25430-81|34955-75|polished+|  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.|||||
-|1981-1982 XLS|25424-81|34966-80|cover and gasket ​are both black+|1971-1972 XLH/XLCH \\ 1974-1976 XLH/XLCH ((1974 Sportster Parts Catalog Supplement))|34949-71|  ​|34955-67|9063|34742-71|37880-71| 
-|1983-E1984 XLX|25433-83|34955-75|aluminum ​finish| +|  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.|||||
-|L1984-1985 XLH/​XLS|25430-84|34955-75|polished+|1973 XLH/​XLCH|34949-73 ((1974 Sportster Parts Catalog Supplement))|  ​|34955-67|9063|34742-71|37880-71| 
-|L1984-1985 XLX|25433-84|34955-75|aluminum ​finish|+|  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||||||
  
  
-====== Gearcase / Cam Cover ====== 
- 
-^{{techtalk:​miscres:​instruction_sheet_header_4.png?​nolink&​803|}}||| 
-|Year Model|Cam / Gearcase Cover \\ Part Number|Gasket| 
-|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 - casting: 25202-52A ((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 - casting 76-25202F ((photo by DirtyCory of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=1297584&​page=9)) ​ | 
-|{{:​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. 
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-**Inspection**:​ \\ 
-Check the operation of the oil separator bushing assembly. \\ 
-The spring should have free action and be fully extended in the gearcase cover. \\ 
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-{{:​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)) \\ 
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-{{:​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)) \\ 
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-====== Crankcase Oil Strainer ====== 
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-  * 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)) ​ 
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-{{:​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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