Differences

This shows you the differences between two versions of the page.

Link to this comparison view

Both sides previous revision Previous revision
Next revision
Previous revision
techtalk:ih:engmech01c [2021/12/31 04:46]
hippysmack [Crankcase Mini-Sump (1977-1985)]
techtalk:ih:engmech01c [2023/12/19 23:52] (current)
hippysmack [Upper Oil Feed Galley]
Line 2: Line 2:
 ====== IH: Engine Mechanicals - Sub-01C ====== ====== IH: Engine Mechanicals - Sub-01C ======
 ====== Ironhead Engine Case Identification ====== ====== Ironhead Engine Case Identification ======
 +
 +
 \\ \\
 ====== 1957-1971 XLH/XLCH Cases ====== ====== 1957-1971 XLH/XLCH Cases ======
Line 16: Line 18:
 These motors are also known as "no hump" motors as the left cases were not cast to accept a starter (kick only cases). \\  These motors are also known as "no hump" motors as the left cases were not cast to accept a starter (kick only cases). \\ 
 1967-1969 XLH was not 1st generation design though many of these second generation parts will retro-fit to the 1st generation design bikes. \\ 1967-1969 XLH was not 1st generation design though many of these second generation parts will retro-fit to the 1st generation design bikes. \\
-Some don't make that an easy task as they are similar but not the same. ((Dr Dick of the XLFORUM DR DICK http://​xlforum.net/​forums/showpost.php?p=4673358&​postcount=14)) \\+Some don't make that an easy task as they are similar but not the same. ((Dr Dick of the XLFORUM DR DICK https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-motor-engine/​sportster-motorcycle-bottom-end/​159882-57-76-xlch-engine-case-interchange?​postcount=14#​post3402296)) \\
 1967-up XLH and 1970-up XLCH motors are also known as "​hump"​ motors as the left case is cast with a "​hump"​ over the tranny to mount a starter. \\ 1967-up XLH and 1970-up XLCH motors are also known as "​hump"​ motors as the left case is cast with a "​hump"​ over the tranny to mount a starter. \\
  
Line 22: Line 24:
 To make room for this, the rear frame down tubes were offset to the rear with a "​dogleg"​ and now the frame got longer than the original. \\ To make room for this, the rear frame down tubes were offset to the rear with a "​dogleg"​ and now the frame got longer than the original. \\
 The original is a "short frame" and the doglegged version is a "long frame"​. \\ The original is a "short frame" and the doglegged version is a "long frame"​. \\
-See the long frame (dogleg) in the pic below. Note the position of the down tubes to the motor mount surface. ((Dr Dick of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1028933&​page=2)) \\+See the long frame (dogleg) in the pic below. Note the position of the down tubes to the motor mount surface. ((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/​110060-mixing-case-halves/​page2?​t=1028933&​page=2)) \\
  
 {{:​techtalk:​ih:​body:​1967_and_1971_seat_post_comparison_-_composite_of_pics_from_ebay_sellers_animalhouse2010_and_rusty_dusty_motorcycle_parts.jpg?​direct&​400|}} \\ {{:​techtalk:​ih:​body:​1967_and_1971_seat_post_comparison_-_composite_of_pics_from_ebay_sellers_animalhouse2010_and_rusty_dusty_motorcycle_parts.jpg?​direct&​400|}} \\
Line 35: Line 37:
 All 1970-up bikes used the long frame. \\ All 1970-up bikes used the long frame. \\
 1967-1976 electric start "​hump"​ engines will bolt directly into the early kick only frames. \\ 1967-1976 electric start "​hump"​ engines will bolt directly into the early kick only frames. \\
-What won't bolt on from there is the matching e-start accessories (oil tank or battery box). ((Dr Dick of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?t=1780075)) \\+What won't bolt on from there is the matching e-start accessories (oil tank or battery box). ((Dr Dick of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-motor-engine/​sportster-motorcycle-bottom-end/​159882-57-76-xlch-engine-case-interchange?postcount=14#​post3402296)) \\
 The e-starter is well forward of the seat tubes. You may have to do a slight amount of clearancing for the aluminum starter housing. \\ The e-starter is well forward of the seat tubes. You may have to do a slight amount of clearancing for the aluminum starter housing. \\
 Or just run kick only and make it real simple. \\ Or just run kick only and make it real simple. \\
-If swapping early motors into 1977-newer frames, just remember to use the front and rear mounts for the year the frame is. ((bobber58 of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1857474&​page=2)) \\ +If swapping early motors into 1977-newer frames, just remember to use the front and rear mounts for the year the frame is. ((bobber58 of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​173104-engine-interchange/​page2?​t=1857474&​page=2)) \\ 
-Short frame motors will bolt into long frames but the dog leg seat posts will show on the later frames. ((keeno of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?t=717941)) \\+Short frame motors will bolt into long frames but the dog leg seat posts will show on the later frames. ((keeno of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​89397-1963-xlch-engine-into-1972-xlh-frame?t=717941)) \\
  
 Swapping case halves: \\ Swapping case halves: \\
-You can physically bolt any 1952-1976 case halves together (need to remove center dowel pin in certain combos). ((Dr Dick of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1715354)) \\+You can physically bolt any 1952-1976 case halves together (need to remove center dowel pin in certain combos). ((Dr Dick of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-motor-engine/​sportster-motorcycle-bottom-end/​159882-57-76-xlch-engine-case-interchange?​t=1715354)) \\
 That does not mean that the cylinder spigots and crankshaft will exactly line up between the two halves. \\ That does not mean that the cylinder spigots and crankshaft will exactly line up between the two halves. \\
 Further machining may need to be done to pair the two halves (look for a good machinist if so). \\ Further machining may need to be done to pair the two halves (look for a good machinist if so). \\
 There usually is a slight mismatch at the base surfaces. It's up to each owner if you need to re-skim these. \\ There usually is a slight mismatch at the base surfaces. It's up to each owner if you need to re-skim these. \\
-Keep in mind the factory work is pretty damned good. It's easy to correct the surface mismatch and introduce a parallelism to crankshaft center line error. ((Dr Dick of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1833649)) \\+Keep in mind the factory work is pretty damned good. It's easy to correct the surface mismatch and introduce a parallelism to crankshaft center line error. ((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/​170873-mismatching-cases?​t=1833649)) \\
  
 ===== 1957-1966 (All) and 1967-1969 (XLCH) Short Frame Cases ===== ===== 1957-1966 (All) and 1967-1969 (XLCH) Short Frame Cases =====
Line 74: Line 76:
 New (XLH only) "hump cases" with "long frames"​ were made to accept the new starter. \\ New (XLH only) "hump cases" with "long frames"​ were made to accept the new starter. \\
 The 1967-1969 XLCH was unaffected until it also succumbed in 1970. \\ The 1967-1969 XLCH was unaffected until it also succumbed in 1970. \\
-1967-1969 (XLH) and 1970-1976 (all) are electric and / or kick start. ((Dr Dick of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1780075)) \\ +1967-1969 (XLH) and 1970-1976 (all) are electric and / or kick start. ((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/​165486-which-ironheads-to-which-frames?​t=1780075)) \\ 
-You may see many XLHs that added the Option Kicker Kit. ((Monte03 of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1093762)) \\+You may see many XLHs that added the Option Kicker Kit. ((Monte03 of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​114512-no-kick?​t=1093762)) ​\\ 
 +1967 XLH had both Kick and Electric start as the Factory wanted to be "​Certain"​ the Electric proved positive. \\ 
 +In 1968, the Kicker was gone on the XLH, you may see many that added the Optional Kicker Kit (thats how HD makes their money). ​\\ 
  
-On long frames, mechanically speaking, 1967-1969 (XLH) and 1970-1971 (all) cases interchange. ((Dr Dick of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1028933&​page=2)) \\+On long frames, mechanically speaking, 1967-1969 (XLH) and 1970-1971 (all) cases interchange. ((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/​110060-mixing-case-halves/​page2?​t=1028933&​page=2)) \\
 Cosmetically speaking, only 1967-1969 XLH cases are identical. \\ Cosmetically speaking, only 1967-1969 XLH cases are identical. \\
  
Line 112: Line 116:
 The crankcase now breathes thru holes drilled in the wall between the crankcase and gearcase and the timed breather was deleted. \\ The crankcase now breathes thru holes drilled in the wall between the crankcase and gearcase and the timed breather was deleted. \\
  
 +===== 1980 XLH Sportster Cases =====
 +This right case has mid 1980 changes to the upper gearcase (mods the factory made to improve sealing between the cover and the case). \\
 +Belly number 780 277004 (October 4, 1979). \\
 +See [[techtalk:​ih:​engmech01c#​upper_oil_feed_galley|Upper Oil Feed Galley]] below for more information. \\
 +
 +{{:​techtalk:​ih:​engmech:​1980_xlh_right_case_-_outer_by_jandms_ebay_store_harley_disney_toys.jpg?​direct&​400|}} ((photo courtesy of J&​M'​s Ebay Store Harley Disney Toys, labeled by Hippysmack [[https://​www.ebay.com/​str/​recycledharleydavidsonparts|Link to Ebay Store]] )) {{:​techtalk:​ih:​engmech:​1980_xlh_right_case_-_inner_by_jandms_ebay_store_harley_disney_toys.jpg?​direct&​400|}} ((photo courtesy of J&​M'​s Ebay Store Harley Disney Toys, labeled by Hippysmack [[https://​www.ebay.com/​str/​recycledharleydavidsonparts|Link to Ebay Store]] )) \\
 ===== E1984 Sportster Cases ===== ===== E1984 Sportster Cases =====
  
Line 129: Line 139:
   * **1957-1969**,​ The engine serial number pad is a rectangle casting on the left case just above the timing hole plug. \\ The serial number is stamped into the left case pad on all 1969 XLH and XLCH models.   * **1957-1969**,​ The engine serial number pad is a rectangle casting on the left case just above the timing hole plug. \\ The serial number is stamped into the left case pad on all 1969 XLH and XLCH models.
     * SOME LATE 1969 XLH MODELS DID HAVE A VIN PAD ON THE RIGHT SIDE CASE BUT IT WAS LEFT BLANK. \\ This was most likely a running change (as is seen on both case halves L69-E71) for the swap to right side VINs on all 1970 models. \\ The first production XLH __right__ cases in 1969 had no VIN pad. \\ Right side blank pads on 1969 XLH models have reportedly been found on XLH models with VINs down into four digits. \\ The casting numbers on either left or right cases from 1969-E1971 did not change when the VIN pad was added. \\ Also the parts order# for the case set is the same from 69-E71 and the 70-E71 case set was available for order as replacement for 67-69 models. \\ THEREFORE, IT IS POSSIBLE that there were some 1967-1968 XLH cases replaced from the factory also with number pads on each side as well.    ​     * SOME LATE 1969 XLH MODELS DID HAVE A VIN PAD ON THE RIGHT SIDE CASE BUT IT WAS LEFT BLANK. \\ This was most likely a running change (as is seen on both case halves L69-E71) for the swap to right side VINs on all 1970 models. \\ The first production XLH __right__ cases in 1969 had no VIN pad. \\ Right side blank pads on 1969 XLH models have reportedly been found on XLH models with VINs down into four digits. \\ The casting numbers on either left or right cases from 1969-E1971 did not change when the VIN pad was added. \\ Also the parts order# for the case set is the same from 69-E71 and the 70-E71 case set was available for order as replacement for 67-69 models. \\ THEREFORE, IT IS POSSIBLE that there were some 1967-1968 XLH cases replaced from the factory also with number pads on each side as well.    ​
-  * **1970-E1971**,​ The new serial number (now called VIN) and it's required casting pad is on the right side case. \\ The VIN is between #3 & #4 tappet blocks with stars on each side of the VIN. ((Dr Dick of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1805624&​page=2)) ((Dr Dick of the XLFORUM http://xlforum.net/forums/​showthread.php?​t=1805624&​page=2)) +  * **1970-E1971**,​ The new serial number (now called VIN) and it's required casting pad is on the right side case. \\ The VIN is between #3 & #4 tappet blocks with stars on each side of the VIN. ((Dr Dick of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/168240-matching-a-900-case-to-a-1000-case?​t=1805624&​page=2)) 
-    * THERE IS STILL A SERIAL NUMBER PAD ON XLH and XLCH LEFT CASES BUT THE PAD WAS LEFT BLANK. \\ Here are a few comments on the left side blank pad from piniongear of the XLForum: \\ The reason for this is because Harley had no reason to change something until the change was important enough to do some retooling. \\ If they were to eliminate the raised rectangle in 1970 when the number switched to the right hand side, they would have to do retooling on the dies. \\ That would be a waste of good money just to eliminate the raised rectangle. So the cheapest way was to simply not stamp the number. \\ Even this required some retooling but it was not like doing die work. \\ Keep in mind that Harley never changed anything until it was absolutely necessary. \\ Just look at how many parts still carry the old 1952 suffix (xxxxx-52) on the part numbers from the old K Model. ((http://​xlforum.net/​forums/showthread.php?​t=898447)) +    * THERE IS STILL A SERIAL NUMBER PAD ON XLH and XLCH LEFT CASES BUT THE PAD WAS LEFT BLANK. \\ Here are a few comments on the left side blank pad from piniongear of the XLForum: \\ The reason for this is because Harley had no reason to change something until the change was important enough to do some retooling. \\ If they were to eliminate the raised rectangle in 1970 when the number switched to the right hand side, they would have to do retooling on the dies. \\ That would be a waste of good money just to eliminate the raised rectangle. So the cheapest way was to simply not stamp the number. \\ Even this required some retooling but it was not like doing die work. \\ Keep in mind that Harley never changed anything until it was absolutely necessary. \\ Just look at how many parts still carry the old 1952 suffix (xxxxx-52) on the part numbers from the old K Model. ((piniongear of the XLFORUM https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​102802-engine-cases-and-vin-numbers?​t=898447)) 
-  * **L1971-1985**,​ there is no longer a number pad cast into the left case and the right case VIN pad was shifted. \\ The VIN pad and number is on the right case between #2 & #3 tappet blocks with stars on each side of the VIN. ((Dr Dick of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1805624&​page=2))+  * **L1971-1985**,​ there is no longer a number pad cast into the left case and the right case VIN pad was shifted. \\ The VIN pad and number is on the right case between #2 & #3 tappet blocks with stars on each side of the VIN. ((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/​168240-matching-a-900-case-to-a-1000-case?​t=1805624&​page=2))
  
-|  1957-1969 Sportster Serial# / Vin Pad Location ​ ((photo courtesy of Ebay seller, chezyrydr. [[https://​www.ebay.com/​sch/​chezyrydr/​m.html?​item=114957642341&​rt=nc&​nma=true&​nordt=true&​orig_cvip=true&​si=zOYpPKkEiEnNnFiXOFT6Zq890Gs%253D&​hash=item1ac4026a65%3Ag%3AToIAAOSwrtdhKV-y&​vxp=mtr&​_trksid=p2047675.l2562|Link to Items for Sale page]] ​ ))  |  1970-E1971 Sportster Serial/VIN Pad Location ((photo by Xdragonchaser of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1997895&​page=2)) ​ |  L1971-1985 Sportster Serial / VIN Pad Location ((photo by Ebay seller, inlinefabrication [[https://​www.ebay.com/​str/​inlinefabrication|Link to Ebay Store]] ))  |+|  1957-1969 Sportster Serial# / Vin Pad Location ​ ((photo courtesy of Ebay seller, chezyrydr. [[https://​www.ebay.com/​sch/​chezyrydr/​m.html?​item=114957642341&​rt=nc&​nma=true&​nordt=true&​orig_cvip=true&​si=zOYpPKkEiEnNnFiXOFT6Zq890Gs%253D&​hash=item1ac4026a65%3Ag%3AToIAAOSwrtdhKV-y&​vxp=mtr&​_trksid=p2047675.l2562|Link to Items for Sale page]] ​ ))  |  1970-E1971 Sportster Serial/VIN Pad Location ((photo by Xdragonchaser of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-general-discussion-and-problems/​186968-picked-up-a-70-ironhead-but-it-s-got-the-broken-trans-corner?​t=1997895&​page=2)) ​ |  L1971-1985 Sportster Serial / VIN Pad Location ((photo by Ebay seller, inlinefabrication [[https://​www.ebay.com/​str/​inlinefabrication|Link to Ebay Store]] ))  |
 |{{:​techtalk:​ih:​engmech:​1957-1969_sportster_vin_pad_location_by_chezyrydr.jpg?​direct&​300|}}|{{:​techtalk:​ih:​engmech:​1970-e1971_sportster_vin_pad_location_right_case_by_xdragonchaser.jpg?​direct&​300|}}|{{:​techtalk:​ih:​engmech:​1971l-1985_sportster_vin_pad_location_by_inlinefabrication.jpg?​direct&​300|}}| |{{:​techtalk:​ih:​engmech:​1957-1969_sportster_vin_pad_location_by_chezyrydr.jpg?​direct&​300|}}|{{:​techtalk:​ih:​engmech:​1970-e1971_sportster_vin_pad_location_right_case_by_xdragonchaser.jpg?​direct&​300|}}|{{:​techtalk:​ih:​engmech:​1971l-1985_sportster_vin_pad_location_by_inlinefabrication.jpg?​direct&​300|}}|
 \\ \\
Line 169: Line 179:
 [[techtalk:​miscres:​miscres51|Click Here]] to see an article on Casting Numbers in general in the Sportsterpedia. \\ [[techtalk:​miscres:​miscres51|Click Here]] to see an article on Casting Numbers in general in the Sportsterpedia. \\
  
 +Casting numbers were created when the mold was created (casting number was "​cast"​ into the part) and will not be stamped into the part. ((brucstoudt of the XLFORUM https://​www.xlforum.net/​forum/​sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​204445-parts-dated-earlier-than-the-model-year/​page2#​post4596454)) \\ 
 Casting numbers on the left and right cases look like (are coded like) part numbers but they are not. \\ Casting numbers on the left and right cases look like (are coded like) part numbers but they are not. \\
 They were put there when the case half was created (cast) and represent a certain base design. \\ They were put there when the case half was created (cast) and represent a certain base design. \\
Line 201: Line 212:
 {{:​techtalk:​ih:​engmech:​1957-up_sportster_various_left_case_casting_numbers.jpg?​direct&​300|}} {{:​techtalk:​ih:​engmech:​1957-up_sportster_various_right_case_casting_numbers.jpg?​direct&​300|}} \\ {{:​techtalk:​ih:​engmech:​1957-up_sportster_various_left_case_casting_numbers.jpg?​direct&​300|}} {{:​techtalk:​ih:​engmech:​1957-up_sportster_various_right_case_casting_numbers.jpg?​direct&​300|}} \\
  
-==== Casting ​Date Code ====+==== Date Codes ====
 Early model cases did not have any manufacturing date codes. \\ Early model cases did not have any manufacturing date codes. \\
 Else you should find, somewhere on the outside of each case half, a set of numbers representing the day and the year that part was cast. \\ Else you should find, somewhere on the outside of each case half, a set of numbers representing the day and the year that part was cast. \\
Line 223: Line 234:
 ==== Crankcase Numbers (AKA Belly Numbers) ==== ==== Crankcase Numbers (AKA Belly Numbers) ====
 Belly numbers don't have anything to do with issuing a VIN and they will not tell you specific model info (XLH or XLCH). \\ Belly numbers don't have anything to do with issuing a VIN and they will not tell you specific model info (XLH or XLCH). \\
-Engine serial / VIN numbers are added much later after assembly. ((mrmom9r of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1696213&​page=2)) \\+Engine serial / VIN numbers are added much later after assembly. ((mrmom9r of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​158490-how-to-determine-what-i-have-without-numbers/​page2?​t=1696213&​page=2)) \\
  
 Belly numbers tell you that a particular set of cases was paired up and finish machined together (line boring, cylinder base surfacing etc). \\ Belly numbers tell you that a particular set of cases was paired up and finish machined together (line boring, cylinder base surfacing etc). \\
Line 236: Line 247:
 |{{:​techtalk:​ih:​engmech:​1974_xl_belly_numbers_by_ironheadjunkie.jpg?​direct&​300|}}|{{:​techtalk:​ih:​engmech:​1975_xlch_left_case_-_crankcase_number_and_casting_date_code_by_carson_s.jpg?​direct&​300|}}|{{:​techtalk:​ih:​engmech:​1975_xlch_right_case_-_belly_number_by_carson_s.jpg?​direct&​300|}}| |{{:​techtalk:​ih:​engmech:​1974_xl_belly_numbers_by_ironheadjunkie.jpg?​direct&​300|}}|{{:​techtalk:​ih:​engmech:​1975_xlch_left_case_-_crankcase_number_and_casting_date_code_by_carson_s.jpg?​direct&​300|}}|{{:​techtalk:​ih:​engmech:​1975_xlch_right_case_-_belly_number_by_carson_s.jpg?​direct&​300|}}|
  
-|  L1984-1985 crankcase number locations ((photo courtesy of Ebay seller, gnarlydavidson1. [[https://​www.ebay.com/​sch/​gnarlydavidson1/​m.html?​item=164269655258&​rt=nc&​nma=true&​nordt=true&​orig_cvip=true&​si=HqcoQgHNj7TAtnE2%252BX5d6I6LD7A%253D&​hash=item263f3c04da%3Ag%3AIDEAAOSw4CRe-35v&​vxp=mtr&​_trksid=p2047675.l2562|Link to Items for Sale page]] ​ ))  || +|  L1984-1985 crankcase number locations ((photo courtesy of Ebay seller, gnarlydavidson1. [[https://​www.ebay.com/​sch/​gnarlydavidson1/​m.html?​item=164269655258&​rt=nc&​nma=true&​nordt=true&​orig_cvip=true&​si=HqcoQgHNj7TAtnE2%252BX5d6I6LD7A%253D&​hash=item263f3c04da%3Ag%3AIDEAAOSw4CRe-35v&​vxp=mtr&​_trksid=p2047675.l2562|Link to Items for Sale page]] ​ ))  ||  Example using Julian Calendars in SP  ​
-|{{:​techtalk:​ih:​engmech:​1984-1985_sportster_left_crankcase_number_by_gnarlydavidson1.jpg?​direct&​300|}}|{{:​techtalk:​ih:​engmech:​1984-1985_sportster_right_crankcase_number_by_gnarlydavidson1.jpg?​direct&​300|}}|+|{{:​techtalk:​ih:​engmech:​1984-1985_sportster_left_crankcase_number_by_gnarlydavidson1.jpg?​direct&​300|}}|{{:​techtalk:​ih:​engmech:​1984-1985_sportster_right_crankcase_number_by_gnarlydavidson1.jpg?​direct&​300|}}|{{:​techtalk:​miscres:​julian_calendar_-_example_dechypering_1977_crankcase_number_by_hippysmack.png?​direct&​300|}}|
  
 ==== Case Match Numbers (1975-Up) ==== ==== Case Match Numbers (1975-Up) ====
Line 251: Line 262:
  
 |  The exact location/​spacing varies from case to case. Some will be close to the middle seam, some will be farther toward the ends of each case.  ||| |  The exact location/​spacing varies from case to case. Some will be close to the middle seam, some will be farther toward the ends of each case.  |||
-|  1976 XLH ((photo by Rhode Warrior of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1822711&​page=14)) ​ |  1981 Sportster ​ ((photo by 78ironhead of the XLFORUM ))  |  L1984 XLS ((photo courtesy of c3cycle.com,​ Link to site:​https://​www.c3cycle.com/​)) ​ |+|  1976 XLH ((photo by Rhode Warrior of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​169851-splitting-cases-on-76-xlh/​page14?​t=1822711&​page=14)) ​ |  1981 Sportster ​ ((photo by 78ironhead of the XLFORUM ))  |  L1984 XLS ((photo courtesy of c3cycle.com,​ Link to site:​https://​www.c3cycle.com/​)) ​ |
 |{{:​techtalk:​ih:​engmech:​1976_case_match_number_locations_by_rhode_warrior.jpg?​direct&​300|}}|{{:​techtalk:​ih:​engmech:​1981_sportster_engine_case_match_numbers_by_78ironhead.jpg?​direct&​300|}}| {{:​techtalk:​ih:​engmech:​1983_case_match_number_locations_by_c3-cycle-tech.jpg?​direct&​300|}}| |{{:​techtalk:​ih:​engmech:​1976_case_match_number_locations_by_rhode_warrior.jpg?​direct&​300|}}|{{:​techtalk:​ih:​engmech:​1981_sportster_engine_case_match_numbers_by_78ironhead.jpg?​direct&​300|}}| {{:​techtalk:​ih:​engmech:​1983_case_match_number_locations_by_c3-cycle-tech.jpg?​direct&​300|}}|
  
Line 304: Line 315:
     * Uses cover gasket (34952-52).     * Uses cover gasket (34952-52).
   * 1957-1966 XL / XLH cases:   * 1957-1966 XL / XLH cases:
-    * In the left picture below, the holes at the yellow circles are not drilled or tapped. \\ The holes at the blue circles are not tapped but have 3/16" dia roll pins. ((Dr Dick of the XLFORUM DR DICK http://​xlforum.net/​forums/showpost.php?p=4673358&​postcount=14)) \\ The right picture below is of a 1960 XLH left case. \\ In this case you don't have all the screw holes needed for the tin primary cover used on 59-69 CH. \\ You'd need to use the 3 hole sportster cover or pull the pins and drill and tap to convert to tin cover.+    * In the left picture below, the holes at the yellow circles are not drilled or tapped. \\ The holes at the blue circles are not tapped but have 3/16" dia roll pins. ((Dr Dick of the XLFORUM DR DICK https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-motor-engine/​sportster-motorcycle-bottom-end/​159882-57-76-xlch-engine-case-interchange?​postcount=14#​post3402296)) \\ The right picture below is of a 1960 XLH left case. \\ In this case you don't have all the screw holes needed for the tin primary cover used on 59-69 CH. \\ You'd need to use the 3 hole sportster cover or pull the pins and drill and tap to convert to tin cover.
     * There are (3) 1/​4"​x20 tapped holes, one of which is on the primary wall, for cover mounting screws. Uses cover gasket (34952-52A).     * There are (3) 1/​4"​x20 tapped holes, one of which is on the primary wall, for cover mounting screws. Uses cover gasket (34952-52A).
   * 1967-1976 XLH and 1970-1976 XLCH cases:   * 1967-1976 XLH and 1970-1976 XLCH cases:
-    * There area (8) 1/​4"​x20 and (1) #10-24 tapped holes for cover mounting screws. Uses cover gasket (34955-67).+    * There area (10) 1/​4"​x20 and (1) #10-24 tapped holes for cover mounting screws. Uses cover gasket (34955-67).
   * 1977-1985 (all):   * 1977-1985 (all):
     * There are (10) 1/​4"​x20 tapped holes for cover mounting screws with the addition of a chain adjuster stud under the engine sprocket protruding thru cover. \\ Chain adjuster stud replaces previous lower front screw and is threaded for a nut to the cover. ​     * There are (10) 1/​4"​x20 tapped holes for cover mounting screws with the addition of a chain adjuster stud under the engine sprocket protruding thru cover. \\ Chain adjuster stud replaces previous lower front screw and is threaded for a nut to the cover. ​
     * All, except 1980-1982 XLS, use gasket (34955-75). 1980-1982 XLS uses the black version gasket (34966-80) to match the case/​cover. ​     * All, except 1980-1982 XLS, use gasket (34955-75). 1980-1982 XLS uses the black version gasket (34966-80) to match the case/​cover. ​
  
-|  1957-1969 XLCH (short frame) primary case ((photo by Dr Dick of the XLFORUM ​http://​xlforum.net/​forums/showpost.php?p=4673358&​postcount=14)) ​ |  1957-1966 XLH (short frame) primary case ((photo by sevenyears of famine of the XLFORUMM)) ​ |+|  1957-1969 XLCH (short frame) primary case ((photo by Dr Dick of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-motor-engine/​sportster-motorcycle-bottom-end/​159882-57-76-xlch-engine-case-interchange?​postcount=14#​post3402296))  |  1957-1966 XLH (short frame) primary case ((photo by sevenyears of famine of the XLFORUMM)) ​ |
 |{{:​techtalk:​ih:​engmech:​1964_xlch_left_case_by_dr_dick.jpg?​direct&​400|}}|{{:​techtalk:​ih:​engmech:​1960_xlh_left_case_by_sevenyears_of_famine.jpg?​direct&​400|}}| |{{:​techtalk:​ih:​engmech:​1964_xlch_left_case_by_dr_dick.jpg?​direct&​400|}}|{{:​techtalk:​ih:​engmech:​1960_xlh_left_case_by_sevenyears_of_famine.jpg?​direct&​400|}}|
  
Line 324: Line 335:
   * L1980-1985 Sportsters came factory with electric start only and no provision for a kicker (hole/gear stop deleted in case).   * L1980-1985 Sportsters came factory with electric start only and no provision for a kicker (hole/gear stop deleted in case).
  
-|  1957-1966 XL/XLH and 1958-1969 XLC/XLCH \\ kick only motors (short frame) ((photos courtesy of Ebay seller, chezyrydr. [[https://​www.ebay.com/​sch/​chezyrydr/​m.html?​item=114957642341&​rt=nc&​nma=true&​nordt=true&​orig_cvip=true&​si=zOYpPKkEiEnNnFiXOFT6Zq890Gs%253D&​hash=item1ac4026a65%3Ag%3AToIAAOSwrtdhKV-y&​vxp=mtr&​_trksid=p2047675.l2562|Link to Items for Sale page]] ​ ))  |  1968-E1980 XLH kicker hole plug ((photos by 74_XLH_WINCHESTER_VA of the XLFORUM, combined by Hippysmack, ​http://​xlforum.net/​forums/showthread.php?​threadid=727978)) ​ |+|  1957-1966 XL/XLH and 1958-1969 XLC/XLCH \\ kick only motors (short frame) ((photos courtesy of Ebay seller, chezyrydr. [[https://​www.ebay.com/​sch/​chezyrydr/​m.html?​item=114957642341&​rt=nc&​nma=true&​nordt=true&​orig_cvip=true&​si=zOYpPKkEiEnNnFiXOFT6Zq890Gs%253D&​hash=item1ac4026a65%3Ag%3AToIAAOSwrtdhKV-y&​vxp=mtr&​_trksid=p2047675.l2562|Link to Items for Sale page]] ​ ))  |  1968-E1980 XLH kicker hole plug ((photos by 74_XLH_WINCHESTER_VA of the XLFORUM, combined by Hippysmack, ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​90145-kicker-install-on-a-74-xlh?​threadid=727978)) ​ |
 |{{:​techtalk:​ih:​engmech:​1957-1966_xlh_1958-1969_xlch_left_case_kicker_shaft_hole_by_chezyrydr_edited_by_hippysmack.jpg?​direct&​300|}}|{{:​techtalk:​ih:​engctl:​1974_xlh_kicker_hole_plug_by_74_xlh_winchester_va.jpg?​direct&​300|}}| |{{:​techtalk:​ih:​engmech:​1957-1966_xlh_1958-1969_xlch_left_case_kicker_shaft_hole_by_chezyrydr_edited_by_hippysmack.jpg?​direct&​300|}}|{{:​techtalk:​ih:​engctl:​1974_xlh_kicker_hole_plug_by_74_xlh_winchester_va.jpg?​direct&​300|}}|
  
Line 338: Line 349:
   * 1977-1985 engines:   * 1977-1985 engines:
     * The oil trough in both cases was deleted with the addition of a minisump and gerotor pump.     * The oil trough in both cases was deleted with the addition of a minisump and gerotor pump.
-    * A mini sump was added to the both case halves. Left case sump designed for oil to be blown or drained to the right case bottom. ​\\ Lower front wheel area was expanded allowing air under the wheels to usher oil to the rear pocket of the sump. \\ A casting boss also steers ​oil flung off the wheels to the right case. +    * A mini sump was added to the both case halves. Left case sump designed for oil to be blown or drained to the right case bottom. 
 +    * The lower front wheel area was expanded allowing air under the wheels to usher oil to the rear pocket of the sump. \\ A channel is cast into the front case floor to steer oil flung off the wheels to the right case. 
     * Oil scavenging to the pump and engine breathing is done by way of machining in the right case.      * Oil scavenging to the pump and engine breathing is done by way of machining in the right case. 
  
Line 355: Line 367:
     * 1972-1985 cases, the side of each cylinder base is milled heavily at the intake tappet and is very noticeable.     * 1972-1985 cases, the side of each cylinder base is milled heavily at the intake tappet and is very noticeable.
  
-|  1957-1971 side of 900 cylinder base ((photo by Xdragonchaser of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=2002731&​page=3)) ​ |  1972-1985 side of 1000 cylinder base ((photo by Ebay seller, inlinefabrication [[https://​www.ebay.com/​str/​inlinefabrication|Link to Ebay Store]] ))  |+|  1957-1971 side of 900 cylinder base ((photo by Xdragonchaser of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​187549-well-you-all-convinced-me-so-here-we-go/​page3?​t=2002731&​page=3)) ​ |  1972-1985 side of 1000 cylinder base ((photo by Ebay seller, inlinefabrication [[https://​www.ebay.com/​str/​inlinefabrication|Link to Ebay Store]] ))  |
 |{{:​techtalk:​ih:​engmech:​1957-1971_sportster_cylinder_base_by_xdragonchaser.jpg?​direct&​300|}}|{{:​techtalk:​ih:​engmech:​1972-1985_sportster_cylinder_base_surface_by_inlinefabrication.jpg?​direct&​300|}}| |{{:​techtalk:​ih:​engmech:​1957-1971_sportster_cylinder_base_by_xdragonchaser.jpg?​direct&​300|}}|{{:​techtalk:​ih:​engmech:​1972-1985_sportster_cylinder_base_surface_by_inlinefabrication.jpg?​direct&​300|}}|
  
Line 365: Line 377:
  
    * 1957-1981 and some E1982 cases have an elongated angled front to back slot for the oil feed galley in the top of the gearcase. \\ A hole is then drilled thru the left end of the slot to feed each rocker box oil line. \\ The casting above the oil slot is taller in that area especially on 77-E79 motors. \\ Cam Cover gasket was modified (25224-52A) to help control leaks by adding a slot to the oil feed hole.    * 1957-1981 and some E1982 cases have an elongated angled front to back slot for the oil feed galley in the top of the gearcase. \\ A hole is then drilled thru the left end of the slot to feed each rocker box oil line. \\ The casting above the oil slot is taller in that area especially on 77-E79 motors. \\ Cam Cover gasket was modified (25224-52A) to help control leaks by adding a slot to the oil feed hole.
-     * Slot construction (for those with the slot): ((Dr Dick of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1535474&​page=5)) \\ On 1957-1963 models, the slot is plunge cut with and end mill. \\ On 1964-up models, the slot is cast into the case.  +     * Slot construction (for those with the slot): ((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/​141725-early-sportster-engine-identification-1969-earlier/​page5?​t=1535474&​page=5)) \\ On 1957-1963 models, the slot is plunge cut with and end mill. \\ On 1964-up models, the slot is cast into the case.  
-   ​* ​L1979 Upper Gearcase Casting Change: \\ November of 1979, the MoCo realized a possibile high pressure oil leak around the upper oil seam between the cam cover and the gearcase. ((TSB M-778 dated May 13,1980)) \\ The case casting was reworked and modified to eliminate this possibility. \\  The upper feed galley (slot) profile was changed. The top boss on the gearcase was shaved back. \\ The cover gasket also changed to match up to the newer profile. \\ The cover gasket (25224-52A) was modified to fit the revised castings and help eliminate possible leaks on earlier crankcases.+   ​* ​M1980 Upper Gearcase Casting Change: \\ In November of 1979, the MoCo realized a possibile high pressure oil leak around the upper oil seam between the cam cover and the gearcase. ((TSB M-778 dated May 13,1980)) \\ The case casting was reworked and modified to eliminate this possibility. \\  The upper feed galley (slot) profile was changed. The top boss on the gearcase was shaved back. \\ The cover gasket (25224-52A) was modified to fit the revised castings and help eliminate possible leaks on earlier crankcases.
    * 1982-1985 and some L1981 cases do not have an upper feed oil slot. \\ The slot was deleted and the large boss is cast around the feed galley area. \\ Oil is fed to the rocker box lines simply by way of a hole drilled thru the large boss in the upper gearcase.    * 1982-1985 and some L1981 cases do not have an upper feed oil slot. \\ The slot was deleted and the large boss is cast around the feed galley area. \\ Oil is fed to the rocker box lines simply by way of a hole drilled thru the large boss in the upper gearcase.
    * L1981-E1982 Overlap: L1981-E1982 engines may have one of two different types of gear case cover and crankcase set combinations. ((TSB M-841 dated October 16, 1981))    * L1981-E1982 Overlap: L1981-E1982 engines may have one of two different types of gear case cover and crankcase set combinations. ((TSB M-841 dated October 16, 1981))
Line 397: Line 409:
  
 **1957-1976 cases use a gear driven type oil pump**. \\ Any 1957-1976 Sportster oil pump (as an assembly) will bolt up to all 1957-1976 motors but the plumbing has to be taken into account. \\ 1957-1976 oil pumps will not bolt to 1977-up cases. **1957-1976 cases use a gear driven type oil pump**. \\ Any 1957-1976 Sportster oil pump (as an assembly) will bolt up to all 1957-1976 motors but the plumbing has to be taken into account. \\ 1957-1976 oil pumps will not bolt to 1977-up cases.
-  * Plumbing: From 1957-1976, there were 3 basic oil pumps with 2 different plumbing styles ((Dr Dick of the XLFORUM ​http://​xlforum.net/​forums/showpost.php?p=3272806&​postcount=204)). \\ The 2 different pump plumbing styles match the plumbing on the 2 different case mount styles for these years.+  * Plumbing: From 1957-1976, there were 3 basic oil pumps with 2 different plumbing styles ((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/​112326-a-photo-catalog-of-ironhead-parts/​page14?​postcount=204#​post2437070)). \\ The 2 different pump plumbing styles match the plumbing on the 2 different case mount styles for these years.
     * 1957-1966 XLH and 1958-1969 XLCH (short frame) have 2 feed and 2 return passages thru the oil pump mounting boss. \\ The feed (inlet) and return (outlet) fittings on top of the case sit over vertical drilled passages down to the rear of oil pump mount. \\ The front side of the oil pump mount has a feed (outlet) and a return (inlet) hole each.      * 1957-1966 XLH and 1958-1969 XLCH (short frame) have 2 feed and 2 return passages thru the oil pump mounting boss. \\ The feed (inlet) and return (outlet) fittings on top of the case sit over vertical drilled passages down to the rear of oil pump mount. \\ The front side of the oil pump mount has a feed (outlet) and a return (inlet) hole each. 
     * 1967-1976 XLH and 1970-1976 XLCH (long frame) have only 1 feed and 2 return passages thru the oil pump mounting boss. \\ The return (outlet) fitting is still on top of the case with a vertical drilled passage down to the rear of oil pump mount. \\ It ends up in the same place as in previous models. \\ The feed passage from the tank was deleted from the case (now feeds to the back of the oil pump). \\ The front side of the oil pump mount has a feed (outlet) and 2 side by side holes at the return (inlet) hole.     * 1967-1976 XLH and 1970-1976 XLCH (long frame) have only 1 feed and 2 return passages thru the oil pump mounting boss. \\ The return (outlet) fitting is still on top of the case with a vertical drilled passage down to the rear of oil pump mount. \\ It ends up in the same place as in previous models. \\ The feed passage from the tank was deleted from the case (now feeds to the back of the oil pump). \\ The front side of the oil pump mount has a feed (outlet) and 2 side by side holes at the return (inlet) hole.
Line 418: Line 430:
 |{{:​techtalk:​ih:​engmech:​1957-1966_xlh_1958-1969_xlch_oil_pump_mounting_boss_by_animal_house.jpg?​direct&​300|}}|{{:​techtalk:​ih:​engmech:​1967-1971_xlh_1970-1971_xlch_oil_pump_mounting_boss.jpg?​direct&​300|}}| |{{:​techtalk:​ih:​engmech:​1957-1966_xlh_1958-1969_xlch_oil_pump_mounting_boss_by_animal_house.jpg?​direct&​300|}}|{{:​techtalk:​ih:​engmech:​1967-1971_xlh_1970-1971_xlch_oil_pump_mounting_boss.jpg?​direct&​300|}}|
  
-|  1972-E1973 XLH/​XLCH ​\\ Oil Pump Mount ((photo courtesy of Frost Cycle Shack [[https://​www.ebay.com/​str/​frostcycleshack|Link to Ebay Store]] ​ ))  |  L1973-1976 XLH/XLCH Oil Pump Mount ((pic courtesy of Ebay seller, sooooemo. [[https://​www.ebay.com/​sch/​sooooemo/​m.html?​item=144179324052&​mkcid=7&​bu=43209991454&​emsid=e11051.m43.l1123&​euid=2a93f8f4ee3349fc8875906cf633140e&​crd=20211229072737&​sojTags=ch%3Dch%2Cbu%3Dbu%2Cosub%3Dosub%2Ccrd%3Dcrd%2Csegname%3Dsegname%2Cchnl%3Dmkcid&​ch=osgood&​osub=-1%7E1&​segname=11051&​mkpid=0&​rt=nc&​_trksid=p2047675.l2562|Link to Items for Sale page]] ))  |  1977-1985 Sportster ​\\ Oil Pump Mount ((photo courtesy of c3cycle.com,​ Link to site: https://​www.c3cycle.com/​)) ​ |+|  1972-E1973 XLH/XLCH Oil Pump Mount ((photo courtesy of Frost Cycle Shack [[https://​www.ebay.com/​str/​frostcycleshack|Link to Ebay Store]] ​ ))  |  L1973-1976 XLH/XLCH Oil Pump Mount ((pic courtesy of Ebay seller, sooooemo. [[https://​www.ebay.com/​sch/​sooooemo/​m.html?​item=144179324052&​mkcid=7&​bu=43209991454&​emsid=e11051.m43.l1123&​euid=2a93f8f4ee3349fc8875906cf633140e&​crd=20211229072737&​sojTags=ch%3Dch%2Cbu%3Dbu%2Cosub%3Dosub%2Ccrd%3Dcrd%2Csegname%3Dsegname%2Cchnl%3Dmkcid&​ch=osgood&​osub=-1%7E1&​segname=11051&​mkpid=0&​rt=nc&​_trksid=p2047675.l2562|Link to Items for Sale page]] ))  |  1977-1985 Sportster Oil Pump Mount ((photo courtesy of c3cycle.com,​ Link to site: https://​www.c3cycle.com/​)) ​ |
 |{{:​techtalk:​ih:​engmech:​1972-1973e_xlh-xlch_oil_pump_mounting_boss_by_frost_cycle_shack.jpg?​direct&​300|}}|{{:​techtalk:​ih:​engmech:​1973_late-1976_oil_pump_mounting_boss_by_sooome.jpg?​direct&​300|}}|{{:​techtalk:​ih:​engmech:​1977-1985_oil_pump_mounting_boss_by_c3-cycle-tech.jpg?​direct&​300|}}| |{{:​techtalk:​ih:​engmech:​1972-1973e_xlh-xlch_oil_pump_mounting_boss_by_frost_cycle_shack.jpg?​direct&​300|}}|{{:​techtalk:​ih:​engmech:​1973_late-1976_oil_pump_mounting_boss_by_sooome.jpg?​direct&​300|}}|{{:​techtalk:​ih:​engmech:​1977-1985_oil_pump_mounting_boss_by_c3-cycle-tech.jpg?​direct&​300|}}|
  
Line 436: Line 448:
       * L1985 right case, from (#785 303002) manuf. after 10-29-1984, has a cam gear oiler installed against the cam wall over the cams. \\ The tube is fed from a tee in the tube center to the upper feed galley. \\ A vertical hole was drilled thru the feed galley connecting feed oil to the cam chest. The hole is plugged at the top. \\ This allows feed oil to spray the cams using tiny holes in the tube (more of a drip at idle). \\ The two large breather holes were instead drilled and tapped for screws for the oiler tube. \\ So L1985 crankcases have only the one small hole in the cam wall to breath thru. \\ (the oil scavenge path also allows air pressure to pass back to the tank then the cam chest as usual) ​       * L1985 right case, from (#785 303002) manuf. after 10-29-1984, has a cam gear oiler installed against the cam wall over the cams. \\ The tube is fed from a tee in the tube center to the upper feed galley. \\ A vertical hole was drilled thru the feed galley connecting feed oil to the cam chest. The hole is plugged at the top. \\ This allows feed oil to spray the cams using tiny holes in the tube (more of a drip at idle). \\ The two large breather holes were instead drilled and tapped for screws for the oiler tube. \\ So L1985 crankcases have only the one small hole in the cam wall to breath thru. \\ (the oil scavenge path also allows air pressure to pass back to the tank then the cam chest as usual) ​
  
-|  1957-1976 XLH/XLCH inner right case oil trough ((photo used with permission)) \\ (900-1000 cases are different, oil scavenge is same)  |  1977-1985 Sportster \\ inner right case oil scavenging paths ((photo courtesy of Ebay seller, hawghd1 [[https://​www.ebay.com/​str/​moschopshop?​_trksid=p2047675.l2563|Link to Ebay Store]] ))  | +|  1957-1976 XLH/XLCH inner right case oil trough ((photo used with permission)) \\ (900-1000 cases are different, oil scavenge is same)  |  1977-1985 Sportster \\ inner right case oil scavenging paths ((photo courtesy of Ebay seller, hawghd1 [[https://​www.ebay.com/​str/​moschopshop?​_trksid=p2047675.l2563|Link to Ebay Store]] ​))  |  57-76 VS 77-85 Crankcase Belly Comparison ((composite photos from Carson S and gnarlydavidson1))  | 
-|{{:​techtalk:​ih:​engmech:​1957-1976_right_crankcase_oil_scavenge_trough.jpg?​direct&​300|}}|{{:​techtalk:​ih:​engmech:​1977-1985_sportster_right_case_-_inner_oil_scavenging_by_hawghd1.jpg?​direct&​300|}}|+|{{:​techtalk:​ih:​engmech:​1957-1976_right_crankcase_oil_scavenge_trough.jpg?​direct&​300|}}|{{:​techtalk:​ih:​engmech:​1977-1985_sportster_right_case_-_inner_oil_scavenging_by_hawghd1.jpg?​direct&​300|}}|{{:​techtalk:​ih:​engmech:​1957-1976_vs_1977-1985_crankcase_belly_comparison_by_carson_s_and_gnarlydavidson1.jpg?​direct&​300|}}|
  
 |  1977-1981 right case breather holes ((photo courtesy of c3cycle.com,​ Link to site:​https://​www.c3cycle.com/​)) ​ |  1982-E1985 right case breather holes ((photo courtesy of Ebay seller, gnarlydavidson1. [[https://​www.ebay.com/​sch/​gnarlydavidson1/​m.html?​item=164269655258&​rt=nc&​nma=true&​nordt=true&​orig_cvip=true&​si=HqcoQgHNj7TAtnE2%252BX5d6I6LD7A%253D&​hash=item263f3c04da%3Ag%3AIDEAAOSw4CRe-35v&​vxp=mtr&​_trksid=p2047675.l2562|Link to Items for Sale page]] ​ ))  |  L1985 right case breather/​cam gear oiler holes ((photos by Iron Mike and iNSaNeSHaNe of the XLFORUM, combined by Hippysmack)) ​ |  |  1977-1981 right case breather holes ((photo courtesy of c3cycle.com,​ Link to site:​https://​www.c3cycle.com/​)) ​ |  1982-E1985 right case breather holes ((photo courtesy of Ebay seller, gnarlydavidson1. [[https://​www.ebay.com/​sch/​gnarlydavidson1/​m.html?​item=164269655258&​rt=nc&​nma=true&​nordt=true&​orig_cvip=true&​si=HqcoQgHNj7TAtnE2%252BX5d6I6LD7A%253D&​hash=item263f3c04da%3Ag%3AIDEAAOSw4CRe-35v&​vxp=mtr&​_trksid=p2047675.l2562|Link to Items for Sale page]] ​ ))  |  L1985 right case breather/​cam gear oiler holes ((photos by Iron Mike and iNSaNeSHaNe of the XLFORUM, combined by Hippysmack)) ​ | 
 |{{:​techtalk:​ih:​engmech:​1977-1981_sportster_right_crankcase_breather_holes_by_c3-cycle-tech.jpg?​direct&​300|}}|{{:​techtalk:​ih:​engmech:​1982-e1985_right_crankcase_breather_holes_by_gnarlydavidson1.jpg?​direct&​300|}}|{{:​techtalk:​ih:​engmech:​1985_late_right_case_breather-oiler_tube_holes_by_iron_mike_and_insaneshane.jpg?​direct&​300|}}| |{{:​techtalk:​ih:​engmech:​1977-1981_sportster_right_crankcase_breather_holes_by_c3-cycle-tech.jpg?​direct&​300|}}|{{:​techtalk:​ih:​engmech:​1982-e1985_right_crankcase_breather_holes_by_gnarlydavidson1.jpg?​direct&​300|}}|{{:​techtalk:​ih:​engmech:​1985_late_right_case_breather-oiler_tube_holes_by_iron_mike_and_insaneshane.jpg?​direct&​300|}}|
    
 +==== Pinion Shaft Bearing Bushing (1957-1976) ====
 +1957-1976 Sportster right case bushing (24585-57) is held in place by way of set screw pins. \\
 +Sportster Pinion Shaft Bearing Bushing Screw Part# (24608-54) x 2. \\
 +1977-up Sportster right cases do not use this bushing or screws. \\
  
 +|  Right Crankcase Pinion Shaft Bushing ((photos courtesy of BIKERSNOS.com. [[https://​www.ebay.com/​str/​bikersnos?​_trksid=p2047675.m3561.l2563|Link to Ebay Store]] ))  |  Pinion Shaft Bearing Bushing Screw ((photo courtesy of Ebay seller, Sum-body'​s Harley Parts, [[https://​www.ebay.com/​str/​sumbodysharleyparts|Link to Ebay Store]] ))  |
 +|{{:​techtalk:​ih:​engmech:​1957-1976_sportster_right_crankcase_bushing_24585-57_by_bikersnos.jpg?​direct&​300|}}|{{:​techtalk:​ih:​engmech:​1957-1976_sportster_pinion_shaft_bearing_bushing_screw_24608-54_by_ebay_sum-body1_pic2.jpg?​direct&​300|}}|
  
 ==== Transmission Countershaft Boss === ==== Transmission Countershaft Boss ===
Line 451: Line 469:
  
 Here is a cross section view of the right case at the countershaft boss. \\ Here is a cross section view of the right case at the countershaft boss. \\
-{{:​techtalk:​ih:​transfinal:​1952-up_transmission_countershaft_boss_variantions_by_dr_dick.jpg?​direct&​400|}} ((illustration by Dr Dick of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1512080)) \\+{{:​techtalk:​ih:​transfinal:​1952-up_transmission_countershaft_boss_variantions_by_dr_dick.jpg?​direct&​400|}} ((illustration by 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/​139355-trans-corner-reinforcement-54-72?​t=1512080)) \\
  
 ==== Speedometer Drive Gear Boss ==== ==== Speedometer Drive Gear Boss ====
   * 1952-1972 K/XL/XLH and 1959-1972 XLCH models use a mechanical speedometer run by a (11T) drive gear unit meshed at the trans countershaft. \\ The drive gear screws into the boss built into the right case for it. This area of the case is notorious for blowing out.   * 1952-1972 K/XL/XLH and 1959-1972 XLCH models use a mechanical speedometer run by a (11T) drive gear unit meshed at the trans countershaft. \\ The drive gear screws into the boss built into the right case for it. This area of the case is notorious for blowing out.
-  * 1973 AND LATER CASES DO NOT HAVE THE SPEEDOMETER DRIVE AT THE COUNTERSHAFT BOSS. \\ The drive gear was deleted on the right case and the new drive unit runs off the front wheel axle. \\ The drive unit boss thru to the inside housing on the right case was also deleted. This leaves more material in that area and more strength. ((brucstoudt of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​p=5927789#post5927789))+  * 1973 AND LATER CASES DO NOT HAVE THE SPEEDOMETER DRIVE AT THE COUNTERSHAFT BOSS. \\ The drive gear was deleted on the right case and the new drive unit runs off the front wheel axle. \\ The drive unit boss thru to the inside housing on the right case was also deleted. This leaves more material in that area and more strength. ((brucstoudt of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​203328-71-xlh-value/​page4#post4545503))
  
 |  1972-earlier speedometer drive gear boss ((photo courtesy of Ebay seller, inlinefabrication. [[https://​www.ebay.com/​str/​inlinefabrication|Link to Ebay Store]] ))  |  1968 case repaired ((photo courtesy of Ebay seller, animalhouse2010,​ [[https://​www.ebay.com/​str/​animalhouse2010?​_trksid=p2047675.l2563|Link to Ebay store:]] ))  |  1973-later have no speedo drive gear boss ((photo courtesy of Frost Cycle Shack [[https://​www.ebay.com/​str/​frostcycleshack|Link to Ebay Store]] ​ ))  | |  1972-earlier speedometer drive gear boss ((photo courtesy of Ebay seller, inlinefabrication. [[https://​www.ebay.com/​str/​inlinefabrication|Link to Ebay Store]] ))  |  1968 case repaired ((photo courtesy of Ebay seller, animalhouse2010,​ [[https://​www.ebay.com/​str/​animalhouse2010?​_trksid=p2047675.l2563|Link to Ebay store:]] ))  |  1973-later have no speedo drive gear boss ((photo courtesy of Frost Cycle Shack [[https://​www.ebay.com/​str/​frostcycleshack|Link to Ebay Store]] ​ ))  |
Line 466: Line 484:
  
   * 1977-1980 models:   * 1977-1980 models:
-    * The transmission was vented to atmosphere starting in 1977. \\ The vent fitting is threaded into the right case at the inner hole closest to case parting seam (previously battery box / oil bracket bolt location). \\ The inner hole is in a position where trans oil doesn'​t seem to get tossed around as much so it doesn'​t eject much oil. \\ All 76< long frame cases (except 71ch) will accept the vent bolt in the 77> position. \\ Conversely installing the vent bolt in any of the four short frame rear mount bolt holes usually results in drips from the vent. ((Dr Dick of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​p=5133975#post5133975)) \\ This particular fitting works with either the Prestolite or Hitachi starters.+    * The transmission was vented to atmosphere starting in 1977. \\ The vent fitting is threaded into the right case at the inner hole closest to case parting seam (previously battery box / oil bracket bolt location). \\ The inner hole is in a position where trans oil doesn'​t seem to get tossed around as much so it doesn'​t eject much oil. \\ All 76< long frame cases (except 71ch) will accept the vent bolt in the 77> position. \\ Conversely installing the vent bolt in any of the four short frame rear mount bolt holes usually results in drips from the vent. ((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/​93964-how-to-remove-the-oil-transfer-valve/​page3#post3744870)) \\ This particular fitting works with either the Prestolite or Hitachi starters.
   * 1980-1985 models: \\   * 1980-1985 models: \\
     * These models have a 1/4" OD metal tube (26272-81) pressed into the right case instead of a threaded fitting. \\ The smaller nipple works with the beefier Nippon Denso starter change in 1981. \\ **1981 cases**: The pressed-in vent nipple is on the top right of the case just under the end of the (new type) starter solenoid. \\ **1982-1985 cases**: The pressed-in vent nipple was moved farther in toward the center, still under the solenoid (back to 77-80 location). ​     * These models have a 1/4" OD metal tube (26272-81) pressed into the right case instead of a threaded fitting. \\ The smaller nipple works with the beefier Nippon Denso starter change in 1981. \\ **1981 cases**: The pressed-in vent nipple is on the top right of the case just under the end of the (new type) starter solenoid. \\ **1982-1985 cases**: The pressed-in vent nipple was moved farther in toward the center, still under the solenoid (back to 77-80 location). ​
Line 480: Line 498:
  
   * 1957-1966 XLH and 1958-1969 XLCH (short frame):   * 1957-1966 XLH and 1958-1969 XLCH (short frame):
-      * These use the 4 hole rear mount and the cases also have 4 top holes and 3 middle studs to hold rear mount to the cases. \\ All 1966 and earlier bikes were kick start only. One mount and one case configuration covered all models. ((Dr Dick of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?p=5381546&​highlight=xlh#​post5381546)) \\+      * These use the 4 hole rear mount and the cases also have 4 top holes and 3 middle studs to hold rear mount to the cases. \\ All 1966 and earlier bikes were kick start only. One mount and one case configuration covered all models. ((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/​122691-84-cubic-inch-900-motor-teardown-pics/​page28?​highlight=xlh#​post3914335)) \\
   * 1967-1969 XLH (long frame):   * 1967-1969 XLH (long frame):
-    * In 1967, the first electric XLH came out and to fit the starter, the cases and the mount were changed from 4 bolt to 2 bolt / 3 studs on XLH only. \\ The front two bolts were dropped to make room for the electric leg (battery box / oil bracket bolted in the vacated area). \\ Then there were two mounts and two case sets, one each for 1967-1976 XLH and 1967-1969 XLCH. ((Dr Dick of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?p=5381546&​highlight=xlh#​post5381546)) ((Dr Dick http://​xlforum.net/​forums/showthread.php?​p=5133975#post5133975)) \\ +    * In 1967, the first electric XLH came out and to fit the starter, the cases and the mount were changed from 4 bolt to 2 bolt / 3 studs on XLH only. \\ The front two bolts were dropped to make room for the electric leg (battery box / oil bracket bolted in the vacated area). \\ Then there were two mounts and two case sets, one each for 1967-1976 XLH and 1967-1969 XLCH. ((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/​122691-84-cubic-inch-900-motor-teardown-pics/​page28?​highlight=xlh#​post3914335)) ((Dr Dick https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​93964-how-to-remove-the-oil-transfer-valve/​page3#post3744870)) \\ 
-  * 1970-1985 All (long frame): \\ In 1970, the old 4 bolt cases/​mounts were dropped completely and the XLCH was redesigned. \\ It was now based on the electric start bike, with the starter removed and a kicker fitted instead. \\ This is how the 1970-1976 XLCH is built (as a stripped down XLH rather than the old traditional kick only design). ((Dr Dick of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?p=5381546&​highlight=xlh#​post5381546))+  * 1970-1985 All (long frame): \\ In 1970, the old 4 bolt cases/​mounts were dropped completely and the XLCH was redesigned. \\ It was now based on the electric start bike, with the starter removed and a kicker fitted instead. \\ This is how the 1970-1976 XLCH is built (as a stripped down XLH rather than the old traditional kick only design). ((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/​122691-84-cubic-inch-900-motor-teardown-pics/​page28?​highlight=xlh#​post3914335))
     * 1970-1981 rear mounts have the hole in middle for a kicker.     * 1970-1981 rear mounts have the hole in middle for a kicker.
     * 1982-1985 rear mounts do not have the kicker hole.     * 1982-1985 rear mounts do not have the kicker hole.