Differences
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techtalk:ih:engmech01c [2023/12/19 23:39] hippysmack [Cylinder Boss] |
techtalk:ih:engmech01c [2023/12/19 23:52] (current) hippysmack [Upper Oil Feed Galley] |
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| * 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. |
| * 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. | * 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. | ||
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| **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. | ||
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| 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]] )) | | ||
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| * 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). | ||
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| * 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. | ||
