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techtalk:ref:engmech03t [2021/04/23 04:06] hippysmack [Installing a 1986 Primary Cover on a 1985 Sportster] |
techtalk:ref:engmech03t [2024/01/14 21:44] (current) hippysmack |
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| [[:techtalk:menu|{{ :techtalk:gototechnicalmenu.jpg|}}]] | [[:techtalk:menu|{{ :techtalk:gototechnicalmenu.jpg|}}]] | ||
| - | ====== REF: Engine Mechanicals - Sub-03K ====== | + | ====== REF: Engine Mechanicals - Sub-03T ====== |
| - | ====== Installing a 1986 Primary Cover on a 1985 Sportster ====== | + | ====== Installing a 1986 Primary Cover on a L1984-1985 Sportster ====== |
| - | This primary cover swap was done by XLForum member, 85IRONDIRT, on a 1985 XLH 1000. ((Link to thread from the XLF http://xlforum.net/forums/showthread.php?t=2078880)) \\ | + | This primary cover swap was done by XLForum member, 85IRONDIRT, on a 1985 XLH 1000. ((Link to thread from the XLF https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/201772-late-84-85-primary-cover-to-86-90-cover?t=2078880)) \\ |
| In 1977, Sportsters got new cases to accommodate the left side shifter. \\ | In 1977, Sportsters got new cases to accommodate the left side shifter. \\ | ||
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| This mod should work for Late 1984-1985 Ironheads. The 86-90 primary cover is more shallow than the L84-85 cover. \\ | This mod should work for Late 1984-1985 Ironheads. The 86-90 primary cover is more shallow than the L84-85 cover. \\ | ||
| But it will bolt up to a L84-85 case and clear everything internally running the L84-85 clutch which uses the spring washer for the pressure plate. \\ | But it will bolt up to a L84-85 case and clear everything internally running the L84-85 clutch which uses the spring washer for the pressure plate. \\ | ||
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| - | {{:techtalk:ref:engmech:1986_primary_on_1985_xlh_1000_pic1_by_85irondirt.jpg?direct&400|}} ((photo by 85IRONDIRT of the XLFORUM http://xlforum.net/forums/showthread.php?t=2078880)) {{:techtalk:ref:engmech:1986_primary_on_1985_xlh_1000_pic2_by_85irondirt.jpg?direct&400|}} ((photo by 85IRONDIRT of the XLFORUM http://xlforum.net/forums/showthread.php?t=2078880)) \\ | ||
| **Considerations**: \\ | **Considerations**: \\ | ||
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| * The lowest front stud will be too long with the 86 cover. | * The lowest front stud will be too long with the 86 cover. | ||
| * The 85 stud for the footpeg sticks out of the 86 cover by about 3 inches and will need to be changed. | * The 85 stud for the footpeg sticks out of the 86 cover by about 3 inches and will need to be changed. | ||
| - | * The shifter shaft will also be about 3 inches too long so you'll need the shorter 86-90 shifter shaft. \\ The 86 shifter shaft \\ The heel of the new aftermarket shaft had to be ground off some as it was contacting the front of the case causing hard shifting. | + | * The shifter shaft will also be about 3 inches too long so you'll need the shorter 86-90 shifter shaft. \\ The heel of the new aftermarket shaft had to be ground off some as it was contacting the front of the case causing hard shifting. |
| * The Ironhead primary chain adjustor looks as if it would have worked but a Hayden Enterprises unit was used instead. | * The Ironhead primary chain adjustor looks as if it would have worked but a Hayden Enterprises unit was used instead. | ||
| * The shorter 86-90 perimeter bolts will have to be used. | * The shorter 86-90 perimeter bolts will have to be used. | ||
| **Parts Acquired**: | **Parts Acquired**: | ||
| - | * Primary Cover (25430-86 or -86A) loaded. | + | * Primary Cover (25430-86) loaded. |
| * Primary Cover Screws (3481) 1/4" x 20 x 1-1/2" Socket Head Screw (10) | * Primary Cover Screws (3481) 1/4" x 20 x 1-1/2" Socket Head Screw (10) | ||
| * Primary Cover Gasket (34955-75) | * Primary Cover Gasket (34955-75) | ||
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| * Clutch Cable, length? OEM are (38619-86 or -86A for 883) and (38621-86 or -86A for 1100) | * Clutch Cable, length? OEM are (38619-86 or -86A for 883) and (38621-86 or -86A for 1100) | ||
| + | Click on any pic below to enlarge: \\ | ||
| + | Here are some measurements on the 86 primary cover mounting holes (in metric) for comparison with a L84-85 cover. \\ | ||
| + | |||
| + | {{:techtalk:ref:engmech:1986_primary_cover_measurements_pic2_by_iron_mike.jpg?direct&300|}} ((photo by Iron Mike of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/201772-late-84-85-primary-cover-to-86-90-cover/page4?t=2078880&page=4)) {{:techtalk:ref:engmech:1986_primary_cover_measurements_pic1_by_iron_mike.jpg?direct&300|}} ((photo by Iron Mike of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/201772-late-84-85-primary-cover-to-86-90-cover/page4?t=2078880&page=4)) {{:techtalk:ref:engmech:1986_primary_cover_measurements_pic3_by_iron_mike.jpg?direct&300|}} ((photo by Iron Mike of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/201772-late-84-85-primary-cover-to-86-90-cover/page4?t=2078880&page=4)) \\ | ||
| + | \\ | ||
| + | \\ | ||
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| + | Comparison between the 85 and 86 primary covers. \\ | ||
| + | |||
| + | {{:techtalk:ref:engmech:1986_primary_on_1985_xlh_1000_pic3_by_85irondirt.jpg?direct&300|}} ((photo by 85IRONDIRT of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/201772-late-84-85-primary-cover-to-86-90-cover/page4?t=2078880&page=4)) {{:techtalk:ref:engmech:1986_primary_on_1985_xlh_1000_pic4_by_85irondirt.jpg?direct&300|}} ((photo by 85IRONDIRT of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/201772-late-84-85-primary-cover-to-86-90-cover/page4?t=2078880&page=4)) {{:techtalk:ref:engmech:1986_primary_on_1985_xlh_1000_pic5_by_85irondirt.jpg?direct&300|}} ((photo by 85IRONDIRT of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/201772-late-84-85-primary-cover-to-86-90-cover/page4?t=2078880&page=4)) \\ | ||
| + | \\ | ||
| + | \\ | ||
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| + | Here is an aftermarket 86-90 shifter shaft by Eastern as compared to the 85 shifter shaft. Eastern part# 1110-0050 (replaces 86-90 shifter shaft 34628-86). \\ | ||
| + | |||
| + | {{:techtalk:ref:engmech:1986_primary_on_1985_xlh_1000_pic6_by_85irondirt.jpg?direct&300|}} ((photo by 85IRONDIRT of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/201772-late-84-85-primary-cover-to-86-90-cover/page4?t=2078880&page=4)) {{:techtalk:ref:engmech:1986_primary_on_1985_xlh_1000_pic7_by_85irondirt.jpg?direct&300|}} ((photo by 85IRONDIRT of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/201772-late-84-85-primary-cover-to-86-90-cover/page4?t=2078880&page=4)) {{:techtalk:ref:engmech:1986_primary_on_1985_xlh_1000_pic8_by_85irondirt.jpg?direct&300|}} ((photo by 85IRONDIRT of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/201772-late-84-85-primary-cover-to-86-90-cover/page4?t=2078880&page=4)) \\ | ||
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| + | \\ | ||
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| + | Here is the 86 cover installed with a few bolts for example before installing the new shifter and peg shafts. Note how far out the 85 shafts are from the cover. \\ | ||
| + | The third pic below with the 86 shifter shaft installed. \\ | ||
| + | |||
| + | {{:techtalk:ref:engmech:1986_primary_on_1985_xlh_1000_pic10_by_85irondirt.jpg?direct&300|}} ((photo by 85IRONDIRT of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/201772-late-84-85-primary-cover-to-86-90-cover/page4?t=2078880&page=4)) {{:techtalk:ref:engmech:1986_primary_on_1985_xlh_1000_pic11_by_85irondirt.jpg?direct&300|}} ((photo by 85IRONDIRT of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/201772-late-84-85-primary-cover-to-86-90-cover/page4?t=2078880&page=4)) {{:techtalk:ref:engmech:1986_primary_on_1985_xlh_1000_pic9_by_85irondirt.jpg?direct&300|}} ((photo by 85IRONDIRT of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/201772-late-84-85-primary-cover-to-86-90-cover/page4?t=2078880&page=4)) \\ | ||
| + | \\ | ||
| + | \\ | ||
| + | |||
| + | Done! A 1986 primary cover on a 1985 Sportster. \\ | ||
| + | |||
| + | {{:techtalk:ref:engmech:1986_primary_on_1985_xlh_1000_pic1_by_85irondirt.jpg?direct&400|}} ((photo by 85IRONDIRT of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/201772-late-84-85-primary-cover-to-86-90-cover?t=2078880)) {{:techtalk:ref:engmech:1986_primary_on_1985_xlh_1000_pic2_by_85irondirt.jpg?direct&400|}} ((photo by 85IRONDIRT of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/201772-late-84-85-primary-cover-to-86-90-cover?t=2078880)) \\ | ||
| - | Here are some measurements on the 86 primary cover mounting holes (in metric) for comparison with the L84-85 cover. \\ | + | \\ |
| - | {{:techtalk:ref:engmech:1986_primary_cover_measurements_pic2_by_iron_mike.jpg?direct&300|}} ((photo by Iron Mike of the XLFORUM http://xlforum.net/forums/showthread.php?t=2078880&page=4)) {{:techtalk:ref:engmech:1986_primary_cover_measurements_pic1_by_iron_mike.jpg?direct&300|}} ((photo by Iron Mike of the XLFORUM http://xlforum.net/forums/showthread.php?t=2078880&page=4)) {{:techtalk:ref:engmech:1986_primary_cover_measurements_pic3_by_iron_mike.jpg?direct&300|}} ((photo by Iron Mike of the XLFORUM http://xlforum.net/forums/showthread.php?t=2078880&page=4)) \\ | + | Comments from 85IRONDIRT regarding this cover swap: \\ |
| + | <blockquote>If you are not doing a lot of customization, the swap is not worth it. It is a much thinner profile but that is about the only difference. \\ | ||
| + | I wanted a non-chrome cover and that is the only reason I went this route considering the cost of used polished aluminum 1985 covers.</blockquote> \\ | ||
| \\ | \\ | ||
