Table of Contents
This is an old revision of the document!
EVO: Engine Mechanicals
Camshafts
Cam Specs - OEM & SE
- 86-87 “T” cams will not work on 88 and up engines.
- 88-90 “C” cams will retrofit to 86-87
Comparing OEM and Andrews Cam Grinds
These figures are from the Sportster Evolution Cams PDF from Andrews Products. 3)
Grind | I/E | Timing @ .053“ Lift | CL | Duration @ .053” Lift | Durarion @ .020“ Lift | Max Lift | TDC Lift |
W | I | 10°/28° | 99° | 218° | 256° | .474” | .122“ |
E | 38°/16° | 101° | 234° | 272° | .474” | .138“ | |
N4 | I | 30°/46° | 98° | 256° | 296° | .490” | .216“ |
E | 52°/24° | 104° | 256° | 296° | .490” | .189“ |
I/E = Intake/Exhaust — CL = Centerline
Thanks to Maxeffort of the XLForum for the following Flywheel Degree Charts of these various cams.4)
Note that the measurements are based on the .053 lift specs and that the intake valve opening occurs on one rotation of the flywheel and the exhaust valve opens on the next rotation of the flywheel.
Removing / Installing Evo Cams
Sub Documents
EVO Cam and Pinion Gear Sets
- 86-99 - Matched cam gear set includes pinion gear and gearcase cover.
- Cam gears are individually matched to each specific gear cover using computer modeling in a controlled environment. 5)
- Cams are colored coded with a colored dot.
- Factory gearcase covers were also color coded on the inside with a color dot at each pinion and cam gear location.
- This allowed for separate colored gears to be factory assembled (and later replaced) using gears optimized for the lowest gear whine and rattle.
The dealer had to match the cover and gear colors for replacement covers.
- 00-03 - Options increased;
- Matched cam gear sets w/ pinion gear,
- Gear sets w/ #2 cam and pinion gear (only).
- The gearcase cover was now sold separately.
- 04 - Matched cam gear sets were only sold with the pinion gear, pinion gear also sold separately.
Year | Model | Cam Grind I.D. Letter | Cam #1 | Cam #2 Outer (big gear) | Cam #2 Inner (small gear) | Cam #3 | Cam #4 | Pinion Gear |
86-87 6) | (25488-86) All cams, pinion gear and cover | T | 28T | 36T | 28T | 28T | 28T | 18T |
88-90 7) | (25488-88) All cams, pinion gear and cover | C | ||||||
91-94 8) | (25488-89) All cams, pinion gear and cover | D | ||||||
95 9) | (25488-89A) All except 1200C cams, pinion gear and cover | D | ||||||
96-97 10) | (25483-96) 1200C chrome cover | D | ||||||
98-99 11) | (25448-89B) Std/Hug/1200 cams, pinion gear and polished cover | D | ||||||
(25483-96A) 1200C cams, pinion gear and chrome cover | D | |||||||
(25491-98) 1200S cams, pinion gear and silver cover | W | |||||||
00 12) | (25193-00) all except 1200S cams and pinion gear only | D | 28T | 46T | 28T | 28T | 28T | 23T |
(25194-00) 1200S cams and pinion gear only | W | |||||||
(25190-00) all except 1200S #2 cam and pinion gear only | D | |||||||
(25191-00) 1200S #2 cam and pinion gear only | W | |||||||
01-03 13) | (25193-00A) all except 1200S cams and pinion gear | D | 35T | 46T | 35T | 35T | 35T | 23T |
(25194-00A) 1200S cams and pinion gear | W | |||||||
04-06 14) | (25193-00B) 883/883C cams and pinion gear | D | ||||||
(25194-00B) 1200C/1200R cams and pinion gear | W | |||||||
07-17 15) | (25194-06) all except XR1200/XR1200X cams and pinion gear | W | ||||||
09-12 16) | (25271-08) XR1200/XR1200X cams and pinion gear | ? |
Cam Gear Changes
- The #2 “W” cam may or may not have a provision for a timing cup after 03. 17)
- If you intend on installing 04-up “W” cams in 03 and prior engines, look at the end of the #2 cam.
- If it does have a provision for a timing cup, they'll work for prior year applications.
- But, you'll have to either update your pinion gear, or use a press to swap your #2 cam's drive gear.
- For 03 and prior year engines, it needs a drilled and tapped hole in the middle of it and the timing cup notch.
- Below (L), you can see the notch on the cam on the right very easily.
- Below (R), shows the (00) #2 cam gear pitch change from the (99) style #2 cam gear.
Tappets (lifters)
Hydraulic Lifters
Sub-Documents
See also in the REF section of the Sportsterpedia:
There was a running change to new style hydraulic lifters in 1986 for Sportsters. 20)
They were the same as those used in 1340cc engines beginning in the 1986 model year.
This change was made to allow for one component to service the entire product line.
Beginning with Sportster crankcase numbers;
883: 1786 127 043
1100: 1886 127 001
The new lifters were identified with the presence of two notches opposite each other in the pushrod socket.
Oil feed to lifters
A hydraulic lifter self-adjusts within a certain range. 21)
In other words, if your pushrods are too long, the lifter automatically shortens, and if the pushrods are too short, it automatically lengthens.
The hydraulic lifters used in HD motors have about .200 of plunger travel.
As long as it's preloaded between about .050 and .150, it adjusts itself properly.
So in other words, there's about a .100” range of pushrod length.
The lifter will automatically adjust it's length to make it all work properly.
91 and up engines have a horizontal passage on the top of the cam box that is fed oil from the filter pad.
This horizontal passage feeds into the lifter bores.
91-99 engines have a single passage in that top area, the tappets are connected by internal passages from this small cavity. | On 2000 and up engines, oil travels to each lifter individually from this cavity. 22) |
91-99 Lifters
91-99 Anti-Rotation Pins
Parts:
4 - screws (884)
4 - washers (6099)
2 - pin plates (36804-89)
4 - O-rings (11176)
4 - anti-rotation pins (18532-89)
Torque: 80-110 in. lbs. (9.0-12.4 Nm) 25)
91-99 anti-rotation pin hardware 26) | ||
App. pin dims 27) | |
App. pin plate dims 28) | ||
Slide the pins in the holes, install the O-rings over the pins. 29) | ||
Then install the plate and torque to 80-110 in lbs. 30) | ||
2000 and Up Lifters
00-05 Lifter Ant-Rotation Screws
Parts:
4 - anti-rotation screws (18532)
This is the redesigned version of the anti-roll pins.
Comprised of a single pin for each lifter as before (4 in all).
However, this is a one piece design that is threaded into the case with no holding plate.
Torque: 55-65 in. lbs. (6.2-7.3 Nm) 33)
00-05 anti-rotation screws 34) | App dims (photos by Hippysmack)) | |
End of screws run up into the case. 35) | |
06-Up Anti-Rotation Device
Parts:
2 - Anti Rotation Device blocks (18505-06)
The ARD is a flexible piece of plastic that is designed to flex in operation to allow for an imperfect lifter bore location. 36)
It is designed for lifters that have a flat cut on each side.
These work OK for stock cams.
But if you're upgrading to bigger cams, anything more than .600 lift has too small a base circle. 37)
(and they will nearly drop out of the ARDs and they can also spin away from them)
The big issue is that they turn sideways with the roller not turning on the cam lobe.
(which can heat up and destroy the roller and the cam lobe)
Pinion Gear
Compatibility 40)
Frame mount Evos 1986-2003 do not list a part number for the pinion gear and it appears the pinion gear is part of the (cam gear set).
Pinion Gear Part# | Year Models |
24047-00 | 2004-2016 All Models |
XL Pinion Gear Color/Size Info here: http://xlforum.net/forums/showthread.php?t=1963918
Timing Cup (Rotor)
Cam Bushings
- The cam bushings get their oil from the fling off of the cam gears and drain back from the top end down the pushrod tubes that puddles in at depressions in the castings where the cam bushing slots are aligned. So basically they are drip fed. Also the cam bushings on the case side are open to the crank behind them, and probably get splash there too. 44)
- Worn bushings can cause excess backlash. 45)