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EVO: Engine Mechanicals - Sub-01C

1986-2003 Sportster Engine Case Identification


1992-1994 Sportster Cases

Crankcase set parts order number (24470-91B) is OEM for all 1992-1994 XL Sportsters.
The oil pressure relief system was deleted as was the discharge hole at the filter pad into the cam chest.
A .060“ hole was drilled from the oil feed galley in the upper right case into the cam chest as a #2 cam squirter instead.

Left and Right Outer Case Views 1)
Left and Right Inner Case Views 2)

1998-1999 Sportster Cases

Specific Engine Case Features

Motor Vin Pad / Location

Starting in 1970, the bike is titled to the frame only and the same number set is stamped on the motor.
Starting in 1981, the motor VIN is only an abbreviation of the frame VIN.
So the numbers on the motor will not fully match the 17 digit VIN on the frame or the title.
But if it is the motor that came with the frame, it will be the same set of numbers as on the frame but with some left out.

  • 1986-1990: The VIN pad is on the right side of the motor between #2 and #3 tappets with the VIN hand stamped into the pad.
    The timing hole plug is on the left side of the motor.
  • 1991 to March 1993: The VIN pad is the case itself not raised, left side in the second rib down from the top with VIN hand stamped there.
    A portion of the second rib was deleted and the Vin was stamped into that area with the rib on each side of it.
    The timing hole plug was moved to the right side of the motor.
  • April 1993-2003: The VIN is “pin stamped” by machine on the left side of the motor in the same location as 91-E93 but slightly off center.
    (more toward the front cylinder and with no raised pad)
    HD issued TSB M-1304/1304A explaining the change was to increase manufacturing efficiency.

Various Numbers Found on Cases

Case Part Numbers

Click Here to see the Engine Case Number page in the Sportsterpedia.
Click Here to see an article on Part Numbers in general in the Sportsterpedia.

You will not find any part numbers on the cases that match the parts listings in the parts catalogs.
Part numbers were never cast or stamped into the cases. Each case half has many numbers on it but none of them show up in the parts books.
There were some parts that did have part numbers on them either stamped or on a sticker label.
Some electrical parts had stickers with the part number on them but no part numbers on cases.

The parts catalog listings are for logistics in which the MoCo stocks parts, sells them to dealerships and customers all under one Part Number.
Basically the part number was created to move the product, not to build the product.
Moving the product can mean, to the builders at the factory, mechanics at the dealership or to the customer.
Part numbers are used in manuals and instructions .
Part numbers are assigned after the parts are built (more accurate to be said the part will be listed as XXXX part number when it gets built).

Each case half has a casting number, not to be confused with a part number. See below.
Beginning with 1976 models and up, cases were only sold as a set so there are no individual part numbers for left or right case halves.
There is only 1 part number that includes both case halves.

Casting Part Numbers

Click Here to see an article on Casting Numbers in general in the Sportsterpedia.

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.
Unlike part numbers, casting numbers do pertain to the building of the part. One could also call them design numbers.
A casting part number does not pertain to any certain model.
Many different year / model motors may carry the same casting numbers but there will still be differences that are important to know.
When the main design changed, so did the casting numbers, but not until then. However, the part number may change several times.

Casting Date Code

Crankcase Numbers

These numbers were originally stamped on the bottom of each case half in the early days and was known as Belly Numbers.
Crankcase numbers don't have anything to do with issuing a VIN.
1957-1985 crankcase#s will not tell you specific model info (XLH or XLCH) and is coded only for the XL family of engines.
1986-present crankcase#s will have a number code representing the size of the engine (883, 1100 or 1200cc).
1991-present motors changed the coding and numbering system several times. See below for those changes.
Engine serial / VIN numbers are added later after assembly.

Crankcase numbers tell you that a particular set of cases was paired up and finish machined together (line boring, cylinder base surfacing etc).
These numbers will tell the year model that the cases are intended to be used, the Julian date and sequential number that day.
The coding for the crankcase numbers changed in 1986.
HD Model Designation (changed to 2 digits) - Year Model Case (2 digits) - Julian Day of the Year (3 digits) - Sequential Number (3 digits)
Each case half should have the same exact crankcase numbers as they came assembled from the factory as such.

From 1986 to mid 1989, crankcase numbers were hand stamped with “Pann-Ident style” numbers.
Starting mid 1989, crankcase #s are “pin stamped” by machine with “block style” and look as though they were formed by a series of “center-punched” dots.
The punch marks are deep enough that they should be able to be recovered with acid after grinding.
The back-up system for the new automated process is the old style hand stamping.
Therefore, it is possible that in the event of a mechanical failure of the pin stamping machine;
Some crankcases, after mid-model year 1989, may have hand stamped numbers.
If that happened, Harley-Davidson will have records of what crankcase numbers were hand stamped.

Below are numbers found on different year Sportster cases and should only be used as a guide.
There may be other numbers that don't match the ones below but these have all been verified.

  • On 1986-1990 motors
    • Model designations were a 2 digit #, example (16 = XR1000, 17 = 883 Evo, 18 = 1100 Evo, 19 = 1200 Evo)
    • The left crankcase is stamped on the outer primary wall (primary cover removed).
    • The right crankcase is stamped horizontally on the outer side of the case under the gearcase.
    • 1986-Mid 1989, the numbers are “hand stamped”.
    • Mid 1989-up, crankcase numbers are “pin stamped” by machine.
    • Example 10 digit crankcase number, 1786126015 translates to:
      • 17 = 883 model
      • 86 = 1986 model (case intended to be used for a 1986 model, not year it was cast)
      • 126 = Julian day #126 of the year or May 6, 1986 (126th day of the year, taking into account the model year season)
      • 015 = 15th off production line that day
  • On 1991-1999 motors
    • Models designations were a 2 digit #, example (24 = 883, 25 = 1200/1200C, 32 = / found on 1200S, 44 = / also found on 1200S)
    • The left crankcase is stamped on the outer primary wall (primary cover removed).
    • The right crankcase is stamped vertically on the outer side of the case on a vertical boss under the front of the gearcase.
      The numbers run top to bottom.
      On 1991-1997 motors, this front vertical boss is hollow (drilled from the bottom and plugged there).
      Oil in the cam chest runs to the bottom of the crankcase thru this boss.
      On 1998-1990 motors, this boss is not hollowed (cam chest oil is scavenged from the cam chest with a redesigned oil pump housing).
    • All crankcase numbers are “pin stamped” by machine.
    • Example 10 digit crankcase number, 2592256026 translates to:
      • 25 = 1200 or 1200C Sportster
      • 92 = 1992 model (case intended to be used for a 1992 model, not the year it was cast)
      • 256 = Julian day #256 of the year or September 13, 1991 (265th day of the year, taking into account the model year season)
      • 026 = 26th off production line that day
  • On 2000-2003 motors
    • Models designations changed to a 3 digit number, example (024 = 883, 025 = 1200)
    • The left crankcase is stamped on the outer primary wall (primary cover removed).
    • The right crankcase is stamped vertically on the outer side of the case on a vertical boss under the front of the gearcase.
      The numbers run bottom to top. This boss is not hollowed.
    • All crankcase numbers are “pin stamped” by machine.
    • Example 10 digit crankcase number, 0240110273 translates to:
      • 024 = 883 Sportster family
      • 01 = 2001 model (case intended to be used for a 2001 model, not the year it was cast)
      • 102 = Julian day #102 of the year or April 12, 2001 (102nd day of the year, taking into account the model year season)
      • 73 = 73rd off production line that day
1986-1990 Sportster Crankcase Number Locations 3)
1991-1999 Sportster Crankcase Number Locations 4)
2000-2003 Sportster Crankcase Number Locations 5)

Case Match Numbers (1975-Up)

In addition to belly numbers, there is a second set of numbers on 75> motors on each case half that should match.
This was added the same time the left case crankcase number moved from the belly to the primary wall on 1975 models.
For lack of public documentation, we'll call these Case Match Numbers and they represent the fact that those two case halves were mated as a factory pair.
These will most likely be a letter(s) and numbers but the exact number set should be on the outside of each case half opposite one another.
The factory crankcase numbers should be the same and the case match numbers should also be the same.
There does not seem to be any connection between the case match numbers and belly numbers (no date coding visible on case match numbers).

  • On 1986-1990 models, they'll be on each case half under the oil filter mount.
  • On 1991-up models, they'll be on top of the cases near or under the starter.

Serial or VIN Numbers

These numbers pertain to the whole bike, not just the engine. Coding for these numbers changed over the years.
Click Here to see the VIN page in the Sportsterpedia for specific information on serial/Vin numbers.
One Sportster may have many different parts, over the whole bike, than others, including engine parts.
The serial/VIN number was (most likely) the last number to be stamped onto the engine case from the factory.
1970-up Sportsters are titled to the frame only so the motor VIN number has nothing to do with ownership of the bike.
However, having the motor abbreviated VIN matching the frame VIN is a plus for those who want factory original parts.
And it helps toward the value (or haggle factor) on resell but the VIN is not the only factor in whether you have an original engine or bike.

Crankcase Mini-Sump

Left Case

Right Case

Upper Oil Feed Galley

Oil Pump Mounting Boss and Oil Passages

Click Here to reference the Evo Sportster Oil Pump page in the Sportsterpedia.
Note: Mixing full oil pump assemblies and engine cases is much easier than mixing individual oil pump parts.

1986-present cases use a gerotor type oil pump but there is a major difference in plumbing between 86-90 models and 91-up models.
However, 1986-1990 cases can be modded to accept 1991-up oil pumps.
Click Here to reference the 5 Speed Oil Pump Conversion for 86-90 Evo engines.

  • 1986-1990 cases have 2 oil passages on the pump mounting boss, feed to the motor and return to the pump.
    (feed passages in the case and cam cover goes to the pinion shaft / crankpin first then up to the lifters)
    It's essentially the same pump mount as in 1977-1985 motors.
    The pump has ext. hose fittings for return line to the oil tank, lines to the oil filter pad and from the oil filter pad back into the pump.
    The pump feeds the motor internally from there thru the feed hole in the oil pump mounting boss.
  • 1991-up cases have only 1 oil passage on the pump mounting boss, return to the pump.
    Cases were redesigned to feed the top end first and then down to the pinion shaft / crankpin.
    The oil pump was also redesigned with only 2 external fittings, feed line to the oil filter pad (then into the motor from there) and return line to the tank.
1986-1990 Oil Pump Mounting Boss 6) 1991-2003 Oil Pump Mounting Boss 7)

Right Case Crankcase Oil Scavenge / Engine Breathing

Case Drains

Primary / Transmission External Vent (1977-1985)

Motor mounts

Rear mounts


1) , 2) , 4)
photos courtesy of West Chester Cycles Inc. Link to Ebay Store
3)
photos courtesy of Robert Evans, labeled by Hippysmack
5)
photos courtesy of Ebay seller, gnarlydavidson1. Link to Items for Sale page
6)
photo courtesy of Robert Evans
7)
photo by Hippysmack
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