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techtalk:ih:engmech01e [2022/04/03 06:34] hippysmack [Shifter Shaft / Brake Shaft Hole Bushings and Plugs] |
techtalk:ih:engmech01e [2023/11/15 14:21] hippysmack [1968-1970 XLH Cover] |
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====== IH: Engine Mechanicals - Sub-01E ====== | ====== IH: Engine Mechanicals - Sub-01E ====== | ||
====== Ironhead Gearcase/Cam Cover Pics and Information ====== | ====== Ironhead Gearcase/Cam Cover Pics and Information ====== | ||
- | \\ | ||
[[techtalk:ih:engmech01g|Click Here]] to go the Ironhead Gearcase/Cam Cover Removal and Installation page in the Sportsterpedia for fastener lists and gaskets. \\ | [[techtalk:ih:engmech01g|Click Here]] to go the Ironhead Gearcase/Cam Cover Removal and Installation page in the Sportsterpedia for fastener lists and gaskets. \\ | ||
- | ====== Shifter Shaft / Brake Shaft Hole Bushings and Plugs ====== | ||
- | **1952-1974 Cam Covers**: \\ | ||
- | 1952-1974 K models and Sportster use shifter shaft bushing (34037-52) in both the right case and the cam cover. \\ | ||
- | This bushing is open ended for the long shift shaft to run through it. \\ | ||
- | Bushing (34037-52) App. Dims: \\ | ||
- | Bushing OD: 5/8" \\ | ||
- | Bushing ID: 1/2" \\ | ||
- | Bushing Length: 3/4" \\ | ||
- | **1975-1976 Cam Covers**: \\ | + | ====== Gearcase / Cam Cover Parts List ====== |
- | 1975-1976 Sportsters use shifter shaft bushing (34037-52) in the right case and bushing (34037-75) in the cam cover. \\ | + | All part numbers were gathered from period specific Sportster parts catalogs from 1957-1985 including supplement and updated catalogs. \\ |
- | As result of the Sportster going left side shift in 1975, the shifter shaft got shorter out of the right case. \\ | + | |
- | The shaft end has linkages back to a crossover arm through the frame. \\ | + | |
- | This bushing has one closed end which is installed on the outside of the cover. \\ | + | |
- | Bushing (34037-75) App. Dims: \\ | + | |
- | Bushing OD: 5/8" \\ | + | |
- | Bushing ID: 1/2" \\ | + | |
- | Bushing Length: 3/4" \\ | + | |
- | **1977-E1981 Cam Covers**: \\ | + | ^{{techtalk:miscres:instruction_sheet_header_4.png?nolink&803|}}||||| |
- | 1977-E1981 cam covers came with a different bushing (25594-75) for a brake shaft. \\ | + | |Year Model|Cam / Gearcase Cover \\ Part Number|Casting Number|Gasket|Shifter \\ Shaft \\ Bushing| |
- | Starting in 1977, the shifter shaft exits out the left case and the old then shifter shaft location in the cam cover became the brake shaft location. \\ | + | |1952-1956 K Models|25200-52|25202-52|25224-52| |
- | This was the brake shaft design from 1977-1979 (even though the rear brakes went hydraulic in 1979). \\ | + | | Notes:|Replaced with 25200-52A in 1963. |||| |
- | However, in 1980, the MoCo moved the brake operating lever to the trans sprocket cover so the hole in the cam cover was now useless (1980-1985). \\ | + | |1957-1962 XL/XLH/XLCH|25200-57|25202-52A|25224-52| |
- | Cam Cover Bushing Bore: .7450" ((Scott of the XLFORUM http://xlforum.net/forums/showthread.php?t=2074151)) \\ | + | | Notes:|Aluminum cover with single horizontal bar and square rear corner (not cut out). \\ Uses generator "daisy wheel" oil deflector w/ sliding separator bushing/spring in cover \\ Replaced by 25200-63A in 1968. |||| |
- | Bushing (25594-75) App. Dims: \\ | + | |1963-1966 XLH \\ 1963-1967 XLCH|25200-63|25202-52A|25224-52| |
- | Bushing OD (before installing): .752" ((Dims from Robison Motorcycles)) \\ | + | | Notes:|Aluminum cover with single horizontal bar and square rear corner (not cut out). \\ Uses generator slinger washer oil deflector w/ stationary bushing in cover. \\ Replaced by 25200-63A in 1968. |||| |
- | Bushing ID (before installing): .6250" ((Scott of the XLFORUM http://xlforum.net/forums/showthread.php?t=2074151)) \\ | + | |1967 XLH|25201-67|25202-52A|25224-52| |
- | Bushing Length: .625" ((Dims from Robison Motorcycles)) \\ | + | | Notes:|1966 style single bar aluminum cover with rear cutout added around new starter. \\ Oil tank vent (62375-62) added to the rear of the cover. \\ Replaced by 25201-67A in 1969.|||| |
- | + | |1968-1969 XLCH|25200-63A|02-68|25224-52| | |
- | **1980-E1981 Cam Covers**: \\ | + | | Notes:|Aluminum cover with 6 horizontal ribs and square rear corner (not cut out).|||| |
- | In 1980, the MoCo used a rubber plug (25221-77) in the now unused brake shaft hole in the cam cover. \\ | + | |1968-1970 XLH|25201-67A|02-68|25224-52| |
- | The brake shaft bushing was still installed presumably to allow later covers to be used on 1979 models. \\ | + | | Notes:|Aluminum cover with 6 horizontal ribs and rear cutout for starter.|||| |
- | The rubber plug inserts into the bushing. \\ | + | |1970 XLCH|25200-70|02-68| | |
- | The parts books (1980-1985) show the rubber plug sold for 1979-E1981 Sportsters. \\ | + | | Notes:|Aluminum cover with 6 horizontal ribs and square rear corner (no cut out). \\ Previous boss for magneto redesigned to accept a circuit breaker. \\ Oil tank vent (62375-57) added to the rear of the cover.|||| |
- | As usual, that means they expected one to upgrade the 1979 system to the 1980 system. \\ | + | |1971-1972 XLH \\ 1974 XLH|25201-71|71-25202|25224-52| |
- | + | | Notes:|Polished. |||| | |
- | **L1981-E1984 Cam Covers**: \\ | + | |1971-1972 XLCH \\ 1974 XLCH|25200-71|71-25202|25224-52| |
- | Once again a change was made in "how to plug a hole that goes nowhere". \\ | + | | Notes:| |||| |
- | There may have been some problems with the rubber plug falling out or other. The bushing and plug was deleted from the cover. \\ | + | |1973 XLH|25201-73 \\ black|71-25202|25224-52| |
- | The hole was still there but threaded for metal plug (2506), 7/16"-14 x 1/2" hex socket bolt, which screws into the cam cover. \\ | + | | Notes:| |||| |
- | L-1984-1985 covers did not use a plug nor did they have a hole for a plug even though the parts books show the plug for L81-85 models. \\ | + | |1973 XLCH|25200-73 \\ black|71-25202|25224-52| |
- | + | | Notes:| |||| | |
- | **1975-1976 Sportster shifter shaft**: ((photos courtesy of Ebay seller, Robison Motorcycles [[ https://www.ebay.com/str/robisonmotorcycles?_trksid=p2047675.l2563 |Link to Ebay Store]] )) \\ | + | |1975-1976 XLH|25211-75|71-25202|25224-52| |
- | {{:techtalk:ih:engmech:1975-1976_shifter_shaft_bushing_34037-75_by_robisonmotorcycles_pic1.jpg?direct&300|}} {{:techtalk:ih:engmech:1975-1976_shifter_shaft_bushing_34037-75_by_robisonmotorcycles_pic2.jpg?direct&300|}} \\ | + | | Notes:|Shifter moved to the left side of the bike in 1975.|||| |
- | + | |1975-1976 XLCH|25205-75|71-25202|25224-52| | |
- | **1977-E1981 Sportster brake shaft bushing**: ((photos courtesy of Ebay seller, Robison Motorcycles [[ https://www.ebay.com/str/robisonmotorcycles?_trksid=p2047675.l2563 |Link to Ebay Store]] )) \\ | + | | Notes:| |||| |
- | {{:techtalk:ih:engmech:1977-e1981_sportster_brake_shaft_bushing_25594-75_by_robisonmotorcycles_pic1.jpg?direct&300|}} {{:techtalk:ih:engmech:1977-e1981_sportster_brake_shaft_bushing_25594-75_by_robisonmotorcycles_pic2.jpg?direct&300|}} \\ | + | |1977-1978 XL \\ 1978 XLCH|25201-75|76-25202F|25244-52A| |
+ | | Notes:| |||| | ||
+ | |1977 XLCH|25200-75|76-25202F|25244-52A| | ||
+ | | Notes:|Replaced by 25201-75 (1978 parts sup).|||| | ||
+ | |1979 XL|25201-79 \\ 25201-79A|79-25202F|25244-52A| | ||
+ | | Notes:|Polished. Original cover has a reed type breather valve assembly (26909-79A). \\ Replaced by 25201-79A which has a deeper boss in the nosecone to mount the ignition. \\ Kit includes a spacer (25262-80) to extend ignition to original location. \\ Rubber plug (25221-77) installed in 1979-E1981 cover.|||| | ||
+ | |1979 XLCH|25200-79|79-25202|25244-52A| | ||
+ | | Notes:|Polished. Original cover has a reed type breather valve assembly (26909-79A). \\ Replaced by 25200-79A which has a deeper boss in the nosecone to mount the ignition. \\ Kit includes a spacer (25262-80) to extend ignition to original location.|||| | ||
+ | |1979 XLS|25205-79 \\ 25205-79A|79-25202|25244-52A| | ||
+ | | Notes:|Gray. Replaced by 25205-79A which has a deeper boss in the nosecone to mount the ignition. \\ Kit includes a spacer (25262-80) to extend ignition to original location.|||| | ||
+ | |1980 XL|25208-80 \\ 25201-79A|80-25222|25244-52A| | ||
+ | | Notes:|Polished|||| | ||
+ | |1980 XLS|25209-80|80-25222|25244-52A| | ||
+ | | Notes:|-80 parts book says, polished. -81 book says black.|||| | ||
+ | |E1981 XL|25227-81|81-25223|25244-52A| | ||
+ | | Notes:|Polished. Angle cut upper feed galley slot. No pins in cam bushings.|||| | ||
+ | |E1981 XLS|25229-81|81-25223|25244-52A| | ||
+ | | Notes:|Black. Angle cut upper feed galley slot.|||| | ||
+ | |L1981-1982 XLS|25209-81|25222-81|25263-81| | ||
+ | | Notes:|Black. Straight cut upper feed galley slot. No casting for tach drive. No pins in cam bushings. \\ 7/16"-14x1/2" allen hd plug screw (2506) installed thru 1985 in place of rubber plug.|||| | ||
+ | |L1981-E1984 XL \\ 1983-E1984 XLS/XLX|25208-81|25222-81|25263-81| | ||
+ | | Notes:|Polished. No casting for tach drive. No pins in cam bushings.|||| | ||
+ | |1983-1985 XLX|25207-83| |25263-81| | ||
+ | | Notes:|Kit w/ aluminum finish. No casting for tach drive.|||| | ||
+ | |L1984 XLX|25207-84|25222-84A|25263-81| | ||
+ | | Notes:|Aluminum finish. Replaced by 25207-84A (-85A parts book)|||| | ||
+ | |L1984 XL/XLS|25208-84|25222-84A|25263-81| | ||
+ | | Notes:|Polished. Replaced by 25219-86 (-85A parts book)|||| | ||
+ | |1985 XLX|25207-84A|25222-84A|25263-81| | ||
+ | | Notes:|Black.|||| | ||
+ | |1985 XL/XLS|25208-84A|25222-84A|25263-81| | ||
+ | | Notes:|Polished. Replaced by 25219-86 (-85A parts book)|||| | ||
====== Internal Comparisons ====== | ====== Internal Comparisons ====== | ||
Line 97: | Line 112: | ||
{{:techtalk:ih:engmech:1963-1966_xlh_1963-1967_xlch_cam_cover_25200-63_by_motorcycle_dreams_pic4.jpg?direct&300|}} {{:techtalk:ih:engmech:1963-1966_xlh_1963-1967_xlch_cam_cover_25200-63_by_motorcycle_dreams_pic5.jpg?direct&300|}} {{:techtalk:ih:engmech:1963-1966_xlh_1963-1967_xlch_cam_cover_25200-63_by_motorcycle_dreams_pic6.jpg?direct&300|}} \\ | {{:techtalk:ih:engmech:1963-1966_xlh_1963-1967_xlch_cam_cover_25200-63_by_motorcycle_dreams_pic4.jpg?direct&300|}} {{:techtalk:ih:engmech:1963-1966_xlh_1963-1967_xlch_cam_cover_25200-63_by_motorcycle_dreams_pic5.jpg?direct&300|}} {{:techtalk:ih:engmech:1963-1966_xlh_1963-1967_xlch_cam_cover_25200-63_by_motorcycle_dreams_pic6.jpg?direct&300|}} \\ | ||
+ | ===== 1967 XLH Cover ===== | ||
+ | Part number (25201-67). Casting number (25202-52A). \\ | ||
+ | Same as 1967 XLCH but has the cut-out for electric start. \\ | ||
+ | |||
+ | {{:techtalk:ih:engmech:1967_xlh_cam_cover_pic1_by_market406.jpg?direct&300|}} ((photo courtesy of Ebay seller, market406. [[https://www.ebay.com/sch/market406/m.html?_nkw=&_armrs=1&_ipg=&_from=|Link to Items for Sale page]] )) {{:techtalk:ih:engmech:1967_xlh_cam_cover_pic3_by_market406.jpg?direct&300|}} ((photo courtesy of Ebay seller, market406. [[https://www.ebay.com/sch/market406/m.html?_nkw=&_armrs=1&_ipg=&_from=|Link to Items for Sale page]] )) \\ | ||
+ | |||
===== 1968-1969 XLCH Cover ===== | ===== 1968-1969 XLCH Cover ===== | ||
- | Cover part number (25200-63A). Casting number is (02-86). \\ | + | Cover part number (25200-63A). Casting number is (02-68). \\ |
The oil tank is still vented to the fitting at the top of the right case behind the rear cylinder. \\ | The oil tank is still vented to the fitting at the top of the right case behind the rear cylinder. \\ | ||
Looks similar to the 68 H cover with exceptions. \\ | Looks similar to the 68 H cover with exceptions. \\ | ||
The XLCH cover has a squared (uncut) rear corner, no 90° fitting on back and the ignition boss on top is set up to accept a magneto. \\ | The XLCH cover has a squared (uncut) rear corner, no 90° fitting on back and the ignition boss on top is set up to accept a magneto. \\ | ||
+ | Click on any pic to enlarge: ((photos courtesy of Brewer's Performance Inc. in Laura, Ohio [[http://www.brewersperformance.com/|Link to website]] )) \\ | ||
+ | {{:techtalk:ih:engmech:1968-1969_xlch_cam_cover_25200-63_pic1_by_shopanuck.jpg?direct&300|}} {{:techtalk:ih:engmech:1968-1969_xlch_cam_cover_25200-63_pic2_by_shopanuck.jpg?direct&300|}} \\ | ||
+ | |||
+ | {{:techtalk:ih:engmech:1968-1969_xlch_cam_cover_25200-63_pic3_by_shopanuck.jpg?direct&300|}} {{:techtalk:ih:engmech:1968-1969_xlch_cam_cover_25200-63_pic4_by_shopanuck.jpg?direct&300|}} \\ | ||
===== 1968-1970 XLH Cover ===== | ===== 1968-1970 XLH Cover ===== | ||
Cover part number (25201-67A). Casting number is (02-68). Top rear corner is cut out for the electric starter. \\ | Cover part number (25201-67A). Casting number is (02-68). Top rear corner is cut out for the electric starter. \\ | ||
Line 110: | Line 135: | ||
Both fittings are 1/8"-27 NPT to 1/4" hose barb 90° elbows. \\ | Both fittings are 1/8"-27 NPT to 1/4" hose barb 90° elbows. \\ | ||
- | Click on a pic to enlarge: ((photos courtesy of Ebay seller, animalhouse2010, [[https://www.ebay.com/str/animalhouse2010?_trksid=p2047675.l2563|Link to Ebay store:]] )) \\ | ||
- | {{:techtalk:ih:engmech:1968-1970_xlh_cam_cover_25201-67a_by_animalhouse2010_pic1.jpg?direct&300|}} {{:techtalk:ih:engmech:1968-1970_xlh_cam_cover_25201-67a_by_animalhouse2010_pic2.jpg?direct&300|}} {{:techtalk:ih:engmech:1968-1970_xlh_cam_cover_25201-67a_by_animalhouse2010_pic3.jpg?direct&300|}} \\ | ||
- | {{:techtalk:ih:engmech:1968-1970_xlh_cam_cover_25201-67a_by_animalhouse2010_pic4.jpg?direct&300|}} {{:techtalk:ih:engmech:1968-1970_xlh_cam_cover_25201-67a_by_animalhouse2010_pic5.jpg?direct&300|}} {{:techtalk:ih:engmech:1968-1970_xlh_cam_cover_25201-67a_by_animalhouse2010_pic6.jpg?direct&300|}} \\ | + | |
===== 1970 XLCH Cover ===== | ===== 1970 XLCH Cover ===== |