Differences

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--- techtalk:ref:engmech03t [2021/04/23 02:27]
hippysmack [Installing an 1986-1990 Primary Cover on a L1984-1985 Sportster]
+++ techtalk:ref:engmech03t [2024/01/14 21:40]
hippysmack
@@ Line 1: / Line 1: @@
 [[:techtalk:menu|{{  :techtalk:gototechnicalmenu.jpg|}}]]
-====== REF: Engine Mechanicals - Sub-03K ======
+====== REF: Engine Mechanicals - Sub-03T ======
-====== Installing an 1986-1990 Primary Cover on a L1984-1985 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)) \\
@@ Line 8: / Line 8: @@
 The OEM primary cover gasket (34955-75) will fit 1977-1990 Sportsters as per the parts catalogs. \\
-However 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. \\
-{{: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**: \\
   * You will have to use all the hardware from an 86-90 model due to the cover not being as deep.
-  * The lowest front stud will be too long.
+  * The lowest front stud will be too long with the 86 cover.
-  * The stud for the footpeg sticks out of the cover by about 3 inches.
+  * 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 86-90 shifter shaft (34628-86).
+  * 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 shorter 86-90 perimeter bolts will have to be used.
-**Parts**:
+**Parts Acquired**:
-  * Primary Cover (25430-86 or -86A) or (25430-88) loaded.
+  * Primary Cover (25430-86) loaded.
   * Primary Cover Screws (3481) 1/4" x 20 x 1-1/2" Socket Head Screw (10)
   * Primary Cover Gasket (34955-75)
   * Shifter Shaft (34628-86)
   * Left Footrest Stud (24752-86) 1/2" x 4-1/8"
+  * 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 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)) \\
+\\
+\\
+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 http://xlforum.net/forums/showthread.php?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 http://xlforum.net/forums/showthread.php?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 http://xlforum.net/forums/showthread.php?t=2078880&page=4))  \\
+\\
+\\
+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 http://xlforum.net/forums/showthread.php?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 http://xlforum.net/forums/showthread.php?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 http://xlforum.net/forums/showthread.php?t=2078880&page=4))  \\
+\\
+\\
+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 http://xlforum.net/forums/showthread.php?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 http://xlforum.net/forums/showthread.php?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 http://xlforum.net/forums/showthread.php?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 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)) \\
+\\
+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> \\
 \\

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