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techtalk:ref:engmech03t [2021/04/23 03:01] hippysmack [Installing an 1986-1990 Primary Cover on a L1984-1985 Sportster] |
techtalk:ref:engmech03t [2024/01/14 21:44] (current) hippysmack |
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| - | ====== REF: Engine Mechanicals - Sub-03K ====== | + | ====== REF: Engine Mechanicals - Sub-03T ====== |
| - | ====== Installing an 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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| The OEM primary cover gasket (34955-75) will fit 1977-1990 Sportsters as per the parts catalogs. \\ | 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. \\ | 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**: \\ | ||
| * You will have to use all the hardware from an 86-90 model due to the cover not being as deep. | * 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. | * The shorter 86-90 perimeter bolts will have to be used. | ||
| - | **Parts**: | + | **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) | ||
| * Shifter Shaft (34628-86) | * Shifter Shaft (34628-86) | ||
| - | * Left Footrest Stud (24752-86) 1/2" x 4-1/8" | + | * 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) | ||
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| + | 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. \\ | ||
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| + | {{: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). \\ | ||
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| + | {{: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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| + | 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)) \\ | ||
| + | \\ | ||
| + | \\ | ||
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| + | Done! A 1986 primary cover on a 1985 Sportster. \\ | ||
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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 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)) \\ | ||
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| + | \\ | ||
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| + | 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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