Differences

This shows you the differences between two versions of the page.

--- techtalk:evo:engmech01 [2022/09/10 03:43]
hippysmack [2003]
+++ techtalk:evo:engmech01 [2023/12/14 17:53]
hippysmack [Transmission Sprocket Cover]
@@ Line 28: / Line 28: @@
 ====== Primary Compartment ======
+===== Primary Cover Gasket =====
+Below is a list of factory gaskets used on Sportster primary covers. \\
+Pics of the different part numbers are listed to the right in the chart. Click on the link to open a picture of the part. \\
+^{{techtalk:miscres:instruction_sheet_header_4.png?nolink&803|}}||||
+|Year Model|Part#|Notes|Pics|
+|1977-1990 Sportster|34955-75|
+|1991-2003 Sportster|34955-89 \\ 34955-89A \\ 34955-89B|-89A replaced original in 1994. ((1994 HD Sportster parts catalog)) \\ -89B shows up in 2013 (-B) series parts catalogs.|{{ :techtalk:evo:engmech:1991-2003_sportster_primary_cover_gasket_34955-89_by_bikersnos_pic1.jpg?linkonly |-89}} ((photo courtesy of BIKERSNOS.com. [[https://www.ebay.com/str/bikersnos?_trksid=p2047675.m3561.l2563|Link to Ebay Store]] ))|
+|2004-Present Sportster|34955-04|
 ===== Shifter Shaft Seal =====
@@ Line 76: / Line 85: @@
 ====== Gearcase / Cam Chest ======
 ===== Cam Cover Gasket =====
-Cam cover gaskets as per the parts manuals are below. \\
+Below is a list of factory gaskets used on Sportster cam covers. \\
--1990 Sportsters used gasket (25263-86). \\
+Pics of the different part numbers are listed to the right in the chart. Click on the link to open a picture of the part. \\
--1993 Sportsters used gasket (25263-90). \\
--1997 Sportsters used gasket (25263-90A). \\
+^{{techtalk:miscres:instruction_sheet_header_4.png?nolink&803|}}||||
--1999 Sportsters used gasket (25263-90B). \\
+|Year Model|Part#|Notes|Pics|
--2003 Sportsters used gasket (25263-90C). \\
+|1986-1990 Sportster|25263-86|  |{{ :techtalk:evo:engmech:1986-1990_sportster_cam_cover_25263-86_by_mg000000.jpg?linkonly |Pic}} ((photo courtesy of Royal Motorworks Citroen Parts Plus, [[https://www.ebay.com/str/royalmotorworkscitroenpartsplus?_trksid=p2047675.m3561.l2563|Link to Ebay Store]]  ))|
+|1991-1993 Sportster|25263-90|
+|1994-1997 Sportster|25263-90A|
+|1998-1999 Sportster|25263-90B|
+|2000-2003 Sportster|25263-90C|**Note: Do not use a pre-2000 gasket on 2000-2003 cam covers** \\ A 1991-1999 style gasket WILL destroy a 2000-2003 engine! \\ See below.| \\
+\\
+-up Sportster engines have an internal rifling hole drilled into the lower left side of the case running past the left side of the oil pump. \\
+That extra hole (in the picture below) is benign and doesn't need a hole in the gasket to match. \\
+That hole is purely an artifact of how they connected two passages for routing crankcase oil up to the oil pump's scavenge section. \\
+They drill that hole to connect the two passages, and then it gets blocked off naturally by the cam box cover and gasket. ((aswracing of the XLFORUM http://xlforum.net/forums/showthread.php?t=2036109&highlight=oil+pump&page=3)) \\
+Also, in 2000, the factory changed the oil routing to the lifters to make manufacturing the cases easier. \\
+The newer cam cover on the left in the pic below and has two extra grooves along the top. These grooves let oil get to the lifters. \\
+If you have an older style gasket, it will not have cutouts for the grooves and you won't get oil to the lifters. \\
+|  Rubbermount Evo vs Rigid Evo Cam Cover Internals ((photo by Moved On of the XLFORUM http://xlforum.net/forums/showthread.php?t=87313))  |
+|{{:techtalk:evo:oil:rubbermount_vs_rigid_evo_cam_cover_comparison_by_moved_on.jpg?direct&600|}}|
+|  Both have been chopped on the outside but the gearcase perimeter is intact on them for reference.  |
+|  1991-1999 cam cover gasket ((photo by Hippysmack))  |  1991-1999 cam cover seals off the extra hole. ((photos by Hippysmack))  ||
+|{{:techtalk:evo:oil:91-99_cam_cover_gasket_2_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:91-99_cam_cover_gasket_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:91-99_cam_cover_gasket_4_by_hippysmack.jpg?direct&300|}}|
+|  2000-up cam cover gasket ((photo by Phillober of the XLFORUM http://xlforum.net/forums/showthread.php?t=1122547&page=7))  |2000-up gasket seals off the extra hole. ((sep69 of the XLFORUM http://xlforum.net/forums/showthread.php?t=2036109&highlight=oil+pump&page=3))|
+|{{:techtalk:evo:oil:2000_up_cam_cover_gasket_by_phillober.jpg?direct&300|}}|{{:techtalk:evo:oil:cam_cover_gasket_on_03_model_by_sep69.jpg?direct&300|}}|
+\\
+==== DON'T INSTALL a 91-99 CAM COVER GASKET ON A 2000-UP MOTOR!!!!!!! ====
+The 91-99 cam cover gasket has no business being on a 2000+ motor at all. It will cause you to lose all oil pressure. ((aswracing of the XLFORUM http://xlforum.net/forums/showthread.php?t=2079110&highlight=oil+tank&page=14)) \\
+The 2000+ gasket supersedes the 91-99 gasket. In other words, it can be used all the way back to 1991. \\
+Most companies completely dropped the 91-99 specific gasket and only offer the one that can be used from 1991-present. \\
+Either James Gasket hasn't done that, or they may have some old stock. \\
+The 1991-1999 lifter feed galley is an internal rifling hole in the case. It's drilled thru the case and only open to the cam cover via the center port to the pinion bushing. \\
+The 2000-up lifter feed galley is external and it takes both the cover and the case mounted together to make up the feed galley. \\
+So 2000-up feed galley is split in half between the case and cover. The slots in the 2000-up cam cover gasket mate to both the case and the cover. \\
+If you have the correct gasket on there, oil would be forced (between the cover and case) to all the lifter feed holes and piston squirters. \\
+With the wrong gasket (1991-1999), oil pressure leaving the filter gets into that (now open) galley. \\
+Then the oil will blow into into the cam chest, therefore bypassing the lifters, piston squirters and rod bearings. \\
+The oil will simply cycle from the oil pump to cam chest to oil pump and back to the oil tank. \\
+The oil light will stay off so you'll get no notice before moving the parts start oil starving and making noises and worse if the noises aren't heeded to quickly. \\
+|  2000-up motor with 1991-1999 cam cover gasket. ((photo by BestCoastXL of the XLFORUM http://xlforum.net/forums/showthread.php?t=2079110&highlight=oil+tank&page=12))  |  Below is a rough cross section of the joint in the \\ feed galley at that first slotted run. ((drawing by Hippysmack))  |
+|{{:techtalk:evo:oil:2000-up_sportster_with_wrong_91-99_cam_cover_gasket_by_bestcoastxl.jpg?direct&300|}}|{{:techtalk:evo:oil:2000-up_sportster_with_wrong_91-99_cam_cover_gasket_by_hippysmack.png?direct&300|}}|
 ===== #2 Cam - Cover Seal (86-03) =====
 Seal number (11124): \\
@@ Line 143: / Line 196: @@
 |{{:techtalk:evo:engmech:crank_pin_boss_washer_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:crank_pin_boss_washer_2_by_hippysmack.jpg?direct&300|}}|
-===== 1995-1999 =====
+===== 1995-1999 Flywheel Assembly =====
 The same flywheel set was used in all Sportsters 95-99. \\
 Sold as a unit: part number (23905-89A) consists of the flywheels, shafts and rods. \\
@@ Line 165: / Line 218: @@
 |{{:techtalk:evo:engmech:flywheels-shafts-rods-23905-89a_pic_10_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:flywheels-shafts-rods-23905-89a_pic_7_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:flywheels-shafts-rods-23905-89a_pic_8_by_hippysmack.jpg?direct&300|}}|
-===== 2000-2002 =====
+===== 2000-2002 Flywheel Assembly =====
 The OEM Flywheel assembly (23905-00) was factory installed in all Sportsters 2000-2003. \\
 That's to say the entire assembly part number is the same from 00-03. \\
@@ Line 181: / Line 234: @@
 |{{:techtalk:evo:engmech:flywheel_assembly_23905-00_by_aussiegazza.jpg?direct&300|}}|{{:techtalk:evo:engmech:flywheel_assembly_23905-00a_by_wilbur.jpg?direct&300|}}|
-===== 2003 =====
+===== 2003 Flywheel Assembly =====
 The original OEM Flywheel assembly (23905-00) was factory installed in all Sportsters 2000-2003. \\
 However, the rods in the 2003 assemblies are reportedly thinner than in the 00-02 assembly and carry -02 casting numbers. ((Randy_rots of the XLFORUM http://xlforum.net/forums/showthread.php?t=1949239&page=34)) \\
@@ Line 201: / Line 254: @@
 |{{:techtalk:evo:engmech:flywheel_assembly_23905-00_pic3_by_randy_rots.jpg?direct&250|}}|{{:techtalk:evo:engmech:flywheel_assembly_23905-00_pic4_by_randy_rots.jpg?direct&250|}}|{{:techtalk:evo:engmech:flywheel_assembly_23905-00_pic5_by_randy_rots.jpg?direct&250|}}|
-===== 2004-Later =====
+===== 2004-Later Flywheel Assembly =====
 The sprocket shaft nut torque for 2004 & later Sportsters and 2003 & later Buell XB models has been changed. ((HD Tech Tip #211 dated September 16,2005)) \\
 The torque has been increased from 190-210 ft-lbs. to 240-260ft-lbs. \\
@@ Line 504: / Line 557: @@
 |Year \\ Model|Part \\ Number|Casting \\ Number|Notes|
 |1986-1990 Sportster|34911-81A ((1986-1990 HD Sportster Parts Catalogs))|  |Polished|
-|1991-1994 Sportster|34911-91|  |  |
+|1991-1994 Sportster|34911-91|34913-91|Polished|
-|1995-2003 Sportster \\ (except XL883C) \\ (except XL1200C) \\ (except XL1200S)|34911-91A|  |Polished|
+|1995-2003 Sportster \\ (except XL883C) \\ (except XL1200C) \\ (except XL1200S)|34911-91A|34907-95|Polished|
-|1996-2003 XL1200C|34932-96|  |Chrome|
+|1996-2003 XL1200C|34932-96|34910-95|Chrome|
-|1998-2003 XL1200S/XL883C|34938-98|  |Silver|
+|1998-2003 XL1200S/XL883C|34938-98|34910-95|Silver|
-|2002-2003 XL883R|34943-02|  |Black|
+|2002-2003 XL883R|34943-02|34910-95|Black|
 \\
 [[:techtalk:menu|{{:techtalk:gototechnicalmenu.jpg|}}]]

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