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techtalk:evo:engmech02 [2022/10/07 22:17]
hippysmack [Cam Cover Gasket]
techtalk:evo:engmech02 [2024/01/03 18:19] (current)
hippysmack
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 [[:​techtalk:​menu|{{ ​ :​techtalk:​gototechnicalmenu.jpg|}}]] [[:​techtalk:​menu|{{ ​ :​techtalk:​gototechnicalmenu.jpg|}}]]
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 ====== EVO: Engine Mechanicals ====== ====== EVO: Engine Mechanicals ======
  
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 #3 Cam - Rotates CW -- Operates Front Intake Valve\\ #3 Cam - Rotates CW -- Operates Front Intake Valve\\
 #4 Cam - Rotates CCW - Operates Front Exhaust Valve\\ #4 Cam - Rotates CCW - Operates Front Exhaust Valve\\
- 
- 
  
 ====== Camshafts ====== ====== Camshafts ======
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 #2 cam rotates counterclockwise and the oil is sprayed on the right side of the cam gear for extra cooling (transferred to all cams). #2 cam rotates counterclockwise and the oil is sprayed on the right side of the cam gear for extra cooling (transferred to all cams).
  
-|  (L) 92-99 ((photo by Hippysmack of the XLFORUM)), (R) 2000 Up ((photo by Bruce of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1118529&​page=2up)) cam oiling hole from the feed galley ​ ||+|  (L) 92-99 ((photo by Hippysmack of the XLFORUM)), (R) 2000 Up ((photo by Bruce of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-motor-engine/​sportster-motorcycle-engine-conversions/​116357-bruce-s-conversion-finally/​page2?​t=1118529&​page=2up)) cam oiling hole from the feed galley ​ ||
 | {{:​techtalk:​evo:​oil:​92-99_cam_oiler_hole_by_hippysmack.jpg?​direct&​300|}} |{{:​techtalk:​evo:​oil:​2000_up_cam_oiler_hole_by_bruce.jpg?​direct&​300|}}| | {{:​techtalk:​evo:​oil:​92-99_cam_oiler_hole_by_hippysmack.jpg?​direct&​300|}} |{{:​techtalk:​evo:​oil:​2000_up_cam_oiler_hole_by_bruce.jpg?​direct&​300|}}|
  
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-Thanks to Maxeffort of the XLForum for the following Flywheel Degree Charts of these various cams.((Maxeffort at this post: http://​xlforum.net/​forums/showthread.php?​t=2074322))+Thanks to Maxeffort of the XLForum for the following Flywheel Degree Charts of these various cams.((Maxeffort at this post: https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-motor-engine/​sportster-motorcycle-bottom-end/​197650-cam-comparison-on-degree-wheel-chart?​t=2074322))
  
 The measurements are based on the .053 lift specs. Also, take note that the predominance of the intake valve opening occurs on one rotation of the flywheel and the predominance of the exhaust valve opening occurs on the next rotation of the flywheel. It takes two full rotations (720°) of the flywheel to complete the four-cycle process. (This view of the flywheel would be from the right side of the engine.) The measurements are based on the .053 lift specs. Also, take note that the predominance of the intake valve opening occurs on one rotation of the flywheel and the predominance of the exhaust valve opening occurs on the next rotation of the flywheel. It takes two full rotations (720°) of the flywheel to complete the four-cycle process. (This view of the flywheel would be from the right side of the engine.)
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 ===== Removing / Installing Evo Cams ===== ===== Removing / Installing Evo Cams =====
-===== Sub Documents ​=====+==== Sub Documents ====
  
   * [[techtalk:​evo:​engmech02a|Installing Evo Cams (91 and Up)]]   * [[techtalk:​evo:​engmech02a|Installing Evo Cams (91 and Up)]]
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 ===== Cam Gear Changes ====== ===== Cam Gear Changes ======
- +  ​* The #2 "​W"​ cam may or may not have a provision for a timing cup after 03. ((aswracing of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-motor-engine/​sportster-motorcycle-engine-conversions/​143982-choosing-a-cam-for-low-compression-883/​page2?​page=2&​t=1560258))
-  ​* The #2 "​W"​ cam may or may not have a provision for a timing cup after 03. ((aswracing of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​page=2&​t=1560258))+
     * If you intend on installing 04-up "​W"​ cams in 03 and prior engines, look at the end of the #2 cam.     * If you intend on installing 04-up "​W"​ cams in 03 and prior engines, look at the end of the #2 cam.
     * If it does have a provision for a timing cup, they'​ll work for prior year applications.     * If it does have a provision for a timing cup, they'​ll work for prior year applications.
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     * Below (Right Pic), compares the '99 #2 cam gear (left-side) and the '01 style #2 cam gear (right-side).     * Below (Right Pic), compares the '99 #2 cam gear (left-side) and the '01 style #2 cam gear (right-side).
  
-{{:​techtalk:​evo:​engmech:​cam_gear_tooth_pitch_by_aswracing.jpg?​direct&​300|}} ((photo by aswracing of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​page=2&​t=1560258)){{:​techtalk:​evo:​engmech:​cam_gear_tooth_pitch_2_by_aswracing.jpg?​direct&​300|}} ((photo by aswracing of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​threadid=1632054)) \\+{{:​techtalk:​evo:​engmech:​cam_gear_tooth_pitch_by_aswracing.jpg?​direct&​300|}} ((photo by aswracing of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-motor-engine/​sportster-motorcycle-engine-conversions/​143982-choosing-a-cam-for-low-compression-883/​page2?​page=2&​t=1560258)){{:​techtalk:​evo:​engmech:​cam_gear_tooth_pitch_2_by_aswracing.jpg?​direct&​300|}} ((photo by aswracing of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-motor-engine/​sportster-motorcycle-bottom-end/​150864-will-1999-x1-cams-fit-in-my-2002-1200c?​threadid=1632054)) \\
  
 ===== Cam Bushings ===== ===== Cam Bushings =====
 ==== Inner Bushings ==== ==== Inner Bushings ====
-  * These bushings get their oil from the fling off of the cam gears and drain back from the top end down the pushrod tubes that puddles in at depressions in the castings where the cam bushing slots are aligned. So basically they are drip fed. Also the cam bushings on the case side are open to the crank behind them, and probably get splash there too. ((Wedge of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1974986&​highlight=bronze+drive+gear&​page=3))+  * These bushings get their oil from the fling off of the cam gears and drain back from the top end down the pushrod tubes that puddles in at depressions in the castings where the cam bushing slots are aligned. So basically they are drip fed. Also the cam bushings on the case side are open to the crank behind them, and probably get splash there too. ((Wedge of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-general-discussion-and-problems/​183583-oil-filter-bypass-no-longer-a-question-damage-porn-inside/​page3?​t=1974986&​highlight=bronze+drive+gear&​page=3))
   * Worn bushings can cause excess backlash. ((1986 HD Dealer Sportster FSM pg 3-45))   * Worn bushings can cause excess backlash. ((1986 HD Dealer Sportster FSM pg 3-45))
  
 |{{:​techtalk:​evo:​engmech:​2010_1200x_cam_inner_bushings_by_lostndallas.jpg?​direct&​400|}}|{{:​techtalk:​evo:​engmech:​2010_1200x_cam_cover_bushings_by_lostndallas.jpg?​direct&​400|}}| |{{:​techtalk:​evo:​engmech:​2010_1200x_cam_inner_bushings_by_lostndallas.jpg?​direct&​400|}}|{{:​techtalk:​evo:​engmech:​2010_1200x_cam_cover_bushings_by_lostndallas.jpg?​direct&​400|}}|
-|  2010 1200X Inner Cam Bushings (broken teeth on oil pump gear) ((photo by lostNdallas of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1974986&​highlight=bronze+drive+gear&​page=6)) ​ |  2010 1200X Cam Cover and Bushings ((photo by lostNdallas of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1974986&​highlight=bronze+drive+gear&​page=4)) ​ |+|  2010 1200X Inner Cam Bushings (broken teeth on oil pump gear) ((photo by lostNdallas of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-general-discussion-and-problems/​183583-oil-filter-bypass-no-longer-a-question-damage-porn-inside/​page6?​t=1974986&​highlight=bronze+drive+gear&​page=6)) ​ |  2010 1200X Cam Cover and Bushings ((photo by lostNdallas of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-general-discussion-and-problems/​183583-oil-filter-bypass-no-longer-a-question-damage-porn-inside/​page4?​t=1974986&​highlight=bronze+drive+gear&​page=4)) ​ |
  
 ==== Outer Bushings ==== ==== Outer Bushings ====
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 |{{:​techtalk:​evo:​oil:​cam_bushing_oiling_6_by_hippysmack.jpg?​direct&​300|}}|{{:​techtalk:​evo:​oil:​cam_bushing_oiling_8_by_hippysmack.jpg?​direct&​300|}}|{{:​techtalk:​evo:​oil:​cam_bushing_oiling_7_by_hippysmack.jpg?​direct&​300|}}| |{{:​techtalk:​evo:​oil:​cam_bushing_oiling_6_by_hippysmack.jpg?​direct&​300|}}|{{:​techtalk:​evo:​oil:​cam_bushing_oiling_8_by_hippysmack.jpg?​direct&​300|}}|{{:​techtalk:​evo:​oil:​cam_bushing_oiling_7_by_hippysmack.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|}}| 
  
 ====== Lifters (tappets) ====== ====== Lifters (tappets) ======
-===== Sub-Documents ​=====+==== Sub-Documents ====
   * [[techtalk:​evo:​engmech02b|91-99 Lifter Pin Upgrade to 00-05 Lifter Pin Screws]]   * [[techtalk:​evo:​engmech02b|91-99 Lifter Pin Upgrade to 00-05 Lifter Pin Screws]]
   * [[techtalk:​evo:​engmech02c|Hydraulic Lifter - Mechanical and Hydraulic Operation]]   * [[techtalk:​evo:​engmech02c|Hydraulic Lifter - Mechanical and Hydraulic Operation]]
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 This oil-based operation allows the hydraulic lifters to self-adjust for minor changes in valve operation caused by heat expansion. \\ This oil-based operation allows the hydraulic lifters to self-adjust for minor changes in valve operation caused by heat expansion. \\
 It eliminates the need for adjustable pushrods. It eliminates the need for adjustable pushrods.
-A hydraulic lifter self-adjusts within a certain range. ​ ((aswracing of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=322680&​page=5)) \\+A hydraulic lifter self-adjusts within a certain range. ​ ((aswracing of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-motor-engine/​sportster-motorcycle-engine-conversions/​59164-i-think-i-screwed-up-with-new-cam-install/​page5?​t=322680&​page=5)) \\
 In other words, if your pushrods are too long, the lifter automatically shortens, and if the pushrods are too short, it automatically lengthens. \\ In other words, if your pushrods are too long, the lifter automatically shortens, and if the pushrods are too short, it automatically lengthens. \\
  
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 Stock lifters can be inserted either way, so long as the roller wheel is aligned with the cam lobe and the flats are aligned with the anti-rotation pins afterwards. \\ Stock lifters can be inserted either way, so long as the roller wheel is aligned with the cam lobe and the flats are aligned with the anti-rotation pins afterwards. \\
- 
  
 1986-up Sportsters were fitted with hydraulic roller lifters (roller tappets) from the factory. \\ 1986-up Sportsters were fitted with hydraulic roller lifters (roller tappets) from the factory. \\
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 {{techtalk:​evo:​engmech:​1991-up_sportster_lifter_anatomy_by_hippysmack.png?​direct&​400|}} ((drawing by Hippysmack)) \\ {{techtalk:​evo:​engmech:​1991-up_sportster_lifter_anatomy_by_hippysmack.png?​direct&​400|}} ((drawing by Hippysmack)) \\
 \\ \\
- 
  
 ===== Checking Lifter Pre-load ===== ===== Checking Lifter Pre-load =====
- +Hydraulic lifters self-adjust over about a .100" range, from .050" preloaded to .150" preloaded. ((aswracing of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-motor-engine/​sportster-motorcycle-engine-conversions/​160330-squish-band-clearance?​t=1720575)) \\
-Hydraulic lifters self-adjust over about a .100" range, from .050" preloaded to .150" preloaded. ((aswracing of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1720575)) \\+
 They'​ll actually work outside that range but they might make noise, so it's best to stay in that range. \\ They'​ll actually work outside that range but they might make noise, so it's best to stay in that range. \\
  
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 The lifter plunger should be preloaded between .050 and .150. Make the measurement if you're not sure. \\ The lifter plunger should be preloaded between .050 and .150. Make the measurement if you're not sure. \\
-{{:​techtalk:​evo:​engmech:​checking_lifter_preload_by_aswracing.jpg?​direct&​300|}} ((photo by aswracing of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?t=113818)) \\+{{:​techtalk:​evo:​engmech:​checking_lifter_preload_by_aswracing.jpg?​direct&​300|}} ((photo by aswracing of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-motor-engine/​sportster-motorcycle-motor-top-end/​42637-push-rod-length?t=113818)) \\
  
 ===== Oil feed to lifters ===== ===== Oil feed to lifters =====
- 
 91 and up engines have a horizontal passage on the top of the cam box that is fed oil from the filter pad. \\ 91 and up engines have a horizontal passage on the top of the cam box that is fed oil from the filter pad. \\
 This horizontal passage feeds into the lifter bores. \\ This horizontal passage feeds into the lifter bores. \\
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 The stock lifters can be inserted either way, so long as the roller wheel is aligned with the cam lobe and the flats are aligned with the anti-rotation pins. \\ The stock lifters can be inserted either way, so long as the roller wheel is aligned with the cam lobe and the flats are aligned with the anti-rotation pins. \\
  
- +|91-99 engines have a single passage in that top \\ area, the tappets are connected by internal \\ passages from this small cavity.|On 2000 and up engines, oil travels to each lifter \\ individually from this cavity. ((photo by aswracing of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-motor-engine/​sportster-motorcycle-engine-conversions/​148387-100-ci-s-s-cases?​t=1611832))|
-|91-99 engines have a single passage in that top \\ area, the tappets are connected by internal \\ passages from this small cavity.|On 2000 and up engines, oil travels to each lifter \\ individually from this cavity. ((photo by aswracing of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1611832))|+
 |{{:​techtalk:​evo:​oil:​cam_alignment_by_aswracing.jpg?​direct&​300|}}|{{:​techtalk:​evo:​oil:​lifter_oiling_by_aswracing.jpg?​direct&​300|}}| |{{:​techtalk:​evo:​oil:​cam_alignment_by_aswracing.jpg?​direct&​300|}}|{{:​techtalk:​evo:​oil:​lifter_oiling_by_aswracing.jpg?​direct&​300|}}|
  
 ====== 1986-1990 models ====== ====== 1986-1990 models ======
- 
- 
- 
 There was a running change in 1986 to new style hydraulic lifters as opposed to the original 1986 versions for Sportsters. ((1986-1990 HD Sportster FSM pg 3-44)) \\ There was a running change in 1986 to new style hydraulic lifters as opposed to the original 1986 versions for Sportsters. ((1986-1990 HD Sportster FSM pg 3-44)) \\
 They were the same as those used in 1340cc engines beginning in the 1986 model year. The change was to allow for one component to service the entire product line. \\ They were the same as those used in 1340cc engines beginning in the 1986 model year. The change was to allow for one component to service the entire product line. \\
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   - Slowly snug all rocker box fasteners in small increments (one turn at a time). \\ Use a cross pattern on the four large bolts that fasten the lower rocker box to head. \\ This will bleed the lifters. Tighten fasteners to the correct torque. Refer to the 1986 XLH Service Manual for the proper tightening sequence. \\ **CAUTION**,​ Do not turn the engine over until both push rods can be turned with fingers to avoid damage to push rods or rocker arms.   - Slowly snug all rocker box fasteners in small increments (one turn at a time). \\ Use a cross pattern on the four large bolts that fasten the lower rocker box to head. \\ This will bleed the lifters. Tighten fasteners to the correct torque. Refer to the 1986 XLH Service Manual for the proper tightening sequence. \\ **CAUTION**,​ Do not turn the engine over until both push rods can be turned with fingers to avoid damage to push rods or rocker arms.
   - Repeat Steps 2 through 5 for other cylinder   - Repeat Steps 2 through 5 for other cylinder
- 
  
 The oil feed to the lifters comes from the oil pump, through a passage in the cam cover to the feed galley in the top of the right case. \\ The oil feed to the lifters comes from the oil pump, through a passage in the cam cover to the feed galley in the top of the right case. \\
 The intake lifters are fed oil from the feed galley hole. Each exhaust lifter is fed from it's corresponding intake lifter bore. \\ The intake lifters are fed oil from the feed galley hole. Each exhaust lifter is fed from it's corresponding intake lifter bore. \\
-|  1986-1990 lifter oiling path ((photo by Mini_blitz of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1974615&​page=3)) ​ |+|  1986-1990 lifter oiling path ((photo by Mini_blitz of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-motor-engine/​sportster-motorcycle-bottom-end/​183493-1986-evolution-sportster-cam-cover-install-help/​page3?​t=1974615&​page=3)) ​ |
 |{{:​techtalk:​evo:​oil:​86-90_engine_lifter_oiling_by_mini_blitz.jpg?​direct&​300|}}| |{{:​techtalk:​evo:​oil:​86-90_engine_lifter_oiling_by_mini_blitz.jpg?​direct&​300|}}|
  
 {{:​techtalk:​evo:​engmech:​86_engine_8_by_xtremraptor.jpg?​direct&​300|}} ((photo by xtremraptor of the XLFORUM)) {{:​techtalk:​evo:​engmech:​86_engine_4_by_xtremraptor.jpg?​direct&​300|}} ((photo by xtremraptor of the XLFORUM)) \\ {{:​techtalk:​evo:​engmech:​86_engine_8_by_xtremraptor.jpg?​direct&​300|}} ((photo by xtremraptor of the XLFORUM)) {{:​techtalk:​evo:​engmech:​86_engine_4_by_xtremraptor.jpg?​direct&​300|}} ((photo by xtremraptor of the XLFORUM)) \\
- 
  
 ====== 91-99 Lifters ====== ====== 91-99 Lifters ======
-1991-1999 engines have AMC-Mopar style lifters (.903" diameter). (("A 4 liter V8 eater" of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1611832)) \\ +1991-1999 engines have AMC-Mopar style lifters (.903" diameter). (("A 4 liter V8 eater" of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-motor-engine/​sportster-motorcycle-engine-conversions/​148387-100-ci-s-s-cases?​t=1611832)) \\ 
  
-|  1991-1999 lifters (18526-89A) ((photos by tara of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​s=ad3665ba90dc78712409c04874bb2687&​p=3198112))  ||| +|  1991-1999 lifters (18526-89A) ((photos by tara of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​frame-mount-evo-sportster-talk-1986-2003-models/​113588-brand-new-stock-tappets-with-rust?​s=ad3665ba90dc78712409c04874bb2687#​post2387173))  ||| 
 |{{:​techtalk:​evo:​engmech:​91-99_lifters_1_by_tara.jpg?​direct&​300|}}|{{:​techtalk:​evo:​engmech:​91-99_lifters_2_by_tara.jpg?​direct&​300|}}|{{:​techtalk:​evo:​engmech:​91-99_lifters_3_by_tara.jpg?​direct&​300|}}| |{{:​techtalk:​evo:​engmech:​91-99_lifters_1_by_tara.jpg?​direct&​300|}}|{{:​techtalk:​evo:​engmech:​91-99_lifters_2_by_tara.jpg?​direct&​300|}}|{{:​techtalk:​evo:​engmech:​91-99_lifters_3_by_tara.jpg?​direct&​300|}}|
  
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 All four lifter bores are capped on the inside of the right case. This left a blind hole between each lifter toward the inside of the case. \\ All four lifter bores are capped on the inside of the right case. This left a blind hole between each lifter toward the inside of the case. \\
  
-|1991-1999 Lifter oil path from filter. ((photo by ehrgeiz of the XLFORUM labeled by Hippysmack ​http://​xlforum.net/​forums/showthread.php?​t=654598&​page=2)) |Capped holes for the lifter bores inside the case. ((photo by WestJC7745 of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1971672)) |+|1991-1999 Lifter oil path from filter. ((photo by ehrgeiz of the XLFORUM labeled by Hippysmack ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-motor-engine/​sportster-motorcycle-engine-conversions/​85487-ehrgeiz-s-stage-3-1250-build-thread/​page2?​t=654598&​page=2)) |Capped holes for the lifter bores inside the case. ((photo by WestJC7745 of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-motor-engine/​sportster-motorcycle-bottom-end/​183128-1995-xlh1200?​t=1971672)) |
 |{{:​techtalk:​evo:​oil:​1999_engine_lifter_oiling_by_ehrgeiz.jpg?​direct&​300|}}|{{:​techtalk:​evo:​oil:​inside_right_case_half_by_westjc7745.jpg?​direct&​300|}}| |{{:​techtalk:​evo:​oil:​1999_engine_lifter_oiling_by_ehrgeiz.jpg?​direct&​300|}}|{{:​techtalk:​evo:​oil:​inside_right_case_half_by_westjc7745.jpg?​direct&​300|}}|
  
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 ===== 91-99 Anti-Rotation Pins ===== ===== 91-99 Anti-Rotation Pins =====
- 
 **Parts**: \\ **Parts**: \\
 4 - screws (884) \\ 4 - screws (884) \\
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 |  Then install the plate and torque to 80-110 in lbs. ((photos by Hippysmack)) ​ ||| |  Then install the plate and torque to 80-110 in lbs. ((photos by Hippysmack)) ​ |||
 |{{:​techtalk:​evo:​engmech:​91-99_anti-rotation_pins_4_by_hippysmack.jpg?​direct&​300|}}|{{:​techtalk:​evo:​engmech:​91-99_anti-rotation_pins_5_by_hippysmack.jpg?​direct&​300|}}|{{:​techtalk:​evo:​engmech:​91-99_anti-rotation_pins_6_by_hippysmack.jpg?​direct&​300|}}| |{{:​techtalk:​evo:​engmech:​91-99_anti-rotation_pins_4_by_hippysmack.jpg?​direct&​300|}}|{{:​techtalk:​evo:​engmech:​91-99_anti-rotation_pins_5_by_hippysmack.jpg?​direct&​300|}}|{{:​techtalk:​evo:​engmech:​91-99_anti-rotation_pins_6_by_hippysmack.jpg?​direct&​300|}}|
- 
- 
  
 ====== 2000 and Up Lifters ====== ====== 2000 and Up Lifters ======
-2000 and up have GM/twin cam style lifters (.842" diameter). ((aswracing of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1611832)) \\+2000 and up have GM/twin cam style lifters (.842" diameter). ((aswracing of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-motor-engine/​sportster-motorcycle-engine-conversions/​148387-100-ci-s-s-cases?​t=1611832)) \\
  
-|Lifter from an 02 XL883 ((photo by Scuba10jdl of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1706033))|+|Lifter from an 02 XL883 ((photo by Scuba10jdl of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-motor-engine/​sportster-motorcycle-bottom-end/​159217-lifters-comparison?​t=1706033))|
 |{{:​techtalk:​evo:​engmech:​02_lifter_1_by_scuba10jdl.jpg?​direct&​300|}}| |{{:​techtalk:​evo:​engmech:​02_lifter_1_by_scuba10jdl.jpg?​direct&​300|}}|
  
Line 327: Line 293:
 So there were no lifter oiling holes to cap on the inside of 2000 and up cases. \\ So there were no lifter oiling holes to cap on the inside of 2000 and up cases. \\
  
-|2000 and Up engine lifter oil path. ((photo by Scuba10jdl of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1959021))|Inside of case has no capped holes for lifter holes. ((photo by meherdad_it of the XLFORUM  ​http://​xlforum.net/​forums/showthread.php?​threadid=944843))|+|2000 and Up engine lifter oil path. ((photo by Scuba10jdl of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-motor-engine/​sportster-motorcycle-bottom-end/​181864-cam-cover-diaster?​t=1959021))|Inside of case has no capped holes for lifter holes. ((photo by meherdad_it of the XLFORUM  ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-motor-engine/​sportster-motorcycle-engine-conversions/​105751-installing-the-90-nrhs?​threadid=944843))|
 |{{:​techtalk:​evo:​oil:​2002_cam_chest_by_scuba10jdl.jpg?​direct&​300|}}|{{:​techtalk:​evo:​oil:​inside_right_case_by_meherdad_it.jpg?​direct&​300|}}| |{{:​techtalk:​evo:​oil:​2002_cam_chest_by_scuba10jdl.jpg?​direct&​300|}}|{{:​techtalk:​evo:​oil:​inside_right_case_by_meherdad_it.jpg?​direct&​300|}}|
  
 ===== 00-05 Lifter Ant-Rotation Screws ===== ===== 00-05 Lifter Ant-Rotation Screws =====
- 
 **Parts**: \\ **Parts**: \\
 4 - anti-rotation screws (18532) \\ 4 - anti-rotation screws (18532) \\
Line 343: Line 308:
 |{{:​techtalk:​evo:​engmech:​00-05_anti-rotation_pins_1_by_hippysmack.jpg?​direct&​300|}}|{{:​techtalk:​evo:​engmech:​00-05_anti-rotation_pins_2_by_hippysmack.jpg?​direct&​300|}}|{{:​techtalk:​evo:​engmech:​00-05_anti-rotation_pins_3_by_hippysmack.jpg?​direct&​300|}}| |{{:​techtalk:​evo:​engmech:​00-05_anti-rotation_pins_1_by_hippysmack.jpg?​direct&​300|}}|{{:​techtalk:​evo:​engmech:​00-05_anti-rotation_pins_2_by_hippysmack.jpg?​direct&​300|}}|{{:​techtalk:​evo:​engmech:​00-05_anti-rotation_pins_3_by_hippysmack.jpg?​direct&​300|}}|
  
-|  End of screws run up into the case. ((photos by JohnK of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1422877&​page=6)) ​ ||+|  End of screws run up into the case. ((photos by JohnK of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-motor-engine/​sportster-motorcycle-motor-top-end/​132786-fixing-a-leaky-top-end-with-pics/​page6?​t=1422877&​page=6)) ​ ||
 |{{:​techtalk:​evo:​oil:​05_tappet_screws_1_by_johnk.jpg?​direct&​300|}}|{{:​techtalk:​evo:​oil:​05_tappet_screws_2_by_johnk.jpg?​direct&​300|}}| |{{:​techtalk:​evo:​oil:​05_tappet_screws_1_by_johnk.jpg?​direct&​300|}}|{{:​techtalk:​evo:​oil:​05_tappet_screws_2_by_johnk.jpg?​direct&​300|}}|
  
 ===== 06-Up Anti-Rotation Device ===== ===== 06-Up Anti-Rotation Device =====
- 
 **Parts**: \\ **Parts**: \\
 2 - Anti Rotation Device blocks (18505-06) \\ 2 - Anti Rotation Device blocks (18505-06) \\
-The ARD is a flexible piece of plastic that is designed to flex in operation to allow for an imperfect lifter bore location. ((aswracing of the XLFORUM ​ http://​xlforum.net/​forums/showthread.php?​t=1768265&​page=28)) \\+The ARD is a flexible piece of plastic that is designed to flex in operation to allow for an imperfect lifter bore location. ((aswracing of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-motor-engine/​sportster-motorcycle-engine-conversions/​164458-cannibal-queen-conversion-cam-carnage/​page28?​t=1768265&​page=28)) \\
 It is designed for lifters that have a flat cut on each side. \\ It is designed for lifters that have a flat cut on each side. \\
  
 These work OK for stock cams. \\ These work OK for stock cams. \\
-But if you're upgrading to bigger cams, anything more than .600 lift has too small a base circle. ((rocketmangb of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?p=5613140&​highlight=anti+rotation#​post5613140)) \\+But if you're upgrading to bigger cams, anything more than .600 lift has too small a base circle. ((rocketmangb of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​rubber-mount-sportster-motorcycle-talk-2004-2006/​22223-carb-rubbermount-collector-s-item/​page10?​highlight=anti+rotation#​post4145786)) \\
 (and they will nearly drop out of the ARDs and they can also spin away from them) \\ (and they will nearly drop out of the ARDs and they can also spin away from them) \\
 The big issue is that they turn sideways with the roller not turning on the cam lobe. \\ The big issue is that they turn sideways with the roller not turning on the cam lobe. \\
 (which can heat up and destroy the roller and the cam lobe) \\ (which can heat up and destroy the roller and the cam lobe) \\
  
-|  ARD block ((photo by rocketmangb of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1768265&​page=31)) ​ |  ARD block installed ((photo by chris_b_owens of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​p=5042968))  | +|  ARD block ((photo by rocketmangb of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-motor-engine/​sportster-motorcycle-engine-conversions/​164458-cannibal-queen-conversion-cam-carnage/​page31?​t=1768265&​page=31)) ​ |  ARD block installed ((photo by chris_b_owens of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-motor-engine/​sportster-motorcycle-engine-conversions/​171908-2013-883-cafe-hammer-performance-1250-conversion/​page2#​post3670671))  | 
 |{{:​techtalk:​evo:​engmech:​06_ard_by_rocketmangb.jpg?​direct&​300|}}|{{:​techtalk:​evo:​engmech:​2013_ard_by_chris_b_owens.jpg?​direct&​300|}}| |{{:​techtalk:​evo:​engmech:​06_ard_by_rocketmangb.jpg?​direct&​300|}}|{{:​techtalk:​evo:​engmech:​2013_ard_by_chris_b_owens.jpg?​direct&​300|}}|
  
Line 420: Line 384:
 1986-1987 Sportster (18T) Pinion Gear: \\ 1986-1987 Sportster (18T) Pinion Gear: \\
 Has internal splines. \\ Has internal splines. \\
-{{:​techtalk:​evo:​engmech:​pinion_gear_1986-1987_pic1_by_c3-cycle-tech.jpg?​direct&​300|}} ​ ((photo courtesy of c3cycle.com,​ Link to site:​https://​www.c3cycle.com/​)) {{:​techtalk:​evo:​engmech:​pinion_gear_1986-1987_pic2_by_c3-cycle-tech.jpg?​direct&​300|}} ​ ((photo courtesy of c3cycle.com,​ Link to site:​https://​www.c3cycle.com/​)) {{:​techtalk:​evo:​engmech:​pinion_gear_1986_and_oil_pump_drive_gear_by_boyd117.jpg?​direct&​300|}} ((photo by Boyd117 of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1603701&​page=3)) \\+{{:​techtalk:​evo:​engmech:​pinion_gear_1986-1987_pic1_by_c3-cycle-tech.jpg?​direct&​300|}} ​ ((photo courtesy of c3cycle.com,​ Link to site:​https://​www.c3cycle.com/​)) {{:​techtalk:​evo:​engmech:​pinion_gear_1986-1987_pic2_by_c3-cycle-tech.jpg?​direct&​300|}} ​ ((photo courtesy of c3cycle.com,​ Link to site:​https://​www.c3cycle.com/​)) {{:​techtalk:​evo:​engmech:​pinion_gear_1986_and_oil_pump_drive_gear_by_boyd117.jpg?​direct&​300|}} ((photo by Boyd117 of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​frame-mount-evo-sportster-talk-1986-2003-models/​147571-1986-sporty-build/​page3?​t=1603701&​page=3)) \\
  
 1988-1990 Sportster (18T) Pinion Gear: \\ 1988-1990 Sportster (18T) Pinion Gear: \\
Line 434: Line 398:
 The ring around the rear sleeve was deleted, has a notch cut out of the rear for the woodruff key (T-key) on the pinion shaft, finer gear mesh and no splines. \\  The ring around the rear sleeve was deleted, has a notch cut out of the rear for the woodruff key (T-key) on the pinion shaft, finer gear mesh and no splines. \\ 
 {{:​techtalk:​evo:​engmech:​pinion_gear_2000-up_sportster_pic2_c3-cycle-tech.jpg?​direct&​300|}} ((photo courtesy of c3cycle.com,​ Link to site:​https://​www.c3cycle.com/​)) {{:​techtalk:​evo:​engmech:​pinion_gear_2000-up_sportster_pic1_c3-cycle-tech.jpg?​direct&​300|}} ((photo courtesy of c3cycle.com,​ Link to site:​https://​www.c3cycle.com/​)) \\ {{:​techtalk:​evo:​engmech:​pinion_gear_2000-up_sportster_pic2_c3-cycle-tech.jpg?​direct&​300|}} ((photo courtesy of c3cycle.com,​ Link to site:​https://​www.c3cycle.com/​)) {{:​techtalk:​evo:​engmech:​pinion_gear_2000-up_sportster_pic1_c3-cycle-tech.jpg?​direct&​300|}} ((photo courtesy of c3cycle.com,​ Link to site:​https://​www.c3cycle.com/​)) \\
- 
 \\ \\
  
Line 444: Line 407:
 [[techtalk:​ref:​genmsr07#​possible_causes_of_a_spun_pinion_shaft_gear|Click Here]] for more information in the Sportsterpedia. \\ [[techtalk:​ref:​genmsr07#​possible_causes_of_a_spun_pinion_shaft_gear|Click Here]] for more information in the Sportsterpedia. \\
  
-{{:​techtalk:​evo:​engmech:​pinion_nub_by_aswracing.jpg?​direct&​250|}} ((photo by http://​xlforum.net/​forums/showthread.php?​t=1666277 of the XLFORUM http://xlforum.net/forums/​showthread.php?​t=1666277)) \\ +{{:​techtalk:​evo:​engmech:​pinion_nub_by_aswracing.jpg?​direct&​250|}} ((photo by aswracing of the XLFORUM https://www.xlforum.net/​forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-bottom-end/155417-pinion-gear?​t=1666277)) \\
- +
- +
  
 ====== Timing Cup (Rotor) ====== ====== Timing Cup (Rotor) ======
- 
 |Timing cup bolt thread size: #10x32 \\ Wrench size: 5/16" \\ Torque: 43-53 in/lbs ((1998 XLH FSM pg 7-56)) \\ Use Loctite 242 (blue) on the bolt threads ((1998 XLH FSM pg 7-56))| |Timing cup bolt thread size: #10x32 \\ Wrench size: 5/16" \\ Torque: 43-53 in/lbs ((1998 XLH FSM pg 7-56)) \\ Use Loctite 242 (blue) on the bolt threads ((1998 XLH FSM pg 7-56))|
 |{{:​techtalk:​evo:​engmech:​timing_cup_bolt_wrench_4_by_hippysmack.jpg?​direct&​300|}}| |{{:​techtalk:​evo:​engmech:​timing_cup_bolt_wrench_4_by_hippysmack.jpg?​direct&​300|}}|