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techtalk:ih:engmech01e [2022/04/03 05:51]
hippysmack [Shifter Shaft / Brake Shaft Hole Bushings and Plugs] 		techtalk:ih:engmech01e [2023/12/20 02:10]
hippysmack [1970 XLCH 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. \\ 
-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. \\ +
-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| 
-Dims: \\ +|  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. |||| 
-Cam Cover Bushing Bore: .7450" ((Scott of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=2074151)) ​\\ +|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**: \\  +|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| 
 +|  Notes:| |||| 
 +|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 ======
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 {{:​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. \\
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 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_pic1_by_flashback_inc.jpg?​direct&​300|}} ​((photo courtesy of Flashback Enterprises in Imlay City, MI, [[https://​www.ebay.com/​str/​flashbackenterprisesinc?​_trksid=p2047675.m3561.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_pic2_by_flashback_inc.jpg?​direct&​300|}} ​((photo courtesy of Flashback Enterprises in Imlay City, MI, [[https://​www.ebay.com/​str/​flashbackenterprisesinc?​_trksid=p2047675.m3561.l2563|Link to Ebay Store]] )) \\ 
 + 
 + 
 +{{:​techtalk:​ih:​engmech:​1968-1970_xlh_cam_cover_25201-67a_pic1_by_cyclewarehouse.jpg?​direct&​300|}} ​((photo courtesy of Ebay seller, cyclewarehouse. [[https://​www.ebay.com/​sch/​cyclewarehouse/​m.html?​_nkw=&​_armrs=1&​_ipg=&​_from=|Link to Items for Sale]] )) {{:​techtalk:​ih:​engmech:​1968-1970_xlh_cam_cover_25201-67a_pic3_by_flashback_inc.jpg?​direct&​300|}} ​((photo courtesy of Flashback Enterprises in Imlay City, MI, [[https://​www.ebay.com/​str/​flashbackenterprisesinc?​_trksid=p2047675.m3561.l2563|Link to Ebay Store]] )) \\
  
-{{:​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 =====
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 The fitting (62375-57) is a 1/​8"​-27 NPT to 1/4" hose barb 90° elbow. \\  The fitting (62375-57) is a 1/​8"​-27 NPT to 1/4" hose barb 90° elbow. \\ 
  
-Click on a pic to enlarge: ((pics by Scott of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=2073823)) \\+Click on a pic to enlarge: ((pics by Scott of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​197215-cam-cover-id-help-please-warning-huge-pics?​t=2073823)) \\
 {{:​techtalk:​ih:​engmech:​1970_xlch_cam_cover_25200-70_pic1_by_scott.jpg?​direct&​300|}} {{:​techtalk:​ih:​engmech:​1970_xlch_cam_cover_25200-70_pic2_by_scott.jpg?​direct&​300|}} {{:​techtalk:​ih:​engmech:​1970_xlch_cam_cover_25200-70_pic3_by_scott.jpg?​direct&​300|}} \\ {{:​techtalk:​ih:​engmech:​1970_xlch_cam_cover_25200-70_pic1_by_scott.jpg?​direct&​300|}} {{:​techtalk:​ih:​engmech:​1970_xlch_cam_cover_25200-70_pic2_by_scott.jpg?​direct&​300|}} {{:​techtalk:​ih:​engmech:​1970_xlch_cam_cover_25200-70_pic3_by_scott.jpg?​direct&​300|}} \\
  

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