Click Here to go the Ironhead Gearcase/Cam Cover Removal and Installation page in the Sportsterpedia for fastener lists and gaskets.

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.
Bushing (34037-52) App. Dims:
Bushing OD: 5/8“
Bushing ID: 1/2”
Bushing Length: 3/4“

1975-1976 Cam Covers:
1975-1976 Sportsters use shifter shaft bushing (34037-52) in the right case and bushing (34037-75) in the cam cover.
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.
Bushing (34037-75) App. Dims:
Bushing OD: 5/8”
Bushing ID: 1/2“
Bushing Length: 3/4”

1977-E1981 Cam Covers:
1977-E1981 cam covers came with a different bushing (25594-75) for a brake shaft.
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.
This was the brake shaft design from 1977-1979 (even though the rear brakes went hydraulic in 1979).
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).
Cam Cover Bushing Bore: .7450“ ¹⁾
Bushing (25594-75) App. Dims:
Bushing OD (before installing): .752” ²⁾
Bushing ID (before installing): .6250“ ³⁾
Bushing Length: .625” ⁴⁾

1980-E1981 Cam Covers:
In 1980, the MoCo used a rubber plug (25221-77) in the now unused brake shaft hole in the cam cover.
The brake shaft bushing was still installed presumably to allow later covers to be used on 1979 models.
The rubber plug inserts into the bushing.
The parts books (1980-1985) show the rubber plug sold for 1979-E1981 Sportsters.
As usual, that means they expected one to upgrade the 1979 system to the 1980 system.

L1981-E1984 Cam Covers:
Once again a change was made in “how to plug a hole that goes nowhere”.
There may have been some problems with the rubber plug falling out or other. The bushing and plug was deleted from the cover.
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.
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.

1975-1976 Sportster shifter shaft: ⁵⁾

1977-E1981 Sportster brake shaft bushing: ⁶⁾

You can interchange some covers if you are not concerned about the look of a stocker for your year bike (better resale trying to stay stock). ⁷⁾

Also be aware that some covers had the round cut out for the electric starter XLH that came out in 1967.
You can slap a cover on and wing it, BUT the proper way is to have the cover line reamed when the motor is apart.
(so the cam cover and the right case half are a match in tolerances)

52-78 cover had only one breather port at 6:00. ⁸⁾
79-85 had two. One at 6:00 and one at 10:00.
52-76 uses .625“ pinion bushing bore.
77-85 uses .562” pinion bushing bore.

1952-1956 Cam Cover - casting: 25202-52 9)	1957-1962 Cam Cover - casting: 25202-52A 10)	1963-1967 Cam Cover - casting: 25202-52A11)

1968-1970 Cam Cover - casting: 02-68 12)	1971-1976 Cam Cover - casting: 25202-71 13)	1977-1978 Cam Cover - casting 76-25202F 14)

1979-1980 Cam Cover - casting: 79-25202 15)	1981 Cam Cover - casting: 81-25223 16)	L1984-1985 Cam Cover - casting: 25222-84A 17) (no date code below casting)

1957 thru 1970 Sportsters had cams designed for an ignition to be mounted on top of the cam cover. ¹⁸⁾
These cams are not interchangeable with post 1971 motors (what can be called the 'cone' cam cover).
Early XLs had XL cams, 1966 thru the 1970s had hotter cams known as P cams.
1970 on had the larger 1-15/16“ intake valve with pistons to match (piston had a relief cut into the dome for the larger valve clearance).
Optional cams were known as PB cams, a bit more umph than P in the upper mid range.
P cams are frequently seen for sale on ebay.
When hunting for parts you want to ask, “Pre 1971 or Post 1971” for cams and covers including the sprocket cover.

Part number (25200-57). Casting number is (25202-52A).

Click on a pic to enlarge: ¹⁹⁾

Part Number (25200-63). Casting number is (25202-52A).

Click on a pic to expand: ²⁰⁾

Cover part number (25200-63A). Casting number is (02-86).
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.
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.

Cover part number (25201-67A). Casting number is (02-68). Top rear corner is cut out for the electric starter.
The oil tank is vented to the cam chest at a 90° fitting on the back of the cam cover.
1968-1969 covers came with oil tank vent fitting (62375-62).
1970 XLH covers came with oil tank fitting (62375-57).
Both fittings are 1/8”-27 NPT to 1/4“ hose barb 90° elbows.

Click on a pic to enlarge: ²¹⁾

Cover part number (25200-70). Casting number (02-68). TOP REAR IS NOT CUT for electric start.
1970-up XLH and XLCH motors all now vent the oil tank air space to the cam chest at a 90° fitting on the back of the cam cover.
The previous year's vent location on the top of the rear engine case was deleted for XLCH.
The fitting (62375-57) is a 1/8”-27 NPT to 1/4“ hose barb 90° elbow.

Click on a pic to enlarge: ²²⁾

Cover part number (25200-71). Casting number (71-25202).
Gasket (25224-52). Updated gasket (25224-52A).
Fasteners: (8) cover screws, (2) generator mounting bolts and (2) solid dowel pins (used at front and rear of cover).
Click Here to see full fastener list.
The difference in this cover from the 1973 XLH cover is this one is polished and the 1973 cover is black.

Click on a pic to enlarge: ²³⁾

Cover part number (25211-75). Casting number (71-25202).
Gasket (25224-52A).
Fasteners: (8) cover screws, (2) generator mounting bolts and (2) solid dowel pins (used at front and rear of cover).
Click Here to see full fastener list.

Cover part number (25205-75). Casting number (71-25202).
Gasket (25224-52A).
Fasteners: (8) cover screws, (2) generator mounting bolts and (2) solid dowel pins (used at front and rear of cover).
Click Here to see full fastener list.

Click on a pic to enlarge: ²⁴⁾

HD Part number (25201-75). Casting number (76-25202F).
Gasket: (25224-52A).
Fasteners: (8) cover screws, (2) generator mounting bolts and (1) front solid dowel pin (rear dowel hole in cover drilled but not in case).
Click Here to see full fastener list.

Click on a pic to enlarge: ²⁵⁾

L1976-1980 Sportsters use a Prestolite starter which required a section of the top rear corner of the cam cover to be factory removed for clearance.
1981-1985 Sportsters use a Nippon Denso starter which doesn't require the cam cover clearance thus the corner is squared off (uncut).

1979-E1982 production cam covers were installed with a reed type breather valve (26909-79).
In L1982, a new rubber umbrella type breather valve was used in production covers.
Breather valve kit (26909-79A) was then introduced to adapt 1979-E1982 covers with the new umbrella valve system.
So you may find used 1979-E1982 covers with the umbrella valves instead.
Click Here for more information on breather valves.
1979-1981 Sportsters use a 1-5/8” slinger washer (31067-63).
1982-E1984 Sportsters use a 1-3/4“ slinger washer (31066-82) to accommodate the larger crankcase breather valve.
L1984-1985 Sportsters don't use a generator or slinger washer.

1979 is the first year a hole was drilled and tapped in top front of the cam cover for the breather vent to connect up to the air cleaner housing
The previous location on the front bottom of the cam cover for the breather tube was plugged off with a 1/8”x27 plug and the tube deleted.
A rubber hose was now piped from the top of the cam cover to the A/C (keeping the breather line from crossing the cover from the bottom).
This design was used from 1979-1990.
Some have removed the lower plug to add a second breather to atmosphere although the reviews for that mod vary.
Click Here for more information on that mod in the Sportsterpedia.

1979 models got a new Prestolite breakerless electronic ignition module in the cam cover nosecone.
1980 models changed to a Magnavox ignition system using different parts in the cam cover nosecone and the module was moved out of the nosecone.
This resulted in the “pocket” in the newer cover nosecone for 1980 models getting a little deeper.
Since the 1980 cover was also sold as replacement for 1979 models, the deeper pocket wouldn't work for 1979 ignitions.
So a spacer (25262-80) was included with the 1979-1980 replacement cover to extend 1979 ignitions to original location when using the newer cover.
The replacement cover part number is (25201-79A) which includes the spacer.

1979 and 1980 nosecone comparison 26)	Here is the spacer from the kit. 27)

L1981-E1982 Gearcase/Cam Cover/Gasket Changes:
Click Here to download TSB M-841.
Cases:
L1981-E1982 engines may have one of two different types of gear case cover and crankcase set combinations.
Old style cases have a slanted slot for an upper oil feed galley to the lifters and no rear dowel pin (or bolt) to attach the cover.
New style cases have a large boss around the upper feed galley with a single hole (no slot) for a feed oil galley to the lifters.
New style cases also have an extra mounting screw hole added to the top rear corner of the cover mounting boss.
Cam Cover Gasket:
Gasket (25224-52A) originally (1977) had a single hole in the top center to transfer oil from the gasket to the upper case galley.
Along with 1979 case changes, the hole was slotted at an angle and along with L1981 case changes, the gasket was redesigned.
Old style gasket (25224-52A) can only be used with the old style covers, XLH (25227-81) and XLS (25229-81).
New style gasket (25263-81) can only be used with the new style covers, XLH (25208-81) and XLS (25209-81).
Cam Cover:
Old style cam covers can be used on new style cases along with the old style gasket.
New style cam covers cannot be used on old style cases.

HD Part number (25201-79 ). Casting number (79-25202F).
Finish: Polished.
Gasket: (25224-52A).
Fasteners: (8) cover screws, (2) generator mounting bolts and (1) front solid dowel pin (rear dowel hole in cover drilled but not in case).
Click Here to see full fastener list.
Replacement cover kit (25201-79A) comes with the 1980 cover and a spacer ring (25262-80) for the ignition module.
See “1979-1980 Ignition Changes” above.

Below is the original cover. Click on a pic to enlarge:

1979 XLH cam cover 28)

1979 XLH cam cover 29)		First year for top breather fitting 30)

HD Part number (25205-79 ). Casting number (79-25202F).
Finish: Gray.
Gasket: (25224-52A).
Fasteners: (8) cover screws, (2) generator mounting bolts and (1) front solid dowel pin (rear dowel hole in cover drilled but not in case).
Click Here to see full fastener list.
Replacement cover kit (25201-79A) comes with the 1980 cover and a spacer ring (25262-80) for the ignition module.
See “1979-1980 Ignition Changes” above.

Below is the original cover. It's the same as the original 1979 XLH cover except for the finish.
Click on a pic to enlarge: ³¹⁾

Part number for cover (25208-80). Casting number (80-25222).
Gasket: (25224-52A).
Fasteners: (8) cover screws, (2) generator mounting bolts and (1) front solid dowel pin (rear dowel hole in cover drilled but not in case).
Click Here to see full fastener list.
This cover was also sold as a replacement cover for 1979 models with an added spacer ring for 1979 ignitions.
Part number for the replacement kit for 1979-1980 models is (25201-79A).

Click on a pic to enlarge: ³²⁾

Part number (25229-81). Casting number (81-25223). Tach drive casting still there but the hole wasn't drilled for the drive unit.
Gasket: Must use gasket (25224-52A).
Fasteners: (8) cover screws, (2) generator mounting bolts and (1) front solid dowel pin (rear dowel hole in cover drilled but not in case).
Click Here to see full fastener list.

Click on a pic to enlarge: ³³⁾

Part number (25208-84A). Casting number (25222-84A). Gasket: (25263-81).
Fasteners: (9) cover screws, (2) oil filter housing bolts, (1) front solid dowel pin in gearcase and (1) rear dowel pin in case near transmission.
Click Here to see full fastener list.
This cover is almost identical to the 1986-1990 Sportster cover.
In fact, the -85A parts book lists the 1986 cover for replacement on L1984 XL/XLS models.
So they are compatible. The main visual difference is in the casting numbers.
1985 casting# (25222-84A) is a standalone number cast in the front, not far from the breather valve with no circle date code.
1986-1990 casting# (25222-84A) is in the same spot but all have a circle date code under the casting number (date of casting is in the circle).

Click on a pic to enlarge: ³⁴⁾

L1984-1985 cover casting# (25222-84A) 35)	1986-1990 cover casting# (25222-84A) 36)