EVO: Engine Mechanicals - Sportsterpedia

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[[:techtalk:menu|{{  :techtalk:gototechnicalmenu.jpg|}}]]
====== EVO: Engine Mechanicals ======
====== Timing Inspection Hole ======

===== Sub-Documents =====
  * [[techtalk:evo:engmech01a|91-03 Timing inspection hole and plug pics and app. dims]]
  * [[techtalk:evo:engmech01c|1986-2003 Sportster Engine Case Identification]]
  * [[techtalk:evo:engmech01g|1986-Up Sportster Cam Cover Pics]]
  * [[techtalk:evo:engmech01f|Removing, Inspecting and Installing the Cam Cover]]
  * [[techtalk:evo:engmech01k|Removing 91-03 Primary Cover]]
  * [[techtalk:evo:engmech04a#removing_the_rocker_boxes|Removing the Rocker Boxes]]

====== Motor Mounts ======
[[techtalk:evo:engmech09|Click here for Engine Mounts]] in the Evo Suspension section of the Sportsterpedia. \\
====== Cylinder Mounting Studs ======

|  Weakest cylinder mounting stud holes in the case. ((photo by Hippysmack))  |
|{{:techtalk:evo:engmech:weakest_cylinder_bolt_threads_by_hippysmack.jpg?direct&300|}}|

====== Timing Hole Plug (1986-2003) ======
[[techtalk:ref:engmech01a#timing_inspection_hole_and_plug_-_sealing_and_thread_repair|Click Here]] to go the Timing Inspection Hole and Plug - Sealing and Thread Repair page in the Sportsterpedia. \\

**1972-2003 Sportster Timing Hole Plug (720)**. \\
Threads: 5/8"-18 x .350" with 3/8" Hex Socket (Allen) Head. \\

{{:techtalk:ref:oil:fitting_720_timing_hole_plug_by_sum-body1_pic1.jpg?direct&300|}} ((photos courtesy of Ebay seller, Sum-body's Harley Parts, [[https://www.ebay.com/str/sumbodysharleyparts|Link to Ebay Store]] )) {{:techtalk:ref:oil:fitting_720_timing_hole_plug_by_sum-body1_pic2.jpg?direct&300|}} ((photos courtesy of Ebay seller, Sum-body's Harley Parts, [[https://www.ebay.com/str/sumbodysharleyparts|Link to Ebay Store]] )) \\


====== Primary Compartment ======
===== Primary Cover Gasket =====
^{{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- Sportster|34955-04|

===== Shifter Shaft Seal =====
Navigate to the appropriate year model transmission pages in the Sportsterpedia for removal/installation. \\ 
Part numbers: \\
2003 and earlier (37101-84) \\
2004-2005 (37101-84A) \\
2006-up (37107-06) \\
There is a steel bushing pressed into the bore in the cover. The seal installs on the outside of the bushing with a light press fit. \\
The seal can be removed/installed without removing the primary cover.

Shifter shaft seal on 1998 1200S primary cover. \\
{{:techtalk:evo:engmech:98_shifter_shaft_seal_1_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) 
{{:techtalk:evo:engmech:98_shifter_shaft_seal_5_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\

Shifter shaft seal on 2006 1200R primary cover. \\
{{:techtalk:evo:engmech:2006_1200r_shifter_shaft_seal_1_by_hdmc_ru2.jpeg?direct&300|}} ((photo by hdmc_ru2 of the XLFORUM, labeled by Hippysmack http://xlforum.net/forums/showthread.php?t=49915&page=7)) {{:techtalk:evo:engmech:2006_1200r_shifter_shaft_seal_2_by_hdmc_ru2.jpeg?direct&300|}} ((photo by hdmc_ru2 of the XLFORUM, labeled by Hippysmack http://xlforum.net/forums/showthread.php?t=49915&page=7)) {{:techtalk:evo:engmech:2006_1200r_shifter_shaft_seal_4_by_hdmc_ru2.jpeg?direct&300|}} ((photo by hdmc_ru2 of the XLFORUM, labeled by Hippysmack http://xlforum.net/forums/showthread.php?t=49915&page=7)) \\

===== Shifter Shaft Bushing =====
1977-2003 Sportster Shifter Shaft Bushing 40520-63: \\

{{:techtalk:evo:engmech:1977-2003_sportster_shifter_shaft_bushing_40520-63_by_robisonmotorcycles_pic1.jpg?direct&300|}} ((photo courtesy of Ebay seller, Robison Motorcycles [[https://www.ebay.com/str/robisonmotorcycles?_trksid=p2047675.l2563|Link to Ebay Store]] )) {{:techtalk:evo:engmech:1977-2003_sportster_shifter_shaft_bushing_40520-63_by_robisonmotorcycles_pic2.jpg?direct&300|}} ((photo courtesy of Ebay seller, Robison Motorcycles [[https://www.ebay.com/str/robisonmotorcycles?_trksid=p2047675.l2563|Link to Ebay Store]] )) \\

{{:techtalk:evo:engmech:1977-2003_sportster_shifter_shaft_bushing_40520-63_by_robisonmotorcycles_pic3.jpg?direct&300|}} ((photo courtesy of Ebay seller, Robison Motorcycles [[https://www.ebay.com/str/robisonmotorcycles?_trksid=p2047675.l2563|Link to Ebay Store]] )) {{:techtalk:evo:engmech:1977-2003_sportster_shifter_shaft_bushing_40520-63_by_robisonmotorcycles_pic4.jpg?direct&300|}} ((photo courtesy of Ebay seller, Robison Motorcycles [[https://www.ebay.com/str/robisonmotorcycles?_trksid=p2047675.l2563|Link to Ebay Store]] )) \\

===== Inspection Covers/Caps =====
==== 1986-1990 ====
1986-1990 Sportsters use the same threaded cap/plug for the primary oil filler hole and clutch inspection hole on the primary cover. \\
The tool access hole looks similar to the "Chevy Bowtie" symbol and uses a similar tool to remove and install it. \\
The plug has no through hole since the primary / transmission breathes out a rubber tube on the top-rear of the transmission. \\
Each plug is sealed with an O-ring (1139). \\
1986-1988 models used a polished aluminum plug (34742-86) that was sold through 1990 models. \\
In 1989, a chrome plug (34745-87) was also available and sold through 1990 for 1986-1990 models. \\

|  1986-1990 Sportster Polished Primary Cover Cap Plug (34742-86) ((photo courtesy of BAD ASS CYCLES ETC, [[https://www.ebay.com/str/badasscyclesetc?_trksid=p2047675.m3561.l2563|Link to Ebay Store]] ))  ||
|{{:techtalk:evo:engmech:1986-1990_sportster_primary_cover_cap_plug_-_polished_34742-86_by_bad_ass_cycles_etc_pic1.jpg?direct&300|}}|{{:techtalk:evo:engmech:1986-1990_sportster_primary_cover_cap_plug_-_polished_34742-86_by_bad_ass_cycles_etc_pic2.jpg?direct&300|}}|

|  1989-1990 Sportster Chrome Primary Cover Cap Plug (34745-87) ((photos courtesy of Ebay seller, animalhouse2010, [[https://www.ebay.com/str/animalhouse2010?_trksid=p2047675.l2563|Link to Ebay store:]] ))  |||
|{{:techtalk:evo:engmech:1989-1990_sportster_primary_cover_cap_plug_-_chrome_34745-87_by_animalhouse2010_pic1.jpg?direct&300|}}|{{:techtalk:evo:engmech:1989-1990_sportster_primary_cover_cap_plug_-_chrome_34745-87_by_animalhouse2010_pic2.jpg?direct&300|}}|{{:techtalk:evo:engmech:1989-1990_sportster_primary_cover_cap_plug_-_chrome_34745-87_by_animalhouse2010_pic3.jpg?direct&300|}}|

===== Crankshaft Seal =====
Here is a trick to hold the spring in place to stop it popping off while you are fitting the seal. ((DEEP DIVER of the XLFORUM http://xlforum.net/forums/showthread.php?p=5489312&highlight=main+seal#post5489312)) \\
Before fitting it, pack some grease around the spring in the seal groove. You only need a small amount. \\

|  Crankshaft Seal (35151-74A) ((photos by pearlmoto of the XLFORUM http://xlforum.net/forums/showthread.php?t=1815630))  ||| 
|{{:techtalk:evo:engmech:crank_seal_35151-74a_pic1_by_pearlmoto.jpg?direct&300|}}|{{:techtalk:evo:engmech:crank_seal_35151-74a_pic2_by_pearlmoto.jpg?direct&300|}}|{{:techtalk:evo:engmech:crank_seal_35151-74a_pic3_by_pearlmoto.jpg?direct&300|}}|

====== Gearcase / Cam Chest ======
===== Cam Cover Gasket =====
Cam cover gaskets as per the parts manuals are below. \\

^{{techtalk:miscres:instruction_sheet_header_4.png?nolink&803|}}||||
|Year Model|Part#|Notes|Pics|
|1986-1990 Sportster|25263-86|
|1991-1993 Sportster|25263-90|
|1994-1997 Sportster|25263-90A|
|1998-1999 Sportster|25263-90B|
|2000-2003 Sportster|25263-90C|

===== #2 Cam - Cover Seal (86-03) =====
Seal number (11124): \\
This surrounds and seals #2 cam when the cover is installed. \\
See also [[techtalk:evo:engmech01f#cam_cover_seal_86-03|Removal / Installation of the #2 cam cover seal]] in the Sportsterpedia. \\

|  This side faces out. ((photo by Hippysmack))  |  This side faces #2 cam shaft. ((photo by Hippysmack))  |
|{{:techtalk:evo:engmech:11124_cam_cover_seal_2_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:11124_cam_cover_seal_1_by_hippysmack.jpg?direct&300|}}|

===== Removing / installing the pinion shaft nut =====

To remove or install the pinion gear nut, \\ You'll need to lock the pinion gear from moving while turning it. \\
It's very important to hold the crank on the pinion side with an appropriate pinion locking tool whenever you take the pinion nut off or put it on. \\
If you hold the crank still from the primary side (or by putting the bike in gear and holding the brake), \\
The twisting torque applied to the pinion nut gets transmitted through the crank, from one side to the other. \\
The crank pin is not designed to resist much twisting force. \\
You'll risk scissoring the crankshaft (knocking the crank out of true), which requires a full tear-down to fix. ((Hammer Performance http://www.hammerperf.com/xlvalvetrain.shtml#grindlock)) \\
So this is one of those situations where it's best to use the proper tool. ((aswracing of the XLFORUM http://xlforum.net/forums/showthread.php?t=2002257&highlight=pinion+locking+tool))
The pinion nut takes a 15/16" wrench size. \\

===== Pinion Shaft Runout =====
Check to see if your crank is out of true. See [[techtalk:ref:svcproc24|Measuring Pinion Shaft Runout]] in the REF section of the Sportsterpedia. \\

====== Flywheel Related Information ======
**Late 1986 flywheels and crankpin bearing changes**. \\
Information from Technical Service Bulletin #M-927. [[techtalk:miscres:miscres05#tsb_900-949|Click here to see the actual bulletin from this page in the Sportsterpedia]]. \\
Beginning with crankcase numbers 883cc (1786 083 003) and 1100cc (1886 090 012), a new (F.A.G.) crank pin bearing set and revised flywheels were installed at the factory. \\
The new crank pin bearing set (using the existing crankpin P/N) consists of three bearings in a package. Early production engines were assembled without thrust washers. \\
L1986-later production flywheels had thrust washers staked into a counter-bore in the flywheels. The L86 crank pin bearing set retrofits earlier models. \\
However, the new bearings require a stepped flywheel thrust washer to provide clearance for the wider bearing cages. \\
You will select the correct thrust washer for your particular assembly and machine off the raised lip in the area of the flywheel thrust washers' I.D. \\
This lip must be machined off or you will crush the bearing cage as you assemble and torque the crankpin nuts. \\
[[techtalk:miscres:miscres04#tech_tips_0-199|See Tech Tip #14]], [[techtalk:miscres:miscres08#bottom_end|Instruction Sheet #J00022]] and [[techtalk:miscres:miscres08#bottom_end|Instruction Sheet #J00025]] in the Sportsterpedia for more information. \\

The L86 XLH883 flywheel assembly is (23905-86A) and the L86 XLH1100 flywheel assembly is (23900-86A). \\
There were new crank pin bearing clearances also. \\
The new crank pin bearing set packages were color coded with either a red or a blue identification. This color coding is used by the bearing manufacturer only. \\
The color coding DOES NOT indicate size selection for crank pin bearing replacement. \\

**1989 flywheel changes**. \\
Information from Technical Service Bulletin #M-971. [[techtalk:miscres:miscres05#tsb_950-999|Click here to see the actual bulletin from this page in the Sportsterpedia]]. \\
Beginning June 1, 1988, flywheels forged from a micro-alloyed steel went into production. Part numbers and color codes of assemblies with the new material were changed. \\

**1991-1994 Flywheels**. \\
From '91 to '94 the Crankshaft/Flywheel was balanced according to the engine size, either for 883 pistons or 1200 pistons. From 1995-later, the flywheels are balanced to be between the weight of the 883 & 1200 pistons. ((http://hammerperf.com/883conversions.shtml)) This is one reason why riders would use Wiseco pistons in early (pre-2004) 883 to 1200 conversions - the Wiseco 1200 piston & pin was closer to the weight of the 883 combination rather than the stock 1200 piston & pin from HD.

**1995-1999 Flywheels**. \\
Flywheel assembly part number (23905-89A). \\
Each flywheel casting number (23931-88A). \\ 

**2000 Flywheels**: \\
There are no timing marks on the wheels for any of the rubber mounts. ((aswracing of the XLFORUM http://xlforum.net/forums/showthread.php?t=1885317&highlight=rods&page=2)) \\
Nor is there a timing window (on the case) to look through to see the mark that's not there. \\
And for that matter, there's no way to change the timing, even if you had a window to see the mark that's not there. \\
The only way to change the timing on a rubber mount is to use an aftermarket ignition that gives you control, through dials and/or a programming kit. \\
And even doing that, there's no way to measure it, you just have to trust that it's delivering the timing you're telling it to. \\ 
|  95-99 Flywheels ((photos by Hippysmack))  ||
|{{:techtalk:evo:engmech:95-99_flywheels_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:95-99_flywheels_2_by_hippysmack.jpg?direct&300|}}|

|  L1986-up crank pin boss washer (6508) ((photos by Hippysmack))  ||
|{{: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 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. \\
Each flywheel casting number (23931-88A) \\
Connecting rod set: part number (24275-86A) \\
Front connecting rod casting number (24321-83) \\
Rear connecting rod casting number (24320-83) \\
Rod bearing set (24354-87A) \\
Rod bearing race - front (2)-(24341-52A) \\
Rod bearing race - rear (2)-(24352-52A) \\
Piston pin bushing std (2)-(24331-36), .01" O.S. (24332-36 \\
Crankpin std (23960-80A), .001" O.S. (23948-87), .002" O.S. (23949-87) \\
Crankpin boss washer (2)-(6508) \\

|{{:techtalk:evo:engmech:flywheels-shafts-rods-23905-89a_pic_2_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:flywheels-shafts-rods-23905-89a_pic_1_by_hippysmack.jpg?direct&300|}}|

|{{:techtalk:evo:engmech:flywheels-shafts-rods-23905-89a_pic_3_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:flywheels-shafts-rods-23905-89a_pic_4_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:flywheels-shafts-rods-23905-89a_pic_11_by_hippysmack.jpg?direct&300|}}|

|{{:techtalk:evo:engmech:flywheels-shafts-rods-23905-89a_pic_9_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:flywheels-shafts-rods-23905-89a_pic_6_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:flywheels-shafts-rods-23905-89a_pic_5_by_hippysmack.jpg?direct&300|}}|

|{{: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 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. \\
However, the rods in the 2000-2002 assemblies are reportedly thicker than the 2003 assembly. ((Randy_rots of the XLFORUM http://xlforum.net/forums/showthread.php?t=1949239&page=34)) \\

The entire assembly was sold as a unit with no published part numbers for it's individual parts. \\
To date, we have no pics or casting numbers on the 00-02 rods for comparison. \\
Rod bearings and races, crankpin and even the shaft nuts were not mentioned in the parts catalogs. \\

Piston Pin bushing, standard (24331-36), 0.01" O.S (24332-36) \\
Inner bearing ring (24658-87) \\
Retaining ring (11177A)

|  Flywheel assembly 23905-00 ((photo by AussieGazza of the XLFORUM http://xlforum.net/forums/showthread.php?t=692835&page=7))  |  Flywheel assembly 23905-00A ((photo by Wilbur of the XLFORUM http://xlforum.net/forums/showthread.php?t=657090))  |
|{{: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 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)) \\
So the original 2003 flywheel version appears to be a one year only version. \\

Entire assembly was sold as a unit with no published part numbers for individual parts for the assembly. \\
Rod bearings and races, crankpin and shaft nuts were not mentioned in the parts catalogs. \\
  * The assembly in the pics below came from a 2003 883R:
    * Front connecting rod casting number (24225-02) \\
    * Rear connecting rod casting number (24224-02) \\
Piston Pin bushing, standard (24331-36), 0.01" O.S (24332-36) \\
Inner bearing ring (24658-87) \\
Retaining ring (11177A)

|  Flywheel assembly 23905-00  ((photos by Randy_rots of the XLFORUM http://xlforum.net/forums/showthread.php?p=5905554#post5905554))  ||
|{{:techtalk:evo:engmech:flywheel_assembly_23905-00_pic1_by_randy_rots.jpg?direct&300|}}|{{:techtalk:evo:engmech:flywheel_assembly_23905-00_pic2_by_randy_rots.jpg?direct&300|}}|

|  Flywheel assembly 23905-00  ((photos by Randy_rots of the XLFORUM http://xlforum.net/forums/showthread.php?p=5905554#post5905554))  |||
|{{: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 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. \\
Remember to clean the threads and generously apply LOCTITE Threadlocker 262 (red) onto the threads of engine sprocket shaft and use a sprocket locking tool. \\
Some examples of sprocket locking tools are [[http://www.sportsterpedia.com/doku.php/techtalk:ref:tools116|here in the tools section]] of the Sportsterpedia. \\

===== Crank Pin =====
Crank pin (23960-80A) was used from L1981-2003. \\

  * Pressurized oil in the pinion bushing is sent through a hole in the (hollow) pinion shaft toward the flywheel. \\ Oil travels to and through the right flywheel via an internal passage from the pinion bore and the crank pin bore in the flywheel. \\ Oil enters the crank pin inside the crank pin bore on the flywheel. \\ Oil is routed out of the crank pin through a hole under the rod bearings in the middle of the pin and circulates to the rod bearings. \\ **This is the end point of static oil pump pressure to the bottom end**.
  * Oil leaving the rod bearings flows into the crankcase to be scavenged by the oil pump (or splashed into the gearcase). \\ Crankcase pressure moves the oil from this point.

|   (used) L81-03 'one hole' crank pin. ((photo by Hippysmack))  |||
|{{:techtalk:evo:oil:crank_pin_oiling_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:crank_pin_oiling_2_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:crank_pin_oiling_3_by_hippysmack.jpg?direct&300|}}|

|  L87-03 crank pin ((photos by Hippysmack))  |||
|{{:techtalk:evo:engmech:l81-03_crank_pin-1_23960-80a_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:l81-03_crank_pin-2_23960-80a_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:l81-03_crank_pin-3_23960-80a_by_hippysmack.jpg?direct&300|}}|

===== Connecting Rods =====
Rod set (24275-86A) includes bearings, crankpin and nuts. \\
Below are pics of just the rods off a 1998 1200S model. \\
The part numbers cast into the rods are front (24321-83) and rear (24320-83). \\
|{{:techtalk:evo:engmech:connecting_rods_5_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:connecting_rods_3_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:connecting_rods_1_by_hippysmack.jpg?direct&300|}}|

|{{:techtalk:evo:engmech:connecting_rods_4_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:connecting_rods_6_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:connecting_rods_2_by_hippysmack.jpg?direct&300|}}|
\\

Below is the rod set known to be fitted to at least 2003 model Sportsters. \\
Front casting number (24225-02) \\ 
Rear casting number (24224-02) \\

{{:techtalk:evo:engmech:connecting_rod_set_for_xls_w_casting_s_24225-02_and_24224-02_pic1_by_houseofparts815.jpg?direct&300|}} ((Pics courtesy of Ebay seller, house of parts 815. [[https://www.ebay.co.uk/str/houseofparts815?_trksid=p2047675.l2563|Link to Ebay Store]] )) {{:techtalk:evo:engmech:connecting_rod_set_for_xls_w_casting_s_24225-02_and_24224-02_pic2_by_houseofparts815.jpg?direct&300|}} ((Pics courtesy of Ebay seller, house of parts 815. [[https://www.ebay.co.uk/str/houseofparts815?_trksid=p2047675.l2563|Link to Ebay Store]] )) {{:techtalk:evo:engmech:connecting_rod_set_for_xls_w_casting_s_24225-02_and_24224-02_pic3_by_houseofparts815.jpg?direct&300|}} ((Pics courtesy of Ebay seller, house of parts 815. [[https://www.ebay.co.uk/str/houseofparts815?_trksid=p2047675.l2563|Link to Ebay Store]] )) \\

===== Pinion Shaft =====


===== Installing 1986-2003 Flywheels =====

**1976 and previous year Sportsters** use a one piece dual Timken bearing race on the left (sprocket shaft) side of motor. \\
These engines also used a press-in outer race on the right (pinion) side. \\
The right bearing race was able to be line-lapped to the left bearing to fit oversize bearings. You need a line-lapping tool to do this. ((bcoons of the XLFORUM http://xlforum.net/forums/showthread.php?t=1041723&page=3)) \\

**1977-E1986 Sportsters** use two separate Timken bearing races on the left side. \\
The right bearing was changed to a single Torrington bearing with an accompanying inner race that presses over the pinion shaft. \\
This bearing is not rebuildable so you don't lap these engines. You just press the bearing out and install a new one. ((bcoons of the XLFORUM http://xlforum.net/forums/showthread.php?t=1041723&page=3)) \\

**L1986-2003 Sportsters** still use the two piece Timken bearing races on the left case. \\
But the right cases are now back to the lap-able race with oversize roller replacements. \\
(only the rollers are in a cage and the inner race is still pressed onto the pinion shaft) \\
Pre-1977 cases had loose rollers and post-86 cases have captive rollers in cage with less choices on bearing over-sizes. ((bcoons of the XLFORUM http://xlforum.net/forums/showthread.php?t=1041723&page=3)) \\

The flywheel assembly doesn't really press into the left case half, that's a misconception that a lot of people have. \\
There are two bearings that get pressed onto the sprocket shaft, and the left case half is sandwiched in between those two bearings. \\
So it's not the crank itself that's pressed in, it's two bearings that are pressed onto the crank. \\
(positioned as one inside and one outside of the left case (inner and outer case positions). ((aswracing of the XLFORUM http://xlforum.net/forums/showthread.php?t=1565018&page=3)) \\

Proper assembly of the lower end requires special tools to remove / install the bearing races into the case halves. ((aswracing of the XLFORUM http://xlforum.net/forums/showthread.php?t=1565018&page=3)) \\ 
Plus you need a puller that can get the inner bearing off to replace it. \\ 
And you need to be able to accurately measure the pinion shaft bearing races to a ten-thousandth (.0001") to select the right replacement size bearing. \\
(which means snap gauges and a couple different sized .0001" reading micrometers) \\
Plus you need to rig up a dial indicator to check your flywheel end play. \\
And if you've already pressed against the flywheel assembly to remove it, it really ought to be put in a truing stand and make sure it's still straight. \\
Also, once it's all together, the sprocket shaft seal ought to be put on with the correct tool. \\
The tool puts it in square and sets the depth correctly. \\

**Left Side Bearing Assembly**:  ((aswracing of the XLFORUM http://xlforum.net/forums/showthread.php?t=1565018&page=2)) \\
  * The inner bearing goes on the crankshaft before installing it through the bore in the left case. \\ And it will remain on the shaft once the shaft is removed from the left case. \\ It's corresponding inner race (Timken bearing outer race) is a cone shaped race that's pressed into the inside of the left case. \\ It will also remain in it's place when the flywheel assembly is removed. \\
  * There is a bearing spacer that resides between the inner and outer bearings that separates the bearings and sets the preload between the two. \\ It basically controls how much gap is left between the bearings and the case half (actually the races which are pressed into the case half). \\ The bearing spacer (shim) is available in sizes from .098" to .114" in steps of .002". \\ It's thickness is sized (selected) to set the flywheel end play. The end play spec is .001" to .005".
  * There is also a bearing race spacer. This spacer is a thick piece of steel that's sandwiched between the inner and outer bearing races. \\ It fits into a notch that's machined into the cases. It has a gap that needs to be pointing straight up as there's an oil hole there where crankcase oil bleeds down into the bearing area. \\ It will most likely (should) stay in the middle of the cases once the flywheel assembly is removed.
  * The left case outer bearing race, like the inner race, this is a cone shaped race that's pressed into the case. \\ It will most likely stay in the case once the flywheel assembly is removed.
  * The outer bearing, same as the inner bearing, is pressed onto the crankshaft and will have to be removed before the flywheel assembly comes out. \\ Then it'll have to be pressed back on when the flywheel assembly is installed. \\
  * There is another spacer that sits directly under the front primary sprocket and holds it away from the outer bearing. \\ The seal rides on this spacer. Don't forget it.
  * Even though both bearing outer races are installed into the case half with a press, you really can't put the sprocket shaft bearings on with a press. \\ Pressing against the flywheel assembly is a really bad thing to do, it'll knock it out of true. \\ There's a special tool for pushing those bearings onto the shaft. It threads onto the end of the shaft, so it never presses against the wheels at all.

**Right Side Bearing Assembly**: ((aswracing of the XLFORUM http://xlforum.net/forums/showthread.php?t=1565018&page=2)) \\
The pinion shaft just slides into the right case. Oil everything up first though. \\
  * The pinion bearing is available in four different sizes.
  * The outer race for the pinion bearing is pressed into the right case.
  * You have to precisely measure the I.D. of the outer then measure the O.D. of the race that's on your pinion shaft.
  * Then there's a table in the service manual that shows you which of the four different available pinion bearings to use based on those two measurements.

==== 90 and Prior Models (4 Speed) ====
|{{:techtalk:ref:tools:pinion_gear_tools_buy_bustert.jpg?direct&300|}}|{{:techtalk:ref:tools:homemade_pinion_gear_tool_by_piniongear.jpg?direct&200|}}|{{:techtalk:ref:tools:pinion_gear_puller_by_75bike.jpg?direct&200|}}|
^Homemade Pinion Gear / Removal / Installation Tools ((photo by bustert of the XLFORUM http://xlforum.net/forums/showthread.php?t=395586&page=5))  ^  Homemade pinion gear press ((photo by piniongear of the XLFORUM http://xlforum.net/forums/showthread.php?t=395586&page=12))  ^  Pinion Gear Puller ((photo by 75bike of the XLFORUM http://xlforum.net/forums/showthread.php?t=395586&page=13))  ^

|{{:techtalk:ref:tools:pinion_gear_puller_1_by_sevenyears_of_famine.jpg?direct&200|}}|{{:techtalk:ref:tools:pinion_gear_puller_2_by_sevenyears_of_famine.jpg?direct&200|}}|{{:techtalk:ref:tools:pinion_gear_puller_3_by_sevenyears_of_famine.jpg?direct&200|}}|
|Large fender washer cut into a "C" shape and a gear puller|||
|  Homemade Pinion Gear Puller ((photo by sevenyears of famine of the XLFORUM http://xlforum.net/forums/showthread.php?t=1888378&highlight=pinion+gear+tool&page=10))  |||

|{{:techtalk:ref:tools:pinion_lock_tool_by_big_al.jpg?direct&300|}}|
|3/8" stainless steel plate with 20° spokes (for 18 teeth), \\ sawed initial groove to depth and widened it with files|
|  Homemade pinion gear locking tool for '89 models ((photo by Big Al of the XLFORUM http://xlforum.net/forums/showthread.php?p=5322902#post5322902))  |

==== 1991-Up Models (5 Speed) ====
See also in the Sportsterpedia: \\
[[techtalk:evo:oil03#oil_pump_drive_gear|Oil Pump Drive Gear]] \\
[[techtalk:ref:tools150|Origin of the Grindlock Tool]] \\

  * You can use a 15/16" 6 point wrench or deep well socket to remove / install the pinion gear nut.
  * The Grindlock Pinion Shaft Locking Tool engages for the full depth of the pinion gear for max. strength.

{{techtalk:ref:tools:93_and_up_pinion_gear_nut_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)){{:techtalk:ref:tools:grindlock_2000_pic_21_by_aswracing.jpg?direct&300|}} ((aswracing of the XLFORUM http://xlforum.net/forums/showthread.php?t=1618841&page=4)) \\

  * Due to a change in the pinion gear in 2000, there are 2 different versions of this tool: \\ (L) - (91-99) year models & (R) - (2000 to present) year models ((Hammer Performance http://www.hammerperf.com/xlvalvetrain.shtml#grindlock)) ((Grindlock 91-99 & Grindlock 2000, designed by XLFORUM member, "~Grind~" and Built by Hammer Performance ((aswracing of the XLFORUM http://xlforum.net/forums/showthread.php?t=1618841)) \\

{{techtalk:ref:tools:grindlock_tool_2_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{techtalk:ref:tools:grindlock_tool_by_aswracing.jpg?direct&300|}} ((aswracing of the XLFORUM http://xlforum.net/forums/showthread.php?t=1618841&page=4)) ((photo by aswracing of the XLFORUM http://xlforum.net/forums/showthread.php?t=1920827&highlight=pinion+gear+locking+tool))

  * Once the pinion shaft nut is removed, the pinion gear may or may not slide off by itself. \\ You can use a gear puller to remove it if it is stuck on. \\
  * It's very important to hold the crank still from the cam side (not the primary side) when torquing the pinion nut. ((aswracing of the XLFORUM http://xlforum.net/forums/showthread.php?t=1666277)) \\ If you for example put the bike in gear and hold the rear brake and torque on the nut, you run the very real risk of knocking the crank out of true. \\ It's not designed to transmit torque from one side to the other and it tries to twist the crankpin connection.
  * In respect to the key shearing, it's a very common issue particularly when heavy valve springs are used. \\ However, it shouldn't be the one thing that keeps the gear from spinning. The clamp load should do that. \\ The caption in the second pic below describes the fix: \\ Loctite red and 70ft-lbs instead of the factory specified 50ft-lbs. You won't have this issue again. \\ 

{{:techtalk:evo:engmech:removing_the_pinion_gear_by_grind.jpg?direct&300|}} ((photo by ~Grind~' of the XLFORUM http://xlforum.net/forums/showthread.php?t=1448694)) {{:techtalk:evo:engmech:pinion_key_nub_by_aswracing.jpg?direct&250|}} ((photo by aswracing of the XLFORUM http://xlforum.net/forums/showthread.php?t=1666277)) {{:techtalk:evo:engmech:oil_pump-pinion_gear_keyways_by_npaisnel.jpg?direct&350|}} ((photo by npaisnel of the XLFORUM, labeled by Hippysmack  http://xlforum.net/forums/showthread.php?t=2077485&page=26)) \\ 



====== Parts Lists ======

==== Engine Cases ====
^{{techtalk:miscres:instruction_sheet_header_4.png?nolink&803|}}||||
|Year Model|Case Set \\ Part#|Left Case \\ Casting# (location)|Right Case \\ Casting# (location)|
|1986-E1987 All|24527-86|24532-86 (outer wall)|24552-86 (outer wall) |
|  Notes|One year only case set. Left over 1986 cases used on early 1987 models. \\ Crank shaft bearings (24729-74) and pinion shaft bearings (24648-77)|||
|1987-1989 All|24527-87|(E87) 24532-86 (outer wall) \\ (L87-89) 24534-86 (inner wall)|24558-86 (inner wall)|
|  Notes|Some early 1987 models may have leftover cases from 1986. \\ 1987-up crankshaft bearings (24729-74) \\ 1987-up pinion shaft bearings (24647-87 / 24650-87 / 24659-87 / 24660-87)|||
|1990 All|24470-87|24534-86 (inner wall)|24558-86 (inner wall)|
|  Notes|Case set supplied with bearings. Replacement set for 1987-1989 Sportsters. \\ Crankshaft bearings (24729-74) \\ Pinion shaft bearings (24647-87 / 24650-87 / 24659-87 / 24660-87)|||
|1991 All|24470-91| | |
|  Notes|Case set supplied with bearings. Crankshaft bearing complete set (2) (48302-85) \\ Pinion shaft bearing (24647-87 / 24650-87 / 24659-87 / 24660-87)|||
|1992-1994 All|24470-91B|24534-89 (outer wall)|24558-89 (inner wall)|
|  Notes|Case set supplied with bearings.Crankshaft bearing complete set (2) (48302-85) \\ Pinion shaft bearing (24647-87 / 24650-87 / 24659-87 / 24660-87)|||
|1995-1997 All (except XL1200C) \\ 1996-1997 XL1200C|24470-91C \\ 24466-96|24534-89 (outer wall)|24558-92A (inner wall)|
|  Notes|Case set supplied with bearings. Crankshaft bearing complete set (2) (48302-85) \\ Pinion shaft bearing (24647-87 / 24650-87 / 24659-87 / 24660-87) \\ XL1200C cases are black, all others are silver.|||
|1998-1999 All (except XL1200C) \\ 1998-1999 XL1200C|24470-98 \\ 24466-98|24534-98 (outer wall)|24558-98 (inner wall)|
|  Notes|Case set supplied with bearings. Crankshaft bearing complete set (2) (48302-85) \\ Pinion shaft bearing (24647-87 / 24650-87 / 24659-87 / 24660-87) \\ XL1200C cases are black, all others are silver.|||
|2000-2002 All (except XL1200C) \\ 2000-2002 XL1200C|24470-00 \\ 24466-00|24534-98A (outer wall)|24558-00 (inner wall)|
|  Notes|Case set supplied with bearings. Crankshaft bearing complete set (2) (48302-85) \\ Pinion shaft bearing (24647-87 / 24650-87 / 24659-87 / 24660-87) \\ XL1200C cases are black, all others are silver.|||
|2003 All (except XL883R/XL1200C) \\ 2003 XL883R/XL1200C|24502-03 \\ 24500-03|24555-03 (outer wall)|24558-00 (inner wall)|
|  Notes|Case set (silver) supplied with bearings. 100th Anniversary restricted sale. \\ Crankshaft bearing complete set (2) (48302-85) \\ Pinion shaft bearing (24647-87 / 24650-87 / 24659-87 / 24660-87) \\ XL883R and XL1200C cases are black, all others are silver.|||
|2004-2005 All (except XL1200C) \\ 2004-2005 XL1200C/XL883R (black)|24470-04 \\ 24466-04|24534-04 (outer wall)|  |
|  Notes|Case set (silver) with bearings.|||
|2006-2007 \\ XL883/XL883C/XL883L/XL1200R|24470-06|  |  |
|  Notes|Case set (silver) with bearings.|||
|2006-2007 XL883R/XL1200C \\ XL1200L/XL50|24466-06|24534-06A (outer wall)|24558-06 (inner wall)|
|  Notes|Case set (black) with bearings.|||
|2007-2008 XL1200N|24745-07|  |  |
|  Notes|Case set (gray) with bearings.|||
|2008 \\ XL883/XL883C/XL883L/XL1200R|24470-06A|  |  |
|  Notes|Case set (silver) with bearings.|||
|2008 \\ XL883R/XL1200C XL1200L|24466-06A|  |  |
|  Notes|Case set (black) with bearings.|||
|2009-2016 XL883/XL883C/XL883L|24470-06B|  |  |
|  Notes|Case set (silver) with bearings.|||
|2009-2016 XL883R/XL883N \\ XL1200C/XL1200C Anv/XL1200L \\ XL1200R/XL1200X/XL1200CP \\ XL1200CA/XL1200CB/XL1200T \\ 2014-2016 XL1200V|24466-06B|  |  |
|  Notes|Case set (black) with bearings.|||
|2009-2013 XL1200N/XL1200V \\ 2016 XL1200V/XL1200CX|24745-07A|  |  |
|  Notes|Case set (gray) with bearings.|||
|2009-2013 XR-1200/XR1200X|24475-08|  |  |
|  Notes|Case set (black) with bearings.|||

==== Engine Case / Shaft Bearings and Races ====
Unless coded in parenthesis, all part numbers below are factory part numbers. \\
Legend for part numbers coded in parenthesis; \\ 
(HD) = Harley Davidson
(Ti) = Timken
(To) = Torrington

^{{techtalk:miscres:instruction_sheet_header_4.png?nolink&803|}}||||||||
|  **1986-2003 Crankshaft Bearings**  ||||||||
|Year Case \\ All Models|Crankshaft \\ Bearing Set \\ w/ races|Timken Bearing \\ w/ Outer Race|Timken Bearing \\ (cone only)|Timken Bearing \\ Outer Race|Bearing Shim|Ret Ring \\ bearing race \\ spacer|Bearing Seal|
|1986|24729-74|48302-85|(HD) 48348-70 \\ (Ti) L44649| (HD) 48315-60 \\ (Ti) L44610|supplied|9119A|35151-74 \\ 2002 upgrade \\ (35151-74A)| 
|1987-2003|:::|:::|:::|:::|9155 (.098") \\ 9142 (.100") \\ 9143 (.102") \\ 9144 (.104") \\ 9145 (.106") \\ 9146 (.108") \\ 9147 (.110") \\ 9148 (.112") \\ 9149 (.114")|:::|:::|
|  **2004-Up Crankshaft Bearings**  ||||||||
|Year Case \\ All Models|Crankshaft \\ Bearing|Bearing \\ Thrust Washer|Inner \\ Retaining Ring|Outer \\ Retaining Ring|Sprocket \\ Shaft Spacer|Bearing Seal||
|2004-2005|24604-00C|8973 (2)|35114-02|35118-03|40254-02|12068||
|2006-2008|24604-00D|8973 (2)|35114-02|35118-03|40254-02|12068||
|2009-2010|24605-07|8972|35114-02|35118-03|40254-02|12068||

^{{techtalk:miscres:instruction_sheet_header_4.png?nolink&803|}}|||||||
|  Transmission Bearings  ||||||
|  |  Left Case (trapdoor)  ||  Right Case  ||||
|Year Case|Mainshaft \\ Bearing \\ includes race|Countershaft \\ Bearing \\ includes race|Mainshaft \\ Bearing|Mainshaft \\ Bearing Race|Countershaft \\ Bearing \\ includes race|Shifter \\ Shaft/Drum \\ Bushing / Bearing|
|1986-1990|(HD) 9025A \\ (NTN) 6207ZZ \\ (Fafnir) 207KDD|35961-52|(HD) 9118 \\ (To) BH2012|35041-84|(HD) 35960-54 \\ (To) M-11121 \\ closed end|bushing \\ 40520-63|
|1991-2003|35030-89|(HD) 8998|(HD) 8996 / 8996A \\ (FAG) 559197 \\ (FAG) 6209 C3 \\ (SKF) 6209 C3|  |(HD) 8977 \\ (FAG) BK2526 \\ (INA) BK2526|bearing \\ 9151|

^{{techtalk:miscres:instruction_sheet_header_4.png?nolink&803|}}|||||||
|    **Pinion Shaft Bearings**  |||||  **Inner Cam Bearings or Bushings**  ||
|Year Case|Pinion Shaft Bearing|Outer \\ Bearing \\ Race|Inner \\ Bearing \\ Race|Bearing \\ Retainer \\ Ring|Bearings|Bushings|
|E1986|24648-77 (includes outer race) \\ (To) HJ-202816||24658-86 \\ (To) IR-162016|n/a|(HD) 9057 \\ (To) BH-117|
|L1986-1990|24650-87 (red) __largest__ \\ 24647-87 (blue) \\ 24659-87 (white/grey) \\ 24660-87 (green) __smallest__ \\ bearing locked to pinion shaft|8881|24658-87|11177 \\ 11177A (95)|(HD) 9057 \\ (To) BH-117|
|1991-2003|:::|:::|:::|:::| |25598-91|

==== Flywheel Assembly ====
^{{techtalk:miscres:instruction_sheet_header_4.png?nolink&803|}}||||
|Year Model ((1986-2019 HD Sportster Parts Catalogs))|Flywheel \\ Assembly|Connecting Rod \\ Assembly|Crankpin|
|**Early 1986 Models**|  |||
|E1986 XLH883|23905-86|24275-86|23960-80A|
|E1986 XLH1100|23900-86|24275-86|23960-80A|
|**Late 1986-1990 Models**|  |||
|L1986 XLH883|23905-86A|24275-86A|23960-80A|
|1987 XLH883|23905-87|24275-86A|23960-80A (std) \\ 23948-87 (.001" O.S.) \\ 23949-87 (.002" O.S.)|
|1988 XLH883|23905-88|:::|:::|
|1989-1990 XLH883|23905-88A|:::|:::|
|L1986 XLH1100|23900-86A|24275-86A|23960-80A (std) \\ 23948-87 (.001" O.S.) \\ 23949-87 (.002" O.S.)|
|1987 XLH1100|23900-87|:::|:::|
|1988 XLH1200|23900-88|24275-86A|23960-80A (std) \\ 23948-87 (.001" O.S.) \\ 23949-87 (.002" O.S.)|
|1989-1990 XLH1200|23900-88A|:::|:::|
|**1991-1999 Models**||||
|1991-1994 XLH883|23905-89|24275-86A|23960-80A (std) \\ 23948-87 (.001" O.S.) \\ 23949-87 (.002" O.S.)|
|1991-1994 XLH1200|23900-90|24275-86A|23960-80A (std) \\ 23948-87 (.001" O.S.) \\ 23949-87 (.002" O.S.)|
|1995-1999 All Models|23905-89A|24275-86A|23960-80A (std) \\ 23948-87 (.001" O.S.) \\ 23949-87 (.002" O.S.)|
|**2000-2003 Models**||||
|2000-2003 All Models|23905-00 \\ 23905-00A|Not Sold \\ Separate|Not Sold \\ Separate|
|**2004-up Models**||||
|2004-2005 All Models|23905-04|Not Sold \\ Separate|Not Sold \\ Separate|
|2006-2009 All Models \\ (Except XR1200)|23905-04A|Not Sold \\ Separate|Not Sold \\ Separate|
|2010-2019 All Models \\ (Except XR1200/X)|23905-04B|Not Sold \\ Separate|Not Sold \\ Separate|
|2009-2013 \\ XR1200 / XR1200X|23999-08|Not Sold \\ Separate|Not Sold \\ Separate|
==== Primary / Chain Cover ====
^{{techtalk:miscres:instruction_sheet_header_4.png?nolink&803|}}|||||
|Year \\ Model|Part \\ Number|Casting \\ Number|Gasket|Shifter \\ Shaft \\ Bushing|
|1986-1987 Sportster|25430-86|Circle \\ Date Stamp|34955-75|40520-63|
|  Notes:|Polished. Replaced by 25430-86A (1989)||||
|1988-1990 Sportster|25430-88|  |34955-75|40520-63|
|  Notes:|Polished||||
|1991-1993 Sportster|25430-89|35950-89|34955-89|40520-63|
|  Notes:|Polished||||
|1994 Sportster|25430-94|  |34955-89A|40520-63|
|  Notes:|Polished||||
|1995-2003 Sportster \\ (except XL1200C) \\ (except XL1200S) \\ (except XL883R)|25430-94A|34951-95|34955-89A|40520-63|
|  Notes:|Polished||||
|1996-2003 XL1200C|25460-94|34951-95|34955-89A|40520-63|
|  Notes:|Chrome||||
|1998-2003 XL1200S/XL883C|25471-97Y|  |34955-89A|40520-63|
|  Notes:|Silver||||
|2002-2003 XL883R|25574-99Y|  |34955-89A|40520-63|
|  Notes:|Black||||
|2004-2005 XL883/XL883L|25430-04|  |34955-04|40520-63|
|  Notes:|Polished||||
|2004-2005 XL1200C|25460-04|34951-04|34955-04|40520-63|
|  Notes:|Chrome||||
|2004-2005 XL883C/XL1200R|25471-04|  |34955-04|40520-63|
|  Notes:|Silver||||
|2005 XL883R|25307-05|  |34955-04|40520-63|
|  Notes:|Polished||||
|2006 XL883R/XL1200R|25307-06|  |34955-04|40574-06|
|  Notes:|Black. New shifter shaft bushing has a flange on one end.||||
|2006 XL883/XL883L|25430-06|  |34955-04|40574-06|
|  Notes:|Polished||||
|2006 XL1200C/XL1200L|25460-06|  |34955-04|40574-06|
|  Notes:|Chrome||||
|2006 XL883C|25471-06|  |34955-04|40574-06|
|  Notes:|Silver||||
|XL1200N|60830-07|  |34955-04|40574-06|
|  Notes:|Gray||||

==== Cam / Gearcase Cover ====
^{{techtalk:miscres:instruction_sheet_header_4.png?nolink&803|}}||||
|Year \\ Model|Part \\ Number|Casting \\ Number|Gasket|
|1986-1990 Sportster|25219-86|25222-84A|25263-86|
|:::|Polished, cover only. See also circled date stamp. \\ 86-87 cover (25488-86) and 88-90 cover (25488-88) include matched cam gear set.|||
|1991-1993 Sportster|25219-91|25222-89|25263-90 \\ 25263-90A (1994)|
|:::|Polished, includes trans vent fitting/clamp, #2 cam seal and bushings. \\ 1991-1994 cover 25488-89 includes the matched cam gear set. \\ See also date stamp.|||
|1994 Sportster|25219-94|  |25263-90A|
|:::|Polished, includes trans vent fitting/clamp, #2 cam seal and bushings.|||
|1995-1997 Sportster \\ (except XL1200C)|25219-91A|25230-95|25263-90A|
|:::|Polished, includes trans vent fitting, #2 cam seal and bushings. \\ 1995-1997 cover 25488-89A includes the matched cam gear set.|||
|1996-1997 XL1200C|25213-96|  |25263-90A|
|:::|Chrome, includes trans vent fitting, #2 cam seal and bushings. \\ 1996-1997 cover 25483-96 includes the matched cam gear set.|||
|1998-1999 Sportster \\ (except XL1200C) \\ (except XL1200S)|25219-91B|25230-98|25263-90B|
|:::|Polished, includes trans vent fitting, #2 cam seal and bushings. \\ 98-99 (except 883C) cover 25488-89B includes matching cam gear set. \\ 1999 XL883C cover 25473-97YA (silver) includes matching cam gear set.|||
|1998-1999 XL1200C|25213-96A|  |25263-90B|
|:::|Chrome, includes trans vent fitting, #2 cam seal and bushings. \\ 98-99 cover 25483-96A includes matching cam gear set.|||
|1998 XL1200S|25252-97Y|  |25263-90B|
|:::|Silver, includes trans vent fitting, #2 cam seal and bushings. \\ 98-99 cover 25491-98 includes matching cam gear set.|||
|1999 XL1200S|25252-97YA|  |25263-90B|
|:::|Silver, includes trans vent fitting #2 cam seal and bushings.|||
|2000-2003 XL883/883HUG \\ XL883C/1200|25219-91C|  |25263-90C|
|:::|Polished, includes trans vent fitting, #2 cam seal and bushings.|||
|2000-2003 XL1200C|25213-96B|  |25263-90C|
|:::|Chrome, includes trans vent fitting, #2 cam seal and bushings.|||
|2000-2003 XL1200S|25252-97YB|  |25263-90C|
|:::|Silver, includes trans vent fitting, #2 cam seal and bushings.|||
|2002-2003 XL883R|25307-99YA|  |25263-90C|
|:::|Black, includes trans vent fitting, #2 cam seal and bushings.|||
|2004-2016 \\ XL883/XL883L|25219-04|25230-04|25263-90D|
|:::|Polished. Has ignition cover plate (32506-90) labeled "5".|||
|2004-2016 XL1200C/Anv, XL1200L \\ XL50/XL1200CP \\ XL1200V/XL1200T|25213-04|25230-04|25263-90D|
|:::|Chrome. Has ignition cover plate (32514-04) with center Bar and Shield.|||
|2004-2010 XL883C \\ 2004-2005 XL1200R|25252-04|25230-04|25263-90D|
|:::|Silver. 883C has ignition cover (32514-04), 1200R has ignition cover (32555-04).|||
|2005-2016 XL883R \\ 2006-2009 XL1200R \\ 2009-2016 XL883N \\ 2011-2016 XL1200X \\ 2012-2016 XL1200CP \\ 2013-2016 XL1200CA/XL1200CB|25486-05|  |25263-90D|
|:::|Black.|||
|2007-2012 XL1200N|25546-07|  |25263-90D|
|:::|Gray.|||
|2009-2010 \\ XR1200/XR1200X|25246-08|25239-08|  |
|:::|Silver.|||
|2010-2013 XR1200/XR1200X HDI|25250-10|  |  |
|:::|Black.|||

==== Transmission Sprocket Cover ====
^{{techtalk:miscres:instruction_sheet_header_4.png?nolink&803|}}||||
|Year \\ Model|Part \\ Number|Casting \\ Number|Notes|
|1986-1990 Sportster|34911-81A ((1986-1990 HD Sportster Parts Catalogs))|  |Polished|
|1991-1994 Sportster|34911-91|  |  |
|1995-2003 Sportster \\ (except XL883C) \\ (except XL1200C) \\ (except XL1200S)|34911-91A|  |Polished|
|1996-2003 XL1200C|34932-96|  |Chrome|
|1998-2003 XL1200S/XL883C|34938-98|  |Silver|
|2002-2003 XL883R|34943-02|  |Black|

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