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techtalk:evo:engmech02 [2023/08/13 01:18] – [Sub Documents] ixl2relaxtechtalk:evo:engmech02 [2025/10/01 06:32] (current) – [Comparing OEM and Andrews Cam Grinds] hippysmack
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 [[:techtalk:menu|{{  :techtalk:gototechnicalmenu.jpg|}}]] [[:techtalk:menu|{{  :techtalk:gototechnicalmenu.jpg|}}]]
  
-===== Sub Documents ===== 
- 
-  * [[techtalk:evo:engmech02g|Notes on Sifton Cams by Tom Sifton]] 
  
 ====== EVO: Engine Mechanicals ====== ====== EVO: Engine Mechanicals ======
 +====== Camshafts ======
 +==== Sub Documents ====
  
-The Camshafts (4 of them) are used to operate the intake and exhaust valves by means of the lifters (AKA: tappets), the pushrods and the rocker arms. The #2 Cam is driven by the Pinion Gear. The Pinion Gear is mounted on the Pinion Shaft which is part of the Flywheel Assembly.+  * [[techtalk:evo:engmech02e|Cam Grind Comparisons]]
  
-#1 Cam - Rotates CW -- Operates Rear Exhaust Valve\\ 
-#2 Cam - Rotates CCW - Operates Rear Intake Valve - Driven by Pinion Gear\\ 
-#3 Cam - Rotates CW -- Operates Front Intake Valve\\ 
-#4 Cam - Rotates CCW - Operates Front Exhaust Valve\\ 
  
 +The Camshafts (4 of them) are used to operate the intake and exhaust valves by means of the lifters (AKA: tappets), the pushrods and the rocker arms. The #2 Cam is driven by the Pinion Gear. The Pinion Gear is mounted on the Pinion Shaft which is part of the Flywheel Assembly.
 +  * #1 Cam - Rotates CW -- Operates Rear Exhaust Valve
 +  * #2 Cam - Rotates CCW - Operates Rear Intake Valve - Driven by Pinion Gear
 +  * #3 Cam - Rotates CW -- Operates Front Intake Valve
 +  * #4 Cam - Rotates CCW - Operates Front Exhaust Valve
  
- +===== Cam Oiling =====
-====== Camshafts ======+
 The cams get oiled by drainage from the rocker boxes and splash oil in the bottom end. \\ The cams get oiled by drainage from the rocker boxes and splash oil in the bottom end. \\
 Oil flows off the pushrod side of the rocker boxes through the pushrod covers, into vertical holes in the lifter bores and into the gearcase. \\ Oil flows off the pushrod side of the rocker boxes through the pushrod covers, into vertical holes in the lifter bores and into the gearcase. \\
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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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 ==== Comparing OEM and Andrews Cam Grinds ==== ==== Comparing OEM and Andrews Cam Grinds ====
 +All of the old Andrews grinds ... the N2/N4/N6/N8 ... were all designed around the 03 & older heads, which are a totally different animal from the newer heads. If you notice, every one of those grinds is at .500" lift or less> That's because .500" was the maximum safe lift for the hardware that came in the older heads. ((aswracing of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-bottom-end/161578-cam-selection#post3442028)) \\
 +
 +W's actually came out in 1998 on the 1200S models. Then in 2004, all the 1200s got them. Then in 2007, all the 883s got them as well. W cams have a really, really early intake close event. What that does is it builds more cylinder pressure, since more of the compression stroke is used for actual compression. This helps bottom end and mid range a lot. But then at higher rpm's, it chokes the motor. So they're a good grind for low to mid rpm's. ((aswracing of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-bottom-end/161578-cam-selection#post3442028)) \\
 +
 These figures are from the Sportster Evolution Cams PDF from Andrews Products. ((Page25 - http://www.bigboarv-twin.com/wp-content/uploads/2015/07/Andrews-Products-Catalogue-20141.pdf)) These figures are from the Sportster Evolution Cams PDF from Andrews Products. ((Page25 - http://www.bigboarv-twin.com/wp-content/uploads/2015/07/Andrews-Products-Catalogue-20141.pdf))
  
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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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 ===== 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|}}|
- 
- 
  
 ====== Lifters (tappets) ====== ====== Lifters (tappets) ======
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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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 \\ \\
  
- 
-===== Checking Lifter Pre-load ===== 
- 
-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. \\ 
- 
-  * **Measure at the rocker box how much the lifter will get preloaded at the rocker box**. ((http://www.hammerperf.com/ttpushrodlength.shtml)) 
-    * Put your pushrods in place (remember, the longer one goes on the exhaust). 
-    * Set the gasket and rocker box on top, and start the four big screws only. 
-    * Finger tighten the left (spark plug) side. \\ (while making sure the right side is resting with the upper pushrod ends sitting in the cups on the rocker arms) 
-    * Now take a simple caliper and measure how much gap you have between the rocker box and the rocker box gasket, as shown in the photo below. 
-    * This won't be an exact answer, but it'll be pretty close. \\ Remember, you'd like to see the plunger preloaded about .100", but anywhere between .050" and .150" should work. \\ You can order pushrod lengths that are longer or shorter than your stock pushrods by the amount it takes to achieve .100" of lifter plunger preload. \\ If you don't have a caliper to measure your stock pushrod lengths, the information is available in most factory service manuals.  
- 
-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)) \\ 
  
 ===== 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 Lifters ====== 
- +These year motors have off-center lifters. If you run a straight line through the center of the lifter, it does not go through the center of the cam. It's offset to one side, to give the lobe a better angle of attack when raising the lifter. \\
  
 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)) \\
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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)) \\
  
 +====== 1991-Up Lifters ======
 +1991-up motors have on-center lifters. In other words, it's a straight line through the center of the lifter to the center of the cam underneath it. \\
  
-====== 91-99 Lifters ====== +===== 1991-1999 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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 |{{:techtalk:evo:oil:inlet_hole_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:hole_toward_the_crankcase_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:hole_toward_the_crankcase_2_by_hippysmack.jpg?direct&300|}}| |{{:techtalk:evo:oil:inlet_hole_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:hole_toward_the_crankcase_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:hole_toward_the_crankcase_2_by_hippysmack.jpg?direct&300|}}|
  
-===== 91-99 Anti-Rotation Pins ===== +==== 1991-1999 Anti-Rotation Pins ====
 **Parts**: \\ **Parts**: \\
 4 - screws (884) \\ 4 - screws (884) \\
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 |{{: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 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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-bottom-end/159217-lifters-comparison?t=1706033))|
-====== 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)) \\ +
- +
-|Lifter from an 02 XL883 ((photo by Scuba10jdl of the XLFORUM http://xlforum.net/forums/showthread.php?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 314: 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 ===== +==== 2000-2005 Lifter Ant-Rotation Screws ====
 **Parts**: \\ **Parts**: \\
 4 - anti-rotation screws (18532) \\ 4 - anti-rotation screws (18532) \\
Line 330: 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 ===== +==== 2006-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|}}|
  
 ====== Pinion Gear ====== ====== Pinion Gear ======
 +
   * **Removal / Installation of the Pinion Gear**:   * **Removal / Installation of the Pinion Gear**:
-    * __Lock the pinion shaft itself, not from the brake pedal, primary side, pistons or anywhere else__: \\ It's very important to hold the crank still from the gearcase side to torque the pinion nut on or off (usually done by holding the pinion gear still). \\ 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. \\ (which requires a full tear-down to fix). \\ It's not designed to transmit torque from one side to the other and it tries to twist the crankpin connection. \\ You'll need a tool to lock the pinion gear for removal or installation. See [[techtalk:ref:tools133#and_up_models_5_speed|tool options]] in the REF section of the Sportsterpedia. \\ Again, holding the flywheel still by any method on the other side of the flywheel assembly or top side runs the risk of knocking the wheels out of true. +      * __Lock the pinion shaft itself, not from the brake pedal, primary side, pistons or anywhere else__: \\ It's very important to hold the crank still from the gearcase side to torque the pinion nut on or off (usually done by holding the pinion gear still). \\ 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. \\ (which requires a full tear-down to fix). \\ It's not designed to transmit torque from one side to the other and it tries to twist the crankpin connection. \\ You'll need a tool to lock the pinion gear for removal or installation. See [[:techtalk:ref:tools133#and_up_models_5_speed|tool options]] in the REF section of the Sportsterpedia. \\  Again, holding the flywheel still by any method on the other side of the flywheel assembly or top side runs the risk of knocking the wheels out of true. 
-    * **Pinion Nut**: \\ __Torque Specs__: \\ The 86-87 pinion gear is located by 6 internal splines mating between 6 external splines on the pinion shaft. \\ There is a lockwasher (7044A) between the nut and the pinion gear. \\ Pry the tabs on it up to remove the pinion nut, bend them down against the flats on the nut to install. \\ Factory torque is (35-45 ft/lbs.) \\ The 1988-up pinion gear is located by a little nub of the key that sits under the oil pump drive gear. \\ That little nub is not nearly strong enough by itself to keep the gear from shearing on the pinion shaft. \\ And instead, it's the clamp load from the nut that keeps the pinion gear where we want it. \\ The factory torque spec on the pinion nut (35-45 ft/lbs). \\ Per Hammer Performance, that has proven woefully inadequate to hold the pinion gear in place (esp. with high pressure valve springs). \\ They highly recommend using 70 ft/lbs of torque instead ((http://hammerperf.com/ttxlcaminstall.shtml#pinionnut)) (as do other performance shops, Zippers cam instructions etc,). \\ __Loctite__: \\ Use red Loctite on the shaft threads per the manual but don't just slather it all over the threads. \\ All it takes is a light bead around 2 or three threads (in the middle of where the nut will end up when tightened. \\ There is no reason to use Loctite on the nut.  +      * **Pinion Nut**: \\ __Torque Specs__: \\ The 86-87 pinion gear is located by 6 internal splines mating between 6 external splines on the pinion shaft. \\ There is a lockwasher (7044A) between the nut and the pinion gear. \\ Pry the tabs on it up to remove the pinion nut, bend them down against the flats on the nut to install. \\ Factory torque is (35-45 ft/lbs.) \\ The 1988-up pinion gear is located by a little nub of the key that sits under the oil pump drive gear. \\ That little nub is not nearly strong enough by itself to keep the gear from shearing on the pinion shaft. \\ And instead, it's the clamp load from the nut that keeps the pinion gear where we want it. \\ The factory torque spec on the pinion nut (35-45 ft/lbs). \\ Per Hammer Performance, that has proven woefully inadequate to hold the pinion gear in place (esp. with high pressure valve springs). \\ They highly recommend using 70 ft/lbs of torque instead ((http://hammerperf.com/ttxlcaminstall.shtml#pinionnut))  (as do other performance shops, Zippers cam instructions etc,). \\ __Loctite__: \\ Use red Loctite on the shaft threads per the manual but don't just slather it all over the threads. \\ All it takes is a light bead around 2 or three threads (in the middle of where the nut will end up when tightened. \\ There is no reason to use Loctite on the nut. 
- +**Compatibility**  ((From HD Parts Catalogs 2004 pg 17, 2005 pg 19, 2006 pg 19, 2007 pg 19, 2008 pg 19, 2009 pg 25-27, 2010 pg 25-27, 2011 pg 25-27, 2012 pg 25-27, 2013 pg 29-31, 2014 pg 17, 2015 pg 19, 2016 pg 19))   \\ 1986-2003 parts books do not list a part number for the pinion gear and it appears the pinion gear is part of the cam gear set (not sold separately). \\ However, a gear could be ordered from the MoCo. The part# coincides with the color scheme coding on the respective cam sets. \\ 2000-up pinion gear part number is (24047-00) as appearing in the 2004-up parts catalogs. \\ 1986–1987 pinion gears have a (6-spline) pinion shaft. \\ 1988-up pinion gears have no splines and have a notch out the back side (not under) to slide around a woodruff key on the non-splined pinion shaft. \\ 1986-1999 pinion gears have the same coarse (13) tooth pitch. \\ 2000-up pinion gears have a fine (23) tooth pitch. \\ XL Pinion Gear Color/Size Info here: [[https://www.xlforum.net/showthread.php?t=1963918|https://www.xlforum.net/showthread.php?t=1963918]] \\ 
-**Compatibility** ((From HD Parts Catalogs 2004 pg 17, 2005 pg 19, 2006 pg 19, 2007 pg 19, 2008 pg 19, 2009 pg 25-27, 2010 pg 25-27, 2011 pg 25-27, 2012 pg 25-27, 2013 pg 29-31, 2014 pg 17, 2015 pg 19, 2016 pg 19)) \\  +**Part numbers and color coding**: \\ 1986-1999 cams continued the color coding as in previous years for optimum noise reduction in the gear mesh. \\ However, from 1986-1990, there were even more color combinations including cam drive gear sizes. \\ Each factory pinion gear was colored coded with a dot (even though it was more like a splotch at times) that matched the same colors on the matching cam drive gear. \\ 1986-1990 cam drive gears came with either one dot or two dots. Their corresponding pinion gear also came with one or two dots respectively to that gear set. \\ 1991-1999 cam drive gears were only colored with one dot and likewise, there will only be one dot on their respective pinion gear. \\ 2000-Up factory pinion gears have no color codes. \\ ^{{:techtalk:miscres:instruction_sheet_header_4.png?nolink&450}}|||||||^{{:techtalk:miscres:instruction_sheet_header_4.png?nolink&450}}||||||||
-1986-2003 parts books do not list a part number for the pinion gear and it appears the pinion gear is part of the cam gear set (not sold separately). \\ +
-However, a gear could be ordered from the MoCo. The part# coincides with the color scheme coding on the respective cam sets. \\ +
-2000-up pinion gear part number is (24047-00) as appearing in the 2004-up parts catalogs. \\ +
-1986–1987 pinion gears have a (6-spline) pinion shaft. \\ +
-1988-up pinion gears have no splines and have a notch out the back side (not under) to slide around a woodruff key on the non-splined pinion shaft. \\ +
-1986-1999 pinion gears have the same coarse (13) tooth pitch. \\ +
-2000-up pinion gears have a fine (23) tooth pitch. \\ +
- +
-XL Pinion Gear Color/Size Info here: +
-http://xlforum.net/forums/showthread.php?t=1963918 \\ +
- +
-**Part numbers and color coding**: \\ +
-1986-1999 cams continued the color coding as in previous years for optimum noise reduction in the gear mesh. \\ +
-However, from 1986-1990, there were even more color combinations including cam drive gear sizes. \\ +
-Each factory pinion gear was colored coded with a dot (even though it was more like a splotch at times) that matched the same colors on the matching cam drive gear. \\ +
-1986-1990 cam drive gears came with either one dot or two dots. Their corresponding pinion gear also came with one or two dots respectively to that gear set. \\ +
-1991-1999 cam drive gears were only colored with one dot and likewise, there will only be one dot on their respective pinion gear. \\ +
-2000-Up factory pinion gears have no color codes. \\+
  
-^{{techtalk:miscres:instruction_sheet_header_4.png?nolink&450|}}|||||||^{{techtalk:miscres:instruction_sheet_header_4.png?nolink&450|}}|||||||| +|  **Factory Pinion Gears by Part Number and Color of Dots**   (★ = 1 Dot, ★★ = 2 Dots)  |||||||||||||||| 
-|  **Factory Pinion Gears by Part Number and Color of Dots** (★ = 1 Dot, ★★ = 2 Dots)  |||||||||||||||| +|  **1986-1987 Sportster**    ||||||||  **1988-1990 Sportster**    ||||||||
-|  **1986-1987 Sportster**  ||||||||  **1988-1990 Sportster**  ||||||||+
 |Part#|Brown|Blue|Red|White|Green|Yellow|Black|Part#|Brown|Blue|Red|White|Green|Yellow|Black| |Part#|Brown|Blue|Red|White|Green|Yellow|Black|Part#|Brown|Blue|Red|White|Green|Yellow|Black|
-|24055-86|  ★  |  |  |  |  |  |  |24055-88|  ★  | +|24055-86|  ★  |   |   |   |   |   |   |24055-88|  ★  | | | | | | | 
-|24056-86|  |  ★  |  |  |  |  |  |24056-88|  |  ★  | +|24056-86|   |  ★  |   |   |   |   |   |24056-88|   |  ★  | | | | | | 
-|24057-86|  |  |  ★  |  |  |  |  |24057-88|  |  |  ★  | +|24057-86|   |   |  ★  |   |   |   |   |24057-88|   |   |  ★  | | | | | 
-|24058-86|  |  |  |  ★  |  |  |  |24058-88|  |  |  |  ★  | +|24058-86|   |   |   |  ★  |   |   |   |24058-88|   |   |   |  ★  | | | | 
-|24059-86|  |  |  |  |  ★  |  |  |24059-88|  |  |  |  |  ★  | +|24059-86|   |   |   |   |  ★  |   |   |24059-88|   |   |   |   |  ★  | | | 
-|24060-86|  |  |  |  |  |  ★  |  |24060-88|  |  |  |  |  |  ★  | +|24060-86|   |   |   |   |   |  ★  |   |24060-88|   |   |   |   |   |  ★  | | 
-|24061-86|  |  |  |  |  |  |  ★  |24061-88|  |  |  |  |  |  |  ★  | +|24061-86|   |   |   |   |   |   |  ★  |24061-88|   |   |   |   |   |   |  ★  | 
-|25737-86|  ★★  |  |  |  |  |  |  |25737-88|  ★★  | +|25737-86|  ★★  |   |   |   |   |   |   |25737-88|  ★★  | | | | | | | 
-|25738-86|  |  ★★  |  |  |  |  |  |25738-88|  |  ★★  | +|25738-86|   |  ★★  |   |   |   |   |   |25738-88|   |  ★★  | | | | | | 
-|25739-86|  |  |  ★★  |  |  |  |  |25739-88|  |  |  ★★  | +|25739-86|   |   |  ★★  |   |   |   |   |25739-88|   |   |  ★★  | | | | | 
-|25740-86|  |  |  |  ★★  |  |  |  |25740-88|  |  |  |  ★★  | +|25740-86|   |   |   |  ★★  |   |   |   |25740-88|   |   |   |  ★★  | | | | 
-|25741-86|  |  |  |  |  ★★  |  |  |25741-88|  |  |  |  |  ★★  | +|25741-86|   |   |   |   |  ★★  |   |   |25741-88|   |   |   |   |  ★★  | | | 
-|25742-86|  |  |  |  |  |  ★★  |  |25742-88|  |  |  |  |  |  ★★  | +|25742-86|   |   |   |   |   |  ★★  |   |25742-88|   |   |   |   |   |  ★★  | | 
-|25743-86|  |  |  |  |  |  |  ★★  |25741-88|  |  |  |  |  |  |  ★★  | +|25743-86|   |   |   |   |   |   |  ★★  |25741-88|   |   |   |   |   |   |  ★★  | 
-^{{techtalk:miscres:instruction_sheet_header_4.png?nolink&450|}}|||||||^{{techtalk:miscres:instruction_sheet_header_4.png?nolink&450|}}|||||||| +^{{:techtalk:miscres:instruction_sheet_header_4.png?nolink&450}}^^^^^^^^{{:techtalk:miscres:instruction_sheet_header_4.png?nolink&450}}^^^^^^^| 
-|  **Factory Pinion Gears by Part Number and Color of Dots**  |||||||||||||||| +|  **Factory Pinion Gears by Part Number and Color of Dots**    |||||||||||||||| 
-|  **1991-1999 Sportster**  ||||||||  **2000-Up Sportsters**  ||||||||+|  **1991-1999 Sportster**    ||||||||  **2000-Up Sportsters**    ||||||||
 |Part#|Brown|Blue|Red|White|Green|Yellow|Black|Part#|24047-00|No Color Coding|||||| |Part#|Brown|Blue|Red|White|Green|Yellow|Black|Part#|24047-00|No Color Coding||||||
-|24055-91|  ★  |  |  |  |  |  |  |  |||||||| +|24055-91|  ★  |   |   |   |   |   |   |   |||||||| 
-|24056-91|  |  ★  |  |  |  |  |  |:::|:::|:::|:::|:::|:::|:::|:::| +|24056-91|   |  ★  |   |   |   |   |   | ::: |||||||| 
-|24057-91|  |  |  ★  |  |  |  |  |:::|:::|:::|:::|:::|:::|:::|:::| +|24057-91|   |   |  ★  |   |   |   |   | ::: |||||||| 
-|24058-91|  |  |  |  ★  |  |  |  |:::|:::|:::|:::|:::|:::|:::|:::| +|24058-91|   |   |   |  ★  |   |   |   | ::: |||||||| 
-|24059-91|  |  |  |  |  ★  |  |  |:::|:::|:::|:::|:::|:::|:::|:::| +|24059-91|   |   |   |   |  ★  |   |   | ::: |||||||| 
-|24060-91|  |  |  |  |  |  ★  |  |:::|:::|:::|:::|:::|:::|:::|:::| +|24060-91|   |   |   |   |   |  ★  |   | ::: |||||||| 
-|24061-91|  |  |  |  |  |  |  ★  |:::|:::|:::|:::|:::|:::|:::|:::| +|24061-91|   |   |   |   |   |   |  ★  | ::: ||||||||
-\\ +
  
-1986-1987 Sportster (18T) Pinion Gear: \\ +1986-1987 Sportster (18T) Pinion Gear: \\ Has internal splines. \\ {{:techtalk:evo:engmech:pinion_gear_1986-1987_pic1_by_c3-cycle-tech.jpg?direct&300|pinion_gear_1986-1987_pic1_by_c3-cycle-tech.jpg}}((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|pinion_gear_1986-1987_pic2_by_c3-cycle-tech.jpg}}((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&}}((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))
-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)) \\+
  
-1988-1990 Sportster (18T) Pinion Gear: \\ +1988-1990 Sportster (18T) Pinion Gear: \\ Has a notch cut out of the rear for the woodruff key (T-key) on the pinion shaft and no splines. \\ {{:techtalk:evo:engmech:pinion_gear_1988-1990_pic2_by_c3-cycle-tech.jpg?direct&300|pinion_gear_1988-1990_pic2_by_c3-cycle-tech.jpg}}((photo courtesy of c3cycle.com, Link to site:https://www.c3cycle.com/)) {{:techtalk:evo:engmech:pinion_gear_1988-1990_pic1_by_c3-cycle-tech.jpg?direct&300|pinion_gear_1988-1990_pic1_by_c3-cycle-tech.jpg}}((photo courtesy of c3cycle.com, Link to site:https://www.c3cycle.com/))
-Has a notch cut out of the rear for the woodruff key (T-key) on the pinion shaft and no splines. \\ +
-{{:techtalk:evo:engmech:pinion_gear_1988-1990_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_1988-1990_pic1_by_c3-cycle-tech.jpg?direct&300|}} ((photo courtesy of c3cycle.com, Link to site:https://www.c3cycle.com/)) \\+
  
-1991-1999 Sportster (18T) Pinion Gear: \\ +1991-1999 Sportster (18T) Pinion Gear: \\ Has a ring cut around the circumference of it's rear sleeve, a notch cut out of the rear for the woodruff key (T-key) on the pinion shaft and no splines. \\ The ring around the sleeve may just be to distinguish the 91-99 gear from the 88-90 gear. \\ {{:techtalk:evo:engmech:pinion_gear_1991-1999_pic1_by_c3-cycle-tech.jpg?direct&300|pinion_gear_1991-1999_pic1_by_c3-cycle-tech.jpg}}((photo courtesy of c3cycle.com, Link to site:https://www.c3cycle.com/)) {{:techtalk:evo:engmech:pinion_gear_1991-1999_pic2_by_c3-cycle-tech.jpg?direct&300|pinion_gear_1991-1999_pic2_by_c3-cycle-tech.jpg}}((photo courtesy of c3cycle.com, Link to site:https://www.c3cycle.com/))
-Has a ring cut around the circumference of it's rear sleeve, a notch cut out of the rear for the woodruff key (T-key) on the pinion shaft and no splines. \\ +
-The ring around the sleeve may just be to distinguish the 91-99 gear from the 88-90 gear. \\ +
-{{:techtalk:evo:engmech:pinion_gear_1991-1999_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_1991-1999_pic2_by_c3-cycle-tech.jpg?direct&300|}} ((photo courtesy of c3cycle.com, Link to site:https://www.c3cycle.com/)) \\+
  
-2000-Up Sportster (23T) Pinion Gear: \\ +2000-Up Sportster (23T) Pinion Gear: \\ 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|pinion_gear_2000-up_sportster_pic2_c3-cycle-tech.jpg}}(( 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|pinion_gear_2000-up_sportster_pic1_c3-cycle-tech.jpg}}(( photo courtesy of c3cycle.com, Link to site:https://www.c3cycle.com/))
-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/)) \\+
  
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 ===== Possible 91-up Woodruff Key Failure Notice ===== ===== Possible 91-up Woodruff Key Failure Notice =====
Line 431: Line 379:
 [[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|}}|

Trace: • REF: Engine Mechanicals - Sub-05I • REF: Tools - 106 • REF: Oiling & Lubrication - Sub-01A • EVO: Engine Mechanicals • REF: General-MSR 01