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| techtalk:evo:engmech02 [2025/05/27 20:09] – [Pinion Gear] hippysmack | techtalk:evo:engmech02 [2025/10/01 06:32] (current) – [Comparing OEM and Andrews Cam Grinds] hippysmack | ||
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| ====== 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: |
| - | #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\\ | ||
| - | ====== Camshafts ====== | + | 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 | ||
| 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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| ==== 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:// | ||
| + | |||
| + | 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' | ||
| + | |||
| These figures are from the Sportster Evolution Cams PDF from Andrews Products. ((Page25 - http:// | These figures are from the Sportster Evolution Cams PDF from Andrews Products. ((Page25 - http:// | ||
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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 https:// | ||
| - | They' | ||
| - | |||
| - | * **Measure at the rocker box how much the lifter will get preloaded at the rocker box**. ((http:// | ||
| - | * 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. \\ | ||
| - | {{: | ||
| ===== Oil feed to lifters ===== | ===== Oil feed to lifters ===== | ||
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| |{{: | |{{: | ||
| - | ====== 1986-1990 | + | ====== 1986-1990 |
| + | 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)) \\ | ||
| They were the same as those used in 1340cc engines beginning in the 1986 model year. The change was to allow for one component to service the entire product line. \\ | They were the same as those used in 1340cc engines beginning in the 1986 model year. The change was to allow for one component to service the entire product line. \\ | ||
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| {{: | {{: | ||
| - | ====== | + | ====== |
| + | 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. \\ | ||
| + | |||
| + | ===== 1991-1999 Lifters | ||
| 1991-1999 engines have AMC-Mopar style lifters (.903" diameter). (("A 4 liter V8 eater" of the XLFORUM https:// | 1991-1999 engines have AMC-Mopar style lifters (.903" diameter). (("A 4 liter V8 eater" of the XLFORUM https:// | ||
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| |{{: | |{{: | ||
| - | ===== 91-99 Anti-Rotation Pins ===== | + | ==== 1991-1999 Anti-Rotation Pins ==== |
| **Parts**: \\ | **Parts**: \\ | ||
| 4 - screws (884) \\ | 4 - screws (884) \\ | ||
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| |{{: | |{{: | ||
| - | ====== 2000 and Up Lifters | + | ===== 2000 and Up Lifters ===== |
| 2000 and up have GM/twin cam style lifters (.842" diameter). ((aswracing of the XLFORUM https:// | 2000 and up have GM/twin cam style lifters (.842" diameter). ((aswracing of the XLFORUM https:// | ||
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| |{{: | |{{: | ||
| - | ===== 00-05 Lifter Ant-Rotation Screws | + | ==== 2000-2005 Lifter Ant-Rotation Screws ==== |
| **Parts**: \\ | **Parts**: \\ | ||
| 4 - anti-rotation screws (18532) \\ | 4 - anti-rotation screws (18532) \\ | ||
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| |{{: | |{{: | ||
| - | ===== 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) \\ | ||
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| * __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 [[: | * __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 [[: | ||
| * **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, | * **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, | ||
| - | **Compatibility** | + | **Compatibility** |
| **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. \\ ^{{: | **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. \\ ^{{: | ||
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| |24061-91| | |24061-91| | ||
| - | 1986-1987 Sportster (18T) Pinion Gear: \\ Has internal splines. \\ {{: | + | 1986-1987 Sportster (18T) Pinion Gear: \\ Has internal splines. \\ {{: |
| - | 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. \\ {{: | + | 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. \\ {{: |
| - | 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. \\ {{: | + | 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. \\ {{: |
| - | 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. \\ {{: | + | 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. \\ {{: |
