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techtalk:evo:oil03 [2024/05/07 00:42] – hippysmacktechtalk:evo:oil03 [2025/10/10 00:27] (current) – hippysmack
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 ===== Sub-Documents ===== ===== Sub-Documents =====
- 
   * **86-90 Sportster Oil Pump**:   * **86-90 Sportster Oil Pump**:
     * [[techtalk:evo:oil03h|86-90 Oil Pump (26204-86) Removal and Disassembly]]     * [[techtalk:evo:oil03h|86-90 Oil Pump (26204-86) Removal and Disassembly]]
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   * **Oil Pump Conversion**:   * **Oil Pump Conversion**:
     * [[techtalk:evo:oil03c|5 Speed Oil Pump on 4 Speed Models (Conversion for 86-90 Evo engines)]]     * [[techtalk:evo:oil03c|5 Speed Oil Pump on 4 Speed Models (Conversion for 86-90 Evo engines)]]
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 Note: Be sure to check the [[techtalk:menu#reference_technical_categories|REFERENCE section]] for additional information related to Oiling, Lubrication and Mods. Note: Be sure to check the [[techtalk:menu#reference_technical_categories|REFERENCE section]] for additional information related to Oiling, Lubrication and Mods.
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 |  86-90 Oil Pump Oiling Paths. ((photo by Hippysmack))  |  91-97 Oil Pump Oiling Paths  ((photo by Hippysmack))  |  98 and Up Oil Pump Oiling Paths ((photo by bsaman of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/rubber-mount-sportster-motorcycle-talk-2004-2006/87615-crank-replacement-documentation/page2?t=691283&page=2))  | |  86-90 Oil Pump Oiling Paths. ((photo by Hippysmack))  |  91-97 Oil Pump Oiling Paths  ((photo by Hippysmack))  |  98 and Up Oil Pump Oiling Paths ((photo by bsaman of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/rubber-mount-sportster-motorcycle-talk-2004-2006/87615-crank-replacement-documentation/page2?t=691283&page=2))  |
 |{{:techtalk:evo:oil:86-90_oil_pump_oiling_paths_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:91-97_oil_pump_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:98-up_oil_pump_oiling_paths_by_bsaman.jpg?direct&300|}}| |{{:techtalk:evo:oil:86-90_oil_pump_oiling_paths_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:91-97_oil_pump_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:98-up_oil_pump_oiling_paths_by_bsaman.jpg?direct&300|}}|
 +
 +====== Oil Pump - Complete Unit Part Numbers ======
 +**1986-1990 Models - XL P/N = 26204-86**\\
 +- pump body catalog p/n 26484-86\\
 +- pump body casting p/n 26485-\\
 +... casting p/n is in return cavity\\
 +... also has a "2" stamped next to casting #\\
 +... also has a "T" stamped into opposite return cavity\\
 +- bottom cover catalog p/n 26486-86\\
 +- bottom cover casting p/n 26487-86\\
 +
 +**1991-1996 Models - XL P/N = 26204-91**\\
 +- pump body casting p/n in 26485-90 \\ 
 +... casting p/n is in the return cavity\\
 +... also has casting #s 1 and 380 in opposite return cavity\\
 +- pump cover casting p/n 26487-90\\
 +... casting p/n is on the outside of the cover\\
 +
 +**1997 Models - XL P/N = 26204-91**\\
 +- pump body casting p/n in 26485-90A \\
 +... casting p/n is in the return cavity\\
 +- pump cover casting p/n 26487-90A\\
 +... casting p/n is on the outside of the cover\\
 +
 +**1998-1999 Models - XL P/N = 26204-98**\\
 +- From the internal P/N changes it appears that this new\\
 +... P/N was generated because of a change in the\\
 +... Gear Shaft and Gerotor Return set of gears\\
 +- has body casting P/N 26487-98 in the return cavity\\
 +- has bottom cover casting P/N 26487-98 on the outside\\
 +
 +**2000-2006 Models - XL P/N = 26204-91A**\\
 +- P/N change appears to be related to fitting changes \\
 +… feed inlet and outlet have -A suffix but no change in fitting size \\
 +- has bottom cover casting P/N 26487-98\\
 +
 +**2007-later Models - XL P/N = 26204-91A (new design)**\\
 +- **is a different design w/same P/N** (How crazy is that?)\\
 +- is retrofitable to 1991-2006\\
 +- has body casting P/N 26211-07 in the return cavity\\
 +- has bottom cover casting P/N 26213-07 on the outside\\
 +
 +**Buell P/N - 26357-02B**\\
 +- same pump as XL 26204-91A (new design) but with different fittings\\
 +- will bolt up but you need to change the fittings over to XL style\\
 +- has bottom cover casting P/N 26213-07\\
 +
 +**Buell P/N - 26357-02**\\
 +- Same pump as 1998-1999 XL 26204-98 but with different fittings \\
 +… same gerotors, same cover casting number \\
 +
 +See these XLForum threads:\\
 +https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-bottom-end/43858-evo-sportster-engine-oil-pump-up-date?t=135265\\
 +https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/rubber-mount-sportster-motorcycle-talk-2004-2006/161897-which-oil-pump-buell-26357-02b-or-xl-2007-26204-91a?t=1738158
  
 ====== Oil Pump Function ====== ====== Oil Pump Function ======
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 Minimum: 7-12 psi (idle) \\ Minimum: 7-12 psi (idle) \\
 Normal riding conditions: 12-17 psi (2500 rpm) \\ Normal riding conditions: 12-17 psi (2500 rpm) \\
- 
  
 1986-1991 models have a high pressure regulator built into the feed path to dump excess pressure to the bottom of the cam chest. \\ 1986-1991 models have a high pressure regulator built into the feed path to dump excess pressure to the bottom of the cam chest. \\
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 So 1992-up models have a constant pressure release in a way. \\ So 1992-up models have a constant pressure release in a way. \\
 [[techtalk:evo:oil01#oil_pressure_regulator_-_92_and_up_models|Click Here]] to read more on in the Sportsterpedia. \\ [[techtalk:evo:oil01#oil_pressure_regulator_-_92_and_up_models|Click Here]] to read more on in the Sportsterpedia. \\
- 
    
 ===== Gauge mounted at oil filter pad ===== ===== Gauge mounted at oil filter pad =====
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 This is why pressure is always highest on cold startup and pressure falls as the oil heats up. \\ This is why pressure is always highest on cold startup and pressure falls as the oil heats up. \\
 Colder oil is thicker and more resistant to flow. Hotter oil is thinner less resistant to flow. \\ Colder oil is thicker and more resistant to flow. Hotter oil is thinner less resistant to flow. \\
- 
  
 ====== Priming the Oil Pump ====== ====== Priming the Oil Pump ======
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     * Another way to prime the pump is to use assembly lube on the gerotors and inside of the pump before installing it. ((aswracing of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-bottom-end/163867-cam-cover-removal#post3491821)) \\ Then you have an instant hydraulic seal to help the oil pump suck oil from the hose.     * Another way to prime the pump is to use assembly lube on the gerotors and inside of the pump before installing it. ((aswracing of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-bottom-end/163867-cam-cover-removal#post3491821)) \\ Then you have an instant hydraulic seal to help the oil pump suck oil from the hose.
     * You can also using a large syringe with a tapered tip inserted into the oil supply hose on the bottom of the oil tank. ((ericfreeman of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/196980-vapor-lock-on-77-and-later-oil-pumps#post4303198)) \\ Then you can force feed oil to the pump and on to the engine using this technique. \\     * You can also using a large syringe with a tapered tip inserted into the oil supply hose on the bottom of the oil tank. ((ericfreeman of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/196980-vapor-lock-on-77-and-later-oil-pumps#post4303198)) \\ Then you can force feed oil to the pump and on to the engine using this technique. \\
- 
-====== Oil Pump - Complete Unit Part Numbers ====== 
- 
-**1986-1990 Models - XL P/N = 26204-86**\\ 
-- pump body catalog p/n 26484-86\\ 
-- pump body casting p/n 26485-\\ 
-... casting p/n is in return cavity\\ 
-... also has a "2" stamped next to casting #\\ 
-... also has a "T" stamped into opposite return cavity\\ 
-- bottom cover catalog p/n 26486-86\\ 
-- bottom cover casting p/n 26487-86\\ 
- 
-**1991-1996 Models - XL P/N = 26204-91**\\ 
-- pump body casting p/n in 26485-90 \\  
-... casting p/n is in the return cavity\\ 
-... also has casting #s 1 and 380 in opposite return cavity\\ 
-- pump cover casting p/n 26487-90\\ 
-... casting p/n is on the outside of the cover\\ 
- 
-**1997 Models - XL P/N = 26204-91**\\ 
-- pump body casting p/n in 26485-90A \\ 
-... casting p/n is in the return cavity\\ 
-- pump cover casting p/n 26487-90A\\ 
-... casting p/n is on the outside of the cover\\ 
- 
-**1998-1999 Models - XL P/N = 26204-98**\\ 
-- From the internal P/N changes it appears that this new\\ 
-... P/N was generated because of a change in the\\ 
-... Gear Shaft and Gerotor Return set of gears\\ 
-- has body casting P/N 26487-98 in the return cavity\\ 
-- has bottom cover casting P/N 26487-98 on the outside\\ 
- 
-**2000-2006 Models - XL P/N = 26204-91A**\\ 
-- P/N change appears to be related to fitting changes \\ 
-… feed inlet and outlet have -A suffix but no change in fitting size \\ 
-- has bottom cover casting P/N 26487-98\\ 
- 
-**2007-later Models - XL P/N = 26204-91A (new design)**\\ 
-- **is a different design w/same P/N** (How crazy is that?)\\ 
-- is retrofitable to 1991-2006\\ 
-- has body casting P/N 26211-07 in the return cavity\\ 
-- has bottom cover casting P/N 26213-07 on the outside\\ 
- 
-**Buell P/N - 26357-02B**\\ 
-- same pump as XL 26204-91A (new design) but with different fittings\\ 
-- will bolt up but you need to change the fittings over to XL style\\ 
-- has bottom cover casting P/N 26213-07\\ 
- 
-**Buell P/N - 26357-02**\\ 
-- Same pump as 1998-1999 XL 26204-98 but with different fittings \\ 
-… same gerotors, same cover casting number \\ 
- 
-See these XLForum threads:\\ 
-https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-bottom-end/43858-evo-sportster-engine-oil-pump-up-date?t=135265\\ 
-https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/rubber-mount-sportster-motorcycle-talk-2004-2006/161897-which-oil-pump-buell-26357-02b-or-xl-2007-26204-91a?t=1738158 
  
 ====== Oil Pump Gaskets / Seals ====== ====== Oil Pump Gaskets / Seals ======
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 ====== Oil Pump Date Code ====== ====== Oil Pump Date Code ======
 ===== 91 and Up Oil Pumps ===== ===== 91 and Up Oil Pumps =====
- 
 The casting date code is in a circle on the mounting surface near the return fitting. \\ The casting date code is in a circle on the mounting surface near the return fitting. \\
 A 'year of manufacture' number is stamped inside the circle with 12 hash marks around the circle. \\ A 'year of manufacture' number is stamped inside the circle with 12 hash marks around the circle. \\

Trace: • REF: General-MSR 11 • EVO: Oiling & Lubrication - Sub-04K • IH: Wheels, Brakes & Tires - Sub-01A • REF: Oiling & Lubrication • W E L C O M E !