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techtalk:evo:engmech01 [2022/10/07 22:19] – [Cam Cover Gasket] hippysmacktechtalk:evo:engmech01 [2025/07/28 22:51] (current) – [Ignition Sensor Seal (1986-2003)] hippysmack
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 Shifter shaft seal on 2006 1200R primary cover. \\ 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)) \\+{{: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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-transmission-clutch-primary-secondary-drive/29955-06-clutch-install/page7?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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-transmission-clutch-primary-secondary-drive/29955-06-clutch-install/page7?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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-transmission-clutch-primary-secondary-drive/29955-06-clutch-install/page7?t=49915&page=7)) \\
  
 ===== Shifter Shaft Bushing ===== ===== Shifter Shaft Bushing =====
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 ===== Crankshaft Seal ===== ===== 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)) \\+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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-general-discussion-and-problems/187883-where-did-this-spring-come-from?highlight=main+seal#post4033034)) \\
 Before fitting it, pack some grease around the spring in the seal groove. You only need a small amount. \\ 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))  ||| +|  Crankshaft Seal (35151-74A) ((photos by pearlmoto of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-transmission-clutch-primary-secondary-drive/169220-left-crank-seal-replacement-questions?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|}}| |{{: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|}}|
  
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 |1994-1997 Sportster|25263-90A| |1994-1997 Sportster|25263-90A|
 |1998-1999 Sportster|25263-90B| |1998-1999 Sportster|25263-90B|
-|2000-2003 Sportster|25263-90C|+|2000-2003 Sportster|25263-90C|**Note: Do not use a pre-2000 gasket on 2000-2003 cam covers** \\ A 1991-1999 style gasket WILL destroy a 2000-2003 engine! \\ See below.| \\ 
  
 \\ \\
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 That extra hole (in the picture below) is benign and doesn't need a hole in the gasket to match. \\ That extra hole (in the picture below) is benign and doesn't need a hole in the gasket to match. \\
 That hole is purely an artifact of how they connected two passages for routing crankcase oil up to the oil pump's scavenge section. \\ That hole is purely an artifact of how they connected two passages for routing crankcase oil up to the oil pump's scavenge section. \\
-They drill that hole to connect the two passages, and then it gets blocked off naturally by the cam box cover and gasket. ((aswracing of the XLFORUM http://xlforum.net/forums/showthread.php?t=2036109&highlight=oil+pump&page=3)) \\+They drill that hole to connect the two passages, and then it gets blocked off naturally by the cam box cover and gasket. ((aswracing of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-bottom-end/190901-no-oil-pressure-going-to-check-filter-and-pump-what-else/page3?t=2036109&highlight=oil+pump&page=3)) \\
  
 Also, in 2000, the factory changed the oil routing to the lifters to make manufacturing the cases easier. \\ Also, in 2000, the factory changed the oil routing to the lifters to make manufacturing the cases easier. \\
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 If you have an older style gasket, it will not have cutouts for the grooves and you won't get oil to the lifters. \\ If you have an older style gasket, it will not have cutouts for the grooves and you won't get oil to the lifters. \\
  
-|  Rubbermount Evo vs Rigid Evo Cam Cover Internals ((photo by Moved On of the XLFORUM http://xlforum.net/forums/showthread.php?t=87313))  |+|  Rubbermount Evo vs Rigid Evo Cam Cover Internals ((photo by Moved On of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-suspension-frame-forks-handlebars-fuel-tank-oil-tank-fenders/40457-whoa-oil-tank-vomits-oil?t=87313))  |
 |{{:techtalk:evo:oil:rubbermount_vs_rigid_evo_cam_cover_comparison_by_moved_on.jpg?direct&600|}}| |{{:techtalk:evo:oil:rubbermount_vs_rigid_evo_cam_cover_comparison_by_moved_on.jpg?direct&600|}}|
 |  Both have been chopped on the outside but the gearcase perimeter is intact on them for reference.  | |  Both have been chopped on the outside but the gearcase perimeter is intact on them for reference.  |
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 |{{:techtalk:evo:oil:91-99_cam_cover_gasket_2_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:91-99_cam_cover_gasket_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:91-99_cam_cover_gasket_4_by_hippysmack.jpg?direct&300|}}| |{{:techtalk:evo:oil:91-99_cam_cover_gasket_2_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:91-99_cam_cover_gasket_1_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:oil:91-99_cam_cover_gasket_4_by_hippysmack.jpg?direct&300|}}|
  
-|  2000-up cam cover gasket ((photo by Phillober of the XLFORUM http://xlforum.net/forums/showthread.php?t=1122547&page=7))  |2000-up gasket seals off the extra hole. ((sep69 of the XLFORUM http://xlforum.net/forums/showthread.php?t=2036109&highlight=oil+pump&page=3))|+|  2000-up cam cover gasket ((photo by Phillober of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-engine-conversions/116696-phillober-s-1250-conversion-thread-pic-heavy/page7?t=1122547&page=7))  |2000-up gasket seals off the extra hole. ((sep69 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-bottom-end/190901-no-oil-pressure-going-to-check-filter-and-pump-what-else/page3?t=2036109&highlight=oil+pump&page=3))|
 |{{:techtalk:evo:oil:2000_up_cam_cover_gasket_by_phillober.jpg?direct&300|}}|{{:techtalk:evo:oil:cam_cover_gasket_on_03_model_by_sep69.jpg?direct&300|}}| |{{:techtalk:evo:oil:2000_up_cam_cover_gasket_by_phillober.jpg?direct&300|}}|{{:techtalk:evo:oil:cam_cover_gasket_on_03_model_by_sep69.jpg?direct&300|}}|
 \\ \\
  
-===== #2 Cam - Cover Seal (86-03) ===== +==== DON'T INSTALL a 91-99 CAM COVER GASKET ON A 2000-UP MOTOR!!!!!!! ==== 
-Seal number (11124): \\ +The 91-99 cam cover gasket has no business being on a 2000+ motor at all. It will cause you to lose all oil pressure. ((aswracing of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-engine-conversions/201980-hammer-1275-clang-noise-slow-oil-feed-kinked-crankcase-vent/page14?t=2079110&highlight=oil+tank&page=14)) \\ 
-This surrounds and seals #2 cam when the cover is installed. \\ +The 2000+ gasket supersedes the 91-99 gasket. In other words, it can be used all the way back to 1991. \\ 
-See also [[techtalk:evo:engmech01f#cam_cover_seal_86-03|Removal / Installation of the #2 cam cover seal]] in the Sportsterpedia. \\+Most companies completely dropped the 91-99 specific gasket and only offer the one that can be used from 1991-present. \\ 
 +Either James Gasket hasn't done that, or they may have some old stock. \\
  
-|  This side faces out. ((photo by Hippysmack))  |  This side faces #2 cam shaft. ((photo by Hippysmack))  | +The 1991-1999 lifter feed galley is an internal rifling hole in the case. It's drilled thru the case and only open to the cam cover via the center port to the pinion bushing. \\ 
-|{{: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|}}|+The 2000-up lifter feed galley is external and it takes both the cover and the case mounted together to make up the feed galley. \\ 
 +So 2000-up feed galley is split in half between the case and cover. The slots in the 2000-up cam cover gasket mate to both the case and the cover. \\ 
 +If you have the correct gasket on there, oil would be forced (between the cover and case) to all the lifter feed holes and piston squirters. \\ 
 +With the wrong gasket (1991-1999), oil pressure leaving the filter gets into that (now open) galley. \\ 
 +Then the oil will blow into into the cam chest, therefore bypassing the lifters, piston squirters and rod bearings. \\ 
 +The oil will simply cycle from the oil pump to cam chest to oil pump and back to the oil tank. \\ 
 +The oil light will stay off so you'll get no notice before moving the parts start oil starving and making noises and worse if the noises aren't heeded to quickly. \\
  
-===== Removing / installing the pinion shaft nut =====+|  2000-up motor with 1991-1999 cam cover gasket. ((photo by BestCoastXL of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-engine-conversions/201980-hammer-1275-clang-noise-slow-oil-feed-kinked-crankcase-vent/page12?t=2079110&highlight=oil+tank&page=12))  |  Below is a rough cross section of the joint in the \\ feed galley at that first slotted run. ((drawing by Hippysmack))  | 
 +|{{:techtalk:evo:oil:2000-up_sportster_with_wrong_91-99_cam_cover_gasket_by_bestcoastxl.jpg?direct&300|}}|{{:techtalk:evo:oil:2000-up_sportster_with_wrong_91-99_cam_cover_gasket_by_hippysmack.png?direct&300|}}|
  
 +===== Ignition Sensor Seal (1986-2003) =====
 +This is a steel shell radial shaft seal (HD# 11124) installed in the cam cover. \\
 +It surrounds and seals #2 cam when the cover is installed. Also used on 1971-1985 Sportster cam covers. \\
 +Dims per XLForum member, Fizzle: \\
 +OD 1.570" (39.878mm), ID 1.050" (26.67mm), W 0.248" (6.2992mm) \\
 +
 +Other brands include James (JGI-11124), Cometic (C9355), Athena (51-A210), Custom Chrome (54-043). \\
 +The rubber shell HD Genuine double lip version is part number (11124-DL). \\
 +Other brands include James (JGI-11124-DL). \\
 +**NOTE**: __SKF makes a radial shaft seal with a part number of 11124 but that IS NOT AN HD PART NUMBER__. \\
 +SKF 11124 IS TOO BIG TO FIT THE COVER and they don't show a compatible seal in their catalog for this application. \\
 +
 +HD Seal (11124): \\
 +
 +{{:techtalk:ih:engmech:1971-2003_nosecone_ignition_seal_11124_by_hippysmack.jpg?direct&400|}} ((photo by Hippysmack))
 +
 +===== 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. \\ 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. \\ 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. \\
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 The crank pin is not designed to resist much twisting force. \\ 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)) \\ 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))+So this is one of those situations where it's best to use the proper tool. ((aswracing of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-bottom-end/187492-bronze-oil-pump-drive-gear?t=2002257&highlight=pinion+locking+tool))
 The pinion nut takes a 15/16" wrench size. \\ The pinion nut takes a 15/16" wrench size. \\
  
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 **2000 Flywheels**: \\ **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)) \\+There are no timing marks on the wheels for any of the rubber mounts. ((aswracing of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-bottom-end/175705-playtime-at-the-hammer-factory/page2?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. \\ 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. \\ 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. \\
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 The OEM Flywheel assembly (23905-00) was factory installed in all Sportsters 2000-2003. \\ 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. \\ 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)) \\+However, the rods in the 2000-2002 assemblies are reportedly thicker than the 2003 assembly. ((Randy_rots of the XLFORUM https://www.xlforum.net/forum/forum-functions/sportsterpedia-com-admin/181086-sportsterpedia-progress/page34?t=1949239&page=34)) \\
  
 The entire assembly was sold as a unit with no published part numbers for it's individual parts. \\ The entire assembly was sold as a unit with no published part numbers for it's individual parts. \\
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 Retaining ring (11177A) 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))  |+|  Flywheel assembly 23905-00 ((photo by AussieGazza of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-engine-conversions/87710-aussiegazzas-rebuild/page7?t=692835&page=7))  |  Flywheel assembly 23905-00A ((photo by Wilbur of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-bottom-end/85637-flywheel-crank-23905-00a?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|}}| |{{: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 ===== ===== 2003 Flywheel Assembly =====
 The original OEM Flywheel assembly (23905-00) was factory installed in all Sportsters 2000-2003. \\ 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)) \\+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 https://www.xlforum.net/forum/forum-functions/sportsterpedia-com-admin/181086-sportsterpedia-progress/page34?t=1949239&page=34)) \\
 So the original 2003 flywheel version appears to be a one year only version. \\ So the original 2003 flywheel version appears to be a one year only version. \\
  
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 Retaining ring (11177A) Retaining ring (11177A)
  
-|  Flywheel assembly 23905-00  ((photos by Randy_rots of the XLFORUM http://xlforum.net/forums/showthread.php?p=5905554#post5905554))  ||+|  Flywheel assembly 23905-00  ((photos by Randy_rots of the XLFORUM https://www.xlforum.net/forum/forum-functions/sportsterpedia-com-admin/181086-sportsterpedia-progress/page23#post4514436))  ||
 |{{: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|}}| |{{: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))  |||+|  Flywheel assembly 23905-00  ((photos by Randy_rots of the XLFORUM https://www.xlforum.net/forum/forum-functions/sportsterpedia-com-admin/181086-sportsterpedia-progress/page23#post4514436))  |||
 |{{: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|}}| |{{: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|}}|
  
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   * 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**.   * 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.+  * Oil leaving the rod bearings lands into the crankcase to be scavenged by the oil pump (or splashed into the gearcase). \\ Crankcase pressure and oil pump suction moves the oil from this point.
  
 |   (used) L81-03 'one hole' crank pin. ((photo by Hippysmack))  ||| |   (used) L81-03 'one hole' crank pin. ((photo by Hippysmack))  |||
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 **1976 and previous year Sportsters** use a one piece dual Timken bearing race on the left (sprocket shaft) side of motor. \\ **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. \\ 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)) \\+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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/110883-sprocket-shaft-bearing-questions/page3?t=1041723&page=3)) \\
  
 **1977-E1986 Sportsters** use two separate Timken bearing races on the left side. \\ **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. \\ 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)) \\+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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/110883-sprocket-shaft-bearing-questions/page3?t=1041723&page=3)) \\
  
 **L1986-2003 Sportsters** still use the two piece Timken bearing races on the left case. \\ **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. \\ 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) \\ (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)) \\+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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/110883-sprocket-shaft-bearing-questions/page3?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. \\ 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. \\ 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. \\ 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)) \\+(positioned as one inside and one outside of the left case (inner and outer case positions). ((aswracing of the XLFORUM https://www.xlforum.net/forum/buell-motorcycle-forum/buell-motorcycle-bottom-end/144359-need-help-with-crankshaft-install/page3?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)) \\ +Proper assembly of the lower end requires special tools to remove / install the bearing races into the case halves. ((aswracing of the XLFORUM https://www.xlforum.net/forum/buell-motorcycle-forum/buell-motorcycle-bottom-end/144359-need-help-with-crankshaft-install/page3?t=1565018&page=3)) \\ 
 Plus you need a puller that can get the inner bearing off to replace it. \\  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. \\ 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. \\
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 The tool puts it in square and sets the depth correctly. \\ 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)) \\+**Left Side Bearing Assembly**:  ((aswracing of the XLFORUM https://www.xlforum.net/forum/buell-motorcycle-forum/buell-motorcycle-bottom-end/144359-need-help-with-crankshaft-install/page2?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. \\   * 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 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".
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   * 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.   * 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)) \\+**Right Side Bearing Assembly**: ((aswracing of the XLFORUM https://www.xlforum.net/forum/buell-motorcycle-forum/buell-motorcycle-bottom-end/144359-need-help-with-crankshaft-install/page2?t=1565018&page=2)) \\
 The pinion shaft just slides into the right case. Oil everything up first though. \\ The pinion shaft just slides into the right case. Oil everything up first though. \\
   * The pinion bearing is available in four different sizes.   * The pinion bearing is available in four different sizes.
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 ==== 90 and Prior Models (4 Speed) ==== ==== 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|}}| |{{: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))  ^+^Homemade Pinion Gear / Removal / Installation Tools ((photo by bustert of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/63858-special-tools/page5?t=395586&page=5))  ^  Homemade pinion gear press ((photo by piniongear of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/63858-special-tools/page12?t=395586&page=12))  ^  Pinion Gear Puller ((photo by 75bike of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/63858-special-tools/page13?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|}}| |{{: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||| |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))  |||+|  Homemade Pinion Gear Puller ((photo by sevenyears of famine of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/175975-one-bolt-at-a-time-the-1960-engine-reassembly-thread/page10?t=1888378&highlight=pinion+gear+tool&page=10))  |||
  
 |{{:techtalk:ref:tools:pinion_lock_tool_by_big_al.jpg?direct&300|}}| |{{: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| |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))  |+|  Homemade pinion gear locking tool for '89 models ((photo by Big Al 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/181287-made-a-pinion-gear-locking-tool-for-my-89-xlh1200#post5322902))  |
  
 ==== 1991-Up Models (5 Speed) ==== ==== 1991-Up Models (5 Speed) ====
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   * The Grindlock Pinion Shaft Locking Tool engages for the full depth of the pinion gear for max. strength.   * 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)) \\+{{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 https://www.xlforum.net/forum/vendors/hammer-performance/149240-pinion-gear-locking-tools-now-available-from-hammer-performance/page4?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)) \\+  * 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 https://www.xlforum.net/forum/vendors/hammer-performance/149240-pinion-gear-locking-tools-now-available-from-hammer-performance?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))+{{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 https://www.xlforum.net/forum/vendors/hammer-performance/149240-pinion-gear-locking-tools-now-available-from-hammer-performance/page4?t=1618841&page=4)) ((photo by aswracing of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-general-discussion-and-problems/178765-oil-pump-drive-gear-question?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. \\   * 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.+  * 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 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-bottom-end/155417-pinion-gear?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. \\    * 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)) \\  +{{:techtalk:evo:engmech:removing_the_pinion_gear_by_grind.jpg?direct&300|}} ((photo by ~Grind~' of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-engine-conversions/134422-~grinds~-hammer-performance-1250-build?t=1448694)) {{:techtalk:evo:engmech:pinion_key_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)) {{:techtalk:evo:engmech:oil_pump-pinion_gear_keyways_by_npaisnel.jpg?direct&350|}} ((photo by npaisnel of the XLFORUM, labeled by Hippysmack  https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-engine-conversions/200486-crank-failure-and-killed-my-1275-hammer-build/page26?t=2077485&page=26)) \\ 
- +
  
 ====== Parts Lists ====== ====== Parts Lists ======
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 |Year \\ Model|Part \\ Number|Casting \\ Number|Notes| |Year \\ Model|Part \\ Number|Casting \\ Number|Notes|
 |1986-1990 Sportster|34911-81A ((1986-1990 HD Sportster Parts Catalogs))|  |Polished| |1986-1990 Sportster|34911-81A ((1986-1990 HD Sportster Parts Catalogs))|  |Polished|
-|1991-1994 Sportster|34911-91|  |  | +|1991-1994 Sportster|34911-91|34913-91|Polished| 
-|1995-2003 Sportster \\ (except XL883C) \\ (except XL1200C) \\ (except XL1200S)|34911-91A|  |Polished| +|1995-2003 Sportster \\ (except XL883C) \\ (except XL1200C) \\ (except XL1200S)|34911-91A|34907-95|Polished| 
-|1996-2003 XL1200C|34932-96|  |Chrome| +|1996-2003 XL1200C|34932-96|34910-95|Chrome| 
-|1998-2003 XL1200S/XL883C|34938-98|  |Silver| +|1998-2003 XL1200S/XL883C|34938-98|34910-95|Silver| 
-|2002-2003 XL883R|34943-02|  |Black|+|2002-2003 XL883R|34943-02|34910-95|Black|
  
 \\ \\
  
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