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| techtalk:evo:engmech02 [2025/05/27 20:16] – [Pinion Gear] hippysmack | techtalk:evo:engmech02 [2025/09/16 17:59] (current) – [1991-Up Lifters] 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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| |{{: | |{{: | ||
| - | ====== 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. \\ {{: |
