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| techtalk:ref:engmech03t [2021/04/23 03:11] – [Installing a 1986 Primary Cover on a 1985 Sportster] hippysmack | techtalk:ref:engmech03t [2024/01/14 21:44] (current) – hippysmack |
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| [[:techtalk:menu|{{ :techtalk:gototechnicalmenu.jpg|}}]] | [[:techtalk:menu|{{ :techtalk:gototechnicalmenu.jpg|}}]] |
| ====== REF: Engine Mechanicals - Sub-03K ====== | ====== REF: Engine Mechanicals - Sub-03T ====== |
| ====== Installing a 1986 Primary Cover on a 1985 Sportster ====== | ====== Installing a 1986 Primary Cover on a L1984-1985 Sportster ====== |
| This primary cover swap was done by XLForum member, 85IRONDIRT, on a 1985 XLH 1000. ((Link to thread from the XLF http://xlforum.net/forums/showthread.php?t=2078880)) \\ | This primary cover swap was done by XLForum member, 85IRONDIRT, on a 1985 XLH 1000. ((Link to thread from the XLF https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/201772-late-84-85-primary-cover-to-86-90-cover?t=2078880)) \\ |
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| In 1977, Sportsters got new cases to accommodate the left side shifter. \\ | In 1977, Sportsters got new cases to accommodate the left side shifter. \\ |
| The OEM primary cover gasket (34955-75) will fit 1977-1990 Sportsters as per the parts catalogs. \\ | The OEM primary cover gasket (34955-75) will fit 1977-1990 Sportsters as per the parts catalogs. \\ |
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| However the 86-90 primary cover is more shallow than the L84-85 cover. \\ | This mod should work for Late 1984-1985 Ironheads. The 86-90 primary cover is more shallow than the L84-85 cover. \\ |
| But it will bolt up to a L84-85 case and clear everything internally running the L84-85 clutch which uses the spring washer for the pressure plate. \\ | But it will bolt up to a L84-85 case and clear everything internally running the L84-85 clutch which uses the spring washer for the pressure plate. \\ |
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| {{:techtalk:ref:engmech:1986_primary_on_1985_xlh_1000_pic1_by_85irondirt.jpg?direct&400|}} ((photo by 85IRONDIRT of the XLFORUM http://xlforum.net/forums/showthread.php?t=2078880)) {{:techtalk:ref:engmech:1986_primary_on_1985_xlh_1000_pic2_by_85irondirt.jpg?direct&400|}} ((photo by 85IRONDIRT of the XLFORUM http://xlforum.net/forums/showthread.php?t=2078880)) \\ | |
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| **Considerations**: \\ | **Considerations**: \\ |
| * You will have to use all the hardware from an 86-90 model due to the cover not being as deep. | * You will have to use all the hardware from an 86-90 model due to the cover not being as deep. |
| * The lowest front stud will be too long. | * The lowest front stud will be too long with the 86 cover. |
| * The 85 stud for the footpeg sticks out of the cover by about 3 inches. | * The 85 stud for the footpeg sticks out of the 86 cover by about 3 inches and will need to be changed. |
| * The shifter shaft will also be about 3 inches too long so you'll need the 86-90 shifter shaft (34628-86). | * The shifter shaft will also be about 3 inches too long so you'll need the shorter 86-90 shifter shaft. \\ The heel of the new aftermarket shaft had to be ground off some as it was contacting the front of the case causing hard shifting. |
| | * The Ironhead primary chain adjustor looks as if it would have worked but a Hayden Enterprises unit was used instead. |
| * The shorter 86-90 perimeter bolts will have to be used. | * The shorter 86-90 perimeter bolts will have to be used. |
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| **Parts**: | **Parts Acquired**: |
| * Primary Cover (25430-86 or -86A) loaded. | * Primary Cover (25430-86) loaded. |
| * Primary Cover Screws (3481) 1/4" x 20 x 1-1/2" Socket Head Screw (10) | * Primary Cover Screws (3481) 1/4" x 20 x 1-1/2" Socket Head Screw (10) |
| * Primary Cover Gasket (34955-75) | * Primary Cover Gasket (34955-75) |
| * Shifter Shaft (34628-86) | * Shifter Shaft (34628-86) |
| * Left Footrest Stud (24752-86) 1/2" x 4-1/8" | * Left Footrest Stud (24752-86) 1/2" x 4-1/8" |
| | * Clutch Cable, length? OEM are (38619-86 or -86A for 883) and (38621-86 or -86A for 1100) |
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| | Click on any pic below to enlarge: \\ |
| | Here are some measurements on the 86 primary cover mounting holes (in metric) for comparison with a L84-85 cover. \\ |
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| | {{:techtalk:ref:engmech:1986_primary_cover_measurements_pic2_by_iron_mike.jpg?direct&300|}} ((photo by Iron Mike of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/201772-late-84-85-primary-cover-to-86-90-cover/page4?t=2078880&page=4)) {{:techtalk:ref:engmech:1986_primary_cover_measurements_pic1_by_iron_mike.jpg?direct&300|}} ((photo by Iron Mike of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/201772-late-84-85-primary-cover-to-86-90-cover/page4?t=2078880&page=4)) {{:techtalk:ref:engmech:1986_primary_cover_measurements_pic3_by_iron_mike.jpg?direct&300|}} ((photo by Iron Mike of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/201772-late-84-85-primary-cover-to-86-90-cover/page4?t=2078880&page=4)) \\ |
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| | Comparison between the 85 and 86 primary covers. \\ |
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| | {{:techtalk:ref:engmech:1986_primary_on_1985_xlh_1000_pic3_by_85irondirt.jpg?direct&300|}} ((photo by 85IRONDIRT of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/201772-late-84-85-primary-cover-to-86-90-cover/page4?t=2078880&page=4)) {{:techtalk:ref:engmech:1986_primary_on_1985_xlh_1000_pic4_by_85irondirt.jpg?direct&300|}} ((photo by 85IRONDIRT of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/201772-late-84-85-primary-cover-to-86-90-cover/page4?t=2078880&page=4)) {{:techtalk:ref:engmech:1986_primary_on_1985_xlh_1000_pic5_by_85irondirt.jpg?direct&300|}} ((photo by 85IRONDIRT of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/201772-late-84-85-primary-cover-to-86-90-cover/page4?t=2078880&page=4)) \\ |
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| | Here is an aftermarket 86-90 shifter shaft by Eastern as compared to the 85 shifter shaft. Eastern part# 1110-0050 (replaces 86-90 shifter shaft 34628-86). \\ |
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| | {{:techtalk:ref:engmech:1986_primary_on_1985_xlh_1000_pic6_by_85irondirt.jpg?direct&300|}} ((photo by 85IRONDIRT of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/201772-late-84-85-primary-cover-to-86-90-cover/page4?t=2078880&page=4)) {{:techtalk:ref:engmech:1986_primary_on_1985_xlh_1000_pic7_by_85irondirt.jpg?direct&300|}} ((photo by 85IRONDIRT of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/201772-late-84-85-primary-cover-to-86-90-cover/page4?t=2078880&page=4)) {{:techtalk:ref:engmech:1986_primary_on_1985_xlh_1000_pic8_by_85irondirt.jpg?direct&300|}} ((photo by 85IRONDIRT of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/201772-late-84-85-primary-cover-to-86-90-cover/page4?t=2078880&page=4)) \\ |
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| | Here is the 86 cover installed with a few bolts for example before installing the new shifter and peg shafts. Note how far out the 85 shafts are from the cover. \\ |
| | The third pic below with the 86 shifter shaft installed. \\ |
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| | {{:techtalk:ref:engmech:1986_primary_on_1985_xlh_1000_pic10_by_85irondirt.jpg?direct&300|}} ((photo by 85IRONDIRT of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/201772-late-84-85-primary-cover-to-86-90-cover/page4?t=2078880&page=4)) {{:techtalk:ref:engmech:1986_primary_on_1985_xlh_1000_pic11_by_85irondirt.jpg?direct&300|}} ((photo by 85IRONDIRT of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/201772-late-84-85-primary-cover-to-86-90-cover/page4?t=2078880&page=4)) {{:techtalk:ref:engmech:1986_primary_on_1985_xlh_1000_pic9_by_85irondirt.jpg?direct&300|}} ((photo by 85IRONDIRT of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/201772-late-84-85-primary-cover-to-86-90-cover/page4?t=2078880&page=4)) \\ |
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| | Done! A 1986 primary cover on a 1985 Sportster. \\ |
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| | {{:techtalk:ref:engmech:1986_primary_on_1985_xlh_1000_pic1_by_85irondirt.jpg?direct&400|}} ((photo by 85IRONDIRT of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/201772-late-84-85-primary-cover-to-86-90-cover?t=2078880)) {{:techtalk:ref:engmech:1986_primary_on_1985_xlh_1000_pic2_by_85irondirt.jpg?direct&400|}} ((photo by 85IRONDIRT of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/201772-late-84-85-primary-cover-to-86-90-cover?t=2078880)) \\ |
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| | Comments from 85IRONDIRT regarding this cover swap: \\ |
| | <blockquote>If you are not doing a lot of customization, the swap is not worth it. It is a much thinner profile but that is about the only difference. \\ |
| | I wanted a non-chrome cover and that is the only reason I went this route considering the cost of used polished aluminum 1985 covers.</blockquote> \\ |
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