REF: Engine Mechanicals - Sub-03T

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====== REF: Engine Mechanicals - Sub-03K ======
====== Installing a 1986 Primary Cover on a 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)) \\

In 1977, Sportsters got new cases to accommodate the left side shifter. \\
And through all the engine changes including case changes and the swap to the Evo cases in 86, the primary cover mounting holes on the cases stayed the same. \\
The OEM primary cover gasket (34955-75) will fit 1977-1990 Sportsters as per the parts catalogs. \\

However 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. \\

{{: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)) \\

**Considerations**: \\
  * 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 with the 86 cover.
  * 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 shorter 86-90 shifter shaft. \\ The 86 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.

**Parts**:
  * Primary Cover (25430-86 or -86A) loaded. 
  * Primary Cover Screws (3481) 1/4" x 20 x 1-1/2" Socket Head Screw (10)
  * Primary Cover Gasket (34955-75)
  * Shifter Shaft (34628-86)
  * 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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