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  #1  
Old 22nd October 2019
farmall farmall is offline
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Default Are 2003-prior cams and cover a bolt-on swap?

Per http://partsfinder.onlinemicrofiche....20GEAR%20COVER

cover gasket and cam bushing numbers it would appear so.

I came upon a carb conversion thread on CC where the owner likely has a bad ignition module and if the swap is sufficiently easy he could ditch the expensive module, fab a basic wiring harness and simplify the rest of his now-carbed, chopped Sporty to early specs. I'm interested in case I acquire a rubbermount since takeoff parts are cheap and the work is easy.
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  #2  
Old 23rd October 2019
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Sportster/Buell Model: Xl1250S
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Other Motorcycle Model: Kawasaki Vulcan 500
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Default

91-99 had the same cover.
2000-up cover has different oil feed galley machining.
http://sportsterpedia.com/doku.php/techtalk:evoil02?s[]=cam&s[]=cover&s[]=gasket#cam_cover_gasket

91-up cam bushings should be the same though.

86-90 cams are offset.
91-up cams are not.

The #2 “W” cam may or may not have a provision for a timing cup after 03.
If you intend on installing 04-up “W” cams in 03 and prior engines, look at the end of the #2 cam.
If it does have a provision for a timing cup, they'll work for prior year applications.
But, you'll have to either update your pinion gear, or use a press to swap your #2 cam's drive gear.
For 03 and prior year engines, it needs a drilled and tapped hole in the middle of it and the timing cup notch.
http://sportsterpedia.com/doku.php/t...m_gear_changes
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Reference the XLFORUM'S Sportsterpedia for additional technical information & advice

In Search of Fuel, Sunshine and a Steady Idle.
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  #3  
Old 23rd October 2019
farmall farmall is offline
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Default

Very cool Sportsterpedia reference! Thanks.
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Old 23rd October 2019
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Default

What year is the bike in question?
Some cams are of different grind but are fit interchangeable:
http://www.sportsterpedia.com/doku.p...:evo:engmech02
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Old 23rd October 2019
farmall farmall is offline
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Default

2010 but it turns out he already converted to a Thunderheart (not mentioned in his first post) so no point in a cam/cover swap for him when the TH is cheaper than a new HD module.

His front cylinder isn't firing so he's troubleshooting what he can while awaiting new intake seals. He'd swapped those but a backfire shot flame past one of them so he's installing a fresh set. Problem predated that set of seals. He doesn't have a spare coil so I suggested swapping coil trigger and plug wires to see if the problem moves since it's single fire. He reports both plugs spark out of the engine but that may not be enough under load. Problem was intermittent before a steady failure. He's going back over his electrical connections for obvious reasons.

He also just reported rapid battery fade so charging may be in play. Yay.....
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