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  #1  
Old 26th April 2018
x1_guy x1_guy is offline
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Sportster/Buell Model: Buell X1 Lightning
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Default Crankcase Interchangeability

I have a 2001 Buell X1 (1203)and need a replacement crankcase. Can I use a Sportster Evo 1200XL case or are there differences in the oil porting and other areas? If so, what year(s)? Thanks in advance for any help with this!
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  #2  
Old 26th April 2018
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Yes, 2000-2003 cases will work. The XL version has some steel inserts shoved into the rear motor mount bolt holes that have to be removed, but they're not hard to get out. Also you may have to remove a plug at the front heim link, the one near the oil filter, so that you can put the bolt in there.

91-99 cases will work as well but you'll need new lifters, as well as a little machine work on the right case half to accommodate the 2001 crank. Also the 00-03 cases have a superior tappet anti-rotation pin design, but it's not hard to upgrade the 91-99 cases to the same setup.

91-97 cases also have a drain from the cam box to the crankcase that's blocked on the 98+ cases. Starting in 1998, they put an inlet in the neck of the oil pump to scavenge the cam box, and they plugged the drain. It's one of several things they've done over the years to fight wet sumping issues that have plagued these bikes for forever (and still do). Plugging that drain is optional but it does mean that much more oil you have to pull out of the crankcase.

Generally it would just be best to get 00-03 cases. They have the most refinements for that generation of bikes.
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  #3  
Old 27th April 2018
x1_guy x1_guy is offline
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Hey aswracing,

Thank you for the reply. I appreciate the info and will begin my search for one of the newer generation cases as they have the benefit of the refinements you mention.
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