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Ironhead Sportster Motorcycle Talk (1957-1985) For all those that wanna talk about Ironhead Sportster Motorcycles

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  #11  
Old 5th January 2015
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Heres a pic of my 77 cam cover if needed for reference.
-Jay
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  #12  
Old 5th January 2015
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on a `77 that should be the foot brake and if so ,a 72 cover should be able to retrofit
because the shift lever for a 72 and a brake lever use the same hole.
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  #13  
Old 5th January 2015
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If I'm not mistaken the 77 uses a different pinion bushing in the cam case.
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  #14  
Old 5th January 2015
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can someone confirm the pinion bushing part number because it is missing from the parts manual for 57-78. shows up as 25593-74 in the 78-85 manual
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  #15  
Old 6th January 2015
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your right.item's 31 thru 35 are missing. we do know '77 started different pinion shaft,pinion gear,and case bearing.
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  #16  
Old 6th January 2015
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what I would do is plumb the vent to a parker flow safety valve with a cracking pressure of 1psi. you could just use hoses but it would look redneck so I would use stainless tubing. the valve could be hidden just about anywhere but make sure the vapor goes to a safe location. if you need a pic, I will post a link.
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  #17  
Old 6th January 2015
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brucs, sounds fine but if only the bushing size is different one could fit an earlier pinion shaft bushing in a 77 cover and visa versa. Thinking the physical size and casting of the cover remained the same
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  #18  
Old 6th January 2015
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52-56


57-62


63-67


68-70


71-76


77-78


79-80


i dont have a pic for 81-e84

L84-85


---------------------------------------------------------------------------------------------
52-78 have only one breather port at 6:00

79-85 have two. one at 6:00 and one at 10:00
--------------------------------------------------------------------------------------------
52-76 use .625 pinion bushing bore.

77-85 use .562 pinion bushing bore.
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  #19  
Old 6th January 2015
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Quote:
Originally Posted by 72 Ironhead XLH View Post
can someone confirm the pinion bushing part number because it is missing from the parts manual for 57-78. shows up as 25593-74 in the 78-85 manual
In my trusty 54 thru 78 FPM, it shows:
25593-57 BUSHING,gear shaft................ 57 to 76-XL,XLH,XLCH
25593-74 BUSHING,gear shaft................77 to 78-XLH,XLCH
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  #20  
Old 6th January 2015
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