My Sportster basket case has arrived!

[VH5150]

Originally Posted by darkdesign

nice start, good to see someone from oz on here. You seem to know your way around the engine pretty well, i look forward to seeing the build progress. Cheers tony

Thanks for the welcome Tony, not sure if I know my way round yet, I have just broken enough "other" gear to learn about going slowly on something new.
The Evo XL motor is a huge leap forward for me, my last HD resto back in '96 was a rigid 74" 1938 U model.
I test rode a new Buell M2 cyclone back in '98 at the local HD dealer which left an impression.
Even though this basket is a bit of a challenge, couldn't resist building up a bike fitted with the 1200 Evolution motor.
Really glad to be building another Sportster.
Cheers, Dave.

[VH5150]

Howdy again,
Did some more dis-assembly today of my '99 based Evo motor.
Removed the primary cover to find a new primary drive chain fitted. (as described before I bought the basket case)

The primary cover fitted to the motor is not the original, was told it is not very old.
v

HD part number of the newer primary cover:


The older original primary cover which came in all the parts had this mechanism screwed on the inside.

Inside view of the original primary cover where the ball bearing cam actuator screws on at 3 points:


The newer primary cover (pn34951-95) is in much better condition than the original and is the one I would like to fit.
So..... can anyone tell me what parts I will need to get the primary cover without the 3 screw holes inside to actuate the clutch?
Also, why are these different anyway?
Help please, really confused Dave.

[VH5150]

Progress this week on my build:
1200 engine stripped right down now to bare cases, ended up having to use 3/4" drive pneumatic impact driver to get the clutch basket left hand threaded nut off the main shaft and the primary drive sprocket nut off. The factory thread sealant had held both nuts on very tight. 5 speed gear box is in great condition, so are the flywheels including the rods and big end bearing.
Frame now stretched 1" in bottom rails, Ironhead rear mount bolt pattern is same as Evo, just need to make two flat block spacers to clear the '77 swing arm pivots. Looks as though the stock Ironhead front engine mounts will work now the bottom rails are 1" longer which saves me having to custom make front plates. Getting new 3/8" UNF bolts tomorrow for front mounts, then I can secure the rear mount in place so I can get the new top bar bent and tig welded into place. Will need to sort out the front cylinder mount also for the stock Evo front cylinder bracket I have.
Have just found out my 2004 model as new OEM pipes I bought from Texas do not fit pre 2004.
Will need to source another set of 86-03 type headers for this '99 motor, bugger!
Nevermind, so far this Sportster is looking very do-able.

[VH5150]

This week the rear brake master cylinder arrived from the U.S. also checked just to make sure the 2004 up OEM headers would not fit, unfortunately only the rear pipe fits. Too bad, I like the look of this system with the Khrome Werks 2.5" mufflers.


Seems like the pipes most likely to clear the Ironhead front tubes using the stock Ironhead front engine mounts are Vance & Hines short shots. Looks like they will suit my mids and rear brake set up as well.

[Deimus]

Did you find your answer about the clutch from 2 weeks ago?

[wagoneer12]

That front pipe looks like its gonna be tight. Fingers crossed.

Can't help with the primary cover/clutch.

As an owner of both an Ironhead and Rubbermount. I will say....those old frames can even make the Evo look almost cool. :P

[Deimus]

You can see your answer for the clutch online.

Ronnie's Harley-Davidson Microfiche URL

The above link should display a parts break down of the clutch that works with the newer primary cover.

[VH5150]

Originally Posted by Deimus

You can see your answer for the clutch online.

Ronnie's Harley-Davidson Microfiche URL

The above link should display a parts break down of the clutch that works with the newer primary cover.

Thanks for the link, will be handy being able to check out the parts microfiche through the Evo re-assembly.
Bought this detent assembly a few weeks back which suits the later primary cover. http://www.ebay.com.au/itm/360468190196
Bought the adjustment screw and the clutch cable coupling from the local HD dealership.
Really helpful to come on here to get parts advice before I go and bother the local HD dealership sales guy about my build when so far the frame is '77, forks '86, motor '99 rear wheel '09 and probably more year models to come by the time I get this XL built!
Thanks for asking about my clutch, Dave

[VH5150]

Originally Posted by wagoneer12

That front pipe looks like its gonna be tight. Fingers crossed.

Can't help with the primary cover/clutch.

As an owner of both an Ironhead and Rubbermount. I will say....those old frames can even make the Evo look almost cool. :P

Yes agree that the front pipe will be really close, may have to trim the V&H short shot front shield when I get 'em. Hoping that the Ironhead frame front tubes are a little closer than the Evo frame front down tubes.

Yep I really like the look of the Ironhead frames too, they just look cool.
Just bought an OEM side mount XLH Ironhead oil tank and the larger XLH Ironhead battery tray this week from the states, my parts are now coming together.
Last few major parts I am after are the V&H pipes, Wiseco K1685 pistons and I still need a stock Ironhead kickstand for my '77 frame.
Dave

[bobscogin]

Dave, great project. The Evo in the early frame should make a great combination. How much will the backbone have to be raised to clear the rear cylinder rocker cover? How will you make the tie in to the seat post tubes. Bend it down behind the rocker cover?

Bob