Iron Sportster bill of material


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Case set

Includes trap door, but not rear mount.
Iron Sportster have three fundamental case designs. Early, electric start, and sump are the basic configurations.

The early cases had no provision for electric start. They were used from 1952 to 1966 on all the models, and carried over for the 1967 to 1969 XLCH.

Electric start came in 1967. This case ran until 1976.

Infused with AMF money, the cases were redesigned in 1977 as a cost reduction and to provide for the government mandate for left-hand shifting.

In 1982 engineers made a major change to provide for the Nippondenso starter motor.		 1952_K-model_24511-52_engine-case-set_3-4

Judging from the factory parts manuals, the case set included the trap door but not the rear motor mount. Including the trap door makes sense since it has to be line-bored with the right case, so the mainshaft runs true.

Indeed, if you replace the trap door, you should align bore the right case bearing. This will make the rollers run perfectly true and distribute the load across the entire length of the roller.

By including the transmission in the same casting, so-called "unit construction" the K-model cases were a huge advancement for Harley, as was the entire bike. The early cases had no provision for electric starting, that came in 1967.
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24511-52

1952-1953

24532-52 left
24556-52 right

In the original K-model engine there is no trap door to access the transmission. You have to split the cases to get to the gears and shift mechanism.

1952_K-model_24511-52_engine-case-set_lf

Boy 1952_K-model_24511-52_engine-case-set_rt
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24511-54

1954

24532-54 left
24556-54 right
Oh man, check out the steel mounts Steve welded up for the crate. The motor, well actually its an engine. Motors are electric, engines are internal combustion. So anyway, the engine is in

24511-54A

1955-56

24532-54A left
24556-54 right
The -54A cracncases were a running change that will retrofit the -54 cases and case-halves. Not known what changes occured.



Here is thteve and Jeannine. Right about now you have to suppress the urge
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24511-57

1957

24532-57 left
24556-57 right
to start taking things apart. There are 20,000 Sportsters in garages all over America that are in pieces since it is so easy to take things apart and so hard to put them back together.



The front of the cases don't have any "zippers," and the fins all look good. Steve did such a nice job crating this up. You can bet your bippee I am saving this crate. It will fit any K-model or Sportster engine from 1952 to 1984, and probably later. You never can tell when you or one of your friends might need to ship a motor.
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24515-58

1958 all

24532-58 left
24556-57 right (carryover)

Improved Sportster case, running cahnge in unknown year to -58A below

24511-58A

1959-66 all 67-69 XLCH

24532-58 left
24555-57A right

Some change in the right case half created this improved case set that you can retrofit to 1958.

1962_XLCH_24515-58_Engine-case-set-lfount. Ther1962_XLCH_24515-58_Engine-case-set-rtff the cyld		 border bar
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Sportster-Engine-Case-Cases-16203-82A_Rear-motor-mount-rt3-4down the shoulder on the kickstarter shaft, you reduce the thrust bearing area. Just hope you don't bend the shaft. Maybe 1962_XLCH_24515-58_Engine-case-set-2one reason to have the hole so tight, is so if you break a sprct. In the old days, b1962_XLCH_24515-58_Engine-case-set-5efore the AMF finance people almost destroyed H1962_XLCH_24515-58_Engine-case-set-3 border bar
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The 1970 bikes attemtepd to use the same cases. The XLCH kick-start bikes had the same starter hump, but there was a steel plateover th1962_XLCH_24515-58_Engine-case-set-6e opening instead of the starter. For some reason, there still had to be changes in the right-side case that were not used on the -67A r1962_XLCH_24515-58_Engine-case-set-7ight case, so this case set includes the -70 only right side case.		 border bar
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24512-67A

1967-71 XLH

24531-67 left
24555-67A right

sunt i1967_XLH_24512-67A_Engine-case-set-01t weakens it. If you turn1967_XLH_24512-67A_Engine-case-set-rt
ascasdc
1967_XLH_24512-67A_Engine-case-set-lf		 border bar
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something so retarded. If you drill out the motor mount i1967_XLH_24512-67A_Engine-case-set-03t weakens it. If 1967_XLH_24512-67A_Engine-case-set-04you turn		 border bar
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something so retarded. If you drill out the motor mount i1967_XLH_24512-67A_Engine-case-set-07t weakens it. If you turn1967_XLH_24512-67A_Engine-case-set-06		 border bar
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something so retarded. If you drill out the motor mount it weakens it. If you turn		 border bar
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24512-70

1970-71 XLCH

24531-67 left
24555-70 right
The 1970 bikes attemtepd to use the same cases. The XLCH kick-start bikes had the same starter hump, but there was a steel plateover the opening instead of the starter. For some reason, there still had to be changes in the right-side case that were not used on the -67A right case, so this case set includes the -70 only right side case.

24505-72

1972 all

? left
? right
parts book look just like this. The parts book does show a "mounting kit" and that does not look like this regulator.
Sportster-Engine-Case-Cases-16203-82A_Rear-motor-mount-lf

24505-73

1973-76 all

? left
? right
The carburetoe longest-running motorcycle model in history.
  The carbt still works. Thanks for the crate, Steve.		 border bar
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24527-75B

1977-78 all; 79-80 XL XLCH (not XLS)

? left
? right
Here I try out the choke for the first time. It is pretty scratchy, but it works. Sixty years old, and it works. Too cool.


The manifold is rusty but the nuts don't look toley ethese big nuts screw to. 		border bar
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24490-79A

1979-80 XLS

? left
? right
Here I try ou
The circuit breaker, sometimes mis-called a distributor, is rusted badly. Harley interchangeability means I can slap in an

24527-81A

1981 XL

? left
? right
Uses 16203-67A rear mount with provision for kickstarter
auto-advance circuit breaker. This one you

24490-81A

1981-82 XLS

? left
? right

advance and retard by hand, with a twist grip on the left side of the handlebars.  		border bar
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24527-82A

1982-84E all

? left
? right
Uses 16203-82A rear mount with no provision for kickstarter 

The valve lcoverever seal oil again.despite it having iron cylinder heads 1982_Sportster_24527-82A_Engine-case-set_rtot covered by1982_Sportster_24527-82A_Engine-case-set_bt this website.		 border bar
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or reference, this site does not cover that model despite it having iron cylinder heads ot covered b1982_Sportster_24527-82A_Engine-case-set_04y this1982_Sportster_24527-82A_Engine-case-set_lf website.1982_Sportster_24527-82A_Engine-case-set_09 border bar
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e is for the clutchernator and is included for reference, this site does not cover that model despite it having iron cylinder heads 1982_Sportster_24527-82A_Engine-case-set_05ot covered by this website.1982_Sportster_24527-82A_Engine-case-set_06 border bar
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he clutchernator and is included for reference, this site does not cover that model despite it having iron cylinder heads 1982_Sportster_24527-82A_Engine-case-set_07ot covered by this website.1982_Sportster_24527-82A_Engine-case-set_08		 border bar
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24480-84A

1984L all

? left
? right
This case is for the clutchernator and is included for reference, this site does not cover that model despite it having iron cylinder heads 

24480-85A

1985E all

? left
? right
This may be a case before the Evo heads, but still with the clutchernator. It is also nSportster_1985-set_billeuzeot covered by this website.http://s448.photobucket.com/user/billeuze/media/bike%20Stuff/85engine%20parts/Engine.jpg.html		 border bar
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A summary table for the Iron Sportster engine cases:
Part Descript Used on Note
24511-52 Case set 1952-1953 all Steel, both large-hole and small-hole versions.
24511-54 Case set 1954 all Transmission trap door introduced.
24511-54A Case set 1955-56 all Service part for above.
24511-57 Case set 1957 First-year Sportster
24515-58 Case set 1958 all
24511-58A Case set 1959-66 all 67-69 XLCH
24512-67A Case set 1967-71 XLH Electric start "hump" added.
24512-70 Case set 1970-71 XLCH
24505-72 Case set 1972 all
24505-73 Case set 1973-76 all 1000cc spigots
24527-75B Case set 1977-78 all; 79-80 XL XLCH Redesign for cost reduction, foot pegs on cases, left-side shift.
24490-79A Case set 1979-80 XLS
24527-81A Case set 1981 XL
24490-81A Case set 1981-82 XLS
24527-82A Case set 1982-84E all Nipondenso electric starter
24480-84A Case set 1984L all
24480-85A Case set 1985E all No hole for kick-starter shaft.
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