Rebuilding my '76 ironhead Sportster. Fortunately the last onwer also did so, fairly recently by the look of the engine, so the crank, pistons, rings, valve guides, etc are all fine. What he didn;t do was the shims and seals, which are all knackered and which are being fixed. The gearbox bushes were completely rooted, to the point where it really didn't want to change gear. It should be pretty tight, though, when done. Stock, but tight.
Any tips on things to look out for? Oil pump is an obvious one to check, gears and bearings all checked out okay. Any other thoughts much appreciated.
The plan is to bring it back to something resembling stock. More like a trimmed version of stock. I'll post some pix when it's done, in a few months, though, I guess.
Yep, thanks for this. The first change-over from left to right braking/right to left gears was perhaps not H-D's finest moment in engineering. There is quite a bit of play in the shaft - the bushes are a bit flogged out. These are currently in the process of being replaced with much deeper bushes (stock is as wide as the crankcase wall, which is not very). I'm also looking at either replacing the shaft or turning it down slightly to get rid of s small amount of wear. I am hoping this will hold the whole plot in one place fairly firmly. The bike will go back to stock foot controls, which means a long gear lever throw but, not being a fan of forward controls and not wanting rear-sets, short of making up a fairly complicated linkage system that's where it has to be. Thankfully it will not be my daily ride when it's done, so I can live with that little bit of grief. But again, thanks for the info.
Having that covered (I hope), anything else you can think of to look out for? (red ink is only a problem if it is on your credit card statement).
I also have a 78 ironhead Sporty to rebuild.I bought the bike as a fixer upper but as i am in regional Qld i am finding it hard(mainly because is my first bike after playing with cars for 20 years)to find a wrecker or someplace where i can walk in and tell them what i am doing and the list of parts that i require rather than relying 100% on the internet and American suppliers of parts for the old bike.Is there any set rules as to what tanks can go on what bikes.I am also looking for an original look with maybe a different paint scheme but still fairly original to look at.Any help or leads is appreciated.
Ebay is the main place to look for parts in Australia, but not much there. H-D Development in Melbourne has some bits too, but mostly for older big twins. US Ebay seems to be the main place and works pretty well, and there's plenty of stores in the US that has NOS and replica parts, as well as after market stuff. There are a number of small difference between models, but especially between ironheads and alloy motors. The seat mounting, for example is different (and within Ironheads, so make sure you get the right seat or something that is adaptable). Tanks are more consistent, although again there can be some differences, e.g. where the tap is placed. When shopping, specify as closely as possible the year you are looking for parts for.
In terms of engines, etc, as has already been noted, the earlier bikes were right side gear change, left brake, moving to a dodgy set-up around 75-76 and then to a better arrangement where the gearbox was designed to have a left side gear change that went through until '90.
Around '7273 the frames received some really basic strengthening at the back guard/shock mount - looks very agricultural. Doesn't make much difference, but the earleir frames were prone to cracking here.
Good luck with it!
Gday DAmien & Ant
Good luck with the builds - post plenty of pic's !
I have an '85 Roadster (last of the iron barrels) waiting on some TLC but the list of "projects" is long. A good build thread may be just what i need to get motivated !
I also had an early "crossover" model with the gear linkage under the motor and a gear lever that was about 2 foot long many years back
Gotta say I am a big fan and keen to see your finished results
Cheers
Philthy
If you are shopping for parts in the US, this place is pretty good - they've got a wide range of stock for older Sporties: http://www.sportyspecialties.com/
and even adding on the shipping cost, this tank looks to be a pretty good buy (I'd avoid a used tank, which are not appreciably cheaper, unless you are good at cleanign them out and applying a sealer):
http://www.ebay.com/itm/CUSTOM-CHROME-PEANUT-CHOPPER-BOBBER-GAS-TANK-1958-1978-HARLEY-SPORTSTER-XL-IRON-/121042765439?pt=Motorcycles_Parts_Accessories&hash=item1c2eb6067f&vxp=mtr
Hey Philthy, that's a great pic.
sorry for the repeat of the 2nd pic. 1st pic just starting (it had a truly horrible tank and seat on it), 2nd pic showing what one can find. That snapped peg bracket is being welded witht he blt in place, then the head of the bolt taken off, the frame sand-blasted and then for painting. But first getting the engine sorted - the bloke who is doing the extra long/strong gear lever shaft bushes is closing his business next week, so I have got to get that done first!
BTW, very nice '85. Looks tidy in the pic. I passed up one one recently - a really good bike, great engine, very good overall condition, but baulked at the price (which upon relfection was very reasonable - I'm a tightarse). Shouldn't have. I do prefer the look of the older ones. But a good ironhead in the hand is worth, well, it's a lot easier than a frame-up re-build. But perhaps not as satisfying. Or feeding an obsession, or whatever it has become.
Thanks for the compliment Damian - I have had it since new so pretty much know it inside and out. That photo is a couple of years ago but the Bike is still in the same nick.
Having said that - not sure if the current problem is mechanical or electrical. Unfortunately AS I Mentioned, I have a few other projects on the cook that have siphoned funds away from the sporty. Your build could influence that . . . . .
PHIlthy
on the 4spd sportie gearbox i have done a lot of them , the gear shaft has a knob thru it that is held in place by a peened over pin across thru the shaft on the pawl carrier side , the pin come's loose & there is slop the the gear lever it's hard too tell by looking, i put them in a vise & check with a shifter spanner it's best too mig weld them up anyway as the old bike's are worn from people hitting the gear lever too hard , you mig on the inside so as it doe's not interfer with the inside of the crankcase bush ,while i'am in there i re-bush the pawl carrier & polish up the shifter fork cam slot's & the de-dent on the shifter cam plate for smoother shifting, Redgrave's Motorcycle's 94849900 have a lot of cast iron sportie g/box bushes , pawl finger roller's andrews gears etc early harley specialty good help there is a lot you can do too make for a nice shiffting g/box shimming etc ,
Philty, there's a real satisfaction in owning a bike for a long time. You've looked after it well, from its aparrent condition. I've had one that's in my garage for 20 years and I could no more sell it than chop off my fingers. Hope you find out what the bug is - what are the symptoms? And yes, having too many projects is a problem, but perhaps a good one.
Daddyracer, thanks for the advice on the gearbox shaft and the Redgrave's number. I'll be sure to follow that as it progresses. The way it looks right now, it seems the previous owner (in the US) spent a bit of money on the engine and gearbox, but did not finish the job properly - like he shopped out the first half and then did the second half himself (as well as what some people might have laughingly called 'cosmetics'). So now going through the bits that still need doing.
Cheers,
Damien
G"Day Damian
The Roadster is breaking down on one pot - have tried carb change/manifolds etc. Could be a dropped guide or electrical - haven't really had the time to look too far into it although more and more I feel I should make the time . . .
Here's a better photo of my old sporty - I Thought it was around '76 vintage but couldn't be sure :
CHeers
Not being an expert on this era (or any other, for that matter), I can't tell if it's a '76 or not. It's around then, but not exactly sure. You should be able to tell from the VIN number, though. There's a couple of web sites that list the serial numbers and associated years. Just google H-D Sportster serial numbers - that should pull it up. The oil tank is not from a '76 and the shocks also look like a later model, although they both could easily have been replaced. The wheels look right, though, for rim shape. I like chatting about this stuff and occasionally fix my own problems (bikes, less so life), but I'm a long way from being a mechanic, except maybe for the 'bush' kind (can fix most things with a pair of pliers and some fencing wire). If it is misfiring on one cylinder only I'd check the plug caps and high-tension leads to start - one might be cracked internally and giving intermittent contact. Next would be coils. After that, I'd probably give up and pay someone who knows what they are doing a bit better than me. Good luck with it and let us know how you get on. BTW, you are lucky to have the stock peg arrangement - I am really not a fan of forward 'controls'.
the last 2 digit's give the yrar on any 1970's harley from 1971 thru untill 1979 if it's a 1976 it will end H6 or if it's a 1973 it will end with H3 the engine & frames were matching number's as well, the shocks were about 13 1/2 " long & 1 model had 15'' long those have had top covers put on & the iol tank is a electric start model from 1967 thru 1978 model XLH, looks like shovel rear mudguard struts sporties are straight , & those are the good itay made aluminium rims original
Hey Daddyracer, you know your stuff - that sounds like what I remember about serial numbers (but my memory ain't what it once was) . My '76 has shocks with shrouds on them - I like the look but they are a bit battered so I'll probably replace them during the build. Didn't know there was a difference between oil tanks on electric and boot start models - interesting. At least I got the rims right. BTW, currently in Tassie on the Road Kill, yesterday went from Devonport along the coast and then down the west to Straughan, back through Cradle Mtn - God made this place for motorcyclists when he was in a good mood ... well, at least in summer time.
Ta Phil, will do. BTW, being warm has a lot to be said for it, too. I had a lt of fun in FNQ when I was a kid, and the roads leading out of Cairns were not too shabby either.
i rode too Tassie with 25 other harleys back in 1998, on a 1971 900 .c.c sporty with the original 1 3/4 gallon fuel tank i took a 1 gal fuel can just in case i never used it but 5 big twins did 1 idiot said i have 5 gallon fuel tanks & didn't think i would run out that was @ 1 am in the morning in the middle between Gunning & Yass , yes my memory is not as what it use too be thats why i like too exercise it on here look out for the logging timber trucks they know there way arround the mountians , have a good tourer, if you get lost you can ask the girl @ the servo if she can show you her map of Tasmania
