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  #1  
Old 9th June 2017
Ryman87 Ryman87 is offline
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Default 66 Sportster rebuild

Hello all. Hoping to get some informative help on a project im starting.
I picked up a 66XLCH that isnt running at the moment. Has good compression. No spark currently(might be an ignition issue or magneto). Going to need tires and fluids and all that. But really where do I start? What do I look for when im going through it and what adjustments should I be making along the way? Any help would be greatly appreciated. Also, what type of oil is prefered. Ive got both a shop manual(70-79) i believe a clymers manual but little bits on insight is always more helpful
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  #2  
Old 9th June 2017
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Read the red stickies section at the top of the Ironheads section. Lots of good stuff!
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  #3  
Old 9th June 2017
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Please post pictures of your "Mistress"
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Old 9th June 2017
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Well from your topic it says that you're looking to rebuild. So my first question is are you looking to rebuild it or just get it running?
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Old 9th June 2017
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I would not call clymers a shop manual. a waste of money. get a reprint fsm. the fsm of this vintage are very good. usedmedical1@yahoo.com has them. on ebay. an original fsm will just fall apart. I like the binders he uses.
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Old 9th June 2017
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FSM: https://www.google.com/search?q=9948...utf-8&oe=utf-8
Parts Book: https://www.google.com/search?q=9945...utf-8&oe=utf-8

Post pictures, and you'll get advice on where to start.

1. No chopping, unless someone else beat you to it. If they haven't, but you're inclined to, please find something less valuable.

2. I like Valvoline VR1 single weight oil.

Stickys:

http://xlforum.net/forums/s....php?t=2001890
http://xlforum.net/forums/s...d.php?t=465866
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Old 10th June 2017
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A lot of guys make the mistake of testing a magneto by pulling both plugs (to make it easy to kick over (which is a good idea) but you must make sure BOTH plugs are grounded or you will not get a spark
The magneto is an AC generating device that requires a complete circuit to function. The circuit goes from one plug lead through it's spark plug and then through the engine where it jumps the gap on the second plug then through that lead back down into the magneto. Break that circuit anywhere and it won't spark at all.
No you know why we set the gaps on our plugs closer for magneto fired bikes. Even when we close them up to 0.020 they have to jump TWO gaps or ).040.

If you test it properly and you get spark and t has enough compression to make it a bit hard to kick the engine over it will run.
It's worth trying to start the engine as if it does it will tell you a lot.
It will also make you feel good.
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Old 11th June 2017
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Do not assume automatically that the engine has to be rebuilt. A lot of these are not ridden much at all. The rod set rollers are the main thing would require a rebuild. I've seen a rod set go forever. Its just a matter of what the other people did to it and if HD built a good one on that day. At some point you can put a set of rings in it look at the valves and at the same time check the rod rollers. If those rollers had good hard facing and the correct oil was used, they may be fine. My Sportster was a 66 and I liked it very much. It was a well made machine. I paid the princely sum of $2000 cash for it in 1971, a couple of guys from NY were selling two and then probably going Calif after that. We didn't require helmets in those days and it was a VERY big deal to most riders. Carl bought both at $2K. The other had a set of PBs in it and they went straight into mine. To put things into perspective, you could buy 2 Kawa Zs for that much, almost 3 Kawa triples. So a used Sportster was the cat's meow in those days. Buy a genuine HD manual. Not a Haynes or Clymer. The difference is like asking a question to a real HD guy vs asking someone who heard someone who knew someone....
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