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

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  #31  
Old 2nd January 2009
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Default Generator gear puller tool

Here is a nifty little two-leg puller from the local auto parts store that gets the gear off the generator. (Take the nut and oil slinger washer off first - this pic is just mocked up for demonstration!)

You have to be sure the puller legs have the thin hooks on the end that will get in behind the gear.

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  #32  
Old 2nd January 2009
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OK, here 're some more hand made tools...

52/71 dry clutch locking tool, driver/driven plates bolted/welded together (bolts are there not to hold them together, just for pulling out afterwards!!!):



72 and later wet clutch, same idea:



"Spider" to improve wet clutch parallel throw out while installed, allows individual nut adjustment:



Patrick
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  #33  
Old 2nd January 2009
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Slotted hand grinder spanner to tighten left hand side swing arm big nut, the one hidden behind clutch:



Patrick
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  #34  
Old 2nd January 2009
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Sportster/Buell Model: KHK
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Other Motorcycle Year: 1966
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Now, a few factory tools that are worth buying if you find them. I've put their part numbers as well if you want to google them:

Rod locking tool, fit on the cases, H-D 95952-33:



Shaft extention and inner Timken extractor, H-D 96015-56:





Tappet block extractor, needs the cams to be still in the cases, H-D 95724-57:



Dry clutch hub puller, H-D 95960-52A:



Patrick
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  #35  
Old 2nd January 2009
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This should def be stickied
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  #36  
Old 5th February 2009
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Sportster/Buell Model: XLCH 1000
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Sportster/Buell Model #2: 75 motor in Norton frame.
Other Motorcycle Model: 42WLA 45, Harton, Narley
Other Motorcycle Year: 1942
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Not home made but one of the handiest gadgets I have bought is this sport bike rear stand from the local riceburner shop. Handy for chain lube, tire changes etc as well as when you just want the bike standing up vertical and not leaning over while you work on it or change oil etc.
The two hooks that are desigened to fit over special bobbins bolted to a modern sportbike swingarm fit just perfect on to the bottom shock/footpeg mounts on the Sportster.

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  #37  
Old 5th February 2009
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Sportster/Buell Model: XLCH 1000
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Other Motorcycle Model: 42WLA 45, Harton, Narley
Other Motorcycle Year: 1942
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Default Clutch spring compressor tool

Fron another thread here is 72 Ironhead XLH's suggested modification to FrenchOwl's excellent clutch tool so it can be used to pull the hub too, a bit more sophisticated than my piece of wood from an old lawn chair.

Quote:
Originally Posted by 72 Ironhead XLH View Post
Mine is similiar but added 2 additional holes to use it on the clutch hub also,and slotted the area for the case screws
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  #38  
Old 5th February 2009
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WOW, i stumbled on this section, this is great.
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  #39  
Old 17th February 2009
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Link to some more home-makeable tools:
http://www.ironheadcycle.com/pages/tools1.htm
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  #40  
Old 1st May 2009
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Other Motorcycle Year: 1942
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Default Carb removal rig - without removing horn or ignition switch

I posted this an answwer to another thread, but figure it could be handy here for the record:

I am just too damn lazy to take my horn and ignition switch off, let alone my gas tank. So I came up with a simple rig that allows me to get in and unbolt the carb on my 77 without removing anything else.

It is a 3/8 ratchtet handle with a 4" extension, universal joint (the type with a spring around it to hold it straightish) and a 1/2" AF deep socket.

It will slide straight in to the top carb stud nut.
It will slide straight in to the bottom carb stud nut if you hold the horn to one side, it flexes on its rubber mounts.

The rig:


Into the top stud


Into the bottom stud.



And like Mick said, don't overtighten. You will bend the flange on the carb into a nice bow that will not seal until you file it flat again. I hold the 3/8 drive handle up close to the head for minimum leverage and just "nip" the nuts up lightly. Never had them come loose or leak.
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