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

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  #21  
Old 1 Week Ago
randy3934's Avatar
randy3934 randy3934 is offline
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Sportster/Buell Model: xlh 1000 69 79 xlch
Sportster/Buell Year: 1977
Sportster/Buell Model #2: 80 FXE 82FLH 83FXR
Other Motorcycle Model: 78FLH 79xlch 96xl 79xlh
Reputation: 152122
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I've done it a few times, if you have the tools a first timer would take a couple hours to remove trans, I can pull one in about 30 minutes.
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I'm not a complete idiot, some parts are missing. not enough room to list all my harleys.
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  #22  
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randy3934 randy3934 is offline
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Sportster/Buell Model: xlh 1000 69 79 xlch
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Other Motorcycle Model: 78FLH 79xlch 96xl 79xlh
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before dissasembly measure the end play "in and out" of the drive sprocket with sprocket cover removed of course. this will let you know if you should re shim the mainshaft.
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  #23  
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Ferrous Head Ferrous Head is online now
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Sportster/Buell Model: XLB, XLCH, Sporton
Sportster/Buell Year: 1962
Sportster/Buell Model #2: XLCH
Sportster/Buell Year #2: 1966
Other Motorcycle Model: XLCH (Another one)
Other Motorcycle Year: 1966
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Quote:
Originally Posted by Beary View Post
OK, thanks. I don't see an easy way to do this.

I'm scared to pull the off the primary cover and clutch because every time I remove something, I expose another problem.

Beary
So, if you don't fx found problems the "self heal" system kickjs in and does NOT leave you stranded 500 miles form home ?

I'm guessing you picked this up very cheap as it is a bike that clearly has a lot of issues.

This could be a great learning opportunity for you. Or, a frustrating waste of time and money. That wil depend on your point of view.

This sounds lie a project bike. Bikes like this generally sell for $1,000 to $1500. But if you start pulling it apart and then want to "get rid of it" while sitting in boxes it is A: hard to sell and B: now worth half what you paid.

If you can turn this into a reliable daily runner you will most likely recoup your moentary costs, Plus you are now experienced in some of the ways of these engines/bikes.

Experience is the best teacher, she is just a bit expensive though.

Of course, this is only my opinion.
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  #24  
Old 1 Week Ago
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Ferrous Head Ferrous Head is online now
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Sportster/Buell Model: XLB, XLCH, Sporton
Sportster/Buell Year: 1962
Sportster/Buell Model #2: XLCH
Sportster/Buell Year #2: 1966
Other Motorcycle Model: XLCH (Another one)
Other Motorcycle Year: 1966
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Quote:
Originally Posted by randy3934 View Post
I've done it a few times, if you have the tools a first timer would take a couple hours to remove trans, I can pull one in about 30 minutes.
2018 Australian Championships I removed and replaced the transmission TWICE between races. On my knees, in the dirt, under the blazing sun.

Without so much as a beer !

(Part of the trick is in ignoring hat the FSM says about installing those 23 rollers,)
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  #25  
Old 1 Week Ago
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Sportster/Buell Model: xlh 1000 69 79 xlch
Sportster/Buell Year: 1977
Sportster/Buell Model #2: 80 FXE 82FLH 83FXR
Other Motorcycle Model: 78FLH 79xlch 96xl 79xlh
Reputation: 152122
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Quote:
Originally Posted by Ferrous Head View Post
2018 Australian Championships I removed and replaced the transmission TWICE between races. On my knees, in the dirt, under the blazing sun.

Without so much as a beer !

(Part of the trick is in ignoring hat the FSM says about installing those 23 rollers,)
I completely believe you, most of my 30 minutes is spent grabbing tools, I've luckily found all 23 rollers except where the race has been line honed and rollers are oversize, then you only get 22.
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  #26  
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Sportster/Buell Model: XLB, XLCH, Sporton
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Other Motorcycle Year: 1966
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Quote:
I completely believe you, most of my 30 minutes is spent grabbing tools
I have two mechanics handing me tools. But getting down on my knees takes me twenty minutes.

If I have to get my own tools it takes me about 4 hours.
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  #27  
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Oh, I think I'm going to give this bike a chance. I can afford to fix it and build it my way, and I don't expect to get that investment back out of it.

But, the challenge is fixing issues that are beyond my skills. I'm not finding many knowledgeable Ironhead experts here in Oklahoma City. I'm good at general mechanics, but when it comes to fixing oval holes where a bolt half it's size should be, I spend more time figuring out how to fix it.

Someone suggested to just keep riding it and fix it along the way. LOL, THAT WAS MY PLAN.

First I needed to install a starter. In the process of installing the starter, I found that the Oil Tank is held to the frame with only one old loose rubber mount. Oh, better fix that! Oh, the Battery Box is very loosely attached to the oil tank by one over size bolt. The other bolt is stripped. Can I fix stripped bolts in the oil tank? Get back to that later, bigger issues are popping up.

The Battery Box is not attached to the frame by any rubber mounts and the one hole on the frame vertical post where it should attach is drilled out to twice the size of the rubber mount nut. What was the thinking behind that? By the way, I could use a picture of what that post mount should look like.

Then after removing the battery box and tank, HEY! Look at those two oval holes in the tranny case. Are those the gears I see. (question: do those holes normally go through the case?

OK, OK, well we will get to those issue, but can't I move the bike. I'm pretty sure I'm in natural. Lift bike, turn the rear wheel; yep! I'm in neutral. Oh, it seems the front caliper is rusted to the disk. Hmm, that's no good. So, I removed the caliper completely, now I can move the bike around.

I've also removed the broken mirror, rusted from brake master cylinder, and all sorts of heavy steel junk the previous owners thought looked cool. Here is a question: Why is everything so heavy on old Harleys. Shesh, the bent left peg must weight 5 pounds. I've decided to put this poor beast on a diet. I've set a goal of 100 lbs and I don't think that will be very hard. The 70's style seat back rest feels like 20 lbs all by itself.

Oh, gas tank has some rust. I need advise on attacking that now. I really wanted to ride the bike at least once before pulling the tank off so I feel any issues in the transmission, but I don't see it now.

The S & S carb looks to be the one bright lite here. Looks good. Filter hasn't been cleaned since Elvis Presley died, but carb looks pretty good.

Did I mention the chunk missing out of the cam cover by the points? Hmm. Need a welder? Replace cam cover?

Most of what scares me about removing the tranny is what else I find. The couple of YouTUBE videos found broken gears and crakes where the side case bolts go.

I really just wanted to start it, ONCE.

Where to start, where to start. LOL

I'm not one to name my vehicles, but this seems to need one. Priscilla?

Beary
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  #28  
Old 1 Week Ago
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If the chunk out of the cam cover is not leaking oil, run it....
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  #29  
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Quote:
Originally Posted by ryder rick View Post
If the chunk out of the cam cover is not leaking oil, run it....
I admit, it's just more of an unsightly flaw that requires something something more unsightly (duct tape) to keep dirt and moisture out. It's a lower priority for now.
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  #30  
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Ferrous Head Ferrous Head is online now
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Location: Sunshine Coast
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Sportster/Buell Model: XLB, XLCH, Sporton
Sportster/Buell Year: 1962
Sportster/Buell Model #2: XLCH
Sportster/Buell Year #2: 1966
Other Motorcycle Model: XLCH (Another one)
Other Motorcycle Year: 1966
Reputation: 1289372
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Given the state of the bike it probably won't matter if you start it once just to hear it. It might even be advisable as you may well discover noises that lead you to investigate a lot further.

Only problem is: If you start this bike and it runs OK you will in all likelihood become omitted to it. Committed by the way, is the same term they use for mental patients.

The sound of an Ironhead is the mechanical equivalent of a human heartbeat. In bio-metric terms it resonates at the same natural frequency as your heart and your brain becomes confused leading you to fall in love.

It's just like holding a pretty girls so close you can feel her heartbeat. If you hold her long enough your heartbeats synchronize and before you know it your buying her a house.

So, buyer beware.

You don't need "expert" Harley mechanics. Think of this engine as a 350 Chevy engine from a 1969 Camaro. Now, could you find people to help you with that 350 ?

Those people will recognize everything inside your engine other than the clutch.

The FSM and parts manual will tell you everything else you need to know.

Document it with pics as you go,. Before and after. Everything.
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