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

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  #1  
Old 2 Weeks Ago
Captain Johnny Captain Johnny is offline
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Default Magneto insulating block removal

1968 XLCH. Removed the cap and pulled the magneto. Tipped it to the side and at least an ounce of water poured out.

Peaked inside and see rust.

Gotta take it apart and go through it. The insulating block was broke.

The insulating block has to come out before the coil can be removed. How does the block come out? Doesn't have a key.
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  #2  
Old 2 Weeks Ago
needspeed needspeed is offline
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Many mags have a 1/8 drain hole drilled in the housing under the coil. Looks like you need one.

See this post for removal of key tumbler.

http://xlforum.net/forums/showpost.p...8&postcount=53
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  #3  
Old 2 Weeks Ago
Captain Johnny Captain Johnny is offline
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Default

Thanks needspeed. It came right out. Removed the coil and it looks like the bottom of a dumpster.

God take me now if I'm lying but this ran like this!!

I was unable to punch the pin that holds the drive gear out. I guess this would be nothing for the small machine shop in town to do, right? Or does anyone have a suggestion for Mr. Shadetree here (me) to get it done at home?

When I did the mag on my '69 a rollpin held the gear. It punched right out and I replaced it with a new one. This looks like a solid pin and I couldn't get it to budge.
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  #4  
Old 2 Weeks Ago
needspeed needspeed is offline
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Have you tried punching the pin from both sides? Sometimes when the pin is installed the end of the pin being hit gets mushroomed over, making removal in the same direction as it was put in impossible.
If the pin appears to be smaller on one end then thats the end to be punching on.

The hole is 7/64 so you'll need a punch slightly smaller than that.
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  #5  
Old 2 Weeks Ago
Iron Mike Iron Mike is offline
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Default

Drill it out. Pin is softer than the gear. Use a center drill https://www.harborfreight.com/center...BoCUrEQAvD_BwE
Remove one side of the pin to remove some of the peened over material. The bit won’t drill the gear, just the pin. Then just drift it out. Support the gear and shaft accordingly of course.
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  #6  
Old 1 Week Ago
Captain Johnny Captain Johnny is offline
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Default

Thanks Iron Mike. Picked up a set of those drill bits but they didn't make a mark on the pin
So I tried again drifting the pin out. Finally got it, came out in 2 pieces.
Got the magneto apart and as expected the lower bearing was shot.
I can't read the number on the bearing. Does anybody know what bearing that is? I know what the H-D part number is but I buy bearings at a bearing supply house, not at a bike shop.

If anybody knows that bearing number I'd appreciate that info.[/img]
Hard to believe this mag ran in this condition. Hardy little piece of machinery.
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  #7  
Old 1 Week Ago
Iron Mike Iron Mike is offline
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Default

Zoom in on this. Looks like 6202-z.
Verify prior of course.

https://www.american-motors-usa.com/...to-bearing-set
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  #8  
Old 1 Week Ago
Captain Johnny Captain Johnny is offline
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Nice work Mike, thanks. What a great forum!
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  #9  
Old 1 Week Ago
GA_Ironhead GA_Ironhead is offline
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Might want to add that information to this thread from the Stickys once you've verified it.
http://xlforum.net/forums/showthread.php?t=548657
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brucstoudt brucstoudt is offline
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Default

running like that? did you see it yourself? water and electricity tend to short out.
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