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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 25th February 2008
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CosmoTG CosmoTG is offline
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Sportster/Buell Model: ironhead
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Default Generator Mount Leak

Spent most of the day tracing down leaks and have found one I,m not sure how to fix. Seems that the mounting bolt holes in the generator are cracked. The bolts are tightening but I am afraid to torque them down for fear of more damage. Just had the generator rebuilt and I hate to shell out the bucks to replace it. Any body have any ideas?...Cosmo
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Old 25th February 2008
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I had that same problem with one of the bolt holes. I had an helicoil installed. Has worked fine for 2 or 3 years. Be sure to use one for fine thread.

If there is a problem with the structural integrity of the gen case i would consider wrapping it with a 4,1/2" hose clamp or two after the helicoils are installed.

Those bolts need only about 10 ft lbs; not very much at all; plus some blue locktite. Easy to over tighten and wreck.

There does need to be a gasket between the gen and the case. I made one from cork gasket material from the auto supply store.
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Old 13th March 2008
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Today I received a new Generator drive cover I ordered From Jireh (part# 53-253) for about 11$. This looks to fix my mount problem. Just gotta be careful not to over tighten...Cos
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