The Basket Case Sportster

[Getting Old]

Hey guys I have been on here a while now but this is my 1st post so not sure if I have landed it in the right place or not.
A mate of mine has kindly given me a 1976 Harley Davidson sportster that belonged to her late husband who unfortunately died during it's rebuild.
The bike to put it bluntly a complete basket case and one hell of a jigsaw puzzle to say the least.
It is in a 1000 pieces and is gunna take some work to get her back together, I feel the biggest problem will be sourcing
the missing bits.
Anyway watch this space guys as I am on a mission to get the old girl on the road as quick as I can.

At this point a big thank you has to go out to Carl (Who is no doubt a member on here) for his help last night in sorting and identifying
parts, I am stoked to have you by my side on this build for without the titivating conversation and your overall mechanical
experience with bikes I am sure this project would take far more time then it is going to.

http://i66.servimg.com/u/f66/12/96/61/91/dscf9010.jpg (http://www.servimg.com/image_preview.php?i=134&u=12966191)

http://i66.servimg.com/u/f66/12/96/61/91/dscf9011.jpg (http://www.servimg.com/image_preview.php?i=135&u=12966191)

http://i66.servimg.com/u/f66/12/96/61/91/dscf9012.jpg (http://www.servimg.com/image_preview.php?i=136&u=12966191)

http://i66.servimg.com/u/f66/12/96/61/91/dscf9013.jpg (http://www.servimg.com/image_preview.php?i=137&u=12966191)

http://i66.servimg.com/u/f66/12/96/61/91/dscf9014.jpg (http://www.servimg.com/image_preview.php?i=138&u=12966191)

http://i66.servimg.com/u/f66/12/96/61/91/dscf9015.jpg (http://www.servimg.com/image_preview.php?i=139&u=12966191)

http://i66.servimg.com/u/f66/12/96/61/91/dscf9016.jpg (http://www.servimg.com/image_preview.php?i=140&u=12966191)

http://i66.servimg.com/u/f66/12/96/61/91/dscf9017.jpg (http://www.servimg.com/image_preview.php?i=141&u=12966191)

http://i66.servimg.com/u/f66/12/96/61/91/dscf9018.jpg (http://www.servimg.com/image_preview.php?i=142&u=12966191)

http://i66.servimg.com/u/f66/12/96/61/91/dscf9019.jpg (http://www.servimg.com/image_preview.php?i=143&u=12966191)

http://i66.servimg.com/u/f66/12/96/61/91/dscf9021.jpg (http://www.servimg.com/image_preview.php?i=145&u=12966191)

http://i66.servimg.com/u/f66/12/96/61/91/dscf9022.jpg (http://www.servimg.com/image_preview.php?i=146&u=12966191)

http://i66.servimg.com/u/f66/12/96/61/91/dscf9023.jpg (http://www.servimg.com/image_preview.php?i=147&u=12966191)

http://i66.servimg.com/u/f66/12/96/61/91/dscf9024.jpg (http://www.servimg.com/image_preview.php?i=148&u=12966191)

[admenk]

Looks like you have quite a job on your hands. Will be interesting to see how it progresses. Good luck with it.

[Getting Old]

Yeah it will be a bit of a mission to say the least, on the plus side I am on holidays until the 10th of Jan so should make some great progress in that time.

[hayd3n]

jingle bells jingle bells

[Paul in NZ]

UM - you appear to have a pre unit BSA timing cover in there as well as a Triumph head and rocker boxes (I'll take that off your hands if ya want.... :yes: )

Good luck with the rebuild...:woohoo: Lots of clever old bike guys up yourway

Should be fun! (I love this stuff)

[Getting Old]

Well spotted Paul. I had a ball with Carl last night sorting out all the bits trying to work out what we had and what we didn't.
I have no ignition or timing system at all. No pistons, and only half of the oil pump so if anyone has any of these parts they
no longer need please let me know as this build will be done on a very tight budget so 2nd parts will have to suffice.
oh and I managed to find out the rego plate number today.... hmmm lots of years riding with no rego me thinks. :yes:

[BIG DOUG]

Piss of paul I need that single carb head lol,but hey I've seen worst get on to mike at harley speed and custom in pukerua bay they have iron head parts and there are still plenty of bits being made for them.

[Paul in NZ]

Piss of paul I need that single carb head lol,but hey I've seen worst get on to mike at harley speed and custom in pukerua bay they have iron head parts and there are still plenty of bits being made for them.

Bloody hell Doug - you cant even figure out which way round the head gos on a triumph mate. Single carb would hit your front down tube :innocent:

I go past pukerau bay most days if it helps?? (and yeah - let me know if you dont want the head - seriously, dont listen to doug, hes evil)

[Paul in NZ]

Well spotted Paul. I had a ball with Carl last night sorting out all the bits trying to work out what we had and what we didn't.
I have no ignition or timing system at all. No pistons, and only half of the oil pump so if anyone has any of these parts they
no longer need please let me know as this build will be done on a very tight budget so 2nd parts will have to suffice.
oh and I managed to find out the rego plate number today.... hmmm lots of years riding with no rego me thinks. :yes:

Is it an XL or XLCH? I guess by 76 the ignition systems were the same but XLCH used to have magnetos (I think)

I have a mate in the states whos mad on the bloody things (actually hes just mad in general) if you need stuff...

[Getting Old]

I go past pukerau bay most days if it helps?? (and yeah - let me know if you dont want the head - seriously, dont listen to doug, hes evil)

Thanks bloke I will keep that in mind if I need something checked out. As for the head I am figuring at some point that will be used as a trade off for a part that I need, as I said this is a budget build.
Out of curiosity guys what sort of $$ would the head be worth?

[Getting Old]

It's a xlch and I think you are right about having a magneto setup. Yet another part that is missing.
It's like I am one box short of the complete bike.....

[Paul in NZ]

Thanks bloke I will keep that in mind if I need something checked out. As for the head I am figuring at some point that will be used as a trade off for a part that I need, as I said this is a budget build.
Out of curiosity guys what sort of $$ would the head be worth?

Totally depends on condition. Frankly some are barely worth the scrap value.

Needs to be flat, un machined, sound valve seats and all fins intact. Hopefully good threads as well.

[Paul in NZ]

It's a xlch and I think you are right about having a magneto setup. Yet another part that is missing.
It's like I am one box short of the complete bike.....

I know some of the 60's ones did and the magnetos are a bit rare (so I'm told) but by 76 I suspect they were all points and coils?

[Getting Old]

Does anyone know of a complete engine going cheap. Figure it may be the cheapest and easiest way.

[Katman]

Does anyone know of a complete engine going cheap. Figure it may be the cheapest and easiest way.

I was going to suggest this as soon as I saw the photo of the crankshaft.

[Paul in NZ]

Theres a very good chance you would end up with a worse pile of munt than you already have albeit in one oily lump. I guess complete HD motors must be about but....

Expensive business restoring / rebuilding bikes.

HD parts are usually pretty cheap (relatively) and nothing is ever beyond hope...

[Getting Old]

I hear what you are saying Paul. I have been looking at prices through the states for all new parts and basically just
using my crank case and to be honest it's a lot cheaper than i thought it would be.

[Paul in NZ]

I hear what you are saying Paul. I have been looking at prices through the states for all new parts and basically just
using my crank case and to be honest it's a lot cheaper than i thought it would be.

Fortunately Iron Head sporties seem to blow up heaps generating a good aftermarket industry. The other good thing is, apparently they are fun to ride hence the blowing up ;-)

[popelli]

Fortunately Iron Head sporties seem to blow up heaps generating a good aftermarket industry. The other good thing is, apparently they are fun to ride hence the blowing up ;-)

put together properly they are fast and reliable

I have owned a few iron heads and have done a ground up rebuild on my 77 and have rebuild a 80 motor and know a little about them

my advice buy a factory manual

other advice 76 had a stupid cross over gear change linkage, ditch it and go for the earlier right hand side gear change the earlier parts fit straight it

pm me if you need any advice I have factory parts and workshop manuals and can email you copies of what you need

[blackdog]

would this help?

http://www.trademe.co.nz/Trade-Me-Motors/Motorbikes/Motorbikes/Classic-vintage/auction-341663032.htm

[sinfull]

put together properly they are fast and reliable

I have owned a few iron heads and have done a ground up rebuild on my 77 and have rebuild a 80 motor and know a little about them

my advice buy a factory manual

other advice 76 had a stupid cross over gear change linkage, ditch it and go for the earlier right hand side gear change the earlier parts fit straight it

pm me if you need any advice I have factory parts and workshop manuals and can email you copies of what you need

Wanna sell your 77 ?

[The Lone Rider]

Hey guys I have been on here a while now but this is my 1st post so not sure if I have landed it in the right place or not.
A mate of mine has kindly given me a 1976 Harley Davidson sportster that belonged to her late husband who unfortunately died during it's rebuild.
The bike to put it bluntly a complete basket case and one hell of a jigsaw puzzle to say the least.
It is in a 1000 pieces and is gunna take some work to get her back together, I feel the biggest problem will be sourcing
the missing bits.
Anyway watch this space guys as I am on a mission to get the old girl on the road as quick as I can.

At this point a big thank you has to go out to Carl (Who is no doubt a member on here) for his help last night in sorting and identifying
parts, I am stoked to have you by my side on this build for without the titivating conversation and your overall mechanical
experience with bikes I am sure this project would take far more time then it is going to.

http://i66.servimg.com/u/f66/12/96/61/91/dscf9010.jpg (http://www.servimg.com/image_preview.php?i=134&u=12966191)

http://i66.servimg.com/u/f66/12/96/61/91/dscf9011.jpg (http://www.servimg.com/image_preview.php?i=135&u=12966191)

http://i66.servimg.com/u/f66/12/96/61/91/dscf9012.jpg (http://www.servimg.com/image_preview.php?i=136&u=12966191)

http://i66.servimg.com/u/f66/12/96/61/91/dscf9013.jpg (http://www.servimg.com/image_preview.php?i=137&u=12966191)

http://i66.servimg.com/u/f66/12/96/61/91/dscf9014.jpg (http://www.servimg.com/image_preview.php?i=138&u=12966191)

http://i66.servimg.com/u/f66/12/96/61/91/dscf9015.jpg (http://www.servimg.com/image_preview.php?i=139&u=12966191)

http://i66.servimg.com/u/f66/12/96/61/91/dscf9016.jpg (http://www.servimg.com/image_preview.php?i=140&u=12966191)

http://i66.servimg.com/u/f66/12/96/61/91/dscf9017.jpg (http://www.servimg.com/image_preview.php?i=141&u=12966191)

http://i66.servimg.com/u/f66/12/96/61/91/dscf9018.jpg (http://www.servimg.com/image_preview.php?i=142&u=12966191)

http://i66.servimg.com/u/f66/12/96/61/91/dscf9019.jpg (http://www.servimg.com/image_preview.php?i=143&u=12966191)

http://i66.servimg.com/u/f66/12/96/61/91/dscf9021.jpg (http://www.servimg.com/image_preview.php?i=145&u=12966191)

http://i66.servimg.com/u/f66/12/96/61/91/dscf9022.jpg (http://www.servimg.com/image_preview.php?i=146&u=12966191)

http://i66.servimg.com/u/f66/12/96/61/91/dscf9023.jpg (http://www.servimg.com/image_preview.php?i=147&u=12966191)

http://i66.servimg.com/u/f66/12/96/61/91/dscf9024.jpg (http://www.servimg.com/image_preview.php?i=148&u=12966191)


Kiwibiker is the wrong place for getting that together.

Go to greasemonkeys.co.nz

Chances are some of them will not only be able to come over and give you a hand putting it together, but will have some spare parts and even help you customize it as you go.

[popelli]

Wanna sell your 77 ?

No - not until hd build something better looking

[popelli]

Kiwibiker is the wrong place for getting that together.




possibly - very few iron heads on kiwi biker

try the Jockey Journal forum, its based primarily around triumph, bsa, iron head and shovel head motors

[vj paul]

I have just fully rebuild a 76 iron and cost me near on 2 grand,but with a few up grades,cv carb and 80S electronic ignition.
76 years didnt have magneto.
With the 76 cases you have the option of kick start and going right shift as well,
i have work shop manuals and parts catalogs if you need info
Rebuild the oil pump as it cant be done while engine is in the frame, check your oil transfer valve is working also i wouldnt run shims on the cams as well, these get chewed up,
These engines are easy to rebuild and run strong
i have plenty of info if you need anything
Paul

[popelli]

i wouldnt run shims on the cams as well, these get chewed up,


how are you taking up the end float on the cams?

without shims or making custom made bushes to take up the end float the motor is going to rattle like £uck

[popelli]

i wouldnt run shims on the cams as well, these get chewed up,


how are you taking up the end float on the cams?

without shims or making custom made bushes to take up the end float the motor is going to rattle like £uck

[vj paul]

how are you taking up the end float on the cams?

without shims or making custom made bushes to take up the end float the motor is going to rattle like £uck


Harley put a service bulletin back in the 80s outlining this,
there have been ongoing debates about this for years,
I will find the bulletin and post it later.
On my rebuild i did put shims in but due to a leak i ended up taking the cam case off when i found the shims chewed up on all cams.

[popelli]

never had a problem with the shims

have found where hd forgot to pin one of the bushes and the bush was spinning quite happily in the cases

[vj paul]

You will just about find all the info on any ironhead rebuild on this site.
http://xlforum.net/vbportal/forums/showthread.php?t=1003853

[popelli]

stopped using the XL forum several years ago

most of the forum is devoted to rubbermount sporties and peiopel more worried about their credit card ratings than their bikes

did get some useful advice from one guy whi had had idenictal problems putting his XLCR together that I encounted

Jockey Journal is a far better forum and more entertaining as well