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techtalk:ih:body04 [2019/06/17 17:02]
techtalk:ih:body04 [2021/03/25 20:16] (current)
hippysmack ↷ Page name changed from techtalk:ih:body03 to techtalk:ih:body04
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 +[[:​techtalk:​menu|{{ ​ :​techtalk:​gototechnicalmenu.jpg|}}]]
 +====== IH: Body Parts ======
 +
 +====== HANDLEBARS, LEVERS & CABLES ======
 +
 +\\
 +
 +Here is a list of OEM handlebars:
 +
 +|Model|Year(s)|Handlebar Serial Number / Type|
 +|XLH|1965-1972|2 piece design: Left (56084-65) / Buckhorn (bare) ((HD XLH XLCH-1000 Parts Catalog (99451-78B) ))| 
 +|   ​|1967-1972|2 piece design: Left (56087-63) / Sport (bare)((HD XLH XLCH-1000 Parts Catalog (99451-78B) ))|
 +|  |1968-1978|2 piece design: Left (56087-68) ((HD XLH XLCH-1000 Parts Catalog (99451-78B) ))|  ​
 +|   ​|1969-1978|2 piece design: Right (56078-69A) / Buckhorn with starter and directional switches((HD XLH XLCH-1000 Parts Catalog (99451-78B) ))|
 +|   |Late 1969-1972|2 piece design: Right (56085-69A) / Sport with starter and directional switches((HD XLH XLCH-1000 Parts Catalog (99451-78B) ))|
 +|   |Late 1969-1972|2 piece design: Right (56088-69A) / Sport with starter switch ((HD XLH XLCH-1000 Parts Catalog (99451-78B) ))| 
 +|   |Late 1969-1972|2 piece design: Right (56083-69A) / Buckhorn with starter switch((HD XLH XLCH-1000 Parts Catalog (99451-78B) ))| 
 +|   ​|1972|2 piece design: Right (56093-70) / Buckhorn (bare)((HD XLH XLCH-1000 Parts Catalog (99451-78B) ))|
 +|   ​|1973|2 piece design: Left (56084-73) / Buckhorn (bare) ((HD XLH XLCH-1000 Parts Catalog (99451-78B) ))| 
 +|   ​|1973|2 piece design: Right (56083-73) / Buckhorn (for switches) - (bare) ((HD XLH XLCH-1000 Parts Catalog (99451-78B) ))| 
 +|   ​|1974-Early 1976|Handlebar Assembly (56003-75) / Buckhorn ((HD XLH XLCH-1000 Parts Catalog (99451-78B) ))|
 +|   |Late 1976 to 1978| Handlebar Assembly (56003-76) / Buckhorn ((HD XLH XLCH-1000 Parts Catalog (99451-78B) ))|
 +|   ​|1974-1976|One piece:​(56083-74) / Buckhorn (bare) ((HD XLH XLCH-1000 Parts Catalog (99451-78B) ))|
 +|  |1977-1978|Handlebar Assembly (56003-77) ((HD XLH XLCH-1000 Parts Catalog (99451-78B) ))|
 +|   ​|1977-Early 1979|One piece:​(56083-77) / Buckhorn (bare) ((HD XLH XLCH-1000 Parts Catalog (99451-78B) )) ((HD 1979 XLH XLCH XLS 1000 Parts Catalog (99451-79A) ))((HD 1979-1985 Sportster Parts Catalog pg 97))|
 +|   |Late 1979-1980|(56083-74) / Buckhorn (bare) ((HD 1979-1985 Sportster Parts Catalog pg 97)) Buckhorn| ​
 +|XLCH|1963-1964|2 piece design: Left (56087-63) / Sport (bare)((HD XLH XLCH-1000 Parts Catalog (99451-78B) ))|
 +|   ​|1968-Late 1969|2 piece design: Right (56089-69) with starter switch ((HD XLH XLCH-1000 Parts Catalog (99451-78B) ))|
 +|   |Late 1969-1972|2 piece design: Right (56088-69A) / Sport with starter switch ((HD XLH XLCH-1000 Parts Catalog (99451-78B) ))| 
 +|   ​|1970-1972|2 piece design: Right (56093-70) / Buckhorn (bare)((HD XLH XLCH-1000 Parts Catalog (99451-78B) ))|
 +|   ​|1970-1972|2 piece design: Left (56087-63) / Sport (bare)((HD XLH XLCH-1000 Parts Catalog (99451-78B) ))|
 +|    |1970-1972|2 piece design: Left (56084-65) / Buckhorn (bare) ((HD XLH XLCH-1000 Parts Catalog (99451-78B) ))| 
 +|    |1970-1972|2 piece design: Right (56068-70) / Sport with directional switch ((HD XLH XLCH-1000 Parts Catalog (99451-78B) ))|
 +|    |1970-1972|2 piece design: Right (56069-70) / Buckhorn with directional switch ((HD XLH XLCH-1000 Parts Catalog (99451-78B) ))| 
 +|    |1970-1972|2 piece design: Right (56082-70) / Sport (bare)((HD XLH XLCH-1000 Parts Catalog (99451-78B) ))| 
 +|    |1973|2 piece design: Left (56084-73) / Buckhorn (bare) ((HD XLH XLCH-1000 Parts Catalog (99451-78B) ))| 
 +|    |1973|2 piece design: Right (56083-73) / Buckhorn (for switches) - (bare) ((HD XLH XLCH-1000 Parts Catalog (99451-78B) ))|
 +|    |1974-Early 1976|Handlebar Assembly (56003-75) / Buckhorn ((HD XLH XLCH-1000 Parts Catalog (99451-78B) ))|
 +|    |1974-1976|(56083-74) / Buckhorn (bare) ((HD XLH XLCH-1000 Parts Catalog (99451-78B) ))|
 +|    |Late 1976 to 1978| Handlebar Assembly (56003-76) / Buckhorn ((HD XLH XLCH-1000 Parts Catalog (99451-78B) ))|
 +|   ​|1977-1978|Handlebar Assembly (56003-77) ((HD XLH XLCH-1000 Parts Catalog (99451-78B) ))|
 +|   ​|1977-Early 1979|One piece:​(56083-77) / Buckhorn (bare) ((HD XLH XLCH-1000 Parts Catalog (99451-78B) )) ((HD 1979 XLH XLCH XLS 1000 Parts Catalog (99451-79A) ))((HD 1979-1985 Sportster Parts Catalog pg 97))|
 +|   |Late 1979-1980|(56083-74) / Buckhorn (bare) ((HD 1979-1985 Sportster Parts Catalog pg 97))| 
 +|XLR|1970 and up through?​|(56027-70R)|
 +|XLCR 1000|1977-1978|(56002-77) ((1977 HD XLCR 1000 Parts Catalog pg 57))|
 +|XLS 1000|1979 and up through?​|(55963-77) Drag Bar ((1979 HD Sportster Parts Catalog pg 59)) |
 +|XR|1970 and up through?​|(56027-70R)|
 +|XL 1000|1981|(56081-81) Buckhorn ((HD 1979-1985 Sportster Parts Catalog pg 97))|
 +|        |1982-1985|(56081-82) Buckhorn (pullback) ((HD 1979-1985 Sportster Parts Catalog pg 97))|
 +|XLS 1000|1979-1980|(55963-77) ​ Straight bar w/ bent ends ((HD 1979-1985 Sportster Parts Catalog pg 97))|
 +|        |1981|(56081-81) Buckhorn ((HD 1979-1985 Sportster Parts Catalog pg 97))|
 +|        |1982|(56081-82) Buckhorn (pullback) ((HD 1979-1985 Sportster Parts Catalog pg 97))|
 +|        |1983-1985|(56082-83) Flat Bar ((HD 1979-1985 Sportster Parts Catalog pg 97))|
 +|XLX-61|1983-1985|(56085-83) (black only) ((HD 1979-1985 Sportster Parts Catalog pg 97))|
 +
 +===== Additional Handlebar Information =====
 +Right side bars with no switch holes were used on all: \\ 
 +k, kk, kh, khk, kr, krm, khrm. \\
 +Also the were used on all xl and xlh prior to 67 provide the bike wasnt fitted with factory directionals. \\
 +And all 70-72 xlch without directionals. \\
 +All 1973. \\
 +So no switch right side bars are very common. \\
 +
 +Conversely, the bikes that did use right side switches are \\
 +59-69 xlch (button as kill) \\
 +67-72 xlh \\
 +70-72 xlch with directionals. \\
 +
 +
 +
 +'​52-'​73. \\
 +As far as factory fitments: \\
 +67> is pretty clear by using part cat listings \\
 +66< not so much. \\
 +For example long bars were fitted up to at least 1960 probl by dealer order, book says e57. \\
 +Speedsters on 66ch is real, but the book realy dont address the right side correctly. \\
 +
 +**In the following: ls= left side - rs= right side** \\
 +
 +**Long Bars** (high bucks)
 +|56083-52 rs|
 +|56084-52 ls|
 +|52 only. uses grip retention collars|
 +|56083-53 rs no switch holes|
 +|56083-58 rs direction switch holes|
 +|56083-53 ls horn and hi-low|
 +
 +**Speedsters**
 +|56085-53 ls horn and hi-low, twist grip|
 +|56085-65 ls horn and hi-low, no twist grip|
 +|56086-53 rs no holes|
 +|56086-58 rs directional|
 +|56065-66? (66ch) rs kill button. \\ part number is unsure. could also be 56086-53a.|
 +
 +
 +**Buckhorns**
 +|56069-70 rs directionals only|
 +|56078-67 rs starter and directional|
 +|56078-69a rs starter and directionals. \\ drilled for front brake lite wires.|
 +|56083-57 rs no holes|
 +|56083-65 rs kill button.|
 +|56083-69a rs kill & drilled for front brake lite wires.|
 +|56093-70 rs no holes (may be same as 56083-57)|
 +|56084-57 ls horn & hi-low, twist grip.|
 +|56084-65 ls horn & hi-low, no twist grip.|
 +
 +
 +**XL Bars**
 +|56081-68 ls horn, hi-low, twist grip|
 +|56087-68 ls horn, hi-low, no twist grip|
 +|56085-68 rs starter, directionals|
 +|56086-69 rs starter, directionals hole for front brake lite wires.|
 +|56089-69 rs kill button.|
 +
 +
 +**Laconias/​Sport**
 +|56087-58 ls (kill 58ch) horn and twist grip capable. \\ Used immolbizing spacer 56227-53.|
 +|56087-58a ls horn, no twist capable.|
 +|56087-63 ls horn, hi-low, no twist.|
 +|56087-65 ls horn, hi-low, twist grip.|
 +|56068-70 rs directional|
 +|56082-70 rs no holes|
 +|56085-67 rs starter, directional|
 +|56085-69a rs starter, directionals,​ hole for front brake lite wire|
 +|56088-58 rs no holes.|
 +|56088-59 rs kill or starter|
 +|56088-69a rs starter drilled for front brake lite wires.|
 +|56088-59 rs kill button.|
 +
 +73 was the half and half year. \\
 +the only bars were bucks, and they still had the internal throttle (last yr for this). \\
 +but \\
 +the switches were now in the perches. and the wire ran along (rather than inside) the bar. \\
 +so \\
 +73 was the only year with internal throttle and external switches / wiring. \\
 +
 +To identify these bars:
 +|56083-73 rs two 1/8" holes along the underside of bar \\ to accept spring clips that held the wires.|
 +|56084-73 ls two 1/8" holes along the underside of bar \\ to accept spring clips that held the wires.|
 +
 +The one pc stainless bars with the external throttle debuted in 74.
 +
 +
 +====== Clutch Levers ======
 +
 +
 +\\
 +
 +====== Clutch Cables ======
 +
 +  * 1957-1970
 +  * A new control cable coil should be app. 47-3/4 in. for speedster (sport) bars and 51-1/16 in. for Buckhorns. ((1959-1969 HD Sportster FSM pg 4B-7))
 +  * See also [[techtalk:​ih:​transfinal02#​adjusting_clutch_release_mechanism|Adjusting Clutch Release Mechanism]]
 +
 +\\
 +
 +====== Brake Levers ======
 +
 +
 +\\
 +
 +====== Brake Cables ======
 +
 +
 +\\
 +
 +====== Grips ======
 +
 +
 +\\
 +
 +====== Throttle Cables ======
 +====== 1981 to 1985 (Present) ======
 +  * All 1981 model motorcycles are equipped with a dual cable (pull-pull) throttle assembly. The throttle cable pulls the throttle butterfly open when turned counter-clockwise (as on previous models) while the idle cable pulls the butterfly closed when the grip is turned clockwise. ​ The  carburetor ​ is equipped with a return spring which closes the throttle when grip is released (as on previous models). ((HD Service Bulletin #M-804 dated November 4, 1980))
 +  * The throttle cable has a 5/​16"​x18 threaded adjuster and is assembled to the right side of the throttle grip. The idle cable has a 1/​4"​x20 threaded adjuster and is assembled to the left side of the throttle grip.
 +  * Check the FSM for cable replacement and routing procedures whenever replacing a cable.
 +  * Adjusting:
 +    * All adjustments must be made with the ad­justing screw backed off far enough to allow free rotation of the throttle grip. Proper adjustment of these two cables is critical for proper throttle function and prevention of stress to or failure of the cables.
 +    * Turn the cable adjusters and locknuts clockwise as far as they will go. Both cables should have zero adjustment to start this procedure.
 +    * Point the front wheel straight ahead. Turn the throttle grip so the throttle is wide open (fully counterclockwise) and hold it there. Now turn the throttle cable adjuster counterclockwise until the throttle cam stop just touches the stop boss on  the carburetor. Tighten the locknut against the throttle cable adjuster and release the throttle.
 +    * Be sure the adjusting screw is backed off far enough to allow the rapid return of the throttle grip to it'​s ​ stop.
 +    * Turn the front wheel full right. Turn the idle cable adjuster counterclockwise until the cable housing just touches the spring in the cable support sleeve. Work the throttle grip to make sure throttle cable returns to idle position when released. If the cable does not return to idle, turn adjuster clockwise to achieve the correct adjust­ment. Tighten the locknut against the idle cable adjuster.
 +
 +
 +
 +\\
 +[[:​techtalk:​menu|{{:​techtalk:​gototechnicalmenu.jpg|}}]]