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1957 - 1969
Chassis
Wheels and Tires
Removal
Assembly
Bearings
Installation
Lacing
Truing
Runout
Tires
Tube
Tubelsss
Alignment
Balancing
Weights
Runout
Brakes
Fork
Hand Controls
Handlebars
Exhaust
Fenders
Seat
Shocks
Jiffy Stand
1957 - 1969 Sportster Service Intervals
Regular Service Interval
| Grease | Oil | Service |
Every 1000 Miles | | Rear Chain |
Air Cleaner
Battery Rear
Chain Adjustment
|
Every 2000 Miles | | |
Tappet Adjustment
Clutch Adjustment
Brake Adjustment
Oil Filter
Front Chain Adjustment
Rear Chain Oiler
Circuit Breaker Points
|
Every 5000 Miles |
Throttle Control Spiral
Spark Control Spiral (if used)
Circuit Breaker Camshaft
Front Wheel Hub (1964 & earlier)
Speedometer and Tachometer Cables
| |
Check Front and Rear Fork Bearing Adjustment
Replace Spark Plugs and Oil Filter Element
Inspect and switch tires
Time Ignition
Clean Gas Tank Strainer
Check Generator Brushes
Check Shock Rubber Bushings
|
Every 10000 Miles | | | |
Every 50000 Miles | | | |
Weekly | | | |
1)
Service Interval Engine and Transmission
| 300 Miles | 1000 Miles | 2000 Miles | 5000 Miles or 1 Year | Spring and Fall |
Engine Oil | Check | Check | Change | | Change |
Transmission Oil | | Check | | Change | Change |
2)
POC for this page — Bert Linson 2016/01/20 20:03
1957 - 1969 Sportster Engine Specifications
Valves
Rocker Arm
Piston
Fit in cylinder: .0025 - .003 in. loose
Ring Gap: .010 - .020 in.
Compression Ring side clearance: .0025 - .004 in.
Oil ring side clearance: .003 - .005 in.
Piston pin fit: Light hand press fit at 70 degrees Fahrenheit.
Connecting Rod
Piston pin fit: .0008 - .001 in. loose
End play between flywheels: .006 - .010 in.
Fit on crank pin: .0008 - .001 in. loose
Oil Pump Pressure
Minimum: 6 lbs. / sq. in. At 20 MPH
Tappets
Guide fit: .0005 - .001 in. press
Fit in guide: .0005 - .001 in. loose
Roller fit: .0005 - .001 in.
Roller end clearance: .008 - .010 in.
Tappet clearance: Just free (no lash) - Engine cold
Gearcase
Flywheel Assembly
Gear shaft nut torque: 100 ft-lbs
Sprocket shaft nut torque: 100 ft-lbs
Crank pin nuts torque: 150 ft-lbs
Runout (flywheels): .002 in. maximum at rim
Runout (main shafts): .001 in. maximum
Sprocket Shaft Bearing
Cup fit in crankshaft: .0005 - .0025 in. tight
Cone fit on shaft: .0002 - .0012 in. tight
End play: .001 - .010 in.
Pinion Shaft Bearing
Ignition Timing
Breaker point gap setting
Dwell: 90 degrees @ 1000 rpm
Spark plug gap setting
Ignition timing
Ignition timing - Retarded
DC Model Idle Port Holes Drill Sizes
Model | Drill Sizes |
DC-1, 1L, 1M, 10 | 70 (.028) |
DC-2 | 56 (.0465) |
DC Model Nozzle Bleed Holes Cleaning Drills
Model | Drill Size |
DC-1, 1L, 1M, 10, 6, 7, 12 | 55 (.052) |
DC-2 | |
Calibration and Setting Chart
DC Model | Idle Bleed | Idle Tube Feed | Fixed Jet | Turns High-Speed Setting | Turns Idle Speed Setting | Throttle Disc Mark |
DC-1 | #53 (.0595) | #69 (.0293) | #9 (.067) | 3/4 to 1-1/4 | 3/4 to 1-1/4 | 9A |
DC-1L | #53 (.0595) | #69 (.0293) | #4 (.0625) | 3/4 to 1-1/4 | 1 to 1-1/4 | 9A |
DC-1M | #53 (.0595) | #69 (0.293) | #1 (.052) | 3/4/ to 1-1/4 | 1 | 9A |
DC-10, 6, 12 | #53 (.0595) | #69 (.0293) | #4 (.0625) | 3/4 to 1-1/4 | 1to 1-1/4 | 9A |
DC-2 | #51 (.067) | #70 (.028) | #20 (.0452) | 3/4 to 1-1/4 | 1 to 1-1/4 | 12 |
DC-7 | #53 (.0595) | #69 (.0293) | - (.070) | 3/4to 1-1/4 | 1 to 1-1/4 | 9A |
1957 - 1969 Sportster Transmission Specifications
1957 - 1969 Sportster Transmission Specifications
Clutch
Chain
Starter
Mainshaft Group
Clutch gear ball bearing in case: .0001 - .0012 in loose
Ball bearing on clutch gear: .0001 in. loose - .0009 in. tight
Clutch gear on mainshaft: .001 - .002 in. loose
Mainshaft right side roller bearing: .0006 - .0014 in. loose
Mainshaft end play: .004 - .009 in.
Third gear
Countershaft Group
Countershaft end bearings: Retained needle roller bearing
Bearing fit on shaft ends: .0005 - .002 in. loose
Bearing fit in case: press
End play: .004 - .009 in.
Second gear
Low gear
Drive gear
Clearance between clutch faces
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