IH: General Technical Information

1957 - 1969

Chassis

Wheels and Tires

Removal
Assembly
Bearings
Installation
Lacing
Truing
Runout
Tires
- Tube
- Tubelsss
- Alignment
- Balancing
- Weights
- Runout

Brakes

General Info and Troubleshooting
Front Master Cylinder
Front Caliper
Rear Master Cylinder
Rear Linkage
Rear Caliper
Brake Lines
Brake Bleeding

Fork

Hand Controls

Foot 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	Rear Brake Shaft Front Brake Shaft Rear Brake Cross-over Shaft Clutch Release Worm Foot Shift Lever Seat Bar Roller and Bolt (Seat post saddle only) Kick Starter Shaft Rear Wheel Hub Tachometer Drive Gear	Rear Brake Rod Clevis Front Brake Cable Clevis Clutch Hand Lever Brake Hand Lever Clutch Control Cable Front Brake Cable Throttle Control Cable Spark Control Cable (if used) Seat Post (saddle only Generator Bearing (1960 & earlier)	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	Repack Rear Fork Pivot Bearings Repack Generator Bearing (1961 and later)
Every 50000 Miles	Repack Steering Head Bearing
Weekly			Check Tires and Battery

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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

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POC for this page — Bert Linson 2016/01/20 20:03

1957 - 1969 Sportster Engine Specifications

Valves

Fit in Guide (EX): .0025 - .0045 in
Fit in Guide (IN): .0015 - .0035 in
Spring (outer)
- 52 - 62 lbs. @ 1-9/32 in. (valve closed)
- 155 - 165 lbs. @ 15/16 in. (valve open)
Spring (inner)
- 30 - 35 lbs. @ 1-3/32 in. (valve open)
- 75 - 85 lbs. @ 3/4 in. (valve closed)
Spring free length:
- 1-1/2 in. (outer)
- 1-23/64 in. (inner)

Rocker Arm

Fit in bushing: .0005 - .002 in. Loose

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

Intermediate gear shaft
- In bushing: .0005 - .001 in.
Cam gear shaft in bushing: .0005 - .002 in.
Cam gear shaft
- In needle bearing: .0005 - .0025 in.
Cam gear end play: .001- .006 in

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

Shaft fit in roller bearing: .0008 - .001 in.
Shaft fit in cover bushing: .0005 - .0012 in.

Ignition Timing

Breaker point gap setting
- Battery ignition: .020 in.
- Magneto ignition: .015 in.
Dwell: 90 degrees @ 1000 rpm
Spark plug gap setting
- Battery ignition: .025 - .030 in.
- Magneto ignition: .020 in.
Ignition timing
- XLH - XLCH: 45 degrees (11/16 in. BTC)
Ignition timing - Retarded
- XLH: 15 degrees (5/64 in BTC)

1957 - 1969 Sportster Carburetor Information

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

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Harley Davidson 1957 - 1969 Service Manual

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