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

GreaseOilService
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

1)

Service Interval Engine and Transmission

300 Miles1000 Miles2000 Miles5000 Miles or 1 YearSpring and Fall
Engine OilCheckCheckChange Change
Transmission Oil Check ChangeChange

2)

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

ModelDrill Sizes
DC-1, 1L, 1M, 1070 (.028)
DC-256 (.0465)

DC Model Nozzle Bleed Holes Cleaning Drills

ModelDrill Size
DC-1, 1L, 1M, 10, 6, 7, 1255 (.052)
DC-2

Calibration and Setting Chart

DC ModelIdle BleedIdle Tube FeedFixed JetTurns High-Speed SettingTurns Idle Speed SettingThrottle Disc Mark
DC-1#53 (.0595)#69 (.0293)#9 (.067)3/4 to 1-1/43/4 to 1-1/49A
DC-1L#53 (.0595)#69 (.0293)#4 (.0625)3/4 to 1-1/41 to 1-1/49A
DC-1M#53 (.0595)#69 (0.293)#1 (.052)3/4/ to 1-1/419A
DC-10, 6, 12#53 (.0595)#69 (.0293)#4 (.0625)3/4 to 1-1/41to 1-1/49A
DC-2#51 (.067)#70 (.028)#20 (.0452)3/4 to 1-1/41 to 1-1/412
DC-7#53 (.0595)#69 (.0293)- (.070)3/4to 1-1/41 to 1-1/49A

1) , 2)
Harley Davidson 1957 - 1969 Service Manual
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