IH: General Technical Information

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====== IH: General Technical Information ======

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====== 1970 - 1977 ======


====== 1970 - 1977 Service Intervals ======
===== Regular Service Interval =====
^ |Grease|Oil|Service|
|Every 1000 Miles|  |Rear Chain|<WRAP>
  * Air Cleaner
  * Battery Rear
  * Rear Chain Adjustment
  * Gasoline Valve, lines and fittings
  * Check fastener tightness
</WRAP>|
|Every 2000 Miles|<WRAP> 
  * Rear Brake Shaft
  * Front Brake Shaft
  * Rear Brake Cross-over Shaft (1974 & earlier)
  * Clutch Release Worm (1970)
  * Foot Shift Lever
  * Seat Bar Roller and Bolt
  * Kick Starter Shaft
  * Rear Wheel Hub
  * Speedometer Drive (1973 & later)
  * Foot Shift Crossover Shaft (1975-76)
</WRAP>|<WRAP>
  * Rear Brake Rod Clevis
  * Front Brake Cable Clevis
  * Clutch Hand Lever
  * Brake Hand Lever
  * Clutch Control Cable
  * Front Brake Cable
  * Throttle Control Cable
  * Seat Post (saddle only
</WRAP>|<WRAP>
  * Tappet Adjustment
  * Clutch Adjustment
  * Brake Adjustment
  * Oil Filter
  * Front Chain Adjustment
  * Rear Chain Oiler (1976 & earlier)
  * Circuit Breaker Points
</WRAP>|
|Every 5000 Miles|<WRAP>
  * Throttle Control Spiral
  * Circuit Breaker Camshaft
  * Front Wheel Hub (1964 & earlier)
  * Speedometer and Tachometer Cables
</WRAP>|   |<WRAP>
  * 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
  * Change Front Fork Oil (1973 & later)
  * Change Brake Fluid
</WRAP>
|Every 10000 Miles|<WRAP>
  * Repack Rear Fork Pivot Bearings
  * Repack Wheel Bearings
</WRAP>|   |   |
|Weekly|  |  |<WRAP>
  * Check Tires and Battery
</WRAP>|
((Harley Davidson 1970 - 1977 Service Manual))

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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|
((Harley Davidson 1970 - 1977 Service Manual))

POC for this page --- //[[bplinson@gmail.com|Bert Linson]] 2016/01/20 20:03//


====== 1970 - 1977 Sportster Fastener Torque Requirements ======

===== Chassis =====
  *Axle Nut: 50 ft-lbs / 67.79 Nm
  *Brake Disc Mounting Screw: 35 ft-lbs / 47.45 Nm (1973)
  *Brake Disc Mounting Screw: 10 ft-lbs / 13.5 Nm (1974 & later)
  *Fork Stem Pinch Bolt: 20 - 25 ft-lbs / 27.11 - 33.89 Nm
  *Handlebar Clamping Bolt: 20 ft-lbs / 27.11 Nm
  *Front Caliper Bolt: 35 ft-lbs / 47.45 Nm
  *Front Brake Disc Bolt: 35 ft-lbs / 47.45 Nm
===== Engine =====
  *Gear Shaft Nut: 100 - 120 ft-lbs / 135.6 - 162.7 Nm
  *Sprocket Shaft Nut: 100 - 120 ft-lbs / 135.6 - 162.7 Nm
  *Crank Pin Nut: 150 ft-lbs / 203.37 Nm
  *Rocker Arm Cover Screw: 20 ft-lbs / 27.11 Nm
  *Cylinder Head Bolt: 65 ft-lbs / 88.12 Nm
  *Carburetor (Tillotson) Inlet Seat Assembly: 40 - 45 in-lbs / 4.519 - 5.084 Nm
  *Carburetor (Tillotson) Accelerator Pump Channel Plug: 23 - 28 in-lbs / 2.598 - 3.163
  *Clutch Hub Nut (1971 & later): 150 ft-lbs / 203.37 Nm
  *Gear Cover Screws, Chain Cover Screws, and Oil Pump: 100 in-lbs / 11.298 Nm
===== Electrical =====
  *Spark Plug: 20 ft-lbs / 27.11 Nm
  *Starter Motor Thru Bolt (Prestolite): 20 - 25 in-lbs / 27.11 - 33.89 Nm
  *Starter Motor Thru Bolt (Hitachi): 20 - 25 in-lbs / 27.11 - 33.89 Nm

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====== 1970 - 1977 Sportster Engine Specifications ======

===== Valves =====
  *Fit in Guide (EX): .0025 - .0045 in
  *Fit in Guide (IN): .0015 - .0035 in
  *Spring (outer)
    * 55 - 66 lbs. @ 1-9/32 in. (valve closed)
    * 152 - 168 lbs. @ 15/16 in. (valve open)
  *Spring (inner)
    * 30 - 36 lbs. @ 1-3/32 in. (valve open)
    * 76 - 88 lbs. @ 3/4 in. (valve closed)
  *Spring free length:
    * 1-1/2 in. (outer)
    * 1-23/64 in. (inner)

===== Rocker Arm =====
  * Fit in bushing: .001 - .0025 in. Loose

===== Piston =====
  *Fit in cylinder: .003 - .004 in. loose
  *Ring Gap: .005 - .025 in.
  *Ring side clearance: .0035 - .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: .005 - .001 in.
  *Fit on crank pin: .0005 - .001 in. loose

===== Oil Pump Pressure =====
At 60 MPH in high gear (oil hot).
  *Minimum: 10 lbs. / sq. in.
  *Maximum: 20 lbs. / sq. in.

=====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

===== Cam Gear Timing =====
  *Intake
    * Opens: 79 - 85 degrees BTC
    * Closes 79 - 85 degrees ABC
  * Exhaust
    * Opens: 81 - 89 degrees BBC
    * Closes: 76 - 84 degrees ATC

=====Gearcase=====
  *Intermediate gear shaft
    * In bushing: .0005 - .001 in.
  *Cam gear shaft in bushing: .0005 - .002 in.
  *Cam gear shaft
    * In needle bearing: .0005 - .003 in.
  * Cam gear end play
    * 1976 & earlier: .001 - .005 in.
    * 1977 & later: .003 - .007 in.
  * Cam gear backlash: .000 - .0005 in.

=====Flywheel Assembly=====
  *Gear shaft nut torque: 150 ft-lbs
  *Sprocket shaft nut torque: 150 ft-lbs
  *Crank pin nuts torque: 150 ft-lbs
  *Runout (flywheels): .003 in. maximum at rim
  *Runout (main shafts): .002 in. maximum

=====Sprocket Shaft Bearing=====
  *Cup fit in crankshaft: .0005 - .0025 in. tight
  *Cone fit on shaft: .0002 - .0015 in. tight
  *End play: .001 - .007 in.

=====Pinion Shaft Bearing=====
  *Shaft fit in roller bearing: .0005 - .0015 in.
  *Shaft fit in cover bushing: .0005 - .0015 in.

=====Ignition Timing=====
  *Breaker point gap setting
    * 1970: .020 in.
    * 1971 & later: .018 in.
  * Dwell
    * 1970 & 1971: 90 degrees @ 2000 rpm
    * 1972 & later: 140 degrees @ 2000 rpm
  * Spark plug gap setting: .025 - .030 in.
  * Ignition timing - Advanced
    * 1971 & earlier: 45 degrees (11/16 in. BTC)
    * 1972 % later: 40 degrees (17/32 in. BTC)
  * Ignition timing - Retarded
    * 1971 & earlier: 15 degrees (5/64 in BTC)
    * 1972 & later: 10 degrees (1/32 in BTC)




====== 1970 - 1977 Sportster Transmission Specifications ======

===== Clutch =====
  *Type
    * 1970: Dry - Multiple disc
    * 1971 & later: Wet - Multiple disc
  * Capacity: 1971 & later: 1900 in-lbs.
  * Set up Spring Pressure
      * 1970: 150 lbs.
      * 1971: 234 lbs.
      * 1972: 257 lbs.
    * Spring adjustment
      * 1970: 3/16 in. from inner surface of spring tension adjusting plate to outer surface of spring cup flange
      * 1971 - 1973: 11/32 in. from outer surface of outer drive plate to outer surface of releasing disc
      * Late 1974 & later: Fixed spacers standard length 1.530 in.
    * Clutch bearing: .0005 - .002 in. loose
    * Clutch cover
      * 1970: Must be leak proof. No gasket sealer
    * Clutch release rod movement
      * 1970: .095 - .115 in.

===== Chain =====
  *Type primary: 3/8 in. pitch triple chain
  *Looseness: 5/8 to 7/8 in. slack (cold engine) - 3/8 to 5/8 in. slack (hot engine)

===== Starter =====
  * Minimum clearance between clutch teeth on starter clutch gear and clutch with starter in up position: .040 in.
  * Crankshaft endplay: .001 - .007 in.

===== Chain =====
  *Type primary: 3/8 in. pitch triple chain
  *Looseness: 5/8 to 7/8 in. slack (cold engine) - 3/8 to 5/8 in. slack (hot engine)
===== Mainshaft Group =====


===== Countershaft Group =====


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