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====== IH: General Technical Information ======
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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 =====
* 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
|
((Harley Davidson 1957 - 1969 Service Manual))
===== 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 1957 - 1969 Service Manual))
POC for this page --- //[[bplinson@gmail.com|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|70 (.028)
===== 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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