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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|<WRAP>
  * Air Cleaner
  * Battery Rear
  * Chain Adjustment
</WRAP>|
|Every 2000 Miles|<WRAP> 
  * 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
</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
  * Spark Control Cable (if used)
  * Seat Post (saddle only
  * Generator Bearing (1960 & earlier)
</WRAP>|<WRAP>
  * Tappet Adjustment
  * Clutch Adjustment
  * Brake Adjustment
  * Oil Filter
  * Front Chain Adjustment
  * Rear Chain Oiler
  * Circuit Breaker Points
</WRAP>|
|Every 5000 Miles|<WRAP>
  * Throttle Control Spiral
  * Spark Control Spiral (if used)
  * 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
</WRAP>|
|Every 10000 Miles|<WRAP>
  * Repack Rear Fork Pivot Bearings
  * Repack Generator Bearing (1961 and later)
</WRAP>|   |   |
|Every 50000 Miles|<WRAP>
  * Repack Steering Head Bearing
</WRAP>|  |  |
|Weekly|  |  |<WRAP>
  * Check Tires and Battery
</WRAP>|
((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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