My Ironhead - A 1984 Harley Davidson Sportster rebuild project

It’s getting warmer!

admin — Sun, 27 Mar 2011 22:30:11 +0000

I’m going to be taking the engine out over the next few days. I’ll post photos as I do. I’m going to disconnect the chain, front and rear bolts that hold the engine to the frame, take off the coil and pull the engine out the left side.

My poor sporty…

admin — Tue, 18 Jan 2011 05:54:07 +0000

It want’s to go out and play SO bad. This project is very overwhelming. I’m by no means a motorcycle mechanic… and this bike needs SO much work. I won’t settle for just fixing the rear head. This thing is a classic and it needs to be treated that way. What I’ve decided to do is strip it down to the frame and rebuild it from the ground up. I’ve got the official HD manual for this bike, so at least I have somewhere to start. I’m going to have a pro rebuild the motor. I’ll add more as I get it taken apart. It’s really depressing looking at it, all naked, half taken apart in my garage.

Warm at last

admin — Thu, 10 Jun 2010 05:08:58 +0000

I’m putting the project on hold for a while, but I’ll start again soon… (i hope!)

S-L-O-W week!

admin — Wed, 21 Apr 2010 17:23:29 +0000

Haven’t worked on the bike this week. It’s pouring snow outside right now. We’ll have one last attempt of winter, then a few weeks of spring, and then a half a year of summer. That’s how it works in Reno. Then I’ll start working on the bike again.

I’m really thinking about tearing everything off the bike and doing it right. I know later on I’ll be glad I did.

First things first

admin — Sat, 10 Apr 2010 05:35:37 +0000

After showing some of the images of the frame to some local Harley gurus, I’ve decided to go with their advice. I’m going to patch up the holes, primer, sand, primer, sand, then paint and get the tank modified so it will mount properly on the frame where it’s suppose to. Then I’ll clean up the engine, which will take forever. Living in Reno, EVERYTHING here gets covered with Nevada dust after 2 weeks. Dust on oil just makes for more of a mess.

I found a local shop that has a mechanic that has been working on these things for over 25 years. I’m going to drop it off to him so he can give it a go-through and tell me what is going on with the bike. I’ll know more from there if I need to tear into the motor.

I was so excited when I got home to start to tear the bike down a little to get it cleaned up, but I’m missing my small ratchet, so I’ve got to stop by sears tomorrow and pick up a new one. I think I have to take the primary cover off to get the starter off so I can clean up around there. It’s a dusty, oily mess. I want to coat the entire thing in easy off oven cleaner, and take it to the car wash… that may not be such a bad idea! I also discovered a yellow wire that abruptly ends under the fuel tank. I have no idea what it is. I’m going to have to trace it and consult my manual to see what it is.

I purchased a complete gasket kit for the engine (which I can’t find) and a new copper head gasket, which I finally found today after tearing apart my computer room, or my man cave as my wife calls it. It was hiding right were I put it so I wouldn’t loose it. I found these tappet guides that are suppose to help with oil leaking out of the bottom of the push rods. I think I’m going to pick up a few of them and use them. One less oil leak to worry about.

http://www.retrocycle.com/CustomChromeParts/3607/Tappet_Guide_for_Sportster_Models.html

Watch the youtube video on them here:

Where to begin??

admin — Fri, 09 Apr 2010 01:36:15 +0000

Okay, so a bit of uncertainty set in today. I’m not sure where to even start on this thing. As you can see, the frame basically needs a new paint job due to the morons who put the new tank on. It looks like they just drilled holes until the new tank fit. I’m asking for help here. Should I tear this bike appart and do it right, or do you think this is fixable without doing that. Remember, the bike only has 22,700 miles on the motor.

I’m not exactly why it’s so hard to get proper hole drilled on a frame. Measure twice, drill once! I guess the 4th time is a charm…

I’m not sure what’s worse. The front, or the back…

That hole in the frame on the top where the rear of the larger tank mounted was way off center. To add to the damage, they let the tank sit on the frame without any rubber mounts, which I assume caused all of the paint chipping.

Anyways, let’s move on. Here are full images of what she looks like with the tank, pipes, rear head, carb and air filter removed…

I’m going to have to think about what needs to be done about this frame. Besides those areas on the top, the frame is in good shape. a scratch here and there, but not deep down to the primer. Praise Jesus it’s not rusting!

Here we go!

admin — Wed, 07 Apr 2010 14:20:03 +0000

I came across a late 1984 Sportster a few years ago. First thing I noticed when I fired it up was it needed a rear head gasket. “No problem”, I thought. Turns out I’m a much better network / computer technician than I am a motorcycle mechanic.

This is a journey down an uncertain road to get my sporty back up and running, and I have a feeling I’m going to need a lot of help, tips and pointers to do so.

I’ve had the local Reno Harley Davidson order a “authentic” repair manual for it. I was told it’s a lot better than others. I’m hoping it will assist me in my journey into the unknown.

About this Harley:

1984 & 1/2 HD XLX Sportster
22,700 miles
1000 cc ironhead motor
Leaks oil out of every possible location it can
All of the buttons, blinkers and horn need replaced. It may need eletrical work as well, but it did start up perfectly before I ripped the rear head off.

I’m going to need help getting this thing back together. I’ll post more pictures once the weather here in Reno warms up.

I have set a date of June 1st, 2010 as a goal to get this thing up and running so I can cruise around Street Vibrations. I seriously doubt I’ll make that, but whatever…