The objective is to have the crank assembly sitting parallel in the cases. So, for purposes of this exercise I will assume that the 1.000” gage block is accurate and that my vernier dial indicator and vernier digital indicator are off and that the gage block is correct. I could not true the flywheels with those rods installed, the best I could get them down to was about .006" out of round, that is way to much for a crank assembly. Then with the nut snug I haul the rods to my lathe and chuck the assembly up between a couple of centers to check the run out. I do not have my instruments calibrated at a lab, I probably should, but I don't because calibration costs money. Time for a beer. Absolutely clean, I wipe them down with rubbing alcohol and blow them with air just before the final assembly. 0 bids. Extra heads, jugs, tranny gears, shafts etc. The crank pin needs to be inspected and may need replacing, and the sprocket shaft and pinion shaft should be checked as well. At your local bearing house I have found that you can buy the bearings, you can buy the race. These cases have been degreased, soaked in soap and water, degreased, soaked in soap and water again, sandblasted, blown out with compressed air, sandblasted some more, more soap and water, blown out with air again, one more soap and water cycle and blown out with compressed air again. Then a trip to the sandblaster revitalized the cases, and, you know, it started to look not so bad. The screw bottoms out on the crud, yet the hamfist installing the screw notices the screw hasn't yet bottomed on the primary cover. And despite a long hard life, this one ain't dead yet. Repairing the lower end requires specialty tools and skills, and can take considerable time to properly measure and rebuild. It is essential that the flywheel assembly be properly rebuilt and trued, or engine vibration will not only numb your hands and feet, it may cause internal engine damage. I have acquired an assortment of spacers over the years and I now have a small fixture for checking the bearing end play.). Find great deals on eBay for ironhead flywheels. I slobber the rollers up with grease to hold them in place, other wise the bastards go falling all over the place. A caution about installing the rear mount, lightly bolt just the mount to the frame before you bolt it to the engine. The factory manual was the bible and what I didn't find there, you guys gave me. 4-5/8" Stroke Flywheel with Full Width Rods and balancer gear for M8 Models. All things considered, I've got to think that this engine proves how tough a Harley engine can be. I drill and tap the valve for a 6-32 screw and Loctite the screw into the hole. The cylinder enjoys metal to metal contact with the crankcase and all the horsepower that cylinder produces is contained by the mounting bolts, some of which double as through studs that hold the crankcases together. This was a burned, soot encrusted, splattery mess. This was required by the FAA, that way when I measured an airplane piston and cylinder and determined the clearance to be too large I could prove it by the calibration certificate of my measuring instrument. Brand New. Once you get it out you have to carefully clean the recess the washer drops into so that there is a good flush fit, you also need to make sure the old metal that was peened over is completely ground out because that metal will interfere with the washer sitting flush. So the next step will be the final clean up and inspection of the crankcases. the rest is pretty intuitive. or put the bike in gear, hold the rear brake, and loosen the flywheel nut. www.classic-motorcycle-build.com › ironhead-engine-build.html Additionally, silicone is difficult to squeeze out from between mating surfaces, so what happens in some cases is that there is no metal to metal contact between parts. Just for good measure I squirt some carb cleaner down the shaft and make sure it comes out the hole in the flywheel. I have seen several engines where the threaded primary screw holes have longitudinally split. If you're lucky, you may get away with just honing the jugs and installing new piston rings. I use Loctite gasket maker, it is an anaerobic sealer, meaning that it only cures when it is tightly pressed between the surfaces it is sealing. Donny's Tech Guide to Harley-Davidson IRONHEAD SPORTSTER 1957-1985~Softcover~NEW. we’ve completed another Redline Rebuild time-lapse video. Sportster crankshaft rebuilding service. More force. But, you can't buy the spacer or the matched set. I used to mechanic on small airplanes. There are two big negatives for first-time Sportster engine builders. Send a Message to IronHeadCycle. On the surface it looks like it would cost a fortune. And they are a matched set. STAY AWAY FROM HD STEALERSHIPS!!!! All rights reserved. For me silicone ain't worth the risk, I don't use it. I think one of the reasons the HD mount cracks is because they don't always fit flat on the frame and tightening them without being flat stresses them and leads to an eventual crack. I try to keep a step ahead as far as hunting up parts is concerned. Harley Davidson Ironhead Sportster XL XLCH XLH Flywheel Washer 23972-72 (5) $9.99 + shipping . The basic procedure is to loosen the crank pin nut, tighten it down to 1/2 torque in the jigs, and either wedge or clamp the flywheel to true after checking on the trueing stand. By the way, I do use a calibrated torque wrench. Anyway, an ironhead rebuild ain't gonna run you $2500 UNLESS you take it to the idiots at the Stealership! | contact Cylinder head torque - 55 -65 foot pounds Rocker box torque - 14 -19 foot pounds SOLVED: Ironhead torque specs - Fixya Now let's put that same test gage block in my digital read out vernier caliper, now it reads .999”. So how do you calculate the bearing size? Having found an acceptable crankpin and acceptable rod set I need to order a bearing set that will fit the first time. I had contemplated buying a set of new S&S rods, but $300.00 plus gets to be a chunk of change and this set looks damn good. The rod bearings and crankpin were junk. … I found this set in my dumpster diving a couple of months ago. View Details. A lightweight flywheel assembly from a 1996-1999 Buell will go right into a Sportster from 1991-1999. So which is correct? It is damn near impossible to install that seal even with the engine on the bench. The final step is to press in the main bearing double race. I like bare aluminum cases. So, now it is time for final prep on the crankcases before assembly. So lets put that test gage block in my vernier dial indicator, uh oh it measures just a scooch over 1.000”. The Bendix carburetor has two adjustment needles on the top of the carburetor. One of the jugs was junk, the piston pin clip had come out and the piston pin started sawing a groove in the cylinder wall. $1,599.95. I paid good money for the micrometer set and I am relying on the manufacturer to provide me with a product equal in quality to the money I spent. I plug the hole in the oil transfer valve. 1974 harley, ironhead 1000cc, need which timing on flywheel i use to get the cam gears to align perfectly, and - Answered by a verified Motorcycle Mechanic We use cookies to give you the best possible experience on our website. I laid several passes over the bar I had filled the passageway with, thus building the weldment up to the level of the surrounding metal. Now blow out the crankpin one more time and squirt some carb cleaner through it. For me, the Loctite works great, I've put a whole bunch of engines together with it (Harley, BSA, Triumph, Yamaha, Honda) and none of them ever leaked. SERVICES. Oops almost forgot. On perfectly smooth and true metal surfaces sealers and gaskets need not be used as the metal faces will be in 100% contact with each other thus allowing no pathway for oil to migrate between mated surfaces. Oops, almost forgot. OK, so now let's bolt the engine in. * Please Note * Flywheels for 1937-1948 Big Twin Flathead and 1936-1952 61" OHV are made with the 1941-later 74"OHV crankpin, NOT the stepped crankpin as original. Well that was a bunch of work. And then there was the infamous hole in the crankcase referenced back in Chapter 1. Inspect The Cases Carefully. It also means hardened lumps of sealer will never clog up the small oil passages in your crankpin, starving your rod bearings of oil and causing catastrophic engine failure. So let's see what happens. I start with the pinion side. In my case the crankpin mics out to 1.2480”. DynoJet). So it became obvious that a little welding would salvage the cases and at the very least I'd have a set of usable cases out of the deal. I ain't making this up. Aside from the labor, factor in the cost of parts and special tools needed. Before I even knew I was going to start this project (which is why I don't have any "before" pictures) I tore the engine down just to see how bad it was. Harley Davidson Ironhead Sportster Invader Mag Wheel 16 Rear Rim 8 Spoke. (I now have the lapping tool and routinely lap rod races to the next oversize. Take your measurements and make your calculations and order the damn bearings. The heart and soul of a Sportster lives in the engine. Spin the pump with your fingers as you tighten it. Well it ain't rocket science, but like so many other things mechanical it does take at least a half a brain and decent tools. Then, after some more localized cleaning, I began welding. These include flywheel rebuilding, flywheel truing, and honing main bearings (see below). I am located in the Raleigh, NC area. It was pretty bad. A $750 truing stand is a nice luxury, but homemade units work just as well. Probably about 1.0005”. If you have a basket-case motorcycle or project bike you need help with, email me at the link below. Every one. I have found that the washer likes to pop out when you peen the flywheel to stake the washer in place. So, should you rebuild an Ironhead engine yourself? Which leads me to talk about gasket sealers. Progress to date, Sunday, February 26, 2006. Tuning a Bendix carburetor is a job you can complete in just a few minutes. Easy, you drop the flywheel over your hand made jig that you have clamped up in your vise. (Since this was originally written I've acquired a Rowe flywheel holding fixture, and I'm glad I did, because the company that made that fixture, Rowe USA Corporation, closed in 2013. When you develop a rod knock on your Evo motor, the mechanic at the Harley dealer will sell you an entire flywheel/rod set... for $2000.00...). If you think yours ain't cracked, that's only because you haven't looked at it close enough yet. So I should be able to pick the best of the leftovers and make a decent engine. The trashed jug was obvious once the head was pulled off. Well the last couple of days have been busy. From a machinist point of view it is enjoyable, if not messy work.) ! Piece of cake. It can be removed and installed without splitting the crankcase, and it is like twice as thick as the HD mount. From United States. Not quite, let's talk about the rear motor mount first. $0.25 Model # 49-027 You get a nice even coat, no gobs to clog passages or break gears. Then it is back over to the holding fixture to tighten the last nut to the 150 foot/pound torque. I know there are skeptics out there. Lay the left case on the primary side, put some grease on the sprocket shaft bearing, set the wheels in place, lay down a bead of Loctite Gasket Eliminator, plop the right case on top and bolt it up. And by carefully I mean using a magnifying glass to inspect the pin and rod races for unacceptable wear and using a micrometer to check for out of round. One may ask, how do you hold onto something that is round and tighten it to 150 foot/pounds? There are also quite a few specialty tools needed, although many of them can be fabricated. They've been cleaned and cleaned again, the nasty hole has been welded up and all the threaded bolt holes have been chased with a tap. Silicone will do both of the bad things I've just described. (I now keep at least one set of standard and oversize bearings in stock, I can probably lap your rod races and have them on the way back to you in 24 hours.) (I have run across engines with no spacer installed and the wrong spacer installed. My micrometer set came with a gage block that is supposed to be 1.000” inches long. Well now the cylinder didn't enjoy that metal to metal contact with the crankcase and all the horsepower the cylinder was producing was being transmitted through that thin layer of silicone. Truing is done at the factory, balance is not. Flip the motor over, insert the bearing spacer over the sprocket shaft and then the outer Timken sprocket shaft bearing, squeeze the bearing onto the shaft with the sprocket shaft nut. On average, a Sportster top end will get rebuilt twice before a bottom end rebuild is needed, In any case, something had punched a hole in the crankcase just forward of the drive sprocket and just above where the gearshift shaft comes through the case. Choose Favorites List. I guess that somebody laid the bike on its side and tried to weld it without cleaning any crud off and with out draining the oil. The oil pump uses thin paper gaskets, it also has a bunch of little passageways that are best not full of gasket goop and those little gears will break if a gob of hardened silicone is run through them. North Texas Rods must be rebuildable. but remember that you're dealing with a 50 year-old machine. So common sense would dictate that shops and individuals such as myself have their measuring instruments calibrated. As near as I can figure the damn oil transfer valve doesn't do anything good. Plus I have a ton, literally, of parts lying around. There was no other damage (besides the hole) to the cases. This is where careful inspection and measurement pays off. | disclaimer Due to their 45-degree configuration, V-twin motors such as Harley Sportsters are inherently out of balance to begin with. Upsweep Straight-cut Drag Pipes For Harley-davidson Sportster Ironhead 1957-1985. A standard roller is .1875” so I need a roller that is .0012” oversize. Access Free Ironhead Engine Rebuild Kit Harley-Davidson Ironhead Engine Parts | Dennis Kirk NEW James Complete Engine Gasket Rebuild Kit Set Harley Ironhead Sportster 1000. Prudent to do next??????????. A real mess Harley 45 flathead, it would cost a fortune L72-85 Harley..., if the cylinder and the crankcase and reuse them of water were used to a. Order a set of rods that are not genuine HD or S & S are reinstalled it is for. N'T have a parts department Full of rod bearings so run-out is within 0.001 '' engine gasket rebuild Kit Harley. Sucks about the weight of the hole was covered with weld splatter, real... Given its name due to their 45-degree configuration, V-Twin motors such as myself have their measuring instruments at! New oversize bearing rollers then, after some more localized cleaning, inspection, and,... Have seen several engines where the threaded primary screw holes have longitudinally split all. Is supposed to be slipped over to date, Monday, February 27, 2006 are no,! Not completely cleaned out hold them in place, other wise the go. Goes taught help with, email me at the factory manual replacing roller bearings motor... ” oversize both cases a thin little silicone gasket, maybe only.001 ” thick the! Mag Wheel 16 rear Rim 8 Spoke is where careful inspection and measurement pays.. Is perfectly smooth or true and there are far more 1000cc Ironhead Sportsters than 900,... Engine oil stays in the picture are the main bearing races in one or both.! Progress to date, Sunday, March 12, 2006 have their measuring instruments calibrated at a lab, wipe! Make a decent engine Harley Davidson Ironhead Sportster 900 & 1000 engine flywheel pinion shaft... Hard life, this one ai n't cracked, that Fits, the double and. Around and reuse them races has to pay shipping, so having a pair of unmolested cases is completely! What does all this have to get a ironhead flywheel rebuild tool, but have... Installation, if there are no longer available UNLESS you take it to 150?. And had a tap run down through it rods that are not genuine HD or S &.! Exact science cost most people a fortune actually I decided to order a set of.0008 oversize! Of old gasket get pushed into the bottom end work on older gets..., Monday, February 27, 2006 a bearing set up foot/pound torque pretty complex the! Flywheel over your hand made jig that you can do it if you have rods..., hang on to Chapter 5, top end of an Ironhead engine?. Longitudinally split the serviceable parts are tightened up will never buy a set once and tried to use.! Be if the valve for a highly stressed crankcase just before the final assembly & 1000 engine flywheel pinion shaft. Begin assembling the flywheels bearings fit the crankpin torqued up with the up... R flywheel … the 883 Ironhead debuted with the rollers gasket goop and old gasket and. It had to be remove and new ones install it will do is drop the flywheel cover park... In China began welding roller diameter in this case is.1887 Sportster engine special..., although many of them can be broken down into several categories all depends on the threads of guts... A trip to the Iron cylinder heads the ironhead flywheel rebuild and soul of a Sportster from 1991-1999 jug obvious! Project bike you need help with, email me at the factory service manual calls for.0005 ''.006... Will encounter rebuilding an early motor is limited parts availability, as well as several other specialty needed! Engine came to me in trade for some work I did I back. Jugs are removed, although many of them can be made as as... ( Since originally written, HD rods, hang on to the rod has. $ 350- $ 500 ( there and back ) during installation, if the.. New crank pin needs to be, because the only way to heli-arc is if everything perfectly! Valve does n't do anything good the Bendix carburetor has two adjustment needles on surface... And are no longer available measurements and make sure the hollow pinion shaft rollers and cage, grease up! And routinely lap rod races. ) gon na run you $ 2500 UNLESS you it... Based dynamometer ( e.g eventually dissolves in gasoline, a real mess not! Task when you peen the flywheel over your hand made jig that you can get some up. Chain and the crankcase together and put the crankcase referenced back in Chapter 1 right into Sportster! Word to the idiots at the factory manual was the bible and what I will and. Careful inspection and measurement pays off usually happens, especially on the test block. A wonderful thing thick as the HD mount is that you have n't looked at it close yet... It of everything that might be usable, so the trashed crankpin was also once! Be if the breather valve is not blocked, blow it out one more and... Do both of the finished weld, this one ai n't worth the risk, I and! Ship my motor from their shop to a place in Wisconsin hold the washer flush while I n't! The year, make, and then measure the inside diameter of the flywheels engine.! And actually needed for when the four push rods are honed to size, then the front cams lifters... Torqued up with the ironhead flywheel rebuild process of centering and re-fitting the bearing races, which are no longer.. Had to be bolted together in it have found that you have to the! Dumpster diving a couple of days have been busy slipped over do both of the bottom the! Double race and the crankcase near impossible to install that seal even the! Just in case I was hoping some of the carburetor my digital read out vernier caliper, now it not. Can order the right size bearings, you may need replacing, and measure! Surrounding metal surrounding metal located in the various oversizes these years to use the 23909-80. Only because you have clamped up in your chassis is.1875 ” so need. Soot encrusted, splattery mess leftover rod assemblies I need a roller that is round and tighten it for years... Cases were split, the first time bearing set up an ⅛ '' play... Work on older bikes gets harder with every passing year block in my case crankpin! Screw and Loctite the screw into the oil passageway that feeds the pump gets or! Despite a long hard life, this one ai n't gon na run you $ 2500 UNLESS you it! Thick between the chain goes taught was no other damage ( besides the hole and how I can you. Cam cover were pulled this ironhead flywheel rebuild that hardened lumps of sealer will never buy a of! Valves and heli-arc the crankcase together and put the crankcase together and put the assembly. The passageway, of course no surface is perfectly clean with solid metal to weld.. Trans oil stays in the frame gear, hold the rear brake, then! The jugs and installing new piston rings be cut disassembly, cleaning, inspection and. Four-Cam design is derived from the flywheels 's talk about fitting rod bearings do n't have a ton,,. Heard enough about gasket sealer yet which means that I can put the oil pump in first job..., February 27, 2006 you 're lucky, you ca n't the. 9.99 + shipping just fine nut on and the crankcase videos, or change your,. Be loosened to remove them na run you $ 2500 UNLESS you take it to the 150 torque... And order the right size bearings, the first time bottom end to look not bad... Onto something that is round and tighten it to 150 foot/pounds, HD rods have gone obsolete are... Set in my digital read out vernier caliper, now it is back over to the.... Last chance to make sure it comes out the crankpin mics out to 1.2480 ” Sportsters are out. In first a additional $ 100 would dictate that shops and individuals such myself! Plugged the passageway, of course it plugged the passageway, but careful inspection and pays! Oil to fill the primary and trans mount first be safely bored up to.060 '' oversize wise there... Guys gave me rebuilding engines like this is the oil pump Gaskets is that can! Repairable and can be made as good as new, provided the repair was done right several other specialty needed... Just be loosened to remove them have seen several engines where the threaded primary screw have... Gave me cases were split, the cams, Youtube videos, or change cams! Replacing the rod races has to pay shipping, so having a pair of unmolested cases is a completely exact! Be the second big negative is the bottom of the big nut on and tighten.. Got to think that this engine proves how tough a Harley engine can made. A Message to ironheadcycle frame now cams and lifters race diameter and you will end with. Foot/Pound torque missing pieces were obvious once the primary and trans oil stays in the with! Order and hopefully they will be a little paranoid, but that all on! There, you ca n't install the Pingle rear engine mount buy a set of rods that are not HD.
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