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  #1 (permalink)  
Old 12-29-2006, 10:54 PM
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76 Sportster Question

I have a 76 Sportster and I had to replace the trans on it. When I bought it, the previous owner had blown out the first and second gears. Actually stripped 1st in 3 different places of all the gears. It was a real mess. I have a replacement trans (off of E-Bay) and have installed it, along with all the parts on the left side all the way out to the cover, and have that sealed as well. I have been working on the right side for quite some time, as this bike now has a Right side Jockey shift. I have it all back together with the shifter looking good and all. Now here is my problem. There is a clearance issue and for me to put the bike into first, I am going to have to either pull it all back apart again, or I can remove the front cover on the carb side of the engine. Then just remove the pinch bolt, and move it back (2) teeth on the arm the has the ball that goes into the trans. Here is my question. Is there any reason I would not want to just pull this cover and fix the issue that way? Is it better to just pull the entire trans back out, and start from scratch? Also the shaft for the kick start is bent just a tiny bit. It will kick over just fine, but even with the spring wound pretty tight, the kick start lever does not come back up on its own. I have to either lift it with my foot, or bend down and lift it with my hand. This means putting my face in the exhaust, and we all know that is not a great feeling. This pig runs rich as hell and I am going to have to do a ton of adjustments too it. Not sure what they guy who owned it before me did for riding it, or if he ever did. I know that the history of this bike is atleast 4 owners in the last 5 years. And I have owned it for the last year myself. I am on a very very tight budget and am trying to just get it to a point where I can ride it back and forth to work. Once I get to a point where I can start riding it more, I want to do more too it. My plans include a springer front end and putting the matching tire and rim on the front. Then I want to replace the rear drum brake with a sproter. I want to move to an internal throttle, a left foot lever clutch, and want to use a proportioning valve and want to put both breaks on the right foot control. This way the handlebars are about as clean as possible. Then I want to put a sight on the tank so I can tell how much fuel is in it, and want to put a clear oil filter on it and replace the oil tank with a custom made one. I want to build a larger tank, and see if I can do a two into one exhaust with a coffin muffler. Right now thought I would like to just get it to the point where I can ride it and get used to shifting with my right hand while riding.
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  #2 (permalink)  
Old 12-30-2006, 07:26 PM
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Bike Year, Make, Engine: 1976 Ironhead Sportster
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Tachout I too have a 76 Ironhead. The only issue i see about removing the right cover is your cams and gears inside. I have never had mine off, but will probally have to some time. If you can get to the pinch bolt with out taking the cover off moving it 2 click should not be a problem. What is the clearance problem.

I am considering converting my ride to a right side shift and get rid of the crossover shaft. That way I could build a wide rear wheel setup. As it is the crossover is in the way of putting an extended front sproket on the trans shaft. I am getting ready to replace my clutch, as i have a shifting issue and hope that that is the problem. I cant shsift into first when the bike is running. I can get it into second and then shift down into 1st.

I like some of your ideas, especially the sproter. I am going to do that or change out the swingarm and rear rim for a 79 thru 81, and use the disc setup on that.


I replaced my sprocket cover and my kick starter has to be pulled up by hand. I found that the bushing inside the cover is to tight and has to be honed and the kick start will come back up.


Well good luck with the fix.

Roger
Loma Rica, Ca
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Old 12-31-2006, 11:04 AM
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First the clearance issue. I put the pinch bolt assy on with the trans in neutral and worked it the wrong way. Did not check to see that it would not hit the case on the front so it will not go into gear. I guess I will just have to pull the trans out and all again. I can get at the bolt itself, however, the end of the shaft goes into a bushing that is in that cover so I cannot slide the pinch bolt assy off and move it where it needs to be. I will take a ton of pictures in that area, and share with you my shifter ideas and all if you like. I bought my bike off of Ebay and it had a trashed trans, and also was already set up for the jockey shift. It was just done like garbage. Not only was the welds trash, but the guy used 1/4 square stock and it was done like garbage and when I got a tight trans back in there and got it assembled, the shifter arm he had, just broke right off. I have a piece of 3/4" dia aluminum bar for the actual shifter arm, and a piece of 3/4" diameter steel for the part that comes out of the case. He had already butchered my cover bad, and I am going to need to replace that cover in the future, however I want to get the setup done first, and want to be able to ride this thing for a bit. As money comes available, I want to get the cover, Cut only the bare minimum, and then trim it. I want to also make a rubber boot to cover the area, or better yet make one out of soft leather. Just for looks, and to keep a little bit of dirt out. As time goes on, I will share what I have done and am doing.
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Old 12-31-2006, 03:17 PM
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Bike Year, Make, Engine: 05 Barefoot Choppa
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Cool, I also have a 76, my 1st harley bought brand new!!! My tranny is blown from too many hole shots. As soon as my present build is done I would like to build the ironhead into a bobber. Alot of issues with mine besides the trans. Have to rebuild the engine and set her up to run on todays unleaded gas. I think stainless steal valve guides is a start but I need to learn more about what I need to do to this engine.
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  #5 (permalink)  
Old 12-31-2006, 09:10 PM
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Well I have a pretty good source for trans parts, as well as, for entire tranny's. The guy might be good to talk to about your engine as well. He drag races with Sportsters too. I have my sportster into a bobber style, that is the way I bought it. Very Rat Rodish looking. I want to do more to it and finish the look. Would like to get someone to do me a special seat and some leather work for it, but other than that, and the front end, I am sure I am going to just ride it for quite some time
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