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Old 05-25-2013, 09:53 PM   #1
guiltyview
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Default small ironhead project

Been looking at getting a sportster for a while now and came across this 1986 sportster that I just had to have

It didn't run when I went and looked at it and it had been sitting outside for a few years (I think he said 8) so you can imagine that it's pretty crusty. He said that he couldn't get it started but didn't really know what was going on with it. there was a few different harley ignitions in the box of spare parts that he gave me with it, so it looks as if he was trying to chase the problem there. Oh well, we'll figure that out later. I'm not sure that I feel as if he should really have been working on a bike like this in the first place.

As of right now, the plan is to get it in a running condition, just to be sure that it does, and then once that's squared away, it will be taken apart completely to be cleaned up. I think this time around I would like to make it look sort of like an older sportster while keeping some of the later parts. I am sure some of the period correctors won't be super psyched on it, but whatever. Here are some pictures of it's current state

Loaded up













Dyna ignition etc just because



also the tank was rusting from the inside so it's trashed. I had this laying around so I'm going to go ahead and use it. Also switched out the bars with some XLX (I believe) bars that were laying around



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Old 05-26-2013, 11:04 PM   #2
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Default Re: small ironhead project

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You got a rare one there....
85 was the last year for the Ironheads...
My eyes aint as good as they used to be...But that last number certainly looks like a 7 to me...
I am extremely confused by that!!
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Old 05-27-2013, 12:02 AM   #3
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Default Re: small ironhead project

86 is the first year for the Evo Sporty, so that one just might be one of the last late 85's sold as a 86.....
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Old 05-29-2013, 12:42 AM   #4
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Default Re: small ironhead project

Ah, too bad I didn't see this sooner, could have just told you we already verified that it was, in fact, a true 1985

Well, instead of messing around with that butterfly carb, I took the money that I made from selling my KZ440 this weekend and bought a Super E first thing this morning. Put it on and with the help from my dad fixed some wiring that had been sort of hacked up off of the battery to the ignition and we got it fired right up

http://www.youtube.com/watch?v=0sMh3IOXCX4


Now starts the tear down..
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Old 05-29-2013, 01:56 AM   #5
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Default Re: small ironhead project

Nice Job!!!
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Old 05-29-2013, 03:30 AM   #6
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Default Re: small ironhead project

And don't even get me started on the case race......
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Old 05-29-2013, 02:23 PM   #7
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Default Re: small ironhead project

Well now that its up and running the entire thing will be taken apart to be gone over and basically rebuilt
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Old 05-30-2013, 03:30 PM   #8
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Default Re: small ironhead project

well my dad did dig up these old .030 pistons he had from 25 years ago. so I will use these. red shift cams will also definitely be used



also, no more kawis unfortunately. but there is an 89 FL with a full twin cam drive train for sale. but I'm sure that interests nobody here haha
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Old 05-30-2013, 04:37 PM   #9
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Default Re: small ironhead project

I believe it's V-Twin that makes the upgraded alternator with the magnets incased.....
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Old 05-30-2013, 06:00 PM   #10
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Default Re: small ironhead project

Minor hi jack here.
Jesse do you have any stroker flyweels and pistons laying around?
You can pm me if you like.
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Old 05-30-2013, 06:57 PM   #11
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Default Re: small ironhead project

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Originally Posted by azironhead View Post
Minor hi jack here.
Jesse do you have any stroker flyweels and pistons laying around?
You can pm me if you like.
That a Rhetorical ????
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Old 05-30-2013, 09:04 PM   #12
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Default Re: small ironhead project

Those ads are pretty cool there. The pistons are actually TRW though
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Old 05-31-2013, 06:56 AM   #13
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Default Re: small ironhead project

Guilty,
I am sure you already know this but:
If you go with the Larger Intake ( 1 15/16" ) your valve to piston
clearance will need to be checked, post 70 OEM pistons had a factory
relief milled into the intake crown side of the piston for additional clearance even with stock P cams
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Old 05-31-2013, 01:03 PM   #14
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Default Re: small ironhead project

Yep that's been accounted for

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Old 05-31-2013, 08:33 PM   #15
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Default Re: small ironhead project

Took the top end partially apart tonight, and found this



just kidding, that's from my dad's old fxr







Last edited by guiltyview; 05-31-2013 at 09:01 PM.
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Old 06-01-2013, 12:16 AM   #16
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Default Re: small ironhead project

hey !! that is how my ironhead project started umm almost 2 years ago ... save those rollers for me Jesse I am gunna pick them up since I have nothing better to do !!

sorry been drinking in the shop again. I may regret this post and pressing in my bearings into my trock door and fine fitting it tonight .. then again maybe not!
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Old 06-02-2013, 05:44 PM   #17
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Default Re: small ironhead project

So I got it ripped apart yesterday a little more yesterday. Everything is still looking pretty healthy despite the exterior










These are the wheels I'll be using. My dad laced them up 25 years ago to be used on one of his projects that he didn't end up getting to. New tires and all ready to go I'll need to take them apart to replace the spokes and polish the rims up. The front hub doesn't work for this year front end so that will have to be changed as well.






Last edited by guiltyview; 08-14-2013 at 11:06 PM.
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Old 06-03-2013, 11:38 PM   #18
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Default Re: small ironhead project

got the bottom end broken apart tonight and cleaned it up just a little. still no surprises luckily



all of the magnets seem to be in great condition



sait it in the parts washer and scrubbed it down really quick to get the heavy shit off. I think it will clean up pretty good





hopefully some actual fun stuff to follow
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Old 06-04-2013, 10:19 AM   #19
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Default Re: small ironhead project

the only pro flow that I know of is attatched to a big twin cutaway here


I'd like to start cleaning the cases a little bit. any ideas of what I should use to get all of the yellowing/stains out? Seems to be in there pretty good



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Old 06-04-2013, 01:36 PM   #20
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Default Re: small ironhead project

Everyone here is actually strongly against glass beading as much as possible because it just impregnates itself into the cast aluminum. It's impossible to get it all out and when you run the engine, the oil heats everything up causing it to expand, which brings it out. Then incomes the nightmares. Have had a few come around here completely trashed because of it

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