I have a Sportster basket case that I recently purchased. I was told that the engine was possibly an 82 but the title says assembled 81. The numbers at the base of the cylinders have been replaced with new numbers that match the "Assembled" title. I am lost, I want to purchase a service manual to start on this bike but do not know where to begin in determining what year of manual I need to purchase. Is there anyone that might be able to help me?

Thank you in advance!

 

BJinaTJ....
I have very little knowledge of Sportsters made after 1975, so I am not certain of what engine size your 1981/82 might be. I would assume it is a 1000cc displacement, but sometime during the 1980's there was an 1100cc made. Maybe another member may be of some help with that.
As for the manual, J&P Cycles shows one for 1979 through 1985 for $58. If you are interested in buying one for that price, I would call them first to make sure that their manual is a HD factory manual. If it is a manual other than a factory (such as a Haynes or Clymers) take a pass on the purchase.
I looked on Ebay and found only one listed. This was a Clymer book. It covers years 1959 to 1985. That is the same as saying, 'I have an outboard engine service manual that covers years 1901 to present and horse power range from 1 to 235hp.' In other words, the Clymer and such manuals are far to general in coverage and lack important information.
So, by all means be sure to get a HD factory manual.......pg

 

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Pic worth a thousand words. It might help me help you.

 

I would be happy to post pictures as soon as I get home tonight. One thing that I have noticed is that ebay seems to show 82-03 sportster ignition covers as a triangle. Mine is round like I seen on a 81. I also have no points (electric ignition module stuffed in there. I just thought that may help.

 

Here are a few pictures.

Thanks!

[IMG]local://upfiles/19662/C1C88650842F4AB8AF9FF46EBF1DEA09.jpg[/IMG]

[IMG]local://upfiles/19662/B794F3091F174997945A604E64F68E4C.jpg[/IMG]

[IMG]local://upfiles/19662/0876AD614BC94CBFBEE90026CFA723AE.jpg[/IMG]

[IMG]local://upfiles/19662/FF2AF86E384A470BA356C59A0CFB1F73.jpg[/IMG]

[IMG]local://upfiles/19662/1BD785B98EC34DCEAA64F53A0E6DF254.jpg[/IMG]

 

Here are a few more...

-Ronnie

[IMG]local://upfiles/19662/082EEEE65D264826B0CEF297441CD45F.jpg[/IMG]

[IMG]local://upfiles/19662/9E2675C48D5347F38F00653DC35CC4E4.jpg[/IMG]

[IMG]local://upfiles/19662/076B860D1A7B4F60BD46960B3ADDACE6.jpg[/IMG]

[IMG]local://upfiles/19662/652A8C9854AB402B901236369EFD85B9.jpg[/IMG]

 

BJinaTJ...
Thanks for the post of the photos. It appears you have an after market frame. Is this a rigid frame?
I see that you have an electric start and a side mount oil tank. That would indicate a set up found on an XLH (as opposed to an XLCH).
One thing does not seem correct to me however, looking at the photo of the right hand side timing cover. As I had stated earlier, I am no expert on something as modern as a 1981 or 1982 but the timing cover on yours has that hole at the rear of the cover that looks to me where the shift lever goes. Perhaps it is a mount hole for the rear brake lever? That would be the case on a 1981/1982 engine.
If however, it is for the shift lever rod, then that makes the engine no later than about 1976. I just could not tell from the photos what the hole is for. I will go back and take a closer view.
What do you plan to do with the bike? Pull the engine and paint or just get it running and ride?.......pg

EDIT NOTE:
Oh, I meant to ask about the engine number. The number on a 1970 and newer Sportster is stamped on the right hand side crankcase at the base of the cylinders. For a 1970 to 1974 (and perhaps later) it goes something like this:
First two letters are stamped 3A (indicates an XLH model) or 4A (indicates an XLCH model)
Second is a 5 digit serial number.
Next is an H (stands for Harley-Davidson)
Last is a single digit number which denotes the year of manufacture.
For example......My 1971 XLCH is stamped 4A2****H1. The 'H1' stands for Harley 1971
If you have an '81 or 82 then your number sequence may be different than this.
Can someone out there tell us how the number sequence was set up for 1981-1982 models?

OK, I had another look and I see the shift lever coming out of the primary side. That agrees with a 1976 and newer. The timing cover hole must be for the rear brake.

 

The brake is on the right side, the shifter is on the left. The only problem with the numbers is that the bike has anassembled title (which means after a police check the bike is a new title and numbers, the numbers are gone and a new VIN is assigned).

-Ronnie

 

Interesting about the number reassignment. I do not think there would be much difference between a 1981 and a 1982 engine. If you can get your hands on a factory service manual it will tell you what you want to know.
You could also log onto J&P's website www.jpcycles.com and click on the riders forum. There you could post a question to sFranta who is a J&P employee and he may be able to tell you of any great difference. You could also ask him at the same time if their manual is a factory issue.
I must admit I am surprised another member here has not come forth with the differences, if any exist......pg

 

My observatios ... in primary cast # is ( if I see it correct) 780 024 0??.
7 = ironhead
80 = year of manufacture
024 = day of manufacture ( january 24)
0?? = numer of day ( 1-7 )

Crankcase breathing hole facing down... starting face back 80's ??? but timingcover has that place ??
VIN # in engine can tell the year and model, H there stands there for 70's and J0 ( J+zero) it's 1980.
Pre 1981 bikes has 9 numers on VIN.
Newer bikes has new 17 digits VIN# on frame and engine has 13 numbers ( last 13 from frame)

-sepixlh-