Sportster Jug Problem
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5th Gear
Joined: Aug 2010
Posts: 9
Likes: 0
From: Columbus, Ohio
Sportster Jug Problem
Hi List, This is my first post to this informative forum. That said, I hope someone will be able to come up with a solution to my dilemma. Took my 79' Sportster out from storage after 8 years, and started to do the necessary to bring her back to life. First started with the SU carb, and after removing the intake manifold from the cylinder, noticed that the left cylinder had some outer ring (rubber band type) breakage with the pieces no longer there, which consequently would not allow for a perfect seal between it and the intake manifold. Was wondering if I could take the bike to a weld shop (would not try it myself) to do a build up on the cylinder intake hole. Is this possible, or should I buy 2 brand new jugs. Any info as to what I should do, would be greatly appreciated. Hate to think I would have to buy 2 new jugs. Here's a pic of the problem: 
Thanks, Rob G
Thanks, Rob G
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5th Gear
Joined: Aug 2010
Posts: 9
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From: Columbus, Ohio
Whoops, on second thought, I better remove the motor from the frame, and unbolt & inspect the cylinder for broken pieces of cast iron. Don't want screw the pooch by ruining the jug walls. Rob G.
Cruiser
Joined: Aug 2010
Posts: 213
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From: N.E.WA. State
Just curious, how did the bike run before it went into storage? You might be able to get by with a temporary fix; piece of inner tube over the the existing o-ring seal before installing the band. By the way, no need to remove engine from the frame to remove the cylinders.
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5th Gear
Joined: Aug 2010
Posts: 9
Likes: 0
From: Columbus, Ohio
Sportster Jug Problem
Thanks for the reply TCMAN. I don't know if I have enough clearance to remove the jug with the engine in place on the frame, but will give it a try. Concerning the rubber tire piece, do you think the engine heat will melt the rubber? Thanks again, rob g
Advanced
Joined: Dec 2007
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I have seen people with this type of problem have brazed the damaged section then remachined it.Still going to have to remove the head,dissassemble it, have it cleaned before the brazing and machine work.It would still be cheaper than a used head.
Cruiser
Joined: Aug 2010
Posts: 213
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From: N.E.WA. State
The intake is one of the coolest spots on the head, a good air to fuel ratio and you shouldn't have any problems with the inner tube; I have done exactly that on an old Shovelhead Harley that I owned years ago, sure miss that bike!
Elite HDF Member
Joined: Dec 2009
Posts: 4,598
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From: navarre ohio
that grove is for a o ring type of seal manifold, the newer ones used a wider rubberband seal that seals on the upper shoulder.. they make plastic rings (v-twin,custom chrome)that fill the grove then you use the rubberbad seals, using the retro fit mounts will take care of the chips and make it seal a lot better.no need to take it apart unless it has bad compression or anouther sign of problems..look in the head intake chamber for pieces or knicks from the cast iron pieces.they most likley fell on the ground and not in the head
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5th Gear
Joined: Aug 2010
Posts: 9
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From: Columbus, Ohio
Hi J1mmy,
Where would I get the plastic rings, and what should I ask for parts wise? I am getting ready to reinstall the manifold and the su carb after I check for the broken pieces inside the head. Thanks for the extra info - I can breathe easier.
Rob G.
Where would I get the plastic rings, and what should I ask for parts wise? I am getting ready to reinstall the manifold and the su carb after I check for the broken pieces inside the head. Thanks for the extra info - I can breathe easier.
Rob G.
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