Well, I either got something cool or a nightmare waiting to happen. Bought it off my uncle who's had it since it had 800 miles on it, currently has 17k. 1977 XLH, hasnt been on the road in about 5 years. Generator light stays on any time the battery is connected, and the brakes need attention. Only other issue is it only has 1 key which makes me nervous.

 

I expect that you have a very good bike there. It will need a lot of regular maintenance, as it is a vintage HD motorcycle.

I get new keys from a regular lock shop. We do have an HD dealership in this city so that may make a difference in them stocking an appropriate blank. But check any locksmith shops where you are.

You will need both of these manuals...
Factory Service Manual 99484-78
Factory Parts Catalog 99451-78B
You can but these at any HD dealership, or by putting the part numbers into the Google, eBay, etc searches.

Generator Refurb ...

Note: The brushes holder and related parts can be dismantled without removing the gen from the bike. This is useful because, in my experience, if the gen light is coming on then one or both of the brushes is probably sticking. This can be easy to fix, at the roadside Normally I always remove the gen from the bike for service.

1. remove both wires from gen terminals
2. remove two long bolts from the right side of bike
3. on left side loosen complete gen body [it may be stuck to the gasket], raise the inner end toward the 11:00 o'clock position, lower the outer end toward 5 o'clock position and wiggle it free
4. look into hole where gen came out and you can see why we lowered it toward 5 o'clock position, and why it must be re-installed the same way.

Note: The oil sepatator washer is 1-5/8 x 5/16. If an oversize one has been installed the gen is more difficult to remove and install. "oil sepatator washer" is the correct terminology. Guys call it other things. There is an "oil deflector" which is a different part.

Note: I am writing this from memory, not while doing it. I think i have the removal process right. We are removing parts only from the outer end of the gen.

5. Remove gen end cap. Remove the bracket and brush cover strap. Remove the commutator end cover. There are 3 screws visible. Two just hold the brushes to the brush holder; these do not need to be removed. The third screw attaches a wire from inside the gen to the brush assembly. Remove this screw. Now the brush assembly can be removed.

6. The brushes will spring out of the brush holder. They must be each longer than 1/2 inch else replace both with new. Reinstall each temporarily and work them between thumb and finger to see if there is any binding.

7. Usually it is quite dirty in there so at this point i use a spray can of electrical contacts cleaner and a toothbrush to clean up the mess.

To re-install brushes in holder use long twist ties from the kitchen. Pick out the twist ties after the holder is re-installed.

For the rest you really need a manual. The FSM is very good. It is usually not necessary to remove the gen drive gear - this requires a gear puller to remove. The rest of the gen dismantles quite easily.

Once opened up you can do more cleaning and inspection; again using the spray can electrical contacts cleaner and a toothbrush.

 

good bike for sure
I love these ironheads

 

Looks in pretty good shape. Last Sporty I had was a '77 XLCH. Great bike. Too bad it doesn't have the matching rear aluminum rim. Never really liked the look of fat bob tanks on a Sporty, but the extra fuel is nice. Take good care of her.