I got rear-ended on my 1980 Sept 1 last year; bike was totalled. Bought this 1978, 75th anniversary edition which "had not been well looked after". Here it is, completely refurbished [not restored!] ...

YouTube- 1978 Sportster 75th Anniversary Edition

The details ...

1978 75th Anniversary IronHead, Refurbish Complete ...

Part 1: Fall 2009 Project - Get It Running

top end rebuild: .030 over, Wiseco pistons, 1000 mile break-in complete
Ultima electronic ignition, single fire
new forward controls, new oil and fuel lines properly routed, K&N air filter
replaced fork seals, oil pressure switch, battery, regulator, solenoid
lubricated cables

Part 2: Winter 2009/2010 Project

gold wheels refurbished
hand painted frame, swing arm, battery box, horn, start relay
drilled and painted air cleaner back plate
cleaned up forks, shocks, tach & speedo, electrical
refurbished carburetor, generator, starter motor, brake calipers, rear brake system, rebuilt brake master cylinder
replaced speedo drive & cable, brake rotors, rear brake cable, generator lite, run switch
replaced shock mount hardware & rubber bushings, rubber mounts for oil tank/battery box
new headlite visor, oil cooler by-pass, petcock for king tank
freed up sticky choke wire
from my old bike: handlebar mounted voltmeter, sissy bar bag, Tim Horton's coffee cup holder, running lights, center stand, windscreen, Sportster mirrors
Mike's Cycle Seats finished minor repair, and a modification to make it more comfortable
Harley tall eagle wing emblem for the sissy bar golded and installed.

Part 3:

Kicker Kit done with all parts OEM NOS except the arm and pedal

Part 4: Paint Etc

Re-striping the fenders, decals and stripes for the king gas tank and oil tank.
Decals for the air cleaner, primary cover, brake calipers, battery box, and front fork installed. Some of these are OEM NOS parts, others are re-pops.

Part 5: TuneUp and ShakeDown Runs

Finalized the tuneup: 180 main jet, 75 slow jet, 1 turn out on pilot screw, 35` ignition timing.

Part 6: Spring 2010

Honda GB500 fork gaiters, pull back risers, old style fork caps and instrument mounts, new handlebar bushings, re-configured handlebar switch cables
New brake shoes and rear tire; rear wheel centered to fit the wider brand of 120 tire
The indie had a nice, used carry rack. Now mine. With tool bag.
New Cycle Shack taper tip mufflers for 1980 to 2003 fitted
Chrome tail light cover installed, broken chain guard re-welded
#1 decals installed

Part 7: Not In The Plan

Polishing up all the aluminum so it looks like chrome. But never say never. My indie will do it for a very reasonable price. I'll consider it when the parts have to be off for some other reason anyway.

 

sweet

 

Did you do the motor rebuild yourself

 

I do all the tearing down and putting back together myself. I let my indie mechanic choose the parts, and the machine shop for the work.

Unless you have your own machine shop and are an expert machinist, this is the way to go. You need a place to work, a methodical approach, and a few special tools such as a piston ring compressor etc, but there is no need to pay a shop guy $50 to $100 per hour to undo and redo nuts and bolts.

 

Looks great,sounds great!
Bet Yer very proud of Her...
What is Her name?

 

very nice I wish I can tear it down and rebuild like that.

 

deeeecent !!!!

 

Very nice! I am just finishing up the "get her running phase" of my own project. I was wondering about the kicker kit. I have a '79 but it is electric start only. As I bought the bike in a wrecked condition, bringing her back to life I have found not much is stock. So I was wondering how difficult it would be to put a kick start on it.

 

1979 was the last year that came from the factory with a kick start; some 1980s were made with left over 1979 parts so some early '80s can also be fitted with a kicker.

You can order a kit specifically for 1979 from any of the catalog companies such as J&P Cycles. If you decide to do this ask me using a PM and i will pass on more helpful information.

 

Very nice Mick, can you tell us how you redid the rims? Did you remove the finish and start over?