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Iron Sportsters and K-models
Blog BOM Custom Design
Garage OSARM Repair Smörg

Sportster BOM

Iron Sportster bill of material

  1. Primary cover
  2. Cam 2
  3. Case set
  4. Cam 3
  5. Right case
  6. Oil pump rotor
  7. Left flywheel
  8. Oil pump body
  9. Right flywheel
  10. Countershaft 2nd gear
  11. Sprocket shaft
  12. Mainshaft low gear
  13. Pinion shaft
  14. Countershaft low gear
  15. Electric starter
  16. Mainshaft 2nd gear
  17. Oil pump plate
  18. Primary gasket
  19. Gerotor outer thick
  20. Engine sprocket
  21. Mainshaft 3rd gear
  22. Primary chain
  23. Cam 4
  24. Clutch basket
  25. Idler gear
  26. Clutch hub
  27. Gerotor outer thin
  28. Clutch friction
  29. Gerotor inner thick
  30. Clutch steels
  31. Engine oil
  32. Primary HW
  33. Engine HW
  34. Primary oil
  35. Case hardware
  36. Gearcase hardware
  37. Cam 1
  38. Gear case
  39. Generator
  40. Breaker cup
  41. Lifter
  42. Gerotor inner thin
  43. Exhaust hardware
  44. Rear exhaust pipe
  45. Carburetor
  46. Kick starter gear
  47. Air filter element
  48. Sprocket cover hardware
  49. Top end hardware
  50. Front cylinder
  51. Pushrod
  52. Front rocker box
  53. Transmission hardware
  54. Countershaft
  55. Mainshaft
  56. Trap door
  57. Primary plug
  58. Main bolt
  59. Secondary bolt
  60. Oil level bolt
  61. Oil level washer
  62. Lock washer
  63. Screw or bolt
  64. Washer
  65. Plug gasket
  66. Plug screws
  67. Needle bearing
  68. Clutch plug
  69. Decal
  70. Shifter seal
  71. Peg nut
  72. Peg washer
  73. Nut 3/8-24
  74. Rear cylinder
  75. Front head
  76. Rear head
  77. Head gasket
  78. Base gasket
  79. Base nuts
  80. Triple clamp
  81. Cam cover
  82. Frame
  83. Sprocket cover
  84. Rear motor mount
  85. Countershaft drive gear
  86. Countershaft 3rd gear
  87. Countershaft spacer
  88. Countershaft thrust washer 2nd gear
  89. Countershaft low gear washer, left
  90. Countershaft low gear washer, right
  91. Mainshaft clutch gear
  92. Mainshaft washer 3rd gear
  93. Clutch gear bushing
  94. Clutch gear bearing
  95. Mainshaft retainer ring
  96. Mainshaft washer left
  97. Clutch gear extension
  98. Clutch gear O-ring
  99. Clutch gear seal
  100. Mainshaft washer right
  101. Mainshaft roller bearings
  102. Mainshaft roller washer
  103. Mainshaft roller retainer ring
  104. Mainshaft ball bearing
  105. Mainshaft ball bearing snap ring
  106. Trapdoor needle bearing
  107. Countershaft oiler plug
  108. Shifter fork shaft
  109. Shifter fork
  110. Shifter top hat
  111. Shifter cam lock tab
  112. Shifter cam holder
  113. Shifter cam spring
  114. Shifter cam
  115. Shifter bolt
  116. Shifter lock tab
  117. Shifter flat washer
  118. Shifter nut
  119. Shifter shim
  120. Shifter support
  121. Shifter support dowel
  122. Shifter support lifter lower
  123. Shifter support lifter upper
  124. Shifter support lifter dowel
  125. Shifter support plug
  126. Shifter cam circlip
  127. Shifter cam washer
  128. Shifter plate
  129. Shifter support spring
  130. Shifter carrier
  131. Shifter carrier spring
  132. Shifter pawl left
  133. Shifter pawl right
  134. Shifter carrier pin
  135. Shifter carrier screw
  136. Shifter pawl retainer
  137. Shifter pawl pin
  138. Shifter pawl circlip
  139. Shifter pawl spacer
  140. Shifter shaft bearing
  141. Shifter shaft
  142. Mainshaft bearing race
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Customization

Personalize your Sportster

  1. 1972 Sportster exhaust
  2. Voltage regulator bracket
  3. Install Buco saddlebags
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Sportster garage

Tools, workbenches, and parts

  1. Yet another Thunderhead tub
  2. The generator tubs
  3. The gas tank cabinets
  4. Another Thunderheads tub
  5. The spare engine shelf
  6. The frame and axle tub
  7. Sportster small parts bins
  8. The primary and sprocket cover tub
  9. The air filter, petcock, gas cap tub
  10. The carburetor tub
  11. The battery and starter tub
  12. The ignition tub
  13. The throttle tub
  14. The transmission tub
  15. The kickstarter and sprocket tub
  16. The clutch tub
  17. The front fork shelf
  18. The Thunderheads tub
  19. The brake tub
  20. The gearcase and pushrod tub
  21. The peg and kickstand tub
  22. The gauge and fork tub
  23. The headlamp and tail lamp tubs
  24. The oil tank and pump tub
  25. The exhaust tub
  26. Hansen socket trays
  27. A tarp to cover your garage door.
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Sportster buzz

A commentary on iron Sportsters

  1. Complete site redesign
  2. Cleaning up Repair and Customization
  3. Building out the site
  4. Setting up the Design section
  5. Moving this site to dreamhost
  6. Trying to add an image to a post
  7. The website gets serious
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Sportster repair

A compilation of Sportster fixes

  1. Iron Sportster problems
  2. Battery replacement
  3. Honing the transmission mainshaft bearing
  4. 1952 K-model shifter rubber
  5. 1952 K-model front fender
  6. 1952 K-model battery carrier
  7. 1952 K-model riders hand book
  8. 1952 K-model shift lever
  9. 1952 K-model gas tank
  10. 1952 K-model air filter backing plate
  11. 1954 K-model battery carrier
  12. 1952 K-model rear shock top covers
  13. 1952 K-model top motor mount
  14. 1954 K-model gas tank
  15. 1952 K-model parts manual
  16. 1952 K-model sprocket cover
  17. 1952 K-model chassis uncrating
  18. 1952 K-model engine uncrating
  19. 1952 K-model rolling chassis purchase
  20. 1952 K-model engine purchase
  21. Primary gasket leak (1996)
  22. Kickstand frame repair
  23. Oil leaking out the generator
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Sportster Smörg

A wiki of our reader's Sportsters

  1. solotommy's 1952 Harley K-model
  2. cholm152's 1964 Sportster XLCH hardtail
  3. motorcyclemichaels' 1971 Sportster XLCH custom
  4. righteousjoe's 1968 XLCH Sportster
  5. iannottibros' 1969 XLCH Sportster
  6. sinisterkustoms' 1985 XLH iron Sportster
  7. mlferguso's 1976 Sportster hardtail bobber
  8. SportsterPaul's 1983 Sportster XR-1000
  9. mworks2012's 1971 Sportster 900cc XLCH
  10. SportsterPaul's 1980 Sportster monoshock
  11. wrensssch's 1976 Sportster ironhead XLH
  12. SportsterPaul's 1979 Sportster chop
  13. imcranco's 1979 Sportster bobber
  14. SportsterPaul's 1977 Sportster XLCH
  15. thegooch22's 1982 springer Sportster
  16. SportsterPaul's 1962 Sportster
  17. Venice Choppers' 1952 Harley K-model
  18. Joe's 1970 Sportster XLH
  19. rockerbox69's 1956 Harley K-model
  20. bayouboy09's 1979 Sportster chopper
  21. hdbab's 1966 Sportster XLCH
  22. theautomojo's 1980 Harley-Davidson XR-750
  23. stjephan1977's 1980 Sporster XR-750 replica
  24. John Lippy's 1977 Sportster flat-tracker
  25. traincrazycat's 1960 Sportster XLH
  26. imonly2yearsold's 1976 Sportster chopper
  27. kawasaki6767's 1969 Sportster XLCH
  28. J Ryan's 1970 Sportster custom bobber
  29. tjsfish56's 1957 Sportster XL
  30. djmoore62's 1959 police Sportster
  31. Lee Custom Cycles' 1966 Sportster XLCH
  32. djp210's 1962 XLH Sportster street tracker custom
  33. bigdadray58's 1953 Harley K-model
  34. andraandrudy's 1966 Sportster XLCH
  35. genevacycleatv's 1975 Sportster XLCH
  36. panshovel2010's 1979 XLH Sportster Chopper
  37. orgor1's 1980 Sportster
  38. justzippy1's 1982 Sportster XLH
  39. slynde's 1959 XLCH Sportster barn fresh
  40. craiginstall's 1958 Harley KR flattrack racer
  41. bigjwijn's 1966 Sportster custom cafe racer
  42. fhatty's 1968 Sportster collectors bike
  43. 302williamb's 1967 Sportster full dresser
  44. norwinda's 1971 Sportster bobber
  45. technoz1's cherry 1979 XLH Sportster
  46. mcdyno's 1967 XLCH
  47. steve*buys' 1979 Sportster XLS Roadster
  48. USA cycles' 1975 factory survivor
  49. mtnbk1's 1966 XLCH restoration
  50. jefftanker1's 1980 Sportster XLH
  51. shvlhed84's 1972 Sportster XLH
  52. 87bigred's 1973 Sportster
  53. littleace1's 1975 cool old Ironhead
  54. louiedogrenda's 1978 retro chopper
  55. Ron's 1978 Harley-Davidson Sportster
  56. 74wolfpack's 1965 classic Sportster
  57. jfit5512's 1979 ironhead Sportster
  58. harleysoftailazman's 1981 Sportster XLH
  59. cotedemontagne's 1957 Sportster
  60. rogerstruck's stock 1967 Sportster XLCH
  61. seanandtibb's 1966 Sportster XLCH
  62. American classic motors' 1977 XLCR 1000
  63. enchant99's 1977 iron head Sportster
  64. panjoe's 1971 springer rigid bobber
  65. mountainstatesales69's 1974 hot rod XLH
  66. rogerstruck's unabused 1976 XLCH
  67. cardenasne's 1982 XLHA anniversary Sportster
  68. spikemike5's 1983 Sportster xlx
  69. joestuff1's 1961 Sportster time capsule
  70. Barnett's black 1953 K-model
  71. Kevin's 1964 bobber hardtail
  72. artsparts1961's 1981 Sporty
  73. 2bigac's 1981 XLS 1000
  74. sporty1973's sweet 1963
  75. lynbdymini's 1967 bagger
  76. lmm4g's 1979 special
  77. clt0730's 1970 kicker
  78. The sportster guy's cruzin' 1967
  79. Ptk2's bright red '65
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Sportster Design

Paper designs and products

  1. Heads, steel
  2. Heads, 3 valve
  3. Heads with evo valves
  4. Billet heads, AME
  5. Wraparound fender struts
  6. Starter, late model
  7. Planetary oil pump
  8. License plate bracket
  9. Clutch release, sidearm
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OSARM

Open-Sport aftermarket replacement motor

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