1976 Sportster Project
Text and Pictures by Mark Trotta
When purchased, this 1976 Sportster XLH had a disassembled motor and the wiring harness had been cut in half - but the price was right!
This is a "Liberty Edition" model, offered one year only in honor of America's 1976 Bicentennial. In addition to special graphics on the gas tank, Liberty Edition models featured alloy spoke wheels (19" front and 18" rear).
Although the original tank came with the bike, it was too badly rusted inside to re-use. The tank seen in the pictures is an aftermarket, which I spray-painted flat black.
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The Purchase
The previous owner had attempted to fix a starting issue, which led to removing the starter motor, then the solenoid, the pinion shaft and gear, and housing. One problem led to another, and he abandoned the project and bought an Evo Sportster, while the '76 sat in his garage for several years.
No, not a 1,000-piece jigsaw puzzle, a 1,000cc jigsaw puzzle!
The plan was to get the bike together using whatever pieces I had, and spend as little money as possible. I also wanted to remove unnecessary clutter to look a little cleaner and hopefully shed a little weight.
Included with the purchase were several boxes of parts.
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Primary Chain and Cover
Replacing the starter Bendix gear on several years of Sportsters requires removing the unit transmission.
Related Articles:
Remove and Install Primary Chain
Remove and Install Ironhead Clutch
Electric Start Ironheads
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Switch to Left-Side Shift
There were two years of Sportsters that had a crossover shaft to make them left-side shift; 1975 and 1976.
I've read that some people have issues with this set-up, but I had no problems shifting or braking my bike.
If yours is giving you issues, check that the inner lever is not stripped or binding.
Here's a direct replacement for the stock piece OEM 34670-75.
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Electrical
With the original wiring harness cut in half, the bike needed a complete rewiring. A lot of things had already been removed, including the starter, solenoid, relay, and voltage regulator.
During the rewire, the original buckhorn bars were replaced with drag bars.
All wiring went inside the handlebars.
Since I was not going to re-use the bulky hand controls which came on the bike, wires for the start and stop buttons and turn-signal switches were no longer needed. They were tagged and removed.
If you're looking to clean up your handlebars and get rid of the switches, JP Cycles offers a nice plain switch cover.
Starting the bike was done with a 3-position key switch mounted on the left side of the motor.
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Brakes
Rebuilding the front brake caliper was followed by rebuilding the master cylinder.
Bleeding the front brake caliper.
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Carburetor Swap
When purchased, the bike came with two carburetors; the original 38mm Bendix and an S&S Super B. The B had come off a Harley Shovelhead, and the previous owner had de-jetted it down three sizes to run on the Sporty, but there was still an off-idle bog. No matter how slow I rolled it, the bog was still there.
Only after re-jetting the Super B several times, the bike ran smoother and faster.
Read: Best Carburetor For Ironhead Sportster
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Over the course of two years, I got this old Sporty back on the road.
My original projection was one year...
After a few months of riding, the leaking fork seals got worse and were replaced.
Read: Replace Fork Seals 35mm
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Service Manuals
I have three different service manuals for Ironhead Sportsters. I've found mistakes and misprints in two of them, so I've learned the art of "defensive reading"
The best manual to have is the factory service manual.
Original FSM's sell for over $100 each; copies sell for half that. Trouble with copy's are, the illustrations aren't clear.
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Harley Sportster Production for 1976 was: 5,238 XLCH models and 12,884 XLH models. It is unknown how many were Liberty Editions.
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Related Articles:
Ironhead Sportster Maintenance
How To Polish Motorcycle Forks
Prep Motorcycle Gas Tank
Install Mikuni Carb on Sportster
Ironhead Generator to Alternator Swap
Basic Motorcycle Wiring
1974-1977 Sportster Caliper Rebuild
