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| ====== IH: Engine Mechanicals - Sub-09J ====== | ====== IH: Engine Mechanicals - Sub-09J ====== |
| ====== Lower Front Motor Mount Bolt Lengths from Parts Catalogs ====== | ====== Lower Front Motor Mount Bolt Sizes and Lengths from Parts Catalogs ====== |
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| | Use the spacers and single bolts of the correct length. \\ This keeps the frame tubes together around the sandwiched engine cases. Very important! ((piniongear of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/118347-front-motor-mounts?t=1145463)) \\ |
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| | **Bolt lengths from parts catalogs** (all have 3/8"x24 threads): \\ |
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| | As you can see below, the lengths are far from being standard length and those lengths changed depending on what parts catalog you reference. \\ |
| | These are general guidelines for bolt sizes: \\ |
| | The front motor mount uses 3 different size bolt (lengths) for the 4 holes. ((Scuba10jdl of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/192227-engine-in-frame-bracketscrews-tightening-order?t=2056655)) \\ |
| | The upper front and lower front holes (attaching to the frame) use the longest bolts. \\ |
| | The upper rear (through the case) uses the shortest. \\ |
| | The lower rear (through the case) uses the remaining middle length one. \\ |
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| | If you use any other length bolts (in the case of the bolt going into the threaded engine plate at the top rear) use the 5-3/16" long bolt. \\ |
| | A longer bolt there will run into the generator mount and the lower one gets close to the oil pressure switch. ((ryder rick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/97896-motor-mount-bolts-need-specs/page2?t=829078&page=2)) \\ |
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| | * **1957-1975**: ((1953-1963 HD Sportster and KH Model Parts catalog (99451-63) pg 11)) ((1954-1976 HD Sportster XLH/XLCH-1000 parts catalog (99451-76A) pg 11)) ((1978 HD Sportster XLH/XLCH Parts catalog (99451-78A) pg 11)) |
| | * Top rear bolt (1), 5-3/16" long (16235-52) grade 5 zinc. \\ Part number changed to (16235-52A) in the -78B catalog (issued in 1989) but the length stayed the same in the book. \\ Correct length is 3/8"x24x5-1/4". |
| | * Bottom rear bolt (1), 5-7/16" long (16236-52) grade 5 zinc. \\ Changed to 5-1/2" long (4413) in 1973 and sold for 54-76 models from the -78B catalog (issued in 1989). |
| | * Front bolts (2), 6-13/16" long (16237-57) grade 5 zinc. \\ '57 to '76 in the -78B catalog. |
| | * **1976-1978**: ((1954-1976 HD Sportster XLH/XLCH-1000 Parts Catalog (99451-76A) pg 11)) ((1978 HD Sportster XLH/XLCH Parts catalog supplement)) ((1978 HD Sportster XLH/XLCH Parts catalog (99451-78A) pg 11)) ((1978 HD Sportster XLH/XLCH Parts catalog (99451-78B) pg 11)) |
| | * Top rear bolt (1), 5-3/16" long (16235-52) grade 5 zinc. \\ Changed to 5-1/4" long in -78A catalog (issued in 1981) for 77-78 models with the same part number for both lengths (16235-52). \\ The correct part number is (16235-52A) |
| | * Bottom rear bolt (1), 5-1/2" long (4413) grade 5 zinc. |
| | * Front bolts (2), 6-13/16" long (16237-57) grade 5 zinc. |
| | * **1979**: ((1979 HD Sportster XLH/XLCH/XLS-1000 parts catalog 99451-79 pg 11)) ((1979 HD Sportster XLH/XLCH/XLS-1000 parts catalog 99451-79A pg 11)) ((1979-1985 Sportster XL parts catalog 99451-85A pgs 13,15)) |
| | * Top rear bolt (1), 6-13/16" long (16237-57) grade 5 zinc. \\ Both the -79 and -79A parts books show a quantity of (3) for this size bolt (same size as the front two) instead of the 5-3/16" bolt. \\ Changed in 1980 to 5-1/4" long which is part # (16235-52A) and correct for 1979 also. |
| | * Bottom rear bolt (1), 5-1/2" long (4413) grade 5 zinc. |
| | * Front bolts (2), 6-13/16" long (16237-57) grade 5 zinc. |
| | * **1980-E1984**: (all lengths sold for 79-85 models) ((1979-1980 HD Sportster XLH/XLCH/XLS-1000 parts catalog 99451-80 pg 11)) ((1979-1981 HD Sportster XLH/XLCH/XLS-1000 parts catalog 99451-81 pgs 11,13)) ((1979-1982 HD Sportster XL Model parts catalog 99451-82 pg 13)) ((1979-1983 HD Sportster XL Model parts catalog 99451-83 pg 13)) ((1979-1984 HD Sportster XL Model parts catalog 99451-84 pgs 13,15)) ((1979-1985 HD Sportster XL Model parts catalog 99451-85 pgs 13,15)) |
| | * Top rear bolt (1), 5-1/4" long (16235-52) grade 5 zinc. \\ Shorter bolt with same part number as the longer bolt in 1978. \\ Part number changed to (16235-52A) in the -85A catalog (issued in 1990) but the length stayed the same in the book. \\ The correct part number is (16235-52A) at 5-1/4" long. |
| | * Bottom rear bolt (1), 5-1/2" long (4413) grade 5 zinc. |
| | * Front bolts (2), 6-13/16" long (16237-57) grade 5 zinc. |
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