Historical Significance:
The Sportster XLH1000 represents a pivotal era in Harley-Davidson's development, a robust and iconic motorcycle that cemented the Sportster line's reputation for performance and ruggedness in the cruiser segment.
Era Competition:
Competed against other American V-twins, as well as growing imports from Japanese manufacturers in the performance and cruiser categories during the 1970s.
Engine Configuration:
Air-cooled, 45-degree V-twin engine. Known for its torque and distinctive Harley-Davidson sound.
Frame Design:
Steel frame, typically a double-cradle design, contributing to its solid handling characteristics.
Design Philosophy:
Focus on reliable, powerful V-twin performance with a straightforward, functional design suitable for a wide range of riding.
Model Years Covered:
1970, 1971, 1972, 1973, 1974, 1975, 1976, 1977, 1978
Engine Variants Covered:
XLH1000 (1000cc Evolution Engine)
Estimated Page Count:
Refer to manual contents; typically 300-500 pages for comprehensive factory service manuals of this era.
Manual Classification:
Factory Service Manual / Workshop Manual
Digital Format:
PDF Download
Engine Systems:
Engine assembly, disassembly, inspection, tuning, lubrication, cooling, ignition system, carburetor service (e.g., Keihin, Bendix Zenith), fuel delivery system, exhaust system.
Transmission Drivetrain:
Clutch, primary drive, transmission case, gears, shifting mechanisms, final drive, chain maintenance.
Electrical System:
Wiring diagrams, lighting system, charging system (generator/alternator), ignition system components (points, coils, spark plugs), battery service, starter motor, switches, fuses.
Chassis Suspension Steering:
Frame inspection and repair, front fork (telescopic), rear suspension (shocks, swingarm), steering head bearings, wheel bearings, wheel and tire service.
Braking System:
Front and rear brake systems (drum brakes typical for early models, potential early disc brake introduction), brake linings, hydraulic components (if applicable), adjustment, maintenance.
Bodywork Fittings:
Fuel tank, fenders, seat, handlebars, controls, footpegs, exhaust pipes, minor body panel adjustments.
Routine Maintenance:
Oil changes, filter replacement, spark plug replacement, chain adjustment and lubrication, brake adjustments, battery checks, tire pressure checks, air filter cleaning/replacement.
Troubleshooting:
Diagnostic charts, symptom-based problem solving, common issues and their remedies for engine, electrical, and mechanical systems.
Major Repairs:
Engine rebuild procedures, transmission overhauls, carburetor rebuilding, electrical component replacement, suspension overhauls, brake system overhauls.
Specifications Data:
Torque specifications for critical fasteners, valve clearances, ignition timing, carburetor jetting specifications, fluid capacities, electrical resistance values.
Depth Of Coverage:
Comprehensive. Covers from basic scheduled maintenance to complete engine, transmission, and electrical system teardown and rebuild. Includes detailed diagnostic procedures.
Engine Type:
Air-cooled, 45-degree V-twin, four-stroke
Displacement:
997 cc (61 cubic inches)
Bore X Stroke:
Refer to manual for specific XR900/XLH1000 designations; typical for XLH1000 was approximately 82.5 mm x 93 mm.
Compression Ratio:
Refer to manual for specific figures; typically around 8.0:1 to 9.0:1 depending on year and variant.
Horsepower Output:
Approximately 55-65 hp (refer to manual for exact figures).
Torque Output:
Approximately 60-70 ft-lbs (refer to manual for exact figures).
Carburetion:
Single carburetor, typically Keihin butterfly or Bendix Zenith type, depending on the specific model year and configuration.
Fuel Type:
Unleaded gasoline
Ignition Type:
Contact breaker points and coil ignition.
Oil System:
Dry sump lubrication with a separate oil tank.
Oil Change Interval:
Refer to manual; typically every 2,000-3,000 miles or annually, whichever comes first, depending on oil type and riding conditions.
Chain Lubrication Adjustment:
Frequent intervals recommended, often every 500-1000 miles or after riding in wet conditions.
Spark Plug Replacement:
Refer to manual; typically every 6,000-10,000 miles.
Engine Oil Type:
Refer to manual; typically Harley-Davidson approved 20W50 or equivalent motorcycle-specific oil.
Primary Chain Case Oil:
Refer to manual; typically Harley-Davidson primary lubricant or an equivalent.
Transmission Oil Type:
Refer to manual; typically Harley-Davidson transmission oil or an equivalent.
Brake Fluid Type:
Refer to manual; if disc brakes are present, DOT 3 or DOT 4 brake fluid (specific type confirmed in manual).
Common Wear Items:
Points and condenser in ignition system, clutch plates, carburetor wear (e.g., throttle shaft wear), fork seals, wheel bearings, brake linings.
Potential Electrical Issues:
Wiring harness degradation, stator/rotor issues, voltage regulator problems (typical for the era).
Engine Tuning Considerations:
Carburetor synchronization and tuning, ignition timing adjustments, valve lash checks are crucial for optimal performance and longevity.
Founder Era:
Harley-Davidson's long-standing history dating back to 1903, known for its iconic V-twin motorcycles and American manufacturing.
Sportster Lineage:
The Sportster line began in 1957, evolving through various displacements and configurations. The XLH1000 represents a significant iteration in the model's performance-oriented evolution.
Manufacturing Location:
United States (Milwaukee, Wisconsin)
Production Period:
1970-1978 covered by this manual.
