Historical Context:
The XLH Sportster of this generation, often referred to as the 'Ironhead,' was Harley-Davidson's iconic performance motorcycle. It competed in the burgeoning performance motorcycle market, appealing to riders seeking a potent and stylish machine.
Competitors:
In its era, it competed with British motorcycles (Triumph, BSA, Norton) and later, Japanese manufacturers (Honda, Kawasaki, Yamaha) entering the performance segment. The Sportster distinguished itself with its V-twin character and American muscle.
Engine Architecture:
Air-cooled, 45-degree V-twin OHV engine (often referred to as the 'Ironhead' due to its iron cylinder heads).
Chassis Design:
Robust steel frame, often a cradle or backbone design, with a focus on handling and stability.
Performance Focus:
Designed for spirited riding, offering strong torque and a distinctive exhaust note.
Primary Coverage:
Factory Repair Service
Maintenance Coverage:
Routine maintenance, adjustments, lubrication
Repair Coverage:
Complete mechanical and electrical repair procedures
Rebuild Coverage:
Complete engine, transmission, and driveline rebuilds
Estimated Pages:
Varies by specific edition, typically 300-600 pages for a comprehensive factory manual of this era.
Type:
Factory Service Manual / Repair Manual
Format:
Likely printed manual, though digital reproductions (PDF) are common for historical manuals.
Engine:
Ironhead OHV V-Twin engine (displacements typically 883cc and 900cc for this period), cylinder head assembly, valve train, crankshaft, connecting rods, pistons, cylinders, oil pump, lubrication system, cooling (air-cooled).
Fuel System:
Carburetor (e.g., Linkert, later Keihin), fuel tank, fuel lines, fuel filter, petcock operation and service.
Ignition System:
Magneto or battery/coil ignition systems (depending on specific year/model within the range), spark plugs, ignition timing, points and condenser (if applicable), wiring diagrams.
Transmission:
4-speed constant mesh manual transmission, clutch operation and adjustment, primary drive system (chain and chaincase), gearbox disassembly, assembly, and internal component service.
Drivetrain:
Final drive (chain), chain tensioner, sprockets, rear wheel hub assembly, drive sprocket replacement.
Suspension:
Front fork (often leading-link or telescopic depending on the exact model year within the range), rear swingarm and shock absorbers, fork oil change and seal replacement, shock absorber servicing.
Brakes:
Front and rear drum brake systems, brake shoe replacement, brake drum service, brake pedal and lever adjustments, hydraulic fluid (if applicable, though drum brakes are typically mechanical for much of this era).
Electrical System:
Wiring diagrams, generator or alternator (depending on year), battery maintenance, lighting system (headlight, taillight, indicators), starter system, horn, switches, and control units.
Frame And Bodywork:
Frame inspection and repair, fender mounting and alignment, fuel tank mounting and removal, seat mounting, handlebars, controls, and basic body component adjustments.
Maintenance:
Oil changes, filter replacement (if applicable), chain lubrication and adjustment, spark plug replacement, battery checks, tire pressure checks, brake adjustments, clutch adjustments, lubrication points.
Troubleshooting:
Diagnostic charts for common performance issues, starting problems, electrical faults, and mechanical noises.
Repair:
Step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, reassembly, and installation for all major systems.
Rebuild:
Detailed procedures for complete engine overhauls, transmission rebuilds, and fork rebuilding, including specifications for wear limits and clearances.
Adjustments:
Carburetor tuning, ignition timing adjustments, clutch and brake lever free play, throttle cable adjustments, and suspension preload (if adjustable).
Depth:
Comprehensive. Covers everything from basic owner maintenance to advanced engine rebuilds and electrical system diagnostics. Suitable for professional mechanics and experienced home mechanics.
Digital Format Notes:
If a digital (PDF) version, expect clear scans of original pages, potentially with searchable text if OCR has been applied. Print quality of original would vary by era.
Original Print Quality:
Typical for factory manuals of the era: black and white line drawings, schematics, and some halftones. Page quality generally good for legibility.
Original Binding:
Likely stapled or perfect bound for factory publications.
Original Paper Type:
Durable, coated paper designed for shop use, though aging can affect paper condition.
Engine Type:
Air-cooled, 45-degree V-twin, Overhead Valve (OHV)
Displacement Cc:
Commonly 883cc (55 cubic inches) and 900cc (55.6 cubic inches), with some variations possible.
Bore X Stroke:
Varies by specific year and displacement. Example for 883cc: 3.00 x 3.56 inches (76.2 x 90.4 mm).
Compression Ratio:
Typically around 8.0:1 to 9.0:1, varying by model year and intended fuel octane.
Horsepower Est:
Estimated 50-60+ hp, depending on specific year, tuning, and carburation.
Torque Est:
Strong low-end and mid-range torque, typically in the 50-60+ ft-lbs range.
Carburetor Type:
Predominantly Linkert 'M' series carburetors in early years, transitioning to Keihin carburetors later in the range or as upgrades.
Fuel Type:
Leaded gasoline (as per original specifications), though modern unleaded with octane boosters or lead substitutes is often used.
Oil Type:
Motorcycle-specific oil, often SAE 50 or 20W-50 for this era, with good ZDDP content for flat tappet engines. Refer to specific manual for exact HD specification.
Oil Capacity Quarts:
Approximately 3 quarts (2.8 liters), including oil in the tank and crankcase. Verify with manual.
Cooling Method:
Air-cooled
Type:
4-speed constant mesh manual transmission
Options Available:
Generally a single 4-speed transmission option for these models.
Clutch Type:
Wet multi-plate clutch
Primary Drive:
Chain drive within a primary chaincase
Final Drive:
Chain drive from transmission sprocket to rear wheel sprocket
Transmission Oil Type:
Motorcycle-specific gear oil, often SAE 75W-90 or 80W-90. Consult manual for exact specification.
Transmission Oil Capacity Quarts:
Approximately 1 pint (0.47 liters). Verify with manual.
Oil Change Interval:
Typically every 1,000-2,000 miles or 3-6 months, depending on riding conditions. Refer to manual for exact interval.
Chain Lube Adjustment:
Lubricate chain every 300-500 miles, adjust tension as needed (typically 1/2 to 3/4 inch slack).
Spark Plug Replacement:
Every 5,000-10,000 miles, or as per manual recommendations.
Valve Adjustment:
Periodic checks and adjustments recommended, often every 2,000-5,000 miles. Consult manual for specific procedure and clearances.
Primary Chaincase Oil:
Motorcycle-specific oil (e.g., SAE 50, 20W-50), refer to manual.
Fork Oil Type:
Specific viscosity fork oil (e.g., 10W or 15W), capacity varies by fork model. Refer to manual.
Brake Fluid:
For drum brakes, typically mechanical adjustment; if hydraulic components were introduced later, Dot 3 or Dot 4 fluid would be specified. Verify specific year.
Oil Leaks:
Common for Ironheads due to aged seals and gaskets. Manual covers seal replacement.
Carburetor Tuning:
Linkert carburetors can be finicky and require specific tuning. Manual provides jetting and adjustment procedures.
Electrical Gremlins:
Aging wiring and components can lead to intermittent issues. Comprehensive wiring diagrams are crucial and included.
Engine Vibration:
Characteristic of V-twins of this era, but excessive vibration can indicate wear. Manual aids in diagnosis.
Harley Davidson Legacy:
Harley-Davidson, founded in 1903, has a long history of producing V-twin motorcycles. The Sportster line, introduced in 1957, became a cornerstone of the brand's performance offerings.
Sportster Development:
The XLH Sportster evolved from the earlier K model. The 1959-1969 'Ironhead' era represents a significant period of development, including updates to engines, transmissions, and chassis components, establishing its iconic status.
Manufacturing Location:
Milwaukee, Wisconsin, USA
Key Production Years:
1959-1969 represents a specific, highly sought-after generation of the Sportster.
