Production Years Covered:
1959, 1960, 1961, 1962, 1963, 1964, 1965, 1966, 1967, 1968, 1969
Engine Codes:
XLCH (Competition Hardtail), XLH (Heavy Duty)
Historical Significance:
The Sportster line, introduced in 1957, represented Harley-Davidson's entry into the lightweight performance motorcycle market, competing with British imports. This era's models are iconic for their raw character and mechanical simplicity.
Key Competitors Era:
Triumph Bonneville, BSA Gold Star, Norton Commando.
Design Philosophy:
Emphasis on a strong, torquey engine, a lightweight and nimble chassis, and a distinctive American V-twin aesthetic.
Manual Value Proposition:
Essential resource for owners and mechanics to maintain, repair, and restore these classic motorcycles, preserving their historical integrity and performance.
Engine Systems:
Engine overhaul, disassembly, assembly, tuning, lubrication, cooling (air-cooled), ignition system (magneto/battery-coil), carburetor tuning and rebuild (Linkert/Keihin), piston/cylinder inspection, valve timing.
Transmission And Drivetrain:
4-speed transmission overhaul and repair, clutch service, chain drive maintenance, final drive sprocket replacement.
Chassis And Suspension:
Front fork service and repair (leading link/telescopic), rear suspension (rigid or basic shock absorber), frame inspection and repair, wheel bearing service, steering head bearing adjustment.
Braking System:
Drum brake service and adjustment (front and rear), brake shoe replacement, linkage lubrication.
Electrical System:
Wiring diagrams, lighting system (headlight, taillight, indicators), battery maintenance, charging system (generator/alternator), ignition coil, starter motor (if applicable).
Fuel System:
Fuel tank removal and cleaning, fuel line maintenance, fuel filter replacement, carburetor linkages.
Bodywork And Trim:
Fender removal and installation, seat maintenance, tank badge/striping information, exhaust system inspection.
Maintenance Procedures:
Oil changes, filter replacement, spark plug replacement, chain lubrication and adjustment, brake adjustment, tire pressure checks, battery charging.
Repair Procedures:
Complete engine rebuilds, transmission disassembly and reassembly, carburetor rebuilding, fork seal replacement, electrical component troubleshooting and replacement, brake system overhauls.
Troubleshooting Guides:
Diagnostic charts for common engine, ignition, and fuel system issues, electrical fault finding.
Diagnostic Capabilities:
Detailed diagnostic procedures, specifications for key components, troubleshooting flowcharts.
Rebuild Instructions:
Comprehensive step-by-step instructions for complete engine and transmission overhauls, including torque specifications and clearances.
Special Tools:
Identification and usage of specialized tools required for specific repair procedures.
File Type:
PDF (Portable Document Format)
Searchability:
Searchable text content for quick information retrieval.
Resolution:
High-resolution scans for clear diagrams and text.
Printability:
Printable for workshop use.
Binding:
N/A (Digital PDF Download)
Paper Type:
N/A (Digital PDF Download)
Engine Type:
Air-cooled, 45-degree V-twin, OHV (Overhead Valve)
Displacement Cc:
883cc (53.9 cubic inches)
Bore X Stroke:
3.00 in x 3.56 in (76.2 mm x 90.4 mm) (approximate, may vary slightly by year/model)
Compression Ratio:
Approximately 7.0:1 to 8.5:1 (depending on model and year)
Horsepower Bhp:
Approximately 40-50 bhp (depending on specific model and tuning)
Torque Ft-Lbs:
Approximately 45-55 ft-lbs (depending on specific model and tuning)
Carburetor Type:
Linkert M-series (e.g., M74, M74B) or Keihin (later models)
Fuel Type:
Gasoline (Leaded fuel was standard for this era)
Oil Type:
Typically SAE 50W or SAE 20W-50 motorcycle-specific oil (non-detergent often recommended for older engines).
Oil Capacity Quarts:
Approximately 3 quarts (engine oil + primary chaincase)
Transmission Type:
4-speed constant mesh, foot shift, hand clutch
Optional Gearbox:
N/A for this period; 4-speed was standard across the Sportster range.
Clutch Type:
Dry multi-plate clutch
Primary Drive:
Duplex chain drive from crankshaft to clutch basket.
Final Drive:
Primary chain (enclosed in chaincase) to transmission, then chain to rear sprocket.
Safety Certification Era:
Safety standards were less stringent than modern motorcycles; focus on mechanical integrity and rider awareness.
Braking System Type:
Dual leading shoe drum brakes front and rear.
Lighting System:
Halogen headlight, taillight, stoplight, and usually front/rear amber turn signals (optional/country-dependent).
Frame Construction:
Robust steel frame designed for durability and handling.
Engine Guard Options:
Aftermarket or optional engine guards were common for crash protection.
Oil Change Interval:
Every 1,000 to 2,000 miles (or as specified in the manual), depending on riding conditions.
Primary Chaincase Oil Change:
Every 2,000 to 3,000 miles.
Spark Plug Replacement:
Every 3,000 to 5,000 miles.
Chain Lubrication Adjustment:
Every 500 miles, and adjust chain tension as needed.
Engine Oil Viscosity:
SAE 50W or SAE 20W-50 (refer to manual for exact year/model recommendation, e.g., Harley-Davidson Genuine Motor Oil SAE 50W or equivalent).
Primary Chaincase Oil:
SAE 50W or SAE 10W-30 motorcycle oil (check manual for specific recommendations).
Transmission Oil:
Typically SAE 80W-90 gear oil or specific Harley-Davidson transmission fluid.
Common Wear Items:
Valve guides, piston rings, primary chain and sprockets, clutch plates, front fork bushings, carburetor diaphragm (if applicable to specific carb model).
Ignition System Quirks:
Magneto or battery coil ignition systems can require careful timing and maintenance. Weak sparks can be a common issue.
Carburetor Tuning:
Linkert carburetors can be finicky and require precise adjustment for optimal performance. Air leaks are a common problem.
Example Oil Filter Pnp:
Sportster models of this era typically used internal oil filters or relied on oil screen cleaning rather than external spin-on filters. Specific part numbers for screens/gaskets would be in the manual.
Founding Principles:
Harley-Davidson, founded in 1903, is synonymous with American motorcycle culture, known for its V-twin engines and robust construction.
Sportster Line Genesis:
The Sportster was developed to offer a more sporting and agile machine compared to the larger Big Twin models, inspired by European performance motorcycles.
1959 Sportster Characteristics:
Featured the Ironhead Sportster engine, introduced in 1957, initially as a 55 cubic inch (900cc) and later expanding to 53.9 cubic inch (883cc). This era saw models like the XLCH (Competition Hardtail, often kick-start only) and XLH (Heavy Duty, often with electric start option later in the period).
Manufacturing Location:
Milwaukee, Wisconsin, USA.
Key Design Changes Era:
The period saw refinements to the Ironhead engine, carburetor improvements, chassis strengthening, and variations in electrical systems (magneto vs. battery ignition).
