Historical Context:
The Harley-Davidson Sportster XLH series represented a significant portion of the brand's offerings during the late 60s and 70s, appealing to a wide range of riders seeking a versatile and iconic American motorcycle.
Contemporary Competitors:
Competed against other American V-twins and rising Japanese motorcycle offerings from brands like Honda, Kawasaki, and Yamaha, particularly in the standard and cruiser segments.
Sportster Appeal:
Known for its distinctive V-twin engine, rugged construction, and customizable platform, the Sportster XLH was a foundational model in motorcycle culture.
Systems Covered:
Engine, Transmission, Drivetrain, Chassis, Electrical System, Fuel System, Ignition System, Brakes, Suspension, Frame, Bodywork, Controls, Accessories
Estimated Page Count:
300-500 (typical for comprehensive workshop manuals of this era)
Manual Type:
Workshop Service Repair Manual
Format:
Digital (PDF) or Printed Copy (as applicable to the specific product offering)
Engine Overhaul:
Complete disassembly, inspection, repair, and reassembly of all engine components including cylinders, pistons, connecting rods, crankshaft, camshafts, valves, and lubrication system.
Transmission And Drivetrain:
Service and repair procedures for the transmission, primary drive, clutch, and final drive (chain/sprockets).
Electrical System:
Wiring diagrams, troubleshooting guides, component testing, and repair for ignition, lighting, charging system (generator/alternator), and instrumentation.
Fuel And Carburetion:
Carburetor adjustment, overhaul, troubleshooting, and fuel delivery system service.
Braking System:
Service and repair of front and rear braking systems, including drum brake mechanisms.
Suspension And Steering:
Front fork (hydraulics, seals, bushings) and rear shock absorber service, as well as steering head bearing maintenance.
Frame And Bodywork:
Frame inspection, alignment checks, fender, tank, and seat mounting procedures.
Routine Maintenance:
Oil changes, filter replacement, chain adjustment, spark plug service, lubrication points, brake adjustment, tire pressure checks.
Troubleshooting:
Systematic diagnostic procedures for common operational issues and failures.
Repair And Rebuild:
Step-by-step instructions for component replacement, repair, and complete engine or transmission rebuilds.
Specifications And Tolerances:
Detailed torque specifications, clearances, and measurement guidelines for all critical components.
Depth Of Coverage:
Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts. Covers everything from basic adjustments to complete engine teardowns and rebuilds.
Digital Format Quality:
High-resolution scans or original digital files ensuring clear text and legible diagrams. Searchable text functionality is a significant advantage if available.
Printed Material Quality:
Durable paper stock (e.g., glossy or matte finish suitable for workshop environments), clear printing of text and illustrations.
Printed Binding:
Spiral-bound or perfect-bound for lay-flat usability in a workshop setting.
Paper Quality For Print:
Heavyweight paper, resistant to grease and workshop handling.
Engine Type:
Air-cooled, 45-degree V-twin
Displacement Variants:
Primarily 1000cc (Ironhead Sportster) variants (e.g., XLCH, XLH). Earlier models may have 900cc (Ironhead) variants as well, though the manual focuses on 1970-1978.
Bore X Stroke:
For 1000cc: Typically 3.1875 in. x 3.75 in. (81 mm x 95.25 mm)
Compression Ratio:
Varies by specific model and year, often around 8.0:1 to 9.0:1
Horsepower Estimate:
Approx. 50-65 HP (depending on specific model and tuning)
Torque Estimate:
Approx. 55-65 ft-lbs (depending on specific model and tuning)
Carburetion:
Typically single AMF/Holley or Linkert carburetors. Later models may feature Keihin carburetors.
Fuel Type:
Unleaded gasoline, octane rating appropriate for the era (e.g., 87-91 octane).
Ignition Type:
Battery and coil (points ignition).
Oil Type:
Viscosity: SAE 20W-50 motorcycle-specific oil. Some manuals might recommend SAE 50 or SAE 30 based on climate.
Oil Capacity:
Approximately 3 quarts (2.8 liters) for engine and transmission combined (dry fill). Check manual for specific dry/wet fill capacities.
Wheelbase:
Approximately 57.5 - 60 inches (1460 - 1524 mm), varies by specific model
Dry Weight:
Approximately 470 - 500 lbs (213 - 227 kg), varies by specific model
Gvwr:
Not typically published for this era of motorcycles, but refers to maximum combined weight of rider, passenger, and cargo.
Oil Change Interval:
Typically every 1,000 - 2,000 miles (1,600 - 3,200 km) or annually, whichever comes first. Consult manual for precise intervals.
Chain Adjustment Interval:
Check and adjust chain slack every 500 miles (800 km) or as needed.
Spark Plug Replacement:
Recommended every 5,000 - 10,000 miles (8,000 - 16,000 km), depending on plug type and condition.
Fork Oil Type:
Motorcycle-specific fork oil, typically SAE 10W or 20W. Capacity varies per fork leg, check manual.
Brake Fluid Type:
Drum brakes of this era do not use hydraulic fluid. Check for proper lubrication of brake pivot points.
Ironhead Engine Quirks:
Oil leaks (common with age), valve guide wear, oil pump inefficiency, charging system issues (generator/regulator), primary chain tensioner wear, carburetor tuning sensitivity.
Carburetor Issues:
Float bowl leaks, jet clogging, diaphragm failure, difficulty maintaining stable idle.
Electrical Component Reliability:
Aging wiring harnesses, regulator/rectifier failures, starter solenoid issues, battery maintenance.
Harley Davidson Legacy:
Founded in 1903, Harley-Davidson is an iconic American manufacturer renowned for its V-twin engines and distinctive motorcycle designs.
Sportster Lineage:
The Sportster line, introduced in 1957, evolved through various engine displacements and configurations, with the 'Ironhead' OHV V-twin being the defining characteristic of the 1970-1978 models.
Manufacturing Location:
York, Pennsylvania, USA, and Milwaukee, Wisconsin, USA.
Production Period Xlh:
The XLH designation specifically refers to the electric start models, alongside the kick-start-only XLCH models, within the Sportster family during this era.
