Model Variant:
XLCH, XLH, XLX, XLS, XLRS, XLH Sportster
Generation Designation:
First Generation Sportster (Ironhead)
Chassis Codes:
XLCH, XLH, XLX, XLS, XLRS
Market Position:
The Sportster XL series represented Harley-Davidson's entry into the lightweight, performance-oriented motorcycle market, competing with European imports and offering a more accessible Harley-Davidson experience.
Competitive Analysis:
Competed against models from Triumph, BSA, Norton, and later Japanese manufacturers, establishing itself as an American icon in its segment.
Key Features:
Air-cooled, pushrod OHV V-twin engine; iconic styling; robust construction; significant customization potential.
Covered Years:
1959, 1960, 1961, 1962, 1963, 1964, 1965, 1966, 1967, 1968, 1969
Estimated Page Count:
300-400
Manual Type:
Factory Service Manual / Repair Manual
Format:
Digital Download (PDF)
Engine Systems:
Engine disassembly, assembly, tuning, lubrication, cooling, oil pump, timing, valve train
Transmission Drivetrain:
Gearbox inspection, repair, clutch service, chain drive maintenance, primary drive
Electrical System:
Ignition system, charging system (generator/alternator), lighting, wiring diagrams, battery, starter
Fuel System:
Carburetor identification, adjustment, repair (e.g., Linkert, S&S), fuel tank, fuel lines
Braking System:
Drum brake inspection, adjustment, repair, hydraulic components (if applicable to later models in the range)
Suspension Steering:
Front fork service, rear shock absorber replacement, steering head bearing adjustment
Frame Bodywork:
Frame inspection, fender removal/installation, seat mounting, fuel tank mounting
Maintenance Procedures:
Oil changes, filter replacement, spark plug service, chain lubrication and adjustment, brake adjustments, battery charging
Repair Procedures:
Engine rebuilds, transmission overhauls, carburetor rebuilds, electrical component replacement, suspension rebuilds
Troubleshooting Guides:
Diagnostic flowcharts for common performance issues, starting problems, electrical faults
Technical Depth:
Comprehensive: Covers basic maintenance to full engine and transmission rebuilds. Includes detailed torque specifications, clearances, and alignment procedures.
Engine Type:
Air-cooled, 45-degree V-twin, pushrod OHV
Engine Displacement Cc:
883cc (53.9 cu in)
Engine Bore X Stroke Mm:
76.2 x 96.8 mm (3.00 x 3.81 in)
Engine Compression Ratio:
8.0:1 (typical, may vary slightly by year/model)
Engine Cylinder Material:
Cast iron cylinders, aluminum alloy heads
Horsepower Bhp:
Approximately 45-50 bhp @ 5500 rpm (estimated)
Torque Lb Ft:
Approximately 48-52 lb-ft @ 3500 rpm (estimated)
Carburetor Type:
Linkert M-series (e.g., M55, M74) or S&S Super E/B (later aftermarket options often specified in manuals)
Fuel Type:
Unleaded gasoline, minimum 87 octane recommended
Fuel Tank Capacity Liters:
Approximately 9.5 - 10.0 liters (2.5 - 2.6 US gallons)
Transmission Type:
4-speed constant mesh manual
Optional Transmission:
N/A for factory specifications of this era
Clutch Type:
Wet, multi-plate
Primary Drive:
Chain drive (43/51 tooth sprockets, 21/25 gear ratio typical)
Final Drive:
Chain drive (e.g., 51/21 primary, 36/21 final chain drive ratio typical)
Transmission Fluid Type:
Harley-Davidson High Performance Formula Plus Lubricant (or equivalent 75W/90 gear oil for transmission, primary chaincase oil)
Overall Length Mm:
Approximately 2100-2250 mm (82.7-88.6 in) - Varies by model variant and fender style
Wheelbase Mm:
Approximately 1480-1500 mm (58.3-59.1 in)
Dry Weight Kg:
Approximately 190-210 kg (420-465 lbs)
Gross Vehicle Weight Rating Kg:
Approximately 360 kg (795 lbs)
Safety Ratings:
N/A (Motorcycles of this era were not subject to standardized crash testing as cars are)
Active Features:
Drum brakes (front and rear), robust frame construction
Passive Features:
Headlight, taillight, brake light, turn signals (depending on model variant and year)
Oil Change Interval Km Miles:
Every 2,000-3,000 miles (3,200-4,800 km) or 6 months, whichever comes first
Spark Plug Replacement Interval Km Miles:
Every 5,000-10,000 miles (8,000-16,000 km), depending on plug type and usage
Chain Lubrication Interval Km Miles:
Every 500-1000 miles (800-1600 km) and after washing or riding in rain
Engine Oil Capacity Liters:
Approximately 2.8 - 3.0 liters (3.0 - 3.2 US quarts)
Engine Oil Type:
Viscosity: SAE 20W-50. Type: Harley-Davidson recommended or API SG/SH/SJ rated petroleum-based motorcycle oil.
Primary Chaincase Oil Type:
Harley-Davidson Primary Chaincase Lubricant or SAE 80W-90 gear oil
Transmission Fluid Capacity Liters:
Approximately 0.95 liters (1.0 US quart)
Common Issues Engine:
Oil leaks (especially from pushrod tubes and base gaskets), worn valve guides, potential for kickstart mechanism wear, generator charging issues.
Common Issues Carburetor:
Linkert carburetor tuning sensitivity, float bowl leaks, emulsion tube wear.
Common Issues Electrical:
Generator output inconsistencies, worn wiring insulation, voltage regulator issues (if applicable to later models).
Common Issues Suspension:
Worn fork seals, worn rear shock absorbers, steering head bearing adjustment requirements.
Brand Heritage:
Founded in 1903, Harley-Davidson is synonymous with American motorcycle culture, known for its V-twin engines and distinctive sound. The Sportster line, introduced in 1957, became a cornerstone of their offering.
Model Evolution Early:
The Sportster XL evolved from the K-model. The 'Ironhead' Sportster, characterized by its cast iron cylinders and heads, dominated production until the early 1980s. The years covered represent the formative period of this iconic design.
Production Location:
Milwaukee, Wisconsin, USA
