Positioning:
The 1971 Sportster XLCH represented Harley-Davidson's pursuit of performance and a sportier riding experience, catering to riders seeking a more aggressive machine than the touring models. It was a direct competitor to European sport motorcycles of the era.
Competitors:
Triumph Bonneville, BSA Rocket Gold Star, Norton Commando, and various Japanese sport motorcycles of the period.
Features:
The XLCH (Custom Hot Competition) model was distinguished by its higher compression, sportier camshafts, revised suspension, and often a smaller fuel tank compared to the XLH. It was designed for riders who valued acceleration and handling.
Primary Coverage:
Harley-Davidson Sportster XLCH 1971
Secondary Coverage:
General Sportster XLCH maintenance and repair procedures applicable to the early 1970s era.
Estimated Pages:
200-300 (typical for factory service manuals of this era)
Type:
Factory Service Manual / Repair Manual
Format:
Printed (assumed, typical for factory manuals of this year)
Engine:
Disassembly, assembly, inspection, repair, and troubleshooting of the Ironhead V-twin engine (including top end, bottom end, lubrication system, ignition system).
Transmission:
Service and repair of the 4-speed constant mesh transmission, including clutch operation and adjustment.
Fuel System:
Carburetor (likely Keihin Butterfly or Linkert) tuning, cleaning, rebuilding, and troubleshooting.
Electrical System:
Wiring diagrams, component testing (generator, ignition coil, battery, lights, switches), troubleshooting of electrical faults.
Chassis:
Frame, suspension (forks, shocks), steering head, brakes (drum brakes), wheels, and bearings.
Bodywork:
Body panel removal and installation, fenders, fuel tank, seat mounting.
Maintenance:
Scheduled maintenance, lubrication points, fluid changes, chain adjustment, brake adjustments.
Repair:
Step-by-step instructions for component replacement, rebuilding, and alignment.
Troubleshooting:
Diagnostic charts and procedures for identifying and resolving common problems.
Disassembly Assembly:
Detailed instructions for taking apart and putting back together all major motorcycle components.
Depth:
Comprehensive, covering from basic adjustments to complete engine and transmission overhauls. Intended for professional mechanics and skilled DIY enthusiasts.
Digital Format:
PDF (if digitally sourced), Print (if physical copy)
Print Quality:
High-resolution scans of original factory documentation, ensuring clarity of diagrams and text.
Binding:
Professional binding (stapled, perfect bound, or spiral bound for usability in a workshop environment).
Paper Quality:
Durable paper stock suitable for workshop environments, resistant to grease and dirt.
Engine Displacement:
90.3 cubic inches (1477 cc)
Engine Configuration:
Air-cooled, 45-degree V-twin
Bore X Stroke:
3.4375 in. x 4.00 in. (87.3 mm x 101.6 mm)
Compression Ratio:
Approximately 8.0:1 (XLCH specific, higher than standard XLH)
Horsepower Approx:
55-60 HP (estimated, factory figures often conservative)
Torque Approx:
70-75 lb-ft (estimated)
Carburetor:
Single Keihin butterfly or Linkert (depending on specific build date/market).
Fuel Type:
Unleaded gasoline (though leaded was common at the time, 91 octane recommended for modern use if possible).
Ignition Type:
Battery and coil ignition with mechanical breaker points and centrifugal advance.
Transmission Type:
4-speed constant mesh manual
Clutch Type:
Wet multi-plate
Primary Drive:
Chain drive to primary transmission.
Final Drive:
Belt drive to rear wheel.
Transmission Fluid:
Harley-Davidson recommended gear oil or equivalent (e.g., SAE 80W-90).
Oil Change Interval:
Every 1,000-2,000 miles or annually (recommended).
Spark Plug Replacement:
Every 5,000-10,000 miles (subject to plug type and usage).
Chain Adjustment Interval:
As needed, typically every 500-1000 miles, checking for proper tension.
Engine Oil Type:
Harley-Davidson recommends specific motorcycle oil, often a heavier weight like SAE 50 or 60 for older Ironheads. Consult manual for exact spec.
Engine Oil Capacity:
Approximately 3 US quarts (2.8 L).
Primary Chain Case Oil:
Separate reservoir, typically using Harley-Davidson primary lubricant or equivalent. Capacity is usually around 1 US quart.
Oil Leaks:
Common on Ironheads due to aging seals and gaskets. Manual will detail common leak points and repair procedures.
Ignition Timing:
Breaker points and advance mechanisms require periodic adjustment for optimal performance and starting. Manual provides timing procedures.
Carburetor Tuning:
Carburetors can be finicky and require regular cleaning and adjustment for smooth running. Manual covers detailed tuning procedures.
Kickstarter Mechanism:
Can wear over time, requiring attention. Manual covers inspection and repair of the kickstart assembly.
Heritage:
Harley-Davidson, established in 1903, is an iconic American motorcycle manufacturer known for its V-twin engines and distinct riding experience.
Sportster Lineage:
The Sportster line debuted in 1957, evolving over decades. The XLCH ('C' for Competition) variant was introduced to offer a more performance-oriented version of the popular Sportster platform.
Production Era:
The 'Ironhead' Sportster, named for its cast iron cylinder heads, was produced from 1957 until 1985. The 1971 model falls within this significant era.
