🏷️ Basic Information

Make:

Harley-Davidson

Model:

Sportster XL / XLH

Year:

1999

Chassis Code:

XLH

Engine Code Prefix:

XL

👋 Introduction

Positioning:

The 1999 Harley-Davidson Sportster line represented a continuation of a highly popular and accessible cruiser platform within the Harley-Davidson lineup. It appealed to riders seeking the iconic Harley-Davidson experience in a more agile and urban-friendly package.

Competitors:

Competed with other entry-level to mid-range cruisers from brands like Indian, Honda (Shadow series), Yamaha (Virago/V-Star series), and Kawasaki (Vulcan series).

Sportster Features:

Evolution V-twin engine, classic styling, rider-friendly ergonomics, customizability.

Value:

This manual is an essential resource for owners and technicians to maintain, diagnose, and repair their 1999 Sportster, ensuring longevity and optimal performance of these iconic motorcycles.

📋 Manual Details

Primary Coverage:

Full Service, Repair, Maintenance, Troubleshooting

Specific Models Covered:

All 1999 Harley-Davidson Sportster XL and XLH models

Estimated Page Count:

300+

Type:

Service and Repair Manual

Language:

English

Format:

Digital (likely PDF, but confirmation needed for specific product listing)

📖 Manual Coverage

Engine:

Engine overhaul, disassembly, assembly, tuning, carburetor service, ignition system, oil pump, lubrication.

Transmission:

5-speed transmission service, clutch operation, gear inspection, fluid changes.

Electrical:

Wiring diagrams, starter system, charging system (alternator/stator, regulator), lighting, ignition, instrument cluster, battery maintenance.

Fuel System:

Carburetor service (CV carb), fuel tank, fuel lines, fuel petcock.

Brakes:

Front and rear brake system service, hydraulic fluid, caliper maintenance, pad replacement, rotor inspection.

Suspension:

Front fork service (preload, damping, oil changes), rear shock absorber inspection and replacement.

Frame And Body:

Frame inspection, body panel removal/installation, fenders, seat, handlebars, controls.

Wheels And Tires:

Wheel bearing service, tire inspection and replacement, spoke maintenance.

Maintenance:

Scheduled maintenance, oil changes, filter replacements, spark plug service, chain adjustment (if applicable), brake adjustments.

Troubleshooting:

Diagnostic procedures for common starting, running, and electrical issues. Symptom-based troubleshooting guides.

Repair:

Detailed step-by-step instructions for component disassembly, repair, and reassembly for all major systems.

Special Tools:

Identification of specific Harley-Davidson special tools required for certain procedures.

Depth:

Comprehensive, covering everything from routine maintenance to complete engine and transmission rebuilds. Suitable for DIY enthusiasts and professional mechanics.

📊 Manual Specifications

Format Details:

Likely a PDF document. Searchable text capability is highly desirable for digital manuals. High-resolution scans for clear diagrams.

Quality:

If printed, expect clear, sharp text and diagrams. Professional binding for durability.

Binding:

Typically saddle-stitched or perfect-bound for printed manuals. Digital format is universally accessible.

Paper:

For printed manuals, high-quality, durable paper stock is expected to withstand workshop use.

⚙️ Engine Specifications

Engine Type:

Air-cooled, 45-degree V-twin, Evolution engine

Displacement Cc:

1200cc (most common for XLH), 883cc (XL variants)

Bore X Stroke Mm:

1200cc: 3.50 in. x 3.81 in. (88.9 mm x 96.8 mm); 883cc: 3.00 in. x 3.81 in. (76.2 mm x 96.8 mm)

Compression Ratio:

1200cc: 9.0:1; 883cc: 8.8:1 (typical for the era, can vary)

Horsepower Hp:

Approx. 60-65 HP for 1200cc (varies by specific tuning)

Torque Ft-Lbs:

Approx. 67-70 ft-lbs for 1200cc (varies by specific tuning)

Carburetor:

Keihin CV (Constant Velocity) 40mm (standard on 1200cc), 34mm (standard on 883cc)

Fuel Type:

Unleaded gasoline, minimum 91 octane (AKI) recommended

Ignition Type:

Electronic Ignition with single fire capability

Oil Type Engine:

Harley-Davidson SYN3 (Synthetic) SAE 20W50 or similar premium V-twin specific oil

Oil Capacity Quarts:

Approx. 3.0 quarts (2.8 liters) with filter change

Cooling Method:

Air-cooled

🔧 Transmission

Transmission Type:

5-speed constant mesh, helical gear, chain drive

Optional Transmissions:

None for this model year

Clutch Type:

Wet, multi-plate, manually operated

Transmission Oil Type:

Harley-Davidson Primary Chain Lubricant or equivalent SAE 80W-90

Transmission Oil Capacity Quarts:

Approx. 2.5 pints (1.2 liters)

📐 Dimensions

Overall Length In:

Approx. 87.0 inches (2209.8 mm)

Wheelbase In:

Approx. 60.0 inches (1524 mm)

Seat Height In:

Approx. 26.0 inches (660.4 mm)

Dry Weight Lbs:

Approx. 495-510 lbs (224-231 kg), depending on configuration

Gross Vehicle Weight Rating Gvwr Lbs:

Not typically specified in owner's manuals for this era, but substantially higher than dry weight.

Fuel Tank Capacity Gallons:

3.5 gallons (13.2 liters)

🛡️ Safety Features

Crash Test Ratings:

Motorcycles of this era did not undergo standardized crash testing like automobiles. Safety is primarily determined by rider skill and adherence to maintenance.

Braking System:

Dual-disc front brakes, single-disc rear brake. Hydraulic actuation.

Lighting:

Halogen headlight, taillight, brake lights, turn signals.

Frame Construction:

Steel cradle frame designed for stability.

Tire Size Front:

Typically 100/90-19 or similar

Tire Size Rear:

Typically 150/80-16 or similar

💡 Technology Features

Infotainment System:

None for this model year. Basic functionality.

Assistance Features:

None. This is a traditional motorcycle focused on rider engagement.

Connectivity Features:

None.

Dashboard Features:

Analog speedometer, tachometer (optional on some models), odometer, trip meter, indicator lights for turn signals, oil pressure, high beam, neutral.

🔧 Maintenance

First Service Miles:

1000 miles (1600 km) or 6 months (whichever comes first)

Subsequent Service Miles:

Every 5000 miles (8000 km) or 12 months thereafter for oil change and basic checks. More detailed inspections every 10,000 miles.

Fork Oil Change Miles:

Recommended every 10,000-15,000 miles, or as needed based on performance.

Spark Plug Replacement Miles:

Typically every 10,000 miles, but consult manual for specific recommendations.

Engine Oil Type:

Harley-Davidson SYN3 SAE 20W-50 or equivalent premium V-twin motorcycle oil.

Primary Chain Lubricant Type:

Harley-Davidson Primary Chain Lubricant or SAE 80W-90 gear oil.

Brake Fluid Type:

DOT 4 hydraulic brake fluid.

Common Wear Items:

Clutch plates, brake pads, wheel bearings, fork seals, and spark plugs are common wear items. Carburetor tuning can require periodic attention.

Ignition System Considerations:

Early Evolution ignitions can be sensitive to voltage fluctuations. Ensure battery and charging system are in good order.

Carburetor Adjustments:

CV carburetors may require adjustments for altitude or modifications. The manual will detail idle mixture and jetting.

📚 Vehicle History

Heritage:

Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer with a rich legacy of V-twin engines, cruiser motorcycles, and a distinct rider culture.

Sportster Lineage:

The Sportster line, introduced in 1957, has been a staple for Harley-Davidson. The 1999 models feature the Evolution engine, which replaced the older Ironhead engine, offering improved reliability and performance.

Manufacturing Location:

United States

Production Years For This Generation:

The Evolution Sportster platform was introduced in the mid-1980s and continued with various updates through subsequent years, with the 1999 model being a distinct iteration.

🏆 Awards & Recognition

Model Recognition:

While specific awards for the 1999 model may not be widely documented, the Sportster line has consistently been recognized for its enduring style, performance, and its role in popularizing the cruiser segment.

Reliability Ratings:

Sportster models from this era are generally considered reliable with proper maintenance. The Evolution engine is known for its robustness.

Emission Standards:

Compliant with applicable US EPA emission standards for 1999 motorcycles.