Positioning:
Essential reference for owners, restorers, and mechanics working on classic Harley-Davidson Sportster models, catering to a passionate niche market valuing originality and performance.
Competitors:
While factory service manuals are the gold standard, aftermarket manuals from publishers like Clymer or Haynes may exist. However, this digital offering provides direct access to factory-level detail.
Feature 1:
Authoritative information directly from Harley-Davidson's engineering and service departments.
Feature 2:
Covers a pivotal decade for the Sportster, including early OHV designs and evolving chassis configurations.
Feature 3:
Crucial for accurate restoration, maintenance, and troubleshooting of these iconic V-twin motorcycles.
Engine:
Detailed coverage of Ironhead Sportster XL engines, including OHV design, cylinder heads, valve train, lubrication systems, cooling (air-cooled), ignition systems (magneto/battery spark), and carburetor tuning.
Transmission:
Comprehensive information on the 4-speed constant mesh transmission, including clutch operation, gear shifting mechanisms, lubrication, and overhaul procedures.
Chassis And Suspension:
Coverage of frame types, front fork assemblies (leading link or telescopic depending on specific sub-models), rear shock absorbers, swingarm pivot, and steering head bearings.
Brakes:
Detailed descriptions and service procedures for drum brake systems front and rear, including brake shoe replacement, drum inspection, and linkage adjustments.
Electrical System:
In-depth schematics and troubleshooting for the electrical system, including lighting, horn, battery charging system (generator or alternator), ignition timing, and wiring diagrams.
Fuel System:
Information on fuel tanks, fuel lines, fuel filters, and carburetor models commonly used (e.g., Linkert, S&S) with adjustment and overhaul procedures.
Exhaust System:
Details on exhaust pipes, mufflers, and mounting hardware.
Bodywork And Trim:
Information on fenders, fuel tanks, seat mounting, and minor body component repairs.
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, spark plug servicing, battery maintenance, tire pressure checks.
Engine Overhaul:
Complete engine disassembly, inspection, component replacement (pistons, rings, valves, bearings), and reassembly instructions.
Transmission Rebuild:
Detailed steps for transmission disassembly, gear inspection, bearing replacement, and reassembly.
Suspension Service:
Fork seal replacement, oil changes, shock absorber servicing, and bearing lubrication.
Brake Service:
Brake shoe replacement, drum cleaning and inspection, linkage adjustment.
Electrical Troubleshooting:
Diagnosis and repair of common electrical faults, wiring harness repair, ignition system testing.
Carburetor Adjustment And Rebuild:
Step-by-step instructions for tuning, cleaning, and rebuilding common carburetor models of the era.
Ignition Timing:
Procedures for setting ignition timing using timing marks or specialized tools.
Depth:
Comprehensive coverage from basic maintenance and adjustments to full engine and transmission rebuilds. Includes detailed diagnostic procedures and specifications for critical components.
Engine Type:
Air-cooled, 45-degree V-twin, OHV (Overhead Valve)
Engine Displacement Early:
888 cc (55 cubic inches) for XLCH and XLH models
Engine Displacement Later:
998 cc (61 cubic inches) for XLCH and XLH models towards the end of the period
Bore X Stroke 55Ci:
3.00 x 3.625 inches (76.2 x 92.075 mm)
Bore X Stroke 61Ci:
3.1875 x 3.625 inches (80.96 x 92.075 mm)
Compression Ratio Typical:
Approximately 7.5:1 to 8.5:1 (varies by model year and compression type)
Cylinder Construction:
Cast iron cylinders with aluminum alloy heads
Valve Train:
Pushrod-actuated overhead valves, two valves per cylinder
Horsepower Estimated 55Ci:
Approximately 45-50 HP at 5000-6000 RPM
Horsepower Estimated 61Ci:
Approximately 50-55 HP at 5000-6000 RPM
Torque Estimated:
Approximately 55-65 ft-lbs at 3000-4000 RPM
Carburetor Common:
Linkert M-series (e.g., M74, M74B) or early S&S Super E/B
Fuel Type Recommended:
Unleaded gasoline with an octane rating of 91 or higher (modern equivalent), or leaded gasoline for original specifications.
Fuel Capacity:
Typically 2.5 to 3.5 US gallons (9.5 to 13.2 liters), depending on tank size.
Type:
4-speed constant mesh manual transmission
Clutch Type:
Wet multi-plate clutch, foot-operated.
Primary Drive:
Chain drive from engine to transmission, typically 1.5" wide chain.
Final Drive:
Chain drive from transmission to rear wheel, typically 5/8" pitch chain.
Transmission Fluid Type:
Typically Harley-Davidson transmission lubricant or SAE 50W gear oil.
Transmission Fluid Capacity:
Approximately 1 US pint (0.47 liters).
Wheelbase:
Approximately 57-59 inches (1450-1500 mm), varies by model year and configuration.
Seat Height:
Approximately 28-30 inches (710-760 mm), unladen.
Dry Weight:
Approximately 400-450 lbs (180-205 kg), varies significantly by model year and trim.
Gross Vehicle Weight Rating:
Not typically published in early manuals, but estimated to be around 750-800 lbs (340-360 kg).
Crash Test Ratings:
Not applicable for motorcycles of this era, as standardized crash testing was not performed.
Braking System:
Mechanical drum brakes front and rear. Dual-leading shoe front brake typically available on higher-spec models.
Lighting:
Headlight, taillight, brake light, turn signals (often optional or added later).
Frame Construction:
Steel tubing, known for its robustness and rigidity.
Oil Change:
Every 1,000 - 1,500 miles (1600 - 2400 km) or at least annually.
Primary Chain Adjustment:
Every 500 - 1000 miles (800 - 1600 km).
Spark Plug Replacement:
Every 5,000 - 7,500 miles (8000 - 12000 km) or as needed based on inspection.
Fork Oil Change:
Every 10,000 - 15,000 miles (16000 - 24000 km) or if performance degrades.
Engine Oil Type:
SAE 20W-50 or SAE 50W motorcycle-specific oil. Historically, mineral oils with high zinc content (ZDDP) were common and beneficial for flat tappet lifters.
Engine Oil Capacity:
Approximately 3 US quarts (2.8 liters) for 55ci, 3.5 US quarts (3.3 liters) for 61ci, including oil filter if applicable.
Transmission Oil Type:
SAE 50W gear oil or Harley-Davidson Transmission Lubricant.
Primary Chain Case Oil Type:
Harley-Davidson Primary Chaincase Lubricant or SAE 20W-50 motor oil.
Primary Chain Case Oil Capacity:
Approximately 1 US quart (0.95 liters).
Oil Leaks:
Common due to aging seals and gaskets. Focus on crankcase seals, pushrod tube seals, and transmission output shaft seal.
Carburetor Performance:
Linkert carburetors can be finicky; require regular cleaning and adjustment. Idle issues and poor starting can be common.
Ignition Timing:
Crucial for optimal performance. Points ignition systems require periodic checking and adjustment.
Valve Adjustment:
Pushrod tubes and valve lifters may require adjustment over time to maintain proper valve lash.
Primary Chain Wear:
The primary drive chain can stretch and wear, requiring frequent adjustment and eventual replacement.
Brake Effectiveness:
Drum brakes are less powerful than modern disc brakes; proper adjustment and clean drums are critical.
Heritage:
Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer renowned for its V-twin engines and distinctive styling.
Introduction Year:
The Sportster line was introduced in 1957.
1959 Features:
Early models featured the 55 cubic inch OHV Ironhead engine and often leading-link front forks. Model designations like XL, XLH (High Compression), and XLCH (Competition Hardtail) were established.
1960S Changes:
Introduction of the 61 cubic inch engine, telescopic front forks replacing leading-link designs on many models, electric start becoming available on some XLH models towards the end of the decade, and evolving styling cues.
Manufacturing Location:
Milwaukee, Wisconsin, USA
Significance:
The Sportster of this era established itself as Harley-Davidson's lighter, sportier alternative to the big twin models, gaining popularity among younger riders and a reputation for performance and customization.
Historic Significance:
The Sportster has been a continuous model line for Harley-Davidson, making it one of the longest-running motorcycle platforms in continuous production. Its influence on motorcycle culture is undeniable.
Owner Satisfaction Historical:
Highly regarded by enthusiasts for its character, sound, and performance relative to its era. Owners often praise its customizable nature.
Certification Standard:
Factory service manuals adhere to Harley-Davidson's internal engineering and service standards of the time.
