Positioning:
The XLCH (Competition/Hot) was Harley-Davidson's performance-oriented Sportster, targeting riders seeking power and sportiness.
Competitors:
Competed against models from British manufacturers like Triumph, BSA, and Norton, as well as early Japanese performance bikes.
Features:
Iconic Ironhead V-twin engine, distinctive styling, kick-start only operation, robust construction.
Primary Coverage:
Service, Repair, Maintenance, Troubleshooting, Adjustments
Estimated Pages:
Likely between 200-400 pages (typical for factory service manuals of this era)
Type:
Factory Service Manual / Repair Manual
Format:
Printed Booklet (as per typical factory offerings)
Engine:
Disassembly, assembly, inspection, tuning, component overhaul (e.g., cylinders, pistons, crankshaft, camshaft, valves, lifters)
Fuel System:
Carburetor (e.g., Linkert, Keihin) service, tuning, fuel lines, fuel tank, petcock
Ignition System:
Ignition timing, points, condenser, spark plugs, coils, wiring
Transmission:
4-speed constant mesh gearbox, clutch service, primary drive, gear inspection and replacement
Electrical System:
Wiring diagrams, lighting, horn, battery charging system (generator/regulator), starter system, switches
Brakes:
Front drum brake, rear drum brake, hydraulic lines, master cylinder, brake pedal/lever adjustment
Suspension:
Front forks (e.g., Girling or aftermarket types), rear shock absorbers, swingarm service
Chassis And Frame:
Frame inspection, steering head bearings, wheel bearings, kickstand, footpegs
Bodywork And Trim:
Fenders, fuel tank, seat, exhaust system, handlebars, controls
Maintenance:
Oil changes, lubrication points, filter replacement, spark plug replacement, brake adjustments, chain adjustment (if applicable)
Repair:
Complete engine rebuilds, transmission overhauls, carburetor rebuilding, electrical component replacement, brake system repairs
Troubleshooting:
Diagnostic procedures for common running issues, starting problems, electrical faults
Assembly Disassembly:
Detailed step-by-step instructions for removing and reinstalling all major components
Adjustments:
Carburetor tuning, ignition timing adjustments, clutch and brake lever adjustments, suspension settings
Depth:
Comprehensive, covering detailed internal component procedures, specifications, and diagnostic charts
Digital Format:
N/A (Likely originally printed, digital versions may exist from third parties)
Print Quality:
High quality, featuring clear diagrams and text (typical of factory manuals)
Binding:
Stapled or perfect bound (common for service manuals of the era)
Paper Quality:
Durable paper stock, suitable for workshop environments
Displacement:
900cc (55 cubic inches)
Engine Code:
Ironhead OHV V-Twin
Bore X Stroke:
3.4375 in x 3.00 in (87.3 mm x 76.2 mm)
Compression Ratio:
Approximately 8.0:1 to 9.0:1 (varies by specific model tune)
Horsepower:
Estimated 50-55 HP at the crankshaft (at that era's rating standards)
Torque:
Estimated 55-60 ft-lbs at the crankshaft
Carburetor Type:
Typically a single Linkert M-series or Keihin butterfly carburetor
Fuel Capacity:
Approx. 2.5-3.5 US gallons (depending on fuel tank option)
Oil Capacity:
Approximately 3 US quarts (2.8 liters) for the dry sump system
Oil Type:
API SF or SG rated motorcycle-specific oil, typically 20W-50
Oil Change:
Every 1,000 - 1,500 miles or annually. Check manual for specific recommendation.
Spark Plug Replacement:
Typically every 3,000 - 5,000 miles.
Chain Adjustment:
As needed, check for approximately 1/2 inch of free play.
Lubrication:
Regular lubrication of pivot points, cables, and wheel bearings as per service schedule.
Engine Oil:
20W-50 Motorcycle Oil (API SF/SG rated)
Transmission Primary Oil:
SAE 80W or 85W Gear Oil
Brake Fluid:
DOT 3 or DOT 4 Brake Fluid (if hydraulic drum brake system is present and sealed)
Common Issues:
Oil leaks (particularly from crankcase seals and rocker boxes), carburetor tuning sensitivity, electrical component reliability (points, regulators), kick-start mechanism wear.
Engine Wear:
Valve guide wear, potential for piston ring wear over high mileage.
Spark Plug:
Typical fitment: Champion L77V or equivalent (refer to manual for exact spec).
Oil Filter:
N/A (Sportsters of this era generally do not have a replaceable spin-on oil filter; oil is filtered by a screen).
Heritage:
Harley-Davidson has a long history of V-twin motorcycles, with the Sportster line being a cornerstone since its introduction in 1957.
Evolution:
The 1972 Sportster XLCH represented an evolution of the earlier models, featuring engine improvements and chassis updates. The 'CH' designation indicated the 'Competition Hot' version, often with higher compression and hotter cams.
Production Period:
The Sportster line, including the XLCH, was in continuous production through this era.
