File Size. Download Links. Harley-Davidson Freewheeler Owner's Manuals. Harley-Davidson Nightster Owner's Manuals. Harley-Davidson Roadster Owner's Manuals. Harley-Davidson Rocker Owner's Manuals. Harley-Davidson Sportster Owner's Manuals.
Harley-Davidson Street Owner's Manuals. Harley-Davidson Switchback Owner's Manuals. Harley Davidson Electra super Service manual to Harley-Davidson Electra super Service manual to Harley-Davidson Sportster Service Manual to Harley-Davidson XL Service manual to Harley-Davidson is a world-famous manufacturer of heavy motorcycles of American origin.
The company produces high-power products, which are intended for movement on highways and very popular among professional bikers. The Harley-Davidson brand has become one of the most recognizable worldwide. Harley-Davidson has created a whole community of fans of this motorcycle technology, which has more than a million people. The story of Harley-Davidson began in when friends Arthur Davidson and William Harley created their first motorcycle model in a small workshop.
Harley Davidson Touring Service Manuals. Harley Davidson sportster troubleshooting manual. Harley Davidson - Softail Service Manual. Harley-Davidson SIP. Harley Davidson Softail Service Manual opt.
Harley Davidson Parts Manual All cc. Harley-davidson Electra super Service. Harley Davidson Electrical Diagnostics Manual. Harley Davidson Electrical Diagnostic Manual. Sportster Model Years in Production. Sportsters Specifications by Specific Year. Online Links to Sportster History Information. These listings are under construction and incomplete at this time so please excuse our progress.
We would like to hang a picture of your 'factory original' ride in the catalog pages. You must own the pictures in order for us to use them.
Please provide year, model and any small modifications that deviate from factory conditions. Below is a summary of the progression of early to present day Sportsters. Included here are general year model changes from models to engines, tires etc. For detailed information on a specific year model go to: Year-by-Year Listing of Sportsters. Click on the wording lit up in blue for further information on the relevant subjects. Speedometer designed into the sheet metal of the fork shroud. Fuel tank capacity 4.
Oil tank 3 quarts located under the seat on the right side using a recirculating oiling system. Stellite-faced free rotating 8 exhaust valves. The early 57s didn't use rocker bushings. Tappet rollers had no needles Hard faced skidshoe. Tank emblem: Round plastic disc with 2 silver and red quadrants with Red Harley-Davidson name over it, press riveted to the tank. Paint Colors : Production Information : New countershaft drive and 2nd gears including a new spacer between them, new C-2nd gear thrust washer.
New sprocket cover includes a filler cap washer. Camshaft gears became integrated with the camshafts, eliminating the need for a woodruff key. Tank emblem redesign to a round plastic disc with two gold and two black quadrants with a red 'Harley Davidson' over it. New model XLH : H designates High compression was introduced with all the features of the XL and higher compression with the same weight of lbs but running 55 horsepower at 6, RPMs. New 2-brush 6V generator A Peanut gas tank 2.
Tank emblem is a large 'V' with a checkered flag in and between the name Harley Davidson in the area behind. Same shocks as XLCH Compression ratio 9. HD implements a service manual program consisting of a master service manual dealer only item covering the complete model line and manuals for individual models that anyone could buy. Sheet metal nacelle headlamp with new Trip-O-Meter speedometer mounted in the nacelle. Arrow-Flite tank emblem designed with an oval red ball behind a chromed arrow with 'Harley Davidson' name in red on arrow shaft.
Magneto Ignition System mounted in a fixed position producing advanced spark timing only—— Harley Davidson purchases half of the bike division of the Italian Aermacchi Company.
HD International HDI is established to provide better control in the overseas market of their motorcycles and accessories. Tetramethyl lead introduced as an additive to automotive fuel which changed the face of Tetraethyl lead in place since Sprint models are on assembly line at the Varese, Italy factory.
Introduction of the Sprint model. Standard dual double duty seat and a new tank decal, long oval containing a long pointed star divided into four quadrants with the name 'Harley Davidson' across the top. H-D recognizes the rising relevance of fiberglass in motorcycle production, and begins manufacturing its own components.
As a result, the Tomahawk Division is established. The Sportster part number is Sprocket teeth for all models: Clutch - 59, Rear Wheel - 51, Engine - XLH transmission sprocket - 21 teeth, High gear ratio - 4. XLCH transmission sprocket - 20 teeth, high gear ratio - 4. New Smith tachometer on late models. It was recommended to install these in previous year Sportsters. The Tomahawk Division is established and is operational as a Harley-Davidson facility by Not long after production, it was found advisable to reinstate the 3rd gear ratio gear sets starting with engine 63XLCH and lower numbers , , , , , , , , and The new higher gear ratios are not listed in the Parts Catalog.
A new style starter pedal and the tank emblem is a stylized version of the Bar and Shield with the bar stretched out to the rear. A rubber mounted sealed beam headlight with a dimmer switch mounted to the handlebar.
The three-wheeled Servi-Car becomes the very first Harley-Davidson motorcycle to receive an electric starter Delco Remy. New full width die-cast aluminum brake drum in the front and aluminum tappet guides.
Warranty claims were now welcomed at any HD dealership regardless of the purchase place with proof of warranty. New 12 volt electrical system, with a new 12 volt generator with both models sharing the same voltage regulator The change to the 12 volt system prompted a Service Bulletin advising not to use the earlier style brushes brushes on the new 12 volt systems which could result in short brush life and damage to the armature commutator.
Starting on April 30, , with engine number 65XLH, the spark plug has been changed from a 5 to a 4 on Sportsters. The 4 is a hotter plug that gave better results for break-in and normal service.
It also eliminated wet fouling tendencies under low loads which are common during engine break-in. The 5 was still recommended after break-in if driven hard at highway speeds of the era. Late production motorcycles were equipped with the new style levers with the exception of the Sportster which only switched to the new throttle side lever.
Batteries were thinner with a pad between them. Magneto Ignition System now mounted on a movable plate allowing for advanced or retarded spark timing Adjusting cam for setting shock pre-load. This adjusting cam on the XLH and Electra Glide covered style shocks later had to be factory changed to a smaller diameter to eliminate the step at the bottom end to prevent contact with the cam and the cover when the shock telescopes to the compressed position.
The mistake should have been re-stamped and corrected by the dealership before delivery to the customer. The MoCo directed the dealerships to check the torque of cylinder base nuts on Electra Glide, Servi-Car and Sportster models before customer delivery due to the discovery at the factory of torque loss and metal stretch due to initial run-in.
A technical bulletin went out to dealerships regarding the need to check the shifter cam assemblies on high mileage Sportsters for possible damage to the support dowel pins before dis-assembling the tranny to diagnose shifting problems. Last year of the complete master service manuals which included all model motorcycles combined , dealer only editions.
They were to be discontinued by the MoCo as a standard practice due to more HD models being added to the line-up which made the manual too large. New year supplements were to be added to the earlier manuals to update them to cover current models.
New two-piece, oil control, piston ring installed on Sportster and Electra Glides featuring a ventilated cast iron double edged scraper ring with a separate expander spring behind it. This replaced the old rail type oil control rings. However, the part number A stayed the same for new style oil control ring as was for the old one. Dual venturi "Tillotson" diaphragm carb with an automatic economizer, positive-action acceleration pump and a large capacity air cleaner.
Starting with engine number 66XLCH produced after August 10, , an update to the Tillotson was implemented featuring a new inlet valve lever, needle and seat to correct problems such as a high speed lean condition caused by vibration and the needle sticking due to dirt in the carburetor. The right crankcase had a fillet added at the base of the countershaft low gear boss starting with engine no. The transmission countershaft low gear received a counter-bore machined at the right case fillet area to provide clearance and prevent the gear from jamming at that point.
Rear Diamond and Rex drive chains now come with a press fit side connecting link for improved chain durability. The slip fit connector used previously was suggested for emergency use only.
Duckworth chains retained the slip fit connector. All early Sportsters up until were kickstart only. This new hose was sold in 25' lengths only and suggested to be resistant to ozone cracks. It was recommended to replace the old type hoses in questionable service when brought in with the new type hose material. This new rubber hose material was originally used only on mid Electra Glides equipped with Tillotson Carbs.
As of October 16, , a new oil recommendation was issued for all HD 4-cyle models to reflect the trend towards lighter oils made possible through the development of better lubricating properties.
The lighter oils greatly improved the ease of kick starting a motorcycle. A safety defect was issued adding a spark plug cable guide to all XLCH models on the carb manifold lower mounting stud to keep the plug wires from coming in conflict with the throttle lever cable. From September 20, through the model season, a Rim, Tire and Tube Flap was installed on the rear wheel only which replaces the standard rim strip. New single 12V battery replaced the dual 6V ones.
The frame on the XLH was doglegged kicked-back just above the swing arm pivot to accommodate the new battery box and electric start. The XLH swing arm was lengthened accordingly. The long frame has the seat post tubes set 1. HD faces a financial crisis.
Beginning on May 1, , all oil is being drained from oil tanks prior to shipment to dealers to prevent wet sumping. If the dealer had the bike an extended period of time, they were instructed to drain the oil again and tag it as empty.
All late Electra Glide and Sportster models received an upgrade on the "Tillotson" carbs incorporating a ball check valve in the accelerator pump passage of the plastic cover.
This was to provide a positive seal against air bleeding back from the venturi into the fuel chamber. All Electra Glide and Sportster models now are equipped with a new clutch and brake control cable anchor pin. The notch for inserting the cable is now in the side of the new anchor pin instead of at the bottom.
The cable ferrule slides into the open slot in the anchor pin with the slot facing toward the inside of the lever. HD was family owned until the buyout from AMF. All motorcycles shipped after Jan 1, are equipped with a front brake lever stoplight switch on the front brake control lever to conform with Federal Motor Vehicle Safety standards The MoCo began a new practice of setting ignition timing on Electra Glide, Servicar and Sportster models with the circuit breaker cam fully advanced instead of in the retarded position done in the past.
Starting on January 3, , the MoCo changed the size of the wire of the two ignition timer weight springs on Electra Glide and Sportster models to increase the speed at which timing advance occurred. This was to insure that the spark timing would be fully retarded at cranking speed and will advance gradually as RPMs increase to the fully advanced position. The MoCo noticed a flywheel sprocket shaft Timken bearing endplay issue on Electra Glides upon replacing the original bearings.
Usually, a set of bearings coming from the manufacturer will supply the correct endplay when installed. However, to bring the endplay within specs it was possible, after careful measurements, to still require a 0. This didn't affect Sportsters as much since the endplay specs are a bit wider ranged Electra Glide - 0.
New standard exhaust with stacked mufflers and separate headers and the first use of the exhaust crossover pipe with stacked duals. It was also suggested to retro-fit earlier motors with this modification.
A new numbering system for both engines and frames is implemented for all Harley Davidson vehicles. It consists of a model code, 5 digit serial number, a manufacturer's identification and the model year.
A number of year model Tillotson Carburetors were received and installed by HD that had a defective idle mixture needle They had a blunt end instead of the tapered end. Defective needles were replaced when discovered. A loose handle on the gas tank valve will not allow enough fuel flow to the engine, possibly resulting in engine slowdown especially at high speeds.
There should be no more than. Add enough shims to provide only a slight clearance when the valve is closed to obtain maximum diaphragm opening when the valve is open. Wheel balancing is recommended by the MoCo.
Because automotive wheel weights would not fit the Sportster aluminum rims and later type steel rims; HD released spoke balancing weights which surround and press onto the spoke nipple and are approved as a wheel balancing alternative.
On the Bonneville salt flats near Wendover, Utah, racer Cal Rayborn breaks the world record for land speed set by a motorcycle. The vehicle is a sixteen foot streamliner powered by a single Sportster engine, and averages just over mph. US auto makers develop catalytic converters and as it was found that the leaded gas was poisoning the converters, fuel manufacturers were ordered to begin building engines to run on unleaded gasoline by A rocker arm gasket was added between the rocker box and the head to prevent possible oil leakage caused by slight differences between the two surfaces.
There was no gasket installed here in prior years. This gasket could be retro-fitted back to Sportsters. HD began installing tapered bead C - Section wheels and 'Special' Goodyear tires as a matched combination.
This new wheel tire combo was only implemented in the Sportster lineup on 'high ground clearance' models with the 'low ground clearance' models using a straight bead set. The affected wheels are identified with the tire off as having a 2. The type Sportster rear brake light switch was now being supplied with mounting hardware as a kit, with wiring, for replacement of earlier switches used back to The engine was housed in a proven KR-style swingarm chassis with Ceriani forks.
The striking orange and black bodywork was the design of the Wixom Brothers. The engine made competitive horsepower, but the heat it produced led to self-destructive tendencies. When it debuted in , there were still teething problems to solve, but the basic package was a winner. The MoCo produced small batches of the complete machine in , , and First year of publication of Easy Rider Magazine A new class of motorcycle, the cruiser, is born. A spark plug port repair kit Heli-Coil was made available for repairing damaged spark plug threads in the head.
A safety defect was issued for some Sportsters produced between February 2 and February 26, assembled with defective rear wheel hubs with incomplete brazed joints causing the tack welds to break. This allowed the spoke flange to move on the hub and loosen the spokes.
The new fuels contain additives such as phosphorous which replaces tetra-ethyl-lead and test results reveal that these additives may not provide the same type of performance and engine protection received from leaded gas. Extensive use of low or non leaded gas may cause piston damage in 2 or 4 cycle and accelerated wear and scuffing of the valves in 4 cycle engines.
The MoCo revealed an easier way to make clutch adjustments by removing the access plug from the chain compartment cover instead of the need to remove the cover as outlined in the FSM and owners manuals for and later Sportsters.
A safety defect was issued on a number of Sportsters produced from November 1, to March 29, without the 3 position stake operation performed on the rear left side fork bearing lock nut on the swingarm. A safety defect was issued on a number of Super Glide and Sportster models produced with the front wheel bearing lock ring installed backwards which can result in the front wheel to be loose or the bearing to lock up. The retaining ring is flat on one side and beveled on the other.
The circuit breaker cam , or ignition timer cam, newly designed for the model year was redesigned for the model year and was recommended as a replacement for parts order on model Sportster, Electra Glide and Super Glide models. XR : The new, more powerful, more reliable aluminum alloy XR debuts with two versions including a dirt track and a road racer model and becomes the dominant dirt track racer through the next three decades.
Rod length 6. Engine weight: app lbs. Rocker arm ratio 1. Ceriani front forks with 4. Dirt Track Version : Wheel base Road Race Version : one year only in production William H Davidson, chairman, retires from the company.
Motorcycle production is upgraded when all assembly operations are moved to a modern , square foot plant in York, PA. All other production operations remain in Milwaukee and Tomahawk. The Capitol Drive plant in Milwaukee begins production of engines.
A safety defect was issued for some early production XL and XLCH models that were made without a retaining clip to hold the wires to the fender near the tail light bulb socket which allowed the wires to loop outward into the tire well. A group of 28 motorcycles initially produced with the reinforced frame issue resolved were sent to the U.
Army that required the fender relocation. After winning at Daytona in , the road racing program struggled as the motorcycle manufacturer entered a period of financial difficulties and could no longer support a team. Though the company would continue to dominate dirt track, and would make a brief return to Daytona in the Battle of the Twins in , Harley-Davidson effectively said goodbye to road racing in But it was just a matter of time before it returned.
I haven't checked it all yet. Got em, thanks Mate. Cheers, Ben. Thank you, good sir. No problem. Just letting you know that part 9 of the CB parts list doesn't work, only a 2 byte file Good looking out, the Cylmers wasn't cutting it.
Paul Z. PM me. ChrisR Enthusiast Posts: Very happy to see that all here and working! Great job Einyodeler! Thanks again!
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