Differences

This shows you the differences between two versions of the page.

--- sportster_history:1957_sportster [2017/03/13 01:05]
hippysmack [Drivetrain]
+++ sportster_history:1957_sportster [2021/11/15 03:56]
hippysmack [Illustrations]
@@ Line 1: / Line 1: @@
 ====== 1957 Sportster ======
-===== Vehicle Identification Number (VIN) =====
-  * The serial number is stamped on the left side of the engine case. The first 5 or 6 digits represent the year and model ((HD Parts Catalog XLH/XLCH-1000 #(99451-78) ))
 The Sportster XL was introduced as “a modern, up-to-date power plant.” {{  http://www.motorcycleclassics.com/~/media/Images/MCC/Editorial/Articles/Magazine Articles/2011/05-01/1957 Harley-Davidson Sportster XL/Sportster-1.jpg?direct&150}}
  In 1952, the W models were replaced with the revered 45-cubic inch side-valve K series. The new K-models included an integrated four-cam engine and four-speed transmission design, along with foot shift, swingarm rear suspension, and telescopic front forks to compete with smaller, sportier motorcycles coming mainly from Great Britain. Essentially, the new XL motor was an updated K-model engine with larger displacement, overhead valves and higher compression. - Harley-Davidson Archives Copyright H-D ((http://www.hotbikeweb.com/harley-sportsters-paying-tribute-hot-rod-legend))
-Number produced: 1983((&#91;&#91;http:&#47;&#47;www&#46;caimag&#46;com&#47;forum&#47;showthread&#46;php?5757-Help-with-1957-xl-sportster&#47;page2|http:&#47;&#47;www&#46;caimag&#46;com&#47;forum&#47;showthread&#46;php?5757-Help-with-1957-xl-sportster&#47;page2&#93;&#93;))
+**Model Production Numbers**
+  * XL - Number Produced: 1,983
-Original Price: $1103
+**Colors**
+  * Skyline Blue with Birch White tank panels. ((https://www.harleykmodel.com/technical/colors/index.html))
+  * Pepper Red with Black tank panels. ((https://www.harleykmodel.com/technical/colors/index.html))
+  * Birch White with Black tank panels. ((https://www.harleykmodel.com/technical/colors/index.html))
+  * Black with Pepper Red tank panels. ((https://www.harleykmodel.com/technical/colors/index.html))
+  * Options (no charge): ((https://www.harleykmodel.com/technical/colors/index.html))
+    * Fenders to match tank panel when panel is a standard color.
+    * Birch White - (indicate either solid or with black panels).
+    * Any standard color without tank panels.
+  * Options (extra charge): ((https://www.harleykmodel.com/technical/colors/index.html))
+    * Metallic Midnight Blue with Birch White tank panels.
+    * Spring Special: Nugget Gold.
-===== Specifications =====
+====== Vehicle Identification ======
+==== Frame Numbers ====
+There was no frame identification for purpose of ownership on 1957-1969 model Sportsters. \\
+However, there were stampings on the different parts of the frame combined with certain features that can be used to date the frame. \\ [[techtalk:ih:body01w|Click Here]] to view Ironhead Frame Identification in the Sportsterpedia. \\
-{{  :sportster_history:1957-sportster-engine.jpg?200}}
+==== Engine Serial Numbers ====
+The only numbers for the purpose of identification were on the engine case. \\
+  * For 1957-1961 models, the engine serial number is stamped on the left side of the engine case between the two cylinders. \\ First 4 or 5 digits are the year and bike model followed by a series of 4 or 5 numbers that established the individual serial number for each bike. \\
-  * Model Designation: XL
+[[sportster_history:99xx-01a|Click Here]] for more specific information on serial numbers and VINs in the Sportsterpedia. \\
-==== Engine ====
-  * Engine type: 4 cycle Overhead Valves, 45 degree V2 ((Harley-Davidson 1957 - 1969 Service Manual))
-  * Displacement: 55 ci / 883 cc (900 cc advertised) ((1957-1969 HD FSM pg 1A-3))
-  * Compression: 7.5:1 ((1957-1969 HD FSM pg 1A-3))
-  * Hemi-spherical style heads
-  * Bore: 3 in / 76.2 mm ((1957-1969 HD FSM pg 1A-3))((https://books.google.de/books?id=bvwDAAAAMBAJ&pg=PA2&num=100&source=gbs_toc&cad=2#v=onepage&q=sportster&f=true))
-  * Stroke: 3.8125 in / 96.8 mm ((1957-1969 HD FSM pg 1A-3))((https://books.google.de/books?id=bvwDAAAAMBAJ&pg=PA2&num=100&source=gbs_toc&cad=2#v=onepage&q=sportster&f=true))
-  * 90 Degree Valve Angle
-  * Horsepower: 42 @ 5,500rpm ((Harley-Davidson 1957 - 1969 Service Manual))
-  * Torque: 48 ft-lb @ 3600 RPM ((1957-1969 HD FSM pg 1A-3))
-  * Fuel System: Linkert DC carburetor ((http://www.hotbikeweb.com/harley-sportsters-paying-tribute-hot-rod-legend))
-==== Capacities =====
+^{{techtalk:miscres:instruction_sheet_header_4.png?nolink&797|}}|||
+|  **Engine Serial Number for 1957 Sportsters**  |||
-  * Fuel capacity: 4 gal / 15.14 l((Harley-Davidson 1957 - 1969 Service Manual))
+|**Model Year** \\ (first 2 digits)|**Model** \\ (next few digits) \\ (up to 4)|**Sequential** \\ **Serial#** \\ (remaining digits)|
-  * Oil Capacity: 3 qts. / 2.83 l ((Harley-Davidson 1957 - 1969 Service Manual))
+|57|XL| (example) \\ 12345|
-  * Transmission Capacity: 1.5 pints / .71 l ((Harley-Davidson 1957 - 1969 Service Manual))
+|  |||
-  * MPG: 50mpg (est.)((http://www.motorcycleclassics.com/classic-american-motorcycles/1957-harley-davidson-sportster.aspx))
+|:::|:::|:::|
+|**Example**: (57XL 12345) indicates a 1957 XL model and is stamped on the Left Engine Case Between the Cylinders ((1953-1963 HD Parts Catalog backside of front cover))|||
+|Example Serial Number on Engine Reads: 57XL12345|||
+|  57  |  XL  |  12345  |
-==== Dimensions ====
+====== Related Manuals and Documentation ======
-  * Weight: 204 lbs ((1959-1964 HD Sportster FSM pg 1A-3))
-  * Wheelbase: 56.5 in / 143.51 cm ((Harley-Davidson 1957 - 1969 Service Manual))
-  * Overall Length: 87 in / 221 cm ((Harley-Davidson 1957 - 1969 Service Manual))
-  * Overall Width: 34 in / 86.36 cm ((Harley-Davidson 1957 - 1969 Service Manual))
-  * Overall Height: 40.5" ((1959-1964 HD FSM pg 1A-3))
-  * Road Clearance: 2.5 in minimum / 6.35 c minimum
-  * Saddle height 26-7/8“ to 29”
-  * Road Clearance 2-1/2“ to 4-5/8” (( 1959-1964 HD Sportster FSM pg 1A-3))
-==== Drivetrain ====
+Below are some suggestions for manuals for your ride. \\
-  * Constant Mesh - Foot shift
+__You should have, at minimum, a Factory Service Manual (FSM) and a Factory Parts Catalog for your year model__. \\
-  * Speeds - 4 Forward
-  * Number of Sprocket Teeth
-    * Engine: 34 ((1957-1969 HD FSM pg 1A-3))
-    * Clutch: 59 ((1957-1969 HD FSM pg 1A-3))
-    * Transmission: 21 ((1957-1969 HD FSM pg 1A-3))
-    * Rear Wheel: 51 ((1957-1969 HD FSM pg 1A-3))
-  * Gear Ratios
-    * 1st: 10.63:1 ((1957-1969 HD FSM pg 1A-3))
-    * 2nd: 7.69:1 ((1957-1969 HD FSM pg 1A-3))
-    * 3rd: 5.82:1 ((1957-1969 HD FSM pg 1A-3))
-    * 4th: 4.21:1 ((1957-1969 HD FSM pg 1A-3))
-==== Tires ====
+**Factory Service Manuals (FSM)**; \\
-  * Front and rear: 3.50 x 18
+The FSM will have the most accurate information, procedures and specs. \\
-  * Tire pressure (based on a rider weighing app. 150 lbs or more)
+Clymer and Haynes make service manuals also for Sportsters but some of the information is in error to the factory FSMs. \\
-  * For each 50 lbs of overload, increase rear tire pressure by 2 lbs., front by 1 lb. ((1959-1964 HD FSM pg 1A-3))but not exceeding max tire pressure.
+And some of the information in the aftermarket manuals is vague in information or procedures but they may have more pictures. \\
-    * Front: 14 psi / .96 bar
+So it is generally said you can get use from both an aftermarket manual and the factory service manuals but get the factory manual first. \\
-    * Rear: 18 psi / 1.24 bar
+**Parts Catalogs**; \\
+The Parts Catalog has part numbers of course but it also has exploded parts views. \\
+However, IT IS NOT INTENDED TO BE AN ASSEMBLY MANUAL. \\
+And some of the exploded views are confusing or not related to each other on the same pages. \\
+But, all in all, the exploded views do help finding what goes where. \\
+Most of the fasteners listed in the relevant parts catalog individual pages have thread sizes and lengths also in case you need those. \\
+**Note: ALL 1957-1978 PARTS CATALOGS LIST PARTS FOR PREVIOUS YEARS**. \\ Below is a simple list of original and "latest edition parts catalogs.
+The in-between year books may show different part numbers for the same year model bike. \\
+[[techtalk:miscres:miscres12|Click Here]] to see the Factory Parts Catalog page in the Sportsterpedia for parts catalog uses and a full list of parts catalog numbers from 1957 to present. \\
+(complete list of other parts catalogs and supplement catalogs that pertain to each year model on the bottom of that page) \\
+Some often acquire several year model parts catalogs and that page will help you decide which ones are right for you. \\
-===== Models =====
+**Suggested Manuals**: \\
-  * XL
+  * **Factory Service Manual (FSM)**:
+    * **Original**: None. The FSM program didn't begin until the 1959 season. \\ The 1959 FSM states "Except for minor differences, it also applies to 1957-1958 model Sportsters.
+    * **Latest Edition**: 1959-1969 Sportster Service Manual (99484-69)
+  * **Factory Parts Catalogs**:
+    * **Original**: 1957 Spare Parts Catalog for all Sportster and K Models Catalog (99451-57)
+      * Issued February 15, 1957.
+      * Full parts catalog and lists parts available in 1957 for 1952-1957 models.
+      * Lists closest to original parts available for 1957 models.
+      * [[http://www.harleykmodel.com/literature/spare-parts-catalogs/documents/99451-57/99451-57.pdf|Click Here]] to download a PDF from Harley K Model site  (32.2mb) (( http:&#47;&#47;www&#46;harleykmodel&#46;com&#47;literature&#47;spare-parts-catalogs&#47;documents&#47;99451-57&#47;99451-57&#46;pdf))
+    * **Latest Edition**: 1954-1978 Sportster XLH/XLCH-1000 Parts Catalog (99451-78B)
+      * Issued in 1989.
+      * Full catalog and lists parts available in 1989 for 1954-1978 models.
+      * Includes some parts that were not available in the -78A catalog.
+  * **Factory Owners Manual**:
+    * 1957 Sportster Rider Handbook (99466-57)
-===== Colors =====
+**Pics of Manual Covers**. \\
+Below are pics of used manual covers (original and latest editions) related to 1957 model Sportsters. \\ See the full list of pertinent catalogs in the link above.  \\
+Click on any pic below to enlarge: \\
-  * Pepper Red / Black Tank Panels((http:&#47;&#47;xlforum&#46;net&#47;vbportal&#47;forums&#47;showpost&#46;php?p=696133&postcount=6))
+|  1957 Rider Handbook \\ (99466-57)  |
-  * Skyline Blue / Birch White Tank Panels((http:&#47;&#47;xlforum&#46;net&#47;vbportal&#47;forums&#47;showpost&#46;php?p=696133&postcount=6))
+|{{:sportster_history:l003-om-1957_edition_cover_99466-57.jpg?direct&150|}}|
-  * Birch White / Black Tank Panels(( http:&#47;&#47;xlforum&#46;net&#47;vbportal&#47;forums&#47;showpost&#46;php?p=696133&postcount=6))
-  * Black / Pepper Red Tank Panels(( http:&#47;&#47;xlforum&#46;net&#47;vbportal&#47;forums&#47;showpost&#46;php?p=696133&postcount=6))
-===== External Links =====
+|  1959 FSM (99484-59) ((pics from a collection by The French Owl of the XLFORUM)) \\ loose leaf inside and outside covers (original)  ||  1959-1969 FSM (99484-69) \\ book bound cover (latest)  |  1957-1969 FSM (no part#) \\ (few page dates of Feb. 1970)  |
+|{{:sportster_history:l001-fsm-1959_edition_cover_1st_for_1957-1964_loose_leaf_binders.jpg?direct&200|}}|{{:sportster_history:l001-fsm-1959_edition_cover_99484-59_for_1957-1959_loose_leaf_inside.jpg?direct&200|}}|{{sportster_history:l001-fsm-1969_edition_cover_99484-69_for_1957-1969_book_bound.jpg?direct&200|}}|{{:sportster_history:l001-fsm-1969_edition_cover_for_1957-1969.jpg?direct&200|}}|
-[[http://www.harleykmodel.com/literature/spare-parts-catalogs/documents/99451-57/99451-57.pdf|1957 Parts Manual]](( http:&#47;&#47;www&#46;harleykmodel&#46;com&#47;literature&#47;spare-parts-catalogs&#47;documents&#47;99451-57&#47;99451-57&#46;pdf))
+|  1952-1957 \\ Parts Catalog (99451-57)  |  1954-1978 \\ Parts Catalog (99451-78B)  |
+|{{:sportster_history:l002-pc-1957_edition_cover_99451-57_for_1952-1957.jpg?direct&200|}}|{{:sportster_history:l002-pc-1978_edition_cover_99451-78b_for_1954-1978.jpg?direct&200|}}|
-Back to [[:sportster_history:start|Sportster History Index]]
+===== The Ironhead Multi-Year Parts Catalog Curse =====
-The Sportster XL was introduced as “a modern, up-to-date power plant” and weighing in at  2)
+Below is a summary of an article on the Sportsterpedia Parts Catalogs page regarding parts book errors. \\
+You can also read the full article from this link: [[techtalk:miscres:miscres12#the_ironhead_multi-year_parts_catalog_curse|The Ironhead Multi-Year Parts Catalog Curse]]. \\
+Due to all of the errors and non corrected editions, it's always a good idea to acquire several year parts catalogs surrounding your year model. \\
+Which year catalogs you'll need will depend on many factors but the main Parts Catalog page in the Sportsterpedia will help you decide which ones you need. \\
+[[techtalk:miscres:miscres12|Click Here]] to see the Parts Catalog page. A full chart of all the parts catalogs made for Ironheads is at the bottom of the page. \\
+  * Not all multi-year catalogs will list factory installed parts on your bike.
+  * You may need several year catalogs to determine factory installed parts for your year model.
+  * Some parts first appeared or only appeared in Parts Supplements, Service Bulletins or other literature
+  * Later catalogs may show parts for older models that were never factory installed on them.
+  * Some catalogs have missing parts and/or missing models in some parts listings.
+  * Some illustrations do not have a part number listed.
+  * Drawings may or may not look like your part number.
+  * Some exploded parts diagrams show the assembly in the wrong order or missing pieces.
+  * There may be misleading information about parts that fit your year model.
+  * Fastener lengths and thread pitch may change depending on catalog used.
+  * The MoCo knew about and tried to correct at least some of the parts catalog mistakes.
+===== Search the Sportsterpedia =====
+See the Navigation menu on the upper left of this page. \\
+From there you can go to the main Ironhead section menu, the Reference section for general and in-depth procedures, and the Misc Resources for documentation. \\
+===== Illustrations =====
+The following illustrations are displayed for historic and period specific parts identification only. Refer to the original OEM documents for additional information. ((illustrations from various academic journals)) \\
+Click on any illustration below to enlarge. \\
+{{sportster_history:1957_xl883_illust_engine.jpg?300}} \\
+\\
+General dimension drawing for 1957-1965 XLH / XLCH frames: \\
+This is a "short frame". Dims shown are 1957-1966 (all) and 1967-1969 XLCH. ((Dr Dick of the XLFORUM http://xlforum.net/forums/showpost.php?p=4370194&postcount=58)) \\
+{{:sportster_history:illust_-_frame_dims_-_general_-_1957-1965_xlh_xlch_the_french_owl.png?direct&400|}} ((illustration from a collection by The French Owl of the XLFORUM)) \\
+====== Specifications ======
+[[techtalk:menu#ironhead_technical_categories|Click Here]] for the main technical menu in the Sportsterpedia. \\
+Also see the "Misc Resources" section on the bottom of that page for technical docs and information. \\
+==== Model Designation ====
+  * XL
+==== Dimensions ====
+  * Wheelbase: 56.5 in / 143.51 cm ((Harley-Davidson 1957 - 1969 Service Manual))
+  * Overall Length: 87 in / 221 cm
+  * Overall Width: 34 in / 86.36 cm
+  * Overall Height: 40.5 in
+  * Saddle height 26-7/8 in to 29 in / 68.26 cm to 73.66 cm
+  * Road Clearance: 2.5 in to 4-5/8 in / 6.35 cm to 11.74 cm
+==== Engine ====
+  * Engine type: 4 cycle Overhead Valves, 45 degree V2 ((Harley-Davidson 1957 - 1969 Service Manual))
+  * Hemi-spherical style heads
+  * Displacement: 53.9 ci / 883 cc (900 cc advertised)
+  * Compression Ratio: 7.5:1
+  * Bore: 3 in / 76.2 mm
+  * Stroke: 3.8125 in / 96.8 mm
+  * Horsepower: 42 @ 5,500 rpm
+  * Taxable Horsepower: 7.2
+  * Torque: 48 ft/lb @ 3.600 RPM
+  * Weight: 204 lbs.
+  * 4 Cams
+  * [[techtalk:ih:oil03|Gear driven type oil pump]]. \\ Oil pump pressure (gauge mounted in place of oil pressure switch):
+    * Idle, with spark retarded (Min: 3-7 psi)
+    * Normal riding conditions: 10-14 psi (6 psi at 20 mph)
+  * [[techtalk:ih:engctl01|Ignition]]: Battery Ignition System (circuit breaker/points/timer/distributor)
+    * Point Gap: .020"
+  * Dwell: 90° at 1000 RPM
+  * Ignition Timing
+    * Advanced: 45° (11/16") BTDC
+    * Retarded: 15° (5/64") BTDC
+  * Spark Plugs
+    * #4 for everyday use.
+    * #5 for hard service.
+      * Gap: .025"-.030"
+  * [[techtalk:ih:carb01#linkert_model_m_and_dc_carbs_1957-1965|Fuel System]]: Linkert DC carburetor.
+  * Starter: Kick start only
+==== Capacities =====
+  * Fuel capacity: 4.1 gal / 15.52 l((Harley-Davidson 1960 Sportster Service Manual))
+  * Oil Capacity: 3 qts. / 2.83 l
+  * Transmission Capacity: 1.5 pints / .71 l
-cid 7.5:1 Compression, hemi-spherical style heads, 90 degree valve angle, OHV V-twin, 4 cams 4)5)
+==== Clutch ====
+  * Multi-Disc dry clutch-pack with alternate steel and fiber friction plates.((1957-1969 HD FSM pg 4A-3))
+==== Drivetrain ====
+  * Constant Mesh - right side foot shift ((1957-1969 HD FSM pg 1A-3))
+  * Speeds - 4 Forward
+  * Number of Sprocket Teeth
+    * Engine: 34
+    * Clutch: 59
+    * Transmission: 21
+    * Rear Wheel: 51
+  * Standard Gear Ratios
+    * 1st: 10.63:1
+    * 2nd: 7.69:1
+    * 3rd: 5.82:1
+    * 4th: 4.21:1
-ft-lbs of torque at 3600 RPMs.
+==== Tires ====
+Tire pressure (based on a rider weighing app. 150 lbs or more). \\
+For each 50 lbs of overload, increase rear tire pressure by 2 lbs, front by 1 lb ((1959-1964 HD FSM pg 1A-3)) but not exceeding manuf max tire pressure. \\
--11/16“ Dia. intake valves 6)
-”x3.8“ bore and stroke
- Piston Displacement (883cc) 53.9 cu. in.
- Kickstart only
-” wheels standard
- Speedometer designed into the sheet metal of the fork shroud.
- Telescoping front forks
- Fuel tank capacity 4.4 gallons.
- Oil tank (3 quarts) located under the seat on the right side using a recirculating oiling system
- Two brush generator w two-unit voltage regulator powering a six volt system
- Coil-over shocks
- 'Jubilee' trumpet horn mounted on the right side of the engine, power pack on the left side
- Paint color, 'HD 100' enamel
- Standard solo seat
- Options included
- Windshield
- Saddlebags
- Dual seat
- Front drum brakes (operated by a lever on the left handlebar)
- Rear drum brakes (operated by a foot pedal on the left side)
- Rear swingarm with Timken bearings at pivots.
- Short-barrel Linkert Carburetor
- Engine ID numbers on a pad located on the left side between the cylinders
- Straight retained bearings on gear shaft
- Roller valve lifters were called (High Speed Racing Tappets)
- Spark plugs were air cooled and could be dis-assembled
- Cams ramped on both closing and opening side
- Stellite-faced exhaust valves
- Aluminum alloy pushrods extend up through the covers to reach the rocker
- Cam-ground aluminum pistons w/ chrome plated top ring, non plated center ring and u-flex lower oil ring
- Aluminum rocker boxes enclose valves and rockers
- Cast iron barrels and heads
- Single-unit construction of engine and transmission
- Four speed transmission with a foot shifter on the right side
- Seven plate clutch (operated by a lever on the left handlebar)
- Primary chain and transmission are lubed by an oil bath separate from engine oil.
- Double tapered Timken roller bearings on sprocket shaft
- Only Year:
- Woodruff keys for camshaft gears
-splines on drive gear/ second gear shaft
- Choke control operated by a left side lever
+  * XL:
+    * Front: 3.50 x 18 (tire pressure: 14 psi / .96 bar)
+    * Rear: 3.50 x 18 (tire pressure: 18 psi / 1.24 bar)
- Tank emblem: Round plastic disc with 2 silver and red quadrants with Red Harley-Davidson name over it, press riveted to the tank.
+----
+Back to [[sportster_history:99xx-01|Sportster History Index]]

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