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sportster_history:1966_sportster [2016/01/20 14:01]
bplinson [Specifications]
sportster_history:1966_sportster [2024/01/25 17:41] (current)
hippysmack
Line 1: Line 1:
 ====== 1966 Sportster ====== ====== 1966 Sportster ======
 +**Model Production Numbers** \\
 +  * XLH 900
 +  * XLCH 3,900
 +  * XLRTT 25
  
-===== Specifications ===== +**Colors** ((https://​www.harleykmodel.com/​technical/​colors/​index.html)) \\ 
-==== Engine ====+  * Black with White Tank Panels. 
 +  * Indigo Metallic with White tank panels. 
 +  * Options: 
 +    * Hi-Fi Blue with White tank panels. 
 +    * Sparkling Burgundy with White tank panels. 
 + 
 +====== 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. \\ 
 + 
 +===== Engine Serial Numbers ===== 
 +The only numbers for the purpose of identification were on the engine case. \\ 
 +  * The engine serial number is stamped on the left side of the engine case between the two cylinders. \\ The first 5 or 6 digits represent the year and model ((HD Parts Catalog XLH/​XLCH-1000 #(99451-78) )) \\ From 1962-1969, models with 4 digit production (serial) numbers have an even-numbered first digit for even years and odd numbered first digit for odd years. \\ 
 + 
 +[[sportster_history:​99xx-01a|Click Here]] for more specific information on serial numbers and VINs in the Sportsterpedia (including the 1962-1969 Even/Odd Rule). \\ 
 + 
 +^{{techtalk:​miscres:​instruction_sheet_header_4.png?​nolink&​797|}}||| 
 +|  **Engine Serial Number for 1966 Sportsters** ​ ||| 
 +|**Model Year** \\ (first 2 digits)|**Model** \\ (next few digits) \\ (up to 4)|**Sequential** \\ **Serial#** \\ (remaining digits)| 
 +|66|XLH \\ XLCH| (example) \\ 12345| 
 +|  ||| 
 +|:::​|:::​|:::​| 
 +|**Example**:​ (66XLCH 12345) indicates a 1966 XLCH 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: 66XLCH12345||| 
 +|  66  |  XLCH  |  12345  | 
 + 
 +====== Related Manuals and Documentation ====== 
 +Below are some suggestions for manuals for your ride. \\ 
 +__You should have, at minimum, a Factory Service Manual (FSM) and a Factory Parts Catalog for your year model__. \\ 
 + 
 +**Factory Service Manuals (FSM)**; \\ 
 +The FSM will have the most accurate information,​ procedures and specs. \\  
 +Clymer and Haynes make service manuals also for Sportsters but some of the information is in error to the factory FSMs. \\ 
 +And some of the information in the aftermarket manuals is vague in information or procedures but they may have more pictures. \\ 
 +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. \\ 
 +[[techtalk:​miscres:​miscres10|Click Here]] to view the Factory Service Manual page in the Sportsterpedia. \\ 
 + 
 +**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. \\ 
 + 
 +**Suggested Manuals**: \\ 
 + 
 +  * **Factory Service Manual (FSM)**: 
 +    * **Original**:​ 1959-1966 Sportster Service Manual (99484-66) in a loose leaf binder 
 +    * **Latest Edition**: 1959-1969 Sportster Service Manual (99484-69) in book bound form 
 +  * **Factory Parts Catalogs**:​ 
 +    * **Original**:​ 1966 Sportster/​KH Model Parts Catalog Supplement (99451-66) 
 +      * Issued October, 1965. 
 +      * Updates the 1955-1965 full parts catalog for Sportster / KH Models (99451-65). 
 +      * Lists closest to original parts available for 1966 models and updates changes (only) to the previous full catalog. 
 +      * [[https://​harleykmodel.com/​literature/​spare-parts-catalogs/​documents/​99451-66/​99451-66.pdf|Click Here]] to download a PDF from Harley K Model site (8.28mb)((https://​harleykmodel.com/​literature/​spare-parts-catalogs/​documents/​99451-66/​99451-66.pdf)) 
 +        * **Use With**: 1955-1965 Sportster/​KH Model Parts Catalog (99451-65) \\ Issued July, 1964. Full parts catalog and lists parts available in 1965 for 1955-1965 models. \\ [[https://​harleykmodel.com/​literature/​spare-parts-catalogs/​documents/​99451-65/​99451-65.pdf|Click Here]] to download a PDF from Harley K Model site (40.9mb)((https://​harleykmodel.com/​literature/​spare-parts-catalogs/​documents/​99451-65/​99451-65.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**: 
 +    * 1966 Sportster Owners Manual (99466-66)  
 + 
 +**Pics of Manual Covers**. \\ 
 +Below are pics of used manual covers (original and latest editions) related to 1966 model Sportsters. \\ 
 +See the full list of pertinent catalogs in the link above. ​ \\ 
 +Click on any pic below to enlarge: \\ 
 + 
 +|  1966 Owners Manual (99466-66) ​ | 
 +|{{:​sportster_history:​l003-om-1966_edition_cover_99466-66.jpg?​direct&​200|}}| 
 + 
 +|  1959-1966 FSM (99484-66) ((pics from a collection by The French Owl of the XLFORUM)) \\ loose leaf outside and inside covers (original) ​ ||  1959-1969 FSM (99484-69) \\ (latest) ​ | 
 +|{{:​sportster_history:​l001-fsm-1965_edition_cover_1st_for_1965-1969_loose_leaf_binders.jpg?​direct&​200|}}|{{sportster_history:​l001-fsm-1966_edition_cover_99484-66_for_1957-1966_loose_leaf_inside.jpg?​direct&​200|}}|{{sportster_history:​l001-fsm-1969_edition_cover_99484-69_for_1957-1969_book_bound.jpg?​direct&​200|}}| 
 + 
 +|  1955-1965 \\ Parts Catalog (99451-65) ​ |  1966 Parts \\ Catalog Supplement (99451-66) ​ |  1954-1978 \\ Parts Catalog (99451-78B) ​ | 
 +|{{:​sportster_history:​l002-pc-1965_edition_cover_99451-65_for_1955-1965.jpg?​direct&​200|}}|{{:​sportster_history:​l002-pc-1966_edition_cover_99451-66_supplement.jpg?​direct&​200|}}|{{:​sportster_history:​l002-pc-1978_edition_cover_99451-78b_for_1954-1978.jpg?​direct&​200|}}| 
 + 
 +===== The Ironhead Multi-Year Parts Catalog Curse ===== 
 +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. \\ 
 + 
 +General dimension drawing for 1957-1965 XLH / XLCH "short frames":​ \\ 
 +Dims shown are 1957-1966 (all) and 1967-1969 XLCH. ((Dr Dick of the XLFORUM https://​www.xlforum.net/​forum/​sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​148782-animal-mother-reigns/​page4?​postcount=58#​post3178758)) \\ 
 + 
 +{{:​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)) \\ 
 + 
 +General frame dimension drawings: \\ 
 + 
 +  * (L) for 1957-1966 XLH / 1957-1969 XLCH "short frames"​ \\ It's a 1966 drawing of a 1966 XLCH frame. 
 +  * (R) This is the '​correct'​ drawing for late 1973-1978 "long frames"​. Dims are also good for 1967-1969 XLH and 1970-E1973 (all models). ((Dr Dick of the XLFORUM https://​www.xlforum.net/​forum/​sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​148782-animal-mother-reigns/​page4?​postcount=58#​post3178758)) \\ 
 + 
 +{{:​sportster_history:​illust_-_frame_dims_-_1957-1966_xlh_1957-1969_xlch.png?​direct&​400|}} {{:​sportster_history:​illust_-_frame_dims_-_general_1973-1978_xlh_xlch.png?​direct&​400|}} \\ 
 + 
 +====== 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 Designations ==== 
 +  * XLH, XLCH 
 + 
 +==== Dimensions ==== 
 +  * Wheelbase: ((Harley-Davidson 1957 - 1969 Service Manual)) 
 +    * XLH, 56.5 in / 143.51 cm 
 +    * XLCH, 57 in / 144.78 cm 
 +  * Overall Length: 
 +    * XLH, 87 in / 220.98 cm 
 +    * XLCH, 83.25 in / 211.45 cm 
 +  * Overall Width: 
 +    * XLH, 34 in / 86.36 cm 
 +    * XLCH,  29.5 in / 74.93 cm 
 +  * Overall Height: 
 +    * XLH, 40-1/2 in / 103 cm 
 +    * XLCH, 42 in / 106.7 cm 
 +  * Road Clearance:​ 
 +    * XLH, 2-1/2 in to 4-5/8 in / 6.35 cm to 11.74 cm 
 +    * XLCH, 4-1/8 in to 6-1/2 in / 10.47 cm to 16.51 cm ((HD 1960, 1962 Sportster Service Manuals)) 
 + 
 +==== Engine ====  
   * Engine type: 4 cycle Overhead Valves, 45 degree V2 ((Harley-Davidson 1957 - 1969 Service Manual))   * Engine type: 4 cycle Overhead Valves, 45 degree V2 ((Harley-Davidson 1957 - 1969 Service Manual))
-  * Displacement:​ 54 ci / 883 cc 
   * Hemi-spherical style heads   * Hemi-spherical style heads
-  * Bore: 3 in / 7.62 cm ((Harley-Davidson 1957 - 1969 Service Manual)) +  ​* Displacement:​ 53.9 ci / 883 cc (900 cc advertised) 
-  * Stroke: 3.8125 in / 9.68 cm ((Harley-Davidson 1957 - 1969 Service Manual)) +  * Compression Ratio: 9:1 
-  * 90 Degree Valve Angle +  ​* Bore: 3 in / 76.2 mm 
-  * Horsepower42 5,500rpm ​(XL) ((Harley-Davidson 1957 1969 Service Manual))+  * Stroke: 3.8125 in / 96.8 mm 
 +  * Horsepower: 55 @ 6,​300rpm ​((Harley-Davidson 1957 - 1969 Service Manual)) 
 +  * Taxable Horsepower: 7.2 
 +  * Torque52 ft-lb 3800 RPM 
 +  * Weight: 
 +    * XLCH - 188lbs. 
 +    * XLH - 204 lbs. 
 +  * Engine serial number stamped on left side case between the two cylinders. \\ [[sportster_history:​99xx-01a|Click Here]] for more information on serial numbers and VINs in the Sportsterpedia.  
 +  * 4 Cams  
 +  * [[techtalk:​ih:​oil03|Gear driven type oil pump]]. \\ Oil pump pressure (gauge mounted in place of oil pressure switch): 
 +    * Idlewith spark retarded ​(Min: 3-7 psi) 
 +    * Normal riding conditions: 10-14 psi (6 psi at 20 mph)  
 +  * [[techtalk:​ih:​engctl01|XLH Ignition]]: Battery Ignition System ​(circuit breaker/​points/​timer/​distributor) 
 +    * Point Gap: .020"​ 
 +  * [[techtalk:​ih:​engctl01#​magneto_ignition_system|XLCH Ignition]]: Magneto Ignition System 
 +    * Point Gap: .015"​ 
 +  * Dwell: 90° at 1000 RPM 
 +  * Ignition Timing 
 +    * Advanced ​XLH, XLCH: 45° (11/​16"​) BTDC 
 +    * Retarded ​XLH: 15° (5/64"BTDC 
 +  * Spark Plugs 
 +    * #4 for everyday use. 
 +    * #5 for hard service. 
 +      * Gap 
 +        * XLH: .025"​-.030"​ 
 +        * XLCH: .020"​ 
 +  * [[techtalk:​ih:​carb01#​tillotson_hd_carb_1966-1971|Fuel System]]: Tillotson HD carburetor. 
 +  * Starter (all): Kick start only
  
-|             ​^XL ​                           ^XLH,​XLCH ​                      ^ 
-^ Compression |7.5:​1 ​                        ​|9.0:​1 ​                         | 
-^ Torque ​     |48 ft-lb / 2.023 Nm @ 3600 RPM|52 ft-lb / 2.191 Nm @ 3800 RPM | 
-((Harley-Davidson 1957 - 1969 Service Manual)) 
 ==== Capacities ===== ==== Capacities =====
-  +  ​* Fuel Capacity((Harley-Davidson 1957 - 1969 Sportster Service Manual)) 
-  ​* Fuel capacitygal / 15.14 l (XLCH 2.gal / 8.328 l)((Harley-Davidson 1957 - 1969 Service Manual)) +    * XL, XLH 3.75 gal / 14.19 l ((HD 1962 Sportster Service Manual)) 
-  * Oil Capacity: 3 qts. / 2.83 l ((Harley-Davidson 1957 - 1969 Service Manual)) +    * XLCH 2.25 gal / 8.51 l  
-  * Transmission Capacity: 1.5 pints / .71 l ((Harley-Davidson 1957 - 1969 Service Manual)) +  * Oil Capacity: 3 qts. / 2.83 l 
-  * MPG: 50mpg (est.)+  * Transmission Capacity: 1.5 pints / .71 l
  
-==== Dimensions ​==== +==== Clutch ​==== 
-  * Weight: 495 lb / 225 kg+  * Multi-Disc dry clutch-pack with alternate steel and fiber friction plates.((1957-1969 HD FSM pg 4A-3))
  
-|              ^XL, XLH                 ​^XLCH ​                       ^ 
-^Wheelbase ​    |56.6 in / 143.51 cm     |57 in / 137.6 cm            |      
-^Overall Length|87 in / 221 cm          |83.25 in / 211.4 cm         | 
-^Overall Width |34 in / 86.36 cm        |29.5 in / 75 cm             | 
-^Overall Height|40.5 in / 103 cm        |42 in / 106.7 cm            | 
-^Road Clearance|2.5 in / 6.35 cm minimum|4 1/8 in / 10.478 cm minimum| ​ 
-((Harley-Davidson 1957 - 1969 Service Manual)) 
 ==== Drivetrain ==== ==== Drivetrain ====
-  * Constant Mesh - Foot shift+  * Constant Mesh - right side foot shift ((1957-1969 HD FSM pg 1A-3))
   * Speeds - 4 Forward   * Speeds - 4 Forward
   * Number of Sprocket Teeth   * Number of Sprocket Teeth
-    * Engine: 34 +    ​* XLH: 
-    * Clutch: 59 +      ​* Engine: 34 
-    * Transmission:​ 21 (XLCH 20) +      * Clutch: 59 
-    * Rear Wheel: 51  +      * Transmission:​ 21 
-  * Gear Ratios (XL,XLH)+      * Rear Wheel: 51 
 +    * XLCH
 +      * Engine: 34 
 +      * Clutch: 59 
 +      * Transmission: ​20 
 +      * Rear Wheel: 51  
 +  * Standard ​Gear Ratios (XLH)
     * 1st: 10.63 to 1     * 1st: 10.63 to 1
     * 2nd: 7.69 to 1     * 2nd: 7.69 to 1
     * 3rd: 5.82 to 1     * 3rd: 5.82 to 1
     * 4th: 4.21 to 1     * 4th: 4.21 to 1
-  * Gear Ratios (XLCH)+  * Standard ​Gear Ratios (XLCH)
     * 1st: 11.16:1     * 1st: 11.16:1
     * 2nd: 8.08:1     * 2nd: 8.08:1
Line 52: Line 223:
  
 ==== Tires ==== ==== 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. \\ 
 +
 +  * XLH:
 +    * Front: 3.50 x 18 (tire pressure: 14 psi / .96 bar)
 +    * Rear: 3.50 x 18 (tire pressure: 18 psi / 1.24 bar)
 +  * XLCH:
 +    * Front: 3.25 / 3.50 x 19 (tire Pressure: 14 psi / .96 bar)
 +    * Rear: 4.0 x 18 (tire pressure: 18 psi / 1.24 bar)
 +
 +====== Models ======
 +
 +==== XLH 883 ====
 +What is the Current KBB Value? ((http://​www.kbb.com/​motorcycles/​harley-davidson/​xlh-sportster/​1966-harley-davidson-xlh-sportster/​trade-in/​))
 + 
 +  *
 +  *
 +  *
 +  *
 +
 +
 +==== XLCH 883 ====
 +What is the Current KBB Value? ((http://​www.kbb.com/​motorcycles/​harley-davidson/​xlch-sportster/​1966-harley-davidson-xlch-sportster/​trade-in/​))
 + 
 +  *
 +  *
 +  *
 +  *
  
-|Tires Size^XL, XLH^XLCH^ 
-^Front|3.50 X 18|3.25/​3.50 X 19| 
-^Rear|3.50 X 18|4.00 X 18| 
  
-  * Tire pressure 
-    * Front: 14 psi / .96 bar 
-    * Rear: 18 psi / 1.24 bar 
-((Harley-Davidson 1957 - 1969 Service Manual)) 
  
-===== Models ===== 
  
 ---- ----
  
-Back to [[:sportster_history:​start|Sportster History Index]]+Back to [[sportster_history:​99xx-01|Sportster History Index]]