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sportster_history:1968_sportster [2021/09/10 04:51] hippysmack [Dimensions] |
sportster_history:1968_sportster [2021/09/29 01:38] hippysmack [Related Manuals and Documentation] |
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====== 1968 Sportster ====== | ====== 1968 Sportster ====== | ||
+ | **Model Production Numbers** \\ | ||
+ | * XLH 1,975 | ||
+ | * XLCH 4,900 | ||
+ | |||
+ | **Colors** ((https://www.harleykmodel.com/technical/colors/index.html)) \\ | ||
+ | * Black with Black Wrinkle tank panels and White Strip. | ||
+ | * On black bikes, the tank panel was most likely plain black, not wrinkle. | ||
+ | * Jet Fire Orange with Black Wrinkle tank panels and White Strip. | ||
+ | * Options: | ||
+ | * Sparkling Burgundy with Black Wrinkle tank panels and White Strip. | ||
+ | * Sparkling Blue with Black Wrinkle tank panels and White Strip. | ||
+ | |||
====== Vehicle Identification ====== | ====== Vehicle Identification ====== | ||
===== Frame Numbers ===== | ===== Frame Numbers ===== | ||
Line 14: | Line 26: | ||
^{{techtalk:miscres:instruction_sheet_header_4.png?nolink&797|}}||| | ^{{techtalk:miscres:instruction_sheet_header_4.png?nolink&797|}}||| | ||
- | ^ **Engine Serial Number for 1968 Sportsters** ||| | + | | **Engine Serial Number for 1968 Sportsters** ||| |
|**Model Year** \\ (first 2 digits)|**Model** \\ (next few digits) \\ (up to 4)|**Sequential** \\ **Serial#** \\ (remaining digits)| | |**Model Year** \\ (first 2 digits)|**Model** \\ (next few digits) \\ (up to 4)|**Sequential** \\ **Serial#** \\ (remaining digits)| | ||
|68|XLH \\ XLCH| (example) \\ 12345| | |68|XLH \\ XLCH| (example) \\ 12345| | ||
Line 22: | Line 34: | ||
|Example Serial Number on Engine Reads: 68XLCH12345||| | |Example Serial Number on Engine Reads: 68XLCH12345||| | ||
| 68 | XLCH | 12345 | | | 68 | 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. \\ | ||
+ | |||
+ | **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**: 1959-1968 Sportster Service Manual (99484-68) in a loose leaf binder | ||
+ | * **Latest Edition**: 1959-1969 Sportster Service Manual (99484-69) in book bound form | ||
+ | * **Factory Parts Catalogs**: | ||
+ | * **Original**: 1967-1968 Sportster/KH Model Parts Catalog Supplement (99451-68) | ||
+ | * Issued July, 1967. | ||
+ | * Updates the 1957-1967 full parts catalog for Sportster / KH Models (99451-67). | ||
+ | * Lists closest to original parts available for L1967-1968 models. | ||
+ | * **Use With**: 1957-1967 Sportster/KH Model Parts Catalog (99451-67) \\ Issued September, 1966. \\ Full parts catalog and lists parts available in 1967 for 1954-1967 models. | ||
+ | * **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. | ||
+ | * **Owners Manual**: | ||
+ | * 1968 Sportster Owners Manual (99466-68) | ||
+ | |||
+ | **Pics of Manual Covers**. \\ | ||
+ | Below are pics of used manual covers (original and latest editions) related to 1968 model Sportsters. \\ | ||
+ | See the full list of pertinent catalogs in the link above. \\ | ||
+ | Click on any pic below to enlarge: \\ | ||
+ | |||
+ | | 1959-1968 FSM (99484-68) ((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-1968_edition_cover_99484-68_for_1957-1968_loose_leaf_inside.jpg?direct&200|}}|{{sportster_history:l001-fsm-1969_edition_cover_99484-69_for_1957-1969_book_bound.jpg?direct&200|}}| | ||
+ | |||
+ | | 1957-1967 \\ Parts Catalog (99451-67) | 1967-1968 Parts \\ Catalog Supplement (99451-68) | 1954-1978 \\ Parts Catalog (99451-78B) | | ||
+ | |{{sportster_history:l002-pc-1967_edition_cover_99451-67_for_1957-1967.jpg?direct&200|}}|{{:sportster_history:l002-pc-1968_edition_cover_99451-68_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. \\ | ||
+ | |||
====== Specifications ====== | ====== 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 ==== | ==== Model Designations ==== | ||
* XLH, XLCH | * XLH, XLCH | ||
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==== Engine ==== | ==== 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)) | ||
+ | * Hemi-spherical style heads | ||
* Displacement: 53.9 ci / 883 cc (900 cc advertised) | * Displacement: 53.9 ci / 883 cc (900 cc advertised) | ||
* Compression Ratio: 9:1 | * Compression Ratio: 9:1 | ||
Line 57: | Line 152: | ||
* 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. | * 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 | * 4 Cams | ||
- | * Oil Pump: Gear driven type oil pump. [[techtalk:ih:oil03|Click Here ]] for the IH Oil Pump section of the Sportsterpedia. | + | * [[techtalk:ih:oil03|Gear driven type oil pump]]. \\ Oil pump pressure (gauge mounted in place of oil pressure switch): |
- | * Oil pump pressure (gauge mounted in place of oil pressure switch): | + | |
* Idle, with spark retarded (Min: 3-7 psi) | * Idle, with spark retarded (Min: 3-7 psi) | ||
* Normal riding conditions: 10-14 psi (6 psi at 20 mph) | * Normal riding conditions: 10-14 psi (6 psi at 20 mph) | ||
- | * Fuel System: Tillotson HD carburetor \\ [[techtalk:ih:carb01#tillotson_hd_carb_1966-1971|Click Here]] to reference the main Ironhead carb page in the Sportsterpedia | + | * [[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 | * Spark Plugs | ||
* #4 for everyday use. | * #4 for everyday use. | ||
* #5 for hard service. | * #5 for hard service. | ||
+ | * Gap | ||
+ | * XLH: .025"-.030" | ||
+ | * XLCH: .020" | ||
+ | * [[techtalk:ih:carb01#tillotson_hd_carb_1966-1971|Fuel System]]: Tillotson HD carburetor. | ||
+ | * Starter | ||
+ | * XLCH: [[techtalk:ih:engctl03|Kick Start]] only. | ||
+ | * XLH: [[techtalk:ih:engctl02|Electric Start]] only (Prestolite). | ||
==== Capacities ===== | ==== Capacities ===== | ||
Line 74: | Line 182: | ||
* Transmission Capacity: 1.5 pints / .71 l | * Transmission Capacity: 1.5 pints / .71 l | ||
+ | ==== 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 (XLH / XLCH): | ||
+ | * Engine: 34 | ||
+ | * Clutch: 59 | ||
+ | * Transmission: 20 | ||
+ | * Rear Wheel: 51 | ||
+ | * Standard Gear Ratios (XLH / XLCH) | ||
+ | * 1st: 11.16:1 | ||
+ | * 2nd: 8.08:1 | ||
+ | * 3rd: 6.11:1 | ||
+ | * 4th: 4.42:1 | ||
+ | |||
+ | ==== 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 (but not exceeding manuf max tire pressure). ((1959-1964 HD FSM pg 1A-3)) \\ | ||
+ | |||
+ | * XLH / XLCH: | ||
+ | * Front: 3.25 / 3.50 x 19 (tire Pressure: 16 psi / 1.10 bar) ((HD TSB #516A dated October 15, 1966)) | ||
+ | * Rear: 4.0 x 18 (tire pressure: 20 psi / 1.37 bar) ((HD TSB #516A dated October 15, 1966)) | ||
+ | |||
+ | ====== Models ====== | ||
===== XLH 883 ===== | ===== XLH 883 ===== | ||
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{{sportster_history:1968_xlch883_by_fdny37.jpg?direct&300|}} ((photo by fdny37 of the XLFORUM http://xlforum.net/forums/showthread.php?t=314377)) | {{sportster_history:1968_xlch883_by_fdny37.jpg?direct&300|}} ((photo by fdny37 of the XLFORUM http://xlforum.net/forums/showthread.php?t=314377)) | ||
- | + | ===== External Links ===== | |
- | + | [[https://www.harleykmodel.com/literature/spare-parts-catalogs/documents/99451-68/99451-68.pdf|1968 Parts Manual]] (1.52mb)((https://www.harleykmodel.com/literature/spare-parts-catalogs/documents/99451-68/99451-68.pdf)) | |
- | + | ||
---- | ---- |