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sportster_history:1968_sportster [2021/09/12 06:12]
hippysmack [Engine]
sportster_history:1968_sportster [2021/09/30 02:04] (current)
hippysmack
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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 =====
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 |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.
 +      * [[https://​www.harleykmodel.com/​literature/​spare-parts-catalogs/​documents/​99451-68/​99451-68.pdf|Click Here]] to download a PDF from Harley K Model site (1.52mb)((https://​www.harleykmodel.com/​literature/​spare-parts-catalogs/​documents/​99451-68/​99451-68.pdf))
 +        * **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. \\ [[https://​harleykmodel.com/​literature/​spare-parts-catalogs/​documents/​99451-67/​99451-67.pdf|Click Here]] to download a PDF from Harley K Model site (49.5mb)((https://​harleykmodel.com/​literature/​spare-parts-catalogs/​documents/​99451-67/​99451-67.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**:
 +    * 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: \\
 +
 +|  1968 Owners Manual (99466-68) ​ |
 +|{{:​sportster_history:​l003-om-1968_edition_cover_99466-68.jpg?​direct&​200|}}|
 +
 +|  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
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   * 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 
-  * 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 =====
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     * Front: 3.25 / 3.50 x 19 (tire Pressure: 16 psi / 1.10 bar) ((HD TSB #516A dated October 15, 1966))     * 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))     * 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))+
  
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