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sportster_history:1978_sportster [2021/09/12 04:44]
hippysmack [Engine]
sportster_history:1978_sportster [2024/01/25 18:05] (current)
hippysmack
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 ====== 1978 Sportster ====== ====== 1978 Sportster ======
 +**Model Production Numbers** \\
 +  * XLH 1000 11,271
 +  * XLH 1000 (75th Anniversary Model) 2,323
 +  * XLCH 1000 2,758
 +  * XLT 1000 (Touring) 6
 +  * XLS 1000 (Roadster) 2
 +  * XLCR 1000 
 +  * XR-750 83 ((1972-2003 HD XR750 Service Manual XR 750 Production Schedule pg 69)) 
 +
 +**Colors** \\
 +  * Birch White, Vivid Black, Brilliant Red, Charcoal Silver, Arctic White, Concord Blue, Chestnut Brown and Black Cherry.
 +
 ====== Vehicle Identification ====== ====== Vehicle Identification ======
 ===== Frame VIN Numbers ===== ===== Frame VIN Numbers =====
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   * The engine VIN is stamped on the right side of the engine crankcase between the cylinders.   * The engine VIN is stamped on the right side of the engine crankcase between the cylinders.
  
-----+====== 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)**: 
 +    * 1970-1978 Sportster XL/​XLH/​XLCH/​XLT-1000 Service Manual (99484-78) 
 +  * **Factory Parts Catalogs**:​ 
 +    * **Original**:​ 1954-1978 XLH/​XLCH-1000 Parts Catalog Supplement (99451-78) 
 +      * Issued October, 1977. 
 +      * Updates the 1954-1976 full parts catalog (99451-76A). 
 +      * Lists closest to original parts available for 1978 models. ​  
 +        * **Use With**: 1954-1976 XLH/​XLCH-1000 Parts Catalog (99451-76A). \\ Issued May, 1976. Full catalog and lists parts available in 1976 for 1954-1976 models. 
 +    * **Updated Edition**: 1954-1978 Sportster XLH/​XLCH-1000 Parts Catalog (99451-78A) 
 +      * Issued April, 1981.  
 +      * Full catalog and lists parts available in 1981 for 1954-1978 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. 
 +  * **Factory Owners Manual**: 
 +    * 1978 XL-1000/​XLCH-1000 Owners Manual (99466-78)  
 + 
 +**Pics of Manual Covers**. \\ 
 +Below are pics of used manual covers (original to latest editions) related to 1978 model Sportsters. \\ 
 +See the full list of pertinent catalogs in the link above. ​ \\ 
 +Click on any pic below to enlarge: \\ 
 + 
 +|  1970-1978 FSM (99484-78) ​ |  1978 Owners Manual (99466-78) ​ | 
 +|{{sportster_history:​l001-fsm-1978_edition_cover_99484-78_for_1970-1978.jpg?​direct&​200|}}|{{:​sportster_history:​l003-om-1978_edition_cover_99466-78.jpg?​direct&​200|}}| 
 + 
 +|  1954-1976 \\ Parts Catalog (99451-76A) ​ |  1954-1978 Parts \\ Catalog Supplement (99451-78) ​ |  1954-1978 \\ Parts Catalog (99451-78A) ​ |  1954-1978 \\ Parts Catalog (99451-78B) ​ | 
 +|{{:​sportster_history:​l002-pc-1976_edition_cover_99451-76a_for_1954-1976.jpg?​direct&​200|}}|{{:​sportster_history:​l002-pc-1978_edition_cover_99451-78_supplement.jpg?​direct&​200|}}|{{:​sportster_history:​l002-pc-1978_edition_cover_99451-78a_for_1954-1978.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 1973-1978 XLH / XLCH frames: \\ 
 +{{:​sportster_history:​illust_-_frame_dims_-_general_1973-1978_xlh_xlch.png?​direct&​400|}} \\
  
 ====== 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 ====
   * XL, XLH, XLCH   * XL, XLH, XLCH
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 ==== Engine ====  ​ ==== Engine ====  ​
   * Engine type: 4 cycle Overhead Valves, 45 degree V2   * Engine type: 4 cycle Overhead Valves, 45 degree V2
 +  * Hemi-spherical style heads
   * Displacement:​ 60.9 ci / 997.5 cc (1,000 cc advertised)   * Displacement:​ 60.9 ci / 997.5 cc (1,000 cc advertised)
   * Compression Ratio: 9:1   * Compression Ratio: 9:1
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   * Torque: 52 ft-lb @ 3800 RPM   * Torque: 52 ft-lb @ 3800 RPM
   * 4 Cams    * 4 Cams 
-  * Gerotor type oil pump. [[techtalk:​ih:​oil03|Click Here ]] for the IH Oil Pump section of the Sportsterpedia. +  * [[techtalk:​ih:​oil03|Gerotor 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):+
     * Minimum: 3-7 psi (idle)     * Minimum: 3-7 psi (idle)
     * Maximum: 15 psi (60 mph in high gear)     * Maximum: 15 psi (60 mph in high gear)
     * Normal riding conditions: 4-15 psi      * Normal riding conditions: 4-15 psi 
-  * Fuel System: Keihin "​butterfly"​ carburetor. ​[[techtalk:​ih:​carb01#bendix_zenith_i6p12_carb_1972-early_1976|Click Here]] to reference ​the main Ironhead carb page in the Sportsterpedia+  * [[techtalk:​ih:​engctl01#battery_ignition_circuit_breaker_points_timer_distributor|XLH/XLCH Ignition]]: Breaker Point and Coil Ignition System (points are in the nose cone in the cam cover) 
 +    * Point Gap: .018"​ 
 +  * Dwell: 140° at 2000 RPM 
 +  * Ignition Timing 
 +    * Advanced: 40° (17/​32"​) BTDC 
 +    * Retarded: 10° (1/​32"​) BTDC
   * Spark Plugs   * Spark Plugs
-    * #4 for break.+    * #4 for break-in.
     * #5 for everyday use and hard service.     * #5 for everyday use and hard service.
 +      * Gap: .025"​-.030"​
 +  * [[techtalk:​ih:​carb01#​keihin_butterfly_or_non-cv_carb_late_1976-1987|Fuel System]]: Keihin (non-cv) Butterfly carburetor.
 +  * Starter
 +    * XLCH: [[techtalk:​ih:​engctl03|Kick Start]] only.
 +    * XLH: [[techtalk:​ih:​engctl02|Electric Start]] only (Prestolite).
  
 ==== Capacities ===== ==== Capacities =====
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     * Rear 3.50 x 18     * Rear 3.50 x 18
  
-===== Models ===== +====== Models ======
  
 ==== XLCR 1000 Cafe Racer ==== ==== XLCR 1000 Cafe Racer ====
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 | {{:​sportster_history:​1978_xlcr_by_moon_wolf.jpg?​direct&​300|}} | | {{:​sportster_history:​1978_xlcr_by_moon_wolf.jpg?​direct&​300|}} |
 |1978 XLCR 1000 - Last year in production - click to enlarge. \\ (Original California model with one state only mufflers.)((Photo courtesy of Moon Wolf of the XLFORUM))| |1978 XLCR 1000 - Last year in production - click to enlarge. \\ (Original California model with one state only mufflers.)((Photo courtesy of Moon Wolf of the XLFORUM))|
 +
 ==== XLH 1000 ==== ==== XLH 1000 ====
 What is the Current KBB Value? ((http://​www.kbb.com/​motorcycles/​harley-davidson/​xlh-sportster-1000/​1978-harley-davidson-xlh-sportster-1000/​trade-in/​)) What is the Current KBB Value? ((http://​www.kbb.com/​motorcycles/​harley-davidson/​xlh-sportster-1000/​1978-harley-davidson-xlh-sportster-1000/​trade-in/​))