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sportster_history:99xx-01 [2019/06/21 04:40]
ixl2relax [2000 - 2009]
sportster_history:99xx-01 [2024/01/25 05:01] (current)
hippysmack
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 {{:​sportster_history:​1957-outline.jpg|}} {{:​sportster_history:​1957-outline.jpg|}}
  
-1957 Orig Ironhead ​- 1967 Elec Start - 1986 Evo Engine ​- 2004 Rubbermount - 07EFI/​14CANbus - -\\+1957 Orig Ironhead - 1967 Elec Start - 1986 Evo Engine - 2004 Rubbermount - 2007 EFI 2014 CANbus\\
 {{:​sportster_history:​orangearrow-right.jpg?​nolink&​600|}}\\ {{:​sportster_history:​orangearrow-right.jpg?​nolink&​600|}}\\
- 
- 
  
 ===== Sub-Documents ===== ===== Sub-Documents =====
  
 {{:​common:​space100x5px.jpg|}}* . . . [[sportster_history:​99xx-01a|Sportster VIN Changes]]\\ {{:​common:​space100x5px.jpg|}}* . . . [[sportster_history:​99xx-01a|Sportster VIN Changes]]\\
 +{{:​common:​space100x5px.jpg|}}* . . . [[sportster_history:​99xx-01d|Charting Sportster Engines and Specs]]\\
 {{:​common:​space100x5px.jpg|}}* . . . [[sportster_history:​99xx-01f|Harley Davidson and the U.S. Clean Air Act of 1978]]\\ {{:​common:​space100x5px.jpg|}}* . . . [[sportster_history:​99xx-01f|Harley Davidson and the U.S. Clean Air Act of 1978]]\\
 {{:​common:​space100x5px.jpg|}}* . . . [[sportster_history:​99xx-01c|AMF Acquisition of the Harley Davidson Company]]\\ {{:​common:​space100x5px.jpg|}}* . . . [[sportster_history:​99xx-01c|AMF Acquisition of the Harley Davidson Company]]\\
 +
  
 \\ \\
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 | [[sportster_history:​99xx-01#​sportsters_specifications_by_specific_year|CLICK HERE >>>>​ for Year-by-Year Listing of Sportsters]] | | [[sportster_history:​99xx-01#​sportsters_specifications_by_specific_year|CLICK HERE >>>>​ for Year-by-Year Listing of Sportsters]] |
  
-  * These listings are under construction and incomplete at this time so please excuse our progress. You can help us populate these pages by contacting the Sportsterpedia Admin Team at any time by clicking on the '​contact'​ button on the lower portion of the  [[http://​sportsterpedia.com/​doku.php|Main Page]] or logging on to [[http://​xlforum.net|The XLFORUM.net]] and posting in the Sportsterpedia section of the forum. We would like to hang a picture of your '​factory original'​ ride in the catalog pages. You must __own__ the pictures in order for us to use them. Please provide year, model and any small modifications that deviate from factory conditions. +  * These listings are under construction and incomplete at this time so please excuse our progress. You can help us populate these pages by contacting the Sportsterpedia Admin Team at any time by clicking on the '​contact'​ button on the lower portion of the  [[http://​sportsterpedia.com/​doku.php|Main Page]] or logging on to [[https://www.xlforum.net/|The XLFORUM.net]] and posting in the Sportsterpedia section of the forum. We would like to hang a picture of your '​factory original'​ ride in the catalog pages. You must __own__ the pictures in order for us to use them. Please provide year, model and any small modifications that deviate from factory conditions. 
- + 
 +\\ 
 + 
 +====== Sportster Model Years in Production ====== 
 + 
 +Additional information needed to complete the Ironhead chart (( Chart by IXL2Relax of the XLFORUM)) 
 + 
 +{{:​sportster_history:​sportster-ironhead-models-years.jpg?​direct&​}} 
 + 
 +{{:​sportster_history:​sportster-evolution-models-years.jpg?​direct&​}} 
 + 
 +{{common:​space100x5px.jpg?​200|}}[[sportster_history:​99xx-01|{{:​sportster_history:​gotohistorymainmenu.jpg|}}]] \\ 
 + 
 +\\ 
 ====== History of Sportster Changes - Year, Model, Feature/​Specs ====== ====== History of Sportster Changes - Year, Model, Feature/​Specs ======
  
 ^**Below is a summary of the progression of early to present day Sportsters. Included here are general year model changes from models to engines, tires etc. For detailed information on a specific year model go to:** [[sportster_history:​99xx-01#​sportsters_specifications_by_specific_year|Year-by-Year Listing of Sportsters]].^  ​ ^**Below is a summary of the progression of early to present day Sportsters. Included here are general year model changes from models to engines, tires etc. For detailed information on a specific year model go to:** [[sportster_history:​99xx-01#​sportsters_specifications_by_specific_year|Year-by-Year Listing of Sportsters]].^  ​
  
-    ​* Some parts below are excerpts from the book "​Harley Davidson Data Book" by Rick Conner published by MBI Publishing Co. 1996. This book does have some errors in it and as the errors are found, they are corrected. ​  +    * 'THE HISTORY OF THE SPORTSTER'​ contributions by: docjimbob, Tim Schumacher, Tom Riccio, & Kev Maher and Bruce'​s Harley Page (check for History on all HD models). ((https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-general-discussion-and-problems/​19467-sportster-timeline?t=32308))
-    ​* 'THE HISTORY OF THE SPORTSTER'​ contributions by: docjimbob, Tim Schumacher, Tom Riccio, & Kev Maher and Bruce'​s Harley Page (check for History on all HD models). ((http://​xlforum.net/​forums/showthread.php?t=32308))+
     * Other sources are referenced accordingly with footnotes.     * Other sources are referenced accordingly with footnotes.
     * Click on the wording lit up in blue for further information on the relevant subjects.     * Click on the wording lit up in blue for further information on the relevant subjects.
- 
  
 ===== 1957 - 1959 ===== ===== 1957 - 1959 =====
Line 52: Line 64:
       * Saddle height 26-7/​8"​ to 29"       * Saddle height 26-7/​8"​ to 29"
       * Road Clearance 2-1/2" to 4-5/8" ((1959-1964 HD Sportster FSM pg 1A-3)) ​   ​       * Road Clearance 2-1/2" to 4-5/8" ((1959-1964 HD Sportster FSM pg 1A-3)) ​   ​
-      * 55cid 7.5:1 Compression,​ hemi-spherical style heads, 90 degree valve angle, OHV V-twin, 4 cams ((http://​xlforum.net/​forums/showthread.php?t=32308))((Credits to the Harley Davidson Data Book by Rick Conner 1996 MBI Publishing Company))+      * 55cid 7.5:1 Compression,​ hemi-spherical style heads, 90 degree valve angle, OHV V-twin, 4 cams ((https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-general-discussion-and-problems/​19467-sportster-timeline?t=32308))
       * 48 ft-lbs of torque at 3600 RPMs.       * 48 ft-lbs of torque at 3600 RPMs.
       * 1-11/​16"​ Dia. intake valves ((1972-2003 HD Shop Dope Service Bulletin No 392 11-27-1957)) ​     ​       * 1-11/​16"​ Dia. intake valves ((1972-2003 HD Shop Dope Service Bulletin No 392 11-27-1957)) ​     ​
Line 82: Line 94:
       * Spark plugs were air cooled and could be dis-assembled       * Spark plugs were air cooled and could be dis-assembled
       * Cams ramped on both closing and opening side       * Cams ramped on both closing and opening side
-      * Stellite-faced (free rotating ((Dr Dick of the XLFORUM ​http://​xlforum.net/​forums/showpost.php?p=3159109&​postcount=10)) ) exhaust valves ​+      * Stellite-faced (free rotating ((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/​112326-a-photo-catalog-of-ironhead-parts?​postcount=10#​post2359742)) ) exhaust valves ​
       * Spark plugs were air cooled and could be dis-assembled       * Spark plugs were air cooled and could be dis-assembled
       * Aluminum alloy pushrods extend up through the covers to reach the rocker       * Aluminum alloy pushrods extend up through the covers to reach the rocker
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         * 6 splines on drive gear/ second gear shaft         * 6 splines on drive gear/ second gear shaft
         * Choke control operated by a left side lever         * Choke control operated by a left side lever
-        * The early 57s didn't use rocker bushings. ((Dr Dick of the XLFORUM ​http://​xlforum.net/​forums/showpost.php?p=3159109&​postcount=10)) +        * The early 57s didn't use rocker bushings. ((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/​112326-a-photo-catalog-of-ironhead-parts?​postcount=10#​post2359742)) 
-        * Tappet rollers had no needles ((Dr Dick of the XLFORUM ​http://​xlforum.net/​forums/showpost.php?p=3159109&​postcount=10))+        * Tappet rollers had no needles ((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/​112326-a-photo-catalog-of-ironhead-parts?​postcount=10#​post2359742))
         * Spark plugs were air cooled and could be dis-assembled         * Spark plugs were air cooled and could be dis-assembled
-        * Hard faced skidshoe. ((Dr Dick of the XLFORUM ​http://​xlforum.net/​forums/showpost.php?p=3159109&​postcount=10))+        * Hard faced skidshoe. ((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/​112326-a-photo-catalog-of-ironhead-parts?​postcount=10#​post2359742))
         * Spark plugs were air cooled and could be dis-assembled         * Spark plugs were air cooled and could be dis-assembled
         * Tank emblem: Round plastic disc with 2 silver and red quadrants with Red Harley-Davidson name over it, press riveted to the tank.         * Tank emblem: Round plastic disc with 2 silver and red quadrants with Red Harley-Davidson name over it, press riveted to the tank.
 +  * **Paint Colors**: ((https://​www.harleykmodel.com/​technical/​colors/​index.html)) 
 +      * Skyline Blue with Birch White tank panels. 
 +      * Pepper Red with Black tank panels. 
 +      * Birch White with Black tank panels. 
 +      * Black with Pepper Red tank panels. 
 +      * Options (no charge): 
 +        * 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): 
 +        * Metallic Midnight Blue with Birch White tank panels. 
 +        * Spring Special: Nugget Gold.
  
  
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       * Tank emblem redesign to a round plastic disc with two gold and two black quadrants with a red '​Harley Davidson'​ over it.       * Tank emblem redesign to a round plastic disc with two gold and two black quadrants with a red '​Harley Davidson'​ over it.
       * Optional 1" extended shock absorbers (same springs with XLCH shocks) ((1953-1963 HD Sportster and K Model Parts catalog pg 58))       * Optional 1" extended shock absorbers (same springs with XLCH shocks) ((1953-1963 HD Sportster and K Model Parts catalog pg 58))
-  * **New model XLH**: ​(H designates High compression) ​was introduced with all the features of the XL and higher compression with the same weight of 204 lbs but running 55 horsepower at 6,300 RPMs. ((1959-1964 HD Sportster FSM pg 1A-3))+  * **New model XLH**: was introduced with all the features of the XL and higher compression with the same weight of 204 lbs but running 55 horsepower at 6,300 RPMs. ((1959-1964 HD Sportster FSM pg 1A-3))
       * Wheel base 56-1/​2"​       * Wheel base 56-1/​2"​
       * Overall length 87"       * Overall length 87"
Line 153: Line 176:
       * Optional 1" extended shock absorbers (same springs with XLCH shocks) ((1953-1963 HD Sportster and K Model Parts catalog pg 58))       * Optional 1" extended shock absorbers (same springs with XLCH shocks) ((1953-1963 HD Sportster and K Model Parts catalog pg 58))
       * New 2-brush 6V generator (29975-58A) ((1955-1965 HD Sportster & KH Model Parts Catalog pg 24))       * New 2-brush 6V generator (29975-58A) ((1955-1965 HD Sportster & KH Model Parts Catalog pg 24))
-  * **New model XLC**: ​(C stands for Competition) ​is an off-road version of the XL featuring:+  * **New model XLC**: is an off-road version of the XL featuring:
       * 55ci 883cc medium compression engine       * 55ci 883cc medium compression engine
       * Four-speed transmission       * Four-speed transmission
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       * The XLC was discontinued after the 1958 model year.       * The XLC was discontinued after the 1958 model year.
       * Same shocks as XLCH ((1953-1963 HD Sportster and K Model Parts catalog pg 58))  ​       * Same shocks as XLCH ((1953-1963 HD Sportster and K Model Parts catalog pg 58))  ​
-  * **New model XLCH**: ​(CH stands for Competition High compression) ​was also an off-road version of the XL with a lower weight of 188 lbs running 55 horsepower at 6,300 RPMs.((1959-1964 HD Sportster FSM pg 1A-3)) featuring:+  * **New model XLCH**: CH was also an off-road version of the XL with a lower weight of 188 lbs running 55 horsepower at 6,300 RPMs.((1959-1964 HD Sportster FSM pg 1A-3)) featuring:
       * Wheel base 57"       * Wheel base 57"
       * Overall length 83-1/​4"​       * Overall length 83-1/​4"​
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       * High domed pistons       * High domed pistons
       * Light ended tappets       * Light ended tappets
-      * Magneto ignition ((http://​xlforum.net/​forums/showthread.php?t=32308))+      * Magneto ignition ((https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-general-discussion-and-problems/​19467-sportster-timeline?t=32308))
       * Larger ports and valves       * Larger ports and valves
       * Peanut gas tank (2.25 gallons) with [[techtalk:​ih:​body01#​petcock_or_fuel_outlet|strainer]] (only) and a 45° fuel outlet - no valve       * Peanut gas tank (2.25 gallons) with [[techtalk:​ih:​body01#​petcock_or_fuel_outlet|strainer]] (only) and a 45° fuel outlet - no valve
Line 201: Line 224:
   * **New model XLRTT**: (Tourist Trophy Racer) was a specialty model with the 55ci 883 OHV V-twin engine   * **New model XLRTT**: (Tourist Trophy Racer) was a specialty model with the 55ci 883 OHV V-twin engine
   * **Paint Colors**: ​   * **Paint Colors**: ​
-      * Skyline Blue tank top w/ Birch White sides +      * Skyline Blue tank top Blue, sides Birch White. 
-      * Sabre Gray Metallic ​tank top w/ Birch White sides +      * Calypso Red - tank top Red, sides Birch White. 
-      * Calypso Red tank top w/ Birch White sides +      * Sabre Gray Metallic - tank top Gray, sides Birch White. 
-      * Black tank top w/ Birch White sides +      * Black tank top Black, sides Birch White. 
-      * Mudguards ​(fendersany standard color +      * Options ​(no charge): 
-  * **Option packages** offered for Sportsters in the Deluxe Equipment GroupSP-1, SP-2 and SP-3 +        * Any standard solid color.
- +
  
 {{common:​space100x5px.jpg?​200|}}[[sportster_history:​99xx-01|{{:​sportster_history:​gotohistorymainmenu.jpg|}}]] \\ {{common:​space100x5px.jpg?​200|}}[[sportster_history:​99xx-01|{{:​sportster_history:​gotohistorymainmenu.jpg|}}]] \\
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     * Honda comes to America to "meet the nicest people"​ and become a stiff competitor.     * Honda comes to America to "meet the nicest people"​ and become a stiff competitor.
     * **Service Notes / Recommendations**:​     * **Service Notes / Recommendations**:​
-      * HD implements a [[parts:partsplus-01a|service manual]] program consisting of a master service manual (dealer only item) covering the complete model line and manuals for individual models that anyone could buy. The Sportster FSM (99484-59) had a dealer purchase price from the MoCo of $4.00 with a list price of $5.00 ((HD Service Bulletin #403 dated December 15, 1958)) +      * HD implements a [[techtalk:miscres:​miscres10|service manual]] program consisting of a master service manual (dealer only item) covering the complete model line and manuals for individual models that anyone could buy. The Sportster FSM (99484-59) had a dealer purchase price from the MoCo of $4.00 with a list price of $5.00 ((HD Service Bulletin #403 dated December 15, 1958)) 
-   + 
-  ​ +
-  +
   * **Production Information**:​   * **Production Information**:​
       * XL (42), $1,175       * XL (42), $1,175
-      * XLH (Super H)(947), $1,200 +      * XLH (947), $1,200 
-      * XLCH (Super CH)(1059), $1,285+      * XLCH (1059), $1,285
       * XLR (5)       * XLR (5)
       * XLRTT (13)       * XLRTT (13)
Line 258: Line 278:
       * The '58 XLH 6V generator was installed on the XLCH but with a different voltage regulator (74510-47A) to power the six volt system ((1955-1965 HD Sportster & KH Model Parts Catalog pgs 24,95))       * The '58 XLH 6V generator was installed on the XLCH but with a different voltage regulator (74510-47A) to power the six volt system ((1955-1965 HD Sportster & KH Model Parts Catalog pgs 24,95))
   * Magneto Ignition System mounted in a fixed position producing advanced spark timing only—— ((-1985 Clymer Sportster Repair Manual pg 215))  ​   * Magneto Ignition System mounted in a fixed position producing advanced spark timing only—— ((-1985 Clymer Sportster Repair Manual pg 215))  ​
-  ​* **Option packages** offered for XL and XLH in the Deluxe Equipment Group: SP-1, SP-1A, SP-1B, SP-2 and SP-3 +  * **Paint Colors**: ​((https://​www.harleykmodel.com/​technical/​colors/​index.html)) 
-  ​* **Paint Colors**: +    * Skyline Blue - tank top Blue, sides Birch White. 
-    * Skyline Blue: Tank top Skyline ​Blue with Birch White side panels +    * Calypso Red - tank top Red, sides Birch White. 
-    * Black: Tank top Black with Birch White side panels +    * Black - tank top Black, sides Birch White. 
-    * Calypso Red: Tank top Calypso Red with Birch White side panels +    ​* Options (no charge): 
-    * Hi-Fi TurquoiseTank top is Hi-Fi Turquoise ​with Birch White side panels +      * Any standard solid color. 
-    * Hi-Fi RedTank top Hi-FiRed with Birch White side panels +    * Options (extra charge) 
-    Any standard solid color was done at no extra cost +      ​* Hi-Fi Turquoise ​Tank top Turquoise, sides Birch White. 
-  * 14.5 sec ¼ mile (90 mph)((http://xlforum.net/​forums/​showthread.php?​t=32308)) +      * Hi-Fi Red Tank top Hi-Fi Red, sides Birch White. 
-  +      Spring SpecialHi-Fi Coral and White  
 + 
 {{common:​space100x5px.jpg?​200|}}[[sportster_history:​99xx-01|{{:​sportster_history:​gotohistorymainmenu.jpg|}}]] \\ {{common:​space100x5px.jpg?​200|}}[[sportster_history:​99xx-01|{{:​sportster_history:​gotohistorymainmenu.jpg|}}]] \\
  
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   * **Production Information**:​   * **Production Information**:​
-      * Total of 2,765 Sportsters sold +      * Total of 2,765 XLH and XLCH Sportsters sold 
-      * XLH (Super H) $1,225 +      * XLH $1,225 
-      * XLCH (Super CH) $1,310+      * XLCH $1,310
       * XLRTT  ​       * XLRTT  ​
   ​   ​
Line 293: Line 315:
   * **XLCH changes include**:   * **XLCH changes include**:
       * Standard 19" front wheel, rear is still 18".       * Standard 19" front wheel, rear is still 18".
-  ​* Option packages offered for Sportsters in the Deluxe Equipment Group: SP-1, SP-1A, SP-2, SP-2A and SP-3 +  * **Paint ​Colors**: ((https://​www.harleykmodel.com/​technical/​colors/​index.html)) 
-  ​* **Paint ​Options**: +      * Skyline Blue with Birch White side panels on the tank. 
-      * Skyline Blue with Birch White side panels on the tank +      * Black with Birch White on the side panels of the tank. 
-      * Black with Birch White on the side panels of the tank +      ​* Options (no charge): 
-      * Any standard solid color without side panel change +        ​* Any standard solid color. 
-      * At extra cost+      * Options (extra charge)
-        * Hi-Fi Blue with Birch White on the side panels of the tank +        * Hi-Fi Turquoise - tank top Turquoise, sides Birch White. 
-        * Hi-Fi Red with Birch White on the side panels of the tank +        * Hi-Fi Red - tank top Hi-Fi Red, sides Birch White. 
-        * Hi-Fi Green with Birch White on the side panels of the tank+        * Spring Special: ​Hi-Fi Coral and White.
  
  
Line 316: Line 338:
   * **Production Information**:​   * **Production Information**:​
     * Total Sportsters sold 2,014.     * Total Sportsters sold 2,014.
-    * XLH (Super H) $1,250 +    * XLH $1,250 
-    * XLCH (Super CH) $1,335+    * XLCH $1,335
     * XLRTT     * XLRTT
   ​   ​
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   * **XLH changes include**:   * **XLH changes include**:
       * 3.75 gallon fuel tank with a creased edge       * 3.75 gallon fuel tank with a creased edge
-  * **Paint Colors**: +  * **Paint Colors**: ​((https://​www.harleykmodel.com/​technical/​colors/​index.html)) 
-      * XLH +  * XLH (No tank panels). 
-        Solid Pepper Red or Solid Black. Hi-Fi BlueHi-Fi Green and Hi-Fi Red available at extra cost+      * Pepper Red
-      * XLCH +      * Black. 
-        * Pepper Red with White panels or Black with White panels. Hi-Fi Blue with White panels, ​Hi-Fi Green with White panels ​and Hi-Fi Red with White panels available at extra cost.+      * Options: 
 +        * Hi-Fi Blue
 +        * Hi-Fi Red. 
 +        * Hi-Fi Green
 +  * XLCH: 
 +        * Pepper Red and White
 +        * Black and White. 
 +        * Options: 
 +          * Hi-Fi Blue and White
 +          * Hi-Fi Red and White. 
 +          * Hi-Fi Green and White. 
  
 {{common:​space100x5px.jpg?​200|}}[[sportster_history:​99xx-01|{{:​sportster_history:​gotohistorymainmenu.jpg|}}]] \\ {{common:​space100x5px.jpg?​200|}}[[sportster_history:​99xx-01|{{:​sportster_history:​gotohistorymainmenu.jpg|}}]] \\
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   * **Production Information**:​   * **Production Information**:​
       * Total Sportsters sold (1,998)       * Total Sportsters sold (1,998)
-      * XLH (Super H) $1,250 +      * XLH $1,250 
-      * XLCH (Super CH) $1,335+      * XLCH $1,335
   ​   ​
   ​   ​
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       * New (Smith) tachometer on late 1962 models. ((HD Service Bulletin #465 dated July 9, 1962 pg OA-29))       * New (Smith) tachometer on late 1962 models. ((HD Service Bulletin #465 dated July 9, 1962 pg OA-29))
       * All 1962 and future XLCH models, beginning with the engine numbers 62 XLCH-2549, starting Sept. 15, 1961 are provided with an oil level dipstick attached to the oil tank cap (part no. 62625-62). It was recommended to install these in previous year Sportsters. ((HD Shop Dope Service Bulletin No 454 December 4, 1961))       * All 1962 and future XLCH models, beginning with the engine numbers 62 XLCH-2549, starting Sept. 15, 1961 are provided with an oil level dipstick attached to the oil tank cap (part no. 62625-62). It was recommended to install these in previous year Sportsters. ((HD Shop Dope Service Bulletin No 454 December 4, 1961))
-  * **Paint Colors**: +  * **Paint Colors**: ​((https://​www.harleykmodel.com/​technical/​colors/​index.html)) 
-      * Black and White or Tango Red and White. Hi-Fi Blue with WhiteHi-Fi Red with White and Hi-Fi Purple ​with White available at extra cost.+      * Black and White
 +      * Tango Red and White. 
 +      * Options: 
 +        * Hi-Fi Blue and White
 +        * Hi-Fi Red and White. 
 +        * Hi-Fi Purple ​and White.
  
  
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   ​   ​
   * **Production Information**:​   * **Production Information**:​
-      * XLH (Super H) (432), $1,270 +      * XLH (432), $1,270 
-      * XLCH (Super CH) (1,001), $1,355 +      * XLCH (1,001), $1,355 
-      * XLRTT is back  +      * XLRTT is back
  
   * **XLH & XLCH changes include**:   * **XLH & XLCH changes include**:
Line 380: Line 418:
       * Improved magneto/​coil with ignition key lock on the magneto       * Improved magneto/​coil with ignition key lock on the magneto
       * "​shorty duals"       * "​shorty duals"
-  * **Option packages offered for Sportsters**: +  * **Paint Colors**: ((https://​www.harleykmodel.com/​technical/​colors/​index.html)
-    * Deluxe Equipment GroupXLH got the SP-1 +    * Black and White
-    * Highway Cruiser Group: XLH got the SP-2 +    * Tango Red and White
-    * Optional Group: XLH got the SP-2 +    * Horizon Metallic Blue and White. 
-    * Optional Group: XLCH got the SP-3H (Low road clearance kit) +    * Options: 
-  * **Paint Colors**: +      * Hi-Fi Turquoise and White
-    * Black and WhiteTango Red and White and Horizon Metallic Blue and White. ​ Hi-Fi Turquois with WhiteHi-Fi Red with White and Hi-Fi Purple ​with White available at extra cost  +      * Hi-Fi Red and White
-  * 14.3 sec ¼ mile (92 mph)+      * Hi-Fi Purple ​and White. ​
  
  
Line 400: Line 438:
        
    * **Production Information**:​    * **Production Information**:​
-      * XLH (Super H) (810), $1,295 +      * XLH (810), $1,295 
-      * XLCH (Super CH) (1950), $1,360+      * XLCH (1950), $1,360
       * XLRTT (30)       * XLRTT (30)
  
Line 412: Line 450:
   * **XLCH changes include**:   * **XLCH changes include**:
       * Chrome panel for the lower fork bracket and a chrome plated primary chain guard.       * Chrome panel for the lower fork bracket and a chrome plated primary chain guard.
-  * **Option packages offered for Sportsters**: +  * **Paint Colors**: ((https://​www.harleykmodel.com/​technical/​colors/​index.html)) 
-    * Deluxe Equipment GroupXLH got the SP-1 +    * Black and White. 
-    * Highway Cruiser Group: XLH got the SP-2 +    * Fiesta Red and White. 
-    * Optional Group: XLH get the SP-2A +    * Options
-    * Equipment GroupXLCH got the SP-3H +      * Hi-Fi Blue and White
-  **Paint Colors**: +      * Hi-Fi Red and White.
-    * Fiesta Red with Birch White and Black with Birch White. Available for an extra cost were Hi-Fi Blue with Birch White and Hi-Fi Red with Birch White+
  
  
Line 431: Line 468:
       * HD implements a uniform warranty service procedure to all dealerships whether servicing motorcycles of regular customers or tourist / transient owners who are covered under warranty. Warranty claims were now welcomed at any HD dealership regardless of the purchase place with proof of warranty. ((HD Service Bulletin #520 dated September 27, 1965 pg OA-45))       * HD implements a uniform warranty service procedure to all dealerships whether servicing motorcycles of regular customers or tourist / transient owners who are covered under warranty. Warranty claims were now welcomed at any HD dealership regardless of the purchase place with proof of warranty. ((HD Service Bulletin #520 dated September 27, 1965 pg OA-45))
   * **Production Information**:​   * **Production Information**:​
-      * XLH (Super H) (955) +      * XLH (955) 
-      * XLCH (Super CH) (2,815)+      * XLCH (2,815)
       * XLRTT (25)       * XLRTT (25)
   ​   ​
Line 448: Line 485:
       * Magneto Ignition System now mounted on a movable plate allowing for advanced or retarded spark timing ((-1985 Clymer Sportster Repair Manual pg 215))       * Magneto Ignition System now mounted on a movable plate allowing for advanced or retarded spark timing ((-1985 Clymer Sportster Repair Manual pg 215))
       * Adjusting cam for setting shock pre-load. This adjusting cam on the XLH and Electra Glide covered style shocks later had to be factory changed to a smaller diameter to eliminate the step at the bottom end to prevent contact with the cam and the cover when the shock telescopes to the compressed position. ((HD Service Bulletin #494 dated September 15, 1964))       * Adjusting cam for setting shock pre-load. This adjusting cam on the XLH and Electra Glide covered style shocks later had to be factory changed to a smaller diameter to eliminate the step at the bottom end to prevent contact with the cam and the cover when the shock telescopes to the compressed position. ((HD Service Bulletin #494 dated September 15, 1964))
-  * **Option packages offered for Sportsters**: +  * **Paint Colors**: ((https://www.harleykmodel.com/​technical/​colors/​index.html)) 
-      * XLH got Deluxe Equipment groupSPH-1, Highway Cruiser: SPH-2 and Group SPH-3. +      * Black and White. 
-      * XLCH got Deluxe Equipment Group: SPH-1 +      * Holiday Red and White. 
-  * **Paint Colors**: +      * Options: 
-      * Black with White tank bottom panels and pinstripes along the panel edge +        * Hi-Fi Blue and White. 
-      * Holiday Red with White tank bottom panels ​and pinstripes along the panel edge +        * Hi-Fi Red and White. 
-      * Police Silver (Police only) and Birch White (Police only)  +
-      Available at extra cost were: Hi-Fi Red with White tank bottom panels ​and pinstripes along the panel edge and Hi-Fi Blue with White tank bottom panels and pinstripes along the panel edge  +
-  +
  
 {{common:​space100x5px.jpg?​200|}}[[sportster_history:​99xx-01|{{:​sportster_history:​gotohistorymainmenu.jpg|}}]] \\ {{common:​space100x5px.jpg?​200|}}[[sportster_history:​99xx-01|{{:​sportster_history:​gotohistorymainmenu.jpg|}}]] \\
Line 473: Line 508:
   ​   ​
   * **Production Information**:​   * **Production Information**:​
-      * XLH (Super H) (900) $1,415 +      * XLH (900) $1,415 
-      * XLCH (Super CH) (3,900) $1,​411  ​+      * XLCH (3,900) $1,​411  ​
       * XLRTT (25)       * XLRTT (25)
   ​   ​
Line 491: Line 526:
       * Rear (Diamond and Rex) drive chains now come with a press fit side connecting link for improved chain durability. The slip fit connector used previously was suggested for emergency use only. (Duckworth) chains retained the slip fit connector. ((HD Service Bulletin #534 dated February 17,1966 pg OC-215)) ((1957-1967 HD Sportster / KH Parts Catalog pg 39))       * Rear (Diamond and Rex) drive chains now come with a press fit side connecting link for improved chain durability. The slip fit connector used previously was suggested for emergency use only. (Duckworth) chains retained the slip fit connector. ((HD Service Bulletin #534 dated February 17,1966 pg OC-215)) ((1957-1967 HD Sportster / KH Parts Catalog pg 39))
   * **XLH changes include**:   * **XLH changes include**:
-      * Deluxe Group options SPH-1, Groups SPH-2, SPH-3, SPH-4, SPH-6, SPH-7, and Highway Cruiser SPH-5. 
   * **XLCH changes include**:   * **XLCH changes include**:
-      * Deluxe Equipment Group options: SPH-1, Group SPCH-2, SPCH-3 and SPCH-4 
       * Hexagonal tank badge          * Hexagonal tank badge   
   * Race developed intake ports, jumbo valves → 60 hp   * Race developed intake ports, jumbo valves → 60 hp
   * All early Sportsters up until 1966 were kickstart only. ((http://​www.classic-motorcycle-build.com/​sportster-history.html))   * All early Sportsters up until 1966 were kickstart only. ((http://​www.classic-motorcycle-build.com/​sportster-history.html))
 +  * **Paint Colors**: ((https://​www.harleykmodel.com/​technical/​colors/​index.html))
 +      * 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.
  
  
Line 513: Line 552:
       * As of October 16, 1967, a new oil recommendation was issued for all HD 4-cyle models to reflect the trend towards lighter oils made possible through the development of better lubricating properties. The lighter oils greatly improved the ease of kick starting a motorcycle. ((HD Service Bulletin #561 dated October 16, 1967 pg OC-259))       * As of October 16, 1967, a new oil recommendation was issued for all HD 4-cyle models to reflect the trend towards lighter oils made possible through the development of better lubricating properties. The lighter oils greatly improved the ease of kick starting a motorcycle. ((HD Service Bulletin #561 dated October 16, 1967 pg OC-259))
     * **Factory Recalls**:     * **Factory Recalls**:
-      * A [[parts:partsplus-01d#​safety_defect_code_001|safety defect (001)]] was issued adding a spark plug cable guide to all 1967 XLCH models on the carb manifold lower mounting stud to keep the plug wires from coming in conflict with the throttle lever cable. ​+      * A [[techtalk:miscres:​miscres07#​safety_defect_code_001|safety defect (001)]] was issued adding a spark plug cable guide to all 1967 XLCH models on the carb manifold lower mounting stud to keep the plug wires from coming in conflict with the throttle lever cable. ​
   ​   ​
   * **Production Information**:​   * **Production Information**:​
-      * XLH (Super H) (2,000) $1,650 +      * XLH (2,000) $1,650 
-      * XLCH (Super CH) (2,500) $1,600+      * XLCH (2,500) $1,600
   ​   ​
   * **XLH and XLCH changes include**:   * **XLH and XLCH changes include**:
Line 530: Line 569:
   * **XLCH changes include**:   * **XLCH changes include**:
       *        * 
-  * **Option packages** offered for Sportsters 
-    * XLH got the Deluxe Equipment and the Highway Cruiser Group. 
-    * XLCH got the Standard Equipment Group and the Deluxe Equipment Group. 
   * **Additional Information**:​   * **Additional Information**:​
     * From 1967 to 1969, the factory was making two cases for the Sportster, one for the kick-start XLCH and the other for the electric start XLH. ((http://​www.classic-motorcycle-build.com/​sportster-history.html))     * From 1967 to 1969, the factory was making two cases for the Sportster, one for the kick-start XLCH and the other for the electric start XLH. ((http://​www.classic-motorcycle-build.com/​sportster-history.html))
 +  * **Paint Colors**: ((https://​www.harleykmodel.com/​technical/​colors/​index.html))
 +    * Black with White tank panels.
 +    * Crystal Blue with White tank panels.
 +    * Options:
 +      * Hi-Fi Blue with White tank panels.
 +      * Sparkling Burgundy with White tank panels.
  
  
Line 544: Line 586:
     * HD faces a financial crisis. With negotiations and meetings with American Machine and Foundry, HD voted on Dec. 18th to merge with AMF.     * HD faces a financial crisis. With negotiations and meetings with American Machine and Foundry, HD voted on Dec. 18th to merge with AMF.
     * **Service Notes / Recommendations**:​     * **Service Notes / Recommendations**:​
-        * The MoCo issued a [[techtalk:​ih:​carb02#​testing_and_repair_checklist|service checklist]] to aid in testing and repairing (instead of returning for warranty) Tillotson carburetors due to some dealers having difficulty diagnosing problems on 1966 → Sportsters & 1967 → Electra Glides. ((HD Service Bulletin #564 dated January 15, 1968))+        * The MoCo issued a [[techtalk:​ih:​carb01g#​testing_and_repair_checklist|service checklist]] to aid in testing and repairing (instead of returning for warranty) Tillotson carburetors due to some dealers having difficulty diagnosing problems on 1966 → Sportsters & 1967 → Electra Glides. ((HD Service Bulletin #564 dated January 15, 1968))
         * Beginning on May 1, 1968, all oil is being drained from oil tanks prior to shipment to dealers to prevent wet sumping. If the dealer had the bike an extended period of time, they were instructed to drain the oil again and tag it as empty. ((HD Service School - Service Bulletin #570 dated May 21, 1968)).         * Beginning on May 1, 1968, all oil is being drained from oil tanks prior to shipment to dealers to prevent wet sumping. If the dealer had the bike an extended period of time, they were instructed to drain the oil again and tag it as empty. ((HD Service School - Service Bulletin #570 dated May 21, 1968)).
         ​         ​
  
   * **Production Information**:​   * **Production Information**:​
-      * XLH (Super H) (1,975) $1,650 +      * XLH (1,975) $1,650 
-      * XLCH (Super CH) (4,900) $1,600+      * XLCH (4,900) $1,600
   ​   ​
   ​   ​
Line 560: Line 602:
       * Kick start was dropped.       * Kick start was dropped.
       * Peanut tank was an option.       * Peanut tank was an option.
-  * **Option packages**: +  * **Paint Colors**: ((https://​www.harleykmodel.com/​technical/​colors/​index.html)) 
-    * XLH got the Deluxe Equipment ​and the Highway Cruiser Group+    * Black with Black Wrinkle tank panels ​and White Strip. 
-    * XLCH got the Deluxe Equipment Group.  +      * On black bikes, ​the tank panel was most likely plain black, not wrinkle
-  * **Additional Information**: +    * Jet Fire Orange with Black Wrinkle tank panels and White Strip
-      * Restyled primary cover?+    Options
 +      * Sparkling Burgundy with Black Wrinkle tank panels and White Strip. 
 +      * Sparkling Blue with Black Wrinkle tank panels and White Strip.
  
  
Line 583: Line 627:
       * Starting on January 3, 1969, the MoCo changed the size of the wire of the two [[techtalk:​ih:​engctl01#​auto_advance_breaker_weight_springs|ignition timer weight springs ]] on Electra Glide and Sportster models to increase the speed at which timing advance occurred. This was to insure that the spark timing would be fully retarded at cranking speed and will advance gradually as RPMs increase to the fully advanced position. ((HD Service Bulletin #562A dated May 1, 1969 pg OC-261))       * Starting on January 3, 1969, the MoCo changed the size of the wire of the two [[techtalk:​ih:​engctl01#​auto_advance_breaker_weight_springs|ignition timer weight springs ]] on Electra Glide and Sportster models to increase the speed at which timing advance occurred. This was to insure that the spark timing would be fully retarded at cranking speed and will advance gradually as RPMs increase to the fully advanced position. ((HD Service Bulletin #562A dated May 1, 1969 pg OC-261))
       * The MoCo noticed a flywheel sprocket shaft (Timken) bearing endplay issue on Electra Glides upon replacing the original bearings. Usually, a set of bearings coming from the manufacturer will supply the correct endplay when installed. However, to bring the endplay within specs it was possible, after careful measurements,​ to still require a 0.003" shim. This didn't affect Sportsters as much since the endplay specs are a bit wider ranged (Electra Glide - 0.0005"​-0.006"​),​ (Sportster - 0.001" - 0.010"​) but it was still advised to be mindful of the endplay on Sportsters as well. ((HD Service Bulletin #591 dated June 23, 1969 pg OC-321)) An endplay issue on the Sprint was also addressed the following September. ​         * The MoCo noticed a flywheel sprocket shaft (Timken) bearing endplay issue on Electra Glides upon replacing the original bearings. Usually, a set of bearings coming from the manufacturer will supply the correct endplay when installed. However, to bring the endplay within specs it was possible, after careful measurements,​ to still require a 0.003" shim. This didn't affect Sportsters as much since the endplay specs are a bit wider ranged (Electra Glide - 0.0005"​-0.006"​),​ (Sportster - 0.001" - 0.010"​) but it was still advised to be mindful of the endplay on Sportsters as well. ((HD Service Bulletin #591 dated June 23, 1969 pg OC-321)) An endplay issue on the Sprint was also addressed the following September. ​  
-  ​ 
   ​   ​
   * **Production Information**:​   * **Production Information**:​
-      * XLH (Super H) (2,700) $1,765 +      * XLH (2,700) $1,765 
-      * XLCH (Super CH) (5,100) $1,698 +      * XLCH (5,100) $1,698
-  ​+
   ​   ​
   * **XLH and XLCH changes include**: ​   * **XLH and XLCH changes include**: ​
Line 601: Line 643:
     * XLH got the Deluxe Equipment and the Highway Cruiser Group.     * XLH got the Deluxe Equipment and the Highway Cruiser Group.
     * XLCH got the Deluxe Equipment Group.     * XLCH got the Deluxe Equipment Group.
-  * **Paint Colors**:+  * **Paint Colors**: ​((https://​www.harleykmodel.com/​technical/​colors/​index.html))
       * XLH       * XLH
-        * Black with Black Wrinkle ​on panel and White strip, ​Jet Fire Orange with Black Wrinkle ​on panel and White strip or Birch White with Black Wrinkle ​panel.  +        * Black with Black Wrinkle ​tank panels ​and White Strip. 
-        * Available at extra cost were Sparkling Burgundy with Black Wrinkle ​panel and White strip, ​Sparkling Blue with Black Wrinkle ​panel and White strip or Sparkling Gold with Black Wrinkle ​panel and White strip.+        * Jet Fire Orange with Black Wrinkle ​tank panels ​and White Strip. 
 +        * Birch White with Black Wrinkle ​tank panels
 +        * Options: 
 +          * Sparkling Burgundy with Black Wrinkle ​tank panels ​and White Strip. 
 +          * Sparkling Blue with Black Wrinkle ​tank panels ​and White Strip. 
 +          * Sparkling Gold with Black Wrinkle ​tank panels ​and White Strip.
       * XLCH       * XLCH
-        * Black with White StripJet Fire Orange with White strip or Birch White. +        * Black with White Strip on tank. 
-        * Available at extra cost were Sparkling Burgundy with White strip, ​Sparkling Blue with White strip and Sparkling Gold with White strip   +        * Jet Fire Orange with White Strip on tank. 
 +        * Birch White. 
 +        * Options: 
 +          * Sparkling Burgundy with White Strip on tank. 
 +          * Sparkling Blue with White Strip on tank. 
 +          * Sparkling Gold with White Strip on tank  ​
   * **Additional Information**:​   * **Additional Information**:​
     * Last year of the magneto ignition system on the XLCH  ​     * Last year of the magneto ignition system on the XLCH  ​
Line 637: Line 689:
   ​   ​
   * **Production Information**:​   * **Production Information**:​
-      * XLH (Super H) (3,033) +      * XLH (3,033) 
-      * XLCH (Super CH) (5,527)+      * XLCH (5,527)
       * XR-750 ​       * XR-750 ​
   ​   ​
Line 656: Line 708:
   * **Paint Colors**:   * **Paint Colors**:
       * Birch White or Hi-Fi Sparkling Blue.       * Birch White or Hi-Fi Sparkling Blue.
- 
  
  
Line 677: Line 728:
       * A spark plug port repair kit (Heli-Coil) was made available for repairing damaged spark plug threads in the head. ((HD Service Bulletin #623 dated April 15, 1971 pg OC-381))       * A spark plug port repair kit (Heli-Coil) was made available for repairing damaged spark plug threads in the head. ((HD Service Bulletin #623 dated April 15, 1971 pg OC-381))
     * **Factory Recalls**:     * **Factory Recalls**:
-      * A [[parts:partsplus-01d#​safety_defect_code_012|safety defect (012)]] was issued for some 1971 Sportsters produced between February 2 and February 26, 1971 assembled with defective rear wheel hubs with incomplete brazed joints causing the tack welds to break. This allowed the spoke flange to move on the hub and loosen the spokes. ((HD Service Bulletin #624 dated April 30, 1971 pg OC-33))+      * A [[techtalk:miscres:​miscres07#​safety_defect_code_012|safety defect (012)]] was issued for some 1971 Sportsters produced between February 2 and February 26, 1971 assembled with defective rear wheel hubs with incomplete brazed joints causing the tack welds to break. This allowed the spoke flange to move on the hub and loosen the spokes. ((HD Service Bulletin #624 dated April 30, 1971 pg OC-33))
  
   * **Fuel notes**:   * **Fuel notes**:
Line 690: Line 741:
   * **XLH and XLCH changes include**:   * **XLH and XLCH changes include**:
       * Wet clutch system with dual (inner & outer) springs.       * Wet clutch system with dual (inner & outer) springs.
-      * Points and condenser ​moved behind plate on timing case cover.+      * Ignition Circuit Breaker ​moved to the cam cover behind ​plate in the (nosecone).
   * **Paint Colors**:   * **Paint Colors**:
       * Birch White, Hi-Fi Sparkling Blue, Sparkling America & Sparkling Burgundy.       * Birch White, Hi-Fi Sparkling Blue, Sparkling America & Sparkling Burgundy.
Line 703: Line 754:
       * The MoCo revealed an easier way to make clutch adjustments by removing the access plug from the chain compartment cover instead of the need to remove the cover (as outlined in the FSM) and owners manuals for 1971 and later Sportsters. ((HS Service Bulletin #634 dated February 18, 1972 pg OC-399))       * The MoCo revealed an easier way to make clutch adjustments by removing the access plug from the chain compartment cover instead of the need to remove the cover (as outlined in the FSM) and owners manuals for 1971 and later Sportsters. ((HS Service Bulletin #634 dated February 18, 1972 pg OC-399))
     * **Factory Recalls**:     * **Factory Recalls**:
-      *  A [[parts:partsplus-01d#​safety_defect_code_015|safety defect (015)]] was issued on a number of 1972 Sportsters produced from November 1, 1971 to March 29, 1972 without the (3 position) stake operation performed on the rear left side fork bearing lock nut on the [[techtalk:​ih:​susp03#​swingarm_rear_fork_info|swingarm]]. +      *  A [[techtalk:​miscres:miscres07#​safety_defect_code_015|safety defect (015)]] was issued on a number of 1972 Sportsters produced from November 1, 1971 to March 29, 1972 without the (3 position) stake operation performed on the rear left side fork bearing lock nut on the [[techtalk:​ih:​susp03#​swingarm_rear_fork_info|swingarm]]. 
-      *  A [[parts:partsplus-01d#​safety_defect_code_017|safety defect (017)]] was issued on a number of 1972 Super Glide and Sportster models produced with the [[techtalk:​ih:​wheels01#​front_wheel_bearing_lock_nut_retainer|front wheel bearing lock ring]] (11035) installed backwards which can result in the front wheel to be loose or the bearing (9009) to lock up. The retaining ring is flat on one side and beveled on the other. ((HD Service Bulletin #638 dated August 14, 1972 pg OC-407)) ​+      *  A [[techtalk:​miscres:miscres07#​safety_defect_code_017|safety defect (017)]] was issued on a number of 1972 Super Glide and Sportster models produced with the [[techtalk:​ih:​wheels01#​front_wheel_bearing_lock_nut_retainer|front wheel bearing lock ring]] (11035) installed backwards which can result in the front wheel to be loose or the bearing (9009) to lock up. The retaining ring is flat on one side and beveled on the other. ((HD Service Bulletin #638 dated August 14, 1972 pg OC-407)) ​
  
   * **Racing notes**:   * **Racing notes**:
Line 711: Line 762:
   ​   ​
   * **Production Information**:​   * **Production Information**:​
-      * XLH 1000 (Super H) (7,500) $2,120 +      * XLH 1000 (7,500) $2,120 
-      * XLCH 1000 (Super CH) (10,650)+      * XLCH 1000 (10,650)
       * XR-750 (200) ((1972-2003 HD XR750 Service Manual XR 750 Production Schedule pg 69))            * XR-750 (200) ((1972-2003 HD XR750 Service Manual XR 750 Production Schedule pg 69))     
       * XRTT-750 (10) ((1972-2003 HD XR750 Service Manual XR 750 Production Schedule pg 69))       * XRTT-750 (10) ((1972-2003 HD XR750 Service Manual XR 750 Production Schedule pg 69))
Line 773: Line 824:
     * **Service Notes / Recommendations**:​     * **Service Notes / Recommendations**:​
     * **Factory Recalls**:     * **Factory Recalls**:
-      * A [[parts:partsplus-01d#​safety_defect_code_020|safety defect (020)]] was issued for some early production XL and XLCH models that were made without a retaining clip to hold the wires to the fender near the tail light bulb socket which allowed the wires to loop outward into the tire well. +      * A [[techtalk:miscres:​miscres07#​safety_defect_code_020|safety defect (020)]] was issued for some early production XL and XLCH models that were made without a retaining clip to hold the wires to the fender near the tail light bulb socket which allowed the wires to loop outward into the tire well. 
-      * A [[parts:partsplus-01d#​safety_defect_code_021|safety defect (021)]] was issued on a number of 1973 XL, XLCH and FX motorcycles that were assembled with defective lower fork bracket forgings. +      * A [[techtalk:miscres:​miscres07#​safety_defect_code_021|safety defect (021)]] was issued on a number of 1973 XL, XLCH and FX motorcycles that were assembled with defective lower fork bracket forgings. 
-      * A [[parts:partsplus-01d#​safety_defect_code_023|safety defect (023)]] was issued (due to some instances of frame breakage, poor handling / possible loss of control) on all 1973 XL and XLCH frames. ​+      * A [[techtalk:​miscres:miscres07#​safety_defect_code_023|safety defect (023)]] was issued (due to some instances of frame breakage, poor handling / possible loss of control) on all 1973 XL and XLCH frames. ​
       * A group of 28 motorcycles (initially produced with the reinforced frame issue resolved) were sent to the U.S. Army that required the fender relocation.       * A group of 28 motorcycles (initially produced with the reinforced frame issue resolved) were sent to the U.S. Army that required the fender relocation.
  
Line 783: Line 834:
   ​   ​
   * **Production Information**:​   * **Production Information**:​
-      * XLH 1000 (Super H) (9,875) +      * XLH 1000 (9,875) 
-      * XLCH 1000 (Super CH) (10,​825)  ​+      * XLCH 1000 (10,​825)  ​
  
   * **First AMF production Harley**   * **First AMF production Harley**
Line 818: Line 869:
   ​   ​
   *  * **Production Information**:​   *  * **Production Information**:​
-      * XLH 1000 (Super H) (13,295) +      * XLH 1000 (13,295) 
-      * XLCH 1000 (Super CH) (10,​535) ​ +      * XLCH 1000 (10,535)
   ​   ​
   ​   ​
Line 833: Line 884:
     * Birch White, Vivid Black, Sunburst Burgundy or Sunburst Blue     * Birch White, Vivid Black, Sunburst Burgundy or Sunburst Blue
   * **Additional Information**:​   * **Additional Information**:​
-    * Last year of the right side shifter ((doodah man of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1728911))+    * Last year of the right side shifter ((doodah man of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​161032-first-and-last-milestones?​t=1728911))
  
  
Line 849: Line 900:
         * By October of 1975, a Service Bulletin from the MoCo reads that all 1975 V-Twin models now operate with the headlight and tail light on in the (ignition) position as well as the (ignition and lights) position due to the increasing number of states requiring headlight operation during daylight hours. ((Management Memorandum No. 74-233 dated December 16, 1974 from the Office of the Deputy Commissioner,​ Caifornia Highway Department)) ((HD Service Letter dated October 25, 1975))         * By October of 1975, a Service Bulletin from the MoCo reads that all 1975 V-Twin models now operate with the headlight and tail light on in the (ignition) position as well as the (ignition and lights) position due to the increasing number of states requiring headlight operation during daylight hours. ((Management Memorandum No. 74-233 dated December 16, 1974 from the Office of the Deputy Commissioner,​ Caifornia Highway Department)) ((HD Service Letter dated October 25, 1975))
     * **Factory Recalls**:     * **Factory Recalls**:
-      * A [[parts:partsplus-01d#​safety_defect_code_029|safety defect (029)]] was issued due to the MoCo experiencing an increase in wheel spoke breakage on front and rear (FL & FLH models) and rear only (FX, FXE, XL & XLCH models), 16" & 18" only.+      * A [[techtalk:miscres:​miscres07#​safety_defect_code_029|safety defect (029)]] was issued due to the MoCo experiencing an increase in wheel spoke breakage on front and rear (FL & FLH models) and rear only (FX, FXE, XL & XLCH models), 16" & 18" only.
   * **Fuel notes**:   * **Fuel notes**:
     * New US car models made with catalytic converters which require unleaded gasoline.((http://​www.lead.org.au/​Chronology-Making_Leaded_Petrol_History.pdf))     * New US car models made with catalytic converters which require unleaded gasoline.((http://​www.lead.org.au/​Chronology-Making_Leaded_Petrol_History.pdf))
Line 855: Line 906:
   ​   ​
   * **Production Information**:​   * **Production Information**:​
-      * XLH 1000 (Super H) (13,515) +      * XLH 1000 (13,515) 
-      * XLCH 1000 (Super CH) (5,895) +      * XLCH 1000 (5,895) 
-      * XR-750 (100) ((1972-2003 HD XR750 Service Manual XR 750 Production Schedule pg 69)) +      * XR-750 (100) ((1972-2003 HD XR750 Service Manual XR 750 Production Schedule pg 69))
  
   * **XLH and XLCH changes include**:   * **XLH and XLCH changes include**:
Line 867: Line 918:
   * **Additional Information**:​   * **Additional Information**:​
       * New 35mm Showa forks.       * New 35mm Showa forks.
- 
               ​               ​
               ​               ​
Line 884: Line 934:
  
     * **Factory Recalls**:     * **Factory Recalls**:
-        * A [[parts:partsplus-01d#​safety_defect_code_030|safety defect (030)]] was issued on the rear brake shoes for XL & XLCH models produced from January 5 to May 20, 1976. The linings could separate from the brake shoe due to a bonding adhesive issue.  ​+        * A [[techtalk:miscres:​miscres07#​safety_defect_code_030|safety defect (030)]] was issued on the rear brake shoes for XL & XLCH models produced from January 5 to May 20, 1976. The linings could separate from the brake shoe due to a bonding adhesive issue.  ​
   ​   ​
   * **Production Information**:​   * **Production Information**:​
-      * XLH 1000 (Super H) (12,844) +      * XLH 1000 (12,844) 
-      * XLH 1000 (Super H) Liberty Edition +      * XLH 1000 Liberty Edition 
-      * XLCH 1000 (Super CH) (5,238) +      * XLCH 1000 (5,238) 
-      * XLCH 1000 (Super CH) Liberty Edition+      * XLCH 1000 Liberty Edition
   ​   ​
   * **XL and XLCH changes include**:   * **XL and XLCH changes include**:
Line 902: Line 952:
   * **Paint Colors**:   * **Paint Colors**:
       *  Birch White, Vivid Black, Sunburst/ Vivid Orange, Vivid Blue, Vivid Red, Vivid Brown or Champagne Silver.       *  Birch White, Vivid Black, Sunburst/ Vivid Orange, Vivid Blue, Vivid Red, Vivid Brown or Champagne Silver.
- 
  
  
Line 926: Line 975:
         * The drum brake lining and rivet set (44432-54A) on XLH,XLCH,FL & FLH models had linings which tended to crack during the riveting process due to the brittle nature of the lining material. These linings, first, had to be bonded and then riveted to the brake shoe by the factory. For this reason, these linings will no longer be sold separately. Use riveted and bonded brake shoe and lining set (44401-49B) instead. ((HD Service Letter ML-52 dated May 11, 1977))         * The drum brake lining and rivet set (44432-54A) on XLH,XLCH,FL & FLH models had linings which tended to crack during the riveting process due to the brittle nature of the lining material. These linings, first, had to be bonded and then riveted to the brake shoe by the factory. For this reason, these linings will no longer be sold separately. Use riveted and bonded brake shoe and lining set (44401-49B) instead. ((HD Service Letter ML-52 dated May 11, 1977))
     * **Factory Recalls**:     * **Factory Recalls**:
-        * A [[parts:partsplus-01d#​safety_defect_code_033|safety defect (033)]] was issued on August 26,1977 regarding a quantity of 100 electric start XL-1000 motorcycles produced from June 24-June 28, 1977 having the new Showa rear shocks assembled with cupped washers on the mounting studs instead of flat washers and 493 of the new design Showa shocks shipped to dealers as spare parts from June 29-July 28, 1977. +        * A [[techtalk:miscres:​miscres07#​safety_defect_code_033|safety defect (033)]] was issued on August 26,1977 regarding a quantity of 100 electric start XL-1000 motorcycles produced from June 24-June 28, 1977 having the new Showa rear shocks assembled with cupped washers on the mounting studs instead of flat washers and 493 of the new design Showa shocks shipped to dealers as spare parts from June 29-July 28, 1977. 
-        * A [[parts:partsplus-01d#​safety_defect_code_040|Safety Defect (040)]] was issued on June 12, 1979 regarding all 1977-1978 XLCR models having pushrods in the rear master cylinder with insufficient contact area with the plastic piston.  ​+        * A [[techtalk:miscres:​miscres07#​safety_defect_code_040|Safety Defect (040)]] was issued on June 12, 1979 regarding all 1977-1978 XLCR models having pushrods in the rear master cylinder with insufficient contact area with the plastic piston.  ​
  
   * **Racing notes**: Jay Springsteen wins Grand Nation Championship and a Number 1 Plate running a XR-750   * **Racing notes**: Jay Springsteen wins Grand Nation Championship and a Number 1 Plate running a XR-750
Line 933: Line 982:
   ​   ​
   * **Production Information**:​   * **Production Information**:​
-      * XLH 1000 (Super H) (12,742) +      * XLH 1000 (12,742) 
-      * XLCH 1000 (Super H) (4,074)+      * XLCH 1000 (4,074)
       * XLT 1000 (1,099)       * XLT 1000 (1,099)
       * XLCR 1000 (1,923) $3,623       * XLCR 1000 (1,923) $3,623
 +      * Confederate Edition Sportsters
 +        * XLH 1000 (299)
 +        * XLCH 1000 (45)
 +        * XLT 1000 (15)
 +      * XR 750 (83)
   ​   ​
   * **XLH and XLCH changes include**:   * **XLH and XLCH changes include**:
Line 976: Line 1030:
       * Bore/ Stroke 81.0 x 96.0 mm (3.2 x 3.8 inches) ((http://​www.bikez.com/​motorcycles/​harley-davidson_xlcr_1000_cafe_racer_1977.php))       * Bore/ Stroke 81.0 x 96.0 mm (3.2 x 3.8 inches) ((http://​www.bikez.com/​motorcycles/​harley-davidson_xlcr_1000_cafe_racer_1977.php))
       * 10" front and rear brakes ((http://​www.bikez.com/​motorcycles/​harley-davidson_xlcr_1000_cafe_racer_1977.php))       * 10" front and rear brakes ((http://​www.bikez.com/​motorcycles/​harley-davidson_xlcr_1000_cafe_racer_1977.php))
 +  * **Confederate Edition Sportsters** were sold for the 1977 season only. [[sportster_history:​1977_sportster#​xlh_1000_confederate_edition|Read more here in the Sportsterpedia]].
 +      * There were reportedly no changes mechanically speaking for this special limited addition to the lineup. \\ There is very little documentation on the Confederate Edition which is accepted as due to it's controversial overtones. ​
 +      * Paint Colors: ((Customer Service letter 787475 dated October 16,2007 https://​www.motorcycleclassics.com/​classic-american-motorcycles/​harley-davidson-confederate))
 +        * Charcoal Silver.
 +        * Rebel flag decal R(61650-77) and L(61651-77) on each side of the gas tank.
 +        * Front fender decal (59100-77) resembling the insignia that was on the caps of the Confederate soldiers during the Civil War.
 +        * Additionally there were a reported 44 Harley Confederate FLH motorcycles and 228 Harley Confederate Super Glide motorcycles. ((http://​www.caimag.com/​wordpress/​2009/​01/​04/​hidden-harley-1977-harley-confederte-edition-motorcycle/​))  ​
   * **Paint colors**   * **Paint colors**
-      *  Birch White, Vivid Black, Vivid Blue, Vivid Brown, Charcoal Silver, Midnight Blue Metallic, Arctic White or Bright Blue. +      *  Birch White, Vivid Black, Vivid Blue, Vivid Brown, Charcoal Silver ​(Confederate Edition), Midnight Blue Metallic, Arctic White or Bright Blue. 
-  68 horses9:1 compression110 mph+      Confirmed colors for XLT from TSB #M-719 are Vivid BlackVivid BlueBrilliant Red, Charcoal Silver and Vivid Brown. \\ [[http://​www.sportsterpedia.com/​doku.php/​parts:​partsplus-01b|See list of technical service bulletins here]] in the Sportsterpedia. 
  
  
Line 994: Line 1056:
       * HD issued a [[techtalk:​ih:​wheels01#​tire_fitment_chart|tire fitment chart]] with a list of all 16",​18"​ & 19" wheels supplied by the MoCo as standard or accessories along with the correct matching of tire, tubes and wheels. ((HD Service Bulletin #M-731 dated June 20, 1978)) and a wheel (hub) bearing spacer recommendation for proper handling and to minimize bearing & tire wear. ((HD Service Bulletin #M-734 dated July 5, 1978)) ​       * HD issued a [[techtalk:​ih:​wheels01#​tire_fitment_chart|tire fitment chart]] with a list of all 16",​18"​ & 19" wheels supplied by the MoCo as standard or accessories along with the correct matching of tire, tubes and wheels. ((HD Service Bulletin #M-731 dated June 20, 1978)) and a wheel (hub) bearing spacer recommendation for proper handling and to minimize bearing & tire wear. ((HD Service Bulletin #M-734 dated July 5, 1978)) ​
     * **Factory Recalls**:     * **Factory Recalls**:
-      * A [[parts:partsplus-01d#​safety_defect_code_040|Safety Defect (040)]] was issued on June 12, 1979 regarding all 1977-1978 XLCR models having pushrods in the rear master cylinder with insufficient contact area with the plastic piston. ​+      * A [[techtalk:miscres:​miscres07#​safety_defect_code_040|Safety Defect (040)]] was issued on June 12, 1979 regarding all 1977-1978 XLCR models having pushrods in the rear master cylinder with insufficient contact area with the plastic piston. ​
  
   * **Production Information**:​   * **Production Information**:​
-      * XLH 1000 (Super H) (11,271)+      * XLH 1000 (11,271)
       * XLH 1000 75th Anniversary Model (2,323) $3,127       * XLH 1000 75th Anniversary Model (2,323) $3,127
-      * XLCH 1000 (Super CH) (2,758) $3,370+      * XLCH 1000 (2,758) $3,370
       * XLT 1000 (Touring)(6)       * XLT 1000 (Touring)(6)
       * XLS 1000 (Roadster) (2)       * XLS 1000 (Roadster) (2)
Line 1045: Line 1107:
         * This coming after many customers and dealers alike have stated that their selling dealer assured them they could return their motorcycle to any dealer for warranty service. This occurred most often when the customer purchased a motorcycle from other than the nearest dealer. Then, when service was required, they naturally expected the local dealer to honor their warranty and were quite upset when warranty service was refused and they were referred to their selling dealer. ((HD Service Letter dated March 2, 1979))         * This coming after many customers and dealers alike have stated that their selling dealer assured them they could return their motorcycle to any dealer for warranty service. This occurred most often when the customer purchased a motorcycle from other than the nearest dealer. Then, when service was required, they naturally expected the local dealer to honor their warranty and were quite upset when warranty service was refused and they were referred to their selling dealer. ((HD Service Letter dated March 2, 1979))
       * The MoCo makes recommendation on [[techtalk:​ih:​engmech02#​cam_gear_selection_for_quiet_operation|proper cam gear selection for quiet operation]]. ((HD Service Bulletin #M-743 dated April 3, 1979 ))       * The MoCo makes recommendation on [[techtalk:​ih:​engmech02#​cam_gear_selection_for_quiet_operation|proper cam gear selection for quiet operation]]. ((HD Service Bulletin #M-743 dated April 3, 1979 ))
-      * HD makes recommendation for corrective measures regarding ​[[techtalk:​ih:​carb02#​lean_condition_adjustments_from_the_moco_1979|carburetion]] and the new (breaker-less) [[techtalk:​ih:​engctl01#​prestolite_electronic_ignition_system|Prestolite electronic ignition system]] on (1100, 1200 and 1340cc) models and emissions control design changes. They operate with leaner air/fuel mixtures and are more sensitive to carburetor mixture settings / ignition spark. ((HD Service Bulletin #M-739 dated November 3, 1978))+      * HD makes recommendation for corrective measures regarding carburetion and the new (breaker-less) [[techtalk:​ih:​engctl01#​prestolite_electronic_ignition_system|Prestolite electronic ignition system]] on (1100, 1200 and 1340cc) models and emissions control design changes. They operate with leaner air/fuel mixtures and are more sensitive to carburetor mixture settings / ignition spark. ((HD Service Bulletin #M-739 dated November 3, 1978))
         * In May of 1980, the MoCo issued a Service Bulletin in response to having some owners of 1000cc and 1340cc engines, built since January 1, 1978, experience a knocking and / or pinging due to the unavailability of fuels with high enough octane ratings. It was recommended to try retarding the timing (up to 10°) on both the Prestolite (1979) and Magnavox (1980) ignition systems. ((HD Service Bulletin #M-780 dated May 23, 1980))         * In May of 1980, the MoCo issued a Service Bulletin in response to having some owners of 1000cc and 1340cc engines, built since January 1, 1978, experience a knocking and / or pinging due to the unavailability of fuels with high enough octane ratings. It was recommended to try retarding the timing (up to 10°) on both the Prestolite (1979) and Magnavox (1980) ignition systems. ((HD Service Bulletin #M-780 dated May 23, 1980))
         * The [[techtalk:​ih:​wheels01#​section1979|procedure for lacing 16 inch wheels]] changed to make them easier to lace in production. The relationship of the spoke flanges on the wheel hubs changed to match the new lacing pattern. Rims, spokes and nipples did not changed. ((HD Service Bulletin #M-738 dated October 17, 1978))         * The [[techtalk:​ih:​wheels01#​section1979|procedure for lacing 16 inch wheels]] changed to make them easier to lace in production. The relationship of the spoke flanges on the wheel hubs changed to match the new lacing pattern. Rims, spokes and nipples did not changed. ((HD Service Bulletin #M-738 dated October 17, 1978))
       * In some cases, the [[techtalk:​ih:​elec02#​starter_relay|1974-1979 starter relay]] used on 1200, 1340 and 1000cc models may develop corroded contacts because of moisture under wet road conditions. ((HD Service Bulletin #M-763 dated Decmber 21, 1979))       * In some cases, the [[techtalk:​ih:​elec02#​starter_relay|1974-1979 starter relay]] used on 1200, 1340 and 1000cc models may develop corroded contacts because of moisture under wet road conditions. ((HD Service Bulletin #M-763 dated Decmber 21, 1979))
     * **Factory Recalls**:     * **Factory Recalls**:
-      * A [[parts:partsplus-01d#​safety_defect_code_036|Safety Defect (036)]] was issued on 568 early 1979 XLH-1000 models with inadequate rear brake linkage parts from February 15, 1978 to March 22, 1978. +      * A [[techtalk:miscres:​miscres07#​safety_defect_code_036|Safety Defect (036)]] was issued on 568 early 1979 XLH-1000 models with inadequate rear brake linkage parts from February 15, 1978 to March 22, 1978. 
-      * A [[parts:partsplus-01d#​safety_defect_code_037|Safety Defect (037)]] was issued by the MoCo on certain 1978-1979 FLH, FLH-80, FX, FXE, FXS and 1979 XLH, XLCH models produced and shipped with an improperly machined front brake master cylinders during from June 7, to June 14, 1978. Within the front brake master cylinders, the plunger piston bore diameter was honed up to .015" over the maximum limit. +      * A [[techtalk:miscres:​miscres07#​safety_defect_code_037|Safety Defect (037)]] was issued by the MoCo on certain 1978-1979 FLH, FLH-80, FX, FXE, FXS and 1979 XLH, XLCH models produced and shipped with an improperly machined front brake master cylinders during from June 7, to June 14, 1978. Within the front brake master cylinders, the plunger piston bore diameter was honed up to .015" over the maximum limit. 
-      * A [[parts:partsplus-01d#​safety_defect_code_039|Safety Defect (039)]] was issued for a total of 370 motorcycles (including, XLH-1000, FLH-1200, FLH-80, FXR-1200, FXEF-1200FXEF-80,​ FXS-1200 and FXS-80) that were produced and shipped to dealers from March 22nd to March 30th 1979 with a possible defect in the front brake master cylinder. +      * A [[techtalk:miscres:​miscres07#​safety_defect_code_039|Safety Defect (039)]] was issued for a total of 370 motorcycles (including, XLH-1000, FLH-1200, FLH-80, FXR-1200, FXEF-1200FXEF-80,​ FXS-1200 and FXS-80) that were produced and shipped to dealers from March 22nd to March 30th 1979 with a possible defect in the front brake master cylinder. 
-      * A [[parts:partsplus-01d#​safety_defect_code_041|Safety Defect (041)]] was issued for 635  XLH and XLS models produced and shipped between March 30 and April 19, 1979 with a possible defect in the assembly of the brake pedal stop bolt jam­ nut not being securely tightened at the time of assembly. +      * A [[techtalk:miscres:​miscres07#​safety_defect_code_041|Safety Defect (041)]] was issued for 635  XLH and XLS models produced and shipped between March 30 and April 19, 1979 with a possible defect in the assembly of the brake pedal stop bolt jam­ nut not being securely tightened at the time of assembly. 
-      * A [[parts:partsplus-01d#​safety_defect_code_044|Safety Defect (044)]] was prompted in August due to a number of 1979 FLH, XL and XLS models with master cylinder pistons made from an incorrect material as received from HD's supplier. 1979 XLCH, FXE, FXEF and FXS models were added to the list in March of 1980.+      * A [[techtalk:miscres:​miscres07#​safety_defect_code_044|Safety Defect (044)]] was prompted in August due to a number of 1979 FLH, XL and XLS models with master cylinder pistons made from an incorrect material as received from HD's supplier. 1979 XLCH, FXE, FXEF and FXS models were added to the list in March of 1980.
  
  
Line 1063: Line 1125:
   ​   ​
   * **Production Information**:​   * **Production Information**:​
-      * XLH 1000 (Super H) (6,525) +      * XLH 1000 (6,525) 
-      * XLCH 1000 (Super CH) (141) Last year in production.+      * XLCH 1000 (141) Last year in production.
       * XLS 1000 Roadster (5,123)       * XLS 1000 Roadster (5,123)
-      * XLCR Café Racer (9) 
   ​   ​
   * **XL, XLCH, XLS changes include**:   * **XL, XLCH, XLS changes include**:
-      * Last official year for kickstart engines ((doodah man of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=1728911))+      * Last official year for kickstart engines ((doodah man of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​161032-first-and-last-milestones?​t=1728911))
       * New breakerless [[techtalk:​ih:​engctl01#​prestolite_electronic_ignition_system|Prestolite electronic ignition system]] ((HD Service Bulletin #M-780 dated May 23, 1980)) replaces the circuit breaker ignition system. A kit was also available to convert 1971-1978 models to the new electronic ignition system. ((1954-1978 HD Sportster Parts Catalog 49))       * New breakerless [[techtalk:​ih:​engctl01#​prestolite_electronic_ignition_system|Prestolite electronic ignition system]] ((HD Service Bulletin #M-780 dated May 23, 1980)) replaces the circuit breaker ignition system. A kit was also available to convert 1971-1978 models to the new electronic ignition system. ((1954-1978 HD Sportster Parts Catalog 49))
       * Carburetor modification kits (including jet(s) and an accelerator pump stop screw) were made available for 1200cc, 1340cc and 1000cc models to provide leaner fuel mixtures when operating at elevations above 4000 feet sea level. ((HD Service Blletin #M-730 dated June 15, 1978))       * Carburetor modification kits (including jet(s) and an accelerator pump stop screw) were made available for 1200cc, 1340cc and 1000cc models to provide leaner fuel mixtures when operating at elevations above 4000 feet sea level. ((HD Service Blletin #M-730 dated June 15, 1978))
Line 1099: Line 1160:
       * Chromed rear sprocket       * Chromed rear sprocket
       * Black front master cylinder  ​       * Black front master cylinder  ​
-  * **Paint colors** +  * **Paint colors** ​\\ {{ pdf-bulletin:​1979_painted_parts.pdf |Click here to download the 1979 Painted Parts List}}, or  {{ pdf-bulletin:​pab0056.pdf |Click here to download HD P&A Bulletin #56}}  
-      Birch White, ​Vivid Black, Brilliant Red, Concord Blue, Chestnut Brown, ​Classic Tan, Classic Chreme, FXS Silver and Charcoal ​Gray.  +    XLH: Vivid Black, Brilliant Red, Concord Blue, Chestnut Brown. ((1979 Painted Parts List pg 51010-82)) 
 +    * XLS: Black/Gray. ((1979 Painted Parts List pg 510, 10-82)) 
 + 
   * **Additional Information**:​   * **Additional Information**:​
-      ​* Last year of XLH and XLCH (Super) mantra +      * For 1979 - 1985, the one-way, external, foo-foo valve and the six-inch metal vent tube at the front of the timing cover were done away with.  Instead, a one-way valve was built-in inside the timing cover. A rubber breather hose then ran from the generator drive area of the timing cover, at the 9 o’clock position, to the stock carb air filter so that any oil mist was fed back through the engine, making the EPA pollutocrats more happier than they were with the idea of engine oil spraying out into the atmosphere. ((Hopper from the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​74149-engine-breather-101-crankcase-vent-101?​t=518948&​highlight=wet+sumping))
-      ​* For 1979 - 1985, the one-way, external, foo-foo valve and the six-inch metal vent tube at the front of the timing cover were done away with.  Instead, a one-way valve was built-in inside the timing cover. A rubber breather hose then ran from the generator drive area of the timing cover, at the 9 o’clock position, to the stock carb air filter so that any oil mist was fed back through the engine, making the EPA pollutocrats more happier than they were with the idea of engine oil spraying out into the atmosphere. ((Hopper from the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=518948&​highlight=wet+sumping))+
  
 {{common:​space100x5px.jpg?​200|}}[[sportster_history:​99xx-01|{{:​sportster_history:​gotohistorymainmenu.jpg|}}]] \\ {{common:​space100x5px.jpg?​200|}}[[sportster_history:​99xx-01|{{:​sportster_history:​gotohistorymainmenu.jpg|}}]] \\
Line 1141: Line 1204:
   * **XLH, XLS changes include**:   * **XLH, XLS changes include**:
       * New "​Q"​ cams installed ((1979-1985 Sportster FSM pg 3-39))       * New "​Q"​ cams installed ((1979-1985 Sportster FSM pg 3-39))
-      * The [[techtalk:​ih:​engctl01f|timing marks have been revised]] on all 1980 and later 1000cc (crankcase number 780-108-001 and up) and 1340cc models to enable the timing to be set electronically at the factory. ((HD Service Bulletin #M-781 dated May 23, 1980))+      * The [[techtalk:​ih:​engctl01#​timing_marks|timing marks have been revised]] on all 1980 and later 1000cc (crankcase number 780-108-001 and up) and 1340cc models to enable the timing to be set electronically at the factory. ((HD Service Bulletin #M-781 dated May 23, 1980))
       * All HD models (including XLs) have new changes including:       * All HD models (including XLs) have new changes including:
           * New [[techtalk:​ih:​engctl01#​magnavox_electronic_ignition_systems|Magnavox Electronic Ignition System]] with a full electronic advance (containing no mechanical advance mechanism to adjust). The entire spark and timing system is controlled by the ignition module assembly. ​ Should the engine timing not advance properly or the spark be off, just replace the entire module. Note, you cannot use a solid core spark plug wire. You must use carbon core plug wires. ((HD Service Letter #ML-131 dated September 14, 1979))           * New [[techtalk:​ih:​engctl01#​magnavox_electronic_ignition_systems|Magnavox Electronic Ignition System]] with a full electronic advance (containing no mechanical advance mechanism to adjust). The entire spark and timing system is controlled by the ignition module assembly. ​ Should the engine timing not advance properly or the spark be off, just replace the entire module. Note, you cannot use a solid core spark plug wire. You must use carbon core plug wires. ((HD Service Letter #ML-131 dated September 14, 1979))
Line 1159: Line 1222:
   * **XR-750** (dirt track) changes include:   * **XR-750** (dirt track) changes include:
       * New Marzocchi front forks with 5.31" travel and a 2.5 gallon gas tank ((1972-2003 HD XR-750 Service Manual pg 3))  ​       * New Marzocchi front forks with 5.31" travel and a 2.5 gallon gas tank ((1972-2003 HD XR-750 Service Manual pg 3))  ​
-  * **Paint ​Colors**: +  * **Paint ​colors** {{ pdf-bulletin:1980_painted_parts.pdf |Click here to download the 1980 Painted Parts List}} 
-      * Birch White, ​Vivid Black, FXS Silver, Charcoal Grey, Rich Red, Bright Blue, Saddle Brown and Candy Red+      * **XLH**: ​Vivid Black, Bright Blue, Saddle BrownCandy Red. ((1980 Painted Parts List pg 505, 1-82)) 
 +      * **XLS**: Fuel tank: Black/​Charcoal. Fenders: Black/Gray. ((1980 Painted Parts List pg 505, 1-82))
  
  
Line 1189: Line 1253:
   * **Production Information**:​   * **Production Information**:​
       * XLH 1000 (8,442)       * XLH 1000 (8,442)
-      * XLS 1000 Roadster (1,​660) ​+      * XLS 1000 Roadster (1,660
 +      * Milwaukee Edition 1000 (804) ((http://​veh-markets.com/​motorcycles/​harley-davidson/​138590-1981-milwaukee-edition-sportster.html)
   ​   ​
   ​   ​
   * **XLH and XLS changes include**:   * **XLH and XLS changes include**:
       * 81 models saw new heads beginning with crankcase (#​781012001),​ all 1981 production XLs utilize [[techtalk:​ih:​engmech03e|3 angle valve seats]] on both intake and exhaust ports. ​       * 81 models saw new heads beginning with crankcase (#​781012001),​ all 1981 production XLs utilize [[techtalk:​ih:​engmech03e|3 angle valve seats]] on both intake and exhaust ports. ​
-      * All 1981 model motorcycles are equipped with a [[techtalk:​ih:​engctl04#to_present|dual cable (pull-pull) throttle assembly]]. The throttle cable pulls the throttle butterfly open when turned counter-clockwise (as on previous models) while the idle cable pulls the butterfly closed when the grip is turned clockwise. ​ The  carburetor ​ is equipped with a return spring which closes the throttle when grip is released (as on previous models). ((HD Service Bulletin #M-804 dated November 4, 1980))+      * All 1981 model motorcycles are equipped with a [[techtalk:​ih:​body04#to_1985_present|dual cable (pull-pull) throttle assembly]]. The throttle cable pulls the throttle butterfly open when turned counter-clockwise (as on previous models) while the idle cable pulls the butterfly closed when the grip is turned clockwise. ​ The  carburetor ​ is equipped with a return spring which closes the throttle when grip is released (as on previous models). ((HD Service Bulletin #M-804 dated November 4, 1980))
       * New petcock with a reserve tube. ((1979-1981 Sportster Parts Catalog pg 87))       * New petcock with a reserve tube. ((1979-1981 Sportster Parts Catalog pg 87))
       * The transmission vent hose routing was changed on late 1981 models and was suggested as a practice for E1981 models as well. The hose should now be routed under the starter, over all of the oil lines and the rear brake line, and down between the pivot bolt and swingarm. ((HD Service Bulletin #M-813 dated January, 30 1981))       * The transmission vent hose routing was changed on late 1981 models and was suggested as a practice for E1981 models as well. The hose should now be routed under the starter, over all of the oil lines and the rear brake line, and down between the pivot bolt and swingarm. ((HD Service Bulletin #M-813 dated January, 30 1981))
Line 1209: Line 1274:
       * Optional 3.3 gallon gas tank       * Optional 3.3 gallon gas tank
       * Longer wheel base (60") ((1979-1985 HD FSM))       * Longer wheel base (60") ((1979-1985 HD FSM))
 +  * **Milwaukee Edition**: [[http://​veh-markets.com/​motorcycles/​harley-davidson/​138590-1981-milwaukee-edition-sportster.html|See more here on this model]]. 
 +      * Limited edition (AKA, the Buy Back Bike or Milwaukee Special) celebrating Harley Davidson'​s rebirth and return into private ownership from AMF.  
 +      * Reportedly, only 804 of these motorcycles were produced. \\ One for every Harley Dealership. \\ One extra for the top 100 Harley Dealers. \\ Four for promotional purposes.  
 +  * **Paint colors** {{ pdf-bulletin:​1981_painted_parts.pdf |Click here to download the 1981 Painted Parts List}}  
 +      * XLH: Vivid Black, Metallic Blue, Candy Red, Candy Root Beer. ((1981 Painted Parts List pg 506)) 
 +        * Large fuel tank (Lg) w/decals: Metallic Blue, Candy Red. ((1981 Painted Parts List pg 508, 10-82)) 
 +        * Additionally,​ a Saddle Brown fuel tank is shown on page 508, 10-82 sheet. 
 +      * XLS: 2-Tone Silver, Black w/Red Pinstripe. ((1981 Painted Parts List pg 508, 10-82)) 
 +      * Milwaukee Edition: Orange/​Black. ((1981 Painted Parts List pg 508, 10-82))
  
  
Line 1263: Line 1336:
       * L1982 models have a new clamp-on two piece exhaust system. The one piece (welded) rear exhaust & muffler assembly (65600-80A) and one piece front exhaust pipe & muffler assembly (65605-80A) is no longer available after the current stock is used up. Due to size differences,​ parts from the two different exhaust systems cannot be interchanged. ((HD Service Bulletin #M-851A dated March 23, 1982))       * L1982 models have a new clamp-on two piece exhaust system. The one piece (welded) rear exhaust & muffler assembly (65600-80A) and one piece front exhaust pipe & muffler assembly (65605-80A) is no longer available after the current stock is used up. Due to size differences,​ parts from the two different exhaust systems cannot be interchanged. ((HD Service Bulletin #M-851A dated March 23, 1982))
       * A foot rest chain protector (50943-82) was made available that fits over the footrest bracket to prevent contact between the final drive chain and the passenger footrest bracket. ((HD Service Bulletin #M-855 dated July 19, 1982))       * A foot rest chain protector (50943-82) was made available that fits over the footrest bracket to prevent contact between the final drive chain and the passenger footrest bracket. ((HD Service Bulletin #M-855 dated July 19, 1982))
-  * **Paint ​Colors**: +  * **Paint ​colors:** {{ pdf-bulletin:1982_painted_parts.pdf |Click here to download the 1982 Painted Parts List}} \\ Both anniversary models came with 25th anniversary graphics and special paperwork about the bike's history signed by Chairman Vaughn Beals, President Charlie Thompson and Styling Vice President, Willie G Davidson.  
-        * Birch White, Vivid Black, Classic Tan, Classic Creme, Metallic Blue, Light Red, Dark Carmine, Orange, Brown, Emerald Green, Red, Pewter or maroon. +        * XLH: Vivid Black, Candy Red, Metallic Blue, Metallic Green. ((1982 Painted Parts List pg 503, 1-82)) 
-  * Both anniversary models came with 25th anniversary graphics and special paperwork about the bike's history signed by Chairman Vaughn Beals, President Charlie Thompson and Styling Vice President, Willie G Davidson. +        * XLS: Red/Black, Black w/Gold pinstriping. ((1982 Painted Parts List pg 503, 1-82)) 
- +        * XLH and XLS Anniversary Models: Dark Maroon and Pewter. ((1982 Painted Parts List pg 507, 10-82)) 
 + 
 {{common:​space100x5px.jpg?​200|}}[[sportster_history:​99xx-01|{{:​sportster_history:​gotohistorymainmenu.jpg|}}]] \\ {{common:​space100x5px.jpg?​200|}}[[sportster_history:​99xx-01|{{:​sportster_history:​gotohistorymainmenu.jpg|}}]] \\
  
Line 1277: Line 1350:
     * International Trade Commission levies a five year tariff on Japanese motorcycles 700cc and over.     * International Trade Commission levies a five year tariff on Japanese motorcycles 700cc and over.
     * Dick O'​Brien,​ long time manager of HDs factory race team, retires.     * Dick O'​Brien,​ long time manager of HDs factory race team, retires.
-    * The first production XLX was given to Jay Springsteen ((Ralphthe3rd of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?t=546367))+    * The first production XLX was given to Jay Springsteen ((Ralphthe3rd of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​76679-xlx-sportster?t=546367))
     * **Service Notes / Recommendations**:​     * **Service Notes / Recommendations**:​
       * Oil tank drain method: Using hose clamp pliers (HD-84 04), loosen and slide the clamp from the oil drain hose to the plug bracket. Disconnect the hose and drain the oil from tank into suitable drain pan. Upon reinstallation of the drain hose, connect the hose to the plug bracket and secure it with the clamp. Fill oil tank with 3 quarts of HD Power Blend Super Premium oil. If the oil pressure light stays on, air may have been introduced in the oil system making it necessary to prime the oil pump. ((HD Service Bulletin #M-856 dated August 6, 1982))       * Oil tank drain method: Using hose clamp pliers (HD-84 04), loosen and slide the clamp from the oil drain hose to the plug bracket. Disconnect the hose and drain the oil from tank into suitable drain pan. Upon reinstallation of the drain hose, connect the hose to the plug bracket and secure it with the clamp. Fill oil tank with 3 quarts of HD Power Blend Super Premium oil. If the oil pressure light stays on, air may have been introduced in the oil system making it necessary to prime the oil pump. ((HD Service Bulletin #M-856 dated August 6, 1982))
Line 1318: Line 1391:
   * **New model XLX-61**: Striped down version of the XLH and built to sell for $3,995, featured:   * **New model XLX-61**: Striped down version of the XLH and built to sell for $3,995, featured:
       * Solo seat       * Solo seat
-      * 2 gallon peanut gas tank ((IronMick of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?t=546367))+      * 2 gallon peanut gas tank ((IronMick of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​76679-xlx-sportster?t=546367))
       * Black staggered shorty dual exhaust       * Black staggered shorty dual exhaust
-      * Black flat track handlebars ((IronMick of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?t=546367))+      * Black flat track handlebars ((IronMick of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​76679-xlx-sportster?t=546367))
       * Speedo only, no tach       * Speedo only, no tach
       * 9 spoke cast aluminum wheels       * 9 spoke cast aluminum wheels
-      * Small front fender with fender struts. ((IronMick of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?t=546367))+      * Small front fender with fender struts. ((IronMick of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​76679-xlx-sportster?t=546367))
       * Satin finish cases. ​       * Satin finish cases. ​
       * Only year       * Only year
Line 1333: Line 1406:
           * 10" dual front disc brakes           * 10" dual front disc brakes
           * Wheel base (60") ((1979-1985 HD FSM))           * Wheel base (60") ((1979-1985 HD FSM))
-          * Engine covers ((IronMick of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=546367)) +          * Engine covers ((IronMick of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​76679-xlx-sportster?​t=546367)) 
-          * Very little chrome. ((IronMick of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=546367)) +          * Very little chrome. ((IronMick of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​76679-xlx-sportster?​t=546367)) 
-          * First year (only), models were available in black paint only. The later ones were available in other colors (mainly red and blue) with chrome pipes. This model Ironhead is what the '86 883 Evo styling was based on. ((IronMick of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?t=546367))+          * First year (only), models were available in black paint only. The later ones were available in other colors (mainly red and blue) with chrome pipes. This model Ironhead is what the '86 883 Evo styling was based on. ((IronMick of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​ironhead-sportster-motorcycle-talk-1957-1985/​76679-xlx-sportster?t=546367))
           * Early build XLX models may have had a VOES with a vacuum operating requirement of 7in-Hg resulting in a longer than necessary retarded ignition curve. This VOES should'​ve been be replaced (by the dealership during warranty period) with a new VOES requir­ing only 4in-Hg vacuum for operation. The new VOES is identified by a white dot at the vacuum hose connection. ((HD Service Bulletin #M-856 dated August 6, 1982)) ​                 * Early build XLX models may have had a VOES with a vacuum operating requirement of 7in-Hg resulting in a longer than necessary retarded ignition curve. This VOES should'​ve been be replaced (by the dealership during warranty period) with a new VOES requir­ing only 4in-Hg vacuum for operation. The new VOES is identified by a white dot at the vacuum hose connection. ((HD Service Bulletin #M-856 dated August 6, 1982)) ​      
-  * **New model XR-1000** based on XLX chassis. ​+  * **New model XR-1000** ​(mid-year edition) ​based on XLX chassis. ​
       * 71HP @ 5,600 rpm, 125 mph, 490 lbs,        * 71HP @ 5,600 rpm, 125 mph, 490 lbs, 
       * Engine is a hybrid or cross of the XR-750 and XL-1000 matched to an identical XL 4 speed transmission:​       * Engine is a hybrid or cross of the XR-750 and XL-1000 matched to an identical XL 4 speed transmission:​
Line 1348: Line 1421:
       * Vacuum advance-V-fire III breaker less ignition       * Vacuum advance-V-fire III breaker less ignition
       * Twin 36mm Dell'​Orto carbs with accel pumps       * Twin 36mm Dell'​Orto carbs with accel pumps
-      * Satin textured cases+      ​* Timer cover - Eagle racing design  
 +      ​* Satin textured ​painted ​cases 
 +      * Timer cover - Eagle racing design
       * 2.5 gallon gas tank       * 2.5 gallon gas tank
 +      * “H-D XR-1000” decal on gas tank
       * 2.5 quart oil capacity ​       * 2.5 quart oil capacity ​
       * Left side high megaphone dual mufflers       * Left side high megaphone dual mufflers
       * 9 spoke cast aluminum wheels: rim valve hole diameter front - .45", rear - .34"       * 9 spoke cast aluminum wheels: rim valve hole diameter front - .45", rear - .34"
       * Tubeless 4 ply tires: 19" front, Dunlop K-291S (100/​90V-19),​ 16" rear, Dunlop K-291S (130-90V-16) ((HD Service Bulletin #M-867 dated March 11, 1983))       * Tubeless 4 ply tires: 19" front, Dunlop K-291S (100/​90V-19),​ 16" rear, Dunlop K-291S (130-90V-16) ((HD Service Bulletin #M-867 dated March 11, 1983))
 +      * Dual disc front brakes
 +      * Black wrinkle finish fork stem and bracket
 +      * Black handlebar
       * Oiled felt air filter       * Oiled felt air filter
       * New designed calipers       * New designed calipers
-  ​* **Paint ​Colors**: +      * Speedometer and Tach 
-      Birch White, ​Vivid Black, ​Classic TanClassic Crème, Pewter, Maroon, Indigo Blue, Claret Red or Slate Gray Metallic +  ​* **Paint ​colors:** {{ pdf-bulletin:1983_painted_parts.pdf |Click here to download the 1983 Painted Parts List}} ​ 
 +        XLH: Vivid Black, ​Candy RedClaret Red, Indigo Blue. ((1983 Painted Parts List pg 50310-82)) 
 +        * XLS: Indigo and Pewter, Black w/Gold pinstriping. ((1983 Painted Parts List pg 503, 10-82)) 
 +        * XLX: Vivid Black. ((1983 Painted Parts List pg 503, 10-82))
  
  
Line 1383: Line 1464:
         * 1000 Sportster - right case (784 044001 and up)         * 1000 Sportster - right case (784 044001 and up)
       * The MoCo advised to use sulfuric acid with a specific gravity of 1.270-1.280 for activating new batteries instead of automotive grade acid with 1.255-1.265 specific gravity due to motorcycle batteries being smaller in size than automotive batteries. The higher specific gravity will increase battery amperage output up to 20%. Also, the ball type hydrometers are not as accurate as the Kent Moore type (HD-96910-35). It is not recommended to add this higher specific gravity acid to batteries already in use. ((HD Service Bulletin #M-891 dated May 18, 1984))       * The MoCo advised to use sulfuric acid with a specific gravity of 1.270-1.280 for activating new batteries instead of automotive grade acid with 1.255-1.265 specific gravity due to motorcycle batteries being smaller in size than automotive batteries. The higher specific gravity will increase battery amperage output up to 20%. Also, the ball type hydrometers are not as accurate as the Kent Moore type (HD-96910-35). It is not recommended to add this higher specific gravity acid to batteries already in use. ((HD Service Bulletin #M-891 dated May 18, 1984))
 +
     * **Factory Recalls**:     * **Factory Recalls**:
 +      * Recall (058) Certain 1984 XL models - alternator rotor magnets. See Service Bulletin M-890. ​
  
   * **Fuel notes**:   * **Fuel notes**:
Line 1426: Line 1509:
       * Diaphragm clutch spring (mid year)       * Diaphragm clutch spring (mid year)
       * Alternator (mid year)            * Alternator (mid year)     
-    ​* **Paint ​Colors**: +  ​* **Paint ​colors:** {{ pdf-bulletin:pab0207.pdf |Click here to download PAB-207}} ​ 
-      * Birch White, ​Vivid Black, ​Classic Tan, Classic Crème, Indigo Blue, Claret ​Red, Candy Purple, ​Rose Metallic or Slate Gray Metallic.+      * XL: Vivid Black, ​Candy Red, Candy Purple. ((1984 Painted Parts List from P&A Bulletin P&A #207)) 
 +      * XLS: Vivid BlackPurple and Silver. ((1984 Painted Parts List from P&A Bulletin P&A #207)) 
 +      * XLX: Vivid Black, Candy Red. ((1983 Painted Parts List pg 503, 10-82)) 
 +      * XR-1000: ​Slate Gray. ((1983 Painted Parts List pg 503, 10-82))
     ​     ​
  
Line 1496: Line 1582:
             * 883: 1786 127 043             * 883: 1786 127 043
             * 1100: 1886 127 001             * 1100: 1886 127 001
 +      * Clutch cables are now made of a new heat resistant material. ((HD Tech Tip dated April 1986)) \\
     * **XLH 883**: ​     * **XLH 883**: ​
       * Engine: 883cc OHV Evolution V-twin with 3 x 3.81" bore and stroke       * Engine: 883cc OHV Evolution V-twin with 3 x 3.81" bore and stroke
Line 1660: Line 1747:
     * The European parts and accessories warehouse opens.     * The European parts and accessories warehouse opens.
     * Upon its introduction,​ the FLSTF Fat Boy® almost instantaneously becomes a modern legend of motorcycle design.((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​1990.html))     * Upon its introduction,​ the FLSTF Fat Boy® almost instantaneously becomes a modern legend of motorcycle design.((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​1990.html))
 +
   * **Racing notes**:   * **Racing notes**:
     * Nigel Gale wins the Twin Sports Championship.     * Nigel Gale wins the Twin Sports Championship.
Line 1670: Line 1758:
         * XLH 1200 (4,598)         * XLH 1200 (4,598)
         * XR-750 Engine Kits (only)         * XR-750 Engine Kits (only)
 +
   * **XLH 883 and XLH 1200 changes include**:   * **XLH 883 and XLH 1200 changes include**:
         * New paper air filter and paint options         * New paper air filter and paint options
-        * 40mm Keihin carb - constant velocity with an accelerator pump+        * 40mm Keihin ​CV carb - constant velocity with an accelerator pump 
 +        * One piece, right hand flywheel (pinion shaft no longer has a taper) 
 +        * Oil pump drive gear, spacer and pinion gear now depend on clamp load to remain in position. The "​T"​ key aligns the pinion for timing.
   * **XR750 engine kits (only)** were sold from 1990-2003 ​   * **XR750 engine kits (only)** were sold from 1990-2003 ​
   * **Paint Colors**:   * **Paint Colors**:
Line 1695: Line 1786:
     * The Dyna line of motorcycles debuts with the 1991 FXDB Dyna Glide Sturgis®. ((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​1990.html))     * The Dyna line of motorcycles debuts with the 1991 FXDB Dyna Glide Sturgis®. ((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​1990.html))
     * New assembly line for 883cc and 1200cc Sportster engines at Capitol Drive Plant results in relief on old line and overall improved quality.     * New assembly line for 883cc and 1200cc Sportster engines at Capitol Drive Plant results in relief on old line and overall improved quality.
 +    * PPG formulated new customized paints for Harley-Davidson for better paint quality, color selection, and match. ((HD Tech Tip #20 dated August 1991))
 +    * All 1991 models came with a plastic bag around the entire motorcycle to prevent corrosion and the need for CRC spray.
 +
   * **Racing notes**:   * **Racing notes**:
     * Scott Zampach wins Twins Sport Series and US Twin Sports Championship with Nigel Gale placing third. ​     * Scott Zampach wins Twins Sport Series and US Twin Sports Championship with Nigel Gale placing third. ​
Line 1709: Line 1803:
       * 5 speed tranny replaced the 4 speed       * 5 speed tranny replaced the 4 speed
       * Hydraulic lifters were replaced with automotive type units       * Hydraulic lifters were replaced with automotive type units
 +      * New ignition module
       * Oil pump given internal cast feed lines       * Oil pump given internal cast feed lines
       * Breather system moved from the crankcase to the heads with (umbrella valves) in rocker boxes       * Breather system moved from the crankcase to the heads with (umbrella valves) in rocker boxes
-      * Alternator moved from behind clutch to the crankshaft+      * Alternator moved from behind clutch to the crankshaft ​(faster spinning rotor produces peak output at lower rpm)
       * Primary cover redesigned for easy removal       * Primary cover redesigned for easy removal
       * New rubber mounted rider foot pegs       * New rubber mounted rider foot pegs
-      * Old Dunlop k-291 tires replaced with K402's+      * New 401/402 series Dunlop tires, old Dunlop k-291 tires replaced with K402's
       * Turn Signals became self-canceling with signals from speedo       * Turn Signals became self-canceling with signals from speedo
       * Right side timing hole       * Right side timing hole
-      * Tappet blocks, rear motor mount, oil filter integrated with case +      * Tappet blocks, rear motor mount, oil filter ​mount integrated with case 
-      * One piece push rod tubes+      * One piece push rod tubes to reduce leakage 
 +      * Camshafts are now supported on the inboard side by bronze bushings for reduced noise
       * 5/8" hex Champion spark plugs       * 5/8" hex Champion spark plugs
-      * 40 oz fluid level for primary/ transmission +      * The crankcase breather (umbrella valves) were relocated to the rocker boxes breathing directly through the A/C backing plate bolts. 
-      * New primary chain adjuster +      * Change from 24oz to 40oz of fluid for primary / transmission 
-      * Jiffy stand re-located further back on frame+      * The clutch pack had an increase in the number of clutch plates, material was also changed from cork to paper. 
 +      * New primary chain adjuster
 +      * Gates belt drive replaced chain on 883 deluxe and 1200 models. 
 +      * Jiffy stand re-located further back on frame for improved customer access. \\ The new location prevents the 5 speed engine from being retrofit to earlier Sportster frames. 
 +      * 1991 replacement crankcases have no oil system bypass and have the cam gear oiler hole in the gearcase ((HD Tech Tip #27 dated October 1991))
   * **XLH 883 and XLH 883 Hugger changes include**:   * **XLH 883 and XLH 883 Hugger changes include**:
-      *  ​An ​O-ring chain final drive  +      * O-ring chain final drive  
-  * Belt drive replaced chain on 883 deluxe and 1200 models+  * **XLH 1200 changes include**:​ 
 +      * Steering stem nut cover
   * **Paint Colors**:   * **Paint Colors**:
       * XL 883 (all models): Vivid Black, Wineberry Pearl, Bright Sapphire Metallic, Vivid Yellow, Bright Candy Ruby. ((HD 1989-1996 Painted Parts Book pg 1-42))       * XL 883 (all models): Vivid Black, Wineberry Pearl, Bright Sapphire Metallic, Vivid Yellow, Bright Candy Ruby. ((HD 1989-1996 Painted Parts Book pg 1-42))
Line 1737: Line 1838:
  
   * **MoCo notes**:   * **MoCo notes**:
-    ​* World wide licensing of trademarks and logos +      ​* World wide licensing of trademarks and logos 
-    * The last year of Japanese made carbon canister emission filters. +      * $32 million robotic painting system set up at the York Plant. 
-    ​* $32 million robotic painting system set up at the York Plant. +      * HD stock worth almost 7 times original price. 
-    * HD stock worth almost 7 times original price. +      * Miss HD, Krisann Whitley, is crowned at Daytona. 
-    * Miss HD, Krisann Whitley, is crowned at Daytona.+      * **Service notes**: 
 +        * A change in the break-in (burnishing) procedure for new 1992 brake pads and discs was issued thru Tech Tip #28. ((HD Tech Tip #28 dated February 1992)) 
 +        * A limited number of used right side crankcase halves made available (useful for line reaming gearcase cover bushings). ((HD Tech Tip #29 dated April 1992)) 
 +      * **Parts notes**: 
 +        * The last year of Japanese made carbon canister emission filters. 
 +        * Oversized crankpins for pre-commonized taper models were made available to permit fitment of late style rod bearings to 1957-E1981 XL's and 1941-E1981 FL / FX's. ((HD Tech Tip #28 dated February 1992)) 
 +        * Dunlop 291 tires no longer available from Dunlop. HD dealerships now the only source for these OEM t1res. ((HD Tech Tip #28 dated February 1992)) 
 +        * Replacement voltage regulators for L1984-1990 XLs (74523-84A) may not be exactly the same as the unit being replaced. The wires exit from the regulator'​s side housing instead of exiting from the rear as in the original. ((HD Tech Top #34 dated July 1993)) 
   * **Racing notes**:   * **Racing notes**:
     * Scott Zampach wins the Twin Sports Championship with Nigel Gale in second place.     * Scott Zampach wins the Twin Sports Championship with Nigel Gale in second place.
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       * XLH 883 '​Sportster Deluxe'​ $5,559       * XLH 883 '​Sportster Deluxe'​ $5,559
       * XLH 1200 $6,400       * XLH 1200 $6,400
-  ​* **All Models receive**: + 
-      * Improved brake pad material +  ​* **All model changes include**: 
-      * New style grease fittings +      * Oiling system bypass in the filter pad was eliminated to '​borrow oil for the cam gear oiler' ((HD Tech Tip #27 dated October 1991)) 
-      * New halogen ​headlight ​assembly +      * Improved oil check ball has a post added to it to positively locate the parting line of the check ball on the ball seat 
-      * Standardized Sportster hand controls +      * Cam gear oiler - additional oil passage is located in gearcase to provide additional cam gear lubrication. ((HD Tech Tip #26 dated September 1991)) 
-      * Re-located ignition switch, now preventing scratching of the horn cover +      * New sprocket nut with a flange to increase the clamp load applied to the face of the sprocket. ((HD Tech Tip #29 dated April 1992)) 
-      * Continuously vented gas tank+      * Wrist pin clips have changed in color from silver to bronze for visual verification of installation ((HD Tech Tip #30 dated July 1992)) 
 +      * Improved brake pad material ​and discs ((HD Tech Tip #26 dated September 1991)) 
 +      * New halogen headlight assembly for improved resistant to vibration and longer service life ((HD Tech Tip #26 dated September 1991)) \\ New style wiring connector plug to maintain clearance inside the headlight bucket. ((HD Tech Top #34 dated July 1993)) 
 +      * New stronger ​headlight ​bracket offers better durability. ((HD Tech Tip #26 dated September 1991)) 
 +      * Standardized Sportster hand controls ​with Teflon Insert For Clutch Lever Pivot ((HD Tech Tip #26 dated September 1991)) 
 +      * Indicator Icons - Internationally identified symbols on the warning lamps for easier identification ((HD Tech Tip #26 dated September 1991)) 
 +      * Re-located ignition switch, now preventing scratching of the horn cover ((HD Tech Tip #26 dated September 1991)) 
 +      * Continuously vented gas tank ((HD Tech Tip #26 dated September 1991))
       * Harder plunger in neutral switch       * Harder plunger in neutral switch
-      * New style horn featuring more power+      * New front belt pulley nut retainer (two bolts retaining the sprocket nut plate to prevent loosening) ((HD Tech Tip #26 dated September 1991)) 
 +      * CV Carburetor changes- New float and needle design. Internal circuitry changed to create a "fast idle" feature ((HD Tech Tip #26 dated September 1991)) 
 +      * Formed fuel and VOES hoses ((HD Tech Tip #26 dated September 1991)) 
 +      * Improved enrichener cable - change in spring design to reduce tension needed to activate enrichener ((HD Tech Tip #26 dated September 1991)) 
 +      * Chassis Fastener Corrosion Protection - Ultra-Seal process insures that fasteners will not corrode ((HD Tech Tip #26 dated September 1991)) 
 +      * California Evap System - new "trap door" recovery system mounted on the air cleaner (butterfly valve activated by a solenoid)to open during engine operation. \\ This externally mounted system eliminates the reed valve from the intake tract. ((HD Tech Tip #26 dated September 1991)) 
 +      * Late '92 - Head bolt counterbore,​ spark plug s1de, was reduced in depth for ease of manufacturing (bolt length increased) ((HD Tech Tip #27 dated October 1991)) 
 +      * Late 1992 - Cylinder base gaskets changed to improve crush resistance and gasket seal-ability ((HD Tech Tip #30 dated July 1992)) 
 +      * In late September, fender struts were slotted to make service and accessory installation easier ((HD Tech Tip #27 dated October 1991)) 
 +  * **XLH 883 changes include**:​ 
 +      * New "​DID"​ O-ring final drive chain. ((HD Tech Tip #26 dated September 1991))
   * **XLH 883 Hugger changes include**: ​   * **XLH 883 Hugger changes include**: ​
-      * A thinner ​seat and lower suspension+      * Thinner contoured ​seat is 1-1/​2" ​lower than current Hugger (3" lower than XL1200) ((HD Tech Tip #26 dated September 1991)) 
 +      * Lower suspension ​accomplished with new forks, shocks and side stand ((HD Tech Tip #26 dated September 1991)) 
 +      * New "​DID"​ O-ring final drive chain. ((HD Tech Tip #26 dated September 1991)) 
 +  * **Deluxe 883 changes include**:​ 
 +      * New, embossed seat and buckhorn handlebars with handlebar mounted turn signals. \\ Early 1992 models will have turn signals mounted to triple clamp. ((HD Tech Tip #26 dated September 1991))
   * **XR-750** now has a key (replacing the splines) to drive the pinion and oil pump gears   * **XR-750** now has a key (replacing the splines) to drive the pinion and oil pump gears
   * **Paint Colors**:   * **Paint Colors**:
 +      * New clearcoat for all models ((HD Tech Tip #26 dated September 1991))
       * XL 883 (all models): Vivid Black, Bright Candy Ruby, Red Voyage Metallic, Candy Sapphire Sun-Glo. ((HD 1989-1996 Painted Parts Book pg 1-34))       * XL 883 (all models): Vivid Black, Bright Candy Ruby, Red Voyage Metallic, Candy Sapphire Sun-Glo. ((HD 1989-1996 Painted Parts Book pg 1-34))
       * XL 1200: Vivid Black, Bright Candy Ruby, Turquoise/ White, Dark Candy Ruby/ Bright Candy Ruby, Candy Sapphire Sun-Glo. ((HD 1989-1996 Painted Parts Book pg 1-34))       * XL 1200: Vivid Black, Bright Candy Ruby, Turquoise/ White, Dark Candy Ruby/ Bright Candy Ruby, Candy Sapphire Sun-Glo. ((HD 1989-1996 Painted Parts Book pg 1-34))
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 <font 15px/​inherit;;​inherit;;​inherit>​**1993**</​font>​ <font 15px/​inherit;;​inherit;;​inherit>​**1993**</​font>​
  
-  * MoCo notes+  ​* **MoCo notes**:
-    ​Now using an American made carbon emission filter manufactured by Miniature Precision Components in Delavan, Wisconsin.+
     * HD buys into the Buell Motorcycle Company, expanding it's capacity to further research and development. Erik Buell created the Company to manufacture American sport motorcycles using Harley-Davidson® XL 883 and 1200 engines.((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​1990.html))     * HD buys into the Buell Motorcycle Company, expanding it's capacity to further research and development. Erik Buell created the Company to manufacture American sport motorcycles using Harley-Davidson® XL 883 and 1200 engines.((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​1990.html))
     * New Buell/ HD model on the drawing board, the "​Thunderbolt"​.     * New Buell/ HD model on the drawing board, the "​Thunderbolt"​.
     * June 12th, for 90th year reunion, first time an interstate highway was ever closed down specifically for HD motorcycle riders. An estimated 100,000 people ride in a parade of motorcycles. ((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​1990.html))     * June 12th, for 90th year reunion, first time an interstate highway was ever closed down specifically for HD motorcycle riders. An estimated 100,000 people ride in a parade of motorcycles. ((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​1990.html))
     * June 12th, Willie G leads 15,000 strong, 35 miles North from the airport in Kenosha to the 90th year reunion held at Milwaukee'​s Summerfest grounds.     * June 12th, Willie G leads 15,000 strong, 35 miles North from the airport in Kenosha to the 90th year reunion held at Milwaukee'​s Summerfest grounds.
-  ​* Racing notes:+    * **Service notes**: 
 +      * While installing a tire on the rim, water based lubricants may contribute to corrosion of the rim. \\ Oil based lubricants can cause deterioration of the rubber of either the inner tube or the tire itself. ​ \\ It is recommended that you use a lubricant that is compatible with the rim and rubber components. ((HD Tech Top #34 dated July 1993)) 
 +    * **Parts notes**: 
 +      * Now using an American made carbon emission filter manufactured by Miniature Precision Components in Delavan, Wisconsin. 
 +      * Replacement screws for CV Carb float bowls no longer have the captive lockwashers. Testing has shown the lockwashers were not necessary. ((HD Tech Tip #33 dated January 1993)) ((HD Tech Tip #37 dated December 1993)) 
 +      * Two retrofit oil tank kits available for earlier Sportsters will retrofit to all 1982-1993 Sportsters (except XR-1000) ((HD Tech Top #34 dated July 1993)) 
 +        * 1982 - E1987  (62482-93) with flared brake lines 
 +        * L1987-1993 (62472-93) - with banjo brake lines 
 + 
 +  * **Racing notes**:
     * Scott Zampach wins the Twin Sports Championship     * Scott Zampach wins the Twin Sports Championship
   ​   ​
   ​   ​
-  * Production Information:​+  ​* **Production Information**:
       * XLH 883 $4,775       * XLH 883 $4,775
       * XLH 883 Hugger ​ $5,420       * XLH 883 Hugger ​ $5,420
       * XLH 883 Deluxe ​ $5,820       * XLH 883 Deluxe ​ $5,820
       * XLH 1200 $6,800       * XLH 1200 $6,800
-  ​* All models+ 
 +  * **All model changes include**:
       * Belt drive now on all Sportster models       * Belt drive now on all Sportster models
       * New Fuel Tank design with larger mounting holes & isolator grommets       * New Fuel Tank design with larger mounting holes & isolator grommets
       * Finger tip "​blade"​ profile brake and clutch levers on all models       * Finger tip "​blade"​ profile brake and clutch levers on all models
-  ​* Paint colors+      * Alternator rotor fasteners changed from countersunk Allen fasteners (41191-74) to hex bolts (4702) ((HD Tech Tip #30 dated July 1992)) 
 +      * New cast iron oil pump drive gear (26318-88A) for increased service life, implemented April 23, 1992, will retrofit to 88-later models ((HD Tech Tip #30 dated July 1992)) 
 +  * **Paint colors**:
       * XL 883 (all models): Vivid Black, Mandarin Orange, Scarlett Red, Bright Victory Red Sun Glo, Bright Aqua Sun Glo, Bright Aqua Sun Glo, Bright Victory Red Sun Glo, Scarlett Red. ((HD 1989-1996 Painted Parts Book pg 1-26))       * XL 883 (all models): Vivid Black, Mandarin Orange, Scarlett Red, Bright Victory Red Sun Glo, Bright Aqua Sun Glo, Bright Aqua Sun Glo, Bright Victory Red Sun Glo, Scarlett Red. ((HD 1989-1996 Painted Parts Book pg 1-26))
       * XL 1200: Vivid Black, Bright Victory Red Sun Glo, Scarlett Red, Dark Victory Red Sun-Glo/ Bright Victory Red Sun Glo, Bright Aqua Sun Glo/ Silver, Bright Wineberry Sun Glo, Silver/ Charcoal Satin Bright, Candy Sapphire Sun-Glo. ((HD 1989-1996 Painted Parts Book pg 1-26))       * XL 1200: Vivid Black, Bright Victory Red Sun Glo, Scarlett Red, Dark Victory Red Sun-Glo/ Bright Victory Red Sun Glo, Bright Aqua Sun Glo/ Silver, Bright Wineberry Sun Glo, Silver/ Charcoal Satin Bright, Candy Sapphire Sun-Glo. ((HD 1989-1996 Painted Parts Book pg 1-26))
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 <font 15px/​inherit;;​inherit;;​inherit>​**1994**</​font>​ <font 15px/​inherit;;​inherit;;​inherit>​**1994**</​font>​
  
-  * MoCo notes:+  ​* **MoCo notes**:
     * Harley-Davidson enters Superbike racing with the introduction of the VR1000, a dual overhead cam, liquid-cooled motorcycle. ((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​1990.html))     * Harley-Davidson enters Superbike racing with the introduction of the VR1000, a dual overhead cam, liquid-cooled motorcycle. ((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​1990.html))
     * The classically-styled FLHR Road King® is introduced. ((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​1990.html))     * The classically-styled FLHR Road King® is introduced. ((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​1990.html))
     * Las Vegas Metro Police unit now totals 8 HDs in their fleet     * Las Vegas Metro Police unit now totals 8 HDs in their fleet
-    * June 1st, Michigan State Police return to riding Harleys on the freeway ​  +    * June 1st, Michigan State Police return to riding Harleys on the freeway 
-  * Racing notes:+    * Service notes: 
 +      * New improved drive belt sprocket nut torquing procedure in production that is capable of doubling the clamp load across that critical joint. ((HD Tech Tip #35 dated August 1993)) 
 +    * **Parts notes**: 
 +      *  All HDI vehicles (except Japanese 1340, XL and Swiss XL) will have High Contact Ratio transmission gears. ((HD Tech Tip #35 dated August 1993)) 
 +      * Starting in late November, 1993, the paint shop changed the internal coating of the fuel tanks to a gray powder coating. ((HD Tech Tip #37 dated December 1993)) 
 + 
 +  ​* **Racing notes**:
     * In 1994, HD returned to the top level of pro road racing with the VR-1000 Superbike Race Team. Despite memorable performances during its eight-year run, including a pole position in 1996 and podium finishes by Pascal Picotte in 1999, Harley-Davidson concluded in 2001 that the VR 1000 was at the end of its development cycle and was no longer competitive in the AMA Superbike series. While the program was ended following the 2001 season, the VR 1000 Superbike racing program helped Harley-Davidson develop and refine technologies such as liquid-cooling and electronic fuel injection. The program also led to the development Harley-Davidson'​s first production liquid-cooled motorcycle, the 2002 VRSCA V-Rod. ((http://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​events/​racing/​racing-history.html))     * In 1994, HD returned to the top level of pro road racing with the VR-1000 Superbike Race Team. Despite memorable performances during its eight-year run, including a pole position in 1996 and podium finishes by Pascal Picotte in 1999, Harley-Davidson concluded in 2001 that the VR 1000 was at the end of its development cycle and was no longer competitive in the AMA Superbike series. While the program was ended following the 2001 season, the VR 1000 Superbike racing program helped Harley-Davidson develop and refine technologies such as liquid-cooling and electronic fuel injection. The program also led to the development Harley-Davidson'​s first production liquid-cooled motorcycle, the 2002 VRSCA V-Rod. ((http://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​events/​racing/​racing-history.html))
   ​   ​
   ​   ​
-  * Production Information:​+  ​* **Production Information**:
       * XLH 883       * XLH 883
       * XLH 883 '​Hugger'​       * XLH 883 '​Hugger'​
       * XLH 883 '​Deluxe'​       * XLH 883 '​Deluxe'​
       * XLH 1200       * XLH 1200
-  ​* Oil tank revised (visually identified by relocated oil drain line which now runs to the frame instead of nipple on underside of battery tray) + 
-  Replaced small Derby cover with large 4-bolt full Derby cover and quick-release clutch cable +  * **All model changes include**:​ 
-  * Revised rear struts – straight w/ chrome steel covers +      * Chamfer added to shift forks to permit adequate clearance of the fork in the new forged gear fork grooves. \\ The chamfer is needed for clearance in the fork groove in the forged slider gears being used in 1994 motorcycles. ((HD Tech Top #34 dated July 1993)) 
-  * New electrical system (wiring harness/​weatherproof ​electrical ​connectors +      ​* Oil tank revised (visually identified by relocated oil drain line which now runs to the frame instead of nipple on underside of battery tray) 
-  * New electrical component tray under the seat +      The oil tank and battery tray mounting brackets have been strengthened to make them more durable ((HD Tech Tip #35 dated August 1993)) 
-  * 883s got an aluminum ​lower triple clamp which was previously stock on only the 1200’s +      * Both the oil tank return and vent lines now routed above the sprocket ​cover on their way to the oil tank. ((HD Tech Tip #38 dated February 1994))  
-  * Interference-fit carburetor float pin pedestal on all models  +      * New rear frame section made of more durable forgings ​and rubber isolated rear fender at all mounting points ((HD Tech Tip #35 dated August 1993)) 
-  ​* Paint colors+      * Revised rear struts – straight w/ chrome steel covers 
 +      * New electrical system (wiring harness/​weatherproof ​Deutsch wiring ​connectors) 
 +      * New ignition switches with an accessory position ((HD Tech Tip #35 dated August 1993)) 
 +      ​* New electrical component tray under the seat 
 +      * New one-piece battery cables ((HD Tech Tip #35 dated August 1993)) 
 +      * Interference-fit carburetor float pin pedestal on all models 
 +      * All XL engines equipped with 1200cc style starter motors as a running change ((HD Tech Tip #38 dated February 1994)) 
 +      * New forged transmission gears (marked with a groove around their circumference for identification) ((HD Tech Tip #35 dated August 1993)) 
 +      * Fuel cap has a new 3/4 turn release feature ((HD Tech Tip #35 dated August 1993)) 
 +      * Rivets are no longer used to retain the mufflers ((HD Tech Tip #35 dated August 1993)) 
 +      * New stainless steel (single use) muffler clamps eliminate the need for silicone or graphite tape to ensure sealing ((HD Tech Tip #35 dated August 1993)) 
 +      * New style cylinder studs and a new silicone beaded base gasket as a L1994 running change. ((HD Tech Tip #39 dated July 1994)) 
 +      * New primary cover ((HD Tech Tip #35 dated August 1993)) 
 +      * Engine sprocket seal now is now reversed during installation with spring side facing engine ((HD Tech Tip #36 dated October 1993)) \\ Seal spacer I.D. also reduced to .995"​-1.000"​ for tighter fit on sprocket shaft (part numbers did not change) 
 +      * Replaced small Derby cover with large 4-bolt full Derby cover and quick-release clutch cable 
 +      * Primary/​transmission fluid level reduced from 40oz to 32oz \\ All 91-94 Sportsters can adopt this new fluid level without any component changes. ((HD Tech Tip #35 dated August 1993)) 
 +      * There has been a change in the material used to construct the wiper portion of valve guide seals. ((HD Tech Tip #35 dated August 1993)) 
 +      * Transmission'​s shifter return spring was redesigned (34481-91A) to eliminate any backlash present at the shifter shaft crank. ((HD Tech Tip #35 dated August 1993)) 
 +  * **XLH 883 changes include**:​ 
 +      * Aluminum ​lower triple clamp which was previously stock on only the 1200’s 
 +  * **Paint colors**":
       * XL 883 (all models): Vivid Black, Aqua Pearl, Bright Victory Red Sun-Glo.((HD 1989-1996 Painted Parts Book pg 1-18))       * XL 883 (all models): Vivid Black, Aqua Pearl, Bright Victory Red Sun-Glo.((HD 1989-1996 Painted Parts Book pg 1-18))
       * XL 1200: Vivid Black, Aqua Pearl/ Silver, Bright Victory Red Sun Glo, Dark Victory Red Sun-Glo/ Bright Victory Red Sun Glo, Aqua Pearl. ((HD 1989-1996 Painted Parts Book pg 1-18))       * XL 1200: Vivid Black, Aqua Pearl/ Silver, Bright Victory Red Sun Glo, Dark Victory Red Sun-Glo/ Bright Victory Red Sun Glo, Aqua Pearl. ((HD 1989-1996 Painted Parts Book pg 1-18))
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 <font 15px/​inherit;;​inherit;;​inherit>​**1995**</​font>​ <font 15px/​inherit;;​inherit;;​inherit>​**1995**</​font>​
  
-  * MoCo notes:+  ​* **MoCo notes**:
     * October 1st, HD announces plans to double production to 200,000 motorcycles annually by the year 2003 (100th anniversary)     * October 1st, HD announces plans to double production to 200,000 motorcycles annually by the year 2003 (100th anniversary)
     * HD announces the probability of building a new plant to accommodate the proposed increase in production.     * HD announces the probability of building a new plant to accommodate the proposed increase in production.
     * The 30th Anniversary Ultra Classic® Electra Glide® becomes the first production Harley-Davidson motorcycle to include sequential port electronic fuel injection. ((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​1990.html))     * The 30th Anniversary Ultra Classic® Electra Glide® becomes the first production Harley-Davidson motorcycle to include sequential port electronic fuel injection. ((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​1990.html))
  
-  * Fuel notes:+  ​* **Fuel notes**:
     * December, US phases out leaded gasoline for road-use vehicles.((http://​www.lead.org.au/​Chronology-Making_Leaded_Petrol_History.pdf)) ​     * December, US phases out leaded gasoline for road-use vehicles.((http://​www.lead.org.au/​Chronology-Making_Leaded_Petrol_History.pdf)) ​
   ​   ​
   ​   ​
-  * Production Information:​+  ​* **Production Information**:
       * XLH 883 $4,995       * XLH 883 $4,995
       * XLH Hugger 883 $5,700       * XLH Hugger 883 $5,700
       * XLH Deluxe 883 $6,120       * XLH Deluxe 883 $6,120
       * XLH 1200 $7,200       * XLH 1200 $7,200
-  * New Larger 3.25 gal gas tank on 1200 models (Bigger Peanut Tank - crimped bottom) + 
-  * New Vacuum operated petcock - Located on leftside of tank +  ​* **All model changes include**:​ 
-  * Ignition switch moved to steering column (because of petcock location) +      ​* New Vacuum operated petcock - Located on leftside of tank 
-  * New electronic speedometer with resettable trip-meter +      * Ignition switch moved to steering column (because of petcock location) 
-  * Paint colors+      * New electronic speedometer with resettable trip-meter 
 +      * Crankcase stamped number (1,2 or 3) to indicate the pinion race size moved to inside the gearcase below #2 cam bushing ((HD HD Tech Tip #40 dated October 1994)) 
 +  ​* **XL 1200 changes include**: ​  
 +     * New larger 3.25 gal gas tank (bigger peanut tank - crimped bottom) 
 +  * **Paint colors**:
       * XL 883 (all models): Vivid Black, Aqua Pearl, Bright Victory Red Sun Glo, Nugget Yellow, Burgundy Pearl. ((HD 1989-1996 Painted Parts Book pg 1-10))       * XL 883 (all models): Vivid Black, Aqua Pearl, Bright Victory Red Sun Glo, Nugget Yellow, Burgundy Pearl. ((HD 1989-1996 Painted Parts Book pg 1-10))
       * XL 1200: Vivid Black, Aqua Pearl, Aqua Pearl/ Silver, Bright Victory Red Sun Glo, Dark Victory Red Sun-Glo/ Bright Victory Red Sun Glo, Nugget Yellow/ Vivid Black. ((HD 1989-1996 Painted Parts Book pg 1-10))  ​       * XL 1200: Vivid Black, Aqua Pearl, Aqua Pearl/ Silver, Bright Victory Red Sun Glo, Dark Victory Red Sun-Glo/ Bright Victory Red Sun Glo, Nugget Yellow/ Vivid Black. ((HD 1989-1996 Painted Parts Book pg 1-10))  ​
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 <font 15px/​inherit;;​inherit;;​inherit>​**1996**</​font>​ <font 15px/​inherit;;​inherit;;​inherit>​**1996**</​font>​
  
-  * MoCo notes:+  ​* **MoCo notes**:
     * Jan 22nd, sale of the Holiday Rambler Recreational Vehicle Division to the Monaco Coach Corp. for $50 million.     * Jan 22nd, sale of the Holiday Rambler Recreational Vehicle Division to the Monaco Coach Corp. for $50 million.
     * Feb 5th, Initial attempt to trademark the '​Harley'​ (Potato-Potato) sound. Company spokeman Steve Piehl "We don't want the sound of our motorcycles to become the generic sound of motorcycles"​.     * Feb 5th, Initial attempt to trademark the '​Harley'​ (Potato-Potato) sound. Company spokeman Steve Piehl "We don't want the sound of our motorcycles to become the generic sound of motorcycles"​.
     * A new, state-of-the-art Parts and Accessories Distribution Center opens in Franklin, WI. By the beginning of 1997, all inventory is moved from the original warehouse at Juneau Avenue to the new 250,000 sq. ft. facility. ((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​1990.html))     * A new, state-of-the-art Parts and Accessories Distribution Center opens in Franklin, WI. By the beginning of 1997, all inventory is moved from the original warehouse at Juneau Avenue to the new 250,000 sq. ft. facility. ((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​1990.html))
     * August 24, HD breaks ground for a new production center in Kansas City, Missouri.     * August 24, HD breaks ground for a new production center in Kansas City, Missouri.
-  ​ +    * **Service notes**: 
-   +      * All OEM oil filters are interchangeable between models (however we recommend that you use the appropriate filter for the model). ((HD Tech Tip #43 dated September 1995)) 
-  * Production Information:​+      * All 1996 motorcycles should have the ignition timing checked with the vehicle at idle (950- 1050 rpm) ((HD Tech Tip #43 dated September 1995)) \\ (not at 1650-1950 rpm as with earlier models) 
 +      * A shortened the oil tank dipstick (62634-84A,​) allowed for communized use between Sportster and Softail models. \\ The location of the lower level mark is the same. The upper fill mark (not previously on Softails) is applicable to all models. ((HD Tech Tip #44 dated January 1996)) 
 +      * Have difficulty removing stubborn Allen fasteners from the clutch and brake levers housings? \\ A 4mm Allen wrench is a slightly tighter fit than a 5/32" Allen. The tighter fit makes it less likely to strip the head during removal. ((HD Tech Tip #44 dated January 1996)) 
 +      * The latest turn signal module (68537-89F) does not incorporate the 10 second delay feature found in earlier modules (required for 1990 and earlier models with self-cancelling turn signal kit (91860-88B). ((HD Tech Tip #44 dated January 1996)) 
 +      * Warmer weather will bring some motorcycles out of storage with a black spot in the odometer display. \\ Apparently the cold temperatures cause this. Running the vehicle in warmer temperatures will cause the spot to disappear. ((HD Tech Tip #45 dated April 1996)) 
 +      * Older mirrors sometimes get wobbly due to rust build-up on the pivot ball. \\ Loosen the screws and spray WD-40 into the pivot and rock the mirror for a minute or so, then retighten the screws. ((HD Tech Tip #45 dated April 1996)) 
 + 
 +  ​* **Production Information**:
       * XLH 883 $5,095       * XLH 883 $5,095
       * XLH Hugger 883 $5,760       * XLH Hugger 883 $5,760
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       * XLH 1200C Custom $7,910       * XLH 1200C Custom $7,910
       * XLH 1200S Sport $8,360       * XLH 1200S Sport $8,360
-  ​* All models received a larger gas tank now 3.3 gal w/rounded bottom edge on 1200 models + 
-  XL 1200S is a new model based on the XLH 1200 featuring ​adjustable-damping front forks, adjustable ​rear shocks ​and a slight power increase. The Sport was first to have  +  * **All model changes include**:​ 
-      * fully-adjustable front & rear suspension +      * New larger gas tank now 3.3 gal w/rounded bottom edge on 1200 models 
-      * dual front floating-disc brakes  +      Cast Wheels upgraded to 13-spokes 
-  * XL1200C, also based on the XLH 1200, features dual staggered shorty pipes, laced front 21" wheel and cast disc rear wheel with slots +      * New oil tank dipstick (see Service Notes above) 
-  * Handlebar switches revised to more rounded style +      * Improved adhesive for reflectors 
-  Cast Wheels upgraded to 13-spokes +      * The spoke nipple ​is a new style, as a running change, which requires a special Torx Plus driver for installation ((HD Tech Tip #44 dated January 1996)) 
-  ​First year for 1200 Custom and Sport models +      * New outer clutch release ramp (25409-94A) has the coupler ​on the inside of the ramp. 
-  ​* Paint colors +  * **XL 1200S**: 
-      * XL 883 (all models): Vivid Black, Patriot Red Pearl, States Blue Pearl, Platinum Silver, Mystique Green. ((HD 1989-1996 Painted Parts Book pg 1-2))+      * Fully adjustable damping front forks and rear shocks ​with a slight power increase 
 +      * Dual front floating disc brakes  
 +  ​* **XL1200C**: 
 +      * Dual staggered shorty pipes 
 +      * Laced front 21" wheel 
 +      * Cast disc rear wheel with slots 
 +      * Handlebar switches revised to more rounded style 
 +   ​* **Paint colors**: 
 +      * XL 883 (all models): Vivid Black, Patriot Red Pearl, States Blue Pearl, Platinum Silver, Mystique Green.((HD 1989-1996 Painted Parts Book pg 1-2))
       * XL 1200: Vivid Black, Patriot Red Pearl, States Blue Pearl, Violet Purple, Two tone Victory Sun Glo and Platinum, Two tone Violet and Red Pearl, Platinum Silver and Black.((HD 1989-1996 Painted Parts Book pg 1-2))        * XL 1200: Vivid Black, Patriot Red Pearl, States Blue Pearl, Violet Purple, Two tone Victory Sun Glo and Platinum, Two tone Violet and Red Pearl, Platinum Silver and Black.((HD 1989-1996 Painted Parts Book pg 1-2)) 
   ​   ​
Line 1890: Line 2077:
 <font 15px/​inherit;;​inherit;;​inherit>​**1997**</​font>​ <font 15px/​inherit;;​inherit;;​inherit>​**1997**</​font>​
  
-  * MoCo notes:+  ​* **MoCo notes**:
     * A new 217,000 sq. ft. Product Development Center opens next to the Capitol Drive plant in Milwaukee. The building is dedicated to Willie G. Davidson. ((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​1990.html))     * A new 217,000 sq. ft. Product Development Center opens next to the Capitol Drive plant in Milwaukee. The building is dedicated to Willie G. Davidson. ((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​1990.html))
     * Powertrain Operations at Capitol Drive expanded its capacity by moving FL engine and transmission production to a newly purchased plant located in Menomonee Falls. XL engines and transmissions,​ as well as Genuine Parts Manufacturing,​ remain at Capitol Drive.((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​1990.html))     * Powertrain Operations at Capitol Drive expanded its capacity by moving FL engine and transmission production to a newly purchased plant located in Menomonee Falls. XL engines and transmissions,​ as well as Genuine Parts Manufacturing,​ remain at Capitol Drive.((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​1990.html))
     * A new 330,000 sq. ft. plant in Kansas City produces its first Sportster. ((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​1990.html))     * A new 330,000 sq. ft. plant in Kansas City produces its first Sportster. ((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​1990.html))
 +    * **Service notes**:
 +      * New head torque procedure for Sportsters ((HD Tech Tip #46 dated October 1997))
 +      * If you replace a rear fender on a '94 and later XL model because of cracking, use P.N. (59722-98) rear fender brace kit. ((HD Tech Tip #46 dated October 1997))
 +      * Battery drain on Dyna and XLs may be due to the ignition switch not placed in the "​off"​ position when the key is removed. ((HD Tech Tip #46 dated October 1997))
 +      * Before replacing a voltage regulator for improper output, check grounds for good connections. Only 30% of regulators replaced have failed output tests. ((HD Tech Tip #46 dated October 1997))
 +      * If you encounter a front brake light flickering or staying on without use of brake, it may be due to the piston return spring not returning to proper length. ((HD Tech Tip #46 dated October 1997))
 +      * If you cannot get the round key into the lock, the tumbler shifts out of the index position when the key is removed. \\ This does not, however, disable the lock permanently. \\ These locks may still be operated by filing the ear from the key and inserting in the required lock position. This will help re-align tumbler. ((HD Tech Tip #46 dated October 1997))
   ​   ​
-  ​ +  ​* **Production Information**:
-  ​* Production Information:​+
       * XLH 883       * XLH 883
       * XLH 883 ‘Hugger’       * XLH 883 ‘Hugger’
Line 1902: Line 2095:
       * XLH 1200C ’Custom’       * XLH 1200C ’Custom’
       * XLH 1200S ’Sport’       * XLH 1200S ’Sport’
-  ​* Larger gas tank (3.3 gal) now on 883 models also+ 
 +  * **All model changes include**:​ 
 +  * **XLH 883 changes include**:​ 
 +    ​* Larger gas tank (3.3 gal)
  
  
Line 1910: Line 2106:
 <font 15px/​inherit;;​inherit;;​inherit>​**1998**</​font>​ <font 15px/​inherit;;​inherit;;​inherit>​**1998**</​font>​
  
-  * MoCo notes:+  ​* **MoCo notes**:
     * HD celebrates its 95th Anniversary. 140,000 plus riders are warmly received by Milwaukee to help with the celebration. ((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​1990.html))     * HD celebrates its 95th Anniversary. 140,000 plus riders are warmly received by Milwaukee to help with the celebration. ((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​1990.html))
     * A new assembly facility opens in Manaus, Brazil, the first operations outside of the U.S.((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​1990.html))     * A new assembly facility opens in Manaus, Brazil, the first operations outside of the U.S.((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​1990.html))
- 
     * HD buys a remaining 49% interest in Buell Motorcycle Company. Erik Buell is named Chairman of Buell operations. ((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​1990.html))     * HD buys a remaining 49% interest in Buell Motorcycle Company. Erik Buell is named Chairman of Buell operations. ((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​1990.html))
 +    * **Service notes**:
 +      * XL batteries cracks in the case is being caused by over tightening the battery hold down strap. \\ The strap nut should be tightened only until the assembly is secure, not to the end of the threads. ((HD Tech Tip #48 dated August 1998))
 +      * When replacing a speedometer on 883’s, label one of the black ground wires on the harness before cutting to ensure it's located on the new speedo correctly. \\ If the 2 black wires are switched, the unit will not power-up and function. ((HD Tech Tip #48 dated August 1998))
 +      * There was a minor change to the rocker box head gaskets (16778-84B) and (16779-84C) \\ The color changed from Gray to Green. The material is still the same, just a different color. ((HD Tech Tip #48 dated August 1998))
 +      * A process change for powder coat fluoride levels will cause the inside of the crankcase to look stained or burnt up. This change will allow the powder coat to bond better. ((HD Tech Tip #48 dated August 1998))
 +      * If you encounter a speedometer cable boot that is damaged at the drive end from contact with the brake rotor
 +screws, you should place silicone in the boot to seal against water entry and reinstall. ((HD Tech Tip #48 dated August 1998))
  
- +  * **Production Information**:
-  ​* Production Information:​+
       * XL 883       * XL 883
       * XL 883C '​Custom'​       * XL 883C '​Custom'​
Line 1924: Line 2125:
       * XL 1200C ’Custom’       * XL 1200C ’Custom’
       * XL 1200S ’Sport’       * XL 1200S ’Sport’
-  ​* Jiffy Stand gets replaceable bushings + 
-  * New ignition module (still dual-fire) - All in nosecone (except 1200S) +  * **All model changes include**:​ 
-  * First year for Bank Angle Sensor (BAS) (External - All models) +      ​* Jiffy Stand gets replaceable bushings 
-  * XL883C ​introduced with the standard ​883 powertrain on a 1200C chassis.((1998 HD Sportster Parts Catalog pg 135)) +      * New ignition module (still dual-fire) - All in nosecone (except 1200S) 
-  * XL1200S ​received upgrades+      * First year for Bank Angle Sensor (BAS) (External - All models) 
-      * 1200S only - Single-fire ignition module (underseat) & quad-output coil +  ​* **XL883C**: 
-      * 1200S only - Dual-plug Buell Lightning heads (with hotter '​W'​ cams) +      * Standard ​883 powertrain on a 1200C chassis.((1998 HD Sportster Parts Catalog pg 135)) 
-      * 1200S only - Manifold Air Pressure (MAP) Sensor (NO VOES)+  ​* **XL1200S ​changes include**
 +      * Engine compression increased to 10:1 
 +      * Single-fire ignition module (underseat) & quad-output coil 
 +      * Dual-plug Buell Lightning heads (with hotter '​W'​ cams) 
 +      * Manifold Air Pressure (MAP) Sensor (NO VOES) 
 +  * **Paint Colors**: 
 +      * XL1200S: Vivid Black, color option code (024). 
    
 {{common:​space100x5px.jpg?​200|}}[[sportster_history:​99xx-01|{{:​sportster_history:​gotohistorymainmenu.jpg|}}]] \\ {{common:​space100x5px.jpg?​200|}}[[sportster_history:​99xx-01|{{:​sportster_history:​gotohistorymainmenu.jpg|}}]] \\
Line 1938: Line 2146:
 <font 15px/​inherit;;​inherit;;​inherit>​**1999**</​font>​ <font 15px/​inherit;;​inherit;;​inherit>​**1999**</​font>​
  
-  * MoCo notes:+  ​* **MoCo notes**:
     * The Touring and Dyna motorcycle families receive the new Twin Cam 88® engine. ((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​1990.html))     * The Touring and Dyna motorcycle families receive the new Twin Cam 88® engine. ((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​1990.html))
 +    * **Parts notes**:
 +      * There was a change made to the Sportster transmission detent plate to improve shift quality. The zinc die cast part has had a material change to powdered metal. The ramps were redesigned as well. The new part number is PN 33656-90A. This retrofits to all five speed XL’s 1991 and later. This change occurred on April 22, 1999. ((HD Tech Tip #50 dated June 1999)) ​
   ​   ​
-  ​ +  ​* **Production Information**:
-  ​* Production Information:​+
       * XLH 883       * XLH 883
       * XLH 883 ‘Hugger’       * XLH 883 ‘Hugger’
Line 1950: Line 2159:
       * XLH 1200S ’Sport’       * XLH 1200S ’Sport’
  
 +  * New transmission shift detent plate (see Service Notes) ((HD Tech Tip #50 dated June 1999))
 +  * First Year for 1200C Forward Controls (stock)
 + 
 {{common:​space100x5px.jpg?​200|}}[[sportster_history:​99xx-01|{{:​sportster_history:​gotohistorymainmenu.jpg|}}]] \\ {{common:​space100x5px.jpg?​200|}}[[sportster_history:​99xx-01|{{:​sportster_history:​gotohistorymainmenu.jpg|}}]] \\
  
Line 1957: Line 2169:
 <font 15px/​inherit;;​inherit;;​inherit>​**2000**</​font>​ <font 15px/​inherit;;​inherit;;​inherit>​**2000**</​font>​
  
-  * MoCo notes:+  ​* **MoCo notes**:
     * The FXSTD Softail® Deuce™ is introduced .((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​2000.html))     * The FXSTD Softail® Deuce™ is introduced .((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​2000.html))
     * The 2000 model year Softail® models are outfitted with the Twin Cam 88B™ engine, a counter-balanced version of the Twin Cam 88. ((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​2000.html))     * The 2000 model year Softail® models are outfitted with the Twin Cam 88B™ engine, a counter-balanced version of the Twin Cam 88. ((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​2000.html))
-    *  Buell introduces the Blast®, a single-cylinder motorcycle. ((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​2000.html)) ​  ​ +    *  Buell introduces the Blast®, a single-cylinder motorcycle. ((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​2000.html)) 
-  * Fuel notes:+    * **Parts notes**: 
 +      * 22 amp and 32 amp voltage regulators are now being painted with a tougher, longer lasting powder coat paint. \\ As a result of testing, a dedicated ground wire will soon be added to XLs produced in Kansas City ((HD Tech Tip #51 dated December 1999)) 
 + 
 +  ​* **Fuel notes**:
     * European Union bans leaded gasoline at the pump.((http://​www.lead.org.au/​Chronology-Making_Leaded_Petrol_History.pdf))     * European Union bans leaded gasoline at the pump.((http://​www.lead.org.au/​Chronology-Making_Leaded_Petrol_History.pdf))
   ​   ​
   ​   ​
-  * Production Information:​+  ​* **Production Information**:
       * XL883       * XL883
       * XL883 '​Hugger'​       * XL883 '​Hugger'​
Line 1977: Line 2192:
       * First year for 4-piston calipers       * First year for 4-piston calipers
       * Pressed together flywheel assembly (supposed to be stronger and hold it’s trueness better)       * Pressed together flywheel assembly (supposed to be stronger and hold it’s trueness better)
-      * New anti-rotation pins are individual screw pins (no plate to hold them as previously)+      * New lifter ​anti-rotation pins are individual screw pins (no plate to hold them as previously
 +      * New AGM type batteries ((HD Tech Tip #52 dated June 2000))
  
  
Line 2005: Line 2221:
 <font 15px/​inherit;;​inherit;;​inherit>​**2002**</​font>​ <font 15px/​inherit;;​inherit;;​inherit>​**2002**</​font>​
  
-  * MoCo notes:+  ​* **MoCo notes**:
     * The Buell® Firebolt® is introduced.((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​2000.html))     * The Buell® Firebolt® is introduced.((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​2000.html))
     * The Open Road Tour debuts in Atlanta, GA, in July to celebrate the upcoming Harley-Davidson 100th Anniversary.((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​2000.html))     * The Open Road Tour debuts in Atlanta, GA, in July to celebrate the upcoming Harley-Davidson 100th Anniversary.((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​2000.html))
-  ​* Racing notes:+    * **Parts notes**: 
 +      * A one-piece metal gasket (18800-84) will replace the two piece paper lower rocker gaskets (16779-84D and 16778-84B). This new gasket is not reuseable. \\ When installing this gasket make sure the letters and numbers printed on the gasket are facing upward. Torque values remain the same. 
 + 
 +  * **Racing notes**:
     * HD launched the Screamin'​ Eagle/Vance & Hines Pro Stock Motorcycle team in 2002 with rider GT Tonglet to compete in the NHRA Drag Racing Series. Harley-Davidson teamed with Vance & Hines Motorsports,​ winner of 23 NHRA titles, to develop a V-Twin engine that would be competitive with the four-cylinder engines prevalent in the Pro Stock Motorcycle class. ((http://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​events/​racing/​racing-history.html))     * HD launched the Screamin'​ Eagle/Vance & Hines Pro Stock Motorcycle team in 2002 with rider GT Tonglet to compete in the NHRA Drag Racing Series. Harley-Davidson teamed with Vance & Hines Motorsports,​ winner of 23 NHRA titles, to develop a V-Twin engine that would be competitive with the four-cylinder engines prevalent in the Pro Stock Motorcycle class. ((http://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​events/​racing/​racing-history.html))
   ​   ​
   ​   ​
-  * Production Information:​+  ​* **Production Information**:
       * XL883       * XL883
       * XL883 '​Hugger'​       * XL883 '​Hugger'​
Line 2051: Line 2270:
 <font 15px/​inherit;;​inherit;;​inherit>​**2004**</​font>​ <font 15px/​inherit;;​inherit;;​inherit>​**2004**</​font>​
  
-  * MoCo notes:+  ​* **MoCo notes**:
     * For the 2004 model year, the Sportster® family models receive rubber engine mounting, a new frame, and a wider rear tire. Some Sportster® models receive a redesigned gas tank. ((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​2000.html))     * For the 2004 model year, the Sportster® family models receive rubber engine mounting, a new frame, and a wider rear tire. Some Sportster® models receive a redesigned gas tank. ((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​2000.html))
-    * The FLHRSI Road King® Custom is introduced. With its low rear suspension and wide handlebars, the FLHRSI brings a beach look to a classic Harley-Davidson motorcycle. ((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​2000.html)) ​+    * The FLHRSI Road King® Custom is introduced. With its low rear suspension and wide handlebars, the FLHRSI brings a beach look to a classic Harley-Davidson motorcycle. ((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​2000.html)) 
 +    * **Parts notes**: 
 +      * Fuel tanks on all 2004 Sportster and Dyna models, and Softail models produced after January 2004, are made from NiClad carbon steel. This material resists corrosion and eliminates the need for an epoxy coating inside the tank. ((HD Tech Tip #58 dated March 8-2004))
   ​   ​
   ​   ​
Line 2090: Line 2311:
     * The XL 883L Sportster® 883 Low brings a lowered seating position to the Sportster® line.((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​2000.html))     * The XL 883L Sportster® 883 Low brings a lowered seating position to the Sportster® line.((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​2000.html))
     * The FLSTNI Softail® Deluxe adds a sleek look to the Softail® line and a paint scheme reminiscent of 1939 Harley-Davidson motorcycles. Also, the FLSTSC/I Softail® Springer® Classic revives looks from the late 1940s. ((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​2000.html))     * The FLSTNI Softail® Deluxe adds a sleek look to the Softail® line and a paint scheme reminiscent of 1939 Harley-Davidson motorcycles. Also, the FLSTSC/I Softail® Springer® Classic revives looks from the late 1940s. ((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​2000.html))
-    * Harley-Davidson and the Muscular Dystrophy Association (MDA) mark the 25th anniversary of their partnership. ((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​2000.html)) ​+    * Harley-Davidson and the Muscular Dystrophy Association (MDA) mark the 25th anniversary of their partnership. ((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​2000.html)) 
 +    * **Service notes**: 
 +      * The torque has been increased for the flywheel sprocket nut for 2004-Later Sportsters from 190-210 to 240-260 ft lbs. ((HD Tech Tip #211 dated 9-16-2005)) \\
   ​   ​
   ​   ​
Line 2102: Line 2325:
       * XL1200R '​Roadster'​       * XL1200R '​Roadster'​
   * Swing arm & rear wheel re-designed including a 1″ [[techtalk:​evo:​wheels01#​rear_axles|rear axle]] and a 1" Sealed 4SSR [[techtalk:​evo:​wheels01#​rear_axle_bearings|wheel bearing]].   * Swing arm & rear wheel re-designed including a 1″ [[techtalk:​evo:​wheels01#​rear_axles|rear axle]] and a 1" Sealed 4SSR [[techtalk:​evo:​wheels01#​rear_axle_bearings|wheel bearing]].
-  * Last year for straight cut gears in the transmission. ((Rico 05R of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=32308&​page=2)) +  * Last year for straight cut gears in the transmission. ((Rico 05R of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-general-discussion-and-problems/​19467-sportster-timeline/​page2?​t=32308&​page=2)) 
-  * Shifter shaft diameter and thus the primary cover different due to bushing opening being larger in 2005 from 2004 ((LuxBlue of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​t=32308&​page=3))+  * Shifter shaft diameter and thus the primary cover different due to bushing opening being larger in 2005 from 2004 ((LuxBlue of the XLFORUM ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-general-discussion-and-problems/​19467-sportster-timeline/​page3?​t=32308&​page=3))
  
  
Line 2204: Line 2427:
       * Front rotors 11.5" x .20" (292.10 mm x 5.08 mm) uniform expansion type.       * Front rotors 11.5" x .20" (292.10 mm x 5.08 mm) uniform expansion type.
       * Rear rotors 10.24" x .28" (260 mm x 7.01 mm)       * Rear rotors 10.24" x .28" (260 mm x 7.01 mm)
 +  * HDI Only - 1st year Jiffy Stand Interlock
  
 {{common:​space100x5px.jpg?​200|}}[[sportster_history:​99xx-01|{{:​sportster_history:​gotohistorymainmenu.jpg|}}]] \\ {{common:​space100x5px.jpg?​200|}}[[sportster_history:​99xx-01|{{:​sportster_history:​gotohistorymainmenu.jpg|}}]] \\
Line 2213: Line 2437:
     * Harley-Davidson announces expansion into India. ((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​2000.html))     * Harley-Davidson announces expansion into India. ((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​2000.html))
     * The 2009 model year brings the first three-wheeler for public purchase in the new FLHTCUTG Tri Glide Ultra Classic. Also new is the history-inspired Cross Bones, a bobbed factory custom.((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​2000.html))     * The 2009 model year brings the first three-wheeler for public purchase in the new FLHTCUTG Tri Glide Ultra Classic. Also new is the history-inspired Cross Bones, a bobbed factory custom.((https://​www.harley-davidson.com/​content/​h-d/​en_US/​home/​museum/​explore/​hd-history/​2000.html))
 +    * On October 30, 2009, Buell Motorcycle Company closed its doors, bringing an end to a 26-year run.
   ​   ​
   ​   ​
Line 2340: Line 2565:
       * XL1200V '​72'​       * XL1200V '​72'​
   * First year of XL1200T '​SuperLowT'​   * First year of XL1200T '​SuperLowT'​
-  * **Significant changes for 2014 ((http://​xlforum.net/​forums/showpost.php?p=4545852&​postcount=162)):​**+  * **Significant changes for 2014 ((https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-general-discussion-and-problems/​154763-2014-dealer-meeting/​page11?​postcount=162#​post3314957)):**
     * All 2014 Sportsters will utilize the "HDLAN electrical system"​ (aka CANBus). ​     * All 2014 Sportsters will utilize the "HDLAN electrical system"​ (aka CANBus). ​
     * The BCM (Body Control Module) controls all things electrical; including the horn, headlight, and starter. ​     * The BCM (Body Control Module) controls all things electrical; including the horn, headlight, and starter. ​
Line 2353: Line 2578:
       * The rear brake is now a dual 35 mm piston.       * The rear brake is now a dual 35 mm piston.
       * ABS optional.       * ABS optional.
-      * All models now fitted with a side mounted rear master cylinder (41700025). ((Redbeard2 of the XLFORUM ​http://​xlforum.net/​forums/showthread.php?​p=5704246#post5704246))+      * All models now fitted with a side mounted rear master cylinder (41700025). ((Redbeard2 of the XLFORUM ​https://www.xlforum.net/​forum/forum-functions/​sportsterpedia-com-admin/​191119-send-a-note-to-sportsterpedia-admin/​page5#post4238440))
     * Bikes fitted with the security system will be shipped for "​keyless"​ operation and ignition switch eliminated.     * Bikes fitted with the security system will be shipped for "​keyless"​ operation and ignition switch eliminated.
     * The rear swing arm mounting changes. ​   ​     * The rear swing arm mounting changes. ​   ​
Line 2383: Line 2608:
       * XL883N '​Iron'​       * XL883N '​Iron'​
       * XL1200C '​Custom'​       * XL1200C '​Custom'​
 +      * XL1200CX '​Roadster'​
       * XL1200T '​SuperLowT' ​       * XL1200T '​SuperLowT' ​
       * XL1200X '​48'​       * XL1200X '​48'​
Line 2453: Line 2679:
  
   * Production Information:​   * Production Information:​
-      * ??? +      * XL883L SuperLow 
- +      * XL883N Iron 883 
 +      * XL1200C 1200 Custom 
 +      * XL1200CX Roadster 
 +      * XL1200T SuperLow 1200T 
 +      * XL1200NS Iron 1200 
 +      * XL1200X Forty-Eight 
 +      * XL1200XS Forty-Eight Special
  
  
Line 2461: Line 2692:
  
  
-. 
  
-----+<font 15px/​inherit;;​inherit;;​inherit>​**2021**</​font>​
  
-.+  * Production Information:​ 
 +      * XL883N Iron 883 
 +      * XL1200NS Iron 1200 
 +      * XL1200X Forty-Eight
  
- 
-==== Sportster Parts Chart ==== 
- 
-This is a chart of the variation in parts that appear on different years of Sportsters… For instance, the size of the axles -and- the various brake pads used… (( Chart by IXL2Relax of the XLFORUM)) {{:​sportster_history:​sportster-model-year-parts.gif?​direct&​}} 
- 
-==== Sportster Model Years in Production ==== 
- 
-Additional information needed to complete the Ironhead chart (( Chart by IXL2Relax of the XLFORUM)) 
- 
-{{:​sportster_history:​sportster-ironhead-models-years.jpg?​direct&​}} 
- 
-{{:​sportster_history:​sportster-evolution-models-years.jpg?​direct&​}} 
  
 {{common:​space100x5px.jpg?​200|}}[[sportster_history:​99xx-01|{{:​sportster_history:​gotohistorymainmenu.jpg|}}]] \\ {{common:​space100x5px.jpg?​200|}}[[sportster_history:​99xx-01|{{:​sportster_history:​gotohistorymainmenu.jpg|}}]] \\
  
 +.
  
 +----
  
 +.
 ====== Sportsters Specifications by Specific Year ====== ====== Sportsters Specifications by Specific Year ======