This is an old revision of the document!


1968 Sportster

Model Production Numbers

  • XLH 1,975
  • XLCH 4,900

Colors 1)

  • Black with Black Wrinkle tank panels and White Strip.
  • On black bikes, the tank panel was most likely plain black, not wrinkle.
  • Jet Fire Orange with Black Wrinkle tank panels and White Strip.
    • Options:
    • Sparkling Burgundy with Black Wrinkle tank panels and White Strip.
    • Sparkling Blue with Black Wrinkle tank panels and White Strip.

Vehicle Identification

Frame Numbers

There was no frame identification for purpose of ownership on 1957-1969 model Sportsters.
However, there were stampings on the different parts of the frame combined with certain features that can be used to date the frame.
Click Here to view Ironhead Frame Identification in the Sportsterpedia.

Engine Serial Numbers

The only numbers for the purpose of identification were on the engine case.

  • The engine serial number is stamped on the left side of the engine case between the two cylinders.
    The first 5 or 6 digits represent the year and model 2)
    From 1962-1969, models with 4 digit production (serial) numbers have an even-numbered first digit for even years and odd numbered first digit for odd years.

Click Here for more specific information on serial numbers and VINs in the Sportsterpedia (including the 1962-1969 Even/Odd Rule).

Engine Serial Number for 1968 Sportsters
Model Year
(first 2 digits)
Model
(next few digits)
(up to 4)
Sequential
Serial#
(remaining digits)
68XLH
XLCH
(example)
12345
Example: (68XLCH 12345) indicates a 1968 XLCH model and is stamped on the Left Engine Case Between the Cylinders 3)
Example Serial Number on Engine Reads: 68XLCH12345
68 XLCH 12345

Specifications

Click Here for the main technical menu in the Sportsterpedia.
Also see the “Misc Resources” section on the bottom of that page for technical docs and information.

Model Designations

  • XLH, XLCH

Dimensions

  • Wheelbase: 4)
    • XLH, 56.5 in / 143.51 cm
    • XLCH, 58-1/2 in / 148.59 cm
  • Overall Length:
    • XLH, 89 in / 226.06 cm
    • XLCH, 83.25 in / 211.45 cm
  • Overall Width:
    • XLH, 34 in / 86.36 cm
    • XLCH, 34 in / 86.36 cm
  • Overall Height:
    • XLH, 40-1/2 in / 103 cm
    • XLCH, 42 in / 106.7 cm
  • Road Clearance:
    • XLH, 5-1/2 in to 6-3/4 in / 13.97 cm to 17.14 cm 5) (67 and 69 FSMs differ)
    • XLCH, 6-1/2 in to 6-7/8 in / 16.51 cm to 17.46 cm

Engine

  • Engine type: 4 cycle Overhead Valves, 45 degree V2 6)
  • Hemi-spherical style heads
  • Displacement: 53.9 ci / 883 cc (900 cc advertised)
  • Compression Ratio: 9:1
  • Bore: 3 in / 76.2 mm
  • Stroke: 3.8125 in / 96.8 mm
  • Horsepower: 55 @ 6,300rpm 7)
  • Taxable Horsepower: 7.2
  • Torque: 52 ft-lb @ 3800 RPM
  • Weight:
    • XLCH - 188lbs.
    • XLH - 204 lbs.
  • Engine serial number stamped on left side case between the two cylinders.
    Click Here for more information on serial numbers and VINs in the Sportsterpedia.
  • 4 Cams
  • Gear driven type oil pump.
    Oil pump pressure (gauge mounted in place of oil pressure switch):
    • Idle, with spark retarded (Min: 3-7 psi)
    • Normal riding conditions: 10-14 psi (6 psi at 20 mph)
  • XLH Ignition: Battery Ignition System (circuit breaker/points/timer/distributor)
    • Point Gap: .020“
  • XLCH Ignition: Magneto Ignition System
    • Point Gap: .015”
  • Dwell: 90° at 1000 RPM
  • Ignition Timing
    • Advanced - XLH, XLCH: 45° (11/16“) BTDC
    • Retarded - XLH: 15° (5/64”) BTDC
  • Spark Plugs
    • #4 for everyday use.
    • #5 for hard service.
      • Gap
        • XLH: .025“-.030”
        • XLCH: .020“
  • Fuel System: Tillotson HD carburetor.
  • Starter

Capacities

  • Fuel Capacity: 8)
    • XLH 4 gal / 15.14 l
    • XLCH 2.2 gal / 8.328 l
  • Oil Capacity: 3 qts. / 2.83 l
  • Transmission Capacity: 1.5 pints / .71 l

Clutch

  • Multi-Disc dry clutch-pack with alternate steel and fiber friction plates.9)

Drivetrain

  • Constant Mesh - right side foot shift 10)
  • Speeds - 4 Forward
  • Number of Sprocket Teeth (XLH / XLCH):
    • Engine: 34
    • Clutch: 59
    • Transmission: 20
    • Rear Wheel: 51
  • Standard Gear Ratios (XLH / XLCH)
    • 1st: 11.16:1
    • 2nd: 8.08:1
    • 3rd: 6.11:1
    • 4th: 4.42:1

Tires

Tire pressure (based on a rider weighing app. 150 lbs or more).
For each 50 lbs of overload, increase rear tire pressure by 2 lbs, front by 1 lb (but not exceeding manuf max tire pressure). 11)

  • XLH / XLCH:
    • Front: 3.25 / 3.50 x 19 (tire Pressure: 16 psi / 1.10 bar) 12)
    • Rear: 4.0 x 18 (tire pressure: 20 psi / 1.37 bar) 13)

XLH 883

What is the Current KBB Value? 14)

XLCH 883

What is the Current KBB Value? 15)

Engine

16)

2)
HD Parts Catalog XLH/XLCH-1000 #(99451-78)
3)
1953-1963 HD Parts Catalog backside of front cover
4) , 6) , 7) , 8)
Harley-Davidson 1957 - 1969 Service Manual
5)
HD 1969 Sportster Service Manual
9)
1957-1969 HD FSM pg 4A-3
10)
1957-1969 HD FSM pg 1A-3
11)
1959-1964 HD FSM pg 1A-3
12) , 13)
HD TSB #516A dated October 15, 1966
This website uses cookies for visitor traffic analysis. By using the website, you agree with storing the cookies on your computer.More information