Table of Contents

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IH: Body Parts

FUEL TANKS

Fuel Cap

  • All 1983 XL/FXR models produced after VIN (1HD1CCH17DY113282) and FL/FX models pro­duced after VIN (1HD1AKK16DY011657) use a new low pressure fuel tank cap. The vent relief pressure has been reduced on the screw type fuel caps by utilizing a softer spring. 1)
  • The low pressure cap was suggested for use on any 1982 FXR/FXRS or any early build 1983 model, except FLT/FLHT, produced before the above VINs that experiences a lean condition (carburetor spit, poor performance or surging). which should eliminate the problem. No labor was be paid to the dealer for changing out the caps upon servicing.
    • The new low pressure cap (61060-82A)for FXR/FXRS can be identified while viewing the inside as having 4 veins (or spokes) instead of 8 with the high pressure cap (61060-82).
    • For all other models, the new low pressure cap (61102-83A) can be identified by pressing down on the relief vent with a pencil, pen etc. The low pressure cap has a weaker spring than the high pressure cap (61102-83) beneath the relief vent in the center and the difference in spring pressure can be felt.

Petcock

Petcock Changes Per Year 2) 3) 4) 5) 6) 7) 8) 9)
57-74 XL/XLH
65-74 XLCH		62125-55BVertical outlet, no reserve
75 XLH/XLCH62160-75 10)Vertical outlet, no reserve
E76 XLH/XLCH62163-75 11)Vertical outlet using Bendix carb, no reserve 12)
L76-80 XLH/XLCH/XLS62164-76Horizontal outlet using Keihin carb, no reserve 13)
80 XLS62165-77Horizontal outlet, no reserve
81-85 XLS
84-85 XLH		62167-81Horizontal outlet with reserve tube
These two part numbers were available for parts order for 81-85 XLH or XLS
81-83 XLH
83-85 XLX		62169-81

Inspection
You can inspect the screen / filter with a flashlight thru the filler hole in the top of the tank to determine if it needs cleaning or repair.
If the filter is OK, you can inspect / rebuild the petcock without uninstalling it from the fuel tank. 14)

FENDERS

Rear Fender Reinforcement Bracket

  • Beginning with late production XL and XLCH models during March of 1974, a spot-welded reinforcement section has been added underneath the fender at the license plate bracket mounting holes. This was done to strengthen that area on the fender where the security system alarm is mounted to protect against cracking of the mounting holes in the fender. 15)
  • A bolt on version was made available for Early 1974 Sportster models as a replacement on models that had already left the factory before this upgrade was done. It was recommended that the dealer install the bolt on version on all 1973 and 1974 models that were equipped with the security system.
  • The bracket (59770-73A) had to be modified at the dealership to fit Sportster models where the bracket (59714-74) for FX and FXE models were a bolt and go. The Sportster bracket was made with tabs on the ends that had to be cut off with a hacksaw to allow for the tail light wiring. 16)

FRAMES

  • From 1957-1969, the VIN is not stamped on the frame. The numbers stamped on the engine are the only useable VIN numbers.
  • From 1970 to present, the frame is stamped with VIN numbers and the engine numbers do not apply to VIN.
  • See Also: History and Charts of Sportster VIN Changes
  • Anti-theft numbers are also printed on some pre-70 frames. 17)
  • More from the XLFORUM starting in post #216 on Frame ID
  • Also refer to the technical section of the Harley K Model site http://www.harleykmodel.com/technical/index.html. Scroll down to frames and download the PDF. 18)
Frame (complete)Part #
1952-1955
All K Models		47014-52B
(replaces 47014-52A) 19) 20)21)
1956 KH 47014-56 22) 23) 24) 25)
1958 XLC47014-58 26) 27)
1957- 1964 XL/XLH47014-56 28) 29) 30) 31)
1965 XL/XLH47014-65 32)
1966 XL/XLH47014-56A 33)
1967 XL/XLH47014-67 34)
1070-1971 XL/XLH47014-67B 35)
1972 XL/XLH47014-70B 36)
1958-1965 XLCH47014-58 37) 38) 39)
1966-1967 XLCH47014-66 40)
1968-1969 XLCH47014-66A 41)
1970-1971 XLCH47014-70A 42)
1972 XLCH47014-70B 43)
1973-1976 XLH/XLCH47014-73 44)
1977-1978 XLH/XLCH
(with steering head cups)		47012-78 45)
1979 XL/XLCH/XLS47265-79 46) 47)
1980-81 XL/XLS47265-80 48)
1982 XL/XLS47265-81A 49)
1983-E1984 XL/XLS/XLX47292-83 50)
L1984-1985 XL/XLS/XLX47150-84 51)


1)
HD Service Bulletin #M-859 dated October 29, 1982
2)
1954-1976 HD Sportster Parts Catalog pg 115
3)
1979 HD Sportster Parts Catalog pg 65
4)
1979-1980 HD Sportster Parts Catalog pg 73
5)
1979-1981 HD Sportster Parts Catalog pg 87
6)
1979-1982 HD Sportster Parts Catalog pg 95
7)
1979-1983 HD Sportster Parts Catalog pg 93
8)
1979-1984 HD Sportster Parts Catalog pg 99
9)
1979-1985 HD Sportster Parts Catalog pg 103
10)
1975 HD Sportster Parts Catalog Supplement
11)
1976 HD Sportster Parts Catalog Supplement
12) , 13)
1954-1978 HD Sportster Parts Catalog Supplement
14)
IronMick of the XLFORUM http://xlforum.net/vbportal/forums/showthread.php?t=1583571
15)
HD Service Bulletin #661 dated April 15, 1974
16)
HD Instruction sheet for Part #59770-73A, 59770-74 orig 3-74
17) , 18)
Chuckthebeatertruck http://xlforum.net/vbportal/forums/showthread.php?threadid=2032196
19) , 22) , 28)
1952-1957 Spare Parts Catalog for all Sportster and K Models pg 38
20) , 23) , 26) , 29) , 37)
1952-1959 Spare Parts Catalog for All Sportster and K Models pg 44
21) , 24) , 27) , 30) , 38)
1963 HD Parts Catalog for 53-63 Sportsters and K Models pg 50
25) , 31)
http://www.harleykmodel.com/technical/frames/oskrg-bulletin-1-v1.1.pdf
32) , 33) , 34) , 35) , 36) , 39) , 40) , 41) , 42) , 43)
http://www.harleykmodel.com/technical/frames/oskrg-bulletin-1-v1.1.pdf pg 32
44) , 45)
HD Parts Catalog #99451-78B for '54-'78 Sportsters pg 111
46)
1979 HD Sportster Parts Catalog pg 53
47) , 48) , 49) , 50) , 51)
1979-1985 HD Sportster Parts Catalog pg 87
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Trace: • W E L C O M E ! • EVO: Wheels, Brakes & Tires • IH: Electrical System - Sub-03T • IH: Body Parts