1991 Sportster

Vehicle Identification Number (VIN)

Example: 1HD1CAP16MY201624 appears on steering head. Abbreviated VIN appears on engine crankcase - CAP16MY201624


Motorcycle Origin

Manufacturer/ Make

Motorcycle Displacement Type

Model Designation

Engine Size

Introduction Date / Special Models

VIN Check Digit

Model Year

Assembly Plant

Serial Number
Made in USA Harley Davidson 1 = 901 cc & up
4 = 351-900 cc
CA = XLH 883
CF= XLH 883 Deluxe
CE = XLH 883 Hugger
CA= XLH 1200
M = 883 CC ENGINE
P = 1200 CC ENGINE
1 = Regular
2 = Mid Year Intro Date
3 = California Models
Can be
0 - 9 or X
M = 1991
Y = YORK, PA

K = Kansas City, MO
1 HD 1 CA P 1 6 M Y 201624

Related Manuals and Documentation

Below are some suggestions for manuals for your ride.
You should have, at minimum, a Factory Service Manual (FSM) and a Factory Parts Catalog for your year model.
Note: Updated manuals sometimes correct mistakes from the original manuals and some are updated simply to add mid year intro models.

Factory Service Manuals (FSM);
The FSM will have the most accurate information, procedures and specs.
Clymer and Haynes make service manuals also for Sportsters but some of the information is in error to the factory FSMs.
And some of the information in the aftermarket manuals is vague in information or procedures but they may have more pictures.
So it is generally said you can get use from both an aftermarket manual and the factory service manuals but get the factory manual first.
Click Here to view the Factory Service Manual page in the Sportsterpedia.

Parts Catalogs;
The Parts Catalog has part numbers of course but it also has exploded parts views.
However, IT IS NOT INTENDED TO BE AN ASSEMBLY MANUAL.
And some of the exploded views are confusing or not related to each other on the same pages.
But, all in all, the exploded views do help finding what goes where.
Most of the fasteners listed in the relevant parts catalog individual pages have thread sizes and lengths also in case you need those.
Below is a simple list of original and “latest edition parts catalogs. The in-between year books may show different part numbers for the same year model bike.
Click Here to see the Factory Parts Catalog page in the Sportsterpedia for parts catalog uses and a full list of parts catalog numbers from 1957 to present.
(complete list of other parts catalogs and supplement catalogs that pertain to each year model on the bottom of that page)
Some often acquire several year model parts catalogs and that page will help decide which ones are right for them.

Suggested Manuals:

  • Factory Service Manual (FSM):
    • Original: 1991 XLH Models Service Manual (99484-91)
    • Updated Edition: 1991-1992 XLH Models Service Manual (99484-92)
  • Factory Parts Catalog:
    • Original: 1991 Five Speed Sportster Parts Catalog (99451-91)
      • Written in 1990 and lists parts available in 1991 for 1991 models.
    • Updated Edition: 1991-1992 Five Speed Sportster Parts Catalog (99451-92)
      • Written in 1991 and lists parts available in 1992 for 1991-1992 models.
  • Factory Owners Manual:
    • 1991 (all) Models Owners Manual (99466-91).

Pics of Manual Covers.
Below are pics of used manual covers related to 1991 model Sportsters.
See the full list of pertinent catalogs in the links above.
Click on any pic below to enlarge:

1991 Owners Manual (99466-91)
1991 FSM (99484-91)
Original Manual
1991-1992 FSM
Updated Manual (99484-92)
1991 Original
Parts Catalog (99451-91)
1991-1992 Updated
Parts Catalog (99451-92)

Specifications

Model Designations

  • Model Designations: XLH-883, XLH-883 Hugger, XLH-883 Deluxe, XLH-1200

Dimensions

  • Wheelbase: 1)
    • XLH-883 / XLH-883 Deluxe / XLH-1200, 60 in / 152.40 cm per the 1991 FSM (1991-1992 FSM says 60.2”)
    • XLH-883 Hugger, 60.5 in / 153.67 cm
  • Overall Length: 2)
    • XLH-883 / XLH-883 Hugger / XLH-883 Deluxe / XLH-1200, 87.5 in / 222.25 cm per the 1991 FSM (1991-1992 FSM says 87.6“)
  • Overall Width: 3)
    • XLH-883, 32 in / 81.28 cm
    • XLH-883 Hugger, 33 in / 83.82 cm
    • XLH-883 Deluxe / XLH 1200 32 in / 81.28 cm per the 1991 FSM (1991-1992 FSM says 33 in / 83.82 cm)
  • Overall Height: 4)
    • XLH-883, 47.5 in / 120.65 cm
    • XLH-883 Deluxe, 47.5 in / 120.65 cm per the 1991 FSM (1991-1992 FSM says 49.75 in / 126.365 cm)
    • XLH-883 Hugger, 49.75 in / 126.365 cm
    • XLH-1200, 49.75 in / 126.36 cm
  • Road Clearance: 5)
    • XLH-883 / XLH-883 Deluxe / XLH-1200, 6.75 in / 17.145 cm
    • XLH-883 Hugger, 5.9 in / 14.986 cm
  • Weight (as shipped from the factory): 6)
    • XLH-883, XLH-883 Hugger, 472 lbs.
    • XLH-883 Deluxe, 484 lbs.
    • XLH-1200, 470 lbs.

Engine

  • Engine type: 4 cycle Overhead Valves, 45 degree V2 7)
  • Displacement:
    • 883cc: 53.9 ci
    • 1200cc: 73.3 ci
  • Compression Ratio: 9:1
  • HP @ 6000 RPM:
    • 883cc, 52
    • 1200cc, 68
  • Torque:
    • 883cc, 53 ft/lbs at 4250 RPM
    • 1200cc, 72 ft/lbs at 4500 RPM
  • Bore:
    • 883: 3 in / 76.2 mm
    • 1200: 3.498 in / 88.8492 mm
  • Stroke: 3.812 in / 96.8248 mm
  • 4 Cams
  • Gerotor type oil pump.
    The oil pump and engine oil routing system was redesigned in 1991. 1990 and prior gerotor oil pumps will not function properly on 91-up engines.
    Oil pump pressure at operating temp (gauge mounted at oil pressure switch location):
    • Minimum: 7-12 psi (idle)
    • Normal riding conditions: 12-17 psi (2500 rpm)
  • Ignition: Electronic Ignition System.
  • Spark Plugs
    • 12mm 6R12, Gap (.038”-.043“), Torque 11-18 ft-lb / 3-5 Nm
  • VOES (vacuum-operated electric switch) for timing advance
  • Fuel System: HD Keihin CV carburetor

Capacities

  • Fuel Capacity:
    • 2.25 gal / 8.517 l 8)
      Reserve: .25 gal / .946 l
  • Oil Capacity: 3 qts. / 1.419 l (quoted from -85 FSM)
  • Transmission Capacity: 1.5 pints / .71 l
  • Front Forks (per fork): Wet 9.0 oz, Dry 10.2 oz

Clutch

  • Multi-Disc wet clutch-pack with alternate steel and fiber friction plates.

Drivetrain

  • Constant Mesh 9)
  • Left Side Shifter
  • Speeds - 4 Forward
  • Number of Sprocket Teeth (all)
    • Engine: 35
    • Clutch: 56
      • Clutch Sprocket to Engine Sprocket Ratio: 1.60:1
    • Transmission:
      • 883, 21
      • 883 Deluxe, 27
      • 1200, 29
    • Rear Wheel:
      • 883, 48
      • 883 Deluxe, 61
      • 1200, 61
    • Primary Belt:
      • 883 Deluxe, 127 (yellow)
      • 1200, 128 (orange)
  • Gear Ratios (XLH / XLS / XLX) 10)
    • Internal Gear Ratios:
      Internal gear ratios indicate number of clutch gear revolutions required to drive mainshaft sprocket one revolution.
      • 1st: 2.78:1
      • 2nd: 2.03:1
      • 3rd: 1.49:1
      • 4th: 1.22:1
      • 5th: 1.00:1
    • Overall Gear Ratios:
      Overall gear ratios indicate number of engine revolutions required to drive rear wheel one revolution.
      • 883
        • 1st: 10.17
        • 2nd: 7.43
        • 3rd: 5.45
        • 4th: 4.47
        • 5th: 3.66
      • 883 Deluxe:
        • 1st: 10.04
        • 2nd: 7.33
        • 3rd: 5.38
        • 4th: 4.4
        • 5th: 3.61
      • 1200:
        • 1st: 9.37
        • 2nd: 6.84
        • 3rd: 5.02
        • 4th: 4.11
        • 5th: 3.37

Tires

Rim size and contour are cast or stamped into the exterior surface of the rim.

  • All 883 and 1200 Models 11)
    • Front:
      • For tube type laced (contour T19x2.50 MTA) or tubeless cast (contour T19x2.15 MT) 19” wheels: Dunlop D401 (100/90-19).
    • Rear:
      • For tube type laced or tubeless cast (contour T16x3.00D) 16“ wheels: Dunlop D401 (130/90-16).
  • Tire pressure based on overall weight.
    • Up to 300 lb load including rider, passenger and cargo:
      • Front 30 psi / 2.06 bar
      • Rear 36 psi / 2.48 bar
    • Up to GVWR maximum load:
      • Front 30 psi / 2.06 bar
      • Rear 40 psi / 2.75 bar

Brake Discs

For all 883cc and 1200cc models; 12)

  • Diameter:
    • Front, 11.5”
    • Rear, 11.5“
  • Minimum Thickness:
    • Front, .180”
    • Rear, .205“

Models

XLH 883

What is the Current KBB Value? 13)

  • Colors: Solid and Candy

XLH 883 Deluxe

What is the Current KBB Value? 14)

  • Colors: Solid and Candy

XLH 883 Hugger

What is the Current KBB Value? 15)

  • Colors: Solid and Candy

XLH 1200

What is the Current KBB Value? 16)

  • Colors: Solid, Candy and Two Tone

Back to Sportster History Index

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