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| sportster_history:99xx-01 [2025/01/25 06:27] – [1980 - 1989] hippysmack | sportster_history:99xx-01 [2025/01/25 06:45] (current) – [1980 - 1989] hippysmack | ||
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| ===== 1980 - 1989 ===== | ===== 1980 - 1989 ===== | ||
| - | <font 15px/ | + | <font 15px/ |
| * **MoCo notes**: | * **MoCo notes**: | ||
| - | | + | |
| - | * In April, Charles K Thompson named president and deputy group executive of HD. | + | * In April, Charles K Thompson named president and deputy group executive of HD. |
| - | * Harley-Davidson debuts the FLT with its vibration dampening, rubber-isolated drivetrain and unique trailing front fork. The engine and five-speed transmission are hard bolted together.((https:// | + | * Harley-Davidson debuts the FLT with its vibration dampening, rubber-isolated drivetrain and unique trailing front fork. The engine and five-speed transmission are hard bolted together.((https:// |
| - | * Harley-Davidson releases the FXB Sturgis model, employing belt drive, black chrome appointments and 80 cubic inch engine.((https:// | + | * Harley-Davidson releases the FXB Sturgis model, employing belt drive, black chrome appointments and 80 cubic inch engine.((https:// |
| - | * The FXWG Wide Glide is introduced for the 1980 model year. ((https:// | + | * The FXWG Wide Glide is introduced for the 1980 model year. ((https:// |
| - | * Last year model of the XR-750 as a full motorcycle production bike. Engine kits (only) were sold from 1990 to 2003 ((-2003 HD XR-750 Service Manual pg 69)) | + | * Last year model of the XR-750 as a full motorcycle production bike. Engine kits (only) were sold from 1990 to 2003 ((1972-2003 HD XR-750 Service Manual pg 69)) |
| - | * **Service Notes / Recommendations**: | + | * **Service Notes / Recommendations**: |
| - | * On a number of 1980 XLH/XLS models, the battery may have been mis-positioned. The pad the battery rests on is thick enough to allow the battery to be pushed over the carrier retaining edge until the battery vent tube fitting is wedged against the oil tank which could break the fitting. The fix was to glue 2 battery cover pads together and attach them the oil tank to create separation of the tank and the battery. ((HD Service Bulletin #M-759 dated October 16, 1979)) | + | * On a number of 1980 XLH/XLS models, the battery may have been mis-positioned. The pad the battery rests on is thick enough to allow the battery to be pushed over the carrier retaining edge until the battery vent tube fitting is wedged against the oil tank which could break the fitting. The fix was to glue 2 battery cover pads together and attach them the oil tank to create separation of the tank and the battery. ((HD Service Bulletin #M-759 dated October 16, 1979)) |
| - | * The condition of the rear shock absorber upper and lower [[:techtalk: | + | * The condition of the rear shock absorber upper and lower [[techtalk: |
| - | * The MoCo found that some parts stock crankpins (date stamped 11/79) used on ' | + | * The MoCo found that some parts stock crankpins (date stamped 11/79) used on ' |
| - | * Some XLH models were originally shipped with XLCR shocks factory installed. These XLCR shocks were modified to incorporate the same spring and damping rate of the XL shocks but were chrome instead of the standard XL black shocks so the only difference is appearance. | + | * Some XLH models were originally shipped with XLCR shocks factory installed. These XLCR shocks were modified to incorporate the same spring and damping rate of the XL shocks but were chrome instead of the standard XL black shocks so the only difference is appearance. |
| - | * Some [[:techtalk: | + | * Some [[techtalk: |
| - | * The affected VINs are: (3A) 27367J0-30533J0 | + | * The affected VINs are: (3A) 27367J0-30533J0 |
| - | * Starting with crankcase # | + | * Starting with crankcase # |
| - | * There is a possibility of high pressure oil leakage around the oil passage between the upper crankcase cover and the crankcase. Since November of 1979, the crankcase castings have been reworked and modified to eliminate this possibility. As a part of that revision, the crankcase cover gaskets used in production and in stock have been modified to not only fit the revised castings but also to eliminate the possibility of oil leakage on earlier crankcases. The oil passage hole in the top (middle) of the gasket was elongated (slotted). The old parts stock at the dealer (without the slots) had to be elongated using a template supplied from the factory. ((HD Service Bulletin #M-778 dated May 13, 1980)) | + | * There is a possibility of high pressure oil leakage around the oil passage between the upper crankcase cover and the crankcase. Since November of 1979, the crankcase castings have been reworked and modified to eliminate this possibility. As a part of that revision, the crankcase cover gaskets used in production and in stock have been modified to not only fit the revised castings but also to eliminate the possibility of oil leakage on earlier crankcases. The oil passage hole in the top (middle) of the gasket was elongated (slotted). The old parts stock at the dealer (without the slots) had to be elongated using a template supplied from the factory. ((HD Service Bulletin #M-778 dated May 13, 1980)) |
| - | * Inspect [[:techtalk: | + | * Inspect [[techtalk: |
| - | * A quantity of [[:techtalk: | + | * A quantity of [[techtalk: |
| - | * **Factory Recalls**: | + | * **Factory Recalls**: |
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| + | * **Production Information**: | ||
| * XLH 1000 (11,841) $5,867 | * XLH 1000 (11,841) $5,867 | ||
| * XLS 1000 (2,926) | * XLS 1000 (2,926) | ||
| - | * XR-750 (180) (( -2003 HD XR750 Service Manual XR 750 Production Schedule pg 69)) | + | * XR-750 (180) ((1972-2003 HD XR750 Service Manual XR 750 Production Schedule pg 69)) |
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| + | | ||
| * **XLH, XLS changes include**: | * **XLH, XLS changes include**: | ||
| - | * New " | + | * New " |
| - | * The [[:techtalk: | + | * The [[techtalk: |
| * All HD models (including XLs) have new changes including: | * All HD models (including XLs) have new changes including: | ||
| - | | + | |
| - | * 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 [[:techtalk: | + | * 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 [[techtalk: |
| - | * " | + | * " |
| - | * Upgrade to cast iron valve guides instead of steel on all HD 1980 models. Cast iron guides can be reamed to size (allowing for more accurate clearances), | + | * Upgrade to cast iron valve guides instead of steel on all HD 1980 models. |
| - | * New heads with [[:techtalk: | + | * New heads with [[techtalk: |
| - | * New intake and exhaust valves. HD had two suppliers for these valves (Nittan and Eaton). Either brand is a standard replacement. These valves will fit all the way back to the 1966 model year but you cannot use old valves (intake 18074-66 or exhaust 18082-57) with any new cast iron valve guide introduced in 1980 due to the 3 angle valve job. (( HD Service Letter #ML-131 dated September 14, 1979)) | + | * New intake and exhaust valves. HD had two suppliers for these valves (Nittan and Eaton). Either brand is a standard replacement. These valves will fit all the way back to the 1966 model year but you cannot use old valves (intake 18074-66 or exhaust 18082-57) with any new cast iron valve guide introduced in 1980 due to the 3 angle valve job. ((HD Service Letter #ML-131 dated September 14, 1979)) ((HD Service Bulletin #M-782 dated June 3, 1980)) |
| - | * In compliance with EPA regulations, | + | * In compliance with EPA regulations, |
| - | * The air cleaner has been tightly sealed and a drain hose and plug has been added to the assembly. This allows the condensation to drip into the hose rather than onto the engine or rider. Simply remove the drain plug every 1250 miles, when you do the normal air cleaner maintenance, | + | * The air cleaner has been tightly sealed and a drain hose and plug has been added to the assembly. This allows the condensation to drip into the hose rather than onto the engine or rider. Simply remove the drain plug every 1250 miles, when you do the normal air cleaner maintenance, |
| - | * New spin-on automotive type oil filter as standard equipment. (( HD Service Letter #ML-131 dated September 14, 1979)) | + | * New spin-on automotive type oil filter as standard equipment. ((HD Service Letter #ML-131 dated September 14, 1979)) |
| - | * The right side cover has been modified to allow you to check the battery water level without removing the cover. (( HD Service Letter #ML-131 dated September 14, 1979)) | + | * The right side cover has been modified to allow you to check the battery water level without removing the cover. ((HD Service Letter #ML-131 dated September 14, 1979)) |
| - | * The inner sprocket cover has been removed which allows for easier brake accessibility for maintenance. (( HD Service Letter #ML-131 dated September 14, 1979)) | + | * The inner sprocket cover has been removed which allows for easier brake accessibility for maintenance. ((HD Service Letter #ML-131 dated September 14, 1979)) |
| - | * The ignition rotor on early 1980 models were attached with a " | + | * The ignition rotor on early 1980 models were attached with a " |
| * **XLH changes include**: | * **XLH changes include**: | ||
| * Optional Hugger package with shorter shocks and thinner seat. | * Optional Hugger package with shorter shocks and thinner seat. | ||
| - | * **XR-750** | + | * **XR-750** (dirt track) changes include: |
| - | * New Marzocchi front forks with 5.31" travel and a 2.5 gallon gas tank (( -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**{{:pdf-bulletin: | + | * **Paint colors** {{ pdf-bulletin: |
| - | * **XLS**: Fuel tank: Black/ | + | * **XLH**: Vivid Black, Bright Blue, Saddle Brown, Candy Red. ((1980 Painted Parts List pg 505, 1-82)) |
| - | {{:common: | + | * **XLS**: Fuel tank: Black/ |
| - | < | + | |
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| + | {{common: | ||
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| + | <font 15px/ | ||
| * **MoCo notes**: | * **MoCo notes**: | ||
| - | * Feb 26, Vaughn Beals heads up a group including Charlie Thompson and Wilie G Davidson and ten other HD executives who sign a letter of intent to buy HD back from AMF. (( https:// | + | * Feb 26, Vaughn Beals heads up a group including Charlie Thompson and Wilie G Davidson and ten other HD executives who sign a letter of intent to buy HD back from AMF. ((https:// |
| - | * June 16, HD history is made when they successfully buy HD back from AMF. HD shareholders celebrate with a York to Milwaukee ride. | + | * June 16, HD history is made when they successfully buy HD back from AMF. HD shareholders celebrate with a York to Milwaukee ride. |
| - | * Close to 200 clerical positions are eliminated. 'The Eagle Soars Alone' slogan is born. | + | * Close to 200 clerical positions are eliminated. 'The Eagle Soars Alone' slogan is born. |
| * A gold dipstick was inserted by Vaughn Beals into the first non-AMF motorcycle to roll off the assembly line at York, Pennsylvania. | * A gold dipstick was inserted by Vaughn Beals into the first non-AMF motorcycle to roll off the assembly line at York, Pennsylvania. | ||
| * **Service Notes / Recommendations**: | * **Service Notes / Recommendations**: | ||
| - | * The [[:sportster_history: | + | * The [[sportster_history: |
| - | * The MoCo had a problem with 1972-1981 piston ring kits (date code 4-80 and 5-80) in that there was a possibility that the oil control rings in the kits were the wrong size. Check ring gap for proper measurement when installing (.012" | + | * The MoCo had a problem with 1972-1981 piston ring kits (date code 4-80 and 5-80) in that there was a possibility that the oil control rings in the kits were the wrong size. Check ring gap for proper measurement when installing (.012" |
| - | * The MoCo also issued a warning regarding brake line maintenance on 80 and 81 XLH/XLS models. Avoid bending or kinking and use caution when routing around the solenoid (electrical shortage) and rear exhaust / heat shield (wearing a hole in brake line). (( HD Service Bulletin #M-813 dated January 30, 1981)) | + | * The MoCo also issued a warning regarding brake line maintenance on 80 and 81 XLH/XLS models. Avoid bending or kinking and use caution when routing around the solenoid (electrical shortage) and rear exhaust / heat shield (wearing a hole in brake line). ((HD Service Bulletin #M-813 dated January 30, 1981)) |
| - | * The torque value in the service manual for rocker arm acorn nuts is incorrect. The correct torque value is 15-20 ft-lbs. (( HD Service Bulletin #M-813 dated January 30, 1981)) | + | * The torque value in the service manual for rocker arm acorn nuts is incorrect. The correct torque value is 15-20 ft-lbs. ((HD Service Bulletin #M-813 dated January 30, 1981)) |
| - | * Always check the fitment of battery covers and avoid contact to the battery positive terminal. (( HD Service Bulletin #M-813 dated January 30, 1981)) | + | * Always check the fitment of battery covers and avoid contact to the battery positive terminal. ((HD Service Bulletin #M-813 dated January 30, 1981)) |
| - | * [[:techtalk: | + | * [[techtalk: |
| - | * App. 800 motorcycles (FXE/ | + | * App. 800 motorcycles (FXE/ |
| - | * In October, HD issues a new tire fitment chart, with the introduction of Dunlop tires, for all models from 1980-1982. (( HD Service Bulletin #M-838 dated October 2, 1981)) | + | * In October, HD issues a new tire fitment chart, with the introduction of Dunlop tires, for all models from 1980-1982. ((HD Service Bulletin #M-838 dated October 2, 1981)) |
| * **Factory Recalls**: | * **Factory Recalls**: | ||
| - | | + | |
| - | * Scott Parker begins racing for team Harley-Davidson on the AMA dirt track circuit. He will become the most successful racer in Harley-Davidson history, accumulating 93 career victories and, more incredibly, winning 9 Grand National Champion titles in a 10-year period. (( https:// | + | * Scott Parker begins racing for team Harley-Davidson on the AMA dirt track circuit. He will become the most successful racer in Harley-Davidson history, accumulating 93 career victories and, more incredibly, winning 9 Grand National Champion titles in a 10-year period. ((https:// |
| + | |||
| * **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:// | + | * Milwaukee Edition 1000 (804) ((http:// |
| + | |||
| + | | ||
| * **XLH and XLS changes include**: | * **XLH and XLS changes include**: | ||
| - | * 81 models saw new heads beginning with crankcase (# | + | * 81 models saw new heads beginning with crankcase (# |
| - | * All 1981 model motorcycles are equipped with a [[:techtalk: | + | * All 1981 model motorcycles are equipped with a [[techtalk: |
| - | * New petcock with a reserve tube. (( -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)) |
| - | * [[:techtalk: | + | * [[techtalk: |
| - | * A special foam tape was made available for XL/FX/FLT models front brake calipers. Applied to the front of the outer caliper half, it helps to prevent caliper rattle. (( HD Service Bulletin #M-832 dated June 12, 1981)) | + | * A special foam tape was made available for XL/FX/FLT models front brake calipers. Applied to the front of the outer caliper half, it helps to prevent caliper rattle. ((HD Service Bulletin #M-832 dated June 12, 1981)) |
| - | * Part number changes to 1980-1985 [[:techtalk: | + | * Part number changes to 1980-1985 [[techtalk: |
| - | * Rear wheel option: wire or cast, 16" or 18" | + | * Rear wheel option: wire or cast, 16" or 18" |
| - | * **XLS changes include**: | + | * **XLS changes include**: |
| - | * Buckhorn handlebars, | + | * Buckhorn handlebars, |
| * Shorty dual exhaust | * Shorty dual exhaust | ||
| - | * 3.3 gallon gas tank with an optional 2.2 gallon tank | + | * 3.3 gallon gas tank with an optional 2.2 gallon tank |
| - | * **XLH changes include**: | + | * **XLH changes include**: |
| * Shorter front forks | * Shorter front forks | ||
| * Optional 3.3 gallon gas tank | * Optional 3.3 gallon gas tank | ||
| - | * Longer wheel base (60") (( -1985 HD FSM)) | + | * Longer wheel base (60") ((1979-1985 HD FSM)) |
| * **Milwaukee Edition**: [[http:// | * **Milwaukee Edition**: [[http:// | ||
| - | * Limited edition (AKA, the Buy Back Bike or Milwaukee Special) celebrating Harley Davidson' | + | * Limited edition (AKA, the Buy Back Bike or Milwaukee Special) celebrating Harley Davidson' |
| - | * Reportedly, only 804 of these motorcycles were produced. \\ | + | * 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. |
| - | One for every Harley Dealership. \\ | + | * **Paint colors** {{ pdf-bulletin: |
| - | One extra for the top 100 Harley Dealers. \\ | + | * XLH: Vivid Black, Metallic Blue, Candy Red, Candy Root Beer. ((1981 Painted Parts List pg 506)) |
| - | Four for promotional purposes. | + | * Large fuel tank (Lg) w/decals: Metallic Blue, Candy Red. ((1981 Painted Parts List pg 508, 10-82)) |
| - | * **Paint colors**{{:pdf-bulletin: | + | |
| - | * Large fuel tank (Lg) w/decals: Metallic Blue, Candy Red. (( Painted Parts List pg 508, 10-82)) | + | |
| * Additionally, | * Additionally, | ||
| - | * XLS: 2-Tone Silver, Black w/Red Pinstripe. (( Painted Parts List pg 508, 10-82)) | + | * XLS: 2-Tone Silver, Black w/Red Pinstripe. ((1981 Painted Parts List pg 508, 10-82)) |
| - | * Milwaukee Edition: Orange/ | + | * Milwaukee Edition: Orange/ |
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| + | {{common: | ||
| - | {{: | + | <font 15px/ |
| - | <font 15px/ | + | |
| * **MoCo notes**: | * **MoCo notes**: | ||
| Line 1281: | Line 1297: | ||
| * US President Ronald Reagan imposes a five year tariff on all Japanese 700cc or larger imports. | * US President Ronald Reagan imposes a five year tariff on all Japanese 700cc or larger imports. | ||
| * Lay-offs total 1,600 out of 3,800 employees | * Lay-offs total 1,600 out of 3,800 employees | ||
| - | * Aggressive program initiated to clean up all bootleg HD merchandise. | + | * Aggressive program initiated to clean up all bootleg HD merchandise. |
| * In May, more than 100 riders leave the Capitol Drive Plant on protest ride to Madison in response to Wisconsin State Police using Kawasaki motorcycles. | * In May, more than 100 riders leave the Capitol Drive Plant on protest ride to Madison in response to Wisconsin State Police using Kawasaki motorcycles. | ||
| * Advertising budget is estimated at about $3 million. | * Advertising budget is estimated at about $3 million. | ||
| * **Service Notes / Recommendations**: | * **Service Notes / Recommendations**: | ||
| * First year application of MAN (materials as needed) or just in time for production. | * First year application of MAN (materials as needed) or just in time for production. | ||
| - | * On Sportster Vins prior to (1HD1CAH15CY111159), | + | * On Sportster Vins prior to (1HD1CAH15CY111159), |
| - | * All standard sized pistons are [[:techtalk: | + | * All standard sized pistons are [[techtalk: |
| - | * The normal brake pad inspection interval is 2500 miles for all 1982 and later models. This is adequate under normal riding conditions. More frequent inspections should be made if the motorcycle is ridden under more adverse conditions (steep hills, heavy traffic, etc.). (( HD Service Bulletin #M-875 dated October 11, 1983)) | + | * The normal brake pad inspection interval is 2500 miles for all 1982 and later models. This is adequate under normal riding conditions. More frequent inspections should be made if the motorcycle is ridden under more adverse conditions (steep hills, heavy traffic, etc.). ((HD Service Bulletin #M-875 dated October 11, 1983)) |
| - | * **Factory Recalls**: | + | * **Factory Recalls**: |
| - | * Sportster fuels requirements have changed. A lower compression ratio was achieved by the addition of a thicker head gasket. This allowed for the use of regular grade unleaded fuel (89 octane) as opposed to the unleaded premium stated in the current service and owner' | + | |
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| + | * **Fuel notes**: | ||
| + | * Sportster fuels requirements have changed. A lower compression ratio was achieved by the addition of a thicker head gasket. This allowed for the use of regular grade unleaded fuel (89 octane) as opposed to the unleaded premium stated in the current service and owner' | ||
| + | |||
| * **Production Information**: | * **Production Information**: | ||
| * XLH 1000 (5,015) | * XLH 1000 (5,015) | ||
| * XLHA 1000 Anniversary Sportster (932) | * XLHA 1000 Anniversary Sportster (932) | ||
| * XLS 1000 (1,261) | * XLS 1000 (1,261) | ||
| - | * XLSA 1000 Anniversary Roadster (778) | + | * XLSA 1000 Anniversary Roadster (778) |
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| * **XLH and XLS changes include**: | * **XLH and XLS changes include**: | ||
| * Lighter frame and longer wheel base | * Lighter frame and longer wheel base | ||
| - | * XLH (60" | + | * XLH (60" |
| - | * XLS (60.76" | + | * XLS (60.76" |
| * Oil tank repositioned | * Oil tank repositioned | ||
| * Battery re-positioned | * Battery re-positioned | ||
| - | * Thicker head gasket to lower compression ratio. (( HD Service Bulletin #M-845 dated November 17, 1981)) | + | * Thicker head gasket to lower compression ratio. ((HD Service Bulletin #M-845 dated November 17, 1981)) |
| * Larger rear disc | * Larger rear disc | ||
| - | * New [[:techtalk: | + | * New [[techtalk: |
| - | * Late 1982 - the internal [[:techtalk: | + | * Late 1982 - the internal [[techtalk: |
| - | * A limited number of E1982 XL engines (782216009-782237017) were assembled without the [[:techtalk: | + | * A limited number of E1982 XL engines (782216009-782237017) were assembled without the [[techtalk: |
| - | * New rear brake caliper with the same square seal design but the brake pads are now supported on the caliper bracket to make changing pads easier. (( HD Service Bulletin #M-837 dated October 2, 1981)) | + | * New rear brake caliper with the same square seal design but the brake pads are now supported on the caliper bracket to make changing pads easier. ((HD Service Bulletin #M-837 dated October 2, 1981)) |
| - | * New hand levers and switches. The front brake master cylinder is made so there is no free play in the brake hand lever when the hand control switch assemblies are positioned correctly. (( HD Service Bulletin #M-837 dated October 2, 1981)) | + | * New hand levers and switches. The front brake master cylinder is made so there is no free play in the brake hand lever when the hand control switch assemblies are positioned correctly. ((HD Service Bulletin #M-837 dated October 2, 1981)) ((HD Service Bulletin #M-853 dated March 19, 1982)) |
| - | * Low maintenance battery. (( HD Service Bulletin #M-837 dated October 2, 1981)) | + | * Low maintenance battery. ((HD Service Bulletin #M-837 dated October 2, 1981)) |
| - | * E1982 models now have a 45° angle cut into the end of the rocker arm shaft. A 0.015“ spacer was made available for 1973-Very Early 1982 models, with the flat cut rocker arm shafts, to prevent O-ring distortion and oil leaks in this area. The washer fits inside the O-ring under the right end screw of the rocker arm shaft. E1982 models, with the new 45° shafts do not need the washer. Never use more than 1 washer on the shaft (( HD Service Bulletin #M-837 dated October 2, 1981)) | + | * E1982 models now have a 45° angle cut into the end of the rocker arm shaft. A 0.015“ spacer was made available for 1973-Very Early 1982 models, with the flat cut rocker arm shafts, to prevent O-ring distortion and oil leaks in this area. The washer fits inside the O-ring under the right end screw of the rocker arm shaft. E1982 models, with the new 45° shafts do not need the washer. Never use more than 1 washer on the shaft ((HD Service Bulletin #M-837 dated October 2, 1981)) |
| - | * 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, | + | * 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, |
| - | * 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:**{{:pdf-bulletin: | + | * **Paint colors:** {{ pdf-bulletin: |
| - | * XLH: Vivid Black, Candy Red, Metallic Blue, Metallic Green. (( Painted Parts List pg 503, 1-82)) | + | * XLH: Vivid Black, Candy Red, Metallic Blue, Metallic Green. ((1982 Painted Parts List pg 503, 1-82)) |
| - | * XLS: Red/Black, Black w/Gold pinstriping. (( Painted Parts List pg 503, 1-82)) | + | * XLS: Red/Black, Black w/Gold pinstriping. ((1982 Painted Parts List pg 503, 1-82)) |
| - | * XLH and XLS Anniversary Models: Dark Maroon and Pewter. (( Painted Parts List pg 507, 10-82)) | + | * XLH and XLS Anniversary Models: Dark Maroon and Pewter. ((1982 Painted Parts List pg 507, 10-82)) |
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| + | {{common: | ||
| - | {{: | + | |
| - | < | + | <font 15px/ |
| * **MoCo notes**: | * **MoCo notes**: | ||
| - | | + | |
| - | * 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' | + | * Dick O' |
| - | * The first production XLX was given to Jay Springsteen (( Ralphthe3rd of the XLFORUM https:// | + | * The first production XLX was given to Jay Springsteen ((Ralphthe3rd of the XLFORUM https:// |
| - | * **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)) |
| - | * Reports were received indicating that tumbling stone contamination may have been existent in Late 1982 - Early 1983 engines with crankcase VINs (782025001-783200001). Tumbling stones are used in the polishing process of tappet bodies and occasionally can become wedged within the tappet body. The retention of a tumbling stone in the tappet assembly will cause premature tappet wear. If contamination has occurred and tumbling stone material is allowed to circulate through the engine for an extended period of time, some engine damage will eventually occur. Affected engines will first show excessive wear of one tappet guide assembly. (( HD Service Bulletin #M-857 dated October 5, 1982)) | + | * Reports were received indicating that tumbling stone contamination may have been existent in Late 1982 - Early 1983 engines with crankcase VINs (782025001-783200001). Tumbling stones are used in the polishing process of tappet bodies and occasionally can become wedged within the tappet body. The retention of a tumbling stone in the tappet assembly will cause premature tappet wear. If contamination has occurred |
| - | * A service bulletin was issued for [[:techtalk: | + | * A service bulletin was issued for [[techtalk: |
| - | * The number of [[:techtalk: | + | * The number of [[techtalk: |
| - | * HD issued a new tire fitment chart for correct matching of tire, tubes and wheels for 1983 models. (( HD Service Bulletin #M-867 dated March 11, 1983)) | + | * HD issued a new tire fitment chart for correct matching of tire, tubes and wheels for 1983 models. ((HD Service Bulletin #M-867 dated March 11, 1983)) |
| - | * **Factory Recalls**: | + | |
| + | | ||
| + | |||
| + | |||
| + | |||
| + | * **Production Information**: | ||
| * XLH 1000 (2,230) | * XLH 1000 (2,230) | ||
| * XLS 1000 Roadster (1,616) | * XLS 1000 Roadster (1,616) | ||
| * XR-1000 (1,018) $6,995 | * XR-1000 (1,018) $6,995 | ||
| * XLX-61 1000 (4, | * XLX-61 1000 (4, | ||
| + | |||
| + | | ||
| * **XLH and XLS changes include**: | * **XLH and XLS changes include**: | ||
| - | * [[:techtalk: | + | * [[techtalk: |
| - | * Higher compression ratio (8.8-1) achieved through new piston design and the use of the earlier style thinner head gasket. This higher compression ratio along with a new two stage ignition system (VOES), provides increased performance while allowing use of leaded regular grade gasoline. (( HD Service Bulletin #M-856 dated August 6, 1982)) | + | * Higher |
| - | * Pistons upgraded with a .040" higher crown surface which adds to the compression ratio also. The piston is identified by a chamfered edge on the crown. (( HD Service Bulletin #M-856 dated August 6, 1982)) | + | * Pistons upgraded with a .040" higher crown surface which adds to the compression ratio also. The piston is identified by a chamfered edge on the crown. ((HD Service Bulletin #M-856 dated August 6, 1982)) |
| - | * Piston rings now include a beveled barrel-faced moly-filled top ring, a taper-faced second ring and a three piece oil control ring with chrome plated rails and a corrugated expander. (( HD Service Bulletin #M-856 dated August 6, 1982)) | + | * Piston rings now include a beveled barrel-faced moly-filled top ring, a taper-faced second ring and a three piece oil control ring with chrome plated rails and a corrugated expander. ((HD Service Bulletin #M-856 dated August 6, 1982)) |
| - | * New finish to cylinder and head gaskets. The gasket surface has a new finish appearing similar to the grooves of a phonograph record. The soft copper head gasket conforms to the finish and prevents oil leakage at the oil return passages. Torque values stayed the same at 55-65 ft-lbs. (( HD Service Bulletin #M860 dated November 12, 1982 pg 1)) | + | * New finish to cylinder and head gaskets. The gasket surface has a new finish appearing similar to the grooves of a phonograph record. The soft copper head gasket conforms to the finish and prevents oil leakage at the oil return passages. |
| - | * A 2-stage computerized microprocessor module including a [[:techtalk: | + | * A 2-stage computerized |
| - | * New ignition module plugs to prevent intermixing of 1983 ignition components with earlier Magnavox modules and sensors. A jumper wire can be fabricated to perform module and sensor checks of 1983 components. (( HD Service Bulletin #M860 dated November 12, 1982 pg 2)) | + | * New ignition module plugs to prevent intermixing of 1983 ignition components with earlier Magnavox modules and sensors. A jumper wire can be fabricated to perform module and sensor checks of 1983 components. ((HD Service Bulletin #M860 dated November 12, 1982 pg 2)) |
| - | * [[:techtalk: | + | * [[techtalk: |
| - | * Gerotor gears now fabricated without the chamfered top and bottom on the outer diameters as was in the E1983 and earlier gerotors. | + | * Gerotor gears now fabricated without the chamfered top and bottom on the outer diameters as was in the E1983 and earlier gerotors. |
| * L83 pump bodies and covers have an under-cut or relief to accommodate for clearances with the new gerotors. | * L83 pump bodies and covers have an under-cut or relief to accommodate for clearances with the new gerotors. | ||
| - | * Passenger footpeg mounts on the swingarm (( -1985 HD Sportster Parts Catalog pg 89)) | + | * Passenger footpeg mounts on the swingarm ((1979-1985 HD Sportster Parts Catalog pg 89)) |
| - | * Models produced after VIN (1HD1CCH17DY113282) use a [[:techtalk: | + | * Models produced after VIN (1HD1CCH17DY113282) use a [[techtalk: |
| - | * New shoulder-less intake and exhaust valve guides for 1000cc engines (beginning with crankcase number (783 101037). (( HD Service Bulletin #M870 dated April 15, 1983)) | + | * New shoulder-less intake and exhaust valve guides for 1000cc engines (beginning with crankcase number (783 101037). ((HD Service Bulletin #M870 dated April 15, 1983)) ((HD Service Bulletin #M-870A dated May 10, 1983)) |
| - | * A new style thrust washer is used on Late 83 XL production engines to control transmission mainshaft endplay. Also, the new washer is thicker and has no tang to prevent rotation as the old style thrust washer has. The roll pin in the crankcase has also been eliminated. (( HD Service Bulletin #M870 dated April 15, 1983)) | + | * A new style thrust washer is used on Late 83 XL production engines to control transmission mainshaft endplay. Also, the new washer is thicker and has no tang to prevent rotation as the old style thrust washer has. The roll pin in the crankcase has also been eliminated. ((HD Service Bulletin #M870 dated April 15, 1983)) ((HD Service Bulletin #M-870A dated May 10, 1983)) |
| - | * Late 83 XL ignition modules (32410-84) and sensor assemblies (32400-84) are being made with rubber rather than plastic components to improve service life and avoid possible separation of the connectors in the field resulting from loose fitting components. (( HD Service Bulletin #M870 dated April 15, 1983)) | + | * New longer positive battery cable (70129-79A) to permit battery removal while servicing, without requiring removal of the seat. ((HD Dealer News, August 1982)) |
| - | * **XLH changes include**: | + | * |
| + | * **XLH changes include**: | ||
| * High bars | * High bars | ||
| * 3.3 gallon gas tank | * 3.3 gallon gas tank | ||
| Line 1362: | Line 1393: | ||
| * **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 https:// | + | * 2 gallon peanut gas tank ((IronMick of the XLFORUM https:// |
| * Black staggered shorty dual exhaust | * Black staggered shorty dual exhaust | ||
| - | * Black flat track handlebars (( IronMick of the XLFORUM https:// | + | * Black flat track handlebars ((IronMick of the XLFORUM https:// |
| * 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 https:// | + | * Small front fender with fender struts. ((IronMick of the XLFORUM https:// |
| - | * Satin finish cases. | + | * Satin finish cases. |
| * Only year | * Only year | ||
| - | | + | |
| - | * 156 watt generator mounted at the front of the cases | + | * 156 watt generator mounted at the front of the cases |
| - | * Loose output roller tranny output shaft | + | * Loose output roller tranny output shaft |
| - | * Output shaft oil seal secured by a bolt on cover | + | * Output shaft oil seal secured by a bolt on cover |
| - | * 3 generator drive gears | + | * 3 generator drive gears |
| - | * 10" dual front disc brakes | + | * 10" dual front disc brakes |
| - | * Wheel base (60") (( -1985 HD FSM)) | + | * Wheel base (60") ((1979-1985 HD FSM)) |
| - | * Engine covers (( IronMick of the XLFORUM https:// | + | * Engine covers ((IronMick of the XLFORUM https:// |
| - | * Very little chrome. (( IronMick of the XLFORUM https:// | + | * Very little chrome. ((IronMick of the XLFORUM https:// |
| - | * 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:// | + | * 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:// |
| - | * 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' | + | * 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' |
| - | * **New model XR-1000** | + | * **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: | ||
| * Aluminum XR style heads w/intake ports on right, exhaust on left, heads ported and polished by Jerry Branch | * Aluminum XR style heads w/intake ports on right, exhaust on left, heads ported and polished by Jerry Branch | ||
| Line 1392: | Line 1423: | ||
| * Vacuum advance-V-fire III breaker less ignition | * Vacuum advance-V-fire III breaker less ignition | ||
| * Twin 36mm Dell' | * Twin 36mm Dell' | ||
| - | * Timer cover - Eagle racing design | + | * Timer cover - Eagle racing design |
| * Satin textured painted cases | * Satin textured painted cases | ||
| * Timer cover - Eagle racing design | * Timer cover - Eagle racing design | ||
| * 2.5 gallon gas tank | * 2.5 gallon gas tank | ||
| * “H-D XR-1000” decal on 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/ | + | * Tubeless 4 ply tires: 19" front, Dunlop K-291S (100/ |
| * Dual disc front brakes | * Dual disc front brakes | ||
| * Black wrinkle finish fork stem and bracket | * Black wrinkle finish fork stem and bracket | ||
| Line 1407: | Line 1438: | ||
| * New designed calipers | * New designed calipers | ||
| * Speedometer and Tach | * Speedometer and Tach | ||
| - | * **Paint colors:**{{:pdf-bulletin: | + | * **Paint colors:** {{ pdf-bulletin: |
| - | * XLS: Indigo and Pewter, Black w/Gold pinstriping. (( Painted Parts List pg 503, 10-82)) | + | |
| - | * XLX: Vivid Black. (( Painted Parts List pg 503, 10-82)) | + | * 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)) | ||
| - | {{:common: | + | |
| - | < | + | {{common: |
| + | |||
| + | |||
| + | <font 15px/ | ||
| * **MoCo notes**: | * **MoCo notes**: | ||
| - | | + | |
| - | * Also witnessed is the debut of the Softail design and its trend-setting method of " | + | * Also witnessed is the debut of the Softail design and its trend-setting method of " |
| - | * Bill Davidson, Willie G's son, joins the company overseeing the National Demo Ride Program. | + | * Bill Davidson, Willie G's son, joins the company overseeing the National Demo Ride Program. |
| - | * HD wins California Highway Patrol contract with 155 motorcycles ordered. | + | * HD wins California Highway Patrol contract with 155 motorcycles ordered. |
| - | * HD receives a US Navy contract for production of gun shell cases. | + | * HD receives a US Navy contract for production of gun shell cases. |
| - | * HD brand beer is sold. | + | * HD brand beer is sold. |
| - | * **Service Notes / Recommendations**: | + | * **Service Notes / Recommendations**: |
| - | * Due to a number of plastic vent hoses coming off the battery hose nipple, starting in mid December of 1983, all motorcycles shipped from York (except FLH with a rubber vent hose) were fitted with a [[:techtalk: | + | * Due to a number of plastic vent hoses coming off the battery hose nipple, starting in mid December of 1983, all motorcycles shipped from York (except FLH with a rubber vent hose) were fitted with a [[techtalk: |
| - | * Additional undersize and oversize shifter forks were now available for XL/XR-1000 parts order to get more precise spacing of the sliding mainshaft 2nd gear and countershaft 3rd gear. The new forks are identified with a stamped (P) for plus or (M) for minus (instead of the + or - symbols) as well as the dimension. (( HD Service Bulletin #M-876 dated January 13, 1984)) | + | * Additional undersize and oversize shifter forks were now available for XL/XR-1000 parts order to get more precise spacing of the sliding mainshaft 2nd gear and countershaft 3rd gear. The new forks are identified with a stamped (P) for plus or (M) for minus (instead of the + or - symbols) as well as the dimension. ((HD Service Bulletin #M-876 dated January 13, 1984)) ((HD Service Bulletin #M-876A dated February 7,1984)) |
| - | * A number of 1984 16” laced wheels were manufactured without a radius on the outer rim flange. Consequently, | + | * A number of 1984 16” laced wheels were manufactured without a radius on the outer rim flange. Consequently, |
| - | * HD issued a new tire fitment chart for correct matching of tire, tubes and wheels for 1984 models. (( HD Service Bulletin #M-883 dated March 13, 1984)) | + | * HD issued a new tire fitment chart for correct matching of tire, tubes and wheels for 1984 models. ((HD Service Bulletin #M-883 dated March 13, 1984)) |
| - | * To aid the stamping operation, the locations of the crankcase numbers on the following case halves were changed to a different location on that case half (opposing case half numbers remained the same as before): (( HD Service Bulletin #M-885 dated April 10, 1984)) | + | * To aid the stamping operation, the locations of the crankcase numbers on the following case halves were changed to a different location on that case half (opposing case half numbers remained the same as before): ((HD Service Bulletin #M-885 dated April 10, 1984)) |
| - | * 1340 Shovelhead - Left Case (1484 044001 and up) | + | * 1340 Shovelhead - Left Case (1484 044001 and up) |
| - | * 1340 Evo - left case (1584 044003 and up) | + | * 1340 Evo - left case (1584 044003 and up) |
| - | * 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**: | + | |
| - | * Recall (058) Certain 1984 XL models - alternator rotor magnets. See Service Bulletin M-890. | + | |
| + | * Recall (058) Certain 1984 XL models - alternator rotor magnets. See Service Bulletin M-890. | ||
| * **Fuel notes**: | * **Fuel notes**: | ||
| - | | + | |
| + | |||
| + | | ||
| * **Production Information**: | * **Production Information**: | ||
| * XLX-61 1000 (4,284) | * XLX-61 1000 (4,284) | ||
| Line 1443: | Line 1481: | ||
| * **All model changes include**: | * **All model changes include**: | ||
| - | | + | |
| - | * Transmission changes: | + | * Transmission changes: |
| - | * Mainshaft 1st gear (35277-52A) is now flat on both sides (allowing it to be installed with either face toward the crankcase) instead of one side having a recess on the rear face. This new gear will retrofit 54 and up models. It also requires the removal of the crankcase roll pin and the replacement of the hooked thrust washer to the newer circular thrust washers. (( HD Service Bulletin #M-876 dated January 13, 1984)) | + | * Mainshaft 1st gear (35277-52A) is now flat on both sides (allowing it to be installed with either face toward the crankcase) instead of one side having a recess on the rear face. This new gear will retrofit 54 and up models. It also requires the removal of the crankcase roll pin and the replacement of the hooked thrust washer to the newer circular thrust washers. ((HD Service Bulletin #M-876 dated January 13, 1984)) ((HD Service Bulletin #M-876A dated February 7,1984)) |
| - | * L84 - replacement mainshaft sprocket nut (35049-71) has been developed to prevent transmission oil leaks from the sprocket splines on 71-84 XL/XR models. The new sprocket shaft nut encloses the end of the mainshaft and creates a metal to metal seal between the sprocket, lockwasher and nut when torqued to 35-65 ft lbs. To use this nut on 71-E84 models, a modification to the inner or outer sprocket cover (respectively) will have to be made to prevent interference between the nut and the cover. (( HD Service Bulletin #M-886 dated April 6, 1984)) | + | * L84 - replacement mainshaft sprocket nut (35049-71) has been developed to prevent transmission oil leaks from the sprocket splines on 71-84 XL/XR models. The new sprocket shaft nut encloses the end of the mainshaft and creates a metal to metal seal between the sprocket, lockwasher and nut when torqued to 35-65 ft lbs. To use this nut on 71-E84 models, a modification to the inner or outer sprocket cover (respectively) will have to be made to prevent interference between the nut and the cover. ((HD Service Bulletin #M-886 dated April 6, 1984)) |
| - | * L84 - new [[:techtalk: | + | * L84 - new [[techtalk: |
| - | * L84 - beginning with crankcase (785 208001) manufactured after July 26,1984, the mainshaft fourth gear bearing assembly is now retained within a shoulder in the new trapdoor. (( HD Service Bulletin #M-894 dated September 7, 1984)) | + | * L84 - beginning with crankcase (785 208001) manufactured after July 26,1984, the mainshaft fourth gear bearing assembly is now retained within a shoulder in the new trapdoor. ((HD Service Bulletin #M-894 dated September 7, 1984)) |
| - | * Countershaft 4th gear (35695-58) also has been redesigned to eliminate the recess on the surface away from the access cover. This new gear will also retrofit 1954 and up models. (( HD Service Bulletin #M-876 dated January 13, 1984)) | + | * Countershaft 4th gear (35695-58) also has been redesigned to eliminate the recess on the surface away from the access cover. This new gear will also retrofit 1954 and up models. ((HD Service Bulletin #M-876 dated January 13, 1984)) ((HD Service Bulletin #M-876A dated February 7,1984)) |
| - | * L84 - Alternator (stator) replaced the generator. The stator is attached directly to the trapdoor. (( HD Service Bulletin #M-894 dated September 7, 1984)) | + | * L84 - Alternator (stator) replaced the generator. The stator is attached directly to the trapdoor. ((HD Service Bulletin #M-894 dated September 7, 1984)) |
| - | * Right crankcase number moved to the lower face below the gear case (near and under #4 cam) beginning with right case # (784 044001) (( HD Service Bulletin #M-885 dated April 10, 1984)) | + | * Right crankcase number moved to the lower face below the gear case (near and under #4 cam) beginning with right case # (784 044001) ((HD Service Bulletin #M-885 dated April 10, 1984)) |
| - | * Torque spec changes include: | + | * Torque spec changes include: |
| - | * Front caliper mounting bolt torque specs changed from 40-45 ft lbs. to 25-30 ft lbs. (( HD Service Bulletin #M-885 dated April 10, 1984)) | + | * Front caliper mounting bolt torque specs changed from 40-45 ft lbs. to 25-30 ft lbs. ((HD Service Bulletin #M-885 dated April 10, 1984)) |
| - | * The rear axle nut torque specs have been changed from 45-50 ft lbs. to 65-70 ft lbs. Wheel bearing endplay, however, remained the same. Bearing endplay must be checked after tightening the axle nut. (( HD Service Bulletin #M-885 dated April 10, 1984)) | + | * The rear axle nut torque specs have been changed from 45-50 ft lbs. to 65-70 ft lbs. Wheel bearing endplay, however, remained the same. Bearing endplay must be checked after tightening the axle nut. ((HD Service Bulletin #M-885 dated April 10, 1984)) |
| - | * Tubeless tires on the cast rims. (( -1985 HD Sportster Parts Catalog pg 73)) | + | * Tubeless tires on the cast rims. ((1979-1985 HD Sportster Parts Catalog pg 73)) |
| * **XLH changes include**: | * **XLH changes include**: | ||
| * One large front disc brake | * One large front disc brake | ||
| Line 1472: | Line 1510: | ||
| * One large front disc brake | * One large front disc brake | ||
| * Diaphragm clutch spring (mid year) | * Diaphragm clutch spring (mid year) | ||
| - | * Alternator (mid year) | + | * Alternator (mid year) |
| - | * **Paint colors:**{{:pdf-bulletin: | + | * **Paint colors:** {{ pdf-bulletin: |
| - | * XLS: Vivid Black, Purple and Silver. (( Painted Parts List from P&A Bulletin P&A #207)) | + | * XL: Vivid Black, Candy Red, Candy Purple. ((1984 Painted Parts List from P&A Bulletin P&A #207)) |
| - | * XLX: Vivid Black, Candy Red. (( Painted Parts List pg 503, 10-82)) | + | * XLS: Vivid Black, Purple and Silver. ((1984 Painted Parts List from P&A Bulletin P&A #207)) |
| - | * XR-1000: Slate Gray. (( Painted Parts List pg 503, 10-82)) | + | * 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)) | ||
| + | | ||
| - | {{:common: | + | {{common: |
| - | < | + | |
| + | |||
| + | <font 15px/ | ||
| * **MoCo notes**: | * **MoCo notes**: | ||
| - | | + | |
| - | * Production trimmed in anticipation of the Evo XL. | + | * Production trimmed in anticipation of the Evo XL. |
| - | * **Service Notes / Recommendations**: | + | * **Service Notes / Recommendations**: |
| - | * Direct lubrication of the XL cam gear teeth allows tighter gear fitment and gear backlash and noise are reduced (a slight gear whine is normal and does not indicate gears are too tight). (( HD Service Bulletin #M-899 dated November 30, 1984)) | + | * Direct lubrication of the XL cam gear teeth allows tighter gear fitment and gear backlash and noise are reduced (a slight gear whine is normal and does not indicate gears are too tight). ((HD Service Bulletin #M-899 dated November 30, 1984)) |
| - | * The new piston pin retaining ring (22589-83) for use on XL engines (same as used on EVO 1340 and XR-1000 pistons) requires a modification to be done on the piston pin retaining ring installer (HD-34623) to extend it's use to the new style pistons (requires cutting a flat area (.250“ from the outer edge) out of the diameter of the business end of the tool. (( HD Service Bulletin #M-899 dated November 30, 1984)) | + | * The new piston pin retaining ring (22589-83) for use on XL engines (same as used on EVO 1340 and XR-1000 pistons) requires a modification to be done on the piston pin retaining ring installer (HD-34623) to extend it's use to the new style pistons (requires cutting a flat area (.250“ from the outer edge) out of the diameter of the business end of the tool. ((HD Service Bulletin #M-899 dated November 30, 1984)) |
| - | * **Factory Recalls**: | + | * **Factory Recalls**: |
| - | * XLH 1000 (4,074) $4,795 | + | |
| + | |||
| + | * **Production Information**: | ||
| + | * XLH 1000 (4,074) $4, | ||
| * XLS 1000 Roadster (616) $5,599 | * XLS 1000 Roadster (616) $5,599 | ||
| * XLX-61 1000 Sportster (1,824) $4,695 | * XLX-61 1000 Sportster (1,824) $4,695 | ||
| + | |||
| * **All model changes include**: | * **All model changes include**: | ||
| - | | + | |
| - | * Beginning with crankcase (785 303002) manufactured after October 29, 1984, a cam gear oiler has been added inside the gearcase to direct oil from the top end oil passage to the gear mesh between first / second gears and third / fourth gears. (( HD Service Bulletin #M-899 dated November 30, 1984)) | + | * Beginning with crankcase (785 303002) manufactured after October 29, 1984, a cam gear oiler has been added inside the gearcase to direct oil from the top end oil passage to the gear mesh between first / second gears and third / fourth gears. ((HD Service Bulletin #M-899 dated November 30, 1984)) |
| * **Paint Colors**: | * **Paint Colors**: | ||
| - | * Birch White, Vivid Black, Classic Tan, Classic Crème, Slate Gray Metallic or Candy Blue. | + | * Birch White, Vivid Black, Classic Tan, Classic Crème, Slate Gray Metallic or Candy Blue. |
| - | {{:common: | + | |
| - | < | + | {{common: |
| + | |||
| + | |||
| + | <font 15px/ | ||
| * **MoCo notes**: | * **MoCo notes**: | ||
| - | | + | |
| - | * Harley-Davidson releases the Heritage Softail®. (( https:// | + | * Harley-Davidson releases the Heritage Softail®. ((https:// |
| - | * December, to diversify its holdings, HD purchases the Holiday Rambler Corporation, | + | * December, to diversify its holdings, HD purchases the Holiday Rambler Corporation, |
| - | * **Service Notes / Recommendations**: | + | * **Service Notes / Recommendations**: |
| - | * For vehicles sold for use in California (as part of the evaporative emissions kit) the carburetor fuel overflow fitting was capped and the overflow line was removed. (( HD Service Bulletin #M-905 dated August 26, 1985)) | + | * For vehicles sold for use in California (as part of the evaporative emissions kit) the carburetor fuel overflow fitting was capped and the overflow line was removed. ((HD Service Bulletin #M-905 dated August 26, 1985)) |
| - | * **Factory Recalls**: | + | * **Factory Recalls**: |
| - | * Japan became the first nation to fully phase-out leaded petrol.(( http:// | + | |
| - | * Sportster Fuel Requirements: | + | * **Fuel notes**: |
| + | * Japan became the first nation to fully phase-out leaded petrol.((http:// | ||
| + | * Sportster Fuel Requirements: | ||
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| * **Production Information**: | * **Production Information**: | ||
| * XLH 883 (8,026) $3,995 | * XLH 883 (8,026) $3,995 | ||
| - | * XLH 883 Deluxe (2,322) | + | * XLH 883 Deluxe (2, |
| * XLH 1100 (3,077) $5,199 | * XLH 1100 (3,077) $5,199 | ||
| - | * XLH 1100 Liberty (954) | + | * XLH 1100 Liberty (954) |
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| * **XLH 883 and XLH 1100**: | * **XLH 883 and XLH 1100**: | ||
| * All new Evolution V-twin engine and updated chassis. | * All new Evolution V-twin engine and updated chassis. | ||
| - | * Beginning with the following crankcase numbers, a new crank pin bearing set and revised flywheels were installed.(( -1990 XLH FSM)) | + | * Beginning with the following crankcase numbers, a new crank pin bearing set and revised flywheels were installed.((1986-1990 XLH FSM)) |
| - | * 883 (1786 083 003) | + | * 883 (1786 083 003) |
| - | * 1100 (1886 090 012) | + | * 1100 (1886 090 012) |
| * Transmission changes: | * Transmission changes: | ||
| - | * 'Late style' gears (both mainshaft and countershaft 2nd and 3rd gear) are app .025" smaller in diameter. The late style gears can also be used for 1957 and up XLH 883 models. (( HD Service Bulletin #M-906 dated August 19, 1985)) | + | * 'Late style' gears (both mainshaft and countershaft 2nd and 3rd gear) are app .025" smaller in diameter. The late style gears can also be used for 1957 and up XLH 883 models. ((HD Service Bulletin #M-906 dated August 19, 1985)) |
| - | * There was a running change to new style hydraulic lifters in 1986 for Sportsters. (( -1990 HD Sportster FSM pg 3-44)) | + | * There was a running change to new style hydraulic lifters in 1986 for Sportsters. ((1986-1990 HD Sportster FSM pg 3-44)) |
| * They were the same as those used in 1340cc engines beginning in the 1986 model year. | * They were the same as those used in 1340cc engines beginning in the 1986 model year. | ||
| * This change was made to allow for one component to service the entire product line. | * This change was made to allow for one component to service the entire product line. | ||
| Line 1530: | Line 1584: | ||
| * 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)) | + | * 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 | ||
| * Aluminum heads and cylinders | * Aluminum heads and cylinders | ||
| Line 1537: | Line 1591: | ||
| * Standard 34 mm fixed venture Keihin carburetor | * Standard 34 mm fixed venture Keihin carburetor | ||
| * Redesigned and powder-coated frame for the new engine | * Redesigned and powder-coated frame for the new engine | ||
| - | * Four speed transmission with the 'late style' gears being a running change as the old style gears were depleted (old or new style gears can be used). (( HD Service Bulletin #M-906 dated August 19, 1985)) | + | * Four speed transmission with the 'late style' gears being a running change as the old style gears were depleted (old or new style gears can be used). ((HD Service Bulletin #M-906 dated August 19, 1985)) |
| * Cast aluminum wheels: 19" in front, 16" in back | * Cast aluminum wheels: 19" in front, 16" in back | ||
| * Solo seat | * Solo seat | ||
| Line 1553: | Line 1607: | ||
| * Deluxe trim | * Deluxe trim | ||
| * Engine: 1100cc OHV V-twin with 85.1 x 96.8mm bore and stroke | * Engine: 1100cc OHV V-twin with 85.1 x 96.8mm bore and stroke | ||
| - | * Four speed transmission with "late style" transmission gears (app .025" smaller dia.). The old style gears cannot be used on 1100 models. (( HD Service Bulletin #M-906 dated August 19, 1985)) | + | * Four speed transmission with "late style" transmission gears (app .025" smaller dia.). The old style gears cannot be used on 1100 models. ((HD Service Bulletin #M-906 dated August 19, 1985)) |
| * Turn signals double as running lights | * Turn signals double as running lights | ||
| * **XLH 1100 Liberty Edition**: | * **XLH 1100 Liberty Edition**: | ||
| Line 1565: | Line 1619: | ||
| * Birch White, Vivid Black, Candy Red, Slate Gray Metallic, Candy Blue, Candy Pearl and Signal Red. | * Birch White, Vivid Black, Candy Red, Slate Gray Metallic, Candy Blue, Candy Pearl and Signal Red. | ||
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| * **MoCo notes**: | * **MoCo notes**: | ||
| - | | + | |
| - | * HD exports 1,600 motorcycles to Canada, 1,200 to Western Europe and 1,300 to Japan. | + | * HD exports 1,600 motorcycles to Canada, 1,200 to Western Europe and 1,300 to Japan. |
| - | * HD again wins California Highway Patrol contract. | + | * HD again wins California Highway Patrol contract. |
| - | * March 17, HD moves to have 5 year tariff lifted earlier than expected, sending a message to Japan that HD can compete. | + | * March 17, HD moves to have 5 year tariff lifted earlier than expected, sending a message to Japan that HD can compete. |
| - | * **Service Notes / Recommendations**: | + | * **Service Notes / Recommendations**: |
| - | * **Factory Recalls**: * **Production Information**: | + | * **Factory Recalls**: |
| - | * XLH 883 (4,990) | + | |
| - | * XLH 883 Deluxe (2,260) | + | |
| - | | + | |
| - | * XLH 1100 (4,018) | + | |
| - | * XLH 1100 Anniversary (600) | + | |
| - | * **883 Hugger (mid-year introduction)**: | + | |
| - | * Fork tubes shortened 2" | + | * XLH 883 (4,990) |
| - | * Revised shock angle by lengthening Swingarm 1/2" | + | * XLH 883 Deluxe (2,260) |
| - | * Softer seat at 26.75", | + | * XLH 883 Hugger (2,106) |
| + | * XLH 1100 (4,018) | ||
| + | * XLH 1100 Anniversary (600) | ||
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| - | {{:common: | + | |
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| * **MoCo notes**: | * **MoCo notes**: | ||
| - | | + | |
| - | * August, James H Patterson named President and CEO of the motorcycle division | + | * August, James H Patterson named President and CEO of the motorcycle division |
| - | * First year of the HD traveling museum pulled by a Peterbilt tractor. The museum displays HD memorabilia and seven motorcycles | + | * First year of the HD traveling museum pulled by a Peterbilt tractor. The museum displays HD memorabilia and seven motorcycles |
| - | * HD, celebrating 85th anniversary with a Homecoming in Milwaukee attended by over 60,000 enthusiasts, | + | * HD, celebrating 85th anniversary with a Homecoming in Milwaukee attended by over 60,000 enthusiasts, |
| - | * H.O.G. membership totaling over 90,000 | + | * H.O.G. membership totaling over 90,000 |
| - | * The springer front end returns in the FXSTS Springer® Softail®. (( https:// | + | * The springer front end returns in the FXSTS Springer® Softail®. ((https:// |
| - | * **Service Notes / Recommendations**: | + | * **Service Notes / Recommendations**: |
| - | * A number of Screaming Eagle carb kits (91731-85A), | + | * A number of Screaming Eagle carb kits (91731-85A), |
| - | * **Factory Recalls**: | + | * **Factory Recalls**: |
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| + | * **Production Information**: | ||
| * XLH 883 (5,387) $3,995 | * XLH 883 (5,387) $3,995 | ||
| * XLH 883 Hugger (4,501) $4,199 | * XLH 883 Hugger (4,501) $4,199 | ||
| - | * XLH 883 Sportster Deluxe (1,893) $4,428 | + | * XLH 883 Sportster Deluxe (1,893) $4, |
| * XLH 1200 (4,752) $5,875 | * XLH 1200 (4,752) $5,875 | ||
| * **XLH 883 changes include**: | * **XLH 883 changes include**: | ||
| Line 1610: | Line 1681: | ||
| * Solo seat and cast wheels | * Solo seat and cast wheels | ||
| * Option package included: | * Option package included: | ||
| - | | + | |
| - | * Spoked wheels | + | * Spoked wheels |
| - | * Dual seat | + | * Dual seat |
| - | * Extra chrome | + | * Extra chrome |
| - | * Tach | + | * Tach |
| * **XLH 883 (Hugger Option)**: | * **XLH 883 (Hugger Option)**: | ||
| * Lowered suspension | * Lowered suspension | ||
| - | * Lowered seat | + | * Lowered seat |
| - | * Buckhorn handlebars | + | * Buckhorn handlebars |
| - | * **XLH 1200** | + | * **XLH 1200** (replacing the XLH 1100) featuring |
| - | * 1200cc Evolution OHV V-twin with 3.498 x 3.812 bore and stroke | + | * 1200cc Evolution OHV V-twin with 3.498 x 3.812 bore and stroke |
| * 39mm front forks | * 39mm front forks | ||
| * Two tone paint | * Two tone paint | ||
| * Dual seat | * Dual seat | ||
| * Buckhorn bars | * Buckhorn bars | ||
| - | * Speedometer and tach | + | * Speedometer and tach |
| * **Paint Colors**: | * **Paint Colors**: | ||
| - | * Vivid Black, Bright Cobalt Candy Blue, Bright Candy Plum, Candy Brandywine, Brandywine and Crimson, Bright Cobalt Candy Blue and Brilliant Silver, Candy Crimson, Candy Bronze and Crème, Vivid Black and Crème, Metallic Blue and Cadet Blue Metallic or Champagne Gold. | + | * Vivid Black, Bright Cobalt Candy Blue, Bright Candy Plum, Candy Brandywine, Brandywine and Crimson, Bright Cobalt Candy Blue and Brilliant Silver, Candy Crimson, Candy Bronze and Crème, Vivid Black and Crème, Metallic Blue and Cadet Blue Metallic or Champagne Gold. |
| + | | ||
| - | {{:common: | + | {{common: |
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| * **MoCo notes**: | * **MoCo notes**: | ||
| - | | + | |
| - | * **Factory Recalls**: | + | * **Factory Recalls**: |
| - | * The HD 883 Twin Sports Road Racing Series begins with full sanctions from the AMA. | + | |
| + | * **Racing notes**: | ||
| + | * The HD 883 Twin Sports Road Racing Series begins with full sanctions from the AMA. | ||
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| * **Production Information**: | * **Production Information**: | ||
| * XLH 883 (6,142) | * XLH 883 (6,142) | ||
| - | * XLH 883 Hugger (4,467) | + | * XLH 883 Hugger (4,467) |
| - | * XLH 883 Sportster Deluxe (1,812) | + | * XLH 883 Sportster Deluxe (1, |
| * XLH 1200 (4,546) | * XLH 1200 (4,546) | ||
| - | * XR-750 Engines Only (37) (( -2003 HD XR750 Service Manual XR 750 Production Schedule pg 69)) | + | * XR-750 Engines Only (37) ((1972-2003 HD XR750 Service Manual XR 750 Production Schedule pg 69)) |
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| * **XLH 883 and XLH 1200 changes include**: | * **XLH 883 and XLH 1200 changes include**: | ||
| * Aluminum intake manifold | * Aluminum intake manifold | ||
| * New air cleaner element | * New air cleaner element | ||
| * Offset piston pins | * Offset piston pins | ||
| - | * Protective coating added to battery positive cable | + | * Protective coating added to battery positive cable |
| - | * **XR-750** | + | * **XR-750** engines got an upgrade ((1972-2003 HD XR-750 Service Manual pg 3)) |
| - | * 12:1 CR (( -2003 HD XR-750 Service Manual pg 3)) | + | * 12:1 CR ((1972-2003 HD XR-750 Service Manual pg 3)) |
| - | * 37mm exhaust valves (( -2003 HD XR-750 Service Manual pg 3)) | + | * 37mm exhaust valves ((1972-2003 HD XR-750 Service Manual pg 3)) |
| - | * Primary drive ratio 25/59 with optional 30/59 (( -2003 HD XR-750 Service Manual pg 3)) | + | * Primary drive ratio 25/59 with optional 30/59 ((1972-2003 HD XR-750 Service Manual pg 3)) |
| * Cam lobes and gears are now pressed onto the shafts individually and then welded. Gears on #s 2&4 shaft assemblies are locked with a grooved pin. | * Cam lobes and gears are now pressed onto the shafts individually and then welded. Gears on #s 2&4 shaft assemblies are locked with a grooved pin. | ||
| - | * Max 9,200 RPM (( -2003 HD XR-750 Service Manual pg 3)) | + | * Max 9,200 RPM ((1972-2003 HD XR-750 Service Manual pg 3)) |
| * **Paint Colors**: | * **Paint Colors**: | ||
| - | * XL 883 and XL 883 Hugger: Vivid Black, Metallic Blue, Candy Brandywine, Bright Candy Plum. (( HD 1989-1996 Painted Parts Book pg 1-58)) | + | * XL 883 and XL 883 Hugger: Vivid Black, Metallic Blue, Candy Brandywine, Bright Candy Plum. ((HD 1989-1996 Painted Parts Book pg 1-58)) |
| - | * XL 1200 Hugger: Vivid Black, Metallic Blue/ Silver, Candy Brandywine, Candy Crimson/ Candy Brandywine, Bright Candy Plum. (( HD 1989-1996 Painted Parts Book pg 1-58)) | + | * XL 1200 Hugger: Vivid Black, Metallic Blue/ Silver, Candy Brandywine, Candy Crimson/ Candy Brandywine, Bright Candy Plum. ((HD 1989-1996 Painted Parts Book pg 1-58)) |
| * Kickstand repositioned further rearward | * Kickstand repositioned further rearward | ||
| - | {{:common: | + | {{common: |
