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Harley Davidson Sportsters 1970 - 2010 Haynes Owners Service & Repair Manual

The Harley-Davidson Sportster is a type of motorbikes created constantly since 1957 by Harley-Davidson. Sportster designs are designated in Harley-Davidson's item code by starting with "XL". In 1952, the predecessors on Sportster, the Model K recreation and recreation solamente motorbikes, had been introduced. These products K, KK, KH, and KHK of 1952 to 1956 have an appartment mind motor, whereas the later XL Sportster models use an overhead valve motor. Initial Sportster in 1957 had many of the same details of the KH including the framework, fenders, large vehicle's gas tank and front suspension system.

The terms longitudinal engine and transverse engine are generally always refer to the crankshaft positioning, however, some means, many prominently Moto Guzzi, make use of the terminology in the other method.

A Moto Guzzi Technical service representative attempted to show Los Angeles occasions columnist Susan Carpenter that Moto Guzzi motors were "called 'transverse' because motor are installed with the crankshaft focused front to back in the place of left to correct." Despite this, it could be believed that people whom contact V-twin bike machines "transverse" when they're attached with the crankshaft front-to-back and also the cylinders protruding the side say that in their mind, the engine's axis could be the range driving from a single cylinder to another, at the right direction toward crankshaft, rather than supposed by the crankshaft's axis. Highly technical sources, such V. Cossleter's Motorcycle characteristics, or Gaetaeno Cocco's Motorcycle build and Technology tend to be cautious not simply to utilize the terms "longitudinal motor" or "transverse system," but rather to indicate that they mark the engine's positioning on the basis of the crankshaft, and in addition they will state "transverse crankshaft motor" or "longitudinal crankshaft engine", or, alternatively, "transversely installed cylinders" in referenced on classic BMW direction, with a longitudinal crankshaft and cylinders at the right direction to your axis for the framework.
Transverse crankshaft mounting
Honda 90 transversely attached V-twin.

The motor is attached in transverse crankshaft position as on Harley-Davidsons, Ducatis and many present Japanese motorcycles. This design brings a twin cylinder motorcycle system that's little or no broader than one. A narrower engine may be attached low in the framework with dealing with advantages. A disadvantage for this configuration for air-cooled motors is the fact that two cylinders get various air-flows and cooling of this rear cylinder is often restricted. Soothing troubles were notably mitigated insurance firms all "four" side of each and every cylinder subjected to air flow. This differs from a parallel-twin cylinder system which has a definite front side, straight back, and sides, nevertheless within each cylinder is not exposed to airflow as cylinders are usually joined as well as a cam sequence operating up through block in-between the cylinders.

Sportster motorbikes were running on a four-stroke, 45 V-twin engine where both linking rods, of this "fork and blade" or "knife & fork" build, share a standard crank pin. The initial Sportster engine was the Ironhead engine, that was replaced utilizing the Evolution motor in 1986. Sportster machines, the 45 cubic inch R, D, grams & W products 1929 side-valve engines, together with 'gigantic Twin' side-valve engines, which were: the flathead 74.0 cu in (1,213 cc) products V, VL etcetera. (1930--1936), systems U and UL (1937--1948), plus the 80.0 cu in (1,311 cc) systems VH and VLH (1935--1936), models UH and ULH (1937--1941) have four individual webcams, wearing one lobe per cam.

The cam followers used in Sportster motors, K versions, larger twin side-valve models, and also the side-valve W design series were a somewhat shorter form of the followers used in the larger engines, however with similar 0.731-inch (18.6 mm) diameter system and 0.855-inch (21.7 mm) diameter roller follower since 1929. The organization put close cam supporters for decades with lesser changes, from the 1929 to the Eighties.
A typical 5-gear, foot-shift transmission on an HD Sportster

Sportster machines retained the K/KH design crankcase design, where transmission was contained in the exact same casting while the system, and driven because of the system with a triple-row #35 chain primary drive and a multi-plate cable-operated clutch. Brands since 1991 have actually five rates; 1990 and earlier brands have four speeds.

The engine is installed directly to the frame from 1957 through 2003 model year. While this system permits the cycle to-be somewhat lighter with additional exact control, it also transmits system vibration straight to the driver. Sportsters released in 2004 and soon after incorporate plastic separation supports and connect hyperlinks to restrict system motion to a single jet, which greatly decrease vibration considered because of the rider. Buell motorbikes constructed with variants associated with the Sportster system used a rubber mount system since 1987.

The Model K, from where the Sportster developed, is the very first civilian bike made by Harley-Davidson with hydraulic surprise absorbers on both rims. Common use calls this a K Model.

That is created from the prior 45 W design, however with the modified flat-head engine and brand-new 4-speed transmission included in the exact same castings as would become the Sportster. The connecting rods would-be inherited because of the Sportster and a number of other design elements and proportions.

Design K and KK 1952--1953: 750 cc side-valve motors, utilising the 45 model bore and stroke of 2.75" x 3.8125" (69.85 x 96.85 mm)
Design KR (racing best) 1953--1969: 750 cc side-valve motors
Model KH and KHK 1954--1956: 888 cc side-valve engines, with the 45 model bore, but with the stroke increased to 4.5625" (115.89 mm). This is the only smaller twin with a lengthier swing than 3.8125". The smaller stroke was usually universal towards the whole 45/K/Sportster line from 1929 to the present (exclusion: XR750, XB9 Buell).

XL show Sportsters
1957 Harley-Davidson XL Sportster

XL, Ironhead, 1957--1985: 883 cc and 1,000 cc Ironhead overhead-valve motors with cast iron heads, K-series framework
XLCH, Ironhead, (unofficial "competitors Hot" moniker) 1958--1971: 883 cc, and 1,000 cc 1972 & up
XR-750 (race with the exception of becoming Evel Knievel's jump bike while sponsored by Harley-Davidson between 1970 and 1977) 1970--1971: 750 cc overhead-valve engine, iron heads
XR-750 (racing just with the exclusion mentioned above) 1972--1985: 750 cc overhead-valve system, alloy heads
XLCR 1977--1978-1979: Cafe racer 1,000 cc overhead-valve system, iron minds, 2000 produced in 77, 1200 in 78, and 9 in 1979
XR-1000 1983--1984: 1,000 cc street model making use of XR racing cylinder head also XR engine components
XLR: 883 cc overhead-valve machines, metal minds

XLS Roadster 1979-1982 1000cc ironhead / 4 speed, stock elements -- 2" longer forks, 2 up seat, sissy bar, highway pegs, 3.3 gallon container

XLS Roadster, 1983-1985, 1,000 cc ironhead, 4 gallon fuel container with system
XL, Evolution (also known as the "Evo"), since 1986: 883 cc, 1,100 cc and 1,200 cc development overhead-valve motor, alloy heads


In XLCH above, the letter C stands for California, the page H in fact stands for lowest compression. Resource = Allan Girdler's Sportster book from very early '90s

1957 "Ironhead" overhead-valve system launched.
1958 XLH touring high compression design and XLCH sportier "Competition Hot" design introduced.
1972 "Ironhead" 1,000 cc overhead-valve motor replaces 900 cc.
1975 Switched to left-side equipment changes (DOT mandate)
1977 & 1979 Dual fatigue "Siamese" pipelines made use of, introduced on XLCR in 1977 all designs 1979, together with the triangular frame and rear hydraulic disk braking system additionally introduced in the XLCR.
1979 just last year when it comes to kickstart just XLCH, best 141 made.
1985 Last year the "Ironhead" overhead-valve engine.
1986 "development" motor introduced in 883 cc and 1,100 cc sizes.
1988 1200 cc system replaces 1,100 cc system.
1988 Constant velocity carburetor replaces butterfly carburetor.
1991 Five-speed transmission replaces four-speed.
1991 gear drive replaces sequence drive on 883 luxurious and all 1200 systems.
1993 Belt drive made standard on all Sportsters.
1994 better oil container, battery pack tray, and clutch made standard.
1994 brand new electric system with sealed connections.
1995 Speedometer happens to be electric, perhaps not technical.
1996 XL1200C Custom design launched.
1998 XL1200S gets twin spark plug heads and high end cameras
2000 launched sealed wheel bearings and updated four-piston braking system calipers.
2003 this past year the framework attached development system.
2004 All-new framework like rubber-mounted system for decreased vibration. Elimination associated with the transmission trap door, New shape hamcan, fatigue balance pipeline moved from running beneath the air conditioner filter and disguised and hidden behind the silencers to show more of engine, new smoother design oil container right side panel with push and turn filler/dipstick, and also the previously subjected power is enclosed in a matching part panel on left
2005 Enlarged rear axle to at least one inches (25.4 mm) for increasing stability.
2006 brand new XR1200 are established at Intermot in Cologne, Germany. The XR1200 may be the first Harley-Davidson to work with Down Draft DDFI II gas shot. Becoming introduced as a late 2006 design. Introduction of helical gears in transmission (2nd-5th).
2007 gasoline injections replaces carburetion on all brands.
2008 forward axle enlarged from 3/4 inch to 25 mm, back axle diminished from 1 inch (25.4 mm) to 25 mm
2009 "One size meets all" front mudguard strategy replaced by better mudguard contour to suit each design's respective wheel diameters.
2010 The ECU try relocated to allow even more variation in aftermarket seat choice
2010 Side-mounted license dish choice on some designs
2014 brand new electric use, latest bigger brakes, antilock brakes (abdominal muscles) alternative, keyless entry, latest speedometer with equipment indicator/tachometer, increasing system compression ratio, catalytic converter



Some transverse V-twins need an individual carburettor in the center of the V-angle to give both cylinders. While this enables an economy of section, it generates further air conditioning difficulties the rear cylinder by putting its hot exhaust interface and pipeline at the back of the cylinder, taken care of or the atmosphere stream.

These big-twin motorcycles capitalize on Harley's stronger benefits on tradition. Because of the rear-wheel suspension hidden under the transmission, they have been visually like the "hardtail" choppers well-known when you look at the sixties and 1970s, along with from their particular earlier records. Consistent with that traditions, Harley offers Softail models with "Springer" forward ends and "traditions" design that include design cues from in their records.

Designation

Softail products utilize the big-twin motor (F) as well as the Softail framework (ST).

Softail versions which use 21" Front Wheels have designations that start with FXST, e.g., FXSTB (Night Train), FXSTD (Deuce), and FXSTS (Springer).
Softail systems that use 16" Front rims posses designations you start with FLST, e.g., FLSTF (Fat son), FLSTC (traditions Softail Classic), FLSTN (Softail Deluxe) and FLS (Softail Slim).
Softail models that use Springer forks with a 21-inch (530 mm) wheel have designations that begin with FXSTS, e.g., FXSTS (Springer Softail) and FXSTSB (Bad son).
Softail products that use Springer forks with a 16-inch (410 mm) wheel has designations that start out with FLSTS, e.g., FLSTSC (Springer Classic) and FLSTSB (Cross Bones).

Dyna
Principal article: Harley-Davidson Super Glide
2005 Dyna Super Glide Personalized.

Dyna-frame motorcycles were created within the 1980s and very early 1990s and premiered into the 1991 design 12 months with all the FXDB Sturgis offered in limited version quantities. In 1992 the range continued with the minimal version FXDB Daytona and a production design FXD Super Glide. The brand new DYNA framework featured big-twin engines and conventional styling. They can be distinguished from the Softail by the conventional coil-over suspension system that links the swingarm towards frame, and from Sportster by their particular bigger motors. On these products, the transmission also houses the engine's oils reservoir.

Just before 2008, Dyna models usually featured a slim, XL-style front side fork and front-wheel, that your manufacturer included the page "X" into the design designation to indicate. This lineup usually included the Super Glide (FXD), Super Glide Customized (FXDC), road Bob (FXDB), and minimum driver (FXDL). One exemption was the Wide Glide (FXDWG), which preserved the width associated with XL forks and a narrow front wheel, but positioned the forks on wider triple-trees that provide a beefier look. In 2008, the Dyna Fat Bob (FXDF) ended up being launched into Dyna lineup, featuring intense styling like a 2--1--2 exhaust, twin headlamps, a 180 mm rear tire, and, for the first time inside Dyna lineup, a 130 mm forward tire. When it comes to 2012 design season, the Dyna Switchback (FLD) became 1st Dyna to break the traditions of experiencing an FX model designation: with removable painted difficult saddlebags, touring windshield, bigger hand pipes, headlight nacelle and a broad front side tire with full fender. The brand new front end resembled the big-twin FL versions from 1968-1971.

The Dyna household used the 88-cubic-inch (1,440 cc) twin cam from 1999 to 2006. In 2007, the displacement ended up being increased to 96 cubic ins (1,570 cc) once the factory increased the stroke to 4.375 inches (111.1 mm). When it comes to 2012 model 12 months, the maker started initially to promote Dyna products with all the 103-cubic-inch (1,690 cc) upgrade. All Dyna products use a rubber-mounted motor to separate engine vibration.

Designation

Dyna brands utilize the big-twin motor (F), small-diameter telescopic forks similar to those applied to the Sportster (X) until 2012 whenever one design put the large diameter forks similar in features to those used on the Touring (L) products, as well as the Dyna framework (D). For that reason, with the exception of the FLD from 2012 to the current, all Dyna designs need designations that begin with FXD, e.g., FXDWG (Dyna open Glide) and FXDL (Dyna Low Rider).
Sportster
Principal article: Harley-Davidson Sportster
2002 Sportster 883 Personalized
2003 Harley-Davidson XL1200 Personalized Anniversary Edition

Introduced in 1957, the Sportster families were conceived as rushing motorbikes, and were popular on dust and flat-track race curriculum through the 1960s and 1970s. Smaller and lighter than the other Harley products, modern Sportsters make use of 883 cc or 1,200 cc development motors and, though often altered, stays comparable in features for their race ancestors.

Up to the 2003 model seasons, the motor regarding the Sportster ended up being rigidly attached towards the framework. The 2004 Sportster gotten a brand new framework accommodating a rubber-mounted system. This made the bicycle heavier and paid off the available lean perspective, while it paid down the actual quantity of vibration sent into framework therefore the driver, offering a smoother ride for rider and passenger.

In 2007 model seasons, Harley-Davidson celebrated the 50th anniversary of the Sportster and produced a limited version known as the XL50, that only 2000 had been created for purchase worldwide. Each bike had been separately numbered and came in one of two colors, Mirage Pearl lime or Vivid Ebony. Furthermore in 2007, electric gas shot had been introduced into Sportster families, additionally the Nightster model is launched in mid-year. Last year, Harley-Davidson included the metal 883 towards the Sportster range, as part of the black Custom show.
2014 Sportster XL1200C

When you look at the 2008 design year, Harley-Davidson released the XR1200 Sportster in European countries, Africa, and Middle East. The XR1200 have an Evolution system tuned to produce 91 bhp (68 kW), four-piston twin front side disc brake system, and an aluminum swing arm. Motorcyclist featured the XR1200 from the address of their July 2008 problem and was generally speaking good about it inside their "very first Ride" tale, in which Harley-Davidson was over and over repeatedly asked to sell they in the us. One possible basis for the delayed accessibility in the us ended up being that Harley-Davidson must obtain the "XR1200" naming liberties from Storz results, a Harley customizing store in Ventura, Calif. The XR1200 was released in america in 2009 in an unique shade plan including Mirage tangerine highlighting its dirt-tracker history. The initial 750 XR1200 products during 2009 are pre-ordered and came with lots 1 tag for the front of the bike, autographed by Kenny Coolbeth and Scott Parker and a thank you/welcome page from the providers, finalized by costs Davidson. The XR1200 is discontinued in model season 2013.

Designation

Excluding the street-going XR1000 for the 1980s plus the XR1200, many Sportsters created for street utilize have the prefix XL in their design designation. When it comes to Sportster advancement motors put considering that the mid-1980s, there have been two system sizes. Motorbikes using the modest system were designated XL883, while people that have the bigger motor had been initially designated XL1100. When the measurements of the more expensive system had been enhanced from 1,100 cc to 1,200 cc, the designation ended up being altered accordingly from XL1100 to XL1200. Subsequent letters within the designation refer to model variations inside the Sportster range, e.g. the XL883C refers to an 883 cc Sportster Personalized, while the XL1200S designates the now-discontinued 1200 Sportster Sport.
VRSC
Main article: Harley-Davidson VRSC
V-Rod

Introduced in 2001, the VRSC family bears small similarity to Harley's more traditional lineup. Contending against Japanese and US muscles bikes into the upcoming power cruiser section, the "V-Rod" utilizes a system developed jointly with Porsche that, for the first time in Harley records, incorporates overhead cameras and liquid cooling. The V-Rod try aesthetically unique, effortlessly identified by the 60-degree V-Twin engine, the radiator together with hydroformed framework customers that offer the round-topped air cleaner cover. The VRSC platform has also been employed for factory drag-racing motorbikes.

In 2008, Harley added the anti-lock braking system as a factory installed solution on all VRSC versions. Harley in addition increasing the displacement regarding the inventory system from 1,130 to 1,250 cc (69 to 76 cu in), which had best formerly been offered by Screamin' Eagle, and included a slipper clutch as standard equipment.

VRSC designs integrate:

VRSCA: V-Rod (2002--2006), VRSCAW: V-Rod (2007--2010), VRSCB: V-Rod (2004--2005), VRSCD: evening Rod (2006--2008), VRSCDX: Night Rod specialized (2007--2014), VRSCSE: Screamin' Eagle CVO V-Rod (2005), VRSCSE2: Screamin' Eagle CVO V-Rod (2006), VRSCR: road Rod (2006--2007), VRSCX: Screamin' Eagle Tribute V-Rod (2007), VRSCF: V-Rod strength (2009--2014).

Designation

VRSC products utilize Revolution system (VR), in addition to road versions were designated Street Custom (SC). After the VRSC prefix common to any or all street transformation bicycles, next page denotes the model, either A (base V-Rod: stopped), AW (base V-Rod + W for open with a 240 mm back tire), B (stopped), D (Night pole: discontinued), R (road Rod: stopped), SE and SEII(CVO Unique Edition), or X (Special version). Further differentiation within systems are produced with an extra letter, e.g., VRSCDX denotes the evening pole certain.
VRXSE

The VRXSE V-Rod Destroyer was Harley-Davidson's production drag race bike, constructed to perform the quarter mile in less than ten moments. It's in line with the same revolution system that powers the VRSC range, however the VRXSE makes use of the Screamin' Eagle 1,300 cc "stroked" incarnation, featuring a 75 mm crankshaft, 105 mm Pistons, and 58 mm throttle figures.

The V-Rod Destroyer isn't a street legal motorcycle. Therefore, they utilizes "X" in the place of "SC" to denote a non-street cycle. "SE" denotes a CVO Special version.
Road
Main article: Harley-Davidson Street

The Street, Harley-Davidson's most recent platform and their first brand new system in thirteen many years, was designed to attract young bikers wanting a light cycle at a less expensive cost. The Street 750 model was launched in India at 2014 Indian automobile exhibition, Delhi-NCR on 5 February 2014. The road 750 weighs 218 kg and has now a ground approval of 144 mm giving they the cheapest fat together with highest surface clearance of Harley-Davidson motorcycles currently available.

The Street 750 makes use of an all-new, liquid-cooled, 60 V-twin engine called the Revolution X. In the pub 750, the motor displaces 749 cc (45.7 cu in) and produces 65 Nm at 4,000 rpm. A six speeds transmission can be used.

The Street 750 plus the smaller-displacement Street 500 is for sale in late 2014. Road series motorcycles for united states marketplace will likely to be integrated Harley-Davidson's Kansas town, Missouri plant, while those for other markets around the world is likely to be built totally within their plant in Bawal, Asia.
In 1901, 20-year-old William S. Harley received up programs for a little motor with a displacement of 7.07 cubic inches (116 cc) and four-inch (102 mm) flywheels. The motor ended up being designed for use within a consistent pedal-bicycle frame. Within the next couple of years, Harley along with his childhood buddy Arthur Davidson handled their motor-bicycle utilizing the northside Milwaukee device store on house of their friend, Henry Melk. It was completed in 1903 with the aid of Arthur's sibling, Walter Davidson. Upon testing their power-cycle, Harley and the Davidson brothers receive it struggling to rise the hills around Milwaukee without pedal aid. They quickly authored down their first motor-bicycle as a very important understanding experiment.

Efforts immediately started on a unique and better second-generation device. This first "real" Harley-Davidson motorcycle have a more impressive motor of 24.74 cubic ins (405 cc) with 9.75 inches (25 cm) flywheels evaluating 28 lb (13 kg). The equipment's advanced loop-frame pattern was like the 1903 Milwaukee Merkel motorcycle (created by Joseph Merkel, later of Flying Merkel popularity). The bigger engine and loop-frame build took it out of motorized bike group and marked the path to future motorcycle design. The boys additionally obtained assistance with their larger engine from outboard engine pioneer Ole Evinrude, who was simply then building gas engines of his own design for automotive utilize on Milwaukee's pond road.
Model

The prototype of new loop-frame Harley-Davidson is put together in a 10 ft 15 ft (3.0 m 4.6 m) shed in the Davidson families garden. A lot of the big components, but were made elsewhere, like some probably fabricated during the West Milwaukee railshops in which oldest bro William A. Davidson was then toolroom foreman. This prototype machine is functional by September 8, 1904, with regards to competed in a Milwaukee motorcycle competition presented at condition Fair Park. It was ridden by Edward Hildebrand and put fourth. This is the very first documented look of a Harley-Davidson motorcycle when you look at the historical record.

In January 1905, little advertising are put in the Automobile and pattern Trade Journal promoting bare Harley-Davidson motors toward do-it-yourself trade. By April, full motorbikes were in production on a rather restricted foundation. That seasons, the very first Harley-Davidson supplier, Carl H. Lang of Chicago, offered three bicycles through the five built in the Davidson yard shed. Years later on the first shed ended up being taken up to the Juneau opportunity factory where it would are a symbol of numerous years as a tribute to the engine organization's modest origins until it was inadvertently ruined by technicians washing the factory backyard during the early 1970s.

In 1906, Harley plus the Davidson brothers built their particular earliest factory on Chestnut Street (later Juneau opportunity), on present venue of Harley-Davidson's business head office. The very first Juneau opportunity plant ended up being a 40 ft 60 ft (12 m 18 m) single-story wooden framework. The company created about 50 motorcycles that seasons.
1907 design.
Harley-Davidson 1,000 cc HT 1916

In 1907, William S. Harley graduated from college of Wisconsin--Madison with a diploma in technical engineering. That 12 months further factory development was included with another flooring and later with facings and improvements of Milwaukee pale yellow ("cream") stone. Because of the brand new services manufacturing risen up to 150 motorbikes in 1907. The business ended up being formally included that September. They even started offering their particular motorbikes to authorities divisions around this time, a market that has been vital that you them ever since.

Production in 1905 and 1906 had been all single-cylinder brands with 26.84 cubic inches (440 cc) engines. In February 1907 a prototype model with a 45-degree V-Twin system is shown on Chicago Automobile program. Although shown and marketed, hardly any V-Twin models are built between 1907 and 1910. These very first V-Twins displaced 53.68 cubic inches (880 cc) and produced about 7 horsepower (5.2 kW). This offered around twice as much power regarding the earliest singles. Top speeds was about 60 miles per hour (100 km/h). Production hopped from 450 motorcycles in 1908 to 1,149 machines in 1909.
Harley-Davidson works in 1911

By 1911, some 150 makes of motorbikes have been built in the usa -- although only a few would survive the 1910s.

In 1911, a greater V-Twin design was introduced. The latest motor have mechanically managed intake valves, instead of the "automatic" intake valves used on earlier in the day V-Twins that opened by system cleaner. With a displacement of 49.48 cubic ins (811 cc), the 1911 V-Twin is smaller than early in the day twins, but gave much better overall performance. After 1913 many bikes from Harley-Davidson will be V-Twin systems.

In 1912, Harley-Davidson introduced their patented "Ful-Floteing Seat", which was suspended by a coil spring within the seat tube. The springtime tension could be modified to accommodate the rider's weight. A lot more than 3 inches (76 mm) of vacation ended up being available. Harley-Davidson would utilize chairs for this kind until 1958.

By 1913, the yellow brick factory was in fact demolished and on your website a unique 5-story structure was in fact built. Begun in 1910, the factory along with its many improvements would take up two-blocks along Juneau opportunity and around the corner on 38th road. Inspite of the competition, Harley-Davidson was already pulling in front of Indian and would dominate bike rushing after 1914. Manufacturing that year swelled to 16,284 machines.

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