Harley Davidson (1970 to 1978) Sportster XL/XLH/XLCH/XLT-1000. Service manual — page 1

FOREWORD
This service and repair manual has been prepared with two purposes in mind. First, it will acquaint the reader with the construction of the Harley-Davidson product and assist him in performing basic maintenance and repair. Secondly, it will introduce to the professional Harley-Davidson mechanic the latest field-tested and factory-approved major repair methods. We sincerely believe that this manual will make your association with Harley-Davidson products more pleasant and profitable.

HOW TO USE YOUR SERVICE MANUAL
SERVICE BULLETINS
Your Service Manual is arranged for quick, easy reference. This manual is divided into numbered sections entitled ''Chassis,” "Engine” and "Transmission.” Sections are then divided into sub-sections. The Engine Section, for example, is comprised of "Cylinder” and "Crankcase" subsections.

Use this manual as follows:

1. Check the Table of Contents located in the front of each section to find subject desired.

2. Page number is listed across from subject.

3. Each section is printed with section number for quick general location of subject. Page number consists of section number and page number.

Information is presented in a definite order as follows:

Minor adjustments Minor maintenance or repair Complete disassembly Cleaning

Major maintenance or repair Assembly

In figure legends the number following a name of a part indicates the quantity necessary for one complete assembly.

All information for servicing a part should be read before repair work is started to avoid needless disassembly.
In addition to the information given in this Service Manual, Service Bulletins are issued to Harley-Davidson Dealers from time to time, which cover interim engineering changes and supplementary information. Service Bulletins should be consulted for complete information on the models covered in this manual.
USE GENUINE REPLACEMENT PARTS
To ensure a satisfactory and lasting repair job, follow the manual instructions carefully and use only genuine Harley-Davidson replacement parts.

This is your insurance that the parts you are using will fit right, operate properly and last longer. When you use genuine Harley-Davidson parts you use the best.
WARNING — Gasoline is extremely flammable and highly explosive under certain conditions, always stop engine, and do not smoke or allow open flame or sparks when refueling or servicing the fuel system, or when using gasoline as a cleaning solvent where specified in this manual.
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Harley-Davidson products are manufactured under one or more of the following patents: U.S. Patents — 2986162, 2987934. 2998809. 3116089. 3144631. 3144860. 3226994. 3229792. 3434887. 3559773. Des. 225 626.

TABLE OF CONTENTS

PRODUCT

SPECIFICATIONS

Dimensions

Capacities

Engine

Transmission Tire Data
SERVICE Servicing a New Motorcycle 1-3 Recommended Operations at First 500 and 1,000 Miles 1 -3 Regular Service Intervals 1-4
Lubricants

TORQUE REQUIREMENTS Fastener Tightening

LOCATING TROUBLES Engine

Lubrication System

Electrical System

Carburetor

Transmission

Clutch

"'таке

«Jussis

DRIVE Front Chain Adjustment Lubrication Replacing Rear Chain Adjustment Rear Chain Oiler Servicing Rear Chain

WHEELS Service Chart Removing and Installing Wheels Hub$

Sprocket Replacement Spoking Wheels Truing Wheels Truing Rim Removing Tire and Tube from Rim Mounting Tire and Tube on Rim Checking Tire Trueness Aligning Wheels

VJDLEBAR THROTTLE

Spiral Type Disassembling

Assembling 2-17

Drum Type 2-18

Disassembling and Assembling 2-18

FRAME 2-19

FORKS

Front Fork 2-21

Servicing 2-21

Disassembling and Repair 2-24 Assembly 2-30

Rear Shock Absorber 2-31

Rear Fork 2-32

BRAKES

Servicing 2-35

Adjusting Front Wheel Brake 2-35

Adjusting Rear Wheel Brake 2-35

Replacing Front Wheel Brake Cable 2-36

Disassembling Brakes 2-36

Inspecting and Repairing Brakes 2-36

Assembling Brakes 2-37

Cross Shaft 2-37

Rear Brake Foot Pedal (1977 & Later) 2-38

Front Disc Brake

(1973 & Later) 2-40

Check List 2-41

1973 Front Disc Brake 2-42

Disassembling and

Reassembling 2-42

1974 and Later Front

Disc Brake 2-43

Front Brake Master Cylinder 2-45

Bleeding Hydraulic System 2-46

FIBERGLASS BODY CARE AND REPAIR

General 2-47

Surface Finishing 2-47

Molded-in-Color Surface Repairs 2-48

Patching of Holes,

Purtfllures and Breaks 2-49

TOOLS. 2-53

ENGINE

GENERAL

‘Specifications 3-1

Description 3-1

Lubrication 3-2

CYLINDER HEAD
Removing 3-11

Disassembling 3-11

Cleaning and Inspecting 3-11

Repair Rocker Arm and Bushings 3-13

Refacing Valves and Valve Seats 3-13

Assembling Cylinder Head 3-14

Adjusting Tappets 3-15

Removing and Installing Push Rods Only 3-15

CYLINDER AND PISTON Removing 3-17

Cleaning and Inspecting 3-17

Refinishing Cylinders 3-17

Fitting Piston Rings 3-19

Connecting Rod Bushing 3-20

Straightening Connecting Rods 3-20

Assembling Cylinder and Piston 3-21

GEARCASE Oil Pump 3-23

Check Valve 3-23

Cleaning and Inspecting Oil Pump 3-24

Assembling Oil Pump 3-25

Disassembling Oil Pump 3-25

Valve Tappets and Guides 3-28

Gearcase Cover and Timing Gears 3-30

Disassembling 3-30

Cleaning and Inspecting 3-31

Bearing Replacement 3-31

Assembling 3-32

CRANKCASE General 3-35

Disassembling Crankcase 3-35

Flywheels 3-37

Assembling Crankcase 3-42

FUEL SYSTEM Carburetor (Tillotson) 3-45

Description 3-45

Operation 3-45

Adjusting 3-48

Inspecting and Testing 3-49

Disassembling 3-51

Cleaning, Inspecting, and Repairing 3-51

Assembling 3-53

Troubleshooting Guide 3-53

Carburetor (Bendix) 3-54

Operation 3-54

Adjusting 3-55

Disassembling 3-56

Cleaning and Inspection 3-56 Assembling 3-58

Carburetor (Keihin) 3-58

Operation 3-58

Adjusting 3-61

Disassembling 3-61

Cleaning and Inspecting 3-62 Assembling 3-62

Installing 3-62

Troubleshooting Chart 3-64

Air Cleaner 3-66

Fuel Tank 3-66

Fuel Supply Valve 3-66

TOOLS 3-69

TRANSMISSION

GENERAL Specifications 4-1

Description 4-1

CLUTCH

Diagnosis Chart 4-3

1970 Clutch Controls 4-3

Adjusting Clutch Release

' Mechanism 4-3

Adjusting Clutch Spring Tension 4-3

Replacing Clutch Control Cable and Coil 4-4

Disassembling Clutch Release Mechanism 4-4

Inspecting Clutch Release Mechanism 4-5

Assembling Clutch Release Mechanism 4-5

1971 and Later Clutch

Controls 4-6

Adjusting Clutch Release Mechanism 4-6

Adjusting Clutch Spring Tension 4-6

Disassembling Clutch Release Mechanism and Clutch Cable 4-6

Inspecting and Repairing Clutch Release Mechanism and Clutch Cable 4-6

Assembling Clutch Release Mechanism and Clutch Cable 4-8

1970 Clutch 4-8

Disassembling 4-8

Inspecting and Repairing 4-8

Replacing Clutch Sprocket

Needle Bearing and Starter Clutch 4-9

Assembling Clutch 4-9

1971 and Later Clutch 4-11

Disassembling 4-11

Inspecting and Repairing 4-11

Assembling Clutch 4-14

Compensating Sprocket 4-15

KICK STARTER General 4-17

Disassembling 4-17

Inspecting and Repair 4-18

Assembling 4-18

ELECTRIC STARTER Starter Drive 4-21

Disassembling Solenoid 4-21

Disassembling Starter Drive Shaft and Housing 4-22

Assembling Starter and Solenoid 4-22

TRANSMISSION General 4-23

1975 and 1976 Shifter Linkage 4-23

Removing Transmission 4-24

Inspecting and Replacing Parts 4-25

Assembling Transmission 4-28

Lubrication 4-30

TOOLS 4-31

ELECTRICAL

WIRING Wiring Diagrams 1970-71 XLH 5-3

1970-71 XLCH 5-5

1972 XLH Std. Seat 5-5

1972 XLCH Std. Seat 5-6

1972 XLH Low Seat 5-7

1972 XLCH Low Seat 5-7

1973-74 XL 5-9

1973-74 XLCH 5-9

1975 & 1976 XL 5-11

1975 & 1976 XLCH 5-11

1977 XL 5-13

1977 XLCH 5-13

1978 XL 5-15

1978 XLCH 5-15

SWITCHES

Button

Solenoid Switch Stop Lamp Front Brake Switch

Starter Relay Switch

LAMPS Headlamp Adjusting Beam Bulb Chart

GENERATOR Checking, Testing and Repair Brushes Field Coils Armature Commutator Disassembling Assembling

CIRCUIT BREAKER Description Operation Troubleshooting Adjusting Points Ignition Timing Disassembling and Assembling Installing Circuit Breaker

Disassembling and Assembling 1971 & Later Models
IGNITION COIL Troubleshooting Replacing Cables

SPARK PLUGS Removing Plugs Cleaning, Inspecting and Repair

Setting Spark Gap Testing Spark Plugs Installing Spark Plugs

REGULATOR -1977 & EARLIER Tests

Test Specifications Testing Method I (Model XLH)

Testing Method I (Model XLCH)

PRODUCT
TABLE OF CONTENTS

PAGE

General . . . . . . . . . . . . . .. 1-1

Service. . . . . . . . . . . . . ... 1-3

Locating Troubles. . . . . . . . . . . 1-15

GENERAL

SPECIFICATIONS

DIMENSIONS

SERVICE

SERVICING A NEW MOTORCYCLE

RE-DELIVERY

Service operations to be performed before delivery to customer are specified in the Setting Up Instructions and Important Instructions included with new vehicle.

CHECK AT FIRST 500 MILES

1. Drain oil tank through drain plug, flush with kerosene and refill with fresh oil.

2. If motorcycle is equipped with oil filter, service the filter.

3. Drain transmission and front chain compartments, clean transmission magnetic drain plug, and refill with fresh oil. Use same grade oil used in engine. Reinstall plug. If an oil leak is noted, reinstall plug along with Seal Washer, Part No. 6370.

4. Lubricate all points indicated for 2000 mile servicing as described in the Regular Service Intervals Chart.

5. Inspect and service air cleaner if needed.

6. Check and adjust chains.

7. Check lubrication and condition of rear chain and adust rear chain oiler if necessary.

. Check all nuts, bolts and screws, and tighten any found loose to specified torque.

9. Check wheel mounting bolts which secure rear wheel to brake assembly. These bolts must be kept very tight. See torque chart.

10. Check battery solution level and add distilled water if needed. Make sure terminals are clean and connections tight.

11. Check tightness of all cylinder head bolts and all cylinder base nuts. See torque chart.

12. Check tappet adjustment and readjust if necessary.

13. Check spark plug electrodes, clean and regap if necessary.

14. Check ignition timing and circuit breaker point condition and gap

15. Check wheel spokes and tighten if necessary.

16. Check front fork and rear fork bearing adjustment.

17. Check clutch adjustment.

18. Check brake adjustment.

19. Aim headlight.

20. Oil all control joints and parts as indicated in 2000 mile regular service intervals.

21. Check gasoline supply valve, lines, and fittings to be iure there are no leaks.
22. Check tire pressure and inspect tread.

23. Change front fork oil.

24. Check fluid level in master cylinder reservoir. Check brake lines and brake caliper for leaks

25. Check carburetor controls and adjustment

26. Inspect brake pad linings and brake discs for wear

27. Check oil lines and fittings for leaks

28. Road test.
CHECK AT FIRST 1000 MILES

1. Drain oil tank through drain plug and refill with fresh

oil.

2. Clean oil filter (if applicable).

3 Check level of oil in transmission and front chain compartments and add oil if needed. Use same grade of oil used in engine.

4 Service air cleaner.

5. Check and adjust chains.

6. Check lubrication and condition of rear chain and adjust rear chain oiler if necessary.

7. Check battery solution level and add distilled water if needed. Make sure terminals are clean and connections tight.

8. Check tappet adjustment and readjust if necessary.

9. Check circuit breaker points and adjust if needed

10. Check clutch adjustment.

11. Check brake adjustment.

12. Check tire pressure and inspect tread.

13. Check gasoline supply valve, lines, and fittings to be sure there are no leaks.

14 Check fluid level in master cylinder reservoir.

15. Check and tighten spokes.

16 Check carburetor controls and adjustment.

17. Lubricate all controls and fittings

18. Inspect brake linings and discs.

19. Check all lines and brake system for leaks.

20. Check all fasteners (nuts, bolts, screws) and make sure they are tight. See torque chart.

21. Check tightness of cylinder base nuts and cylinder head bolts. See torque chart.

22. Road test.

All operations are fully described in subsequent sections