Information och ändringar Sportster XL 1957-2005

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Harley Davidson Sportster History


Contributions by: docjimbob, Tim Schumacher, Tom Riccio, & Kev Maher and Bruce’s Harley Page (check for History on all HD models)
Timeline:

• Model “K”: 1952-1956
• Ironhead: 1957-1985
• Evolution: 1986-Present

1957:

• The Sportster XL was introduced as “a modern, up-to-date power plant.”
• 55cid 7.5:1 Compression, hemi-spherical style heads, 90 degree valve angle, 4 cams
• Production Information:
• XL (1983), $1,103

1958:

• XLH introduced with higher compression and larger valves
• Camshaft gears became integrated with the camshafts, eliminating the need for a woodruff key.
• Drive gearshaft was enlarged .125 in.
• Drive gear and second gear support shaft was enlarged .125 in and had 8 splines (instead of 6).
• Choke control lever moved from left side to the air cleaner.
• Heavier clutch cover and new gasket.
• New oil resistant clutch hub seal and gearshaft o-ring.
• Two brush generator.
• Optional turn signals and 1 in over suspension.
• The XLC & XLCH (Competition/California Hot)
• Larger ports and valves
• High domed pistons
• Light ended tappets
• Magneto ignition
• Production Information:
• XL (579) $1,155
• XLH (711),
• XLC, XLCH (239)

1959:

• New dual exhaust on XLH with twin mufflers.
• Nacelle headlamp on XLH
• 5 ¾ in headlamp with eyebrow on XLCH
• Trip-o-meter on XLCH
• Nylon chain tensioner
• Single switch ignition on left fork
• Valanced front fender
• End relieved connecting rod bearings
• 14.5 sec ¼ mile (90 mph)
• Production Information:
• XL (42), $1,175
• XLH (947), $1,200
• XLCH (1059), $1,285

1960:

• New shock absorbers.
• Production Information:
• Sportsters (2,765)
• XLH $1,225
• XLCH $1,310

1961:

• Creased edge on fuel tank.
• Production Information:
• Sportsters (2014)
• XLH $1,250
• XLCH $1,335

1962:

• Aluminum upper triple tree.
• XLR appeared for TT racing.
• Production Information:
• Sportsters (1998)
• XLH $1,250
• XLCH $1,335

1963:

• Both XLH & XLCH got 1.323:1 3rd gear ratios (were 1.381)
• Final ratio 5.56:1 on the H
• Final ratio 5.85:1 on the CH
• XLCH got “shorty duals”
• XLCH got an ignition key and improved magneto/coil
• 14.3 sec ¼ mile (92 mph)
• Production Information:
• XLH (432), $1,270
• XLCH (1,001), $1,355

1964:

• Chrome panel for XLCH lower fork bracket.
• New graphic for the XLH (oil tank).
• Full width aluminum brake drum in the front.
• Aluminum tappet guides.
• Production Information:
• XLH (810), $1,295
• XLCH (1950), $1,360

1965:

• XLH and XLCH received a 12 volt electrical system.
• XLH got automatic spark advance.
• Racing-type ball end levers.
• High fidelity horn.
• New shocks
• 3.7 gal fuel tank
• Production Information:
• XLH (955)
• XLCH (2815)

1966:

• P Cams, race developed intake ports, jumbo valves -> 60 hp
• Tillotson diaphragm carb
• “Ham-can” air cleaner
• Carb heat insulator
• Hexagonal tank badge.
• Production Information:
• XLH (900) $1,415
• XLCH (3,900) $1,411
• XLRTT (25)

1967:

• Electric start option.
• New shocks
• Production Information:
• XLH (2,000) $1,650
• XLCH (2,500) $1,600

1968:

• New forks (damping and travel) and the fork boots were canned.
• Kick start was dropped from the XLH.
• Restyled primary cover.
• Peanut tank was an option on the XLH
• Production Information:
• XLH (1,975) $1,650
• XLCH (4,900) $1,600

1969:

• First use of the exhaust crossover pipe (increases hp by 5 to 58 hp) with stacked duals
• New head castings.
• Safety bead wheel rims.
• Production Information:
• XLH (2,700) $1,765
• XLCH (5,100) $1,698

1970:

• XLH got the headlamp eyebrow of the XLCH
• Optional boat tail (again in 71)
• Magneto ignition on the XLCH replaced with XLH’s points/coil.
• First year for XR-750
• Production Information:
• XLH (3,033)
• XLCH (5,527)

1971:

• Wet clutch with single spring.
• Points and condenser moved behind plate on timing case cover.
• Production Information:
• XLH (3,950)
• XLCH (6,825)

1972:

• The 61 cid (called a 1000cc) XL replaced the 900.
• Rated for 61 hp, 9:1 CR, 110+mph, 13.38 sec ¼ mile (97.7 mph), and 43 mpg.
• Bendix/Zenith carb.
• Wet clutch.
• New oil pump.
• Oil tank placed near chain
• Seat is thinner w/less padding.
• Production Information:
• XLH (7,500) $2,120
• XLCH (10,650)

1973:

• First AMF production Harley
• Mandatory turn signals.
• New 35mm Kayaba forks, single disc front brakes.
• Production Information:
• XLH (9,875)
• XLCH (10,825)

1974:

• Throttle used return springs.
• Production Information:
• XLH (13,295)
• XLCH (10,535)
• XR (100)

1975:

• Left hand side gear shifting, right hand side rear brake (Fed mandated)
• New 35mm Showa forks.
• Production Information:
• XLH (13,515)
• XLCH (5,895)

1976:

• Production Information:
• XLH (12,844)
• XLCH (5,238)

1977:

• New cases to accommodate the left side shifting.
• Frame designed for removal of oil pump with engine in frame.
• XLT (touring) became available
• included thicker seat
• 3.5 gallon tank
• touring handle bars
• saddlebags from FLH
• geared higher
• windshield
• XLCR was introduced at Daytona (available again in 78).
• cast aluminum wheels
• fiberglass tail section w/solo seat
• wrinkle black engine paint
• bikini fairing
• black siamese exhaust
• dual disc front brakes
• low bars
• black paint scheme [on everything]
• 4 gallon gas tank
• 68 horses, 9:1 compression, 110 mph
• Production Information:
• XLH (12,742)
• XLCH (4,074)
• XLT (1,099)
• XLCR (1,923) $3,623

1978:

• Cast wheels option
• Front dual disc brakes
• Electronic ignition
• Battery and oil tank moved inboard
• HD 75th anniversary model XLH
• Midnight black w/gold trim
• anniversary graphics
• gold aluminum wheels
• Production Information:
• XLH (11,271)
• XLH Anniv model (2,323) $3,127
• XLCH (2,758) $3,370
• XLT (6)

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1979:

• All models got the XLCR frame and exhaust (Siamese).
• XLT was dropped from the product line.
• Kick starter was dropped.
• Disc brakes front and rear.
• Hugger model available for the first time.
• Last year for XLCH
• New model XLS appeared:
• Extended forks
• 16″ rear wheel
• siamese exhaust
• drag bars on 3.5″ risers
• sissy bar w/leather pouch
• highway pegs
• 2 piece seat
• chromed rear sprocket
• Production Information:
• XLH (6,525)
• XLCH (141)
• XLS -(5,123)
• XLCR (9) (?leftover ’78′s?)

1980:

• A 16 in wheel replaced the XLH 18 in.
• Production Information:
• XLH (11,841) $5,867
• XLS (2,926)

1981:

• Buy back from AMF
• wire or cast wheels options, 16″ or 18″ rear wheel options
• XLS
• buckhorn handlebars
• shorty dual exhaust
• 3.3 gallon, 2.2 gallon tank optional.
• XLH
• shorter front forks
• 3.3 gallon optional.
• Production Information:
• XLH (8,442)
• XLS (1,660)

1982:

• Lighter frame
• oil tank repositioned
• Thicker head gasket w/lower 8:1 compression
• Larger rear disc
• XLS repositioned the battery
• Production Information:
• XLH (5,015)
• XLS (1,261)

1983:

• XLH:
• high bars
• vacuum advance (VOES?)
• 3.3 gallon tank option
• new seat
• less restrictive exhaust.
• New model XLX-61: (built to sell for $3,995)
• solo seat
• peanut tank
• staggered dual exhaust
• speedo only
• 9 spoke wheels
• vacuum advance (VOES?)
• satin finish cases. {only year}
• six coil springs in clutch
• 156 watt generator
• loose output roller tranny
• output shaft oil seal secured by a bolt on cover
• 3 generator drive gears
• 10″ dual front disc brakes.
• New model – XR-1000, based on XLX chassis
• aluminum SR style heads w/intake ports on right, exhaust on left
• polished and bored by Jerry Branch
• helicoil inserts where rocker boxes bolt to head,
• 9:1, XR pistons
• light aluminum pushrods
• eccentric rocker shafts adjust valve lash
• iron cylinders (shortened half an inch to make room for the ‘Branch’ heads)- w/through bolts
• vacuum advance-V-fire III breaker less ignition
• twin 36mm Dell’Orto carbs
• satin textured cases
• 9 spoke cast wheels
• oiled felt air filter
• The XR-1000 had 71HP @ 5,600 rpm, 125 mph, 490 lbs
• 2.5 gallon tank, 2.5 quart oil capacity $6,995.
• Production Information:
• XLX-61 (4,892) $3,995
• XLH (2,230)
• XLS (1,616)
• XR-1000 (1,018) $6,995

1984:

• Diaphragm spring clutch (mid year)
• Generator replaced by the alternator. (mid year)
• XLH used the Peanut tank again.
• XR, improved brakes, orange/black HD racing color option
• XLH/X/S Single (larger) front disc.
• Production Information:
• XLX-61 (4,284)
• XLH (4,442)
• XLS (1,135)
• XR-1000 (759)

1985:

• Production trimmed in anticipation of the Evo XL.
• Production Information:
• XLX-61 (1,824)
• XLH (4,074)
• XLS (616)

1986:

• First year of the Evo Sportster
• came in 883 and 1100cc flavors
• XLX frame
• Aluminum heads and cylinders
• hydraulic lifters
• 34mm fixed-venturi Keihin carb
• powder coat frame paint
• cast aluminum wheels
• solo seat
• low bars
• speedo only
• turn signals double as running lights
• 30″ seat height
• Upgrade package=special paint and trim.
• Production Information:
• XLH 883 (8,026) $3,995
• XLH 883 (2,322) (upgrade)
• XLH 1,100 (3,077) $5,199
• XLH 1,100 (954) ‘Liberty’

1987:

• Sportsters 30th Anniversary
• first year for the Evo Hugger:
• The fork tubes were shortened 2″
• revised shock angle
• a softer seat at 26.75″, (1.75″ lower than standard)
• Production Information:
• XLH 883 (4,990)
• XLH 883 (2,106) ‘Hugger’
• XLH 883 (2,260) (upgrade)
• XLH 1,100 (4,018)
• XLH 1,100 (600) ‘Anniversary’

1988:

• new 39mm Fork Tubes replaced the older 35mm unit
• new 40mm constant velocity Keihin slide carb
• first year for the 1200 (replacing the 1100)
• Production Information:
• XLH 883 (5,387)
• XLH 883 (4,501) ‘Hugger’
• XLH 883 (1,893) ‘Sportster Deluxe’
• XLH 1,200 (4,752)

1989:

• kickstand repositioned father rearward
• price increase jumped from $3995 to $3999 for the base model 883
• Production Information:
• XLH 883 (6,142)
• XLH 883 (4,467) ‘Hugger’
• XLH 883 (1,812) ‘Sportster Deluxe’
• XLH 1,200 (4,546)

1990:

• new paper air filter and paint options
• 40mm Keihin carb – constant velocity w/accelerator pump
• Production Information:
• XLH 883 (5,227) $4,250
• XLH 883 (4,040) ‘Hugger’
• XLH 883 (1,298) ‘Sportster Deluxe’
• XLH 1,200 (4,598)

1991:

• 5 speed tranny replaced the 4 speed
• belt drive replaced chain on 883 deluxe and 1200 models
• hydraulic lifters were replaced with automotive type units
• oil pump given internal cast feed lines
• breather system moved from the crankcase to the heads (umbrella valves)
• alternator moved from behind clutch to the crankshaft
• primary cover redesigned
• new foot peg mounts
• old Dunlop k-291 tires replaced with K402′s
• Self canceling signals
• right side timing hole
• tappet blocks, rear motor mount, oil filter integrated with case
• one piece push rod tubes
• Production Information:
• XLH 883 (4,922) $4,359
• XLH 883 (3,487) ‘Hugger’
• XLH 883 (3,034) ‘Sportster Deluxe’
• XLH 1,200 (6,282) $6,245

1992:

• Hugger model made even lower
• Standardized hand controls
• Production Information:
• XLH 883 $4,499
• XLH 883 ‘Hugger’ $5,075
• XLH 883 ‘Sportster Deluxe’ $5,559
• XLH 1,200 $6,400

1993:

• belt drive now on all Sportster models
• Production Information: XLH 883 $4,775, XLH 883 ‘Hugger’ $5,420, XLH 883 ‘Sportster Deluxe’ $5,820, XLH 1,200 $6,800

1994:

• Oil tank revised (visually identified by relocated oil drain line which now runs to the frame instead of nipple on underside of battery tray)
• Derby cover revised from small cover over center of clutch to large 4-bolt cover (with this came a new quick-release clutch cable)
• Revised rear struts with chromed steel covers.
• New electrical system (wiring harness/weatherproof electrical connectors, new electrical component tray under the seat)
• 883s got an aluminum lower triple clamp which was previously stock on only the 1200’s

1995:

• New Larger standard gas tank (3.25 gal) on 1200 models
• Vacuum operated petcock added to Sportster line
• Ignition switch moved to steering column (because of petcock)
• Switched to electric speedo
• Production Information: XLH 883 $4,995, XLH 883 ‘Hugger’ $5,700, XLH 883 ‘Sportster Deluxe’ $6,120, XLH 1,200 $7,200

1996:

• Switchgear revised, more rounded style
• First year for 1200 Custom and Sport models
• Production Information: XLH 883 $5,095, XLH 883 ‘Hugger’ $5,760, XLH 1,200 $7,360, XLH 1,200 ’1200C Custom’ $7,910, XLH 1,200, ’1200S Sport’ $8,360

1997:

• New Larger standard gas tank (3.25 gal) on 883 models

1998:

• Revised ignition system (single fire)
• 1200S gets dual-plug heads (along with hotter cams)

1999:

• First year of the 883C

2000:

• First year for sealed wheel bearings
• First year for 4-piston calipers
• Pressed together flywheel assembly (supposed to be stronger and hold it’s trueness better)

2002:

• First year for the 883R
• Introduction of the bullet-style turn signals across the line

2003:

• Final year for solid mount models
• New style mirrors.
• Special Harley-Davidson 100th Anniversary paint/badges

2004:

• Engine is rubber mounted
• Trap door transmission eliminated (cases must now be split to access transmission).
• Oil tank is mounted further under the seat
• Seat height is lowered by an inch
• Rear tire width increased to 150 mm
• Custom models get 4.5 gallon gas tanks
• New air cleaner cover
• Brake calipers, master cylinder, switch housings and handgrips replaced, now exclusive to Sportster models.

2005:

• Swing arm & rear wheel re-designed to accommodate 1″ rear axle.