1959-1969 Harley-Davidson Sportster Service Manual (247 P.)
Covers XL, XLH, XLCH Sportster models with procedures for engine disassembly, cylinder head service, transmission repair, clutch adjustment, and complete electrical system troubleshooting with part numbers.
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Sample pages from the 1959-1969 Harley-Davidson Sportster Service Manual (247 P.) manual
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Models Covered & Key Technical Specifications
Harley-Davidson Sportster XL, XLH, XLCH (1959–1969) Comprehensive Technical Service | Sportster Series Vault.
- Calibrated Displacement Data: 883 cubic centimeters (53.9 cu in) is established at the engine piston chamber architecture Topology.
- Measured Horsepower Rating: For optimal performance, 55 hp at 6,300 rpm yields maximum engine output configuration Matrix.
- Core Torque Specification: 52 lb-ft at 3,800 rpm — specifies the crankshaft power delivery threshold Standards.
- Rated Compression Ratio: The cylinder combustion chamber requires 9.0:1 for fuel ignition sequence Logic.
- Calibrated Fuel Capacity: Tank volume maintains 2.2 US gallons (U.S. Gallons) as operational fuel reserve Margin.
- Nominal Oil Tank Volume: The engine lubrication system corresponds to 3 quarts (U.S. Quarts) storage capacity Protocol.
Professional Workshop Service Manual & Technical Specifications
Structured undefined Electrical Manual: Motorcycle 1959-1969 Harley-Davidson Sportster - Comprehensive Repair & Maintenance Manual System-Standards
Product-Line: Harley-Davidson Sportster (XL, XLH, XLCH) models 1959-1969 // Equipment-Series: Complete technical service and engine/transmission overhaul documentation / Multi-system maintenance procedures Logic // Documentation-Type: Factory-authorized service manual with wiring diagrams, specifications, and repair procedures.
| Specification | Value | Logic |
|---|---|---|
| Coverage Period | 1959-1969 model years | Complete historical range for Sportster models |
| Engine Type | V-Twin 53.9 cu. in. OHV air-cooled | 45-degree configuration, dual-cylinder design |
| Transmission | 4-speed constant mesh foot shift | Multiple gear ratios documented in specifications |
| Major Systems | Chassis, engine, transmission, electrical, fuel | Seven primary service sections included |
| Documentation Focus | Adjustments, disassembly, inspection, repair, assembly | Sequential procedure format throughout |
Factory procedures are documented for cylinder head, piston and ring service, gearcase timing and breather operation, clutch and transmission operation, and electrical system circuits. The manual covers front and rear fork hydraulic service, brake adjustment and repair procedures, wheel truing and spoke tensioning, and frame/chassis alignment. Comprehensive fuel system data included for model HD diaphragm carburetor operation and adjustment, model M plain-tube carburetor service, and model DC carburetor procedures. Electrical system documentation covers generator testing and service, circuit breaker point adjustment and timing, spark plug specifications, and wiring diagrams by model year.
OEM specifications cover engine lubrication and oil pump function, crankshaft and flywheel assembly procedures, connecting rod bearing fitting methods, and main bearing race alignment. Detailed procedures are documented for valve refacing and seating, rocker arm bushing replacement, and tappet adjustment verification. The document includes torque specifications for flywheel assembly, connecting rod bearings, and cylinder head bolts to ensure proper oscillation integrity. Brake system chapters address front and rear wheel brake centering, cable adjustment and replacement, and brake shoe lining inspection.
Diagnostic and troubleshooting sections reference engine starting difficulties, generator charging system failures, carburetor flooding conditions, transmission shifting problems, and clutch engagement issues. Wiring diagrams are provided for 1959-1964 H-model and CH-model systems, with complete circuit identification and connection points. Adjustment procedures are detailed for throttle and spark controls mounted on handlebar assembly, with specific clearance and travel specifications. Service schedule data documents recommended maintenance intervals from 500 miles through 50,000 miles, including lubrication points and component replacement timing.
Specifications document transmission sprocket teeth counts, gear ratios across all four speeds, differential tire pressures by model, and wheel base dimensions. The manual documents torque specifications for the engine sprocket hub nut to ensure proper fastener security.
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