Harley-Davidson Sportster XL/XLH/XLCH 1959–1969 Service Manual (P/N 99484-69)

Harley-Davidson’s factory service manual P/N 99484-69 covers the 1959–1969 Sportster XL, XLH, and XLCH. It also contains shared service material and component references for K/KH models.

Printable PDF, Navigation, and Page Content

Search and wiring detail: Text search and embedded PDF bookmarks are unavailable. Small wiring-diagram numbers and color codes are readable with enlargement in the checked diagrams. The file contains repeated service pages and some pages outside their printed sequence.

Supplied as one printable English-language 247-page PDF. This total already includes the cover, five introductory/contents pages, six section dividers, and 17 blank pages, along with the repeated service pages.

Engine Rebuilding, Drivetrain Service, and Electrical Diagnosis

These selected workshop topics show the principal repair coverage without reproducing the full contents. Additional subjects include handlebar-control servicing and seat-post repair.

• Engine overhaul: Cylinder-head work, piston and ring service, tappet adjustment, engine removal, timing-gear inspection, and crankcase and flywheel rebuilding.

• Carburetor repair: Step-by-step disassembly, inspection, rebuilding, and adjustment for Model HD, M, and DC carburetors, supported by troubleshooting and fuel-supply service.

• Clutch and transmission: Dry-clutch inspection and assembly, release-mechanism repair, gearbox rebuilding, shifter checks, and kick-starter and electric-starter drive work.

• Chassis service: Spoke replacement and wheel truing, hub inspection, front-fork rebuilding, rear-suspension adjustment, and front and rear drum-brake repair.

• Ignition and charging: H/CH wiring diagrams, magneto and circuit-breaker service, generator output checks, regulator tests, and starter-motor inspection and repair.

• Workshop reference data: Maintenance and lubrication charts, tightening specifications, bearing fits, component clearances, wear limits, spring settings, and electrical test values.

The foreword addresses basic maintenance and repair as well as major repair methods for professional Harley-Davidson mechanics; the overhaul sections require precision measuring equipment and task-specific tools.

Engine Internals and Oil Circulation

Engine coverage extends to connecting-rod bushing reaming, main-bearing race lapping, piston-ring fitting, and flywheel truing. The associated inspection data address cylinders, pistons, valves, rocker arms, and bearings.

Gearcase material explains bearing replacement, cam-gear clearance checks, oil-pump check-valve service, and breather timing. Illustrations titled Oiling System and Timing Crankcase Breather connect the oil passages with their timing references.

The gearcase-cover cautions explain why misplaced or omitted gasket holes can obstruct oil circulation and put internal components at risk.

Coverage gap: Printed page 3A-15 is missing, interrupting the oil-filter/oiling-system text and the opening engine-repair discussion.

Dry Clutch, Gearbox, and Starting Mechanisms

Clutch illustrations identify the 1967 XLH shell, hub seals, and two-bearing arrangement separately from the earlier design retained on the 1967 XLCH. Plate inspection, spring-tension adjustment, release-mechanism repair, and compensating-sprocket service are included.

Coverage gap: Printed page 4B-5 is missing from the clutch diagnosis and release-adjustment material.

Gearbox instructions cover the shifter assembly and mainshaft/countershaft end-play checks. The Countershaft and Mainshaft Group - Exploded View identifies the internal parts, while the access-cover procedure calls for puller 95560-57.

Interchangeability notes distinguish straight-dowel access covers from earlier conical-dowel covers. They identify cover 34844-57 and K/KH replacement crankcases marked D, allowing the case and cover arrangement to be checked before replacement parts are selected.

Carburetor Tests and Applicability

The Carburetor Cross Section - Model HD identifies the accelerating pump, inlet needle, main-nozzle check valve, and economizer valve. Diagnostic material separates idle, intermediate-speed, high-speed, acceleration, and flooding complaints. Inlet-needle leakage checks use tester 94750-68.

Model M and DC material adds float adjustment, passage inspection, and assembly details. A DC-specific caution explains how incorrect engagement of the float-valve mechanism can damage the nylon lever fingers.

The Model MD section applies specifically to 1966 and later Servi-Car models; it should not be read as a Sportster carburetor application.

Ignition Variants and Charging Tests

The electrical sections distinguish magneto ignition from coil/circuit-breaker systems and separate manual-advance arrangements from automatic advance. Drawing examples include Late 1969 Sportster H - Wiring Diagram and Internal Connections of Magneto.

Coverage gap: Printed page 5F-13 is missing from the opening magneto point-adjustment and timing instructions.

Generator tests address field coils and armatures. Delco-Remy and Bosch regulator material includes test circuits and VAT 26 methods. Starter-motor coverage distinguishes Delco-Remy and Prestolite units, with additional service information for batteries, lamps, switches, horns, speedometers, and tachometers.

Suspension, Brakes, and Fiberglass Work

Wheel material separates early and later hub designs and spoke patterns. Fork-slider bushings, steering-head bearings, rear-fork bearings, and rear-shock spring adjustment receive dedicated treatment. Defective rear shock absorber units are replaced rather than internally repaired.

Frame dimensions, chain adjustment and lubrication, and front/rear brake inspection support chassis repairs. Fiberglass procedures address gel-coat touch-up, molded-in-color surfaces, and patches for holes and breaks.

Verify the applicable factory torque specifications and follow workshop safety practices, especially when working with fuel, electrical circuits, and brakes.

Examples of Piston Fits and Cam-Gear Clearances

Piston and ring fit: The engine specification table gives piston-to-cylinder fit as 0.0025–0.003 in. loose and ring end gap as 0.010–0.020 in. These values accompany the cylinder-measurement and ring-fitting material.

Cam-gear clearance: The gearcase section specifies 0.001–0.006 in. end play, supported by measurement and shim-selection instructions.