Harley-Davidson 1979 Sportster XLH/XLCH-1000 Service Manual (P/N 99484-79)

Harley-Davidson’s factory service manual P/N 99484-79 covers maintenance, diagnosis, and repair for the 1979 XLH-1000 and XLCH-1000 Sportster models.

PDF Search and Wiring Diagram Readability

Search, bookmarks, and diagram detail: The PDF has no text search or embedded bookmarks. Small wire color codes and component numbers in the XLH and XLCH wiring diagrams are readable when enlarged.

The download is one printable English-language PDF with 152 pages, including six original front-matter pages: the cover, important notice, title and section guide, foreword, and two contents pages.

Sportster Engine, Chassis, and Electrical Service

These are selected workshop topics from the manual. It also covers regular service intervals and speedometer and tachometer drive cable service.

• Engine repair: Cylinder head overhaul, valve and seat refacing, piston and cylinder inspection, connecting rod bearing work, and step-by-step flywheel truing procedures.

• Lubrication and cam gears: Gerotor oil pump inspection and priming, oil pressure testing, gearcase bushing replacement, cam gear end play checks, and timing mark alignment.

• Keihin carburetor: Overhaul procedures cover float level, choke adjustment, and accelerator pump service. The Keihin Carburetor Trouble Chart organizes diagnosis by symptom.

• Clutch and transmission: Wet multiple-disc clutch repair, clutch release adjustment, shifter inspection, gearbox disassembly, and mainshaft and countershaft end play checks.

• Chassis and brakes: Front fork repair, steering head bearing service, wheel balancing, disc brake caliper overhaul, and front and rear master cylinder service.

• Electrical diagnosis: Separate XLH and XLCH wiring diagrams, breakerless ignition tests, generator and regulator checks, starter relay testing, and Prestolite and Hitachi starter motor service.

The manual supports basic maintenance and repair. Harley-Davidson wrote the major repair procedures for professional mechanics, and jobs such as connecting rod race lapping and flywheel truing call for specialized tooling.

Top-End Repair and Flywheel Work

The cylinder heads, cylinders, and pistons can be serviced with the crankcase in the frame. Crankcase repair requires engine removal. The engine section gives bore inspection and ring-fitting procedures, running clearances, wear limits, and component torque specifications. The Valve Seat Specifications drawing helps determine when a seat can be refaced and when it needs a new insert.

Push rod seals: The exploded views show cork washers on early 1979 assemblies and O-rings on late 1979 assemblies. The drawings help identify which seals to order by matching the installed assembly.

Flywheel and bearing work: The manual explains connecting rod alignment, race lapping, and roller bearing selection. The Correcting Flywheel Alignment illustration accompanies the truing procedure. Specified tools include the Connecting Rod Lapping Arbor (P/N 96740-36) and Flywheel Truing Device (P/N 96650-30).

Keihin Fuel Circuits and Gerotor Oil Flow

The carburetor section explains low-speed and main metering, mid-range operation, and the accelerator pump circuit. The manual warns that wire or drills can burr or alter the carburetor’s metering openings.

The Oiling System diagram traces supply and return flow through the feed and scavenge stages. The lubrication section gives fluid capacities and explains how oil temperature and engine speed affect pressure readings.

Drive Chains, Gearbox Access, and Starting Systems

The chassis section covers adjustment and lubrication of the primary and rear chains. The transmission chapter describes gearbox removal through the access cover and a separate approach for crankcase disassembly. It also gives shifter fork selection, gear engagement checks, and factory gear ratios.

The XLCH kick starter and XLH electric starter have separate service procedures. Electric starter coverage includes the Bendix drive and solenoid, along with service procedures for both Prestolite and Hitachi motors.

Fork Alignment and Hydraulic Brakes

The Wheel Service Chart ties handling symptoms to wheel trueness, alignment, tire condition, and bearing checks. The Frame with Basic Dimensions drawing provides reference dimensions for alignment assessment.

The fork section describes straightening with a press and dial indicator. Sharp bends rule out straightening because the metal is fatigued. The chassis section also covers rear fork bearings and rear shock inspection.

Brake procedures include front and rear caliper teardown, master cylinder inspection, hydraulic bleeding, and rear brake linkage adjustment. Support the motorcycle securely and disconnect the battery before engine, drivetrain, or electrical service.

Ignition and Charging Fault Checks

The model-specific wiring diagrams have separate component keys and wire color legends. Breakerless ignition diagnosis covers sensor air gap, mechanical advance, coil testing, and strobe timing. Incorrect coil wiring can permanently damage the sealed ignition module, which the manual tests as a unit.

Generator procedures cover field-coil and armature testing, commutator repair, and polarization. The solid-state regulator checks account for temperature, helping distinguish a regulator fault from low generator output.

Sample Gerotor and Ignition Clearances

The oil pump inspection gives a maximum clearance of 0.004 in. between the meshed inner and outer members of each gerotor set. It also specifies how far the feed gerotor should project above the pump cover surface: 0.001–0.011 in.

For the breakerless ignition, the sensor-to-trigger-rotor gap is 0.005–0.011 in. at both rotor lobes. The manual pairs this check with an ignition timing check after sensor adjustment.