Official Harley-Davidson Sportster XL, XLH, XLCH, XLT-1000, XLA (1970-1978): Factory Maintenance & Diagnostic Manual (1970-1978)

1970-1978 Harley-Davidson Sportster XL / XLH / XLCH / XLT-1000 Service Manual – The Ultimate Repair & Restoration Guide

Master the maintenance and restoration of your classic ironhead with the official factory-style service manual for the 1970-1978 Harley-Davidson Sportster series. This comprehensive manual, identified by Part No. 99484-78, is the definitive resource for every Sportster owner, from the dedicated garage enthusiast to the professional vintage motorcycle mechanic.

Whether you are performing a simple oil change or a complete ground-up engine rebuild, this guide provides the factory-approved methods required to keep your machine in peak operating condition.

Detailed Model & Series Coverage

This manual is engineered specifically for the legendary 1000cc and early Sportster platforms. It covers a wide range of configurations that defined an era of American motorcycling:

• Harley-Davidson Sportster XL (1973-1978): The versatile base for custom builds.
• Harley-Davidson Sportster XLH (1970-1978): The classic electric-start "Super H" model.
• Harley-Davidson Sportster XLCH (1970-1978): The iconic kick-start "Competition Hot" variant.
• Harley-Davidson Sportster XLT-1000 (1977-1978): The rare touring Sportster featuring a larger fuel tank and seat.
• Harley-Davidson Sportster XLA (1978): The specialized military/agency version.

Professional-Grade Technical Content

This is not a generic after-market guide. It is a deep-dive technical encyclopedia that follows the exact construction and service logic used by Harley-Davidson dealerships.

ENGINE & TRANSMISSION OVERHAUL

• Full coverage of the 1000cc Ironhead engine, including cylinder head service, valve grinding, and crankcase splitting.
• Precise instructions for the 4-speed transmission, clutch assembly, and primary drive adjustments.
• Critical specifications for gear side clearances and oil pump tolerances (e.g., .0005 in. gear face depth).

CHASSIS & SUSPENSION

• Complete teardown and assembly for front forks and rear shock absorbers.
• Wheel bearing service, brake system bleeding (drum and disc variants), and tire fitment.
• Frame inspection and alignment procedures to ensure highway stability.

ELECTRICAL & FUEL SYSTEMS

• Comprehensive wiring diagrams for troubleshooting ignition systems, charging circuits, and lighting.
• Step-by-step carburetor tuning and cleaning for Bendix and Keihin units used throughout the 70s.
• Detailed procedures for the XLH electric starter motor and solenoid repair.

Engineered for the DIY Mechanic

• Clear Hierarchy: The manual is divided into numbered sections (Chassis, Engine, Transmission) and further into sub-sections for rapid navigation.
• Factory Specifications: Includes official torque values, wear limits, and specialized tool lists (Part No. 99484-78).
• Real-World Accuracy: Specifically highlights the importance of "factory-made" gaskets and the dangers of "home-made" alternatives for critical oil passages.

Essential for Mobile & Garage Use

Optimized for quick reference, this manual serves as a roadmap for keeping your Sportster on the road. The clear formatting ensures that even when you are in the middle of a teardown, you can find the exact clearance or torque spec you need instantly. Don't rely on guesswork when working on your classic Harley-Davidson; use the data the professionals trust.