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  #71  
Old 15th June 2014
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sportsterdoc sportsterdoc is offline
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Sportster history with 2004 up updates per Kevin/Bone, as submitted to Sportster.org circa Aug 2010 (as referenced by Chris/Parrothead)

This was saved from Sportster.org, which disappeared March, 2012.
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)
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.

The following update was posted by Kevin/Bone circa Aug 2010 and submitted to Sportster.org, but by that time Doug Mansfield had turned it over to a profiteer and the website went rapidly downhill…the update was never posted.

2004
* 1200 Models get Buell Spec Heads and W Cams

Models:
XL883
XL883C Custom
XL1200R Roadster
XL1200C Custom

2005
* Added clear optic reflector headlight
* Last year for straight cut gears in transmission
* Last year for silver motor on 1200R
* Larger diameter shifter shaft and new primary cover
Models:
XL883
XL883L Low
XL883C Custom
XL883R
XL1200R Roadster
XL1200C Custom

2006
* Last year for Carbs
* First year for black motor on 1200R

Models:
XL883
XL883L Low
XL883C Custom
XL883R
XL1200L Low
XL1200R Roadster
XL1200C Custom

2007

* 50th Anniversary of Sportster
* First year for EFI
* EFI 883 receives W cams also
* 883L lowered further
* Last year for 833R in the US
* Last year for 3.3 gallon tank on 1200R
* EFI changes include some parts from 04-06 won't fit anymore including seats and rear fender for ECM location
* Introduction of 1200N mid-year (model different in some markets including taller shocks in Europe, no cut fender or side-mount plate in Canada)

Models:
XL883
XL883L Low
XL883C Custom
XL883R
XL1200L Low
XL1200R Roadster
XL1200C Custom
XL1200N Nightster

2008

* Last year for base 883 and 1200R in the US
* Only year 1200R had 4.5 Gallon tank (in US)
* Intro of XR1200 in Europe
* Intro of hollow axles to reduce unsprung weight, front axle also changed to 1" (from 0.75")

Models:
XL883
XL883L Low
XL883C Custom
XL883R (International only)
XL1200L Low
XL1200R Roadster
XL1200C Custom
XL1200N Nightster
XR1200 (International only)


2009
* Intro of XR1200 in US (Limited edition 750 models)
* First year 883N
* Front fender revised - sits closer to tire (previous model fender used for nearly 30 years)

Models:
XL883 (International only)
XL883N Iron
XL883L Low
XL883C Custom
XL883R Roadster (International only)
XL1200L Low
XL1200C Custom
XL1200N Nightster
XR1200

2010
* Revised Oil Tank, Electrical Junction Box and ECM
* ECM relocated behind rear jug (allows seats and rear fenders from 04-06 to fit)
* Last year of 1200C
* Intro of the 48
* Intro of the XR1200X - an XR with floating discs, and adjustable front and rear suspensions (including Showa Big Piston forks)

Models:
XL883N Iron
XL883L Low
XL883C Custom (International only)
XL883R Roadster (International only)
XL1200L Low
XL1200C Custom
XL1200N Nightster
XL1200X 48
XR1200
XR1200X (International only)

2011
* SuperLow replaces 883L (first stock XL with radial tires but on smaller wheels with more shock travel - seat height slightly higher than previous 883L)
* XR1200 dropped, replaced with XR1200X

Models:
XL883N Iron
XL883L SuperLow
XL883R Roadster (International only)
XL1200L Low
XL1200N Nightster
XL1200X 48
XR1200X
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  #72  
Old 18th July 2014
mouse in my cup mouse in my cup is offline
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Sportster/Buell Model: XL883
Sportster/Buell Year: 2006
Other Motorcycle Model: FLHTCUI
Other Motorcycle Year: 1999
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This is good stuff
__________________
99 FLHTCUI Bunch o' stuff 06 XL883 Bunch o' stuff
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  #73  
Old 28th July 2014
Fe Long's Avatar
Fe Long Fe Long is offline
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Posts: 301
Sportster/Buell Model: XLH
Sportster/Buell Year: 1979
Sportster/Buell Model #2: XLH - Hybrid upgrade
Sportster/Buell Year #2: 1979
Reputation: 60807
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For 1979:

1. The last year the kick starter preparation was available. It was listed as an additional option for the last time before being dropped altogether.

2. The points and condenser were replaced with a simple black "ON/OFF" electronic module. The older mechanical advance mechanism, however, was retained along with the older style 5 ohm coil.

3. The rear master cylinder was mounted high up on the secondary chain guard for one year only.

4. The oil filler tube and dip stick were hidden behind the right side bolt on tin cover - requiring tools just to check the oil level.


The above are a few of the other anomalies gifted by AMF for 1979 only.
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  #74  
Old 13th May 2018
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Hippysmack Hippysmack is offline
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Hippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond repute
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Most of the information in this document are excerpts from the book “Harley Davidson Data Book” by Rick Conner published by MBI Publishing Co. 1996. This book does have some errors in it. This information has been transposed into the XLFORUM's Sportsterpedia and as the errors are found, they are corrected. This new list also has further information included such as transcribed factory recalls and service bulletins. You can view it here: http://sportsterpedia.com/doku.php/s...istory:99xx-01

If you find any information to be in error, please post it to this XLF thread and it will be corrected:
Send a note to Sportsterpedia Admin http://xlforum.net/forums/showthread.php?t=2039687
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Reference the XLFORUM'S Sportsterpedia for additional technical information & advice

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