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btkicker
31st October 2006, 19:10
The story so far....

Here's the '07 HD press release for the XL:

http://www.harley-davidson.com/CO/NEW/en/PressRelease_date.asp?locale=en_US&bmLocale=en_US&HDCWPSession=G3qLGp2XsyPH38bpWLPBRX9Rb4zCmzTXtwQ4m 4GwHnjSly7sMJMx!-1789337985&id_in=965&dspmm=7&dspyy=2006&FROM=NEWS

HARLEY-DAVIDSON MARKS 50 YEARS OF SPORTSTER PERFORMANCE

Milwaukee, Wis. (July 14, 2006) - The Harley-Davidson XL Sportster family of motorcycles has thrived on street-bred racing performance since being introduced in 1957. With a special 50th Anniversary model, new standard Electronic Sequential Port Fuel Injection (ESPFI), new handlebar wiring and gauges, reduced clutch and brake lever effort and increased performance on XL 883 models, the 2007 Sportster family of eight models is ready for the street and beyond.
“Throughout the last half century, the Sportster models have grown and evolved based on innovation and changing preferences of our customers,” said Lance Onan, Sportster Marketing Platform Director. “The 2007 model year is another major milestone that celebrates Sportster heritage with a look to the future. Sportster riders are part of the evolution of a true hot rod motorcycle, from the first 1957 Sportster to the XR-750 racers of the 1970s to the new 2007 models and beyond.”

To incorporate ESPFI as standard for all 2007 Sportster models, Harley-Davidson redesigned the Sportster rear fender, seat, fuel tank, coil, stator, exhaust pipes, wiring and induction system, while also revising the frame. With oxygen feedback acting independently on each cylinder, the system learns and adjusts to changing conditions to deliver optimal performance.

New gauges on the 2007 Sportster models provide a clock on the odometer, low fuel warning light and two trip set odometers. The Sportster ride is also enhanced through an eight percent reduction in clutch lever effort and an 11 to 14 percent reduction in front brake lever effort, depending on model. Sportster customizing is made easier by a two-inch lengthening of handlebar wiring.

The four Sportster XL 883 models have been retuned for increased performance, providing about 15 percent more torque at 2500 rpm. Riders of the XL 883, XL 883 Low, XL 883R and XL 883 Custom will enjoy excellent throttle response and a smooth ride.

With the significant innovations for 2007, the Sportster family retains connection to a history with deep performance and racing roots. Sportsters have given rise to such engaging terms from Harley lore like “competition hot, peanut fuel tank, café racer,” and “hugger.” True to their heritage, Sportsters use the latest technology to give today’s riders a superb blend of responsive handling, a smooth ride and sleek styling.

Sportsters are powered by the XL Evolution V-Twin engine, rubber-mounted in the frame to reduce vibration and tuned to provide a responsive throttle for maximum street performance. The transmission is integrated with the powertrain, sharing a die-cast case with the engine. Helical-cut gears mesh quietly and lightweight dog rings slide easily to reduce shift effort. The Harley-Davidson Smart Security System, featuring new hands-free fob and auto arming/disarming, is an available option on all Sportster models.

The Sportster line-up is more versatile than ever with distinctive choices in engine displacement, ergonomics, fuel tank, graphic and color schemes, wheels and raw-boned styling. Whether it’s a matter of feeling a little racing retro or needing simple styling for the street, the Sportster family offers plenty for 2007.

50th Anniversary Sportster
Marking the evolution of a hot rod, the 50th Anniversary Sportster honors the family heritage with a special 1200cc model sure to stun on the street. With the new standard Electronic Sequential Port Fuel Injection (ESPFI) system, new gauges and handlebar wiring, the 50th Anniversary Sportster stands out in the tradition of previous commemorative Harley-Davidson models. Special features include gold “50th” tank emblem, serialized bar clamp nameplate with “50th” logo, “H” logo silk screening on side cover and embroidered seat marking 50 years of production. Paying tribute to a legend, the Anniversary Sportster is offered in two appropriate commemorative colors, Mirage Orange and Vivid Black. Production will be limited to 2,000 motorcycles.

50th Anniversary Sportster features:


Rubber-mounted XL Evolution 1200cc engine
Black powder-coated engine with chrome treatment
Standard Electronic Sequential Port Fuel Injection (ESPFI)
Chrome Steel Laced 19-inch front wheel
Serialized name plate with “50th” logo on top handle bar clamp
New fender striping
New gold “50th” emblem on 3.3-gallon peanut fuel tank
New “H” side cover silk screening
Embroidered seat noting 50 years of production
New lighter clutch effort
New sidestand design
New gauges with odometer clock, low fuel warning light and two trip set odometers
Single disc front brake
Chrome headlamp bucket and eyebrow
Lowered rear shocks
XL 883 Sportster 883
All 2007 Sportster 883 models are retuned for increased performance, including this most affordable Harley-Davidson model. New cams and Electronic Sequential Port Fuel Injection (ESPFI) enable the Sportster 883 to generate more torque at lower rpms, giving the rider greatly improved throttle response and better performance in the normal operating zone. With the addition of ESPFI and reductions in clutch lever and brake effort, the Sportster 883 will provide a most responsive ride. New gauges allow the Sportster 883 rider to better track mileage and the time. The Sportster 883 combines performance with straight-ahead styling such as the distinctive “peanut” fuel tank, chrome, staggered dual shorty exhaust, sleek solo seat and Silver, 13-spoke Cast Aluminum wheels. Chrome Laced Steel wheels and the Smart Security System are options. The Sportster 883 is offered in four solid colors for 2007.

XL 883 Sportster 883 features:


Rubber-mounted XL Evolution 883cc engine
Silver powder-coated engine
Standard Electronic Sequential Port Fuel Injection (ESPFI)
New cams on retuned powertrain for improved performance
New gauges with odometer clock, low fuel warning light and two trip set odometers
New lighter clutch effort
Low-rise handlebar
Classic solo seat
Chrome staggered shorty dual exhaust
Mid-mount foot controls
Classic 3.3-gallon fuel tank
XL 883R Sportster 883R
It is the racing history of the Sportster family, specifically the Harley-Davidson XR flat-track racers, that fuels the 2007 XL Sportster 883R design. A fuel-injected Evolution V-Twin powertrain with new cams for better performance is finished in wrinkle-black powdercoat. New gauges include a clock on the odometer, low fuel warning light and two trip set odometers. Front brake lever effort is reduced by 14 percent and clutch lever effort is eight percent easier. The 13-spoke Cast Aluminum wheels, handlebar, fork sliders, headlamp eyebrow, air cleaner cover and rear springs are finished in black. The original Harley-Davidson racing-inspired graphics on the fuel tank are at home on the street or at the track. Chrome Laced Steel wheels and the Smart Security System are options. Available for 2007 in Vivid Black, Mirage Orange Pearl or Pewter Pearl.

XL Sportster 883R features:


Rubber-mounted XL Evolution 883cc engine
Black powder-coated engine with wrinkle-black treatment
Standard Electronic Sequential Port Fuel Injection (ESPFI)
New cams on retuned powertrain for improved performance
New gauges with odometer clock, low fuel warning light and two trip set odometers
New lighter clutch effort
Black low-rise handlebar, air cleaner cover, fork sliders, headlamp eyebrow and springs
Race-inspired fuel tank graphics
One-piece, two-up seat
Black, 13-spoke Cast Aluminum wheels
Dual front disc brakes
Chrome staggered shorty dual exhaust
Mid-mount foot controls
Classic 3.3-gallon fuel tank
XL 883L Sportster 883L
The XL Sportster 883L goes even lower for 2007. Now with a seat height of just 25.3 inches, the 883L features new rear shocks, new front fork springs and damper tubes, new side stand and new foot pegs with feelers. These ergonomics provide precise handling for smaller riders or anyone who enjoys a narrow and agile ride. Like all Sportster 883 models, the 883L features ESPFI, new cams, new gauges and reduced clutch and brake lever effort to help inspire a confident ride. Offered in eight solid colors for 2007 with a special tank graphic.

XL Sportster 883L features:


Rubber-mounted XL 883cc Evolution engine
Silver powder-coated engine
Standard Electronic Sequential Port Fuel Injection (ESPFI)
New cams on retuned powertrain for improved performance
Lowered front and rear suspension
New coil-over, dual-adjustable preload rear shocks
New front fork springs and damper tubes
New foot pegs with feelers
New gauges with odometer clock, low fuel warning light and two trip set odometers
New lighter clutch effort
New side stand design
Silver, 13-spoke Cast Aluminum wheels
Wide polished handlebar
Low solo seat
Special fuel tank graphics
Chrome staggered shorty dual exhaust
Mid-mount foot controls
Classic 3.3-gallon fuel tank
XL 883C Sportster 883 Custom
A sleek look combined with a straight style for the boulevard and street make the Sportster 883 Custom a distinctive ride for 2007. Topped by a 4.5-gallon fuel tank and two-up seat, the XL Sportster 883C is powered by a fuel-injected 883cc Evolution engine with new cams for a responsive throttle and performance. Reduced clutch and brake lever effort on forward controls and a pullback handlebar provide a low profile, laid-back ride. While 21-inch Chrome Laced Steel front wheel and Silver Solid Disc Cast Aluminum rear wheel are standard, Chrome Profile Laced Aluminum wheels are optional. Choose from five solid and three two-tone paint combinations, plus three two-tone custom color options.

XL 883C Sportster 883 Custom features:


Rubber-mounted XL Evolution 883cc engine
Silver powder-coated engine
Standard Electronic Sequential Port Fuel Injection (ESPFI)
New cams on retuned powertrain for improved performance
New lighter clutch effort
New gauges with odometer clock, low fuel warning light and two trip set odometers
4.5-gallon fuel tank
Chrome staggered shorty dual exhaust
Chrome pullback handlebar riser
Chrome, Laced Steel 21-inch front wheel and Silver, Solid Disc Cast Aluminum 16-inch rear wheel
One-piece, two-up seat
Forward foot controls
XL 1200R Sportster 1200 Roadster
The XL Sportster 1200 Roadster is in a street-fighting mood for 2007, adding electronic fuel injection to its already high-performing, rubber-mounted 1200cc Evolution engine. New gauges are added to a high-mount tachometer and longer handlebar wires allow for easier customization. A polished handlebar proudly announces the arrival of the XL Sportster 1200R. Brake lever effort is reduced by 14 percent and clutch lever effort is improved by eight percent to enhance an already quick and agile ride. Dual front disc brakes and Silver, 13-spoke Cast Aluminum wheels are standard with Chrome, Laced Steel wheels as an option. Offered in seven solid color choices for 2007.

XL 1200R Sportster 1200 Roadster features:


Rubber-mounted XL Evolution 1200cc engine
New Black powder-coated engine and wrinkle-black treatment
Standard Electronic Sequential Port Fuel Injection (ESPFI)
New lighter clutch effort
New gauges with odometer clock, low fuel warning light and two trip set odometers
Classic 3.3-gallon fuel tank with new graphic
High-compression, high-flow cylinder heads
High-performance cams
Triple-disc brakes
High-mount tachometer
Mid-mount foot controls
Silver, 13-spoke Cast Aluminum wheels
Wide polished handlebar
XL 1200L Sportster 1200 Low
The XL 1200L Sportster Low is a long and low motorcycle with plenty of power. A wide, pullback handlebar and a low two-up seat provide comfortable ergonomics. The reduced clutch and brake lever effort makes the 1200 Low a relaxed ride. Electronic Sequential Port Fuel Injection (ESPFI) provides smooth operation. The 1200cc rubber-mounted XL Evolution engine combines with a 4.5-gallon tank for longer range. The new gauge include a clock, low-fuel warning light and two trip set odometers, while longer handlebar wires provide more customization options. The special Black, 13-spoke Cast Aluminum 19-inch front wheel combines with a Black, 13-spoke Cast Aluminum 16-inch rear wheel and mid-mounted foot controls for a sweet ride. Chrome, Laced Steel wheels are optional as is the Smart Security System. Five solid and three two-tone color options are offered for 2007.

XL 1200L Sportster 1200 Low features:


Rubber-mounted XL Evolution 1200cc engine
Black powder-coated engine with chrome treatment
Standard Electronic Sequential Port Fuel Injection (ESPFI)
New lighter clutch effort
New gauge with odometer clock, low fuel warning light and two trip set odometers
Integrated chrome gauge housing and handlebar clamp
Two-up seat
4.5-gallon fuel tank
Black, 13-spoke Cast Aluminum 19-inch front and 16-inch rear wheels
Mid-mounted foot controls
Wide pullback handlebar
XL 1200C Sportster 1200 Custom
A powerful performer that goes the distance in style, the XL Sportster 1200 Custom features a 4.5-gallon fuel tank and fuel-injected XL Evolution 1200cc engine. New gauges include a clock, low-fuel warning light and two trip set odometers, while longer handlebar wires provide more customization options. Reduced clutch and break lever effort make the XL Sportster 1200C that much more fun to ride. Chrome Laced Steel 21-inch front wheel, Chrome Slotted Disc Cast Aluminum rear wheel, forward controls and a riser-mounted pullback handlebar take to the street in style. Chrome, Profile Laced Aluminum wheels are an available option. Eight solid and four two-tone color options are offered for 2007, plus three two-tone custom color combinations.

XL 1200C Sportster 1200 Custom features:


Rubber-mounted XL Evolution 1200cc engine
Black powder-coated engine with chrome treatment
Standard Electronic Sequential Port Fuel Injection (ESPFI)
New lighter clutch effort
New gauges with odometer clock, low fuel warning light and two trip set odometers
4.5-gallon fuel tank
High-compression, high-flow cylinder heads
High-performance cams
Chrome, Laced Steel 21-inch front wheel and Chrome, Slotted Disc Cast Aluminum 16-inch rear wheel
Forward foot controls
Chrome pullback handlebar riser
Chrome bullet headlight

btkicker
31st October 2006, 19:13
Main xlforum 2007 thread(huge amount of info):

http://xlforum.net/vbportal/forums/showthread.php?t=33203

btkicker
31st October 2006, 19:41
'07 XL Mechanical Differences (from HD pdf):

The Sportster® family
Celebrates 50 years
• 50th Anniversary 1200 model
• Limited production of 2,000
• Serialized nameplate on
handlebar clamp
• Gold “50th” emblem on
fuel tank
• New “H” silk-screening
on side covers represents
the cultural history of
the Sportster® family
• Embroidered seat
• XL custom rear shocks
NEw 883l model
• Lowered 25.25 in.
seat height
• New front and rear shocks
• New seat
• Parts retrofit
• Higher torque for
883 models
• All 2007 XL motorcycles
use “W” cams
• 15% More torque
at 2500 rpm
• Requires 1200 mufflers
for Japan market

Electronic Sequential Port
fuel injection (E.S.P.f.i.)
for all Xl models
• 45 mm induction module
for all models
• 15-Degree injectors
• New wiring harness
with Molex® connectors
• Frame updated with
new brackets to secure
new wire harness
• Low fuel light
• 91 Octane for all 2007

Redesigned Oil Pump
• Redesigned pump body,
feed and scavenge gerotors
• New feed and
scavenge porting
• Scavenge gerotors have
larger diameter and are
taller for more capacity
• Feed gerotors are thinner
to accommodate taller
scavenge gerotors in
original pump body
height but redesigned
for no loss of capacity
• Internal parts do not interchange
with earlier pumps
• Pump assembly will retrofit

• Head temperature sensor
is located in rear cylinder
head similar to Buell® models
• Special tool available

Electronic Sequential
Port fuel injection
(E.S.P.f.i.) Sensors
• New TMAP sensor
• Combined sensor MAP/IAT
• Top of Induction
Module (IM)
• IAC: top of IM
• TP sensor: left side of IM

Fuel Pump
• Mounted in new fuel tank
• Check Sportster® model
Service Manual for
pressure specifications
• Uses current fuel
pressure gauge adapter
(P/N HD-44061)

Oxygen Sensors
• Front and rear exhaust
O2 sensors
• Closed loop system
like 2006 Dyna™ models

New Ignition Coils
• New coil mounting bracket
• New spark plug wires
• New primary and secondary
resistance values
• Check Sportster® model
Electrical Diagnostics
Manual for proper
specifications

Intake Flanges
• New intake flanges
and fasteners
• Wider flanges allow for
better fastener access
• Uses four hex bolts
rather than allen bolts
• New cylinder heads to
accommodate new flanges
• 1200 Heads have changes
to intake port and intake
valve seat
• No service procedure
changes to new heads,
only part number changes

New ECM and
fuse location
• ECM is located underneath
the seat on the rear fender
• Additional fuses are
required
• New rear fenders and
seats accommodate ECM

New Rocker Boxes
• Rocker boxes have been
changed to feature an
improved sealing cavity
• New press-in-place gaskets
• Gaskets do not retrofit

32-amp Charging System
• Increased power to
32 amps from 22 amps to
power the E.S.P.F.I. system
• Check Electrical
Diagnostic Manual
for proper specifications
• Rotor does retrofit
• New stator and
voltage regulator
do not retrofit

Reduced-Effort
front Brake lever
• DOT 4™ brake fluid is used
in all 2007 XL motorcycles
• New calipers
• New master cylinders
• New brake lines
• Changes result in an 11%
effort reduction for 883,
883L, 883C, 1200L and
1200C models
• Changes result in a 14%
effort reduction for 883R
and 1200R models
• New rear brake pads
improve rear brake feel
• Rear brake pads
do not retrofit

New Handlebar Wiring
• Harnesses are lengthened
by 2 in. to allow for easier
changing of handlebars
• Extra harness is tucked
into the electrical caddy
underneath the fuel tank

btkicker
31st October 2006, 19:52
Known '07 Issues:
Overly enthusiastic low fuel LED. Banked right-hand turns will cause light to come on early (half a tank) then go back out after a few seconds. Not really an issue, but hey, if that's all we can come up with...

btkicker
31st October 2006, 20:00
Stage 1 Info:

http://xlforum.net/vbportal/forums/showthread.php?t=40722&highlight=stage

Sportster uses the same kind of learning ecm as with Buell’s. Remapping for stage 1 (cartridge $150) shouldn't be needed.

Remapping info:
http://xlforum.net/vbportal/forums/showthread.php?t=37283