Sportster
Encyclopedia
The Sportster is a line of motorcycle
s produced continuously since 1957 by the Harley-Davidson Motor Company
. Sportster models are designated in Harley-Davidson's product code by beginning with "XL". In 1952, the predecessors to the Sportster, the Model K Sport and Sport Solo motorcycles, were introduced. These models K, KK, KH, and KHK of 1952 to 1956 had a flat head engine, whereas the later XL Sportster models use an overhead valve engine. The first Sportster in 1957 featured many of the same details of the KH including the frame, fenders, large gas tank and front suspension.
Sportster motorcycles are powered by 45 degree V-twin engines in which both connecting rods, of the "fork and blade" or "knife & fork" design, share a common crank pin
. The original Sportster engine was the Ironhead engine
, which was replaced with the Evolution engine
in 1986. Sportster engines, the 45" R, D, G & W Models 1929 side-valve motors, and the 'Big Twin' side-valve motors, which were: the flathead
74 cubic-inch (1213 cc) Models V, VL etc. (1930–1936), Models U and UL (1937–1948), and the 80 cubic-inch (1,311 cc) Models VH and VLH (1935–1936), Models UH and ULH (1937–1941) have four separate cams, sporting one lobe per cam.
The cam followers used in Sportster engines, K models, big twin side valve models, and the side-valve W Model series were a slightly shorter version of the followers used in the larger motors, but with the same 0.731 in (19 mm) diameter body and 0.855 in (22 mm) diameter roller follower since 1929. The company used similar cam followers for decades with minor changes, from the 1929 to the Eighties.
Sportster engines retained the K/KH design crankcase design, in which the transmission is contained in the same casting as the engine, and driven by the engine with a triple-row #35 chain primary drive and a multi-plate cable-operated clutch. Models since 1991 have five speeds; 1990 and earlier models had four speeds.
The engine was mounted directly to the frame from 1957 through the 2003 model year. While this system allows the bike to be somewhat lighter with more precise handling, it also transmits engine vibration directly to the rider. Sportsters released in 2004 and later use rubber isolation mounts and tie links to limit engine movement to a single plane, which greatly reduces vibration felt by the rider. Buell
motorcycles built with variants of the Sportster engine have used a rubber mount system since 1987.
The Model K, from which the Sportster evolved, was the first civilian motorcycle produced by Harley-Davidson with hydraulic shock absorbers on both wheels. Common usage calls this a K Model.
The Harley Iron was released in 2009 as a smaller displacement version of the Nightster. The major differences are blacked out engine, cast wheels instead of laced; narrower handlebars; different seat, belt guard, and front mudguard, and of course the smaller engine displacement.
featured the XR1200 on the cover of its July 2008 issue, and was generally positive about it in their "First Ride" story, in which Harley-Davidson was repeatedly asked to sell it in the United States. One possible reason for the delayed availability in the United States was the fact that Harley-Davidson had to obtain the "XR1200" naming rights from Storz Performance, a Harley customizing shop in Ventura, Calif.
The XR1200 was released in the United States in 2009, in a special color scheme including Mirage Orange highlighting its dirt-tracker heritage. The first 750 XR1200 models in 2009 were pre-ordered and came with a number 1 tag for the front of the bike, autographed by Kenny Coolbeth
and Scott Parker
and a thank you/welcome letter from Harley-Davidson
, signed by Bill Davidson.
Motorcycle
A motorcycle is a single-track, two-wheeled motor vehicle. Motorcycles vary considerably depending on the task for which they are designed, such as long distance travel, navigating congested urban traffic, cruising, sport and racing, or off-road conditions.Motorcycles are one of the most...
s produced continuously since 1957 by the Harley-Davidson Motor Company
Harley-Davidson
Harley-Davidson , often abbreviated H-D or Harley, is an American motorcycle manufacturer. Founded in Milwaukee, Wisconsin, during the first decade of the 20th century, it was one of two major American motorcycle manufacturers to survive the Great Depression...
. Sportster models are designated in Harley-Davidson's product code by beginning with "XL". In 1952, the predecessors to the Sportster, the Model K Sport and Sport Solo motorcycles, were introduced. These models K, KK, KH, and KHK of 1952 to 1956 had a flat head engine, whereas the later XL Sportster models use an overhead valve engine. The first Sportster in 1957 featured many of the same details of the KH including the frame, fenders, large gas tank and front suspension.
Construction
Crank pin
In a reciprocating engine, the crankpins, also known as crank journals are the journals of the big end bearings, at the ends of the connecting rods opposite to the pistons....
. The original Sportster engine was the Ironhead engine
Ironhead engine
The ironhead was a Harley-Davidson motorcycle engine, so named because of the composition of the cylinder heads. The engine is a two cylinder, two valves per cylinder, pushrod V-twin. It was produced from 1957 until 1985 and was replaced by the Evolution engine 1986.This name may also be applied...
, which was replaced with the Evolution engine
Evolution engine
The Evolution engine is an air-cooled, 45-degree, V-twin engine manufactured since 1984 by the Harley Davidson Motor Company for the company's motorcycles. It was made in the displacement for Harley Davidson Big V-twins bikes, replacing the Shovelhead engine, until 1999 when it was replaced by...
in 1986. Sportster engines, the 45" R, D, G & W Models 1929 side-valve motors, and the 'Big Twin' side-valve motors, which were: the flathead
Flathead
Flathead may refer to:* Flat-head screwdriver, a screwdriver designed to turn slotted screws* Flat-head screw, a screw with a flat top, designed to be installed in a countersunk hole* Flathead engine, a valve configuration...
74 cubic-inch (1213 cc) Models V, VL etc. (1930–1936), Models U and UL (1937–1948), and the 80 cubic-inch (1,311 cc) Models VH and VLH (1935–1936), Models UH and ULH (1937–1941) have four separate cams, sporting one lobe per cam.
The cam followers used in Sportster engines, K models, big twin side valve models, and the side-valve W Model series were a slightly shorter version of the followers used in the larger motors, but with the same 0.731 in (19 mm) diameter body and 0.855 in (22 mm) diameter roller follower since 1929. The company used similar cam followers for decades with minor changes, from the 1929 to the Eighties.
The engine was mounted directly to the frame from 1957 through the 2003 model year. While this system allows the bike to be somewhat lighter with more precise handling, it also transmits engine vibration directly to the rider. Sportsters released in 2004 and later use rubber isolation mounts and tie links to limit engine movement to a single plane, which greatly reduces vibration felt by the rider. Buell
Buell Motorcycle Company
The Buell Motorcycle Company was an American motorcycle manufacturer based in East Troy, Wisconsin and founded in 1983 by ex-Harley-Davidson engineer Erik Buell.Harley-Davidson acquired 49% of Buell in 1993, and it became a wholly owned subsidiary by 2003....
motorcycles built with variants of the Sportster engine have used a rubber mount system since 1987.
The Model K, from which the Sportster evolved, was the first civilian motorcycle produced by Harley-Davidson with hydraulic shock absorbers on both wheels. Common usage calls this a K Model.
Model K series
This is developed from the earlier 45 W model, but with the revised flat head engine and new 4-speed transmission contained in the same castings as would become the Sportster. The connecting rods would be inherited by the Sportster along with many other design features and dimensions.- Model K and KK 1952–1953: 750 cc side-valve engines, using the 45 model bore and stroke
- Model KR (racing only) 1953–1969: 750 cc side-valve engines
- Model KH and KHK 1954–1956: 885 cc side-valve engines, using the 45 model bore, but with the stroke increased to 4.5625" (115.89 mm). This is the only small twin with a longer stroke than 3.8125", which is otherwise universal to the entire 45/K/Sportster line from 1929 to the present (exception: XR750, XB9 Buell).
X series Sportsters
- XL, Ironhead, 1957–1984: 883 cc and 1,000 cc Ironhead overhead-valve engines with cast iron heads, K series frame
- XR-750Harley-Davidson XR-750The XR-750 is a Harley-Davidson racing motorcycle made since 1970, primarily for dirt track racing, but also for road racing in the XRTT variant...
(racing only) 1970–1971: 750 cc overhead-valve engine, iron heads - XR-750 (racing only) 1972–1985: 750 cc overhead-valve engine, alloy heads
- XLCR 1977–1978: Cafe racerCafé racerA café racer is a type of motorcycle as well as a type of motorcyclist. Both meanings have their roots in the 1960s British counterculture group the Rockers, or the Ton-up boys, although they were also common in Italy, Germany, and other European countries...
1,000 cc overhead-valve engine, iron heads - XR-1000 1983–1984: 1,000 cc street model using XR racing cylinder head and other XR engine parts.
- XLR: 883 cc overhead-valve engines, iron heads
- XL, Evolution (also known as the "Evo"), since 1986: 883 cc, 1,100 cc and 1,200 cc Evolution overhead-valve engine, alloy heads
Significant changes by model year
- 1957 "Ironhead" overhead-valve engine introduced.
- 1972 "Ironhead" 1000 cc overhead-valve engine replaces 900 cc.
- 1975 Switched to left-side gear change (DOT mandate)
- 1978 Only year (H8) of the sportster that Harley produces with dual exhaust as opposed to staggered exhaust.
- 1984 Last year for the "Ironhead" overhead-valve engine.
- 1986 "Evolution" engine introduced in 883 cc and 1100 cc sizes.
- 1988 1200 cc engine replaces 1,100 cc engine.
- 1988 Constant velocity carburetor replaces butterfly carburetor.
- 1991 Five-speed transmission replaces four-speed.
- 1991 Belt drive replaces chain drive on 883 Deluxe and all 1200 models.
- 1993 Belt drive made standard on all Sportsters.
- 1994 Improved oil tank, battery tray, and clutch made standard.
- 1994 New electrical system with sealed connectors.
- 1995 Speedometer is now electronic, not mechanical.
- 1998 XL1200S gets dual spark plug heads and high performance cams
- 1998 XL1200C Custom model introduced.
- 2000 Introduced sealed wheel bearings and updated 4-piston brake calipers.
- 2003 Last year for the frame mounted Evolution engine.
- 2004 All-new frame including rubber-mounted engine for decreased vibration. Elimination of the transmission trap door, New shape hamcan, Exhaust balance pipe moved from running under the air filter and disguised and hidden behind the silencers to show more of engine, new smoother style oil tank right side panel with push and turn filler/dipstick, and the previously exposed battery is now enclosed in a matching side panel on the left
- 2005 Enlarged rear axle to 1" for increased stability.
- 2006 New XR1200 is announced at IntermotIntermotINTERMOT Cologne is a biennial trade show for motorcycle manufacturers. The trade show began in Munich in 1998, though originally founded in Cologne. Since 2004 it has moved to koelnmesse in Cologne. The Intermot 2006 had over 1.000 exhibitors and some 187.000 visitors....
in Cologne, Germany. The XR1200 is the first Harley-Davidson to utilize Down Draft DDFI II fuel injection. To be released as a late 2006 model. - 2007 Fuel injection replaces carburetion on all models.
- 2009 "One size fits all" front mudguard approach replaced by improved mudguard contour to match each model's respective wheel diameters.
- 2010 The ECU is relocated to allow more variation in aftermarket seat selection
Production and notable Sportster models
- XL900 the original mid compression version
- XLH900 same as the standard XL but with the "H" denoting the high compression engine
- XLC900 off-road version of the XL, The XLC has magneto ignition and kickstart only (as well as several other changes to eliminate weight). the 'C' is thought to stand for California - some say 'Competition'
- XLCH900 off-road version of the XLH - or the XLC with the high compression engine! - the "CH" denoting "competition/high-compression". after a year lights, speedo and full road legal spec arrived.
- XLX-61 an entry level "Ironhead" era Sportster, available with sparse trim, in black only.
- XLS1000
- XLT1000 "Tourer" '77 special model (1099 units) featured a Superglide tank, screen, bigger seat and panniers
- XLCR1000 "Cafe Racer" is the Cafe Racer model, available in 1977 & 1978, and quite collectible today
- XR1000, Highly desirable, with two high rise flat track style exhausts on the left and two staggered K&N type filters poking out on the right. Featured a 1,000cc engine and a combination of XLX Sportster and modified XR-750 parts.
- XLH883 -
- XLH1100
- XLH1200
- XLH883 "Deluxe", twin seat, tachometer, buckhorn bars, and spoke wheels (vs single seat, speedometer only, low bars and cast wheels for the XLH883 standard model)
- XLH883 "Hugger", with reduced single seat height and reduced suspension, the precursor to the "XL low" models
- XL53C "Custom 53" (EU) XL883C "Custom" (US) '98 - '03 (53 cubic inches is approx 883cc), Forward-controls, duelseat, solid rear wheel and drag bars mounted on a riser. This became the XL883C "Custom" worldwide with the '04 rubbermount version
- XL883 "Sportster 883" single seat standard model, mid-controls, 13 spoke mags or wires
- XL883C "Custom" has wider, flatter "custom" tank, forward-controls, duelseat and 21" wire and 16" solid disc wheels
- XL1200C "Custom" Frame mount models had a chunkier duelseat and normal tank, rubber mounts get smoother seat and flatter wider "custom" tank, all have 21" wire and 16" slotted disc wheels and forward-controls
- XL883L "Low"; Single seat, very low shocks, mid-controls, 13 spoke mags or wires
- XL1200L "Low"; Dualseat, mid shox, mid-controls, wider flatter "Custom" tank, 13 spoke mags or wires
- XL1200S "Sport" – this Sportster has adjustable suspension with piggyback shox, dual disc front brakes, hotter cams and 13 spoke mags, later models get dual plug cylinder heads with single fire ignition
- XL883R "Roadster" Frame mount models have a 2-1 exhaust, 13 spoke mags, black engine and are available in orange with 'R' grapics, rubber mounts get 2-2 exhaust, slightly different dualseat, wire wheel option and more 'R' colors, all have triple discs and rev-counter. In 2010 the XL883R officially gets the "Roadster" suffix
- XL1200R "Roadster" Black engine with highlighted fins, triple discs, rev-counter, orange paint available but no 'R' graphics and '08 models get the wider flatter "custom" tank which distance it further from the 883R
- XL50 1200 "50th Anniversary" 2007 limited production of 2,000 models
- XL1200N "Nightster" first of the Dark Customs, combined LED tail/brake/indicator lights, 13'5" shox, and tapered silencers (EU) and side mounted LED lit licence plate, 11" shox, and baloney cut silencers (US), mid-controls and wire wheels
- XL883N "Iron 883", blacked out 883 similar to the Nightster with more black and 13 spoke mags, mid-cotrols.
- XR1200 More sports orientated "Euro" style bike, upside down forks, reworked sportster engine, new chassis, four-pot double discs, 120/70-18 and 180/55-17 split 3 spoke mags, rear-controls - has its own race series
- XL1200X "Forty-Eight", in the "Dark" Nightster style but has the classic '48 style small peanut tank, wire wheels, forward-controls, a whole new 130mm front tire, and super small single seat
- XR1200X Blacked out XR1200 with piggyback shox
- XL883L "SuperLow", new for 2011 has black split 5-spoke mags with polished rims and 120/70-18 and 150/60-17 tires, wider flatter "Custom" tank, mid-controls
- XL1200C "1200 Custom" As of 2011 has a 130/90B16 front tyre, wide front end, 5-spoke mags (UK gets wires), new shape eyebrow, wider flatter "Custom" tank and introduces "H-D1"...where you can either buy the standard bike or create one from thousands of parts, bars, paint, wheels etc. and H-D make it for you.
Nightster
Introduced in 2007, the XL1200N Nightster includes (then) unique features such as a bobbed rear fender, front fork gaiters, and a side mount license plate. The riding position and 25.3 in (643 mm) seat height of the Nightster are the same as those of the XL883L Sportster Low - UK version (along with Iron 883 and Forty-Eight) has central number plate, 13.5" rear shocks, tapered silencers, and combined LED indicator/tail/brake lights.The Harley Iron was released in 2009 as a smaller displacement version of the Nightster. The major differences are blacked out engine, cast wheels instead of laced; narrower handlebars; different seat, belt guard, and front mudguard, and of course the smaller engine displacement.
XR1200
In the 2008 model year, Harley-Davidson released the XR1200 Sportster in Europe, Africa, and the Middle East. The XR1200 had an Evolution engine tuned to produce 91 bhp, four-piston dual front disc brakes, and an aluminum swing arm. MotorcyclistMotorcyclist (magazine)
Motorcyclist is a motorcycling magazine in the United States. The magazine is headquartered in Los Angeles, and is published by Source Interlink Media. The current Editor in Chief, Brian Catterson, was formerly Executive Editor at rival Cycle World....
featured the XR1200 on the cover of its July 2008 issue, and was generally positive about it in their "First Ride" story, in which Harley-Davidson was repeatedly asked to sell it in the United States. One possible reason for the delayed availability in the United States was the fact that Harley-Davidson had to obtain the "XR1200" naming rights from Storz Performance, a Harley customizing shop in Ventura, Calif.
The XR1200 was released in the United States in 2009, in a special color scheme including Mirage Orange highlighting its dirt-tracker heritage. The first 750 XR1200 models in 2009 were pre-ordered and came with a number 1 tag for the front of the bike, autographed by Kenny Coolbeth
Kenny Coolbeth
Kenny Coolbeth is a flat track motorcycle racer from New Milford, Connecticut, United States. He won the 2006 A.M.A. Grand National Championship. He races in the #2 bike on the Harley-Davidson factory team. He attended Wamogo Regional High School...
and Scott Parker
Scott Parker (motorcyclist)
Scott Parker is an American professional motorcycle dirt track racer.- Racing career :Parker is a nine-time winner of the A.M.A. Grand National Championship...
and a thank you/welcome letter from Harley-Davidson
Harley-Davidson
Harley-Davidson , often abbreviated H-D or Harley, is an American motorcycle manufacturer. Founded in Milwaukee, Wisconsin, during the first decade of the 20th century, it was one of two major American motorcycle manufacturers to survive the Great Depression...
, signed by Bill Davidson.
Current models
The Sportster is offered in a number of different models. The 2010 models, which are not all offered in the same countries, are:- 883 Low - XL883L (offered as the 883 SuperLow for 2011)
- 883 Custom - XL883C (discontinued for 2011)
- 883 Roadster - XL883R (U.K.)
- Iron 883 - XL883N
- Nightster - XL1200N
- 1200 Low - XL1200L
- 1200 Custom - XL1200C
- Forty Eight - XL1200X
- XR1200 (offered as the XR1200X for 2010-2012)