1986-2005 Harley-Davidson Sportster XLH 883, XL 1200 service manual

Product Information

Table of Contents

PRODUCT

• General
• Servicing a New Motorcycle
• Regular Maintenance Intervals
• Side Views
• Storage
• Fluid Requirements
• Metric Conversion Table
• Fastener Torque Values
• Troubleshooting
• Shop Practices
• Tool Safety
• Tools

CHASSIS

• Specifications
• Wheels
  • Front Wheel
  • Rear Wheel
  • Lacing Wheels
  • Truing Laced Wheel
  • Checking Cast Rim Runout
  • Tires
• Brakes
  • Front Brake Master Cylinder
  • Rear Brake Master Cylinder
  • Rear Brake Linkage and Spacer Cover
  • Front Brake Caliper
  • Rear Brake Caliper
  • Brake Lines
  • Bleeding Hydraulic System
• Front Fork
  • Front Fork Assembly
  • Front Fork Disassembly and Repair
  • Fork Stem and Bracket Assembly
• Rear Fork
  • Rear Fork
  • Rear Shock Absorber
• Clutch Control
• Exhaust System
• Front Fender
• Rear Fender
• Jiffy Stand
• Seat
• Handlebars
• Throttle Control

ENGINE

• Specifications
• Engine
• Stripping Motorcycle for Engine Repair
• Installing the Engine
• Cylinder Head
• Cylinder and Piston
• Engine Lubrication System
  • Oil Pump
  • Oil Lines and Hoses
  • Oil Filter
• Valve Tappets
• Gearcase Cover and Cam Gears
• Crankcase
  • Crankcase Disassembly
  • Crankcase Assembly
  • Crankshaft, Connecting Rods, and Bearings
  • Balancer
  • Main Shaft and Countershaft
  • Starter Clutch
  • Cylinder Studs
  • Engine Breather

FUEL SYSTEM

• Specifications
• Carburetor
• Carburetor Maintenance
  • Cleaning
  • Adjustments
  • Troubleshooting
• Air Cleaner
• Fuel Supply Valve
• Fuel Tank
• Evaporative Emissions Control - California Models

ELECTRIC STARTER

• Specifications
• Electric Starter System
• Starter Motor
• Starter Relay
• Solenoid

DRIVE/TRANSMISSION

• Specifications
• Primary Drive
  • Chain
  • Chain Tensioner
  • Adjustments
• Clutch
  • Clutch Cable
  • Clutch Adjustments
• Transmission
  • Transmission Disassembly
  • Transmission Assembly
  • Transmission Maintenance

ELECTRICAL

• Specifications
• Battery
• Charging System
• Ignition System
• Electric Starter System
• Lighting System
• Horn
• Turn Signal System
• Instrument Panel
• Wiring Diagrams

INDEX

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This repair manual is a valuable resource for mechanics, technicians, and owners as it provides detailed information on troubleshooting, maintenance, and repair procedures for the 1986-2005 Harley Davidson Sportster XLH 883, XL 1200. It covers a wide range of topics including engine maintenance, suspension, brakes, and electrical systems.

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