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1986-1994 Harley-Davidson Sportster service manual Preview image 1
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1986-1994 Harley-Davidson Sportster service manual

Models covered in this manual:

- Harley-Davidson Sportster XL883
- Harley-Davidson Sportster XLH883
- Harley-Davidson Sportster XL883 Deluxe
- Harley-Davidson Sportster XLH883 Deluxe
- Harley-Davidson Sportster XLH883 Hugger
- Harley-Davidson Sportster XL1200
- Harley-Davidson Sportster XLH1200
- Harley-Davidson Sportster XLH1200S
- Harley-Davidson Sportster XLH1200 Sport
- Harley-Davidson Sportster XL1200C Custom
- Harley-Davidson Sportster XLH883 Custom

Production year(s): 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994

File specifications

File size: 28.49 MB
File type: ZIP
Language: English

Printable: Yes
Estimated download time: 0.58 Minutes
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Product Information

Table of Contents

Chapter One: General Information

  • Manual organization
  • Notes, cautions and warnings
  • Safety first
  • Cleaning parts
  • Handling gasoline safely
  • Service hints
  • Torque specifications
  • Fasteners
  • Lubricants
  • Threadlocking compound
  • RTV gasket sealant
  • Expendable supplies
  • Serial numbers
  • Warning and information labels
  • Basic hand tools
  • Precision measuring tools
  • Special tools
  • Fabricating tools
  • Mechanic's tips
  • Bearing replacement
  • Seals
  • Storage

Chapter Two: Troubleshooting

  • Operating requirements
  • Troubleshooting instruments
  • Starting the engine
  • Starting difficulties
  • Engine is difficult to start
  • Engine starting system
  • Charging system
  • Ignition system
  • Electronic throttle control
  • Fuel system
  • Engine overheating
  • Engine
  • Engine noises
  • Cylinder leak down test
  • Power train
  • Steering
  • Frame noise
  • Brakes

Chapter Three: Lubrication, Maintenance and Tune-Up

  • Pre-ride checklist
  • Tires and wheels
  • Battery
  • Battery electrical cable connectors
  • Periodic lubrication
  • Periodic maintenance
  • Unscheduled inspection and maintenance
  • Engine tune-up

Chapter Four: Engine Top End

  • Engine principles
  • Engine cooling
  • Engine lubrication
  • Servicing the engine in the frame
  • Exhaust system
  • Cylinder head cover
  • Rocker arm assembly
  • Camshaft
  • Cylinder head
  • Valves and valve components
  • Cylinder block
  • Piston and piston rings
  • Camshaft chain and sprockets
  • Break-in procedure

Chapter Five: Engine Lower End

  • Engine
  • Flywheel and stator plate
  • Recoil starter
  • Crankcase
  • Crankshaft inspection
  • Balancer shaft inspection
  • Shaft end float measurement and shim selection
  • Oil pump
  • Oil system one-way check valve
  • Break-in procedure

Chapter Six: Fuel System

  • Carburetor operation
  • Carburetor
  • Carburetor cleaning and inspection
  • Carburetor tests and adjustments
  • Throttle cable replacement
  • Starting enrichment (choke) cable
  • Fuel tank
  • Fuel shutoff valve
  • Air filter air box
  • Fuel pump

Chapter Seven: Cooling Systems

  • Polaris variable transmission (PVT) air cooling system
  • Engine cooling system
  • Safety precautions
  • Hoses and hose clamps
  • Engine gaskets/seals
  • Cooling system inspection
  • Radiator
  • Cooling fan
  • Coolant pump
  • Thermostat
  • Temperature sensors

Chapter Eight: Clutch/Drive Belt System

  • Drive unit
  • Drive pulley
  • Special tools
  • Driven pulley
  • Drive belt
  • Drive pulley
  • Driven pulley
  • Clutch outer and inner cover (all models)

Chapter Nine: Transmission

  • Transmission
  • Transmission inspection
  • Shift shafts
  • Front output shaft
  • Transmission gearcase oil seal inspection and replacement
  • Shift selector linkage

Chapter Ten: Front Drive System

  • Front hub and Hillard clutch
  • Front drive axle, boots and CV (constant velocity) joints
  • Front drive shaft
  • Front drive unit

Chapter Eleven: Electrical System

  • Basic information
  • Negative battery terminal
  • Charging system
  • Alternator stator
  • Voltage regulator/rectifier
  • Capacitor discharge ignition
  • Ignition coil
  • Ignition stator coils
  • Electric starting system
  • Starter drive gears
  • Starter solenoid
  • Lighting system
  • Electrical components
  • Switches
  • Wiring diagrams

Chapter Twelve: Front Suspension and Steering

  • Front wheel
  • Front hub
  • Front strut cartridge and spring
  • Front strut/spindle
  • Control arm
  • Handlebar
  • Tie rods
  • Steering shaft
  • Tires and wheels

Chapter Thirteen: Rear Suspension

  • Rear wheels
  • Tire changing and tire repairs
  • Shock absorber
  • Rear hub and bearing carrier
  • Rear axles
  • Upper control arm
  • Lower control arm
  • Upper and lower control arm inspection
  • Stabilizer linkage
  • Stabilizer support

Chapter Fourteen: Brakes

  • Disc brakes
  • Front brake pad replacement
  • Front caliper
  • Output shaft brake pad replacement (1996-1997 models)
  • Output shaft brake caliper (1996-1997 models)
  • Output shaft brake pad replacement (1998-on models)
  • Output shaft brake caliper (1998-on models)
  • Front master cylinder
  • Rear master cylinder
  • Brake hose replacement
  • Rear brake pedal
  • Rear brake lever (1996-1997 Sweden models)
  • Foot brake (1998-on Sweden models)
  • Brake disc
  • Bleeding the system

Chapter Fifteen: Body

  • Seat
  • Front rack and grille
  • Side panels
  • Front fender
  • Front bumper (models so equipped)
  • Radiator guard
  • Rear rack
  • Rear fender
  • Footwells
  • Rear bumper (models so equipped)

Supplement: 2001-2003 Service Information

  • Starting the engine
  • Ignition system
  • Periodic maintenance
  • Engine tune-up
  • Cylinder block
  • Piston and piston rings
  • Engine
  • Flywheel and stator plate
  • Carburetor (Sportsman 500 H.O. models)
  • Cleaning and inspection
  • Carburetor tests and adjustments
  • Drive belt
  • Driven pulley (2003 models built after 07/08/02)
  • Transmission
  • Lighting system
  • Electrical components
  • Steering shaft (2002-on models)
  • Rear hub and bearing carrier (2003 models)
  • Rear brake pad replacement (2003 models)
  • Rear calipers (2003 models)
  • Front master cylinder
  • Rear master cylinder (2003 models)
  • Rear brake disc (2003 models)
  • Brake hose replacement (2003 models)

Index

  • 470

Wiring Diagrams

  • 476

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