1995-2003 Harley-Davidson Sportster repair manual

1995-2003 Harley-Davidson Sportster repair manual Preview image 1
1995-2003 Harley-Davidson Sportster repair manual Preview image 1
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  • File Type: ZIP
  • Language: English
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Models Covered in this Manual

Sportster /(XL) Harley-Davidson Motor Company

  • Harley Davidson Sportster 883
  • Harley Davidson Sportster 883 Custom
  • Harley Davidson Sportster 883 Hugger
  • Harley Davidson Sportster 883R
  • Harley Davidson Sportster 1200
  • Harley Davidson Sportster 1200 Custom
  • Harley Davidson Sportster 1200 Sport
  • Harley Davidson Sportster 1200C Custom
  • Harley Davidson Sportster 1200S Sport
  • Harley Davidson Sportster XLH883
  • Harley Davidson Sportster XLH883 Custom
  • Harley Davidson Sportster XLH883 Deluxe
  • Harley Davidson Sportster XLH883 Hugger
  • Harley Davidson Sportster XLH883L
  • Harley Davidson Sportster XLH883R
  • Harley Davidson Sportster XLH1200
  • Harley Davidson Sportster XLH1200 Custom
  • Harley Davidson Sportster XLH1200 Sport
  • Harley Davidson Sportster XLH1200S Sport
  • Harley Davidson Sportster XL1200C Custom
  • Harley Davidson Sportster XL1200S Sport
  • Harley Davidson Sportster XL1200R Roadster
  • Harley Davidson Sportster XL1200S Sport
  • Harley Davidson Sportster XL1200S Sportster Sport
  • Harley Davidson Sportster XL1200X Forty-Eight
  • Harley Davidson Sportster XL1200V Seventy-Two
  • Harley Davidson Sportster XL1200N Nightster
  • Harley Davidson Sportster XL1200L Low
  • Harley Davidson Sportster XL1200R Roadster
  • Harley Davidson Sportster XL883N Iron
  • Harley Davidson Sportster XL883L Superlow
  • Harley Davidson Sportster XL883R Roadster
  • Harley Davidson Sportster XL883C Custom
  • Harley Davidson Sportster XL883L Low
  • Harley Davidson Sportster XL883 Sport

Production year(s): 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003

Product Information

Table of Contents

Chapter One

  • General Information
  • 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

Wiring Diagrams


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