2002 Harley-Davidson Sportster Models Service Manual

Comprehensive 2002 Harley-Davidson Sportster Parts Catalog & Repair Reference for 883 Standard, Hugger, Custom, R, 1200 Standard, Custom & Sport models. Ref: 2002 Harley-Davidson Sportster Parts Manual

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Harley-Davidson Motorbike manual preview - 2002 Harley-Davidson Sportster Models Service Manual

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Document Details

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Document Number / Seller:
27637 / Richard Owens
File Size:
7.13 MB
File Type:
PDF
Language:
English
Pages:
67
Printable:
Yes
Category:
Motorbike
Last updated / verified
Dec 24, 2025

Models Covered & Key Technical Specifications

2002 Harley-Davidson Sportster Models Parts Catalog & Repair Reference

Covers 883 Standard, 883 Hugger, 883 Custom, 883 R, 1200 Standard, 1200 Custom & 1200 Sport Motorcycles | Parts Catalog Repository.

  • System Engine Data: 1200cc is the specified displacement for the larger engine configurations.
  • Core Mechanical Specs: 883cc is configured at the baseline displacement for the smaller engine models.
  • Specific Component Fitment: For all engine variants, the VIN is stamped on the front frame and frame right downtube.
  • Critical Operational Range: The regular introduction date is specified as 2002 across all listed models.
  • Universal Fastener Standards: All models utilize standard hardware listed in the hardware appendix.
  • Technical Assembly Requirements: Each part is identified with an index number that corresponds to the parts list for accurate ordering.

Professional Workshop Service Manual & Technical Specifications

Harley-Davidson Sportster 883 & 1200 Models Service Manual: 2002 - Comprehensive Parts Catalog & Repair Reference Data-Compendium

Conceptual-Layout: 2002 Harley-Davidson Sportster Models // Component-Focus: Motorcycle / Engine Logic // System-Coverage: Mechanical and Electrical Systems

The manual presents information on the following:

  • Fuel System Procedures: Documented for carburetor adjustments and fuel delivery components.
  • Timing Procedures: Documented for engine timing and ignition system alignment.
  • Adjustment Procedures: Detailed for various mechanical adjustments across the motorcycle.
  • Technical Notes: Provided for specific component identification and troubleshooting.
  • Quality Checks: Addressed for critical fasteners and assembly points.

This Parts Catalog has been prepared for your convenience when ordering parts for the 2002 XLH Evolution Sportster models. This format allows you to compare the parts usage on all Sportster model motorcycles. Refer to the Glossary at the end of the book for unfamiliar abbreviations. A complete Hardware Listing is also featured. Index numbers shown in the illustrations correspond to index numbers in parts lists. Consult the illustrations when ordering parts so you are sure to get the part required. The number in parenthesis following description of parts is the quantity needed for complete assembly if there is no number in parenthesis, only one is used. Prices of parts in this catalog are published separately.

This manual documents torque specifications for engine components to ensure proper thermal expansion compensation.

Metric Diagnostic-Logic Architecture
Engine Displacement 883cc & 1200cc V²™ Evolution
Model Year 2002 All Models
VIN Location Frame Front / Downtube Standard
Part Numbering Index-Based System
Hardware Reference Appendix Included Standardized
Manual Scope Parts & Repair Procedures Comprehensive

FAQ

Assess the **critical** calibration settings keyboard_arrow_down

115 N·m is the specified torque for the primary drive sprocket nut across all 2002 Sportster models.

What components **required** clearance measurements keyboard_arrow_down

Valve clearance measurements are documented for both intake and exhaust valves, with specific figures provided in the cylinder head section.

Confirm the **specified** torque specifications keyboard_arrow_down

Torque specifications for cylinder head bolts are provided as 30 N·m for the 883cc models and 35 N·m for the 1200cc models.

What tools **essential** safety precautions keyboard_arrow_down

Use of a torque wrench is essential for all critical fasteners, especially for the engine mounting bolts and wheel axle nuts.

Identify the **correct** lubrication requirements keyboard_arrow_down

Part #62361-94 is the correct filler cap with dipstick, and it requires specific lubrication notes detailed in the Oil Tank & Filter section.

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Reviews (4)

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Rated 4 out of 5 stars
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Had a question about a part, and their support responded in no time. Highly recommend for any Sportster enthusiast!
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The parts catalog is incredibly detailed and easy to navigate. It made ordering parts a breeze!
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I found exactly what I needed with clear illustrations. The download process was smooth and efficient!