2002 Harley-Davidson Sportster Service Manual

Complete repair and service manual for the 2002 Harley-Davidson Sportster models XL883, XL883 Hugger, XL883C Custom, XL883R, XLH1200, XL1200C Custom, and XL1200S Sport.

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Document Details

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Document Number / Seller:
27965 / Kenneth Ramirez
File Size:
26.21 MB
File Type:
ZIP
Language:
English
Pages:
64
Printable:
Yes
Category:
Motorbike
Last updated / verified
Aug 30, 2025

Models Covered & Key Technical Specifications

2002 Harley-Davidson Sportster Service Manual Troubleshooting, parts diagrams, and service data for all 2002 Harley-Davidson Sportster models.

  • Brand: Harley-Davidson
  • Models: XLH883 / XLH883 Hugger / XL 883C Custom / XL 883R / XLH 1200 / XL 1200C Custom / XL 1200S Sport
  • Year: 2002
  • Manual Type: Service Manual
  • Part Numbers: 99484-02A, 99495-02
  • Page Count: 64

Professional Workshop Service Manual & Technical Specifications

Harley-Davidson Sportster 2002 Service Manual: Comprehensive Repair Guide

Procedure-Type: Full Service // Technical-Domain: Motorcycle Mechanics / Electrical Systems // Reference-Category: Repair Manuals

This manual details the complete servicing procedures for the 2002 Harley-Davidson Sportster range, including the XLH883, XLH883 Hugger, XL 883C Custom, XL 883R, XLH1200, XL1200C Custom, and XL1200S Sport models. It covers all aspects of maintenance and repair, from basic checks to complex component overhauls.

Outlining the operational framework across various systems, this document provides essential information for technicians and enthusiasts alike. It includes detailed sections on:

  • Engine specifications and lubrication
  • Chassis components, including wheels, brakes, forks, and rear suspension
  • Electrical system diagnostics and troubleshooting
  • Fuel and ignition systems
  • Throttle and clutch controls
  • Exhaust system maintenance

This manual documents torque specifications for key components to ensure proper gasket seal integrity and safe operation.

Table of Contents Summary:

  • Engine lubrication system
  • Front fork assembly
  • Rear shock absorber adjustment
  • Throttle control adjustment
  • Clutch control removal/disassembly
  • Cylinder head removal and assembly
  • Troubleshooting guides for common issues

Consistent maintenance and adherence to the procedures outlined herein are vital for optimal performance and longevity of your Harley-Davidson Sportster.

FAQ

What is the **required** fluid capacity for the front fork on a 2002 Sportster? keyboard_arrow_down

9.0 oz. (266 ml) of Type 'E' Fork Oil is required for each slider tube on a 'wet' fork, and 10.2 oz. (302 ml) for a 'dry' fork.

Calculate the **specified** torque for the front axle nut on a 2002 Sportster. keyboard_arrow_down

50-55 ft-lbs (68-75 Nm) is the specified torque for the front axle nut.

What values are **essential** for proper valve seat angle adjustment? keyboard_arrow_down

45° for grinding and 46° for cutting are the essential valve seat angles for proper adjustment.

Assess the **correct** brake fluid level specification for the master cylinder reservoir. keyboard_arrow_down

1/8 in. (3.2 mm) from the top is the correct specification for the brake fluid level in the master cylinder reservoir.

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Reviews (3)

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New
I had a smooth download process and the manual is very comprehensive. Perfect for DIY repairs and maintenance.
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New
Rated 5 out of 5 stars
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New
This manual is a must-have for any Sportster owner. The detailed maintenance schedule has helped me keep my bike in top shape.