2003 Harley-Davidson Sportster service manual

2003 Harley-Davidson Sportster service manual Preview image 1
2003 Harley-Davidson Sportster service manual Preview image 1
2003 Harley-Davidson Sportster service manual Preview image 2
2003 Harley-Davidson Sportster service manual Preview image 3
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  • File Size: 26.21 MB
  • File Type: ZIP
  • Language: English
  • Printable: Yes
  • Estimated Download Time: 0.54 Minutes
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Models Covered in this Manual

Harley-Davidson Motor Co

  • Harley-Davidson XLH 883 Sportster
  • Harley-Davidson XL 883C Sportster Custom
  • Harley-Davidson XL 883R Sportster R
  • Harley-Davidson XL 1200C Sportster Custom
  • Harley-Davidson XL 1200S Sportster Sport
  • Harley-Davidson XL 1200R Sportster Roadster

Production/model years: 2003

Product Information

Table of Contents

Section 1: General

  1. General Information
    • Servicing a New Motorcycle
    • Safe Operating Maintenance
    • Shop Practices
      • Repair Notes
      • Safety
      • Removing Parts
      • Cleaning
      • Disassembly and Assembly
    • Repair and Replacement Procedures
      • Hardware and Threaded Parts
      • Wiring, Hoses and Lines
      • Instruments and Gauges
      • Bearings
      • Gears
      • Shafts
      • Part Replacement
      • Cleaning Process
      • Rust or Corrosion Removal
      • Bearings
    • Tool Safety
      • Air Tools
      • Wrenches
      • Pliers/Cutters/Prybars
      • Hammers
      • Punches/Chisels
      • Screwdrivers
      • Ratchets and Handles
      • Sockets
      • Storage Units

Section 2: Fuel and Oil

  1. Fuel and Oil
    • Fuel
      • Gasoline Blends
    • Engine Oil
    • Winter Lubrication

Section 3: Chassis

  1. Chassis
    • Frame
    • Front Forks
    • Rear Suspension
    • Wheels
    • Tires
    • Brakes

Section 4: Engine

  1. Engine
    • Engine Removal/Installation
    • Engine Disassembly/Assembly
    • Cylinder Head
    • Valves
    • Pistons
    • Crankshaft
    • Camshaft
    • Timing

Section 5: Fuel System

  1. Fuel System
    • Carburetor
    • Fuel Tank
    • Fuel Lines

Section 6: Starter

  1. Starter
    • Starter Motor
    • Starter Solenoid
    • Starting Circuit

Section 7: Drive/Transmission

  1. Drive/Transmission
    • Primary Drive
    • Clutch
    • Transmission
    • Drive Belt

Section 8: Electrical

  1. Electrical
    • Charging System
    • Ignition System
    • Lighting
    • Switches
    • Wiring Diagram

Appendix

  1. Electrical Diagnostics
    • Starting & Charging
    • Instruments
    • Turn Signals
    • Engine Management
    • Wiring

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