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1986-2005 Harley-Davidson Sportster XL, XLH 883, 1100, 1200 manual Preview image 1
1986-2005 Harley-Davidson Sportster XL, XLH 883, 1100, 1200 manual Preview image 2
1986-2005 Harley-Davidson Sportster XL, XLH 883, 1100, 1200 manual Preview image 3
1986-2005 Harley-Davidson Sportster XL, XLH 883, 1100, 1200 manual Preview image 4
1986-2005 Harley-Davidson Sportster XL, XLH 883, 1100, 1200 manual Preview image 5
1986-2005 Harley-Davidson Sportster XL, XLH 883, 1100, 1200 manual Preview image 6

1986-2005 Harley-Davidson Sportster XL, XLH 883, 1100, 1200 manual

Models covered in this manual:

- XLH883 1986-2003 
- XL883R 1986-2003 
- XL/XLH1200 1986-2003 
- XLH1100 1986-2003 
- 1996-2003 HARLEY-DAVIDSON Sportster XL1200 C Custom
- 1996-2003 HARLEY-DAVIDSON Sportster XL1200 Sport
- 2002-2003 HARLEY-DAVIDSON Sportster XL883R
- 1986-1987 HARLEY-DAVIDSON Sportster XLH1100
- 1988-2003 HARLEY-DAVIDSON Sportster XLH1200
- 1986-2003 HARLEY-DAVIDSON Sportster XLH883
- 1999-2003 HARLEY-DAVIDSON Sportster XLH883 C Custom
- 1986-1995 HARLEY-DAVIDSON Sportster XLH883 D Deluxe
- 1987-2003 HARLEY-DAVIDSON Sportster XLH883 H Hugger
  • PRIMARY DRIVE & CLUTCH (1986-1990 MODELS)
  • PRIMARY DRIVE & CLUTCH (1991-2003 MODELS)
  • 4SPD TRANSMISSION (1986-1990 MODELS)
  • 5SPD TRANSMISSION (1991-2003 MODELS)
  • FUEL/EMISSIONS CONTROL & EXHAUST SYSTEMS (1986-1987 MODELS)
  • FUEL/EMISSIONS CONTROL & EXHAUST SYSTEMS (1988-2003 MODELS)

Production/model years: 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005.

File specifications

File size: 29.64 MB
File type: PDF
Language: English
Pages:636

Printable: Yes
Estimated download time: 0.61 Minutes
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Product Information

Table of Contents

General Information

  1. Warnings, Cautions and Notes
    • Safety
    • Handling Gasoline Safely
  2. Cleaning Parts
  3. Serial Numbers
    • Vehicle Identification Number (VIN)
  4. Torque Specifications
  5. Self-Locking Fasteners
  6. Washers
  7. Cotter Pins
  8. Lubrication
  9. Maintenance Schedule
  10. Break-In Procedure
  11. Tool Recommendations
  12. Troubleshooting

Engine

  1. General Engine Specifications
    • Engine Lubrication
    • Engine Cooling
  2. Cylinder Head
    • Removal and Installation
    • Inspection
  3. Valves and Valve Springs
    • Removal and Installation
    • Inspection
  4. Camshaft
    • Removal and Installation
    • Inspection
  5. Timing
    • Setting Timing
    • Inspection

Transmission

  1. General Transmission Specifications
  2. Clutch
    • Removal and Installation
    • Inspection
  3. Transmission Gears
    • Removal and Installation
    • Inspection
  4. Drive Chain/Belt
    • Adjustment
    • Inspection

Fuel System

  1. Fuel Tank
    • Removal and Installation
    • Inspection
  2. Carburetor
    • Removal and Installation
    • Adjustment
    • Inspection
  3. Fuel Lines
    • Inspection
    • Replacement

Electrical System

  1. Battery
    • Inspection
    • Charging
  2. Ignition System
    • Spark Plugs
    • Ignition Coil
    • Ignition Timing
  3. Charging System
    • Alternator
    • Regulator/Rectifier
  4. Lighting System
    • Headlight
    • Taillight
    • Turn Signals
  5. Wiring Diagram
    • Overview
    • Troubleshooting

Chassis

  1. Frame
    • Inspection
    • Repair
  2. Suspension
    • Front Forks
    • Rear Shocks
  3. Wheels
    • Removal and Installation
    • Inspection
  4. Brakes
    • Front Brake
    • Rear Brake
  5. Steering
    • Adjustment
    • Inspection

Body

  1. Seat
    • Removal and Installation
    • Inspection
  2. Fenders
    • Removal and Installation
    • Inspection
  3. Fuel Tank
    • Removal and Installation
    • Inspection

Appendix

  1. Torque Specifications
  2. Special Tools
  3. Conversion Tables
    • Metric to Standard

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