1986-2003 Harley Davidson XL / XLH 883 1100 1200 Sportster Service Repair Manual and WIRING DIAGRAMS TROUBLESHOOTING ENGINE OVERHAUL

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4 VEHICLE IDENTIFICATION NUMBER (VIN) (1986-2003 SPORTSTER)

CHAPTER ONE

4

Motorcycle Made in U.S.A.

Model Designation CA = XLH883, XLH883 Deluxe (1986/1987), XLH1100, XLH1200 CE = XLH883 Hugger CF = XLH833 Deluxe CG = XL1200 Custom CH = XL1200 Sport CJ = XLH883 Custom CK = XLH883 Custom

Engine Size M = 883 cc engine N = 1100 cc engine P = 1200 cc engine

Introduction Date and Special Models 1 2 3 4 5 = = = = = Regular introduction date Mid-year introduction date California model Special edition California-only special edition

VIN Check Digit Varies; can be 0 through 9, or X.

Model Year M= N = P = R = S = T = V = W= X = Y = 1 = 2 = 3 = 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003

1

HD

4

CA

M

1

3

R

Y

Y

Serial Number

Assembly Plant Manufacturer and Make Harley Davidson Motorcycle Type 1 = Heavyweight (901 cc and larger engine displacement) 4 = Middleweight (351-900 cc engine displacement) K = Kansas City Y = York, Pennsyvania

FASTENERS Proper fastener selection and installation is important to ensure the motorcycle operates as designed and can be serviced efficiently. The choice of original equipment fasteners is not arrived at by chance. Make sure that replacement fasteners meet all the same requirements as the originals. Threaded Fasteners WARNING Do not install fasteners with a strength classification lower than what was originally installed by the manufacturer. Doing so may cause equipment failure and/or damage.

Threaded fasteners secure most of the components on the motorcycle. Most are tightened by turning them clockwise (right-hand threads). If the normal rotation of the component being tightened would loosen the fastener, it may have left-hand threads. If a left-hand threaded fastener is used, it is noted in the text. Two dimensions are required to match the size of the fastener: the number of threads in a given distance and the outside diameter of the threads. Two systems are currently used to specify threaded fastener dimensions: the U.S. Standard system and the metric system (Figure 5). Pay particular attention when working with unidentified fasteners; mismatching thread types can damage threads.

GENERAL INFORMATION

5 The measurement across two flats on a nut or bolt indicates the wrench size. Torque Specifications

1

5

U.S. Standard

Metric

60°

60°

The materials used in the manufacture of the motorcycle may be subjected to uneven stresses if the fasteners of the various subassemblies are not installed and tightened correctly. Fasteners that are improperly installed or work loose can cause extensive damage. It is essential to use an accurate torque wrench, as described in this chapter, with the torque specifications in this manual. Specifications for torque are provided in foot-pounds (ft.-lb.), inch-pounds (in.-lb.) and Newton-meters (N·m). Refer to Table 6 for general torque specifications. To use Table 6, first determine the size of the fastener as described in this section. Torque specifications for specific components are at the end of the appropriate chapters. Torque wrenches are covered in this chapter. Self-Locking Fasteners

6
T

D

Grade marking

L

NOTE To ensure that the fastener threads are not mismatched or cross-threaded, start all fasteners by hand. If a fastener is hard to start or turn, determine the cause before tightening with a wrench. The length (L, Figure 6), diameter (D) and number of threads per inch (TPI) (T) classify U.S. Standard screws and bolts. A typical bolt may be identified by the numbers 1/4­20×1-1/2. This indicates the bolt has a 1/4-inch diameter, 20 threads per inch and the length is 1-1/2 inches. Sometimes thread count is noted as either course or fine. Always measure bolt length as shown in L, Figure 6 to avoid purchasing replacements of the wrong length. Markings on top of the fastener (Figure 6) indicate the strength of U.S. Standard screws and bolts. The greater the number of head markings, the stronger the fastener. Unmarked fasteners are the weakest. Many screws, bolts and studs are combined with nuts to secure particular components. To indicate the size of a nut, manufacturers specify the internal diameter and the TPI
.

Several types of bolts, screws and nuts incorporate a system that creates interference between the two fasteners. Interference is achieved in various ways. The most common types are the nylon insert nut and a dry adhesive coating on the threads of a bolt. Self-locking fasteners offer greater holding strength than standard fasteners, which improves their resistance to vibration. Self-locking fasteners cannot be reused. The material used to form the lock becomes distorted after the initial installation and removal. Discard and replace self-locking fasteners after their removal. Do not replace self-locking fasteners with standard fasteners. Washers There are two basic types of washers: flat washers and lockwashers. Flat washers are simple discs with a hole to fit a screw or bolt. Lockwashers are used to prevent a fastener from working loose. Washers can be used as spacers and seals, or to help distribute fastener load and to prevent the fastener from damaging the component. As with fasteners, when replacing was
hers make sure the replacement washers are of the same design and quality. Cotter Pins A cotter pin is a split metal pin inserted into a hole or slot to prevent a fastener from loosening. In certain applications, such as the rear axle on a motorcycle, the fastener must be secured in this way. For these applications, a cotter pin and castellated (slotted) nut are used. To use a cotter pin, first make sure the diameter is correct for the hole in the fastener. After correctly tightening the

6 fastener and aligning the holes, insert the cotter pin through the hole and bend the ends over the fastener (Figure 7). Unless instructed to do so, never loosen a tightened fastener to align the holes. If the holes do not align, tighten the fastener just enough to achieve alignment. Cotter pins are available in various diameters and lengths. Measure length from the bottom of the head to the tip of the shortest pin. Snap Rings and E-clips Snap rings (Figure 8) are circular-shaped metal retaining clips. They are required to secure parts and gears in place on parts such as shafts, pins or rods. External type snap rings are used to retain items on shafts. Internal type snap rings secure parts within housing bores. In some applications, in addition to securing the component(s), snap rings of varying thickness also determine endplay. These are usually called selective snap rings. Two basic types of snap rings are used: machined and stamped snap rings. Machined snap rings can be installed in either direction, si
nce both faces have sharp edges. Stamped snap rings (Figure 9) are manufactured with a sharp edge and a round edge. When installing a stamped circlip in a thrust application, install the sharp edge facing away from the part producing the thrust (Figure 10). E-clips are used when it is not practical to use a circlip. Remove E-clips with a flat blade screwdriver by prying between the shaft and E-clip. To install an E-clip, center it over the shaft groove and push or tap it into place. Observe the following when installing snap rings: 1. Remove and install snap rings with circlip pliers. Refer to the Tools section in this chapter. 2. In some applications, it may be necessary to replace snap rings after removing them. 3. Compress or expand snap rings only enough to install them. If overly expanded, they lose their retaining ability. 4. After installing a snap ring, make sure it seats completely. 5. Wear eye protection when removing and installing snap rings. SHOP SUPPLIES Lubricants and Fluids Periodic lubricati
on helps ensure a long service life for any type of equipment. Using the correct type of lubricant is as important as performing the lubrication service, although in an emergency the wrong type is better than not using one. The following section describes the types of lubricants most often required. Make sure to follow the manufacturer's recommendations for lubricant types.

CHAPTER ONE

7

Correct installation of cotter pin

8

Internal snap ring

Plain circlip

External snap ring

E-clip

Engine oils Engine oil is classified by two standards: the American Petroleum Institute (API) service classification and the Society of Automotive Engineers (SAE) viscosity rating. This information is on the oil container label. Two letters indicate the API service classification. The number or sequence of numbers and letter (10W-40 for example) is the oil's viscosity rating. The API service classification and the SAE viscosity index are not indications of oil quality. The service classification indicates that the oil meets specific lubrication standards. The first letter in the classification, S, indicates the oil is for gasoline engines.