Harley Davidson Sportster XL/XLH All Models 1986-2003 Service Repair Manual

Loaded with illustrations, instructions, photos, and diagrams, complete to service and repair your HARLEY. Read and print pages directly, or copy the entire manual to your hard drive.

637 Pages

Models Covered :

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


Manual Covers :

GENERAL INFORMATION

TROUBLESHOOTING

LUBRICATION, MAINTENANCE AND TUNE-UP
Maintenance schedule / Oil and filter change / Tune-up / Air filter / Compression test / Spark plugs / Ignition timing adjustment

ENGINE TOP END
Rocker cover / Cylinder head / Valves and components / Pushrods and covers / Cylinder / Pistons and rings / Oil tank and oil lines

ENGINE LOWER END
Removal and installation / Valve tappets and guides / Valve tappets / Gearcase cover and timing gears / Oil pump / Oil filter mount / Crankcase and crankshaft / Cylinder studs / Engine break-in

PRIMARY DRIVE AND CLUTCH
Primary drive cover / Clutch release mechanism / Primary chain adjuster / Primary drive / clutch / Clutch cable

FOUR-SPEED TRANSMISSION (1986-1990 MODELS)
Transmission / Shifter mechanism

FIVE-SPEED TRANSMISSION (1991-2003 MODELS)
Transmission / Shift forks and shift drum / Mainshaft and countershaft / Main drive gear / Access door bearings / Right transmission case bearings / Shift mechanism

FUEL, EMISSION CONTROL AND EXHAUST SYSTEMS
Air filter backplate / Carburetor / Intake manifold / Fuel hose and clamps / Throttle and idle cables / Choke cable / Fuel tank / Fuel shutoff valve / Exhaust system / Evaporative emission control system (California models)

ELECTRICAL SYSTEM
Battery / Charging system / Alternator / Ignition system / Ignition coil / Bank angle sensor / Manifold absolute pressure (MAP) sensor (1998-2003 1200S models) / Starter / Starter solenoid / Lighting system / Electronic speedometer / tachometer / Switches / Horn / Electrical bracket / Turn signal flasher / Turn signal module / Circuit breakers / Fuses / Wiring diagrams

WHEELS, TIRES AND SECONDARY DRIVE
Motorcycle stands / Front wheel / Front hub / Rear wheel and hub / Drive chain and sprockets / Drive belt and sprockets / Wheel runout / Laced wheels / Disc and cast wheels / Wheel balance / Tires

FRONT SUSPENSION AND STEERING
Handlebar / Front fork / Steering head and stem / Steering head bearing / Steering play

REAR SUSPENSION
Shock absorbers / Swing arm

BRAKES
Brake fluid selection / Brake service / Front and rear brake pads (1986-1999 models) / Front and rear brake caliper / Front and rear master cylinder / Brake hose and line / Brake disc / Bleeding the system / Brake fluid draining / Flushing the brake system

BODY
Seat / Front fender / Rear fender / Footrests / Forward foot controls (1999-2003 883C and 1200C models) / Sidestand / Fork lock

WIRING DIAGRAMS




This manual is the same as the manual used by workshops. Service Manual contains detailed instructions and step by step diagrams for all workshop procedures.

Language: English
Format: PDF

COMPATIBLE WITH ALL WINDOWS & MAC COMPUTERS
(WINDOWS 10, WINDOWS 8, WINDOWS 7, VISTA 32 and 64, XP, ME, 98, NT, 2000 ETC.)

Windows/Mac/Tablet/Phone Friendly
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