This detailed and comprehensive manual covers
1986-2003 XL/XLH Sportster models. The text provides
complete information on maintenance, tune-up, repair and
overhaul. Hundreds of photos and drawings guide the
reader through every job.
A shop manual is a reference tool and as in all Service
manuals, the chapters are thumb tabbed for easy reference.
Important items are indexed at the end of the book. All pro￾cedures, tables and figures are designed for the reader who
may be working on the motorcycle for the first time. Fre￾quently used specifications and capacities from individual
chapters are summarized in the Quick Reference Data at the
front of this manual.
MANUAL ORGANIZATION
All dimensions and capacities are expressed in U.S. stan￾dard and metric units of measurement.
Specifications, when applicable, are listed in the tables at
the end of each chapter.
This chapter covers shop safety, tool use, service funda￾mentals and shop supplies. Tables 1-12 at the end of the
chapter include the following:
1. Model designations.
2. General motorcycle dimensions.
3. Motorcycle weight.
4. Gross vehicle weight.
5. Fuel tank capacity.
6. General torque recommendations.
7. Conversion formulas.
8. Technical abbreviations.
9. U.S. standard tap and drill sizes.
10. Metric tap and drill sizes.
11. Decimal and metric equivalents.
12. Special tools.
Chapter Two provides methods for quick and accurate di￾agnosis of problems. Troubleshooting procedures present
typical symptoms and logical methods to pinpoint and re￾pair the problem.
Chapter Three explains all routine maintenance neces￾sary to keep the motorcycle running well. Chapter Three
also includes recommended tune-up procedures, eliminat￾ing the need to constantly consult the chapters on the vari￾ous assemblies.
Subsequent chapters describe specific systems such as
engine, primary drive and clutch, transmission, emissions,
fuel and exhaust systems, the electrical system, suspension,
brakes and body. Each disassembly, repair and assembly
procedure is discussed in step-by-step form.