Download Complete Service Manual for 1986-2003 Harley-Davidson XLH883, XL883R, XLH1100 & XL/XLH1200 Sportster.
This Service Repair Manual offers all the service and repair information about 1986-2003 Harley-Davidson XLH883, XL883R, XLH1100 & XL/XLH1200 Sportster. The information on this manual covered everything you need to know when you want to repair or service 1986-2003 Harley-Davidson XLH883, XL883R, XLH1100 & XL/XLH1200 Sportster.
Models Covered:
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
Service Manual:
Manual organization / Warnings, cautions and notes / Safety / Serial numbers / Fasteners / Shop supplies / Tools / Measuring tools / Electrical system fundamentals / Service methods / Storage / SpecificationsCHAPTER TWO / TROUBLESHOOTING
Starting the engine / Engine performance / Electrical component replacement / Starting system / Charging system / Ignition system (1986-1997 models) / Ignition system (1998-2003 models, except 1200S models) / Ignition system (1998-2003 1200S models) / Fuel system / Engine noises / Engine smoke / Leakdown test / Engine lubrication / Clutch / Transmission / Electrical testing / Electronic speedometer/tachometer / Turn signal module (1991-1996 models) / Turn signal module (1997-2003 models) / Excessive vibration / Front suspension and steering / Brake problems / Specifications
CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Maintenance schedule / Oil and filter change / Tune-up / Air filter / Compression test / Spark plugs / Ignition timing adjustment / Specifications
CHAPTER FOUR / ENGINE TOP END
Rocker cover / Cylinder head / Valves and components / Pushrods and covers / Cylinder / Pistons and rings / Oil tank and oil lines / Specifications
CHAPTER FIVE / 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 / Specifications
CHAPTER SIX / PRIMARY DRIVE AND CLUTCH (1986-1990 MODELS)
Primary drive cover / Clutch release mechanism / Primary chain adjuster / Primary drive / clutch / Clutch cable / Specifications
CHAPTER SEVEN / PRIMARY DRIVE AND CLUTCH (1991-2003 MODELS)
Primary drive cover (1991-1993 models) / Primary drive cover (1994-2003 models) / Clutch release mechanism (1991-1993 models) / Clutch release mechanism (1994-2003 models) / Primary chain adjuster / Primary drive/clutch / Clutch cable / Specifications
CHAPTER EIGHT / FOUR-SPEED TRANSMISSION (1986-1990 MODELS)
Transmission / Shifter mechanism / Specifications
CHAPTER NINE / 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 / Specifications
CHAPTER TEN / FUEL, EMISSION CONTROL AND EXHAUST SYSTEMS (1986-1987 MODELS)
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) / Specifications
CHAPTER ELEVEN / FUEL, EMISSION CONTROL AND EXHAUST SYSTEMS (1988-2003 MODELS)
Air filter backplate / Carburetor / Intake manifold / Fuel hose and clamps / Throttle and idle cables / Starting enrichment valve (choke) cable / Fuel tank / Fuel shutoff valve (1988-1994 models) / Fuel shutoff valve (1995-2003 models) / Exhaust system (all models except 883R models) / Exhaust system (883R models) / Evaporative emission control system (California models) / Specifications
CHAPTER TWELVE / 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 / Specifications
CHAPTER THIRTEEN / 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 / Specifications
CHAPTER FOURTEEN / FRONT SUSPENSION AND STEERING
Handlebar / Front fork / Steering head and stem / Steering head bearing / Steering play / Specifications
CHAPTER FIFTEEN / REAR SUSPENSION
Shock absorbers / Swing arm / Specifications
CHAPTER SIXTEEN / 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 / Specifications
CHAPTER SEVENTEEN / BODY
Seat / Front fender / Rear fender / Footrests / Forward foot controls (1999-2003 883C and 1200C models) / Sidestand / Fork lock / Specifications
INDEX
COLOR WIRING DIAGRAMS
This manual can be used by anyone from a first time owner/amateur to a professional technician.Even the most novice mechanic can also easily follow the step-by-step guides which are made simple by the illustrations and drawings.Keep this manual handy and use it often. Performing routine, preventive maintenance will save you time & money by helping to prevent premature failure and unnecessary repairs.
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Compatible: All Versions of Windows & Mac
Language: English