1986-2003 Harley Davidson Sportster XL & XLH Service Manual
Download Service Manual for Harley Davidson Sportster XL & XLH 1986-2003 Models.
Models covered in this Service Repair Manual are: Harley Davidson Sportster XL & XLH models, including XLH883, XL883R, XLH1100, XL1200, and XLH1200.
Years Covered in this Sportster Manual: XLH883 (1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2001, 2002 and 2003 models), XLH883 CUSTOM (1999, 2000, 2001 and 2003 models), XLH883 DELUXE (1986, 1987, 1988, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994 and 1995 models), XLH883 HUGGER (1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002 and 2003 models), XL883R (2002-2003 models), XLH1100 (1986-1987 models), XLH1200 (1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002 and 2003 models), XL1200 CUSTOM (1996, 1997, 1998, 1999, 2000, 2001, 2002 and 2003 models), XL1200 SPORT (1996, 1997, 1998, 1999, 2000, 2001, 2002 and 2003 models), XL XLH 883, 1200 and 1200.
Contents of this Harley Davision XL, XLH Sportster Service and Repair Manual: This instant eBook contains fully detailed step-by-step repair procedures with hundreds of high quality photos and illustrations to guide you through any repair, maintenance, overhaul, service specifications or troubleshooting procedure. This expert text guide book will give you the knowledge and experience you need to perform simple basic maintenance or more complicated service procedures like engine overhaul. Covers every thing you will ever need to know to fix anything on your your Harley Davison Sportster motorcycle.
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Superbly organized, this Sportster XL XLH XLH883, XL883R, XLH1100, XL1200, and XLH1200, repair manual is book marked by chapter for quick and easy navigation allowing you to find everything you need in the quickest time possible. You will not find a better or more convenient manual anywhere.
QUICK REFERENCE DATA
HARLEY DAVIDSON XL XLH SPORTSTER GENERAL INFORMATION
Manual Organization, Warnings Cautions and Notes, Safety, Serial Numbers, Fasteners, Shop Supplies, Tools, Measuring Tools, Electrical System Fundamentals, Service Methods, Storage.
HARLEY DAVIDSON XL XLH SPORTSTER TROUBLESHOOTING
Starting the Engine, Performance, Electrical Component Replacement, Starting System, Charging System, Ignition System (1986-1997 models), Ignition System (1998-2003 models), Ignition System (1998-2003 1200S models), Fuel System, Engine Noise, Engine Smoke, Leakdown Test, Engine Lubircation, Clutch, Transmission, Electrical Testing, Electronic Speedometer and Tachometer, Turn Signal Module (1991-1996 models), Turn Signal Module (1997-2003 models), Excessive Vibration, Front Suspension and Steering, Brake Problems.
HARLEY DAVIDSON XL XLH SPORTSTER LUBRICATION/MAINTENANCE & TUNE-UP
Fuel Type, Maintenance Schedule, Routine Saftey Checks, Tires and Wheels, Periodic Lubercation, Tune-Up, Air Filter, Compression Test, Spark Plugs, Ignition Timing Adjustment.
HARLEY DAVIDSON XL XLH SPORTSTER ENGINE TOP END
Tools, Rocker Cover Assembly, Cylinder Head, Valves and Valve Components, Pushrods and Covers, Cylinder, Piston and Piston Rings, Oil Tank and Oil Lines.
HARLEY DAVIDSON XL XLH SPORTSTER ENGINE LOWER END
Tools, Engine Service, Engine Stand, Engine, Valve Tappets and Guides (1986-1990 models), Valve Tappets (1991-2003 models), Grease Cover and Timing Gears, Oil Pump (1986-1990 models), Oil Pump (1991-2003 models), Oil Filter mount (1986-1990 models), Oil Filter Mount (1991-2003 models), Crankcase & Crankshaft, Cylinder Studs, Engine Break-In.
HARLEY DAVIDSON XL XLH SPORTSTER PRIMARY DRIVE & CLUTCH (1986-1990 MODELS)
Primary Drive Cover, Clutch Release Mechanism, Primary Chain Adjuster, Primary Drive Clutch, Clutch Cable.
HARLEY DAVIDSON XL XLH SPORTSTER PRIMARY DRIVE & 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.
HARLEY DAVIDSON XL XLH SPORTSTER 4SPD TRANSMISSION (1986-1990 MODELS)
Transmission, Shifter Mechanism.
HARLEY DAVIDSON XL XLH SPORTSTER 5SPD TRANSMISSION (1991-2003 MODELS)
Transmission, Sift Forks and Shift Drum, Mainshaft and Countershaft, Main Drive Gear, Access Door Bearings, Right Transmission Case Bearings, Shift Mechanism.
HARLEY DAVIDSON XL XLH SPORTSTER FUEL/EMISSIONS CONTROL & EXHAUST SYSTEMS (1986-1987 MODELS)
Air Filter Backplate, Carburetor, Intake Manifold, Fuel Hose and Clamps, Throttle and Idle Cables, Choke Cable, Fuel Tank, Fuel Shut Off Valve, Exhaust System, EVAP, Evaporative Emission Control system (California Models).
HARLEY DAVIDSON XL XLH SPORTSTER FUEL/EMISSIONS CONTROL & EXHAUST SYSTEMS (1988-2003 MODELS)
Air Filter Backplate, Carburetor, Intake Manifold, Fuel Hose and Clamps, Throttle and Idle Cables, Starting Enrichment Valve (Choke), Fuel Tank, Fuel Shutoff Valve (1988-1994 models), Fuel Shutoff Valve (1995-2003 models), Exhaust System all Models(Except 883R model, Exhaust System (883R models), EVAP, Evaporative Emission Control system (California Models).
HARLEY DAVIDSON XL XLH SPORTSTER ELECTRICAL SYSTEM
Electrical Component System, Electrical Connections, Battery (1986-1996 models), Battery (1997-2003 models), Charging System, Alternator for (1986-1990 models), Alternator for Sportster (1991-2003 models), Ignition System (1986-1997 models), Ignition System (1998-2003 models), Ignition System (1998-2003 1200s models), Ignition Coil, Bank Angel Sensor, Mainfold Absolute Pressure (MAP) Sensor, Starter, Starter Solenoid, Lighting System, Electronic Speedometer and Tachometer, Switches, Horn, Electrical bracket, Turn Singal Flashers (1986-1990 models), Turn Singal Module (1991-2003 models), Circuit breakers (1986-1997 models), Fuses (1998-2003 models), Electrical Connectors, Wiring Diagrams.
HARLEY DAVIDSON XL XLH SPORTSTER WHEELS/TIRES & SECONDARY DRIVE
Motorcycle Stands, Front Wheel, Front Hub (1986-1999 models), Front Hub (2000-2003 models), Rear Wheel, Rear Hub (1986-1999 models), Rear Hub (2000-2003 models), Drive Chain and Sprockets, Drive Belt and Sprockets, Wheel Runout, Laced Wheels, Wheel Balance, Tires.
HARLEY DAVIDSON XL XLH SPORTSTER FRONT SUSPENSION & STEERING
Handlebar, Front Fork (all models except 1200S model), Front Fork (1200S model), Steering Head and Stem, Steering Head and bearing, Steering Play Adjustment.
HARLEY DAVIDSON XL XLH SPORTSTER REAR SUSPENSION
Shock Absorbers, Swing Arm.
HARLEY DAVIDSON XL XLH SPORTSTER BRAKES
Brake Fluid Selection, Brake Service, Brake Pad, Front Brake Pads, Front Brake Caliper, Front Master Cylinder, Rear Brake Pads, Rear Brake Caliper, Rear Master Cylinder, Brake Hose and Line Replacement, Brake Disc and Pads, Bleeding the Brake System, Brake Fluid Draining, Flushing the Brake System (All modles are covered in this section).
HARLEY DAVIDSON XL XLH SPORTSTER BODY
Seat, Front Fender, Rear Fender, Footrest, Forward Foot Controls, (1999-2003 883C and 1200C models), Side Stand, Fork Lock.
HARLEY DAVIDSON XL XLH SPORTSTER INDEX
HARLEY DAVIDSON XL XLH SPORTSTER WIRING DIAGRAMS
Wiring Diagrams for all 1986-1990 Models, Wiring Diagrams for all 1991-1993 Models (except HDI models), Wiring Diagram for 1991-1993 (HDI models), Wiring Diagram for all models 1994-1996 (except 1996 1200C models), Wiring Diagram for 1996 1200C models, Wiring Diagram for all 1997 models, Wiring Diagram for all models (except 1200S models), Wiring Diagram for 1998 1200S Models, Wiring Diagram for all 1999-2002 models (except 1200S models), Wiring Diagram for 1999-2002 1200S Models, 2003 Wiring Diagram for all Models (except 1200S models), Wiring Diagram for 2003 1200S Models.
Tired of asking your Harley Davidson Sportster XL & XLH, XLH883, XL883R, XLH1100, XL1200, and XLH1200 Motorcycle mechanic repair questions with no answers about your aliening problems? This great Harley Davidson Sportster owners service repair manual will give you the answers you need. Here are some of the most common questions some of you may have asked.
My harley Sportster XL XLH engine wont start.
My Sportster has difficulty starting.
My XL, XLH 883, 1100, 1200 Sportster engine will not crank over.
Why is my Sportster overheating?
Whats causing my spark plugs to be fouled on my chopper?
Why is my Sportster blowing alot of smoke out of the exhaust pipes?
Whats causing my HD Sportster to misfire?
What would cause my Sportster to run rough?
Why is my Sportster loosing power?
I start accelerating but its lacking acceleration, why?
Whats causing my strange valve noise?
How can I test to see if my starter is bad?
My starter is not spinning.
My starter on my Sportster is spinning but not engaging. What is causing this?
Stop asking all the questions and start getting the answers you need, download your owners service repair manual now. Servicing and maintaining your Harley Chopper, motorcycle to factory specifications will reduce trips to the shop, save money and and avoid all common questions.
Manual Language: ENGLISH
File Format: PDF
File Delieverd In: PDF Format
Book Marked Indexed for easy navigation: YES
Zoom in/out: YES
What is a service & repair manual? A service & repair manual is collection of information and instructions to guide the user in fixing, repairing or maintaining a part or parts in a logical mathematical sequence to restore, rebuild for maintaining proper function.
Whether your a first time mechanic or a seasoned repair technician crucial service data, repair procedures, maintenance, assembly and disassembley service procedures are a requirement for the proper mechanical flow of operation for the vehicle. A service repair manual doesn’t become a simple guide for the mechanic but rather a essential tool of knowledge. The following is a sample of information typically found in each service repair manual.
* Book marked chapters for easy navigation allowing you to identify exact repair service procedures in the quickest time possible.
* Notes, cautions and warnings throughout each chapter pinpointing critical service information.
* Numbered instructions guide you through every repair procedure in a step-by-step fashion.
* Bold figured numbers help you quickly match illustrations with instructions.
* Detailed illustrations, exploded diagrams, drawings and photos guide you through every service repair procedure.
* Enlarged insets help you identify and examine parts in detail and in the manner of which they are assembled and disassembled to factory oem specifications.
* Numbered table of contents easy to use so that you can find the information you need fast.
* A service manual also makes it easy to diagnose and repair problems with your machines electrical system. Troubleshooting and electrical service procedures are combined with exploded detailed wiring diagrams for ease of use.
* Maintenance schedules, service data along with precise torque specifications allow the mechanic to accurately repair and maintain the vehicle to the factory specifications.
Since its launch in the first decade of the 20th Century, the Harley Davidson Motorcycle has been one of the most popular Motorycles purchased in America. Its success can be attributed to its consistently high level of fit and finish and an impressive reputation for reliability of the Harley Davidson and low running costs. High fuel economy, environmental awareness and engaging performance have also played a large role in making the Harley Davidson a top choice for many Americans and enthusist world wide.
The current Harley Davidson models are the best yet and comes in a wide range of models. It is also the most radically designed Harley Davidsons to date. For small Motorcycel shoppers looking for a used motorcycle, the harley davidson is a smart choice, as its long production run and wide range of models make it easy to find what you are looking for.
In order to care for and maintaine your Harley davidson Motorcycle service repair manuals have been provided to help your service and repair your harley davidson to keep it running it right. Service Repair Manuals are provided for a wide range of Harely davidson Motorcyels and are listed below.