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

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 from the CD, or copy the entire manual to your hard drive. 

637 Pages

 

Years:

1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003

 

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 – Indexed and Searchable

COMPATIBLE WITH ALL WINDOWS & MAC COMPUTERS 
(WINDOWS 11, WINDOWS 10, WINDOWS 8, WINDOWS 7, VISTA 32 and 64, XP, ME, 98, NT, 2000 ETC.) 

Windows/Mac/Tablet/Phone Friendly

32 / 64 bit