• MOTORCYCLE SERVICE MANUAL

MOTORCYCLE SERVICE MANUAL

MOTORCYCLE SERVICE MANUAL

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MODELS COVERED:

Harley-Davidson Sportster XLH883 (1986-2003)
Harley-Davidson Sportster XLH883 C Custom (1999-2003)
Harley-Davidson Sportster XLH883 D Deluxe (1986-1995)
Harley-Davidson Sportster XLH883 H Hugger (1987-2003)
Harley-Davidson Sportster XL883R (2002-2003)
Harley-Davidson Sportster XL1200 C Custom (1996-2003)
Harley-Davidson Sportster XL1200 Sport (1996-2003)
Harley-Davidson Sportster XLH1100 (1986-1987)
Harley-Davidson Sportster XLH1200 (1988-2003)

This Harley-Davidson Sportster Motorcycle Manual is 640 pages.

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Safety / Serial numbers / Fasteners / Shop supplies / Tools / Measuring tools / Electrical system fundamentals / Service methods / Storage / Specifications

CHAPTER 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

Materials

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Dimensions

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Care Instructions

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MOTORCYCLE SERVICE MANUAL

$84.99

Product Specifications

General Information

Brandclymer
LabelHARLEY-DAVIDSON XL/XLH SPORTSTER 1986-2003
Universemoto
Categorymanuel_d_entretien
Supplier Part #CM4295
ITL ID252-M4295

Dimensions & Physical

Weight 3.351 lbs
Length11
Width8.5
Thickness1.25

Vehicle Fitment

Total Applications68
Applications HARLEY-DAVIDSON XL1200 SPORTSTER 1994HARLEY-DAVIDSON XL1200 SPORTSTER 1995HARLEY-DAVIDSON XL1200 SPORTSTER 1996HARLEY-DAVIDSON XL1200 SPORTSTER 1997HARLEY-DAVIDSON XL1200 SPORTSTER 1998HARLEY-DAVIDSON XL1200 SPORTSTER 1999HARLEY-DAVIDSON XL1200 SPORTSTER 2000HARLEY-DAVIDSON XL1200 SPORTSTER 2001HARLEY-DAVIDSON XL1200 SPORTSTER 2002HARLEY-DAVIDSON XL1200 SPORTSTER 2003HARLEY-DAVIDSON XL1200C CUSTOM 1996HARLEY-DAVIDSON XL1200C CUSTOM 1997HARLEY-DAVIDSON XL1200C CUSTOM 1998HARLEY-DAVIDSON XL1200C CUSTOM 1999HARLEY-DAVIDSON XL1200C CUSTOM 2000HARLEY-DAVIDSON XL1200C CUSTOM 2001HARLEY-DAVIDSON XL1200C CUSTOM 2002HARLEY-DAVIDSON XL1200C CUSTOM 2003HARLEY-DAVIDSON XL1200S SPORT 1996HARLEY-DAVIDSON XL1200S SPORT 1997HARLEY-DAVIDSON XL1200S SPORT 1998HARLEY-DAVIDSON XL1200S SPORT 1999HARLEY-DAVIDSON XL1200S SPORT 2000HARLEY-DAVIDSON XL1200S SPORT 2001HARLEY-DAVIDSON XL1200S SPORT 2002HARLEY-DAVIDSON XL1200S SPORT 2003HARLEY-DAVIDSON XL883H SPORTSTER HUGGER 1994HARLEY-DAVIDSON XL883H SPORTSTER HUGGER 1995HARLEY-DAVIDSON XL883H SPORTSTER HUGGER 1996HARLEY-DAVIDSON XL883H SPORTSTER HUGGER 1997HARLEY-DAVIDSON XL883H SPORTSTER HUGGER 1998HARLEY-DAVIDSON XL883H SPORTSTER HUGGER 1999HARLEY-DAVIDSON XL883H SPORTSTER HUGGER 2000HARLEY-DAVIDSON XL883H SPORTSTER HUGGER 2001HARLEY-DAVIDSON XL883H SPORTSTER HUGGER 2002HARLEY-DAVIDSON XL883H SPORTSTER HUGGER 2003HARLEY-DAVIDSON XL883R ROADSTER 2002HARLEY-DAVIDSON XL883R ROADSTER 2003HARLEY-DAVIDSON XLH1100 SPORTSTER 1986HARLEY-DAVIDSON XLH1100 SPORTSTER 1987HARLEY-DAVIDSON XLH1200 SPORTSTER 1988HARLEY-DAVIDSON XLH1200 SPORTSTER 1989HARLEY-DAVIDSON XLH1200 SPORTSTER 1990HARLEY-DAVIDSON XLH1200 SPORTSTER 1991HARLEY-DAVIDSON XLH1200 SPORTSTER 1992HARLEY-DAVIDSON XLH1200 SPORTSTER 1993HARLEY-DAVIDSON XLH883 SPORTSTER 1986HARLEY-DAVIDSON XLH883 SPORTSTER 1987HARLEY-DAVIDSON XLH883 SPORTSTER 1988HARLEY-DAVIDSON XLH883 SPORTSTER 1989HARLEY-DAVIDSON XLH883 SPORTSTER 1990HARLEY-DAVIDSON XLH883 SPORTSTER 1991HARLEY-DAVIDSON XLH883 SPORTSTER 1992HARLEY-DAVIDSON XLH883 SPORTSTER 1993HARLEY-DAVIDSON XLH883D SPORTSTER DELUXE 1987HARLEY-DAVIDSON XLH883D SPORTSTER DELUXE 1988HARLEY-DAVIDSON XLH883D SPORTSTER DELUXE 1989HARLEY-DAVIDSON XLH883D SPORTSTER DELUXE 1990HARLEY-DAVIDSON XLH883D SPORTSTER DELUXE 1991HARLEY-DAVIDSON XLH883D SPORTSTER DELUXE 1992HARLEY-DAVIDSON XLH883D SPORTSTER DELUXE 1993HARLEY-DAVIDSON XLH883H SPORTSTER HUGGER 1987HARLEY-DAVIDSON XLH883H SPORTSTER HUGGER 1988HARLEY-DAVIDSON XLH883H SPORTSTER HUGGER 1989HARLEY-DAVIDSON XLH883H SPORTSTER HUGGER 1990HARLEY-DAVIDSON XLH883H SPORTSTER HUGGER 1991HARLEY-DAVIDSON XLH883H SPORTSTER HUGGER 1992HARLEY-DAVIDSON XLH883H SPORTSTER HUGGER 1993
Makes HARLEY-DAVIDSON
Models XL1200 SPORTSTERXL1200C CUSTOMXL1200S SPORTXL883H SPORTSTER HUGGERXL883R ROADSTERXLH1100 SPORTSTERXLH1200 SPORTSTERXLH883 SPORTSTERXLH883D SPORTSTER DELUXEXLH883H SPORTSTER HUGGER
Years 198619871988198919901991199219931994199519961997199819992000200120022003

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Highlight 1

Built for everyday use, the product features carefully chosen components that balance durability with visual appeal.

Highlight 2

Featuring a streamlined and compact design, the product is crafted to fit seamlessly into a variety of spaces and lifestyles.

Highlight 3

We offer a hassle-free returns policy to ensure your complete satisfaction. If you're not happy, simply return it within 30 days for a full refund.

Does it come with a warranty?

most items in store come with a manufacture defect warranty to give you peace of mind. we always strive to keep our customers happy with any issues on fitment or quality.

What happens if what i ordered does not fit?

If what you ordered does not fit, we will do a quick check for fitment via pictures of the item and your machine to verify. if the fitment widget was wrong-return cost is on us and a refund or instore credit will apply. Any other return is subject to a re-stocking fee and customer pays for return freight.

How fast is shipping?

most products leave same day if orderd before 11am. or next day if after that. delivery is anywhere from 2-7 days depending location in canada.

What's the returns policy?

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