1986-2003 Harley-Davidson XLH883, XL883R, XLH1100 & XL/XLH1200 Sportster Service Repair Workshop Manual

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Complete 1986-2003 Harley-Davidson XLH883, XL883R, XLH1100 & XL/XLH1200 Sportster Service Repair Workshop Manual

This manual can be used by anyone from a first time owner/amateur to a professional technician.Easy to read type,And give you all the information needed to do the procedure correctly.Keep this shop manual handy and use it often. Performing routine,preventive maintenance will save you time & money by helping to prevent premature failure and unnecessary repairs.

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
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Service Manual:

QUICK REFERENCE DATACHAPTER 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

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File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English

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