1986-2003 Harley Davidson XL XLH Sportster Service Repair Manual Instant Download

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1086-2003
SŒ\ñCE 1980 2003
2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Chapter One General Information Chapter Two
Troubleshooting Chapter Three Periodic
Lubrication, Maintenance Tune-up Chapter Four
Engine Top End Chapter Five Engine Lower
End Chapter Six Primary Drive Clutch (1986-1990
Models) Chapter Seven Primary Drive Clutch
(1991-2003 Models) Chapter Eight 4Speed
Transmission (1986-1990 Models) Chapter
Nine 5-Speed Transmission (1991-2003
Models) Chapter Ten Fuel, Emission Control
Exhaust Systems (1986-1987 Models) Chapter
Eleven Fuel, Emission Control Exhaust Systems
(1988-2003 Models) Chapter Twelve Electrical
System Chapter Thirteen Wheels, Tires Secondary
Drive Chapter Fourteen Front Suspension
Steering Chapter Fifteen Rear Suspension Chapter
Sixteen Brakes Chapter Seventeen Body
Index
Chapter Nineteen Wiring Diagrams
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CONTENTS
QUICK REFERENCE DATA .............................
....................... IX CHAPTER ONE GENERAL
INFORMATION.......................................
............... 1
Tools Measuring tools Electrical system
fundamentals Service mcthods Storage
Manual organization Warnings. cautions and notes
Safety Serial numbers Fastcncrs Shup supplies
CHAPTER TWO TROUBLESHOOTING ......................
.................................. 32
Leakdown test Engine lubrication Clutch
Tmnsmission Eleceical testing Electronic
speedometer/tachometer Turn signal module
(1991-1996 models) Turn signal module (1997-2003
models) Excessive vibration Front suspension and
steering Brake problems
Starting the engine Engine performance Electrical
component replacement Starting system Charging
system Ignition system 1986-1997
models) Ignition system ( 1998-2003 modem, except
I 200S models) Ignition system ( 199-2003 I 200S
models) Fuel system Engine noises Engine smoke
CHAPTER THREE LUBRICATION, MAINTENANCE AND
TUNE-UP .................................. 113
Tune-up Air filter Compression test Spark
pJugs Ignition timing adjustment
Fuel type Maintenance schcdulc Routine safcty
checks Tires and wheels Periodic lubrication
Periodic maintenance
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CHAPTER FOUR ENGINE TOP END ......................
.................................... 151
Tool.s kJkcr cut cr as ci\ably Cylindei
head V. Ives and val ve components
Pushrods and cover.s C'ylindcr Pistons and piston
rings Oil tank nnd cil lines
CHAPTER FIVE ENGINE LOWER END ....................
................................... 197
Tuuls nui c Servic Enui nc stand Ian
inc III e iappcts and \iidvs I I V86- 1990
Mcdels T Value tapptx ( I 9J I -2(Jtl M
odcls) ric. r .we cc cr and linking 'rears
Oil pump ( I 98f- 1000 models) Uil pump ( 100.1
-2003 modeIs) Oil fi Iter mount ( I EXT- 1990
models) Oil fiher mount ( I OP I -?U03 mJdels)
Crankcase and crankshar Vy liiJdcr studs Engine
break-in
CHAPTER SIX PRIMARY DRIVE AND CLUTCH (1986-1990
MODELS)
CHAPTER SEVEN PRIMARY DRIVE AND CLUTCH (1991-2003
MODELS)
Primary drive.'cluich C lutcli cablc
Priiiiiry dti c co cr l 1994-2003 models) CI
utcli rele.ise inccha n isiii t 199.1 - 19'4 3
modc 1s) C'l utcli rc lcasc iiiecliani sin ( l
994-2003 niodels)
CHAPTER EIGHT FOUR-SPEED TRANSMISSION (1986-1990
MODELS) .............................
284 Tranxizzission Shifter nzechtinisMz CHAPTER
NINE FIVE-SPEED TRANSMISSION (1991-2003 MODELS)
.............................. 304
Access door bearings Right transmission case
bearings Shift mechanism
Transmission Hiiti forks and slii ti dnliai M
ainchaIt and cJunicr IJuI t Main drive gear
CHAPTER TEN FUEL, EMISSION CONTROL AND EXHAUST
SYSTEMS (1986-1987 MODELS)......... 333
Fuel tan k Fuel sliutotâ' val ve Exhausl
system Evaporati ve cmissiun control
system (C'cIitomia models)
.A ir li ltcr backpl ate Carburetor Intake man
iftsld F ucI I sc an1 c l4inp Throttle and
idle c\bIes C'hoke earth
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CHAPTER ELEVEN FUEL, EMISSION CONTROL AND EXHAUST
SYSTEMS (1988-2003 MODELS)........ . 350
Air filter baekplate Cnrburetor Intake
manifold Fuel hose and clamps Throttle and idle
cables Sinning enrichment valve (choke) cable
Fuel tank Fuel shutoff valve ( 1988-1994 models)
fuel shutoff valve ( 1995-2003 modelsl Exhaust
system (all models except tltl3 R models) Exhaust
system (8tt3 R models) Evaporative emission
control system (California models)
CHAPTER TWELVE ELECTRICAL SYSTEM
..................................................
.... 392
Starter Starter solenoid Lighting
system Electronic speedometer/tachometer Switches
Horn Electrical bracket Turn signal flasher
(1986-1990 models) Turn signal module ( 1991-2003
models) Circuit breakers (1986-1997 models) Fuscr
( l99tl-2003 models) Electrical connectors Wiring
diagrams
Electrical component replacement Electrical
connectors Batcery ( 1056-1996 models) Battery (
1997-2003 modelr) Charging system Alternator (
l98b- 1990 models) Alternator ( l99I -2003
models) ignition system ( 1986- 1997
models) Ignition system ( 1996-2003, all
models except 1200S models) Ignition system (
1998-2003 I 200S models) Ignition coil Bnnk angle
scnrnr ( I 998-2003 models) Manifold absolute
pressure (MAF) sensor (1998-2003 l200S models)
CHAPTER THIRTEEN WHEELS, TIRES AND SECONDARY
DRIVE Motorcycle stands From wheel Front hub
(l98fi-1999 models) Front hub (2000-2003 models)
Rearwheel Rear hub (1986-1999 models) Rcur hub
(2000-2003 models)
Drive chain nnd sprockets Drive belt and
sprockets Wheel runoul Laced wheels Disc and cast
wheels Wheel balance Tires
CHAPTER FOURTEEN FRONT SUSPENSION AND STEERING
...........................
Handlebar Front fork (all models except 12005
models) From fork (12005 models)
Steering head and stem Steering head bearing
Steering play adjustment
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CHAPTER FIFTEEN REAR SUSPENSION
..................................................
...... 526 Shock cbsorbcrs Swing arm
CHAPTER SIXTEEN BRAKES. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . Brake
tluid selection Brake service Front brake pads (
1966-J 999 models) Front brake pads (2000-2003
models) Front brake caliper ( I 986-1 991 models)
From bnlke caliper (2000-2003 models) Front
master cylinder (l986-l995 mcdels) Frunc master
cylinder ( I 596-2003 models) Rear hrake pads (
I986-early 1987 mudels) Rear brake pads (late
1987- 1199 models) Rear brake pads (2000-2003
models)
Rear brakc caliper (1986-early 1987 models) Rear
brake caliper (late 1987-1999 models) Rear brake
caliper (2000-2003 models) Rear master cylinder t
1986-early 1987 models) Rear master cylinder
(late 1987-2003 models) Brake hose and line
replacement Brake disc Bleeding the system Brake
fluil draining Flushing the brake system
CHAPTER SEVENTEEN BODY ...........................
......................................... 590
Scat Front fender Rear fender Footrests
Forward fooi controls ( t999-2003 883C and I 200C
models) Sidestand Fork lock
INDEX ............................................
........................ 601 WIRING DIAGRAMS
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QUICK REFERENCE DATA MOTORCYCLE DATA MODEL
ENGINE SERIAL NUMBER caRauREFoR sERIAL
NuMBER TIRE INFLATION PRESSURE (COLD)

Up to 300 Ib. load Front 1200 models 30 207 BBC and 1100 models 1986-1990 26 179 19912003 30 207 Rear 1200 models 36 24g BBC and 1100 models 1986-1990 30 207 1991-2003 36 248 Up to GVWR maximum load Front 1200 models 30 207 883 and 1100 models 1986-1990 26 179 1991-2003 30 207 Rear 1200 models 40 276 883 and 1100 models 1986-1990 32 220 199J -20O3 40 276
Tire inflatlon preseure is for original equipment tires. Aftermarket tires may require a different inflation pressure. 300 lb. load Includes rider, passenger and cargo. The gross vehicle welght rating (GVWR) is listed on a decal mounted on the frame.
ENGINE OIL SPECIFICATIONS
Tags HD rating Viseoaity Amlsient operating temperature
HD Multi-grade HD360 SAE J0W/40 Below40 F
HD Multl-grade HD360 SAE20W/50 Above40 F
HDRegularheavy HD360 SAE50 Above60 F
HDExtra heavy HD360 SAE60 Above80 F
Not recommended for use when ambient temperature Is below 50 F. Not recommended for use when ambient temperature Is below 50 F. Not recommended for use when ambient temperature Is below 50 F. Not recommended for use when ambient temperature Is below 50 F.
ENGINE AND PRIMARY DRIVE/TRANSMIS3ION OIL
CAPACITIES
3.0 qt. (2.8 L)
Oil tank refill capacity with filter replacement
Transmission (Includes primary chalncase)
1986-1992 models 1993-2003 models
24 oz. (710 ml) 32 o-t846 ml)
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