1986-2003 Harley Davidson Sportster Motorcycle Service Reapir Manual for: XL & XLH models, including XLH883, XL883R, XLH1100, XL1200, XLH1200 (883/1100/1200), Custom, Sportster Deluxe, Hugger, Custom and Sport model years 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002 and 2003.

 

2005 H-D Sportster XL Service Manual & 2005 H-D Sportster XL Electrical Diagnostics Manual for: 2005 Harley-Davidson XL 1200C Sportster 1200 Custom, 2005 Harley-Davidson XL 1200R Sportster 1200 Roadster, 2005 Harley-Davidson XL 883C Sportster 883 Custom, 2005 Harley-Davidson XL 883 Sportster 883, 2005 Harley-Davidson XL Sportster 883L, 2005 Harley-Davidson XL883R Sportster (XL883, XL883L, 883R, XL883C, XL1200C, XL1200R, XL1200).

 

2006 Harley-Davidson Sportster Motorcycle Factory Service Manual for: 2006 XL 883 Sportster, 2006 XL883, 2006 XL 883L 883 Low, 2006 XL 883C Sportster 883C Custom , XL 883R Sportster 883R, XL 1200C Sportster 1200 Custom, XL 1200R Sportster 1200 Roadster, XL 1200L Sportster 1200 Low.

 

2007 H-D Sportster XL Service Manual & 2007 Harley Davidson Electrical Diagnostics Manual for Harley Models: 2007 XL SPORTSTER 883 (XL883), 2007 XL SPORTSTER 883L (883-L), 2007 XL SPORTSTER 883R (883-R), 2007 XL SPORTSTER 1200L (1200-L), 2007 XL SPORTSTER 1200 N (1200N), 2007 XL SPORTSTER 1200 R (1200R), 2007 XL SPORTSTER 883C/XL 1200C, 2007 XL SPORTSTER 50 motorcycles.

 

2008 Harley Davidson Sportster Motorcycle Factory Service Manual for: 2008 XL 883 Sportster, 2008 XL 883C Sportster, 2008 XL 883L Sportster, XL 1200L Sportster, XL 1200R Sportster, XL 1200N Sportster, Harley Davidson XL 1200C Sportster, XL 1200C Sportster Custom 105th Anniversary Edition. 08 Harley Custom, 08 Harley Nightster, 08 Roadster, Sportster Low.

This reference manual/repair manual covers the rocker covers, rocker arms, cylinder heads, valves, cylinder blocks, pistons, piston rings and oil tank for the XLH883 (1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2001, 2002 and 2003 models), XLH 883 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), XL1200C CUSTOM (1996, 1997, 1998, 1999, 2000, 2001, 2002 and 2003 models), XL1200 SPORT (1996, 1997, 1998, 1999, 2000, 2001, 2002 and 2003 models), XLH 883, XL 883R, XLH 1100, XL 1200 and XLH 1200S Motorcycle.

Engine service requires a number of special tools. These

tools and their part numbers are listed with the individual

procedures. For a complete list of the special tools mentioned

in this manual, refer to

Table 12

in Chapter One.

The rocker cover assembly

outer rocker cover, middle rocker cover and inner rocker

cover, which contains the rocker arms and shafts.

The rocker covers can be removed from either cylinder

with the engine installed in the frame.

consists of the

 

 

When purchasing tools from a dealership or parts supplier,

be sure to specify the tools required are for the

specific Sportster model being worked on. Many of the

tools are specific to the engine. Tools for other engine models

may be slightly different.

The manufacturer’s part number is provided for many of

the tools mentioned in this manual. These part numbers are

correct at the time of original publication. The publisher

cannot guarantee the part number or the tools in this manual

will be available in the future.

 

ROCKER COVER ASSEMBLY

 

 

CYLINDER HEAD

Removal

 

1. Remove the exhaust system as described in Chapter Ten

or Chapter Eleven.

2. Remove the air filter assembly and backplate as described

in Chapter Ten or Chapter Eleven.

3. On 1986-1994 models, disconnect the ignition switch

wires and remove the ignition switch as described in Chapter

Twelve. Remove the choke knob bracket (

Figure 25

) as

Due to the number of special tools, it is generally more

 

To obtain an accurate cylinder bore measuremnt, the cylinder

must be secured between torque plates. Torque plates

are available from several sources. This arrangement simulates

the distortion imparted on a cylinder when it is

clamped down by the cylinder head and the cylinder bolts

are tightened to the specified torque. Measurements made

without the engine torque plate can vary by 0.001 in. (0.025

mm). If you do not have access to the torque plates, refer

service to a repair shop.

 

 

Piston Pin Inspection

The piston pins used on 883 and 1200 models are different.

The 1200 model piston pins are marked with a

V-groove in one end of the pin (

Figure 120

). The 883

model pins are not marked. When purchasing replacement

piston pins, note the difference.

 

 

 

 

 

practical to remove the cylinder head and entrust valve service

to a dealership or machine shop. The following procedures

describe how to check for valve component wear and

to determine what type of service is required.

 

VALVES AND VALVE COMPONENTS

 

 

 

Studs and bolts

The cylinder studs and cylinder head bolts must be in

good condition and properly cleaned prior to installing the

cylinders and cylinder heads.

1. Examine the cylinder head bolts (

Figure 106

) for head

 

Refer to

Figure 98

.

1. Remove the cylinder head and cylinder as described in

this chapter.

2. Stuff clean shop rags into the crankcase opening to prevent

objects from falling into the crankcase.

3. Install a hose around each stud to protect the piston and

studs from damage.

4. Install a piston holding tool to stabilize the piston. Construct

the tool from wood as shown in

Figure 101

.

5. Lightly mark the pistons with an

F (front) or R

(rear) so

or thread damage. Replace if necessary. 

 

Piston and Piston Rings Removal

 

 

PISTONS AND PISTON RINGS

 

Valve Seat Inspection

.

1. Clean the valves of all carbon, then clean the valve as

described in the

2. The most accurate method of checking the valve seat

width and position is to use machinist’s dye. To check the

valve seat with machinist’s dye, perform the following.

in this section.

 

 

Valve Lapping

 

Valve lapping restores the valve seal without machining

if the amount of wear or distortion is not excessive.

 

 

Valve Seat Replacement

 

Due to the number of special tools needed to replace the

valve seats, it is generally more practical to refer this work

to a repair shop.

 

 

CYLINDER

 

Both cylinders can be removed with the engine mounted

in the frame.

Removal

Refer to

Figure 98

.

1. Remove all dirt and debris from both cylinders. Mark

the cylinder to ensure it is installed in its original position.

2. Remove the cylinder head as described in this chapter.

3. Remove the O-rings around the dowel pins (

Figure 99

).

 

 

Inspection

 

4. Disconnect the spark plug wires and set them out of the way. 

If necessary, also remove the dowel pins described in Chapter Ten.

 

 

 

 

they may be installed into the correct cylinder.

 HD (H-D) Sportster Service Manual, Repair Manual, WorkShop Manual Shop Manual, Book, Handbook, Text Book, Reference Manual, Maintenance manual 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 00, 01, 02, 03, 04, 05, 06, 07, 08, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008