1.HERE IS A SAMPLE OF 1986-2003 SPORTSTER FACTORY SERVICE MANUAL

2. HERE IS THE FULL 1986-2003 SPORTSTER FACTORY SERVICE MANUAL BOOK 


LUBRICATION, MAINTENANCE AND TUNE-UP for 1986-2003 Sportster XL/XLH 883-1200

HARLEY DAVIDSON SERVICE MANUALS 

FULL ACCESS SERVICE MANUALS BELOW

 

1

 

Sportster Models

Touring Models

Dyna Models



 

SPORTSTER MODELS
 
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.

Lubrication, maintenance and tune-up procedures could never be easier with a manual. The following are the models coverd in this book to help guide you through these procedures with pictures and diagrams to help you along the way: Harley Davidson Sportster XL & XLH models, including XLH883, XL883R, XLH1100, XL1200, XLH1200, Custom, Sportster Deluxe, Hugger, Custom and Sport.

All of the following Models and Years are Covered in this Sportster Lubrication, Maintenance and Tune-Up Manual: XLH883 (1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2001, 2002 and 2003 models), XLH883 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.

MAINTENANCE SCHEDULE

Check brake fluid level; refill with DOT 5 brake fluid

2

2

Lubricate rear swing arm bearing

Inspect rear brake caliper mounting pins and boots; lubricate

pins and boots during reassembly

Inspect and lubricate rear brake and shifter linkage assembly

Lubricate throttle control sleeve

Lubricate speedometer cable

Verify proper operation of bank angle sensor (models so equipped)

Replace spark plugs

Replace front fork oil

Lubricate steering bearings

Check steering play adjustment

Clean and lubrlcate wheel bearings

 

 

Idle Speed Adjustment

Prior to adjusting the idle speed, make sure the air filter is

clean and the engine compression and ignition timing are

within specification. Refer to the appropriate section in this

chapter.

Idle speed specifications are in

Table 8

 

SPARK PLUGS

As each spark plug is removed, label it with its cylinder

location and refer to

Reading

in this section.

1. Grasp the spark plug lead (

Figure 84

by the cap portion,

not by the wire. Pull the lead off the plug.

Gap

Adjust the gap of new plugs to ensure a reliable, consistent

spark. To do this, use a spark plug gapping tool with a

wire gauge.

 

 

Installation

1. Apply a light coat of antiseize compound onto the

threads (B,

Figure 87

) of the spark plug before installing it.

 

 

Oil fouled

 

The tip of an oil fouled plug has a black insulator tip, a

damp oily film over the firing end and a carbon layer over

the entire nose. The electrodes are not worn. Oil fouled

spark plugs may be cleaned in an emergency, but it is better

to replace them. It is important to correct the cause of the

fouling before the engine is returned to service. Common

causes for this condition are:

Remove any compound that contacts the plug electrodes.

 

 

Reading

 

Do not use engine oil on the plug threads. 

COMPRESSION TEST

A compression test is one of the quickest ways to check

the internal condition of the engine (piston rings, pistons,

 

AIR FILTER

Removal/Cleaning/Installation

 

Remove and inspect the air filter at the interval in

Table

1

. If necessary, clean the element. Replace the element if it

 

Choke Cable Adjustment

(1986-1987 Models)

The choke cable on 1986-1987 models operates the

choke plate in the carburetor (

may be necessary to obtain proper operation.

1. Remove the air cleaner as described in Chapter Ten.

2. Operate the choke control knob (

that the choke plate operates correctly.

Figure 73). Cable adjustmentFigure 74) and verify

 

 

Starting Enrichment Valve (Choke) Cable

Adjustment (1988-2003 Models)

CAUTION

The starting enrichment (choke) cable must

have sufficient cable resistance to work properly.

Do not lubricate the enrichment cable or

its conduit.

The starting enrichment (choke) knob (

Figure 75

Brake Fluid Change

To change brake fluid, follow the brake bleeding procedure

in Chapter Sixteen. Continue adding new fluid to the

master cylinder until the fluid leaving the caliper is clean

and free of contaminants and air bubbles.

 

 

 

 

Electrical Equipment and Switches

 

 

 

 

 

To change brake fluid, follow the brake bleeding procedure

in Chapter Sixteen. Continue adding new fluid to the

master cylinder until the fluid leaving the caliper is clean

and free of contaminants and air bubbles.

 

Brake Pad Inspection

 

It may be necessary to dismount the caliper in

the following steps if there is not sufficient access

to the brake pads. Refer to Chapter

Sixteen.

1. Inspect the brake pads for damage.

2. Measure the thickness of each brake pad lining on the

front caliper(s) (

Figure 47) and rear caliper (Figure 48

).Replace the

Replace the brake pad if its thickness is worn to the minimumthickness.

 

brake pads as described in Chapter Sixteen.

 

Drive Chain (Models So Equipped)

Adjustment

Check and adjust the drive chain at the intervals specified

in

Table 1

. If the motorcycle is operated at sustained high

speeds or if it is repeatedly accelerated very hard, inspect

the drive chain adjustment more often. The correct amount

of drive chain free play (

Figure 35

), when pushed up midway

on the lower chain run (with the rider seated), is listed

in

Table 7

.

 

 

 

 

Remove any compound that contacts the plug electrodes.

 

 

 

 

Removal

 

 

Check rear brake pedal adjustment; adjust if necessary

Perform general lubrication to equipment specified in this chapter

Check ignition timing

Check vacuum operated electric switch (VOES)

Check rear swing arm pivot shaft tightness

Check engine mount bolt tightness

Inspect rear shock absorber

Check all exposed fasteners for tightness

Service Manual, Repair Manual, Repair Guide, Workshop Manual, Handbook, Text Book, Shop Manual, Owners Manual, Owners Repair Manual

Brake Fluid Change

Lubricate rear swing arm bearing

Lubricate speedometer drive gear (models so equipped)

Check steering play adjustment

Verify proper operation of air cleaner EVAP valve (models

so equipped)

 Check engine oil level

Check primary drive/transmission oil level

Check brake pad wear

Check brake disc wear

Inspect fuel valve, fuel line and all fittings for leaks

Check engine idle speed

Check battery fluid level; refill with distilled water

Check electrical equipment and switches for proper operation

Check throttle operation

Operate and check enrichener cable operation

Check tire pressure and tread wear

Lubricate speedometer drive gear (models so equipped)

Verify proper operation of air cleaner EVAP valve (models

so equipped)

 Check spark plug gap and condition

Check steering play adjustment

Change engine oil and replace oil filter

Inspect and clean air filter

Check rear drive chain or belt tension; adjust if necessary

Inspect primary chain

Check primary chain tension; adjust if necessary

Change primary drive/transmission oil

Check clutch adjustment; adjust if necessary

Check brake fluid level; refill with DOT 5 brake fluid

Check rear brake pedal adjustment; adjust if necessary

Perform general lubrication to equipment specified in this chapter

Check ignition timing

Check vacuum operated electric switch (VOES)

Check MAP sensor (1200S)

Check rear swing arm pivot shaft tightness

Check engine mount bolt tightness

Inspect rear shock absorber

Check all exposed fasteners for tightness