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

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


1986-2003 Sportster XL/XLH Service Manual

HARLEY DAVIDSON SERVICE MANUALS 

FULL ACCESS SERVICE MANUALS BELOW

 

1

Sportster Models

Touring Models

Dyna Models



Models covered in this Service Repair Manual are: Harley Davidson Sportster XL & XLH models, including XLH883, XL883R, XLH1100, XL1200, and XLH1200.

Years Covered in this Sportster Service Repair 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), XL1200 CUSTOM (1996, 1997, 1998, 1999, 2000, 2001, 2002 and 2003 models), XL1200 SPORT (1996, 1997, 1998, 1999, 2000, 2001, 2002 and 2003 models), XL XLH 883, 1200 and 1200.

Index to this service repair manual and a TINY portion of topics coverd in this sporster manual are:

Air filter . . . . . . . . . . . . . . . . . . 139-140

backplate

1986-1987 models. . . . . . . . . . . . 333

1988-2003 models. . . . . . . . . . . . 350

Alternator

1986-1990 models . . . . . . . . . 403-404

1991-2003 models . . . . . . . . . 404-408

B

Battery

1986-1996 models . . . . . . . . . 393-398

1997-2003 models . . . . . . . . . 398-402

charging rates/times

approximate . . . . . . . . . . . . . . . . . 464

Body

fender

front . . . . . . . . . . . . . . . . . . . 590-591

rear. . . . . . . . . . . . . . . . . . . . 591-594

footrests . . . . . . . . . . . . . . . . . . . . . 594

fork lock . . . . . . . . . . . . . . . . . . . . 599

forward foot controls,

1999-2003 883C

and 1200C models . . . . . . . . 594-598

seat. . . . . . . . . . . . . . . . . . . . . . . . . 590

sidestand. . . . . . . . . . . . . . . . . 598-599

torque. . . . . . . . . . . . . . . . . . . . . . . 600

Brake

adjustment . . . . . . . . . . . . . . . . . . . 131

bleeding the system . . . . . . . . 586-588

caliper

front

1986-1999 models . . . . . . . 540-544

2000-2003 models . . . . . . . 545-548

caliper

rear

1986-early 1987 models . . 567-569

late 1987-1999 models . . . 569-572

2000-2003 models . . . . . . . 572-575

disc front and rear . . . . . . . . . . 584-586

fluid,

change . . . . . . . . . . . . . . . . . . . . . 131

draining . . . . . . . . . . . . . . . . 588-589

level inspection . . . . . . . . . . 129-130

selection . . . . . . . . . . . . . . . . . . . 533

flushing the brake system . . . . . . . . 589

front brake lever pivot pin

lubrication . . . . . . . . . . . . . . . . . . 123

hose and line replacement . . . . 581-584

inspection . . . . . . . . . . . . . . . . 129-130

light switch

front . . . . . . . . . . . . . . . . . . . 446-447

rear . . . . . . . . . . . . . . . . . . . . . . . 450

master cylinder

front

1986-1995 models . . . . . . . 548-552

1996-2003 models . . . . . . . 552-557

rear

1986-early 1987 models . . 575-577

late 1987-2003 models . . . 577-581

pads

front

1986-1999 models . . . . . . . 535-538

2000-2003 models . . . . . . . 538-540

inspection . . . . . . . . . . . . . . . . . . 129

rear

1986-early 1987 models . . 557-561

2000-2003 models . . . . . . . 565-567

late 1987-1999 models . . . 561-565

service . . . . . . . . . . . . . . . . . . 533-535

specifications . . . . . . . . . . . . . . . . . 589

torque. . . . . . . . . . . . . . . . . . . . . . . 589

troubleshooting . . . . . . . . . . . . . . . 111

18

 

Carburetor . . . . . . . . . 333-340, 350-366

specifications

1986-1987 models. . . . . . . . . . . . 349

1988-2003 models. . . . . . . . . . . . 390

Charging system,

troubleshooting . . . . . . . . . . . . . . 41-44

Choke cable adjustment

(1986-1987 models) . . . . . . . . . . . . 136

Clutch

adjustment . . . . . . . . . . . . . . . 131-134

1986-1990 models . . . . . . . . . 254-261

clutch cable . . . . . . . . . . . . . 261-262

lever pivot pin lubrication . . . . . . 123

release mechanism . . . . . . . . 252-254

1991-2003 models . . . . . . . . . 271-279

clutch cable . . . . . . . . . . . . . 279-283

release mechanism

1991-1993 models. . . . . . . . . . . . 269

1994-2003 models . . . . . . . . 269-270

specifications

1986-1990 models. . . . . . . . . . . . 262

1991-2003 models. . . . . . . . . . . . 283

torque

1986-1990 . . . . . . . . . . . . . . . . . . 263

1991-2003 . . . . . . . . . . . . . . . . . . 283

troubleshooting . . . . . . . . . . . . . . . . 90

Compression test. . . . . . . . . . . . 140-141

Control cables

(non-nylon lined) . . . . . . . . . . 122-123

Crankcase and crankshaft . . . . . 233-246

Cylinder . . . . . . . . . . . . . . . . . . 179-184

head . . . . . . . . . . . . . . . . . . . . 157-169

stud . . . . . . . . . . . . . . . . . . . . . 246-247

D

Diagnostic trouble codes. . . . . . . . 57-58

Drive belt and sprocket . . . . . . . 483-487

periodic maintenance . . . . . . . 127-128

adjustment. . . . . . . . . . . . . . . . . . 128

Drive chaing and sprocket . . . . . 479-483

periodic maintenance . . . . . . . 125-127

adjustment. . . . . . . . . . . . . . . . . . 125

lubrication . . . . . . . . . . . . . . 123-124

E

Electrical

alternator

1986-1990 models . . . . . . . . 403-404

1991-2003 models . . . . . . . . 404-408

bank angle sensor,

1998-2003 models . . . . . . . . . . . . 418

battery

1986-1996 models . . . . . . . . 393-398

1997-2003 models . . . . . . . . 398-402

charging rates/times

(approximate) . . . . . . . . . . . . . . 464

charging system . . . . . . . . . . . 402-403

circuit breakers,

1986-1997 models . . . . . . . . 456-457

component replacement . . . . . . . . . 392

troubleshooting . . . . . . . . . . . . . . . 35

connectors . . . . . . . . . . . . . . . 392-393

service . . . . . . . . . . . . . . . . . 457-463

electrical bracket . . . . . . . . . . 452-453

electronic speedometer/

tachometer . . . . . . . . . . . . . . 437-440

fundamentals . . . . . . . . . . . . . . . 17-18

fuses, 1998-2003 models . . . . . . . . 457

horn . . . . . . . . . . . . . . . . . . . . 450-452

ignition system

1986-1997 models . . . . . . . . 408-412

1998-2003, except

1200S models. . . . . . . . . . . 412-414

1998-2003, 1200S models . . 414-417

ignition coil . . . . . . . . . . . . . 417-418

lighting system . . . . . . . . . . . . 426-437

MAP sensor,

1998-2003 1200S models . . . 418-419

specifications . . . . . . . . . 112, 463-464

starter . . . . . . . . . . . . . . . . . . . 419-425

starter motor, specifications . . . . 464

starter solenoid. . . . . . . . . . . 425-426

switches . . . . . . . . . . . . . . . . . 440-450

torque. . . . . . . . . . . . . . . . . . . . . . . 465

troubleshooting, testing . . . . . . . 91-95

turn signal

flasher, 1986-1990 models. . 453-454

module, 1991-2003 models . 454-456

wiring diagrams . . . . . . . . . . . 606-629

Electronic speedometer/

tachometer. . . . . . . . . . . . . . . . 437-440

troubleshooting. . . . . . . . . . . . . 95-101

Emission control

1986-1987 models

evaporative emission control

system, California models . 347-348

throttle and idle cable

replacement . . . . . . . . . . . . 342-343

1988-2003 models

evaporative emission control

system, California models . 378-389

throttle and idle cable

replacement . . . . . . . . . . . . 368-370

torque. . . . . . . . . . . . . . . . . . . . . . . 349

Engine

installation . . . . . . . . . . . . . . . 202-210

lower end

break-in . . . . . . . . . . . . . . . . . . . . 247

crankcase and crankshaft . . . 233-246

cylinder, stud . . . . . . . . . . . . 246-247

engine . . . . . . . . . . . . . . . . . 197-202

flywheel end play shim

thickness . . . . . . . . . . . . . . . . . . 249

gearcase, cover and

timing gears . . . . . . . . . . . . 214-221

installation . . . . . . . . . . . . . . 202-210

oil

and filter change . . . . . . . . 117-119

filter mount

1986-1990 models. . . . . . 231-232

1991-2003 models. . . . . . 232-233

level check . . . . . . . . . . . . . . . . 115

pump . . . . . . . . . . . . . . . . . 228-231

1986-1990 models. . . . . . 221-228

service . . . . . . . . . . . . . 197, 248-249

stand . . . . . . . . . . . . . . . . . . . . . . 197

tools. . . . . . . . . . . . . . . . . . . . . . . 197

torque. . . . . . . . . . . . . . . . . . 249-250

valve, tappets and guides

1986-1990 models . . . . . . . 210-212

1991-2003 models . . . . . . . 213-214

oil, specifications . . . . . . . . . . . . . . 149

primary drive/transmission oil,

capacities . . . . . . . . . . . . . . . . . . . 149

removal. . . . . . . . . . . . . . . . . . 197-200

top end

cylinder . . . . . . . . . . . . . . . . 179-184

head . . . . . . . . . . . . . . . . . . . 157-169

oil

tank and lines. . . . . . . . . . . 190-192

pistons and piston rings . . . . 184-189

pushrods and covers. . . . . . . 175-179

rocker cover assembly . . . . . 151-157

service . . . . . . . . . . . . . . . . . 193-195

specifications . . . . . . . . . . . . . . . 193

tools. . . . . . . . . . . . . . . . . . . . . . . 151

torque . . . . . . . . . . . . . . . . . . . . . 196

valve

spring compression . . . . . . . . . . 195

valves and valve

components . . . . . . . . . . . 169-175

troubleshooting

lubrication . . . . . . . . . . . . . . . . . . . 90

noises . . . . . . . . . . . . . . . . . . . . . . 88

performance . . . . . . . . . . . . . . . 34-35

smoke . . . . . . . . . . . . . . . . . . . . . . 89

starting . . . . . . . . . . . . . . . . . . . 32-34

Evaporative emission control system,

California models . . . . . . . . . . 347-348

1988-2003. . . . . . . . . . . . . . . . 378-389

Exhaust system

1986-1987

air filter, backplate . . . . . . . . . . . 333

exhaust system . . . . . . . . . . . . . . 347

1988-2003

air filter, backplate . . . . . . . . . . . 350

1988-2003, except

883R models. . . . . . . . . . . . . 375-378

torque . . . . . . . . . . . . . . . . . . . . . 391

1988-2003, 883R models. . . . . . . . 378

inspection. . . . . . . . . . . . . . . . . . . . 137

torque. . . . . . . . . . . . . . . . . . . . . . . 349

F

Fasteners . . . . . . . . . . . . . . . . . . . . . . 4-6

Fork oil change . . . . . . . . . . . . . 121-122

Fuel

1986-1987 models

carburetor. . . . . . . . . . . . . . . 333-340

specifications . . . . . . . . . . . . . . 349

choke cable . . . . . . . . . . . . . . . . . 343

 

For the rest of the information in this Sportster Service Manual see the top of the page for the free service manual sample download and the full access manual.

 

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.

 

Service manual, Repair Manual, Harley Sportster Handbook, Sportster Owners Repair Guide, Text Book 

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