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 Troubleshooting

HARLEY DAVIDSON SERVICE MANUALS 

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Sportster Models

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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.

Models covered in this  Troubleshooting Service Guide Manual are: Harley Davidson Sportster XL & XLH models, including XLH883, XL883R, XLH1100, XL1200, XLH1200, Custom, Sportster Deluxe, Hugger, Custom and Sport.

Different Models Years Included in this Sportster Troubleshooting Service Manual are: 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.

Troubleshooting the Sportster XL & XLH 883-1200 Motorcycle.

This chapter covers troubleshooting procedures. Each

section provides typical symptoms and logical methods for

isolating the cause(s). There may be several ways to solve a

problem, but only a systematic approach will be successful

in avoiding wasted time and possibly unnecessary parts replacement.

An engine needs three elements to run properly: correct

air/fuel mixture, compression and a spark at the right

time.

If one basic requirement is missing, the engine will not

run.

Gather as much information as possible to aid in diagnosis.

Never assume anything and do not overlook the obvious.

Make sure there is fuel in the tank. Make sure the fuel

shutoff valve is in the on position.

In most cases, specialized test equipment is not needed to

determine whether repairs can be performed at home. On

the other hand, be realistic and do not attempt repairs beyond

personal capabilities.

If the motorcycle does require the attention of a professional,

describe the symptoms, conditions and previous

repair attempts accurately and fully. The more information

a technician has available, the easier it will be to diagnose.

 

 

STARTING THE ENGINE

Engine Fails to Start (Spark Test)

Perform the following spark test to determine if the ignition

system is operating properly:

 

1. Disconnect the spark plug wire and remove the spark

plug as described in Chapter Three.

Engine is Difficult to Start

ENGINE PERFORMANCE

The following check lists assume the engine runs, but isSpark Plugs Fouled

 

 

 

not operating at peak performance. Refer to the following

procedure(s) that best describes the symptom(s).

 

 

Engine Runs But Misfires

 

 

Engine Overheating

1. Incorrect carburetor adjustment or jet selection.

2. Incorrect ignition timing or defective ignition system

components.

3. Improper spark plug heat range.

4. Low oil level.

5. Oil not circulating properly.

6. Leaking valves.

7. Heavy engine carbon deposits.

Engine Runs Rough with Excessive Exhaust Smoke.

 

Engine Lacks Acceleration

 

 

ELECTRICAL COMPONENT REPLACEMENT

Most dealerships and suppliers will not accept the return

of any electrical part. Consider and test results carefully before

replacing a component that tests only slightly out of

specification.

 

STARTING SYSTEM

The starting system consists of the battery, starter, starter

relay, solenoid, start button, starter mechanism and related

wiring.

When the ignition switch is turned on and the start button

is pushed in, current is transmitted from the battery to the

starter relay. When the relay is activated, it activates the

starter solenoid that mechanically engages the starter with

the engine.

Starting system problems are most often related to a loose

or corroded electrical connection.

Refer to

Figure 4 for starter and solenoid terminal identification .

 

Loud grinding noises when the starter turns

Incorrect starter pinion gear and clutch shell ring gear engagement

(B,

mechanism (

and inspect the starter as described in Chapter Twelve.

Figure 8) or a broken overrunning clutchFigure 12) can cause this problem. Remove

 

CHARGING SYSTEM

The charging system consists of the battery, alternator

and a solid state voltage regulator/rectifier.

The alternator generates alternating current (AC) which

the rectifier converts to direct current (DC). The regulator

maintains the voltage to the battery and load (lights, ignition

and accessories) at a constant voltage despite variations

in engine speed and load.

A malfunction in the charging system generally causes

the battery to remain undercharged.

 

NO CHECK ENGINE LIGHT WITH KEY ON

 

CHECK ENGINE LIGHT CIRCUIT

 

CHECK ENGINE LIGHT CONTINUOUSLY ON

 

ENGINE NOISES

1. A knocking or pinging during acceleration can be

caused by using a lower octane fuel than recommended or a

poor grade of fuel. Incorrect carburetor jetting and an incorrect

spark plug heat range (too hot) can cause pinging. Refer

to

Spark Plugs

in Chapter Three. Also check for

excessive carbon buildup in the combustion chamber or a

defective ignition module.

 

 

 

 Shop Manual, Service Manual, Repair Manual, Repair Guide, Handbook Text Book, Workshop Manual Sportster XL & XLH Models, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008