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
If one basic requirement is missing, the engine will not
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
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
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
1. Incorrect carburetor adjustment or jet selection.
2. Incorrect ignition timing or defective ignition system
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
The starting system consists of the battery, starter, starter
relay, solenoid, start button, starter mechanism and related
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
Starting system problems are most often related to a loose
or corroded electrical connection.
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
and inspect the starter as described in Chapter Twelve.
Figure 8) or a broken overrunning clutchFigure 12) can cause this problem. Remove
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
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
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