Harley Davidson XL XLH Sportster 1986-2003 Clymer Owners Service and Repair Manual
Softcover - 640 pages - Harley Davidson XL XLH Sportster 1986 - 2003 Clymer Owners Service Repair Manual covers the following Sportster XL and XLH models: XLH883 (1986 - 2003) XLH883 Custom (1999 - 2003) XLH883 Deluxe (1986 - 1995) XLH883 Hugger (1987 - 2003) XL883R (2002 - 2003) XLH1100 (1986 - 1987) XLH1200 (1988 - 2003) XL1200 Custom (1996 - 2003) XL1200 Sport (1996 - 2003)Contents: QUICK REFERENCE DATA GENERAL INFORMATIONManual organization / Warnings cautions and notes / Safety / Serial numbers / Fasteners / Shop supplies / Tools / Measuring tools / Electrical system fundamentals / Service methods / Storage / Specifications TROUBLESHOOTINGStarting the engine / Engine performance / Electrical component replacement / Starting system / Charging system / Ignition system (1986-1997 models) / Ignition system (1998-2003 models except 1200S models) / Ignition system (1998-2003 1200S models) / Fuel system / Engine noises / Engine smoke / Leakdown test / Engine lubrication / Clutch / Transmission / Electrical testing / Electronic speedometer/tachometer / Turn signal module (1991-1996 models) / Turn signal module (1997-2003 models) / Excessive vibration / Front susp
Harley Davidson Sportsters 1970 - 2010 Haynes Owners Service and Repair Manual
Hardcover - 228 pages - Harley Davidson Sportsters 1970 - 2010 Haynes Owners Service Repair Manual Covers the following Models: XL XLH XLCH 883 Hugger Sportster Deluxe Custom Low Roadster 1970 - 1971 1986 - 2010 XL XLX-61 XLH XLCH XLS 1000 Sportster Roadster Anniversary 1972 - 1985 XL XLH 1100 Sportster. 1986 - 1987 XL XLH 1200 1200C 1200S 1200N 1200L 1200R Sportster 1998 - 2010DOES NOT include XR-1000 engine information or 2009-on XR models.Contents Living With Your Harley Davidson- Introduction- Milwaukee Magic- Ackowledgements- About this Manual- Identification Numbers- Buying Spare Parts- Decoding the Vehicle Identification Number (VIN)- Safety First! Daily (Pre-Ride) Checks- Engine Oil Level Check- Suspension Steering and Final Drive Checks- Legal and Safety Checks- Tyre Checks Maintenance- Routine Maintenance and Servicing- Specifications- Recommended Lubricants and Fluids- Component Locations- Maintenance
Harley-Davidson Sportsters 1959 - 1985 Clymer Owners Service and Repair Manual
Softcover - 376 pages - Harley-Davidson Sportsters 1959 - 1985 Clymer Owners Service Repair Manual Covers the following Models: Harley-Davidson H Sportster (1959-1969) Harley-Davidson CH Sportster (1959-1969) Harley-Davidson XLCH Sportster (1970-1980) Harley-Davidson XLH Sportster (1970-1972 1978-1985) Harley-Davidson XLCR Sportster (1977-1978) Harley-Davidson XLX Sportster (1983-1985) Harley-Davidson XLS Sportster (1980-1985) Harley-Davidson XL Sportster (1973-1977)Contents: QUICK REFERENCE DATA GENERAL INFORMATION TROUBLESHOOTING PERIODIC LUBRICATION MAINTENANCE AND TUNE-UPMaintenance schedule intervals / Periodic lubrication / Engine oil and filter change / Periodic maintenance / Suspension adjustment / Breaker point ignition service / Magneto / Breakerless ignition system / Carburetor adjustments ENGINERemoval installation / Pushrods / Valves and components / Cylinder / Oil pump / Gearcase / Tappets and guides / Crankcase / Drive sprocket and seal / Engine seals / Starter drive shaft and housing / Specifications CLUTCH PRIMARY DRIVE KICKSTARTER AND TRANSMISSIONClutch / Primary chain / Kickstarter / Transmiss
Harley-Davidson Sportster XL883, XL1200 2004 - 2013Clymer Owners Service and Repair Manual
Softcover - 616 pages - Harley-Davidson Sportster XL883 XL1200 2004 - 2013 Clymer Owners Service Repair Manual covers the following models: Sportster XL833 (2004-2009) XL883C Custom (2004-2010) XL883L Super Low (2004-2013) XL883N Iron (2009-2013) XL883R Roadster (2004-2013) XL1200C Custom (2004-2013) XL1200L Super Low (2004-2011) XL1200N Nightster (2007-2012) XL1200R Roadster (2004-2009) XL1200V 72 (2010-2013) Sportster XL1200X 48 (2010-2013)Note: this manual DOES NOT include XR1200Contents: AMENDMENTOn the 2/1 edition page X (QRD) and page 538 have been changed to note the engine oil capacity on: 2008 - 2009 models is 2.8 qt (2.65 litre) 2004 - 2007 models the capacity is 3.6 qt. (3.4 litre) QUICK REFERENCE DATA GENERA
Read an adequate amount of Harley-Davidson's record also it rapidly becomes evident that the Sportster makes their mark in almost every niche in motorcycling. The Sporty's ability can be so wide so it happens to be characterized as anything from the best stud device and two-wheeled road pole to an entry-level bike and great bicycle for females.
It had been a Sportster motor built by Warner Riley and George Smith that driven Cal Rayborn's globe land speeds record-setting streamliner to 265.492 miles per hour in 1970. And there were other people -- Leo Payne built his 202.379 miles per hour land speeds record Harley around a Sportster engine in 1970; Tom Reiser grabbed both pull racing and mountain rise brands on Sportster centered devices, and Harley's dominant flat track XR750s owe their particular genetics to your Sportster.
Harley-Davidson Sportster background
2015 Harley 1200 C Personalized
The cause of the Sportster's do-it-all character probably owes about partly to the fact that the Sportster has been doing continuous manufacturing since 1957, with regards to had been introduced with a brand new OHV pushrod 883 cc air-cooled engine.
It is often the subject of constant product development and improvement for 57 many years. Without a doubt, that makes it the longest constantly produced motorcycle brands on the planet.
Best 1,983 Sportsters --- design designation XL --- had been integrated that earliest full year of production, but the enhanced overall performance the OHV system offered on the side valve flathead KH intended the midsize bikes in range would shortly be Sportsters---by 1958, the KH, KHK and KHR are gone.
In 1958, the conventional XL had been joined inside product line by the XLH, XLC and XLCH systems with an increased compression ratio---the XLC becoming a sporting version and the XLCH the off-road variation.
By 1959, the XLCH became the totally complete street-legal hot-rod as well as the XLH arrived loaded with highest lift intake webcams.
Harley-Davidson buyers were quick to embrace the Sportster as Harley's first drop-the-hammer athletics bicycle to contend with the light, fast Uk twins regarding the late fifties and early sixties---especially after the victory 650 cc Bonneville arrived in 1959.
By 1960, manufacturing had increased almost 40 % from seasons one, climbing to 2,765 products. By 1967, production had soared to 4,500 devices, second simply to the top of the range Electra-Glide.
By 1970, the Sportster became the utmost effective manufacturing design for Harley-Davidson when 8,560 models were built; nearly 1,000 significantly more than the Electra-Glide. That seasons, Harley furthermore introduced the XR750 -- a Sportster-based design for competition in the AMA's Class C rushing.
In 1974, Sportster mania achieved its top with manufacturing soaring to 23,830 devices in aftermath of displacement being bumped up from 883 cc to 1,000 cc in 1972.
In 1977 and 1978, the Sportster range included the XLCR, a factory caf racer version of this original Sportster and the XLT touring bicycle that was included with Electra-Glide seat bags, touring windshield and handlebars, thickly padded chair, taller equipment ratios and bigger (by Sportster standards) 3.5 gallon gasoline tank. These two are dropped through the line-up by 1979.
Harley-Davidson Sportster on the market
In consideration of brand new AMA principles for lessons C racing, a Sportster-based bike, the XR 750 racer was introduced in 1970.
By 1979, Harley-Davidson dropped all of the minuscule of its bicycles plus the Sportster became the littlest displacement Harley in line-up, nevertheless at 1,000 cc.
In 1986, the Sportster have a re-fresh with return of this 883 cc motor and introduction associated with the 1,100 cc motor, both on the basis of the newer Evolution engine, but still operating four speed transmissions. In 1988, the Sportster range included three 883 cc alternatives now featuring Keihin carburetors, the 1100 cc model had been bumped to 1,200 cc as well as the reduced seat level Hugger had been launched.
In 1991, Sportsters eventually got the five speed transmission they so richly deserved, rubber-mounted footpegs and gear best drive on 883 luxurious; by 1993 gear drive had been on all the 883s.
As the Sportster rolled on in to the 21st century, many improvement, some not visually noticeable to the everyday observer, carried on to move the bike up the technologies scale. For instance, in 2000 system and transmission internals got crucial updates, as performed forward brake calipers, crankshaft, wheel bearings and enhanced consumption and fatigue circulation triggered best power.
Through the 2000s the Sportster types has actually continuing to evolve and develop with newer sophistication and edgy design like that of XR 1200 launched in 2007. Numerous sub-models additionally evolved, making the bicycle attract a much broader readers.
For 2015, Harley provides six Sportster products: XL1200T SuperLow, XL 883L SuperLow, XL 883N metal 883, XL 1200C 1200 Custom, XL 1200X Forty-Eight and XL 1200V Seventy-Two.
The termination of some sort of war actually leaves chaos. Civilian production of cars and fridges happens to be interrupted and needs to be re-started. Cash to pay for bombs, vessels, shells, planes and weapons was imprinted by the boxcar-load, risking a steep post-war inflation, followed closely by anxiety. Whenever WW II concluded, England's pockets are pulled inside-out and her once-grand-but-now-shrinking kingdom could no further refill all of them. In 1946 Lord Keynes moved prior to the US Congress to plead that since The united kingdomt "endured alone against Hitler for just two ages" (from Sept. 1939 to Dec. 7, 1941), she should obtain a post-war loan. The vote was a resounding "No way, Jack" (The united kingdomt was a wartime ally, but was today a postwar trade competition).
To scratch up essential tough currency, The united kingdomt must export every little thing feasible, additionally the early star performers had been whiskey and motorbikes. Shortly Argentina was importing Vincent Vee-Twins as authorities bikes, and Triumphs -- best periodically seen in The united states into the belated 1930s -- became a winner in america. United States domestic bikes had after 1913 shed their particular transport purpose to Henry's cheaper Model T car. The usa business -- once the pioneer that easily ruled the 1911 Isle of guy TT races -- could no longer pay for much R&D. US bikes had been rugged (which could imply heavy) dependable (that many situations additionally meant sluggish), and elemental (this is certainly, they retained the give change, fat tires, three-speed gearboxes, and rigid structures of start). Us motorcyclists are genuine lovers -- they decided to go to races and rallies plus they proceeded roadway trips -- but because numerous Us americans now have cars, there were number of all of them.
The sudden alternate of overhead-valve (OHV) Uk bicycles -- latest, lighter, fast-accelerating, and maneuverable -- was a shock into United States marketplace, and sales exploded. At Kiwanis, businessmen drink toasts into concept of competitors nonetheless they don't take a liking to the genuine thing one little bit.
Indian fought fire by what they hoped is fire -- their very own light singles and parallel twins. They fizzled, killing the company. Harley-Davidson in 1951 lobbied for huge tariff on brought in motorbikes, and for 1952 cautiously modernized their particular line-up with a 4-speed unit-construction 750 flat-head (or 'side-valve', in England-speak) with base shift and rear suspension. The united kingdomt have an easy response -- puffing up 500s into 600s and 650s, accompanied immediately by more compression, twin carburetors, and back suspension system. Harley could stroke also, enlarging their particular flat-head to 888-cc.
It was nonetheless no contest -- also a 'little' 650 OHV was too powerful for Harley's weightier low-compression KH-model flat-head. It was time for you bring really serious. The K-model had inherited their four geared-together separate camshafts, every one running a side-valve right above they. Why not simply unbolt the side-valve minds and cylinders, then shed positioned latest pushrod OHV cylinders making use of their rocker-arms placed straight above those same four cameras, the good news is operated by pushrod? This way, the brand new engine could largely become machined for a passing fancy range which had created the K-models. Cylinders and heads will be of cast iron, creating the split, shrunk-in hard valve chairs of aluminum heads unnecessary, saving once more on machining price. Bore and swing were modernized to 3 X 3 13/16", making simply timid of 55 cubes. Why all those sixteenths? Previous Harley race management the belated penis O'Brien when said, "If our companies require anything more precise than a carpenter's guideline to make everything we require, they simply do not want to do it."
This four-speed, unit-construction, hydraulic-suspended OHV Sportster XL of 1957 made 32-hp at 4200, putting Harley in the overall game of Just who procedures the Streets. Every thing depended in your standpoint. If you longed to beat the Bonnevilles and the Super Rockets, you rejoiced. If you rode British, your scoffed. In the event that gigantic Twin was the sole Bike for your needs, your scorned the XL as "A delivery-boy's bike." As with every human being affairs, it absolutely was difficult. But it had been enjoyable!
On all sides associated with the concern, builders got hectic stroking, dull, porting, frequently overstepping the limitations of prudence. Plenty of chips had been tossed onto countless store flooring and a lot ended up being learned. a Triumph "night hunter" we came across ran 12-to-one pistons on the street in 1963, maintaining their "Sportster Destroyer" system together and knock-free by fueling it only from a drum of purple aviation gas which he kept in a secret shack, far from man habitation or prying vision. Really serious stuff! Wizards for the Harley areas system or trick machinists with very large beards could place crankpins virtually anyplace your wished them, causing larger, larger, greatest Sportsters with odd con-rods and also stranger cylinder heights.
1957 Harley-Davidson XL Sportster fixed side view
And several regarded the Sportster as only a happily light variety of Harley that still spoke forth the interesting fatigue rumble. Saturday evenings, out in front of "The Ebb Tide", north of Boston, soon after last call, when Chuck Berry or the Flamingos have played the past ready, arrived the truly amazing Magneto crisis. There were the Sportsters, backed to the curb, front tires cocked jauntily upward. Can these athletic younger motorcyclists, possibly a few beverages towards good, beginning these muscular, somewhat cantankerous machines? We collected to watch while they flung on their own into the atmosphere, coming down over and over on the kick-start levers.
Suddenly the overall game altered. Kawasaki's H1 two-stroke Triple arrived in 1969, handing optimal bang when it comes to money to another audience of evening hunters; remain forward across cycle, put the tach needle here, get 'er whirling, pin it and sit down. The Brit markets sickened and passed away. In 1972 the Kawi Triple have a 50% displacement boost and 12 months from then on emerged the 903-cc Z1.
Living critters adjust, so do motorbikes. Some, anyway. Of overhead, just the Sportster survives -- however air-cooled, however using its four webcams. For some time in the 1980s, the 883 Sportster is repurposed as a $4000 reduction frontrunner to "bring visitors to the brand name". A substantial wide range of them had been females. Consecutive displacement improves held its sporting overtones and AMA spec-class racing, very first as an 883 and later as a 1200, kept its larger rumble into the ears of "industry thought-leaders". Thirty-five years back, when the musical noise of accelerating Triples floated within my window I understood it had been closing amount of time in the nearby old mill town. Within five years that noise gone silent, making nowadays only the rumble of Sportsters.
The Harley-Davidson Sportster try a type of motorbikes produced continually since 1957 by Harley-Davidson. Sportster designs are designated in Harley-Davidson's goods code by beginning with "XL". In 1952, the predecessors into the Sportster, the design K recreation and Sport Solo motorcycles, had been introduced. These brands K, KK, KH, and KHK of 1952 to 1956 have a sidevalve ('flat head') motor, whereas the subsequent XL Sportster products use an overhead device motor. Initial Sportster in 1957 had most same details of the KH like the framework, fenders, big gas tank and forward suspension system.
Sportster motorbikes become powered by a four-stroke, 45 V-twin motor by which both connecting rods, for the "fork and blade" or "knife & fork" build, share a typical crank pin. The initial Sportster engine was the Ironhead motor, that was changed using the advancement engine in 1986. Sportster engines, the 45 cubic inch R, D, G & W Models 1929 side-valve motors, plus the 'gigantic Twin' side-valve motors, of: the flathead 74.0 cu in (1,213 cc) Models V, VL an such like. (1930--1936), systems U and UL (1937--1948), together with 80.0 cu in (1,311 cc) designs VH and VLH (1935--1936), models UH and ULH (1937--1941) posses four split webcams, displaying one lobe per cam.
The cam followers utilized in Sportster engines, K systems, big double side-valve systems, additionally the side-valve W model show were a slightly reduced type of the followers found in the more expensive engines, however with exactly the same 0.731-inch (18.6 mm) diameter body and 0.855-inch (21.7 mm) diameter roller follower since 1929. The business used similar cam followers for decades with small modifications, through the 1929 towards the Eighties.
Sportster engines retained the K/KH build crankcase build, where transmission try included in the same casting whilst the system, and driven because of the motor with a triple-row #35 string biggest drive and a multi-plate cable-operated clutch. Versions since 1991 have actually five rates; 1990 and previous products have four rates.
The engine is attached right to the framework from 1957 through the 2003 model season. Although this system allows the bike becoming somewhat light with more accurate management, it also transmits motor vibration straight to the driver. Sportsters circulated in 2004 and later incorporate rubberized separation supports and link hyperlinks to restrict system movement to one airplane, which greatly reduces vibration considered by the rider. Buell motorbikes constructed with variants of this Sportster engine have used a rubber mount system since 1987.
The design K, from where the Sportster developed, ended up being initial civil bike produced by Harley-Davidson with hydraulic shock absorbers on both wheels. Common consumption calls this a K Model.
1957 "Ironhead" overhead-valve motor launched.
1958 XLH touring high compression model and XLCH sportier "competitors Hot" model introduced.
1967 electricity beginning introduced on XLH
1972 "Ironhead" 1,000 cc overhead-valve engine replaces 900 cc. Advertised power had been 61 hp (45 kW) @ 6,200 rpm and a top speed of 116 miles per hour (187 km/h)
1975 Switched to left-side gear change (DOT mandate)
1977 & 1979 Dual fatigue "Siamese" pipes put, launched on Willie G. Davidson's XLCR caf racer in 1977 all systems 1979, along with the triangular framework and rear hydraulic disk brake additionally introduced on XLCR. In 1977 a restricted edition Confederate Edition Sportster is introduced for starters year best.
1979 just last year when it comes to kickstart just XLCH, only 141 made.
1985 this past year for "Ironhead" overhead-valve system.
1986 "development" system launched in 883 cc and 1,100 cc sizes.
1988 1200 cc system replaces 1,100 cc system.
1988 Constant velocity carburetor replaces butterfly carburetor.
1991 Five-speed transmission replaces four-speed.
1991 Belt drive replaces string drive on 883 luxurious and all 1200 designs.
1993 Belt drive made standard on all Sportsters.
1994 enhanced oils tank, battery tray, and clutch made standard.
1994 brand new electrical program with sealed connectors.
1995 Speedometer is currently electronic, maybe not mechanical.
1996 XL1200C Customized model launched.
1998 XL1200S gets dual spark-plug minds and powerful cams
2000 Introduced sealed wheel bearings and updated four-piston brake calipers.
2003 Last year the frame mounted Evolution motor.
2004 All-new framework including rubber-mounted motor for decreased vibration. Removal for the transmission trap door, brand new form hamcan, fatigue stability pipeline moved from running underneath the air filter and disguised and concealed behind the silencers showing more of motor, new smoother design oil container right side panel with drive and turn filler/dipstick, as well as the previously subjected electric battery is now enclosed in a matching side panel on remaining
2005 Enlarged rear axle to 1 inches (25.4 mm) for increased stability.
2006 New XR1200 was revealed at Intermot in Cologne, Germany. The XR1200 could be the first Harley-Davidson to make use of Down Draft DDFI II fuel shot. To be released as a late 2006 design. Introduction of helical gears in transmission (2nd-5th).
2007 gasoline injections replaces carburetion on all designs.
2008 front axle increased from 3/4 inches to 25 mm, back axle diminished from 1 inches (25.4 mm) to 25 mm
2009 "One dimensions meets all" front mudguard method replaced by enhanced mudguard contour to suit each model's respective wheel diameters.
2010 The ECU try relocated to permit more variation in aftermarket seat selection
2010 Side-mounted license dish option on some products
2014 new electric harness, brand-new bigger brake system, antilock brake system (ABS) solution, keyless entry, brand new speedometer with equipment indicator/tachometer, increased system compression proportion, catalytic converter