1986-2003 Harley Davidson XL XLH Sportster Service Manual – PDF DOWNLOAD
DESCRIPTION:
1986-2003 Harley Davidson XL XLH Sportster Service Manual – PDF DOWNLOAD
GENERAL INFORMATION:
- This detailed and comprehensive manual covers 1986-2003 XL/XLH Sportster models. The text provides complete information on maintenance, tune-up, repair and overhaul. Hundreds of photos and drawings guide the reader through every job.
- A shop manual is a reference tool and as in all Service manuals, the chapters are thumb tabbed for easy reference. Important items are indexed at the end of the book. All procedures, tables and figures are designed for the reader who may be working on the motorcycle for the first time. Frequently used specifications and capacities from individual chapters are summarized in the Quick Reference Data at the front of this manual.
MANUAL ORGANIZATION :
All dimensions and capacities are expressed in U.S. standard and metric units of measurement.
Specifications, when applicable, are listed in the tables at the end of each chapter.
This chapter covers shop safety, tool use, service fundamentals and shop supplies. Tables 1-12 at the end of the chapter include the following:
1. Model designations.
2. General motorcycle dimensions.
3. Motorcycle weight.
4. Gross vehicle weight.
5. Fuel tank capacity.
6. General torque recommendations.
7. Conversion formulas.
8. Technical abbreviations.
9. U.S. standard tap and drill sizes.
10. Metric tap and drill sizes.
11. Decimal and metric equivalents.
12. Special tools.
- Chapter Two provides methods for quick and accurate diagnosis of problems. Troubleshooting procedures present typical symptoms and logical methods to pinpoint and repair the problem. Chapter Three explains all routine maintenance necessary to keep the motorcycle running well.
- Chapter Three also includes recommended tune-up procedures, eliminating the need to constantly consult the chapters on the various assemblies. Subsequent chapters describe specific systems such as engine, primary drive and clutch, transmission, emissions, fuel and exhaust systems, the electrical system, suspension, brakes and body. Each disassembly, repair and assembly procedure is discussed in step-by-step form.
TABLE OF CONTENTS:
1986-2003 Harley Davidson XL XLH Sportster Service Manual – PDF DOWNLOAD
QUICK REFERENCE DATA IX
CHAPTER ONE
GENERAL INFORMATION 1
Manual organization
Warnings cautions and notes
Sa tety
Serial numbers
Fusteners
Shop upplies
CHAPTER TWO
Tools
Measuring tools
Electrical system fundamentals
Service methods
S1orage
TROUBLESHOOTING 32
S1arting the engine
Engine rerformancc
Electrical component rcplaccmen1
S1ar1ing system
Charging system
Ignition system ( 1986- 1997 models)
Ignition system ( 1998-2003 models
except 1200S models)
Ignition system ( I 998-2003 1200S models)
Fuel system
Engine noises
Engine smoke
CHAPTER THREE
Leakdown test
Engine lubrication
Clutch
Transmission
Electrical testing
Electronic speedometer/tachometer
Tum signal module ( 199 1- 1996 models)
Turn signal module ( 1997-2003 models)
Excessive vibration
Front suspension and steering
Brake problems
LUBRICATION, MAINTENANCE AND TUNE-UP 113
Fuel type
Maintenance schedule
Routine safety checks
Tire and wheels
Periodic lubrication
Periodic maintenance
Tune-up
Air filter
Compression test
Spark plugs
Ignition timing adjustment
CHAPTER FOUR
ENGINE TOP END 151
Tools
Rocker cover assembly
Cylinder head
Valves and valve components
CHAPTER FIVE
Pushrods and covers
Cylinder
Pistons and piston rings
Oil tank and oil lines
ENGINE LOWER END 197
Tools
Engine service
Engine stand
Engine
Valve tappets and guides ( 1986- 1990 models)
Valve tappets ( 1991 -2003 models)
Gearcase cover and timing gears
CHAPTER SIX
Oil pump ( 1986-1990 models)
Oil pump ( 1991 -2003 models)
Oil filter mount ( 1986-1990 models)
Oil filter mount (199 I -2003 models)
Crankcase and crankshaft
Cylinder studs
Engine break-in
PRIMARY DRIVE AND CLUTCH (1986-1990 MODELS) 251
Primary drive cover
Clutch re lease mechanism
Primary chain adjuster
CHAPTER SEVEN
Primary drive/clutch
Clutch cable
PRIMARY DRIVE AND CLUTCH (1991-2003 MODELS) 264
Primary drive cover ( 199 1-1993 models)
Primary drive cover ( J 994-2003 models)
Clutch release mechanism ( 1991 – 1993 models)
Clutch release mechanism ( 1994-2003 models)
CHAPTER EIGHT
Primary chain adjuster
Primary drive/clutch
Clutch cable
FOUR-SPEED TRANSMISSION (1986-1990 MODELS) 284
Transmiss ion Shifter mechanism
CHAPTER NINE
FIVE-SPEED TRANSMISSION (1991-2003 MODELS) 304
Transmission
Shift forks and shift dnim
Mainshaft and coun1ershaft
Main drive gear
CHAPTER TEN
Access door bearings
Right transmission case bearings
Shift mechanism
FUEL, EMISSION CONTROL AND EXHAUST SYSTEMS (1986-1987 MODELS) 333
Ai r filter backplate
Carburetor
Intake mani fo ld
Fuel hose and c lamps
Throttle and idle cables
Choke cable
Fuel tank
Fuel shutoff valve
Exhaust system
Evaporative emission control system
(California models)
CHAPTER ELEVEN
FUEL, EMISSION CONTROL AND EXHAUST SYSTEMS (1988-2003 MODELS) 350
Air fi ller backplate
Carburetor
Intake manifold
Fuel hose and clamps
Throttle and idle cables
Starting enrichment valve tchoke)
cable
CHAPTER TWELVE
Fuel tank
Fuel shutoff valve ( 1988- 1994 model ·)
Fuel shutoff valve ( 1995-2003 models)
Exhau t ystem (a ll models except 883R models)
Exhaust system (883R models)
Evaporative emission control system
(Cal ifornia models)
ELECTRICAL SYSTEM 392
Electrical component replaceme111
Electrical connectors
Battery ( 1986-1996 models)
Bat tery ( 1997-2003 models)
Charging system
Al ternator ( 1986-1 990 model )
A llernator ( 1991-2003 models)
Ignition ystem ( 1986-1997 models)
Ignition system ( 1998-2003 all model
except I 200S model )
Ignition system ( 1998-2003 I200S models)
Ignition coil
13ank angle sensor ( 1998-2003 models)
Manifold absolute pres ure (MAP) cnsor
( 1998-2003 1200S models)
CHAPTER THIRTEEN
Starter
Starter solenoid
Lighting ·ystem
l::leetronic speedometer/tachometer
Switche
Horn
Electrical bracket
Turn signal nasher ( 1986- 1990 models)
Turn signal module ( 1991-2003 models)
Circuit breaker ( 1986- 1997 models)
Fuses ( 1998-2003 models)
Electrica I connectors
Wiring diagrams
WHEELS, TIRES AND SECONDARY DRIVE 466
Motorcyc le stand
Front wheel
Front hub ( 1986-1999 models)
Front hub (2000-2003 models)
Rear wheel
Rear hub ( 1986-1999 models)
Rear hub (2000-2003 models)
CHAPTER FOURTEEN
Drive chain and prockets
Drive belt and sprockets
Wheel runout
Laced wheels
Disc and cast wheel
Wheel balance
Tire ·
FRONT SUSPENSION AND STEERING 500
Handlebar
Front fork (all models except 1200S models)
Front fork ( 1200S models)
Steering head and stem
Sreering head bearing
Steering play adj ustment
CHAPTER FIFTEEN
REAR SUSPENSION 526
Shock ab orbers Swing arm
CHAPTER SIXTEEN
BRAKES 533
Brake fluid election
Brake service
Front brake pad ( 1986-1999 model )
f ront brake pads (2000-2003 models)
f- ront brake ca liper ( 1986- 1999 models)
Front brake ca liper (2000-2003 models)
Front master cylinder ( 1986-1 995 models)
Front master cylinder ( 1996-2003 models)
Rear brake pad ( 1986-early 1987 models)
Rear brake pad – ( late: 1987- 1999 models)
Rear brake pads (2000-2003 models)
CHAPTER SEVENTEEN
Rear brake ca liper ( I986-early 1987 models)
Rear brake caliper ( late 1987-1999 models)
Rear brake caliper (2000-2003 model )
Rear master cylinder ( 1986-carly 1987 models)
Rear master cyl inder (late 1987-2003 models)
Brake ho c and line replacement
Brake disc
Bleeding the system
Brake Ouid draining
Flushing the brake system
BODY 590
cat
Front fender
Rear tender
Footrests
Forward foot controls ( 1999-2003 883C
and I 200C model )
Sidcstand
Fork lock
INDEX 601
WIRING DIAGRAMS 606
VIDEO PREVIEW OF THE MANUAL:
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]
S.V