Harley-Davidson Sportster Repair Manual: XL, XLH, XLCH, XLS, XLX-61, 883, 1100, 1200 1970-2010 |
 The Haynes 1970-2010 Harley-Davidson Sportster XL, XLH, XLCH, XLS, XLX-61, 883, 1100, 1200 Repair Manual covers:
- 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. 1998-2010.
Note: this manual DOES NOT include XR-1000 engine information or 2009-on XR models.
Book Excerpt: 1970-2010 Harley-Davidson Sportster Repair Manual: XL, XLH, XLCH, XLS, XLX-61, 883, 1100, 1200
THE ENGINE and TRANSMISSION
All Sportster models are equipped with an air-cooled V-twin engine/transmission unit, with a 45-degree angle between cylinders.
Valves are operated by four separate camshafts (one for each valve), pushrods and rocker arms. The cams are gear driven off the crankshaft.
The whole assembly is constructed from aluminum alloy and the crankcase is divided vertically.
Engines used in 1970-1985 models have cast-iron cylinder heads and cylinders, and are popularly referred to as "pre-Evo" engines, due to the shape of the heads. The 1986 and later engine, called the Evolution, is basically the same engine with aluminum cylinders and heads.
Power from the crank is routed to the tranny via a primary drive chain and clutch. 1970 models have a dry clutch with coil springs. Later models came with wet, multi-plate clutch types.
Transmission is a four- or five-speed constant-mesh unit and is mounted on the back of the engine.
TABLE of CONTENTS:
LIVING WITH YOUR HARLEY-DAVIDSON SPORTSTER
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 | Tire checks
MAINTENANCE
Routine Maintenance and Servicing
Specifications | Recommended lubricants and fluids | Component locations | Maintenance schedule | Maintenance procedures
REPAIRS AND OVERHAUL
Engine, Transmission and Associated Systems
Engine | Clutch, primary drive and transmission | Fuel and exhaust systems | Ignition system
Chassis and Bodywork Components
Steering | Suspension | Final Drive | Brakes | Wheels | Tires | Frame and bodywork
Electrical System | Color Wiring Diagrams
REFERENCE
Dimensions and weight | Tools and workshop tips | Conversion factors | Motorcycle chemicals and lubricants | Storage | Troubleshooting | Troubleshooting equipment | Technical terms explained
Subject: 1970, 1971, 1972, 1973, 1974, 1975, 1976, 1977, 1978, 1979, 1980, 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010 Harley-Davidson Sportster service, maintenance, repair. ISBN-10: 1563928477 | ISBN-13: 9781563928475 | Haynes 2534
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