Harley-Davidson XL, XLH Sportster Repair Manual 1986-2003

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Item # M429-5  ISBN: 9781599691497




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This repair & service manual covers Harley Davidson Sportster XL and XLH models, including XLH883, XL883R, XLH1100, XL1200, and XLH1200, 1986 to 2003.

Table of Contents

QUICK REFERENCE DATA

CHAPTER ONE: GENERAL INFORMATION
Manual organization | Warnings, cautions and notes | Safety | Serial numbers | Fasteners | Shop supplies | Tools | Measuring tools | Electrical system fundamentals | Service methods | Storage

CHAPTER TWO: TROUBLESHOOTING
Starting 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 suspension and steering | Brake problems

CHAPTER THREE: LUBRICATION, MAINTENANCE and TUNE-UP
Fuel type | Maintenance schedule | Routine safety checks | Tires and wheels | Periodic lubrication | Periodic maintenance | Tune-up | Air filter | Compression test | Spark plugs | Ignition timing adjustment

CHAPTER FOUR: ENGINE TOP END
Tools | Rocker cover assembly | Cylinder head | Valves and valve components | Pushrods and covers | Cylinder Pistons and piston rings | Oil tank and oil lines

CHAPTER FIVE: ENGINE LOWER END
Tools | Engine service | Engine stand | Engine | Valve tappets and guides (1986-1990 models) | Valve tappets (1991-2003 models) | Gearcase cover and timing gears | Oil pump (1986-1990 models) | Oil pump (1991-2003 models) | Oil filter mount (1986-1990 models) | Oil filter mount (1991-2003 models) | Crankcase and crankshaft | Cylinder studs | Engine break-in

CHAPTER SIX: PRIMARY DRIVE and CLUTCH (1986-1990 MODELS)
Primary drive cover | Clutch release mechanism | Primary chain adjuster | Primary drive | clutch | Clutch cable

CHAPTER SEVEN: PRIMARY DRIVE and CLUTCH (1991-2003 MODELS)
Primary drive cover (1991-1993 models) | Primary drive cover (1994-2003 models) | Clutch release mechanism (1991-1993 models) | Clutch release mechanism (1994-2003 models) | Primary chain adjuster | Primary drive | clutch | Clutch cable

CHAPTER EIGHT: FOUR-SPEED TRANSMISSION (1986-1990 MODELS)
Transmission | Shifter mechanism |

CHAPTER NINE: FIVE-SPEED TRANSMISSION (1991-2003 MODELS)
Transmission | Shift forks and shift drum | Mainshaft and countershaft | Main drive gear | Access door bearings | Right transmission case bearings | Shift mechanism

CHAPTER TEN: FUEL, EMISSION CONTROL and EXHAUST SYSTEMS (1986-1987 MODELS)
Air filter backplate | Carburetor | Intake manifold | Fuel hose and clamps | 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)
Air filter backplate | Carburetor | Intake manifold | Fuel hose and clamps | Throttle and idle cables | Starting enrichment valve (choke) cable | Fuel tank | Fuel shutoff valve (1988-1994 models) | Fuel shutoff valve (1995-2003 models) | Exhaust system (all models except 883R models) | Exhaust system (883R models) | Evaporative emission control system (California models)

CHAPTER TWELVE: ELECTRICAL SYSTEM
Electrical component replacement | Electrical connectors | Battery (1986-1996 models) | Battery (1997-2003 models) | Charging system | Alternator (1986-1990 models) | Alternator (1991-2003 models) | Ignition system (1986-1997 models) | Ignition system (1998-2003, all models except 1200S models) | Ignition system (1998-2003 1200S models) | Ignition coil | Bank angle sensor (1998-2003 models) | Manifold absolute pressure (MAP) sensor (1998-2003 1200S models) | Starter | Starter solenoid | Lighting system | Electronic speedometer | tachometer | Switches | Horn | Electrical bracket | Turn signal flasher (1986-1990 models) | Turn signal module (1991-2003 models) | Circuit breakers (1986-1997 models) | Fuses (1998-2003 models) | Electrical connectors | Wiring diagrams

CHAPTER THIRTEEN: WHEELS, TIRES and SECONDARY DRIVE
Motorcycle stands | Front wheel | Front hub (1986-1999 models) | Front hub (2000-2003 models) | Rear wheel Rear hub (1986-1999 models) | Rear hub (2000-2003 models) | Drive chain and sprockets | Drive belt and sprockets | Wheel runout | Laced wheels | Disc and cast wheels | Wheel balance | Tires

CHAPTER FOURTEEN: FRONT SUSPENSION and STEERING
Handlebar | Front fork (all models except 1200S models) | Front fork (1200S models) | Steering head and stem | Steering head bearing | Steering play adjustment

CHAPTER FIFTEEN: REAR SUSPENSION
Shock absorbers | Swing arm

CHAPTER SIXTEEN: BRAKES
Brake fluid selection | Brake service | Front brake pads (1986-1999 models) | Front brake pads (2000-2003 models) | Front brake caliper (1986-1999 models) | Front brake caliper (2000-2003 models) | Front master cylinder (1986-1995 models) | Front master cylinder (1996-2003 models) | Rear brake pads (1986-early 1987 models) | Rear brake pads (late 1987-1999 models) | Rear brake pads (2000-2003 models) | Rear brake caliper (1986-early 1987 models) | Rear brake caliper (late 1987-1999 models) | Rear brake caliper (2000-2003 models) | Rear master cylinder (1986-early 1987 models) | Rear master cylinder (late 1987-2003 models) | Brake hose and line replacement | Brake disc | Bleeding the system | Brake fluid draining | Flushing the brake system

CHAPTER SEVENTEEN: BODY
Seat | Front fender | Rear fender | Footrests | Forward foot controls (1999-2003 883C and 1200C models) | Sidestand | Fork lock

COLOR WIRING DIAGRAMS | INDEX

Clymer motorcycle repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from maintenance and troubleshooting, all the way to complete teardown and rebuild.

Harley-Davidson XL, XLH Sportster Repair Manual 1986-2003