Harley-Davidson Sportster Motorcycle (1986-2003) Service Repair Manual

The online edition of this manual will be available immediately without download. The physical manual will be dispatched directly by Haynes and will arrive separately from any other parts ordered.

Clymer motorcycle repair manuals are written specifically for the do-it-yourself enthusiast. From basic maintenance to troubleshooting to complete overhaul, Clymer manuals provide the information you need. The most important tool in your tool box may be your Clymer manual, get one today.Every Clymer manual contains hundreds of original photographs and illustrations developed from a complete disassembly and assembly of a motorcycle. This, in addition to extensive research, allows Clymer to achieve an unmatched level of detail, accuracy and clarity.The step-by-step instructions and two-column text with large print are user-friendly. Bold figure numbers make it easy to quickly match instructions with illustrations and photos. Thumb-tabbed chapters, numbered table of contents and an extensive index make it possible to locate the desired section quickly.

The Haynes Online Manual gives you the trusted content of the famous printed Workshop Manual with extra features to get the job done. Online Manuals provide the following benefits: Troubleshooting tool for fast diagnosis of common problems. Colour-coded wiring diagrams for key systems. Videos tutorials for common DIY tasks. Colour photographs with approximately 750 in each manual. Photos can be zoomed in to observe key details. Fully searchable Dictionary of automotive terms. Hyperlinks to additional relevant information in other manual chapters. Print any page at home.

Harley-Davidson XLH883, XL883R, XLH1100 and XL/XLH1200 Manual. Includes Color Wiring Diagrams.

What's Covered

THIS HARLEY-DAVIDSON SPORTSTER MOTORCYCLE MANUAL IS 640 PAGES.

• QUICK REFERENCE DATA
• CHAPTER ONE / GENERAL INFORMATIONMANUAL ORGANIZATION / WARNINGS, CAUTIONS AND NOTES / SAFETY / SERIAL NUMBERS / FASTENERS / SHOP SUPPLIES / TOOLS / MEASURING TOOLS / ELECTRICAL SYSTEM FUNDAMENTALS / SERVICE METHODS / STORAGE / SPECIFICATIONS
• CHAPTER TWO / 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 SUSPENSION AND STEERING / BRAKE PROBLEMS / SPECIFICATIONSCHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UPMAINTENANCE SCHEDULE / OIL AND FILTER CHANGE / TUNE-UP / AIR FILTER / COMPRESSION TEST / SPARK PLUGS / IGNITION TIMING ADJUSTMENT / SPECIFICATIONS
• CHAPTER FOUR / ENGINE TOP ENDROCKER COVER / CYLINDER HEAD / VALVES AND COMPONENTS / PUSHRODS AND COVERS / CYLINDER / PISTONS AND RINGS / OIL TANK AND OIL LINES / SPECIFICATIONS
• CHAPTER FIVE / ENGINE LOWER ENDREMOVAL AND INSTALLATION / VALVE TAPPETS AND GUIDES / VALVE TAPPETS / GEARCASE COVER AND TIMING GEARS / OIL PUMP / OIL FILTER MOUNT / CRANKCASE AND CRANKSHAFT / CYLINDER STUDS / ENGINE BREAK-IN / SPECIFICATIONS
• CHAPTER SIX / PRIMARY DRIVE AND CLUTCH (1986-1990 MODELS)PRIMARY DRIVE COVER / CLUTCH RELEASE MECHANISM / PRIMARY CHAIN ADJUSTER / PRIMARY DRIVE / CLUTCH / CLUTCH CABLE / SPECIFICATIONS
• 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 / SPECIFICATIONS
• CHAPTER EIGHT / FOUR-SPEED TRANSMISSION (1986-1990 MODELS)TRANSMISSION / SHIFTER MECHANISM / SPECIFICATIONS
• 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 / SPECIFICATIONS
• 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) / SPECIFICATIONS
• 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) / SPECIFICATIONS
• CHAPTER TWELVE / ELECTRICAL SYSTEMBATTERY / CHARGING SYSTEM / ALTERNATOR / IGNITION SYSTEM / IGNITION COIL / BANK ANGLE SENSOR / MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR (1998-2003 1200S MODELS) / STARTER / STARTER SOLENOID / LIGHTING SYSTEM / ELECTRONIC SPEEDOMETER / TACHOMETER / SWITCHES / HORN / ELECTRICAL BRACKET / TURN SIGNAL FLASHER / TURN SIGNAL MODULE / CIRCUIT BREAKERS / FUSES / WIRING DIAGRAMS / SPECIFICATIONS
• CHAPTER THIRTEEN / WHEELS, TIRES AND SECONDARY DRIVEMOTORCYCLE STANDS / FRONT WHEEL / FRONT HUB / REAR WHEEL AND HUB / DRIVE CHAIN AND SPROCKETS / DRIVE BELT AND SPROCKETS / WHEEL RUNOUT / LACED WHEELS / DISC AND CAST WHEELS / WHEEL BALANCE / TIRES / SPECIFICATIONS
• CHAPTER FOURTEEN / FRONT SUSPENSION AND STEERINGHANDLEBAR / FRONT FORK / STEERING HEAD AND STEM / STEERING HEAD BEARING / STEERING PLAY / SPECIFICATIONS
• CHAPTER FIFTEEN / REAR SUSPENSIONSHOCK ABSORBERS / SWING ARM / SPECIFICATIONS
• CHAPTER SIXTEEN / BRAKESBRAKE FLUID SELECTION / BRAKE SERVICE / FRONT AND REAR BRAKE PADS (1986-1999 MODELS) / FRONT AND REAR BRAKE CALIPER / FRONT AND REAR MASTER CYLINDER / BRAKE HOSE AND LINE / BRAKE DISC / BLEEDING THE SYSTEM / BRAKE FLUID DRAINING / FLUSHING THE BRAKE SYSTEM / SPECIFICATIONS
• CHAPTER SEVENTEEN / BODYSEAT / FRONT FENDER / REAR FENDER / FOOTRESTS / FORWARD FOOT CONTROLS (1999-2003 883C AND 1200C MODELS) / SIDESTAND / FORK LOCK / SPECIFICATIONS
• INDEX
• COLOR WIRING DIAGRAMS
• MODELS: SPORTSTER XL1200C CUSTOM XLH1200S SPORT XLH1100 XLH1200 XLH883 XLH883C CUSTOM XLH883D DELUXE XLH883H HUGGER XL883R C S D H XL 1200 XLH 1100 883 883R 1200C 1200S 883C 883D 883H XL883 XL1200