Book - Clymer Harley Davidson XL/XLH Sportster 1986-2003

 



This Harley-Davidson Sportster Motorcycle Manual is 640 pages.

CHAPTER ONE / GENERAL INFORMATION

CHAPTER TWO / TROUBLESHOOTING

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Maintenance schedule / Oil and filter change / Tune-up / Air filter / Compression test / Spark plugs / Ignition timing adjustment

CHAPTER FOUR / ENGINE TOP END
Rocker cover / Cylinder head / Valves and components / Pushrods and covers / Cylinder / Pistons and rings / Oil tank and oil lines

CHAPTER FIVE / ENGINE LOWER END
Removal 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

CHAPTER SIX AND SIX/ PRIMARY DRIVE AND CLUTCH
Primary drive cover / Clutch release mechanism / 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 AND ELEVEN / FUEL, EMISSION CONTROL AND EXHAUST SYSTEMS
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 TWELVE / ELECTRICAL SYSTEM
Battery / 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

CHAPTER THIRTEEN / WHEELS, TIRES AND SECONDARY DRIVE
Motorcycle 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

CHAPTER FOURTEEN / FRONT SUSPENSION AND STEERING
Handlebar / Front fork / Steering head and stem / Steering head bearing / Steering play

CHAPTER FIFTEEN / REAR SUSPENSION
Shock absorbers / Swing arm

CHAPTER SIXTEEN / BRAKES
Brake 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

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

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 

 

 


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