Harley Davidson XL XLH Sportster 1986-2003 Clymer Owners Service & Repair Manual

1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003

by Clymer Staff

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Harley Davidson XL XLH Sportster 1986-2003 Clymer Owners Service & Repair Manual - Front Cover

Front Cover

Front Cover

Rear Cover

Rear Cover

description

Harley Davidson XL XLH Sportster 1986 - 2003 Clymer Owners Service & Repair Manual covers the following Sportster XL and XLH models:
● XLH883 (1986 - 2003)
● XLH883 Custom (1999 - 2003)
● XLH883 Deluxe (1986 - 1995)
● XLH883 Hugger (1987 - 2003)
● XL883R (2002 - 2003)
● XLH1100 (1986 - 1987)
● XLH1200 (1988 - 2003)
● XL1200 Custom (1996 - 2003)
● XL1200 Sport (1996 - 2003)

Contents:
QUICK REFERENCE DATA

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

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 / Specifications

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

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

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 / Specifications

PRIMARY DRIVE AND CLUTCH (1986-1990 MODELS)
Primary drive cover / Clutch release mechanism / Primary chain adjuster / Primary drive / clutch / Clutch cable / Specifications

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

FOUR-SPEED TRANSMISSION (1986-1990 MODELS)
Transmission / Shifter mechanism / Specifications

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

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

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

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 / Specifications

WHEELS, TYRES 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 / Tyres / Specifications

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

REAR SUSPENSION
Shock absorbers / Swing arm / Specifications

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 / Specifications

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

COLOUR WIRING DIAGRAMS

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.

General information on Repair Manuals

Please note that workshop manuals are usually written for models sold in a specific country. Differences in specification can exist between models sold in different countries and items such as engines can vary. Please check that the manual will cover your model before purchase and if you are unsure please contact us first.

product details

  • Publisher: Clymer Publications
  • ISBN: 1599691493 (1-599-69149-3)
  • ISBN-13: 9781599691497 (978-1-599-69149-7)
  • Format: Softcover, 640 pages
  • Date Published: 2008

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