Harley Davidson Motorcycle Sportster workshop manuals Motorbike workshop manuals

Harley Davidson Motorcycle Sportster workshop manuals

The Harley-Davidson Sportster are a type of motorbikes created constantly since 1957 by Harley-Davidson. Sportster motorbikes were running on a four-stroke, 45° V-twin system where both linking rods, regarding the "fork and blade" or "knife & fork" build, share a common

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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 DOES NOT include XR-1000 engine information or 2009-on XR models. Contents * Living With Your Harley Davidson - 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 - Tyre 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 - Tyres - Frame and Bodywork * Electrical System - Colour Wiring Diagrams more here.....

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(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 / 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 lots more

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DOES NOT include XR1200 Contents: * AMENDMENT On the 2/1 edition page X (QRD) and page 538 have been changed to note the engine oil capacity on: * 2008 - 2009 models is 2.8 qt (2.65 litre) * 2004 - 2007 models the capacity is 3.6 qt. (3.4 litre) * QUICK REFERENCE DATA * GENERAL INFORMATION Manual organization / Warnings cautions and notes / Safety / Serial numbers / Fasteners / Shop supplies / Tools / Measuring tools / Electrical system fundamentals / Basic service methods / Storage / Specifications * TROUBLESHOOTING Engine operating requirements / Engine starting / Engine performance / Starting system / Charging system / Ignition system / Electronic diagnostic system / Fuel system / Engine noises / Engine lubrication / Clutch / Transmission / Excessive vibration / Suspension and steering / Brakes / Specifications * LUBRICATION MAINTENANCE AND TUNE-UP Fuel type / models) / Main drive gear / Crankcase bearing / Transmission drive sprocket / Specifications * FUEL EMISSION CONTROL AND EXHAUST SYSTEMS Air filter backplate / Carburetor / Intake manifold / Fuel hose and clamps / Throttle and idle cables / Starting enrichment valve (choke) / cable replacement / Fuel extra info

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Sportster (1959-1969) * Harley-Davidson XLCH Sportster (1970-1980) * Harley-Davidson XLH Sportster (1970-1972 1978-1985) * Harley-Davidson XLCR Sportster (1977-1978) * Harley-Davidson XLX Sportster (1983-1985) * Harley-Davidson XLS Sportster (1980-1985) * Harley-Davidson XL Sportster (1973-1977) Contents: * QUICK REFERENCE DATA * GENERAL INFORMATION * TROUBLESHOOTING * PERIODIC LUBRICATION MAINTENANCE AND TUNE-UP Maintenance schedule intervals / Periodic lubrication / Engine oil and filter change / Periodic maintenance / Suspension adjustment / Breaker point ignition service / Magneto / Breakerless ignition system / Carburetor adjustments * ENGINE Removal installation / Pushrods / Valves and components / Cylinder / Oil pump / Gearcase / Tappets and guides / Crankcase / Drive sprocket and seal / Engine seals / Starter drive shaft and housing / Specifications * CLUTCH WIRING DIAGRAMS more advice

The Harley-Davidson Sportster are a type of motorbikes created constantly since 1957 by Harley-Davidson. Sportster designs were designated in Harley-Davidson's item rule by starting with "XL". In 1952, the predecessors towards the Sportster, the design K Sport and recreation Solo motorcycles, are launched. These models K, KK, KH, and KHK of 1952 to 1956 had a sidevalve engine, whereas the later XL Sportster designs make use of an overhead valve system. The first Sportster in 1957 have most same information on the KH such as the frame, fenders, huge gas tank and forward suspension system.

Sportster motorbikes were running on a four-stroke, 45° V-twin system where both linking rods, regarding the "fork and blade" or "knife & fork" build, share a common crank pin. The original Sportster motor ended up being the Ironhead motor, that has been replaced utilizing the development motor in 1986. Sportster engines, the 45 cubic inch R, D, grams & W products 1929 side-valve engines, additionally the 'gigantic Twin' side-valve motors, that have been: the flathead 74.0 cu in brands V, VL etc., versions U and UL, while the 80.0 cu in brands VH and VLH, versions UH and ULH need four separate webcams, sporting one lobe per cam.

The cam followers found in Sportster motors, K systems, big double side valve systems, therefore the side-valve W model show were a slightly smaller form of the supporters used in the more expensive motors, however with the exact same 0.731-inch diameter system and 0.855-inch diameter roller follower since 1929. The business made use of close cam supporters for decades with minor modifications, from the 1929 towards the Eighties.
A typical 5-gear, foot-shift transmission on an HD Sportster

Sportster engines retained the K/KH design crankcase build, where transmission was included in the exact same casting given that motor, and driven because of the engine with a triple-row #35 string main drive and a multi-plate cable-operated clutch. Systems since 1991 have five rates; 1990 and prior products have four rates.

The engine ended up being attached right to the frame from 1957 through 2003 design 12 months. Although this system allows the bicycle becoming notably lighter with increased accurate handling, it transmits motor vibration directly to the rider. Sportsters introduced in 2004 and later use plastic isolation mounts and link hyperlinks to restrict engine movement to one jet, which considerably lowers vibration felt by the rider. Buell motorbikes constructed with variants of this Sportster motor purchased a rubber mount system since 1987.

The design K, from where the Sportster developed, had been 1st civil motorcycle made by Harley-Davidson with hydraulic surprise absorbers on both rims. Typical consumption calls this a K Model.

This can be created from previous 45 W model, but with the revised flat-head motor and new 4-speed transmission included in the same castings as would get to be the Sportster. The connecting rods could be passed down because of the Sportster and many other build elements and measurements.

Design K and KK 1952–1953: 750 cc side-valve motors, using the 45 design bore and stroke of 2.75" x 3.8125"
Design KR 1953–1969: 750 cc side-valve engines
Model KH and KHK 1954–1956: 888 cc side-valve machines, using the 45 model bore, but with the stroke increased to 4.5625". This is basically the best tiny twin with an extended swing than 3.8125". The shorter stroke is otherwise universal into the whole 45/K/Sportster range from 1929 to the present.

XL show Sportsters

XL, Ironhead, 1957–1985: 883 cc and 1,000 cc Ironhead overhead-valve machines with cast-iron minds, K-series framework
XLCH, Ironhead, 1958–1971: 883 cc, and 1,000 cc 1972 & up
XR-750 1970–1971: 750 cc overhead-valve engine, iron minds
XR-750 1972–1985: 750 cc overhead-valve system, alloy minds
XLCR 1977–1978-1979: Cafe racer 1,000 cc overhead-valve engine, iron heads, 2000 built in 77, 1200 in 78, and 9 in 1979
XR-1000 1983–1984: 1,000 cc road design utilizing XR racing cylinder mind and other XR motor parts
XLR: 883 cc overhead-valve engines, metal heads

XLS Roadster 1979-1982 1000cc ironhead / 4 speed, stock elements—2" longer forks, 2 up seat, sissy bar, highway pegs, 3.3 gallon container

XLS Roadster, 1983-1985, 1,000 cc ironhead, 4 gallon gas tank with console
XL, Evolution, since 1986: 883 cc, 1,100 cc and 1,200 cc Evolution overhead-valve motor, alloy heads


1957 "Ironhead" overhead-valve engine introduced.
1958 XLH touring high compression design and XLCH sportier "competitors Hot" design launched.
1972 "Ironhead" 1,000 cc overhead-valve engine replaces 900 cc. Stated power had been 61 hp @ 6,200 rpm and a premier speeds of 116 mph
1975 Switched to left-side gear change
1977 & 1979 Dual fatigue "Siamese" pipes put, introduced on Willie G. Davidson's XLCR café racer in 1977 all products 1979, together with the triangular framework and back hydraulic disk brake additionally introduced regarding XLCR. In 1977 a restricted version Confederate version Sportster had been launched for starters 12 months best.
1979 a year ago for the kickstart only XLCH, just 141 made.
1985 a year ago when it comes to "Ironhead" overhead-valve engine.
1986 "Evolution" motor launched in 883 cc and 1,100 cc models.
1988 1200 cc motor replaces 1,100 cc motor.
1988 Constant velocity carburetor replaces butterfly carburetor.
1991 Five-speed transmission replaces four-speed.
1991 Belt drive replaces string drive on 883 luxurious and all 1200 models.
1993 gear drive made standard on all Sportsters.
1994 Improved oils tank, electric battery tray, and clutch made standard.
1994 brand new electrical program with sealed connections.
1995 Speedometer is digital, not technical.
1996 XL1200C Custom model introduced.
1998 XL1200S gets double spark-plug heads and high end cameras
2000 launched sealed wheel bearings and up-to-date four-piston brake calipers.
2003 Last year when it comes to framework installed Evolution engine.
2004 All-new frame like rubber-mounted engine for diminished vibration. Reduction of the transmission trap door, New form hamcan, fatigue stability pipeline moved from run in air conditioning filter and disguised and concealed behind the silencers showing a lot more of engine, newer smoother design oils container right-side panel with push and turn filler/dipstick, as well as the earlier subjected power happens to be enclosed in a matching part panel in the remaining
2005 Enlarged back axle to at least one inches for increased security.
2006 unique XR1200 are established at Intermot in Cologne, Germany. The XR1200 may be the very first Harley-Davidson to work well with Down Draft DDFI II fuel shot. Become revealed as a late 2006 model. Introduction of helical gears in transmission.
2007 gasoline injection replaces carburetion on all systems.
2008 forward axle enlarged from 3/4 inch to 25 mm, rear axle decreased from 1 inches to 25 mm
2009 "One dimensions fits all" forward mudguard approach changed by enhanced mudguard contour to suit each model's particular wheel diameters.
2010 The ECU is relocated to permit most difference in aftermarket chair choice
2010 Side-mounted license dish option on some versions
2014 newer electric harness, newer bigger brakes, antilock brake system solution, keyless entry, newer speedometer with equipment indicator/tachometer, increased engine compression proportion, catalytic converter


With an unbroken manufacturing run of 53 years, the overhead valve Harley-Davidson Sportster have outlived most of their very early competitors, and is still in a position to raise its middle finger towards vagaries of this motorcycle marketplace. Driving a 2010 design immediately channels initial Sportster of 1957, although the characteristic motor vibes have now been softened by rubberized mountings.

The Sportster is an instant hit-in 1957, but by the 70s it was showing their age. Imports effortlessly outperformed and outsold it. In a pattern magazine seven-bike shootout in 1973, the XL Sportster placed lifeless final overall and propped within the various other six bikes in nearly every performance group. However, reviewers liked its torquey, long-legged highway operating and simple in-town visitors ways. They also liked its conventional styling and offbeat engine noise.

The Sportster’s future had been written, much less a competition toward all-conquering four-across-the-frame Universal Japanese bike, but as a bastion of American durability and timeless design. So why can you desire a person today?
Conception and birth

Introduced in 1952, the model K was really a WL bottom end up in device construction problems with a dry clutch and 4-speed transmission. At the top end were brand-new alloy, side-valve heads. Cylinders were iron, and displacement ended up being 45ci. The system showcased a right-side leg shifter — a primary for H-D — and a new frame with a swingarm rear end. For 1954, the swing ended up being lengthened to an impressive 4.56 ins for 887cc, or 54ci, in addition to new model designated KH. Increased overall performance KHK with hot cams and polished harbors arrived in 1955.

But flathead machines were brief in power, and an alteration had been needed seriously to match the Brits. The 1957 XL Sportster have overhead-valve minds even though the crank utilized the model K’s faster swing with a more substantial 3-inch bore for 883cc. Energy had been around 40hp on crank, which propelled the 460-pound machine to more than 90mph. Finally, here is an American bike that may compete with the Limeys.

For 1958, the XLCH activities design arrived, essentially a stripped-down XL, but with the identical engine requirements. To save lots of body weight, the XL’s battery was eliminated, with sparks and lighting via a magneto/generator. Only minor modifications are made-up to 1964 when brand-new full-width aluminum hubs arrived, but nevertheless with single-leading-shoe drum brake system. Electricity starting is added to the XLH in 1967. The XLH shed its kickstarter entirely the next 12 months, whilst XLCH remained kickstart best. The XLCH in addition moved battery/coil ignition in 1970, and both products turned to a wet clutch in 1971.


XL900 the first middle compression version
XLH900 identical to the typical XL however with the "H" denoting the high-compression engine
XLC900 off road form of the XL, The XLC features magneto ignition and kickstart only.
XLCH900 off road version of the XLH - or even the XLC because of the high compression engine! - the "CH" denoting "competition/high-compression". after annually lights, speedo and complete roadway legal specs arrived.
XLX-61 an entry level "Ironhead" era Sportster, readily available with simple trim, in black colored with black exhaust and handlebars or red with chrome exhaust and handlebars.
XLS1000
XLT1000 "Tourer" 1977 special model have a Superglide tank, display, larger seat and panniers
XLCH, XLH and XT types of the 1977 Harley-Davidson Confederate version that had commemorative paint and tank and fender decals. Very low amount production of only 45 XLCH, 229 XLH and 15 XT brands.
XLCR1000 "Cafe Racer" may be the Cafe Racer model, obtainable in 1977 and 1978.
XR1000, two-high rise flat track design exhausts on the remaining as well as 2 staggered K&N kind filters feeding Dell'Orto carburetors regarding right. Had a 1,000 cc motor and a variety of XLX Sportster and changed XR-750 parts.
XLH883 -
XLH1100
XLH1200
XLH883 "Deluxe", double chair, tachometer, buckhorn pubs, and spoke tires
XLH883 "Hugger", with minimal single chair level and paid off suspension, the precursor towards "XL reasonable" systems
XL53C "Customized 53" XL883C "Custom" '98–'03, Forward-controls, duelseat, solid rear wheel and drag taverns mounted on a riser. This became the XL883C "Personalized" internationally aided by the '04 rubbermount variation
XL883 "Sportster 883" single seat standard design, mid-controls, 13-spoke mags or wires
XL883C "Custom" possess broader, slimmer "personalized" tank, forward-controls, duelseat and 21-inch wire and 16-inch solid disk wheels
XL1200C "Custom" framework mount designs had a chunkier duelseat and regular tank, plastic mounts get smoother chair and flatter larger "personalized" tank, all need 21-inch line and 16-inch slotted disc wheels and forward-controls
XL883L "Low"; solitary chair, suprisingly low shocks, mid-controls, 13-spoke mags or cables
XL1200L "minimum"; Dualseat, middle bumps, mid-controls, larger slimmer "Customized" container, 13-spoke mags or wires
XL1200S "recreation" – this Sportster has actually flexible suspension with piggyback shox, double disc forward brakes, hotter cams and 13-spoke mags, later on models get twin connect cylinder heads with single-fire ignition
XL883R "Roadster" framework attach designs posses a 2–1 fatigue, 13-spoke mags, black motor consequently they are available in orange with 'R' layouts, rubber mounts bring 2–2 fatigue, somewhat various dualseat, line wheel alternative and much more 'R' colors, all have triple disks and rev-counter. This year, the XL883R officially gets the "Roadster" suffix
XL1200R "Roadster" Ebony motor with highlighted fins, triple disks, rev-counter, orange paint offered but no 'R' artwork and '08 designs get the wide flatter "custom" tank which distance they further from the 883R
XL50 1200 "50th Anniversary" 2007 limited creation of 2,000 brands
XL1200N "Nightster" first of the deep traditions, combined LED tail/brake/indicator lights, tapered silencers and part attached LED lit licence dish, 11-inch shocks, and baloney slice silencers, mid-controls and wire tires
XL883N "metal 883", blacked away 883 similar to the Nightster with increased black colored and 13-spoke mags, mid-controls.
XR1200 More recreations focused "Euro" style bicycle, male-slider forks, reworked Sportster engine with XR minds, new chassis, four-pot dual disks, 120/70-18 and 180/55-17 separate 3-spoke mags, rear-controls - features its own race show
XL1200X "Forty-Eight", when you look at the "Dark" Nightster design but gets the classic 1948 style small peanut container, wire rims, forward-controls, another 130 mm front tire, and extremely little single seat
XR1200X beginning as a XR1200 with piggyback/fully flexible shocks, totally adjustable front end, available in either Black Denim or light Denim paint colors
XL883L "SuperLow", brand-new for 2011 have black split 5-spoke mags with polished wheels and 120/70-18 and 150/60-17 tires, wider slimmer "Personalized" container, mid-controls
XL1200C "1200 Customized" Since 2011 possess a 130/90B16 front tyre, wider forward end, 5-spoke mags, brand-new form eyebrow, wider slimmer "Personalized" tank and introduces "H-D1".
XL1200V "72" revolutionary Chopper with build empowered because of the classic styling associated with early '70s chopper/bobbers that were prevalent during this time. Bicycle has got the chopper bobber looks, rough Candy Personalized paint was recommended.

Nightster
2008 XL1200N Nightster

Introduced in 2007, the XL1200N Nightster included unique elements such as for instance a bobbed rear fender, front hand gaiters, and a part mount license dish. The riding position and 25.3-inch seat height associated with the Nightster are the same as those of the XL883L Sportster minimal - UNITED KINGDOM version possess central quantity dish, 13.5-inch rear shocks, tapering silencers, and blended LED indicator/tail/brake lighting. The bike features a measured HP of 57.2 hp and 64.4 lb·ft and a high speeds of 107 miles per hour and a wet fat of 564 lb.

The Harley metal was released during 2009 as a smaller sized displacement type of the Nightster. The most important variations become blacked out system, throw rims in the place of laced; narrower handlebars; not to mention small motor displacement.
XR1200
2010 Harley-Davidson XR1200 Sportster

In the 2008 model 12 months, Harley-Davidson introduced the XR1200 Sportster in Europe, Africa, together with Middle East. The XR1200 had an Evolution motor tuned to make 91 bhp, four-piston dual front disk brakes, and an aluminum move arm. Motorcyclist have the XR1200 on the cover of their July 2008 problems, and ended up being typically good about any of it within their "very first Ride" tale, by which Harley-Davidson is repeatedly requested to offer it in the usa. One feasible basis for the delayed supply in the usa ended up being the fact that Harley-Davidson had to obtain the "XR1200" naming legal rights from Storz overall performance, a Harley modifying shop in Ventura, Calif. The XR1200 premiered in the usa last year, in an unique colors system like Mirage lime highlighting its dirt-tracker history. 1st 750 XR1200 designs last year were pre-ordered and included a number 1 label for the front side of the bicycle, autographed by Kenny Coolbeth and Scott Parker and a thank you/welcome letter from Harley-Davidson, finalized by costs Davidson. The XR1200 was stopped on usa Market for the 2013 lineup. The bicycle have a measured HP of 79.26 hp and 67.53 lb·ft and a premier speed of 120.7 mphand a wet weight of 580 lb.
Forty-Eight
Harley-Davidson Sportster Forty-Eight

Inside 2010 model year, Harley-Davidson launched the XL1200X "Forty-Eight" design. It's just like the "Dark" Nightster design but has the classic 1948 style small peanut tank, cable tires, forward-controls, a wider forward tire with a fat front end and chopped forward fender, a slammed speedo with under mount mirrors, low solamente solitary seat, and reduced suspension system.
Seventy-Two

Into the 2012 design 12 months, Harley-Davidson introduced the XL1200V "Seventy-Two" design. It offers the classic styling of early '70s chopper/bobbers that have been prevalent during this time period. It offers the peanut vehicle's gas tank, cable rims, white-wall tires, forward-controls, some additional rake and slightly much longer front forks, a chopped backside fender, side-mounted permit plate, reasonable solamente single chair, mini-ape hanger handlebars, and lowest suspension. The cycle have a measured HP of 54.67 hp and 59.81 lb·ft and a high rate of 108 miles per hour with a wet fat of 559.5 lb.
Roadster

In the 2016 design 12 months, Harley-Davidson introduced the XL1200CX "Roadster" model. This is the stylish Sportster it's café bike styling and position. With mid-position pegs and a slammed drag club provide a small lean forward operating place. A 43mm inverted cartridge hand plus the rear preload-adjustable emulsion-type shocks assist the roadster to truly have the greatest slim direction of any Sportster. In addition double 300mm drifting discs and a tach and speedo. The bike has actually a measured HP of 65.4 hp and 69.7 lb·ft.
Existing versions

The Sportster exists in many different the latest models of. The 2016 brands, that are not all offered in the same region, is:

SuperLow - XL883L
Metal 883 - XL883N
883 Roadster - XL883R
1200 Customized - XL1200C
SuperLow 1200T - XL1200T
Forty-Eight - XL1200X
Seventy-Two - XL1200V
Roadster - XL1200CX

Buell
1999 Buell M2 Cyclone 1203cc sportster motor

Buell going with water-cooled two-stroke square-fours and finished with a water-cooled four-stroke V-Twin, although vast majority of these bikes used reworked 883 and 1200 Sportster machines. With Buell-designed heads, drums, plus in 1999 gasoline injection, these all resulted in a increase in horse power. They even have plastic mounting and a fan that cools the trunk cylinder.

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