Harley Davidson 1986-2003 XL/XLH Sportster. Service Manual — page 1

CHAPTER ONE

GENERAL INFORMATION

This

detailed and

comprehensive

manual covers

1986-2003 XL/XLH Sportster models. The text provides
complete information on maintenance, tune-up, repair and
overhaul. Hundreds of photos and drawings guide the
reader through every job.

A shop manual is a reference tool and as in all

Service

manuals, the chapters are thumb tabbed for easy reference.
Important items are indexed at the end of the book. All pro-
cedures, tables and figures are designed for the reader who
may be working on the motorcycle for the first time. Fre-
quently used specifications and capacities from individual
chapters are summarized in the

Quick Reference Data

at the

front of this manual.

MANUAL ORGANIZATION

All dimensions and capacities are expressed in U.S. stan-

dard and metric units of measurement.

Specifications, when applicable, are listed in the tables at

the end of each chapter.

This chapter covers shop safety, tool use, service funda-

mentals and shop supplies. Tables 1-12 at the end of the
chapter include the following:
1. Model designations.

2. General motorcycle dimensions.
3. Motorcycle weight

.

4. Gross vehicle weight.
5. Fuel tank capacity.
6. General torque recommendations.
7. Conversion formulas.
8. Technical abbreviations.
9. U.S. standard tap and drill sizes.
10. Metric tap and drill sizes.
11. Decimal and metric equivalents.
12. Special tools.

Chapter Two provides methods for quick and accurate di-

agnosis of problems. Troubleshooting procedures present
typical symptoms and logical methods to pinpoint and re-
pair the problem.

Chapter Three explains all routine maintenance neces-

sary to keep the motorcycle running well. Chapter Three
also includes recommended tune-up procedures, eliminat-
ing the need to constantly consult the chapters on the vari-
ous assemblies.

Subsequent chapters describe specific systems such as

engine, primary drive and clutch, transmission, emissions,
fuel and exhaust systems, the electrical system, suspension,
brakes and body. Each disassembly, repair and assembly
procedure is discussed in step-by-step form.

1

WARNINGS, CAUTIONS AND NOTES

The terms, WARNING, CAUTION and NOTE have spe-

cific meanings in this manual.

A WARNING emphasizes areas where injury or even

death could result from negligence. Mechanical damage
may also occur. WARNINGS

are to be taken seriously

.

A CAUTION emphasizes areas where equipment dam-

age could result. Disregarding a CAUTION could cause
permanent mechanical damage, though injury is unlikely.

A NOTE provides additional information to make a step

or procedure easier or clearer. Disregarding a NOTE could
cause inconvenience, but would not cause equipment dam-
age or personal injury.

SAFETY

Professional mechanics can work for years and never sus-

tain a serious injury or mishap. Follow these guidelines and
practice common sense to safely service the motorcycle.
1. Do not operate the motorcycle in an enclosed area. The
exhaust gasses contain carbon monoxide, an odorless, col-
orless and tasteless poisonous gas. Carbon monoxide levels
build quickly in small enclosed areas and can cause uncon-
sciousness and death in a short time. Make sure the work
area is properly ventilated or operate the motorcycle
outside.
2.

Never

use gasoline or any flammable liquid to clean

parts. Refer to

Handling Gasoline Safely

and

Cleaning

Parts

in this section.

3.

Never

smoke or use a torch in the vicinity of flammable

liquids.
4. If welding or brazing on the motorcycle, remove the fuel
tank, carburetor and shocks to a safe distance at least 50 ft.
(15 m) away.
5. Use the correct type and size tools to avoid damaging
fasteners.
6. Keep tools clean and in good condition. Replace or re-
pair worn or damaged equipment.
7. When loosening a tight fastener, be guided by what
would happen if the tool slips.
8. When replacing fasteners, make sure the new fasteners
are of the same size and strength as the original ones.
9. Keep the work area clean and organized.
10. Wear eye protection

any time

eye safety is in question.

This includes procedures involving drilling, grinding, ham-
mering, compressed air and chemicals.
11. Wear the correct clothing for the job. Tie up or cover
long hair so it can not get caught in moving equipment.
12. Do not carry sharp tools in clothing pockets.
13. Always have an approved fire extinguisher available.
Make sure it is rated for gasoline (Class B) and electrical
(Class C) fires.
14. Do not use compressed air to clean clothes, the motor-
cycle or the work area. Debris may be blown into your eyes
or skin.

Never

direct compressed air at anyone. Do not al-

low children to use or play with any compressed air
equipment.

15. When using compressed air to dry rotating parts, hold
the part so it can not rotate. Do not allow the force of the air
to spin the part. The air jet is capable of rotating parts at ex-
treme speed. The part may be damaged or disintegrate,
causing serious injury.

16. Do not inhale the dust created by brake pad and clutch
wear. These particles may contain asbestos. In addition,
some types of insulating materials and gaskets may contain
asbestos. Inhaling asbestos particles is hazardous to health.

17. Never work on the motorcycle while someone is work-
ing under it.

18. When placing the motorcycle on a stand, make sure it
is secure before walking away.

Handling Gasoline Safely

Gasoline is a volatile flammable liquid and is one of the

most dangerous items in the shop. Because gasoline is used
so often, many people forget that it is hazardous. Only use
gasoline as fuel for gasoline internal combustion engines.
Keep in mind, when working on a motorcycle, gasoline is
always present in the fuel tank, fuel line and carburetor. To
avoid an accident when working around the fuel system,
carefully observe the following precautions:

1.

Never

use gasoline to clean parts. See

Cleaning Parts

in

this section.

2. Wear protective gloves to prevent skin contact with gas-
oline. If your skin contacts gasoline, wash thoroughly with
soap and water.

3. When working on the fuel system, work outside or in a
well-ventilated area.

4. Do not add fuel to the fuel tank or service the fuel system
while the motorcycle is near open flames, sparks or where
someone is smoking. Gasoline vapor is heavier than air, it
collects in low areas and is more easily ignited than liquid
gasoline.

5. Allow the engine to cool completely before working on
any fuel system component.

2

CHAPTER ONE

1

6. When draining the carburetor, catch the fuel in a plastic
container and then pour it into an approved gasoline storage
devise.
7. Do not store gasoline in glass containers. If the glass
breaks, an explosion or fire may occur.
8. Immediately wipe up spilled gasoline with rags. Store
the rags in a metal container with a lid until they can be
properly disposed of, or place them outside in a safe place
for the fuel to evaporate.
9. Do not pour water onto a gasoline fire. Water spreads the
fire and makes it more difficult to put out. Use a class B, BC
or ABC fire extinguisher to extinguish the fire.
10. Always turn off the engine before refueling. Do not
spill fuel onto the engine or exhaust system. Do not overfill
the fuel tank. Leave an air space at the top of the tank to al-
low room for the fuel to expand due to temperature
fluctuations.

Cleaning Parts

Cleaning parts is one of the more tedious and difficult

service jobs performed in the home garage. There are many
types of chemical cleaners and solvents available for shop
use. Most are poisonous and extremely flammable. To pre-
vent chemical exposure, vapor buildup, fire and serious in-
jury, observe each product warning label and note the
following:

1. Read and observe the entire product label before using
any chemical. Always know what type of chemical is being
used and whether it is poisonous and/or flammable.

2. Do not use more than one type of cleaning solvent at a
time. If mixing chemicals is called for, measure the proper
amounts according to the manufacturer.

3. Work in a well-ventilated area.

4. Wear protective gloves.

5. Wear safety glasses.

6. Wear a vapor respirator if the instructions call for it.

7. Wash hands and arms thoroughly after cleaning parts.

8. Keep chemical products away from children and pets.

9. Thoroughly clean all oil, grease and cleaner residue
from any part that must be heated.

10. Use a nylon brush to clean parts. Metal brushes may
cause a spark.

11. When using a parts washer, only use the solvent recom-
mended by the manufacturer. Make sure the parts washer is
equipped with a metal lid that will lower in case of fire.

Warning Labels

Most manufacturers attach information and warning la-

bels to the motorcycle. These labels contain instructions
that are important to personal safety when operating, ser-
vicing, transporting and storing the motorcycle. Refer to
the owner’s manual for the description and location of la-
bels. Order replacement labels from the manufacturer if
they are missing or damaged.

SERIAL NUMBERS

Serial numbers are stamped on various locations on the

frame, engine and carburetor. Record these numbers in the

Quick Reference Data

section in the front of the book. Have

these numbers available when ordering parts.

The VIN number is stamped on the right side of the steer-

ing head (Figure 1). The VIN number also appears on a la-
bel affixed to the right, front frame downtube.

The engine serial number is stamped on a pad at the left

side surface of the crankcase between the cylinders (Figure
2). The engine serial number consists of digits used in the
VIN number.

The carburetor serial number (Figure 3) is located adja-

cent to the accelerator pump linkage.

NOTE

In addition to model year designations,
Harley-Davidson also uses early and late
model designations. Refer to the “Introduc-
tion Date and Special Models” information
in

Figure 4

to help determine the model iden-

tity of a motorcycle. If in doubt, take the VIN
number to a dealership.

GENERAL INFORMATION

3

1

2

3

FASTENERS

Proper fastener selection and installation is important to

ensure the motorcycle operates as designed and can be ser-
viced efficiently. The choice of original equipment fasten-
ers is not arrived at by chance. Make sure that replacement
fasteners meet all the same requirements as the originals.

Threaded Fasteners

WARNING

Do not install fasteners with a strength classi-
fication lower than what was originally in-
stalled by the manufacturer. Doing so may
cause equipment failure and/or damage.

Threaded fasteners secure most of the components on the

motorcycle. Most are tightened by turning them clockwise
(right-hand threads). If the normal rotation of the compo-
nent being tightened would loosen the fastener, it may have
left-hand threads. If a left-hand threaded fastener is used, it
is noted in the text.

Two dimensions are required to match the size of the fas-

tener: the number of threads in a given distance and the out-
side diameter of the threads.

Two systems are currently used to specify threaded fas-

tener dimensions: the U.S. Standard system and the metric
system (Figure 5). Pay particular attention when working
with unidentified fasteners; mismatching thread types can
damage threads.

4

CHAPTER ONE

4

VEHICLE IDENTIFICATION NUMBER (VIN)

(1986-2003 SPORTSTER)

Motorcycle

Made in U.S.A.

Model Designation

CA = XLH883, XLH883 Deluxe

(1986/1987), XLH1100,
XLH1200

CE = XLH883 Hugger
CF = XLH833 Deluxe
CG = XL1200 Custom
CH = XL1200 Sport
CJ = XLH883 Custom
CK = XLH883 Custom

Engine Size

M = 883 cc engine
N = 1100 cc engine
P = 1200 cc engine

Introduction Date and Special Models

1 = Regular introduction date
2 = Mid-year introduction date
3 = California model
4 = Special edition
5 = California-only special edition

VIN Check Digit

Varies; can be 0 through 9, or X.

Model Year

M = 1991
N = 1992
P = 1993
R = 1994
S = 1995
T = 1996
V = 1997
W = 1998
X = 1999
Y = 2000
1 = 2001
2 = 2002
3 = 2003

Serial Number

Assembly Plant

K = Kansas City
Y = York, Pennsyvania

Motorcycle Type

1 = Heavyweight (901 cc and larger engine displacement)
4 = Middleweight (351-900 cc engine displacement)

Manufacturer and Make

Harley Davidson

1

HD

4

CA

M

1

3

R

Y

Y

ENGINE LOWER END

201

5

7

TOP FRONT ENGINE MOUNT

1. Bolt
2. Lockwasher
3. Washer
4. Frame downtube
5. Nut plate
6. Engine
7. Bolt
8. Nut
9. Top front engine mount

10. Stud

8

9

8. Inspect the wiring harness for signs of damage that may
have occurred when removing the engine. Repair or replace
damaged wires as required.

Installation

1. Make sure the frame is supported properly before in-
stalling the engine. The jack and piece of plywood will not
be required until after the engine is resting in the frame.
2. Be sure all clamps or ties are in place before engine in-
stallation. See Figure 27 and Figure 28.
3. Lay out the engine mount plates and fasteners in the or-
der shown in Figure 22 and Figure 26.
4. If the frame protectors were removed, reinstall them.
5. Position all of the wiring connectors and hoses so that
they are out of the way when installing the engine.
6. Place the engine in the frame from the right side.
7. Slide the jack with the piece of plywood underneath the
engine. Use the jack to align the rear engine-to-frame
mounting holes. Insert the lower engine dowel pins into the
rear frame engine mount bracket as shown in Figure 29.
8. Apply an antiseize lubricant to all of the engine mount-
ing bolts prior to installation.
9. To install the rear engine mount assembly (Figure 26),
perform the following:

a. Install a flat washer on the two upper engine mount

bolts and install the bolts through the frame and en-
gine. Install the locknut and washer on the right bolt.
Install the hex nut and washer on the left bolt. Do not
install the battery ground cable at this time.

b. Install a lockwasher and flat washer on the two lower

engine mount bolts and install the bolts through the
frame and thread into the engine hand-tight.

10. Install the left and right lower front engine mount
plates, bolts, washers and nuts as shown in Figure 22.
Tighten the bolts hand-tight.
11. Tighten the rear engine mounting bolts and nuts (Fig-
ure 26) to 25-30 ft.-lb. (34-41 N•m).
12. Tighten the lower front engine bolts (A, Figure 30) to
25-30 ft.-lb. (34-41 N•m). Tighten the lower front frame
bolts (B, Figure 30) to 25-30 ft.-lb. (34-41 N•m).
13. Install the top center engine mount assembly (Figure
31) as follows:

a. Install the top center engine mount bolts and washers

through the engine mount.

b. Place the shim (if used) onto the top center engine

mount bolts.

NOTE

Three different shim thicknesses are avail-
able: 0.030 in. (0.076 mm), 0.060 in. (1.52
mm) and 0.090 in. (2.27 mm). When installing
an engine that did not have any major compo-
nents replaced (engine cases, cylinder heads,
top center engine mount or frame), the origi-
nal thickness shim can be installed. If one of

202

CHAPTER FIVE

10

11

12

13

ENGINE LOWER END

203

5

14

15

16

17

18

VOLTAGE REGULATOR

(1994-2003 MODELS)

1. Nut
2. Lockwasher
3. Frame dwontube
4. 1-pin connector

(charging wire to
main circuit breaker)

5. 2-pin connector

(voltage regulator to
alternator stator)

6. Lockwasher
7. Bolt
8. Voltage regulator