Content .. 2 3 4 5 ..

Harley Davidson 1986-2003 XL/XLH Sportster. Service Manual - page 4

Table 2 GENERAL DIMENSIONS (continued)

XLH883, XLH883 Deluxe (continued)

Width

1986-1994 models

32 in. (813 mm)

1995-2003 models

33 in. (838 mm)

Height

1986-2001 models

47.5 in. (1207 mm)

2002-2003 models

49.5 in. (1257 mm)

Ground clearance

1986-1994 models

6.75 in. (171.5 mm)

1995-2003 models

6.70 in. (170 mm)

XLH883 Custom

Wheelbase

59.0 in. (1499 mm)

Length

1999-2001 models

87.25 in. (2216 mm)

2002-2003 models

89.0 in. (2261 mm)

Width

35 in. (889 mm)

Height

49.75 in. (1264 mm)

Ground clearance

6.70 in. (170 mm)

XLH883 Hugger

Wheelbase

1986-1992 models

60.5 in. (1537 mm)

1993-2003 models

59.0 in. (1499 mm)

Length

1986-1991 models

87.6 in. (2225 mm)

1992-2001 models

87.25 in. (2216 mm)

2002-2003 models

88.0 in. (2235 mm)

Width

1986-1994 models

33 in. (838 mm)

1995-2003 models

35 in. (889 mm)

Height

49.75 in. (1264 mm)

Ground clearance

1986-1992 models

5.9 in. (150 mm)

1993-2001 models

4.5 in. (114 mm)

2002-2003 models

4.7 in. (119 mm)

XL883R

Wheelbase

60.0 in. (1524 mm)

Length

88.1 in. (2238 mm)

Width

33.0 in. (838 mm)

Height

47.5 in. (1207 mm)

Ground clearance

6.70 in. (170 mm)

XLH1100

Wheelbase

60.2 in. (1529 mm)

Length

87.6 in. (2225 mm)

Width

33 in. (838 mm)

Height

49.75 in. (1264 mm)

Ground clearance

6.75 in. (171.5 mm)

XLH1200

Wheelbase

60.2 in. (1529 mm)

Length

87.6 in. (2225 mm)

Width

33 in. (838 mm)

Height

49.75 in. (1264 mm)

Ground clearance

6.75 in. (171.5 mm)

XL1200 Custom

Wheelbase

59.0 in. (1499 mm)

Length

1996-2001 models

87.25 in. (2216 mm)

2002-2003 models

88.0 in. (2235 mm)

Width

35 in. (889 mm)

Height

49.75 in. (1264 mm)

Ground clearance

6.70 in. (170 mm)

XL1200 Sport

Wheelbase

60.2 in. (1529 mm)

Length

1996-2001 models

87.6 in. (2225 mm)

2002-2003 models

88.5 in. (2248 mm)

(continued)

GENERAL INFORMATION

Table 2 GENERAL DIMENSIONS (continued)

XL1200 Sport (continued)

Width

1996-2001 models

35 in. (889 mm)

2002-2003 models

33 in. (838 mm)

Height

1996-2001 models

49.75 in. (1264 mm)

2002-2003 models

49.5 in. (1257 mm)

Ground clearance

6.70 in. (170 mm)

Table 3 OVERALL MOTORCYCLE WEIGHT

XLH883

1986-1990 models

463 lb. (210 kg)

1991-1993 models

472 lb. (214 kg)

1994-2003 models

488 lb. (221 kg)

XLH883 Custom

489 lb. (222 kg)

XLH883 Deluxe

1986-1990 models

463 lb. (210 kg)

1991-1993 models

484 lb. (220 kg)

1994 models

494 lb. (224 kg)

XLH883 Hugger

1987-1990 models

463 lb. (210 kg)

1991-1993 models

472 lb. (214 kg)

1994-2003 models

485 lb. (220 kg)

XL883R

503 lb. (228 kg)

XLH1100

457 lb. (207 kg)

XLH1200

1988-1990 models

457 lb. (207 kg)

1991-1993 models

470 lb. (213 kg)

1994-1996 models

490 lb. (222 kg)

1997-1998 models

494 lb. (224 kg)

1999-2003 models

491 lb. (223 kg)

XL1200 Custom

1996-1998 models

483 lb. (219 kg)

1999-2003 models

491 lb. (223 kg)

XL1200 Sport

1996-1998 models

497 lb. (225 kg)

1997-2003 models

501 lb. (227 kg)

Table 4 VEHICLE WEIGHT

Gross vehicle weight rating (GVWR)*

1986-1994 models

900 lb. (408 kg)

1995-2003 models

948 lb. (430 kg)

Gross axle weight ratings (GAWR)

Front

1986-1994 models

320 lb. (145 kg)

1995-2003 models

353 lb. (160 kg)

Rear

1986-1994 models

580 lb. (263 kg)

1995-2003 models

595 lb. (270 kg)

*GVWR is the combined weight of the vehicle, rider(s) and accessories.

Table 5 FUEL TANK CAPACITY

Gal.

Liters

1986-1994 models

Total

2.25

8.5

Reserve

0.25

0.9

(continued)

CHAPTER ONE

Table 5 FUEL TANK CAPACITY (continued)

Gal.

Liters

1995-1996 models

XLH883/XLH883 Hugger

Total

2.25

8.5

Reserve

0.25

0.9

All other models

Total

3.30

12.5

Reserve

0.50

1.8

1997-2003 models

Total

3.30

12.4

Reserve

0.50

1.8

Table 6 GENERAL TORQUE RECOMMENDATIONS (ft.-lb.)

Type

1/4

5/16

3/8

7/16

1/2

9/16

5/8

3/4

7/8

SAE 2

155

206

310

SAE 5

114

154

257

382

587

SAE 7

110

154

215

360

570

840

SAE 8

119

169

230

380

600

700

1. Convert ft.-lb. specification to N•m by multiplying by 1.3558.
2. Fastener strength of SAE bolts can be determined by the bolt head grade markings. Unmarked bolt heads and cap screws
are usually mild steel. More grade markings indicate higher fastener quality.

Table 7 CONVERSION FORMULAS

Multiply:

By:

To get the equivalent of:

Length

Inches

25.4

Millimeter

Inches

2.54

Centimeter

Miles

1.609

Kilometer

Feet

0.3048

Meter

Millimeter

0.03937

Inches

Centimeter

0.3937

Inches

Kilometer

0.6214

Mile

Meter

3.281

Feet

Fluid volume

U.S. quarts

0.9463

Liters

U.S. gallons

3.785

Liters

U.S. ounces

29.573529

Milliliters

Imperial gallons

4.54609

Liters

Imperial quarts

1.1365

Liters

0.2641721

U.S. gallons

Liters

1.0566882

U.S. quarts

Liters

33.814023

U.S. ounces

Liters

0.22

Imperial gallons

Liters

0.8799

Imperial quarts

Milliliters

0.033814

U.S. ounces

Milliliters

1.0

Cubic centimeters

Milliliters

0.001

Liters

(continued)

GENERAL INFORMATION

SAE 2

SAE 7

SAE 5

SAE 8

Table 7 CONVERSION FORMULAS continued)

Multiply:

By:

To get the equivalent of:

Torque

Foot-pounds

1.3558

Newton-meters

Foot-pounds

0.138255

Meters-kilograms

Inch-pounds

0.11299

Newton-meters

0.7375622

Foot-pounds

Newton-meters

8.8507

Inch-pounds

Meters-kilograms

7.2330139

Foot-pounds

Volume

Cubic inches

16.387064

Cubic centimeters

0.0610237

Cubic inches

Temperature

Fahrenheit

(°F

–

32)

0.556

Centigrade

(°C

1.8)

Fahrenheit

Weight

Ounces

28.3495

Grams

Pounds

0.4535924

Kilograms

Grams

0.035274

Ounces

Kilograms

2.2046224

Pounds

Pressure

Pounds per square inch

0.070307

Kilograms per

square centimeter

Kilograms per square

14.223343

Pounds per square inch

centimeter

Kilopascals

0.1450

Pounds per square inch

6.895

Kilopascals

Speed

Miles per hour

1.609344

Kilometers per hour

0.6213712

Miles per hour

Table 8 TECHNICAL ABBREVIATIONS

Ampere

Alternating current

A• h

Ampere hour

Celsius

Cubic centimeter

CDI

Capacitor discharge ignition

Centimeter

cu. in.

Cubic inch and cubic inches

cyl.

Cylinder

Direct current

Fahrenheit

fl. oz.

Fluid ounces

ft.

Foot

ft.-lb.

Foot pounds

gal.

Gallon and gallons

Horsepower

Hertz

in.

Inch and inches

in.-lb.

Inch-pounds

in. Hg

Inches of mercury

Kilogram

kg/cm

Kilogram per square centimeter

kgm

Kilogram meter

Kilometer

km/h

Kilometer per hour

kPa

Kilopascals

Kilowatt

Liter and liters

L/m

Liters per minute

lb.

Pound and pounds

Meter

MAP

Manifold absolute pressure

(continued)

CHAPTER ONE

Table 8 TECHNICAL ABBREVIATIONS (continued)

Milliliter

Millimeter

MPa

Megapascal

Newton

N• m

Newton meter

oz.

Ounce and ounces

Pascal

psi

Pounds per square inch

pt.

Pint and pints

qt.

Quart and quarts

rpm

Revolution per minute

TDC

Top dead center

Volt

VAC

Alternating current voltage

VDC

Direct current voltage

Watt

Table 9 AMERICAN TAP AND DRILL SIZES

Tap thread

Drill size

Tap thread

Drill size

#0-80

3/64

1/4-28

No. 3

#1-64

No. 53

5/16-18

#1-72

No. 53

5/16-24

#2-56

No. 51

3/8-16

5/16

#2-64

No. 50

3/8-24

#3-48

5/64

7/16-14

#3-56

No. 46

7/16-20

#4-40

No. 43

1/2-13

27/64

#4-48

No. 42

1/2-20

29/64

#5-40

No. 39

9/16-12

31/64

#5-44

No. 37

9/16-18

33/64

#6-32

No. 36

5/8-11

17/32

#6-40

No. 33

5/18-18

37/64

#8-32

No. 29

3/4-10

21/32

#8-36

No. 29

3/4-16

11/16

#10-24

No. 25

7/8-9

49/64

#10-32

No. 21

7/8-14

13/16

#12-24

No. 17

1-8

7/8

#12-28

No. 15

1-14

15/16

1/4-20

No. 8

Table 10 METRIC TAP AND DRILL SIZES

Metric

Drill

Decimal

size

equivalent

fraction

Nearest fraction

0.50

No. 39

0.0995

3/32

0.60

3/32

0.0937

3/32

0.70

No. 30

0.1285

1/8

0.75

1/8

0.125

1/8

0.80

No. 19

0.166

11/64

0.90

No. 20

0.161

5/32

1.00

No. 9

0.196

13/64

1.00

16/64

0.234

15/64

1.00

0.277

9/32

1.25

17/64

0.265

17/64

1.00

5/16

0.3125

5/16

1.25

5/16

0.3125

5/16

1.25

11/32

0.3437

11/32

1.50

0.339

11/32

1.50

3/8

0.375

3/8

1.50

13/32

0.406

13/32

1.75

13/32

0.406

13/32

GENERAL INFORMATION

Table 11 DECIMAL AND METRIC EQUIVALENTS

Decimal

Metric

Decimal

Metric

Fractions

in.

Fractions

in.

1/64

0.015625

0.39688

33/64

0.515625

13.09687

1/32

0.03125

0.79375

17/32

0.53125

13.49375

3/64

0.046875

1.19062

35/64

0.546875

13.89062

1/16

0.0625

1.58750

9/16

0.5625

14.28750

5/64

0.078125

1.98437

37/64

0.578125

14.68437

3/32

0.09375

2.38125

19/32

0.59375

15.08125

7/64

0.109375

2.77812

39/64

0.609375

15.47812

1/8

0.125

3.1750

5/8

0.625

15.87500

9/64

0.140625

3.57187

41/64

0.640625

16.27187

5/32

0.15625

3.96875

21/32

0.65625

16.66875

11/64

0.171875

4.36562

43/64

0.671875

17.06562

3/16

0.1875

4.76250

11/16

0.6875

17.46250

13/64

0.203125

5.15937

45/64

0.703125

17.85937

7/32

0.21875

5.55625

23/32

0.71875

18.25625

15/64

0.234375

5.95312

47/64

0.734375

18.65312

1/4

0.250

6.35000

3/4

0.750

19.05000

17/64

0.265625

6.74687

49/64

0.765625

19.44687

9/32

0.28125

7.14375

25/32

0.78125

19.84375

19/64

0.296875

7.54062

51/64

0.796875

20.24062

5/16

0.3125

7.93750

13/16

0.8125

20.63750

21/64

0.328125

8.33437

53/64

0.828125

21.03437

11/32

0.34375

8.73125

27/32

0.84375

21.43125

23/64

0.359375

9.12812

55/64

0.859375

22.82812

3/8

0.375

9.52500

7/8

0.875

22.22500

25/64

0.390625

9.92187

57/64

0.890625

22.62187

13/32

0.40625

10.31875

29/32

0.90625

23.01875

27/64

0.421875

10.71562

59/64

0.921875

23.41562

7/16

0.4375

11.11250

15/16

0.9375

23.81250

29/64

0.453125

11.50937

61/64

0.953125

24.20937

15/32

0.46875

11.90625

31/32

0.96875

24.60625

31/64

0.484375

12.30312

63/64

0.984375

25.00312

1/2

0.500

12.70000

1.00

25.40000

Table 12 SPECIAL TOOLS

Tool description

Part No.

Manufacturer

Bearing installation tool handle

33416-80

JIMS

Belt tension gauge

HD-35381-A

H-D

Breakout box

HD-42682

H-D

Breakout box adapters

HD-42962

H-D

Bushing reamer tool

1726-2

JIMS

Clutch spring compression tool

34761-84

JIMS

Clutch spring compression tool

38515-90/91

JIMS

Clutch spring compression tool

HD-38515A

H-D

Connecting rod bushing hone

HD-35102

H-D

Connecting rod bushing tool

95970-32C

JIMS

Connecting rod clamp tool

1284

JIMS

Countershaft support plate

HD-37404

H-D

Fork oil gauge

HD-59000A

H-D

Fork seal driver

HD-36583

H-D

Fork spring compressor (1200S models)

HD-41549A

H-D

Fork spring plate tool

HD-41551

H-D

Hose clamp pliers

HD-97087-65B

H-D

Ignition system harness test kit

HD-41404

H-D

Main drive gear needle bearing installation tool

1991-1994 models

HD-37842

H-D

1995-2003 models

HD-37842A

H-D

Main drive gear remover and installer

HD-35316-A

H-D

Multimeter

HD-35500

H-D

Neway valve seat cutter set

HD-35758-B

H-D

(continued)

CHAPTER ONE

Table 12 SPECIAL TOOLS (continued)

Tool description

Part No.

Manufacturer

Pinion gear locking tool

2234

JIMS

Pinion gear oil seal

See text

Retaining ring tool

1710

JIMS

Rocker arm bushing reamer

HD-94804-57

H-D

Scanalyzer

HD-41325

H-D

Shock absorber spring compressor

HD-97010-52A

H-D

Speedometer tester

HD-41354

H-D

Sprocket locking link

HD-38362

H-D

Sprocket shaft bearing cone installer

HD-37047A/HD-42759

H-D

Sprocket shaft bearing race

2246/94547-80B

JIMS

Steering head bearing race installation tool

HD-39302

H-D

Terminal pick

HD-39621-28

H-D

Terminal tool

HD-97364-71

H-D

Transmission cross plate

HD-35316-91

H-D

Transmission gear spacing tool

HD-35820

H-D

Vacuum pump

HD-23738

H-D

Valve guide brush

HD-34751

H-D

Valve guide driver handle/remover

HD-34740

H-D

Valve guide hone

HD-34723

H-D

Valve guide installation tool

HD-34731A

H-D

Valve guide reamer

HD-39932/HD-39932-CAR

H-D

GENERAL INFORMATION

CHAPTER TWO

TROUBLESHOOTING

This chapter covers troubleshooting procedures. Each

section provides typical symptoms and logical methods for
isolating the cause(s). There may be several ways to solve a
problem, but only a systematic approach will be successful
in avoiding wasted time and possibly unnecessary parts re-
placement.

An engine needs three elements to run properly: cor-

rect air/fuel mixture, compression and a spark at the right
time.

If one basic requirement is missing, the engine will not

run.

Gather as much information as possible to aid in diagno-

sis. Never assume anything and do not overlook the obvi-
ous. Make sure there is fuel in the tank. Make sure the fuel
shutoff valve is in the on position.

In most cases, specialized test equipment is not needed to

determine whether repairs can be performed at home. On
the other hand, be realistic and do not attempt repairs be-
yond personal capabilities.

If the motorcycle does require the attention of a profes-

sional, describe the symptoms, conditions and previous
repair attempts accurately and fully. The more informa-
tion a technician has available, the easier it will be to di-
agnose.

Refer to Table 1 and Table 2 at the end of this chapter.

STARTING THE ENGINE

Engine Fails to Start (Spark Test)

Perform the following spark test to determine if the igni-

tion system is operating properly:

CAUTION

Before removing the spark plugs, clean all de-
bris from the plug base and surrounding area.
Dirt that falls into the cylinder causes rapid
engine wear.

1. Disconnect the spark plug wire and remove the spark
plug as described in Chapter Three.

NOTE

A spark tester is a useful tool for testing spark
output.

Figure 1

shows the Motion Pro Igni-

tion System Tester (part No. 08-0122). This
tool is inserted in the spark plug cap and its
base is grounded against the cylinder head.
The tool’s air gap is adjustable, and it allows
the visual inspection of the spark while test-
ing the intensity of the spark.

2. Cover the spark plug hole with a clean shop cloth to re-
duce the chance of gasoline vapors being emitted from the
hole.

the eyes open and flood with cool, clean wa-
ter for approximately 15 minutes.

WARNING

When performing the following procedures,
protect eyes, skin and clothing.

CAUTION

Be careful not to spill battery electrolyte on
painted or polished surfaces. The liquid is

highly corrosive and will damage the finish. If
it is spilled, wash it off immediately with
soapy water and thoroughly rinse with clean
water.

Clean and inspect the battery at periodic intervals. The

original equipment battery on 1997-2003 models is a
sealed, maintenance-free battery.

On all models in this manual, the negative side is the

ground. When removing the battery, disconnect the nega-
tive cable first, then the positive cable. This minimizes the
chance of a tool shorting to ground when disconnecting the
battery positive cable.

Cable Service

To ensure good electrical contact between the battery and

the electrical cables, the cables must be clean and free of
corrosion.
1. If the electrical cable terminals are corroded, disconnect
them from the electrical system.
2. Clean each connector with a wire brush and a baking
soda solution. Rinse thoroughly with clean water and wipe
dry with a clean cloth.
3. After cleaning, apply a thin layer of dielectric grease to
the battery terminals before reattaching the cables.
4. Reconnect the electrical cables to the electrical system if
they were disconnected.
5. After connecting the electrical cables, apply a light coat
of dielectric grease to the terminals to retard corrosion and
decomposition of the terminals.

Removal

1. Remove the seat (Chapter Seventeen).
2. Remove the battery strap (A, Figure 14).
3. Remove the battery top cover (B, Figure 14).
4. Disconnect the negative battery cable from the battery
(A, Figure 15).
5. Remove the positive battery cable bolt, positive battery
cable and spacer (Figure 16).
6. Remove the battery.

Tray
Cleaning and Inspection

1. Inspect the battery tray and cushion (Figure 17, typical)
for contamination or damage. Clean with a solution of bak-
ing soda and water.
2. Check the entire battery case (Figure 18) for cracks,
warp, discoloration or other damage.
3. Check the battery hold-down strap for acid damage,
cracks or other damage. Replace the strap if required.
4. Check the positive battery cable routing connection in
the battery tray. Tighten the bolt, if necessary.

ELECTRICAL SYSTEM

399

POSITIVE

BATTERY CONNECTION

(1994-1996 MODELS)

1. Bolt
2. Positive

battery cable

3. Spacer
4. Nut
5. Battery

5. Check the battery terminal parts for corrosion or dam-
age. Clean parts thoroughly with a solution of baking soda
and water. Replace corroded or damaged parts.
6. Clean the top of the battery with a stiff bristle brush us-
ing the baking soda and water solution.
7. If necessary, remove the battery tray and clean it.
Replace damaged parts.
8. Check the battery cable clamps for corrosion and dam-
age. If corrosion is minor, clean the battery cable clamps
with a stiff wire brush. Replace severely worn or damaged
cables.

Installation

1. Note the proper routing of the positive battery cable
(A,Figure 15).
2. Place the battery into the battery tray. Make sure the rub-
ber cushion (Figure 17) is installed in the bottom of the tray
before installing the battery. Install the battery strap to se-
cure the battery.
3. Install the spacer, positive battery cable and bolt (Figure
16). Tighten the bolt securely.

CAUTION

Be sure the battery cables are connected to
their proper terminals. Connecting the bat-
tery backward will reverse the polarity and
damage the rectifier.

4. Install and tighten the negative battery cable (A, Figure
15).
5. Coat the battery connections with dielectric grease.
6. Place the top cover (B, Figure 14) on the battery.
7. Attach the forward end of the battery strap (A, Figure
14) under the front side of the battery tray. Then lay the
strap over and into the groove in the battery top. Insert the
threaded stud on the rear end of the battery strap into the
hole at the rear side of the battery tray. Install the washer
and nut. Tighten the nut securely.

Inspection and Testing

The battery electrolyte level cannot be serviced in a

maintenance-free battery. Never attempt to remove the
sealing bar cap from the top of the battery. The battery does
not require periodic electrolyte inspection or water refill-
ing. Refer to any labels (Figure 19) on the battery, particu-
larly if an aftermarket battery is installed.

Even though the battery is sealed, protect eyes, skin and

clothing. The corrosive electrolyte may have spilled out
and can cause severe chemical skin burns and permanent
injury. The battery case may be cracked and leaking elec-
trolyte. If electrolyte is spilled or splashed on clothing or
skin, immediately neutralize it with a baking soda and wa-
ter solution, then flush with an abundance of clean water.
1. Remove the battery as described in this chapter. Do not
clean the battery while it is mounted in the frame.

2. Set the battery on a stack of newspapers or shop cloths to
protect the surface of the workbench.
3. Check the entire battery case for cracks or other damage.
If the battery case is warped, discolored or has a raised top,
the battery has been overcharged and overheated.
4. Check the battery terminal bolts, spacers and nuts for
corrosion or damage. Clean parts thoroughly with a baking
soda and water solution. Replace corroded or damaged
parts.
5. If the top of the battery is corroded, clean it with a stiff
bristle brush using the baking soda and water solution.
6. Check the battery cable ends for corrosion and damage.
If corrosion is minor, clean the battery cable ends with a
stiff wire brush. Replace worn or damaged cables.
7. Connect a digital voltmeter between the battery negative
and positive leads. Note the following:

a. If the battery voltage is 13.0-13.2 volts at 68

(20

C) the battery is fully charged.

b. If the battery voltage is 12.0 to 12.5 volts at 68

F (20

C), or lower, the battery is undercharged and requires
charging.

8. If the battery is undercharged, recharge it as described in
this section. Then test the charging system as described in
Chapter Two.
9. Inspect the battery case for contamination or damage.
Clean it with a baking soda and water solution.
10. Install the battery as described in this section.

Charging

Refer to the

Initialization

in this section if the battery is

new.

To recharge a maintenance-free battery, a digital voltme-

ter and a charger with an adjustable amperage output are re-
quired. If this equipment is not available, have the battery
charged by a shop with the proper equipment. Excessive
voltage and amperage from an unregulated charger can
damage the battery and shorten service life.

The battery should only self-discharge approximately

one percent of its given capacity each day. If a battery not in
use, without any loads connected, loses its charge within a
week after charging, the battery is defective.

400

CHAPTER TWELVE

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