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

2. Remove the circlip (B, Figure 121) from the crankcase
groove. This circlip is located behind the main drive gear
oil seal.
3. Drive the main drive gear bearing out of the crankcase,
working from inside the transmission housing, with a suit-
able bearing driver. Discard the bearing.
4. Clean the bearing bore and dry with compressed air.
Check the bore for nicks or burrs. Check the circlip groove
for damage.

NOTE

The main drive gear remover and installer
and cross plate tool, used to remove the main
drive gear, are used to install the new bear-
ing. Refer to

Main Drive Gear

for further in-

formation on these tools.

NOTE

Install the bearings with the manufacturer’s
name and size code facing out.

5. Install the new bearing onto the main drive gear remover
and installer and cross plate tools as shown in Figure 124.

NOTE

Insert the two cross plate pins into the pin
holes in the transmission housing (

Figure

125

). This will center the cross plate with the

main drive gear bearing.

6. Tighten the puller nut to pull the bearing into the crank-
case. Continue until the bearing bottoms out against the
bearing bore surface.
7. Disassemble and remove the puller tool assembly.
8. Install the circlip, with its beveled side facing into the
crankcase groove. Make sure the circlip is fully seated in
the groove.

NOTE

The main drive gear bearing oil seal is installed
during the transmission installation procedure.
Refer to

Transmission

in this chapter.

9. Lubricate the bearing with new transmission fluid.

Countershaft Needle Bearing Replacement

1. Drive the countershaft needle bearing (A, Figure 122)
out of the crankcase, working from inside the transmission
housing, with a suitable bearing driver. Discard the bearing.
2. Clean the bearing bore and dry with compressed air.
Check the bearing bore for nicks or burrs.
3. Align the new bearing, with its closed side facing out,
with the crankcase bearing bore.
4. Drive in the new bearing until its outer surface is flush
with or 0.030 in. (0.76 mm) below the bushing bore inside
surface.

5. Lubricate the bearing with new transmission fluid.
Shift Drum Needle Bearing Replacement

1. Drive the shift drum needle bearing (B, Figure 122) out
of the crankcase, working from inside the transmission
housing, with a suitable bearing driver. Discard the bearing.
2. Clean the bearing bore and dry with compressed air.
Check the bearing bore for nicks or burrs.
3. Align the new bearing, with its closed side facing out,
with the crankcase bearing bore.
4. Drive in the new bearing until its outer surface is flush
with or 0.030 in. (0.76 mm) below the bushing bore inside
surface.
5. Lubricate the bearing with new transmission fluid.

SHIFT MECHANISM

To inspect and service the shift shaft assembly, the trans-

mission must be disassembled as described in this chapter.
The shift lever can be removed by loosening the pinch bolt.
Tighten the pinch bolt to 90-110 in.-lb. (10-12 N•m).

330

CHAPTER NINE

124

Crankcase

Thrust bearing

Nut

Driver

Mainshaft
ball bearing

Bolt

Cross plate

125

Pin

Crankcase

Cross plate

Pin

Table 1 TRANSMISSION SPECIFICATIONS

Primary drive sprockets (engine-to-transmission)

Number of gear teeth

Engine sprocket

Clutch sprocket

Ratio

1.60:1

Final drive sprockets

(transmission-to-rear wheel)–1991-1992 models
Number of sprocket teeth

Transmission sprocket

Chain drive

Belt drive

883 models

1200 models

Rear wheel sprocket

Chain drive

Belt drive

Ratio

883 Standard and Hugger models

2.29:1

883 Deluxe models

2.26:1

1200 models

2.10:1

Secondary drive belt

Number of teeth

883 Deluxe models

1991 models (yellow color code)

127

1992-2003 models (orange color code)

128

1200 models (orange color code)

128

Final drive sprockets

(transmission-to-rear wheel)–1993-2003 models
Number of sprocket teeth

Transmission sprocket

883 models

1200 models

Rear wheel sprocket

Ratio

883 models

2.26:1

1200 models

2.10:1

Overall gear ratios (U.S. models)

1991-1992 883 Standard and Hugger models

1st

10.16

2nd

7.41

3rd

5.44

4th

4.45

5th

3.66

1991-1992 883 Deluxe and all 1993-1994 883 models

1st

10.04

2nd

7.32

3rd

5.38

4th

4.39

5th

3.61

1995-2003 883 models

1st

9.71

2nd

7.12

3rd

5.18

4th

4.26

5th

3.61

1991-1994 1200 models

1st

9.35

2nd

6.82

3rd

5.01

4th

4.09

5th

3.36

1995-2003 1200 models

1st

9.04

2nd

6.62

3rd

4.82

4th

3.97

5th

3.36

(continued)

FIVE-SPEED TRANSMISSION (1991-2003 MODELS)

331

Table 1 TRANSMISSION SPECIFICATIONS (continued)

Overall gear ratios (HDI models)

1993-2003 883 models

1st

9.71

2nd

7.12

3rd

5.18

4th

4.26

5th

3.61

1993-1996 1200 models

1st

9.04

2nd

6.62

3rd

4.85

4th

3.96

5th

3.25

1997-2003 1200 models

1st

9.04

2nd

6.62

3rd

4.82

4th

3.97

5th

3.36

Overall gear ratios (Switzerland models)

1993-1996 883 models

1st

9.05

2nd

6.60

3rd

4.85

4th

3.96

5th

3.25

1993-1996 1200 models

1st

8.43

2nd

6.14

3rd

4.51

4th

3.68

5th

3.03

Table 2 TRANSMISSION TORQUE SPECIFICATIONS

ft.-lb.

in.-lb.

N•m

Transmission access door bolts*

–

156-204

18-23

Countershaft retainer collar screw*

–

156-204

18-23

Detent screw/nut

–

156-204

18-23

Shift lever pinch bolt

–

90-110

10-12

Lower shift shaft locknut

–

90-110

10-12

Upper shift shaft nut

–

90-110

10-12

*Apply threadlock (Loctite 242 or equivalent).

332

CHAPTER NINE

CHAPTER TEN

FUEL, EMISSION CONTROL AND EXHAUST

SYSTEMS (1986-1987 MODELS)

This chapter covers fuel, emissions control and exhaust

systems. Air filter service is covered in Chapter Three. Ta-
ble 1 and Table 2 are at the end of the chapter.

Refer to

Safety

in Chapter One prior to working on the

fuel system.

AIR FILTER BACKPLATE

Removal/Installation

Refer to Figure 1.

1. Remove the air filter element (Chapter Three).

2. Remove the three screws (Figure 2).

3. Remove the two bolts (Figure 3) and pull the backplate
slightly away from the carburetor.

4. Disconnect the vent hose from the back of the backplate,
then remove the backplate.

5. If necessary, replace the carburetor gasket (Figure 4).

6. Install by reversing the preceding steps while noting the
following:

a. Tighten the backplate-to-cylinder head bolts to

120-144 in.-lb. (14-16 N•m).

b. Tighten the backplate-to-carburetor screws to 36-60

in.-lb. (4-7 N•m).

CARBURETOR

Operation

The carburetor atomizes fuel, and mixes it in correct pro-

portions with the air drawn in through the air intake. At the
primary throttle opening (idle), a small amount of fuel is si-
phoned through the pilot jet by the incoming air. As the
throttle is opened further, the air stream begins to siphon
fuel through the main jet and needle jet. The tapered needle
increases the effective flow capacity of the needle jet as it is
lifted, and occupies progressively less of the area of the jet.
At full throttle, the carburetor venturi is fully open and the
needle is lifted far enough to permit the main jet to flow at
full capacity.

The choke circuit is a starting enrichment valve system.

The choke knob under the fuel tank on the left side of the
engine opens an enrichment valve. In the open position, the
slow jet discharges a stream of fuel into the carburetor
venturi enriching the mixture when the engine is cold.

The accelerator pump circuit reduces engine hesitation

by injecting a fine spray of fuel into the carburetor intake
passage during sudden acceleration.

Removal/Installation

1. Remove the air filter backplate as described in this chapter.

9. If necessary, remove the intake manifold as described in
this chapter.

10. Cover the exposed manifold opening to prevent the en-
try of small objects.

11. Install by reversing the removal steps while noting the
following:

a. Tighten the intake manifold-to-carburetor nuts to

180-204 in.-lb. (20-23 N•m).

b. Adjust the throttle cable (Chapter Three).

c. Adjust the choke cable as described in

Periodic

Maintenance

in Chapter Three.

d. Adjust the idle speed as described in

Ignition Timing

in Chapter Three.

Disassembly/Assembly

Refer to Figure 8.

1. Remove the accelerator pump housing (Figure 9) at the
bottom of the float bowl. Then remove the spring (Figure
10) and diaphragm (Figure 11).
2. Remove the O-ring (Figure 12) from the accelerator
pump housing cover.
3. Remove the float bowl (Figure 13).
4. Remove the rubber boot (Figure 14) and O-ring (Figure
15) from the float bowl.
5. Remove the main jet (Figure 16).
6. Remove the plug (Figure 17) and remove the pilot jet
(Figure 18).
7. Remove the float pin screw (Figure 19) and withdraw
the float pin and float (Figure 20) as an assembly.
8. Detach the fuel valve from the float (Figure 21).
9. If necessary, tap the main nozzle (Figure 22) out with a
punch.
10. Detach and remove the accelerator pump rod (Figure
23).
11. The throttle (Figure 24) and choke (Figure 25) valve
assemblies are matched to the individual carburetor during
manufacturing. If these parts are damaged, the carburetor
must be replaced. Do not remove them.
12. Installation is the reverse of the preceding steps while
noting the following:

a. Check and adjust the float level before installing the

float bowl. Refer to

Fuel Level Measurement

in this

section.

b. Align the accelerating pump rod with the rubber boot

and the pump housing during reassembly. Refer to
Figure 26.

Inspection/Cleaning

CAUTION

Do not clean rubber, plastic or other
non-metal parts in carburetor cleaner. The
chemical will destroy these parts.

1. Clean all metal parts in a suitable carburetor cleaner.
Follow the manufacturer’s instructions.
2. Remove all parts from the cleaner and blow dry with
compressed air. Make sure all residue has been removed
from the float bowl (Figure 27). Blow out the jets with
compressed air. Do not use a drill or piece of wire to clean
them as minor gouges in a jet can alter the flow rate and the
air/fuel mixture.
3. If the float is suspected of leaking, put it in a small con-
tainer of water and push it down. If the float sinks or if bub-
bles appear indicating a leak, replace the float.
4. Check the float needle (Figure 28) and seat contact ar-
eas. Both contact surfaces should appear smooth without
any damage. Replace both needle and seat as a set if any
one part is damaged.

FUEL, EMISSION CONTROL AND EXHAUST SYSTEMS (1986-1987 MODELS)

335

5. Inspect the accelerator pump diaphragm (Figure 29) for
holes and cracks. Replace if necessary.
6. Replace the accelerator pump rod if bent or worn thin at
any point.
7. Replace all O-rings. Replace all gaskets.

Fuel Level Measurement

1. Remove the carburetor as described in this section.

NOTE

It is not necessary to remove the accelerator
pump cover (A,

Figure 30

) when removing

the float bowl. However, it is necessary to re-
move the one long accelerator pump/float
bowl screw (45,

Figure 8

2. Remove the float bowl (B, Figure 30).
3. Turn the carburetor to position the float bowl as indi-
cated in Figure 31. Measure the float height from the float
bowl gasket surface to the top float surface. The measure-
ment should be 0.63-0.67 in. (16.0-17.0 mm). If incorrect,
perform the following:

a. Remove the float pin screw (Figure 32) and with-

draw the float pin and float (Figure 33) as an assem-
bly.

b. Detach the fuel valve from the float (Figure 21).
c. Bend the float tang (Figure 34) to adjust.
d. Reinstall the float and recheck the float height.

4. Reinstall the float bowl and install the carburetor as de-
scribed in this section.

INTAKE MANIFOLD

Removal/Installation

Refer to Figure 35.

1. Remove the carburetor as described in this chapter.

NOTE

It may be necessary to use a ball-end type or
shortened Allen wrench for access to the in-
take manifold bolts.

340

CHAPTER TEN

Lip

Valve fully closed

2. Remove the bolts and nuts securing the intake manifold
(Figure 36) to the cylinder heads.

NOTE

The front and rear intake manifold flanges
are different. If the flanges are not marked
(

Figure 37

), label them with an F and R to re-

install them in the correct location.

3. Remove the intake manifold, flanges and manifold
seals.
4. Inspect the intake manifold. Inspect the intake manifold
seals (A, Figure 38) for wear, deterioration or other dam-
age. Replace the seals as a set if necessary.
5. Install the carburetor and spacer on the intake manifold.
Tighten the intake manifold-to-carburetor mounting bolts
to 180-204 in.-lb. (20-23 N•m).
6. Install the flanges and seals onto the intake manifold.
Note that the seals (A, Figure 38) and flanges (B) have a ta-
pered side. Fit the seal taper into the flange taper. Be sure
the correct flange (F or R) is located at the front or rear of
the manifold.
7. Install the intake manifold onto the cylinder head intake
ports. The slotted ends of the flanges must point to the left.
8. Make sure the front and rear seals seat squarely against
the cylinder head mating surfaces.
9. Install the intake manifold mounting bolts and nuts.
Tighten the bolts and nuts to 72-120 in.-lb. (8-14 N•m).

FUEL, EMISSION CONTROL AND EXHAUST SYSTEMS (1986-1987 MODELS)

341

INTAKE MANIFOLD

1. Gasket
2. Intake manifold
3. Washer
4. Bolt
5. Screw
6. Washer

7. Rear flange
8. Seal
9. Nut

10. Washer
11. Stud
12. Front flange

10. Complete carburetor installation as described in this
chapter.

FUEL HOSE AND CLAMPS

CAUTION

Discard removed crimp-type hose clamps. Do
not attempt to reuse removed clamps.

The fuel supply hose between the fuel valve and carbure-

tor is secured at the hose ends with non-reusable hose
clamps (A, Figure 39). Use diagonal pliers or other suitable
tool to separate the clamp bands, then remove the clamp.
Use hose clamp pliers (part No. HD- 97087-65B or
equalent) to compress the clamp bands during installation.
A screw-type hose clamp may be substituted in place of the
original equipment hose clamp.

NOTE

End cutting pliers (B,

Figure 39

) may be

modified to compress the band clamps. Be
sure to test the performance of the tool by
checking the fit and integrity of the installed
clamp.

THROTTLE AND IDLE CABLES

Removal/Installation

Refer to Figure 40.

1. Remove the fuel tank as described in this chapter.
2. Remove the air filter backplate as described in this chap-
ter.
3. Loosen the two cable adjuster locknuts and turn the ca-
ble adjusters (Figure 41) to obtain as much cable slack as
possible.
4. Remove the throttle housing screws and separate the up-
per and lower housings.
5. Unhook the cables from the throttle grip and lower hous-
ing. Account for the ferrules from the ends of both cables.
6. Disconnect the throttle cables at the carburetor. See Fig-
ure 42.
7. Tie a piece of heavy string or cord to the end of the throt-
tle cable at the carburetor. Wrap this end with masking or
duct tape. Do not use an excessive amount of tape as it will
be pulled through the frame loop during removal. Tie the
other end of the string to the frame. The piece of string at-
tached in the next step will be used to pull the new throttle
cable back through the frame so it can be routed in the exact
same position.
8. Pull the cable and attached string out through the frame
loop, past the electrical harness and from behind the head-
light housing. Make sure the attached string follows the
same path as the cable through the frame.
9. Remove the tape and untie the string from the old cable.
10. Tie the string to the new throttle cable and wrap it with
tape.

342

CHAPTER TEN

HANDLEBAR THROTTLE

CONTROL ASSEMBLY

1. Screw
2. Upper housing
3. Lower housing
4. Ferrule
5. Control cable
6. Throttle grip
7. Friction spring
8. Spring
9. Adjusting screw

10. Adjusting nut
11. Handlebar

11. Pull the string back through the frame, routing the new
cable through the same path as the old cable.

12. Remove the tape and untie the string from the cable
and the frame.

13. Lubricate the new cables as described in the

Periodic

Lubrication

in Chapter Three.

14. Slip the cable in through the carburetor bracket. Then,
while holding the lever up with one hand, engage the cable
at the carburetor lever.

15. Attach the throttle cables to the throttle/switch housing
and install the housing.

16. Repeat for the other cable.

17. Operate the throttle grip and make sure the carburetor
throttle linkage is operating correctly and with no binding.
If operation is incorrect, check that the cables are attached
correctly and there are no tight bends in the cables.

18. Adjust the throttle cables as described in Chapter
Three.

19. Install all throttle attaching bolts or brackets.

20. Install the fuel tank.

21. Start the engine and turn the handlebar from
side-to-side. Do not operate the throttle. If the engine speed
increases as the handlebar assembly is turned, the throttle
cables are routed incorrectly. Remove the fuel tank and re-
check the cable routing.

22. Install the air filter backplate.

CHOKE CABLE

Removal/Installation

1. Remove the fuel tank as described in this chapter.

2. Remove the air filter backplate as described in this chap-
ter.

3. Loosen the choke cable (Figure 43) setscrew on the car-
buretor and slide it out of its holder.

4. Loosen the choke nut at the choke knob (Figure 44) and
remove the nut and choke knob.

5. Remove the choke cable.

6. Install by reversing the preceding steps.

7. Adjust the choke cable as described in this section.

Adjustment

1. Remove the air filter backplate as described in this
chapter.

2. Check that the choke valve (Figure 45) operates in the
positions shown by the choke knob in Figure 46.

3. If necessary, adjust the choke by loosening the nuts at
the choke knob and adjusting the length of the cable.
Tighten the nuts and recheck.

FUEL, EMISSION CONTROL AND EXHAUST SYSTEMS (1986-1987 MODELS)

343

FUEL TANK

WARNING

Some fuel may spill from the fuel tank hose
during this procedure. Because gasoline is
extremely flammable and explosive, perform
this procedure away from all open flames, in-
cluding appliance pilot lights and sparks. Do
not smoke or allow anyone to smoke in the
work area, as an explosion and fire may oc-
cur. Always work in a well-ventilated area.
Wipe up any spills immediately. Refer to

Safety

in Chapter One.

WARNING

Route the fuel tank vapor hoses so they can-
not contact hot engine or exhaust compo-
nents.

Removal/Installation

Refer to Figure 47.

1. Disconnect the battery negative lead (Chapter Twelve).
2. Turn the fuel valve (Figure 48) to the off position.
3. Remove the hose clamp and disconnect the fuel hose
from the valve.
4. Drain the fuel tank as follows:

a. Connect a drain hose to the fuel valve and secure it

with a hose clamp. Insert the end of the drain hose
into a gas can.

b. Turn the fuel valve (Figure 48) to the reserve posi-

tion so the fuel will start to flow into the gas can.

c. When fuel stops flowing through the hose, turn the

fuel valve off and disconnect the drain hose.

5. Remove the front mounting bolt and washer (Figure 49)
6. Remove the rear mounting bolt and washer (Figure 50).
7. Lift and remove the fuel tank.

WARNING

Store the fuel tank in a safe place away from
open flames or where it could be damaged.

8. Drain any remaining fuel into a gas can.
9. Inspect the fuel tank as described in this section.
10. Installation is the reverse of removal while noting the
following:

a. Tighten the front and rear mounting bolts to 19 ft.-lb.

(26 N•m).

b. Reconnect the fuel hose to the fuel valve and secure it

with a new hose clamp as described in this chapter.

c. Refill the tank and check for leaks.

Inspection

1. Inspect the fuel hose and vent hose for cracks, deteriora-
tion or damage. Replace damaged hoses with the same type
and size materials. The fuel lines must be flexible and able
to withstand engine heat and vibration.

2. Check the fuel hose insulating sleeve for damage. Re-
place if necessary.

3. Check for damaged mounting brackets.

4. Inspect the fuel tank for leaks.

5. Remove the filler cap and inspect the tank for rust or
contamination. If present, thoroughly flush and clean the
tank. Replace the tank, if necessary.

FUEL SHUTOFF VALVE

The fuel shutoff valve is mounted on the left side of the

fuel tank (Figure 48). A replaceable fuel filter is mounted at
the top of the fuel shutoff valve.

Removal

Refer to Figure 51.

1. Remove the fuel tank as described in this chapter.

2. Place the fuel tank on a protective pad and position it so
fuel will not spill out when removing the fuel shutoff valve.

3. Loosen the fuel valve nut and remove the fuel shutoff
valve from the fuel tank. Drain residual gasoline from the
tank after valve removal.

344

CHAPTER TEN

1st position
(choke plate fully open)

2nd position
3rd position

4th position
(choke plate
fully open)

Harley Davidson 1986-2003 XL/XLH Sportster. Service Manual - page 33