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  Harley Davidson Sportster Repair Manual (XL883, XL1200) 2004-2013
Harley Davidson Sportster Service and Repair Manual
Harley Davidson Sportster Repair Manual


 
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Description
 

Harley Davidson Sportster Service and Repair Manual (XL883, XL1200)

Buy the Harley Davidson Sportster service and repair manual and learn to perform every service and repair job on your Sportster 883 and 1200 model motorcycle. Our Clymer repair manuals are written for the do-it-yourself mechanic and the experienced pros. This service manual contains many original photographs, illustrations and wiring diagrams obtained from the complete teardown and rebuild of the Harley Davidson XL Sportster. This, in addition to extensive research is how Clymer repair manuals achieve an unmatched level of detail and accuracy.

Harley Sportster Model Years Covered:

  • 2004
  • 2005
  • 2006
  • 2007
  • 2008
  • 2009
  • 2010
  • 2011
  • 2012
  • 2013

Harley Davidson Sportster Models Covered:

2004-2013 HARLEY-DAVIDSON XL1200C Sportster Custom
2004-2011 HARLEY-DAVIDSON XL1200L Sportster Low
2007-2012 HARLEY-DAVIDSON XL1200N Sportster Nightster
2004-2009 HARLEY-DAVIDSON XL1200R Sportster
2012-2013 HARLEY-DAVIDSON XL1200V Sportster 72 Seventy-Two
2010-2013 HARLEY-DAVIDSON XL1200X Sportster 48 Fourty-Eight
2004-2009 HARLEY-DAVIDSON XL883 Sportster
2004-2010 HARLEY-DAVIDSON XL883C Sportster Custom
2004-2013 HARLEY-DAVIDSON XL883L Sportster Low
2009-2013 HARLEY-DAVIDSON XL883N Sportster Iron
2004-2013 HARLEY-DAVIDSON XL883R Sportster

Harley Davidson Sportster Repair Manual Chapters:

Does not cover XR1200.


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 L). On 2004-2007 models the capacity is 3.6 qt. (3.4 L).

Does not cover XR1200.



This Harley-Davidson Sportster XL Manual is 616 pages.

CHAPTER ONE - 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

CHAPTER TWO - 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

CHAPTER THREE - LUBRICATION, MAINTENANCE AND TUNE-UP
Fuel type / Pre-ride inspection / Tires and wheels / Periodic lubrication / Periodic maintenance / Tune-up / Air filter element / Engine compression test / Spark plugs / Idle speed adjustment / Specifications

CHAPTER FOUR - ENGINE TOP END
Outer rocker covers / Inner rocker covers / Cylinder head / Valves and valve components / Pushrods and covers / Cylinder / Pistons and piston rings / Oil tank and oil hoses / Specifications

CHAPTER FIVE - ENGINE LOWER END
Engine removal installation / Valve tappets / Gearcase cover and timing gears / Oil pump / Oil filter mount / Crankcase and crankshaft / Engine mounting system / Specifications

CHAPTER SIX - PRIMARY DRIVE, CLUTCH AND EXTERNAL SHIFT MECHANISM
Primary drive cover / Clutch release mechanism / Primary chain adjuster / Primary drive/clutch / Clutch cable / Shift lever assembly / Shift shaft / Specifications

CHAPTER SEVEN - TRANSMISSION AND INTERNAL SHIFT MECHANISM
Internal gearshift mechanism / Transmission / Mainshaft / (2004-2005 models) / Countershaft / (2004-2005 models) / Transmission / (2006-on models) / Mainshaft / (2006-on models) / Countershaft / (2006-on models) / Main drive gear / Crankcase bearing / Transmission drive sprocket / Specifications

CHAPTER EIGHT - 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 tank / Fuel shutoff valve / Exhaust system / Evaporative emission control system / (California models) / Specifications

CHAPTER NINE - ELECTRICAL SYSTEM
Electrical component replacement / Battery / Charging system / Alternator / Ignition system / Starter / Starter solenoid / Lighting system / Switches / Horn / Starter relay switch / Speedometer / Tachometer / Vehicle speed sensor / Turn signal module (TSM) and turn / signal security module (TSSM) / Security system / Fuses / Maxi-fuse / Electrical connectors / Specifications

CHAPTER TEN - WHEELS, TIRES AND DRIVE BELT
Motorcycle stands / Front wheel / Rear wheel / Front and rear hubs / Driven sprocket assembly / Drive sprocket / Drive belt / Wheel inspection / Laced wheels / Disc and cast wheels / Wheel balance / Tires / Specifications

CHAPTER ELEVEN - FRONT SUSPENSION AND STEERING
Handlebar / Front fork / Steering head and stem / Steering head bearing race / Steering play adjustment / Specifications

CHAPTER TWELVE - REAR SUSPENSION
Shock absorbers / Swing arm / Specifications

CHAPTER THIRTEEN - BRAKES
Brake fluid type / Brake service / Front brake pads / Front brake caliper / Front brake master cylinder / Rear brake pads / Rear brake caliper / Rear master cylinder / Brake hose and line replacement / Brake disc / Rear brake pedal / Brake bleeding / Brake fluid draining and flushing / Specifications

CHAPTER FOURTEEN - BODY
Seat / Front fender / Rear fender / Left side cover / Right side cover / Footrests / Footrest brackets / Sidestand / Fork lock / Specifications

SUPPLEMENT 2007-2013 SERVICE INFORMATION
Engine starting / Engine performance / Starting system / Charging system / Ignition system / Electronic diagnostic system / Fuel system / Brakes / Periodic maintenance / Cylinder head / Engine / Gearcase cover and timing gears / Shift lever assembly / Primary drive/clutch / Air filter backplate / Electronic fuel injection (EFI) / Depressurizing the fuel system / Induction module / Fuel injectors / Throttle position (TP) sensor / TMAP sensor / Idle air control (IAC) / Oxygen (O2) sensor / Throttle body / Intake manifold / Fuel tank / Fuel pump module / Throttle and idle cables / Fuel pressure test / Evaporative emission control system / (California models) / Exhaust system / Electrical Component Replacement / Battery / Charging system / Alternator / Ignition system / Electronic control module (ECM) / Engine temperature (ET) sensor / Lighting system / Security system / Hands-free security module (HFSM) / HFSM antenna / Fuel level sender resistor / Speedometer / Vehicle speed sensor (VSS) / Clutch switch / Side stand sensor / Wire harness caddy / Relays / Fuses / Electrical connector service / Front wheel / Rear wheel / Handlebar / Front forks / Brake fluid / Front brake master cylinder / Rear brake pedal / Rear fender / Specifications

INDEX

COLOR WIRING DIAGRAMS

    Repair Manual Information:

    • Publisher: Clymer Manuals - 2013
    • Binding: Paperback - 8.25 x 10.75 inches
    • Pages: 616- Hundreds of b&w photos and illustrations
    • ISBN: 9781599696423

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    Tags: Harley, Davidson, Sportster, Service, Repair, Manual, Clymer, XL883, XL883C, XL883L, XL883N, XL883R, XL1200, XL1200C, XL1200L, XL1200N, XL1200R, XL1200X, 883, 1200


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