Provides service, repair and maintenance information for 1986-2003 Harley Sportster Evolution XLH883 and 1986-2003 Harley Sportster Evolution XLH1200 models. Includes everything you need to know to perform tune-up and routine maintenance on the engine, clutch and transmission, fuel and exhaust, ignition system, steering and suspension, wheels, brakes and tires, electrical system, frame and body. Features complete wiring diagrams and has 629 pages, hundreds of photographs and illustrations.

QUICK REFERENCE DATA

CHAPTER ONE/GENERAL INFORMATION

Manual organization/Warnings, cautions and notes/Safety/Serial numbers/Fasteners/Shop supplies/Tools/Measuring tools/Electrical system fundamentals/Service methods/Storage
CHAPTER TWO/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 speedometer/tachometer/Turn signal module (1991-1996 models)/Turn signal module (1997-2003 models)/Excessive vibration/Front suspension and steering/Brake problems
CHAPTER THREE/LUBRICATION, MAINTENANCE AND TUNE-UP

Fuel type/Maintenance schedule/Routine safety checks/Tires and wheels/Periodic lubrication/Periodic maintenance/Tune-up/Air filter/Compression test/Spark plugs/Ignition timing adjustment
CHAPTER FOUR/ENGINE TOP END

Tools/Rocker cover assembly/Cylinder head/Valves and valve components/Pushrods and covers/Cylinder Pistons and piston rings/Oil tank and oil lines
CHAPTER FIVE/ENGINE LOWER END
Tools/Engine service/Engine stand/Engine/Valve tappets and guides (1986-1990 models)/Valve tappets (1991-2003 models)/Gearcase cover and timing gears/Oil pump (1986-1990 models)/Oil pump (1991-2003 models)/Oil filter mount (1986-1990 models)/Oil filter mount (1991-2003 models)/Crankcase and crankshaft/Cylinder studs/Engine break-in
CHAPTER SIX/PRIMARY DRIVE AND CLUTCH (1986-1990 MODELS)
Primary drive cover/Clutch release mechanism/Primary chain adjuster/Primary drive/clutch/Clutch cable
CHAPTER SEVEN/PRIMARY DRIVE AND CLUTCH (1991-2003 MODELS)
Primary drive cover (1991-1993 models)/Primary drive cover (1994-2003 models)/Clutch release mechanism (1991-1993 models)/Clutch release mechanism (1994-2003 models)/Primary chain adjuster/Primary drive/clutch/Clutch cable
CHAPTER EIGHT/FOUR-SPEED TRANSMISSION (1986-1990 MODELS)
Transmission/Shifter mechanism/
CHAPTER NINE/FIVE-SPEED TRANSMISSION (1991-2003 MODELS)
Transmission/Shift forks and shift drum/Mainshaft and countershaft/Main drive gear/Access door bearings/Right transmission case bearings/Shift mechanism
CHAPTER TEN/FUEL, EMISSION CONTROL AND EXHAUST SYSTEMS (1986-1987 MODELS)
Air filter backplate/Carburetor/Intake manifold/Fuel hose and clamps/Throttle and idle cables/Choke cable/Fuel tank/Fuel shutoff valve/Exhaust system/Evaporative emission control system (California models) CHAPTER ELEVEN/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 valve (1995-2003 models)/Exhaust system (all models except 883R models)/Exhaust system (883R models)/Evaporative emission control system (California models) CHAPTER TWELVE/ELECTRICAL SYSTEM Electrical component replacement/Electrical connectors/Battery (1986-1996 models)/Battery (1997-2003 models)/Charging system/Alternator (1986-1990 models)/Alternator (1991-2003 models)/Ignition system (1986-1997 models)/Ignition system (1998-2003, all models except 1200S models)/Ignition system (1998-2003 1200S models)/Ignition coil/Bank angle sensor (1998-2003 models)/Manifold absolute pressure (MAP) sensor (1998-2003 1200S models)/Starter/Starter solenoid/Lighting system/Electronic speedometer/tachometer/Switches/Horn/Electrical bracket/Turn signal flasher (1986-1990 models)/Turn signal module (1991-2003 models)/Circuit breakers (1986-1997 models)/Fuses (1998-2003 models)/Electrical connectors/Wiring diagrams
CHAPTER THIRTEEN/WHEELS, TIRES AND SECONDARY DRIVE
Motorcycle stands/Front wheel/Front hub (1986-1999 models)/Front hub (2000-2003 models)/Rear wheel Rear hub (1986-1999 models)/Rear hub (2000-2003 models)/Drive chain and sprockets/Drive belt and sprockets/Wheel runout/Laced wheels/Disc and cast wheels/Wheel balance/Tires
CHAPTER FOURTEEN/FRONT SUSPENSION AND STEERING
Handlebar/Front fork (all models except 1200S models)/Front fork (1200S models)/Steering head and stem/Steering head bearing/Steering play adjustment
CHAPTER FIFTEEN/REAR SUSPENSION
Shock absorbers/Swing arm
CHAPTER SIXTEEN/BRAKES
Brake fluid selection/Brake service/Front brake pads (1986-1999 models)/Front brake pads (2000-2003 models)/Front brake caliper (1986-1999 models)/Front brake caliper (2000-2003 models)/Front master cylinder (1986-1995 models)/Front master cylinder (1996-2003 models)/Rear brake pads (1986-early 1987 models)/Rear brake pads (late 1987-1999 models)/Rear brake pads (2000-2003 models)/Rear brake caliper (1986-early 1987 models)/Rear brake caliper (late 1987-1999 models)/Rear brake caliper (2000-2003 models)/Rear master cylinder (1986-early 1987 models)/Rear master cylinder (late 1987-2003 models)/Brake hose and line replacement/Brake disc/Bleeding the system/Brake fluid draining/Flushing the brake system
CHAPTER SEVENTEEN/BODY
Seat/Front fender/Rear fender/Footrests/Forward foot controls (1999-2003 883C and 1200C models)/Sidestand/Fork lock
INDEX
WIRING DIAGRAMS