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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 procedures, tables and figures are designed for the reader who may be working on the motorcycle for the first time. Frequently 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. standard 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 fundamentals 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 diagnosis of problems. Troubleshooting procedures present typical symptoms and logical methods to pinpoint and repair the problem. Chapter Three explains all routine maintenance necessary to keep the motorcycle running well. Chapter Three also includes recommended tune-up procedures, eliminating the need to constantly consult the chapters on the various 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.