Clymer Shop Repair Manual

Clymer Harley XL/XLH Sportster 1986-2003 Repair Manual

Clymer repair manuals are written specifically for the do-it-yourselfer.

For routine maintenance or more extensive repairs involving engine and transmission disassembly, it has all the information you need.

Step-by-step procedures, detailed photography and extensive use of exploded views based on the complete disassembly of the machine.

Clymer Manuals are perfect for everyone, from the first-time user to the seasoned professional.

CHAPTER ONE / GENERAL INFORMATION
CHAPTER TWO / TROUBLESHOOTING

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Maintenance schedule / Oil and filter change / Tune-up / Air filter / Compression test / Spark plugs / Ignition timing adjustment
CHAPTER FOUR / ENGINE TOP END
Rocker cover / Cylinder head / Valves and components / Pushrods and covers / Cylinder / Pistons and rings / Oil tank and oil lines
CHAPTER FIVE / ENGINE LOWER END
Removal and installation / Valve tappets and guides / Valve tappets / Gearcase cover and timing gears / Oil pump / Oil filter mount / Crankcase and crankshaft / Cylinder studs / Engine break-in
CHAPTER SIX AND SIX/ PRIMARY DRIVE AND CLUTCH
Primary drive cover / Clutch release mechanism / 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 AND ELEVEN / FUEL, EMISSION CONTROL AND EXHAUST SYSTEMS
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 TWELVE / ELECTRICAL SYSTEM
Battery / Charging system / Alternator / Ignition system / Ignition coil / Bank angle sensor / Manifold absolute pressure (MAP) sensor (1998-2003 1200S models) / Starter / Starter solenoid / Lighting system / Electronic speedometer / tachometer / Switches / Horn / Electrical bracket / Turn signal flasher / Turn signal module / Circuit breakers / Fuses /
WIRING DIAGRAMS
CHAPTER THIRTEEN / WHEELS, TIRES AND SECONDARY DRIVE
Motorcycle stands / Front wheel / Front hub / Rear wheel and hub / 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 / Steering head and stem / Steering head bearing / Steering play
CHAPTER FIFTEEN / REAR SUSPENSION
Shock absorbers / Swing arm
CHAPTER SIXTEEN / BRAKES
Brake fluid selection / Brake service / Front and rear brake pads (1986-1999 models) / Front and rear brake caliper / Front and rear master cylinder / Brake hose and line / 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

WIRING DIAGRAMS

Product Note: This manual is not exclusive to the model specified in this listing and contains information on a variety of makes and models.

Specification	Details
Country of Origin	Varies (make selection above)
ISBN	Varies (make selection above)
Pages	Varies (make selection above)
Quantity	Varies (make selection above)
ISBN	9781599691497
Pages	640

Vehicle Fitment

Fitment is guaranteed or your money back plus free return shipping.
Don’t waste time installing a product that doesn't fit. We worked hard ensuring that this product is an exact fit on the vehicles listed below.

XL1200C Sportster 1200 Custom 1996-2003
XL1200S Sportster 1200 Sport 1996-2003
XL883C Sportster 883 Custom 1999-2003
XL883R Sportster 883R 2002-2003
XLH1100 Sportster 1100 1986-1987
XLH1200 Sportster 1200 1988-2003
XLH883 Sportster 883 1986-2003
XLH883DLX Sportster 883 Deluxe 1986-1995
XLH883HUG Sportster 883 Hugger 1987-2003

Customer Reviews

Came as advertised.

Exactly what I requested. Great job

Great value!

It's all black and white there is no color

Nice informative manual much more in depth and detail than the older Clymer manual.

This manual was exactly what I needed to help with my restore.

Big help in my project. Thanks

Great value! A must have on older motorcycles.

Excellent job

Good book

I am glad to have the manual.

Very good for the price.

Worked out great.

Great!

Lousy descriptions, lousy photos. Some required remove or replace instructions missing completely. Vehicle: 2008 Polaris Sportsman 500 H.O.

Exactly what I wanted.

Much needed. Worth every penny I paid.

The manual was exactly what I needed to complete the work on my bike. Arrived in brand new condition. Couldn't be more pleased.

Very detailed manual, excellent information. Thanks, it's working much better than searches on internet. From people that want to be your go to guy and want to charge you for something they have no idea what they are talking about. So people get a printed manual you will be pleasantly surprised how your stress level will go away. Thanks best money I have spent an actually got information I can use.

It's nice to read the manual to figure out how to repair things.

The service manual was perfect and new.

Nice book

Was exactly what I was looking for and the price was right.

The manual is what I was looking for and shipping was fast.

Was exactly what I was looking for.

Can't live without it.

Very informative

This is exactly what I was looking for.

Perfect h d repair manual for the bikes listed in this book!

Great manual great illustrations. And highly recommended.

Exactly what I expected

A quick "go to" informational guide. Makes troubleshooting and repairs non problematic.

Replaced cam, lifters, and pushrods in my bike, manual very helpful with procedure, tolerances. Repaired some of the wiring, schematics were incredible.

Good book

Manual was just what I needed to allow me to work on my newly acquired v rod with confidence. You guys rock!

Not knowing a lot about the cl160 I was working on this manual helped me out quite a bit. Nice manual.

Everything I want or need to know is easy to find and understand. This manual has given me the confidence to get my bike up on the stand and take care of it, a tall order for an old retired woman. Thank you.

Pleased with quality.

Helpful.

Must have!

Clymer's manual is excellent for doing bike rebuild projects. I have both this and the Kawasaki service manual, and this goes into further detail than the Kawaski manual. Very happy.

Fantastic service, and shop book

How many stars would you give this product? Write a review.

Questions & Answers

I have a 2012 HD softail slim.I want to replace everything in the gas tank.Is this a good book for this or is it a better one for that job. Thanks for the help

By Jimmy

If you're a novice mechanic, you'll certainly find this book useful. It goes over the fuel tank console, fuel tank itself, fuel pump and the fuel filter assembly. All of that's covered to help you service your bike.

By Tom

does the 2001 honda cr125 manual have torqe specifications.

By Anon.

Yes, the manual would include torque specifications.

By Andy

Are the Electrical Schematics for 75Honda750F Color Coded?

By Mike

Yes, this manual would have color coded wiring schematics for that 1975 CB750F.

By Andy

Does this have wiring schematics for the listed machines?

By Tsmith1600

Yes, absolutely! Clymer's electrical schematic diagrams are some of the nicest in the repair manual business.

By Staff

Will this cover a 2006 drifter?

By Mike

Yes, if you were to select the 2006 Kawasaki VN1600D Vulcan 1600 Nomad Clymer service manual from our fit guide, you'd receive the correct book for servicing your machine.

By Staff

Does the book have a page(s) dedicated for the necessary tools?

By Nes

It varies, depending on what machine it is that you have, but the required tool descriptions really only outline what specialty tools are required to get the job done. Other than that, you can pretty easily get an idea of the basic tools required by reading up ahead of time on the job you want to do. There's TONS of photos in each one of these books and, even for the novice mechanic, they provide an excellent reference on which to get the work done.

By Staff

will this manual show how to tear down and reassemble.The total 1000 engine?

By Fab king wrench

complete reassemble of the engine with all torque specs for total engine and lower ends also?

This manual will cover general service procedures including teardown and reassembly of engine components. It is not an exact step-by-step guide like a FSM. It will cover each piece of the disassembly procedure and list toques and specs at the beginning or end of each chapter.

By Staff

Replace chain

By America

Yes, this manual will cover chain maintenance and replacement for the model you select at checkout. Guidance for tensioning and whatnot is usually included as well.

By Staff

Have a question? Please ask our experts and customers who own this product.

Clymer Shop Repair Manual Clymer Harley XL/XLH Sportster 1986-2003 Repair Manual

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