Category:
Cruiser Motorcycle
Target Audience:
Harley-Davidson Sportster XLH 2005 owners, mechanics, enthusiasts seeking in-depth repair and maintenance information.
Manual Value Proposition:
Provides a critical resource for maintaining and repairing a specific model year of a popular Harley-Davidson line, offering significant cost savings over dealership service.
Documentation Level:
This is a comprehensive 'Full Service Repair Manual', indicating it goes beyond basic owner's manual tasks.
Model Specificity:
Highly specific to the 2005 Harley-Davidson Sportster XLH, ensuring accurate and relevant information.
Engine Overhaul:
Complete rebuild procedures, including disassembly, inspection, component replacement, and reassembly for the Evolution V-Twin engine.
Carburetor System:
Detailed instructions for Harley-Davidson Keihin CV carburetor service, adjustment, and troubleshooting.
Ignition System:
Information on electronic ignition module, ignition coil, spark plugs, and timing procedures.
Electrical Diagnostics:
Comprehensive wiring diagrams, component testing, troubleshooting of lighting, starting, charging, and ignition circuits.
Clutch And Primary Drive:
Service procedures for clutch assembly, primary chain tensioner, and chain adjustment.
Transmission Service:
Detailed steps for gearbox inspection, repair, fluid changes, and shift mechanism adjustments.
Frame And Swingarm:
Procedures for frame inspection, swingarm bearing service, and suspension component maintenance.
Front Forks:
Service and overhaul of the front fork assembly, including fluid changes and seal replacement.
Rear Shock ABSorbers:
Information on rear shock removal, replacement, and adjustment.
Brake System:
Service and bleeding procedures for front and rear hydraulic disc brakes, including caliper and master cylinder maintenance.
Wheel Bearings:
Inspection and replacement of wheel bearings.
Body Panel Removal:
Instructions for removing and reinstalling fenders, fuel tank, side covers, and other body components.
Routine Maintenance:
Oil changes, filter replacements, spark plug replacement, chain lubrication and adjustment, brake pad inspection.
Engine Rebuilding:
Complete engine teardown, part replacement, and reassembly with detailed torque specifications.
Transmission Overhaul:
Gearbox disassembly, bearing replacement, and reassembly.
Carburetor Tuning:
Detailed procedures for idle speed, mixture, and accelerator pump adjustment.
Electrical Troubleshooting:
Systematic diagnostic steps for electrical faults, including use of multimeters and wiring diagrams.
Brake Bleeding:
Proper procedures for hydraulic brake system bleeding to ensure optimal performance.
Fork Seal Replacement:
Step-by-step guide for replacing leaky front fork seals.
Clutch Adjustment:
Correct procedures for adjusting clutch lever play and clutch engagement.
Depth:
Comprehensive, suitable for home mechanics and professional technicians alike, covering everything from basic maintenance to complete engine and transmission rebuilds.
Engine Family:
Evolution (Evo) V-Twin
Engine Type:
Air-cooled, 45-degree V-twin, pushrod actuated overhead valves
Displacement:
88 cubic inches (1442 cc)
Bore X Stroke:
3.437 in. x 3.812 in. (87.3 mm x 96.8 mm)
Horsepower Approx:
Approx. 65-70 HP (Varies slightly by specific model variant within XLH)
Torque Approx:
Approx. 70-75 ft-lbs (Varies slightly by specific model variant within XLH)
Fuel Delivery:
Carburetor (Harley-Davidson Keihin CV 40mm)
Fuel Type:
Unleaded gasoline, minimum 91 octane (RM/R&M)
Fuel Tank Capacity:
4.2 US gallons (15.9 liters)
Safety Certification:
Meets Federal Motor Vehicle Safety Standards (FMVSS) for motorcycles.
Brakes:
Hydraulic disc brakes front and rear.
Lighting:
Headlight, tail light, brake light, turn signals.
Frame Construction:
Steel frame providing a rigid foundation.
Instrumentation:
Speedometer, tachometer, indicator lights for oil pressure, neutral, turn signals, and high beam.
First Service:
1,000 miles or 3 months (whichever comes first) - typically oil change, primary chain tensioner check, chain lubrication.
Subsequent Service:
Every 5,000 miles or 6 months - includes engine oil and filter change, transmission oil check/change, drive belt check, brake inspection, etc. (Refer to manual for specific details).
Engine Oil:
Harley-Davidson recommended 20W50 Synthetic or Harley-Davidson Genuine V-Twin Oil.
Engine Oil Capacity:
Approx. 3 US quarts (2.8 liters) with filter change.
Transmission Oil:
Harley-Davidson Formula+ Transmission Lubricant or equivalent SAE 85W-140.
Primary Chain Case Oil:
Harley-Davidson Formula+ Transmission Lubricant or equivalent SAE 85W-140.
Brake Fluid:
DOT 4 (Harley-Davidson recommends their own branded fluid).
Primary Chain Tensioner:
Early models (pre-2007) had an automatic tensioner that could wear and cause noise or damage; manual adjustment or upgrade kits are common. The manual will detail inspection and replacement.
Carburetor Idle Drift:
Keihin CV carburetors can sometimes exhibit inconsistent idle; requires proper adjustment and potential cleaning/rebuild.
Electrical Connections:
Corrosion or loose connections in the wiring harness can lead to intermittent electrical issues. The manual's diagrams are crucial for diagnosing these.
Brand Legacy:
Harley-Davidson is an iconic American motorcycle manufacturer with a history dating back to 1903, known for its V-twin engines and cruiser styling.
Sportster Line:
The Sportster line, introduced in 1957, is one of Harley-Davidson's longest-running models, evolving significantly over the decades while retaining its core identity.
2005 Updates:
The 2005 model year Sportster XLH was part of the era featuring the 88 cubic inch Evolution engine, receiving electronic fuel injection on some models later in the generation, but the XLH typically signifies a carbureted model.
Manufacturing Location:
United States (Harley-Davidson's primary manufacturing facilities)
