Segment:
Cruiser Motorcycle
Target Audience:
Harley-Davidson XLH Sportster owners, mechanics, and enthusiasts seeking detailed repair and maintenance information.
Competitors For Model:
Japanese cruisers (e.g., Yamaha Virago, Honda Shadow, Kawasaki Vulcan) and other American V-twin motorcycles of the era.
Model Heritage:
The Sportster line is one of Harley-Davidson's longest-running and most iconic models, known for its V-twin engine and customizability.
Manual Purpose:
Provides the essential technical knowledge required to service, repair, and maintain the Harley-Davidson XLH 883cc and 1100cc models from 1986-1988 to factory specifications.
Engine:
V-twin Evolution engine, top end (cylinder heads, valves, camshafts), bottom end (crankshaft, connecting rods, pistons), lubrication system, cooling (air-cooled), ignition system (dual-fire ignition, spark plugs).
Fuel System:
Carburetion (Keihin CV carburetors), fuel lines, fuel tank, fuel pump (if applicable to specific sub-models).
Transmission:
4-speed constant mesh transmission, clutch operation and adjustment, primary drive system, final drive (chain).
Brakes:
Front and rear disc brake systems, hydraulic lines, master cylinders, calipers, brake pads, brake fluid specifications.
Electrical System:
Wiring diagrams, lighting systems (headlight, taillight, turn signals), battery, charging system (stator, regulator/rectifier), starter system, horn, fuses, ignition switch, switches.
Chassis And Suspension:
Frame inspection and repair, front fork (telescopic), rear shock absorbers, wheel bearings, steering head bearings.
Bodywork And Trim:
Fenders, fuel tank, seat assembly, handlebars, controls, instrument cluster, side covers.
Maintenance:
Scheduled maintenance intervals, oil changes, filter replacements, chain lubrication and adjustment, brake checks, tire pressure checks, carburetor cleaning and adjustment, battery maintenance.
Repair:
Engine overhaul (top and bottom end), transmission disassembly and assembly, clutch replacement, brake caliper and master cylinder rebuild, fork seal replacement, shock absorber replacement, electrical component diagnosis and replacement.
Troubleshooting:
Diagnostic charts for common starting issues, running problems, electrical faults, braking issues, and transmission performance.
Installation:
Procedures for replacing major components such as engines, transmissions, wheels, forks, and electrical parts.
Depth:
Comprehensive: Covers everything from basic routine maintenance and adjustments to complete engine and transmission rebuilds, advanced electrical diagnostics, and frame repairs. Includes torque specifications for virtually every fastener.
Digital Format:
PDF (Portable Document Format), typically optimized for digital viewing and printing.
Resolution And Clarity:
High-resolution scans of original factory manuals, ensuring clear text and legible diagrams/illustrations. Searchable text functionality is often included.
Physical Binding:
N/A (Digital download, not physically bound).
Original Paper Type:
N/A (Digital download, not physically printed).
Engine Type:
Air-cooled, 45-degree V-twin, Evolution engine
Bore X Stroke 883Cc:
76.2 mm x 96.8 mm (3.00 in x 3.81 in)
Bore X Stroke 1100Cc:
82.5 mm x 96.8 mm (3.25 in x 3.81 in)
Compression Ratio 883Cc:
Approximately 8.5:1 (factory spec may vary slightly)
Compression Ratio 1100Cc:
Approximately 8.5:1 (factory spec may vary slightly)
Valve Train:
Overhead Valve (OHV), pushrod actuated
Horsepower 883Cc:
Approx. 45-50 HP (at crankshaft, depending on tuning and emissions regulations)
Torque 883Cc:
Approx. 50-55 ft-lbs (at crankshaft, depending on tuning)
Horsepower 1100Cc:
Approx. 55-60 HP (at crankshaft, depending on tuning)
Torque 1100Cc:
Approx. 60-65 ft-lbs (at crankshaft, depending on tuning)
Carburetor Type:
Keihin CV (Constant Velocity) 34mm
Fuel Type:
Unleaded gasoline, 87 octane (minimum, 91+ recommended for optimal performance)
Fuel Capacity:
Approx. 3.0 gallons (11.4 L) for standard tank
Transmission Type:
4-speed, constant mesh
Clutch Type:
Wet, multi-plate
Primary Drive:
Chain drive (883cc: 1.77:1, 1100cc: 1.71:1 - verify with manual)
Final Drive:
Belt drive (51 tooth rear pulley, 29 tooth front pulley common for 883cc, adjust for 1100cc and variations)
Gear Ratios:
Manual will list specific gear ratios for each of the 4 speeds.
Transmission Fluid Type:
Harley-Davidson Formula + Transmission Oil or equivalent SAE 50 motorcycle-specific gear oil (verify in manual for exact specification).
Length:
Approx. 89 inches (2260 mm) - varies by model year and specific configuration
Width:
Approx. 35 inches (890 mm) - varies by handlebar configuration
Height:
Approx. 48 inches (1220 mm) - varies by handlebar and windshield configuration
Dry Weight 883Cc:
Approx. 500-520 lbs (227-236 kg)
Dry Weight 1100Cc:
Approx. 520-540 lbs (236-245 kg)
Gross Vehicle Weight Rating Gvwr:
Check manual for exact GVWR, typically around 900-1000 lbs.
Crash Test Ratings:
N/A (Motorcycles are not subjected to the same crash testing standards as automobiles).
Braking System:
Dual hydraulic disc brakes (front and rear) with single piston calipers on most models of this era.
Lighting:
Halogen headlight, taillight, brake light, turn signals.
Frame Construction:
Steel tube frame designed for stability and rider support.
Audio System:
N/A (Stock models from this era typically did not include integrated audio systems).
ABS:
N/A (Anti-lock Braking Systems were not typically offered on Sportster models of this vintage).
Bluetooth:
N/A (No onboard connectivity features).
Gauges:
Speedometer, odometer, basic indicator lights (oil pressure, neutral, turn signals, high beam). Tachometer was often an optional accessory.
First Service:
Typically 500-1000 miles (800-1600 km) for initial oil change and inspection.
Regular Oil Change:
Every 2,500-5,000 miles (4,000-8,000 km) or annually, whichever comes first (refer to manual for exact spec).
Chain Adjustment Lubrication:
Every 500-1000 miles (800-1600 km) or after riding in rain.
Spark Plug Replacement:
Check manual for specific mileage, often around 10,000-15,000 miles.
Engine Oil Type:
Harley-Davidson V-Twin Synthetic or equivalent SAE 20W-50 motorcycle oil (verify specific viscosity for ambient temperatures in manual).
Engine Oil Capacity:
Approx. 3 US quarts (2.8 L) for 883cc/1100cc with filter change.
Brake Fluid Type:
DOT 4 brake fluid (verify in manual for exact type and any potential DOT 5 silicone fluid usage in later models, but DOT 4 is typical for this era).
Carburetor Tuning:
Keihin CV carburetors can require periodic adjustment or cleaning for optimal performance, especially with age.
Clutch Slippage:
Can occur with age or improper adjustment; manual provides adjustment procedures.
Electrical Connections:
Corrosion or loose connections can lead to intermittent electrical issues; manual includes detailed wiring diagrams for troubleshooting.
Evolution Engine Oil Leaks:
Common wear item: potential leaks from pushrod tubes, rocker box gaskets, and primary cover gaskets. Manual details seals and gasket replacement.
Harley Davidson Legacy:
Founded in 1903, Harley-Davidson is a legendary American motorcycle manufacturer with a rich history in performance, racing, and cultural influence.
Sportster Lineage:
The Sportster was introduced in 1957 and has been continuously evolved. The Evolution engine was introduced in 1984, marking a significant modernization for the Sportster line, leading to the 883cc and 1100cc models covered in this manual.
Engine Changes Era:
The 1100cc model was a short-lived displacement for the Evolution Sportster, primarily produced from 1986-1987, before being largely superseded by the 1200cc version in 1988. This manual covers the transitional period.
Manufacturing Location:
United States (York, Pennsylvania and Milwaukee, Wisconsin)
