Target Audience:
Harley-Davidson Sportster owners, DIY mechanics, service technicians
Value Proposition:
Provides essential knowledge for maintaining and repairing a classic Harley-Davidson model, saving significant costs on professional service.
Completeness:
Comprehensive coverage that aims to be the definitive resource for the 1991 Sportster models.
Primary Coverage:
Full Service, Repair, Maintenance, Troubleshooting
Specific Models Covered:
Harley-Davidson Sportster XL, XLH models
Estimated Page Count:
500+
Type:
Service and Repair Manual
Format:
Digital (likely PDF)
Engine:
Engine disassembly, assembly, tuning, lubrication, cooling system
Transmission:
Transmission overhaul, clutch, gear shifting mechanisms
Electrical System:
Ignition system, charging system, lighting, starter, wiring diagrams
Fuel System:
Carburetor service and tuning, fuel tank, fuel lines
Brakes:
Brake system maintenance, hydraulic components, caliper service
Suspension:
Front fork service, rear shock absorber replacement and adjustment
Frame And Bodywork:
Frame inspection, body panel removal and installation, fenders, seat
Wheels And Tires:
Wheel bearing service, tire replacement, spoke tensioning (if applicable)
Controls:
Handlebar controls, throttle, clutch, brake levers
Maintenance:
Scheduled maintenance, oil changes, filter replacements, lubrication points
Troubleshooting:
Diagnostic procedures, common problems and solutions, fault finding
Repair:
Step-by-step repair instructions for all major components
Rebuilds:
Comprehensive procedures for engine and transmission rebuilds
Disassembly And Assembly:
Detailed instructions for component removal and reinstallation
Adjustments:
Carburetor synchronization, clutch adjustment, brake lever adjustment
Depth:
Comprehensive, covering all aspects from basic maintenance to full engine rebuilds
Scan Quality:
High-resolution scans of original factory manual pages
Physical Binding:
N/A (Digital)
Physical Paper:
N/A (Digital)
Searchable Text:
Likely, if OCR was applied during digitization
Illustrations:
Includes diagrams, schematics, and photographic illustrations
Engine Type:
Air-cooled V-twin Evolution Engine
Displacement:
883cc (53.9 cu in) and 1200cc (73.7 cu in) variants
Bore X Stroke 883Cc:
3.00 in x 3.8125 in (76.2 mm x 96.8 mm)
Bore X Stroke 1200Cc:
3.50 in x 3.8125 in (88.9 mm x 96.8 mm)
Compression Ratio 883Cc:
8.0:1 (typical)
Compression Ratio 1200Cc:
9.0:1 (typical)
Horsepower 883Cc:
Approx. 46-50 HP
Horsepower 1200Cc:
Approx. 58-62 HP
Torque 883Cc:
Approx. 48-50 ft-lbs
Torque 1200Cc:
Approx. 60-65 ft-lbs
Carburetor:
Keihin CV (Constant Velocity) Carburetor, 34mm (typical)
Fuel Type:
Unleaded Gasoline, 87 Octane Minimum
Crash Safety Rating:
N/A (Motorcycle safety is assessed differently than cars)
Braking:
Front: Single disc brake; Rear: Drum brake (early 1991 models) or Disc brake (late 1991 models, XLH)
Lighting:
Headlight, taillight, brake light, turn signals
Oil Change:
Every 2,000 - 3,000 miles or 6 months (refer to manual for exact specification)
Primary Chain Tension:
Check and adjust every 5,000 miles
Spark Plug Replacement:
Every 10,000 miles
Engine Oil Type:
Harley-Davidson Genuine V-Twin Oil 20W50, SAE 20W50 Motorcycle Oil
Engine Oil Capacity:
3 US quarts (2.8 liters) for 883cc, 3.4 US quarts (3.2 liters) for 1200cc (with filter change)
Primary Chain Case Oil:
Harley-Davidson Genuine Primary Chaincase Lubricant, SAE 80W-90 Gear Oil
Primary Chaincase Oil Capacity:
Approx. 1 US quart (0.95 liters)
Transmission Oil Type:
Harley-Davidson Genuine Transmission Lubricant, SAE 85W-140 Gear Oil (or equivalent)
Transmission Oil Capacity:
Approx. 20 fl oz (0.6 liters)
Carburetor Tuning:
Keihin CV carburetor can require periodic adjustment for optimal performance and idle stability.
Primary Chain Tension:
Incorrect primary chain tension can lead to premature wear on the chain and sprockets.
Rear Brake Wear:
Drum rear brakes (on some models) may require more frequent adjustment and can wear out faster than disc brakes.
Oil Leaks:
Older models can develop minor oil leaks from gaskets or seals, which the manual will detail for repair.
Founding:
Harley-Davidson Motor Company founded in 1903
Sportster Introduction:
The Sportster line debuted in 1957, evolving significantly over decades.
Evolution Engine Introduction:
The 'Evolution' engine (often called 'Evo') was introduced for the Sportster line in 1986, replacing the Ironhead engine.
Manufacturing Location:
USA (Milwaukee, Wisconsin and later York, Pennsylvania)
