Target Audience:
Owners, technicians, and enthusiasts seeking in-depth service information for the 2002 Harley-Davidson Sportster XLH.
Value Proposition:
Provides essential, accurate, and comprehensive factory-level data, eliminating guesswork and ensuring correct repair procedures, unlike generic online forums or aftermarket manuals.
Completeness:
The definitive guide to maintaining and repairing the 2002 Sportster XLH, covering every aspect of the motorcycle.
Accuracy:
Official factory documentation ensures the highest level of accuracy for specifications and procedures.
Engine:
Complete engine overhaul, inspection, repair, and diagnostics for Evolution V-Twin engines.
Transmission:
Service and repair procedures for the 5-speed constant mesh transmission, including clutch and primary drive.
Electrical System:
Detailed wiring diagrams, component testing, ignition system, charging system, lighting, and instrumentation.
Fuel System:
Carburetor adjustment and overhaul (Keihin CV carburetor), fuel tank, fuel lines, and petcock service.
Brakes:
Front and rear brake system maintenance, bleeding, caliper service, and hydraulic component troubleshooting.
Suspension And Steering:
Fork service, rear shock absorber replacement, wheel bearing maintenance, and steering head bearing adjustment.
Chassis And Frame:
Frame inspection, swingarm service, and component mounting.
Bodywork And Trim:
Fender removal/installation, fuel tank mounting, seat service, and accessory mounting.
Preventive Maintenance:
Oil changes, filter replacements, spark plug service, chain adjustment, and lubrication schedules.
Troubleshooting Guides:
Systematic diagnostic procedures for common performance issues and malfunctions.
Disassembly And Assembly:
Detailed step-by-step instructions for component removal and reinstallation.
Torque Specifications:
Precise torque values for all critical fasteners and bolts.
Depth Of Information:
Comprehensive factory-level repair and maintenance procedures, suitable for professional mechanics and experienced DIY enthusiasts.
Engine Type:
Evolution V-Twin, Air-Cooled
Engine Displacement Options:
883cc (53.9 cu in) and 1200cc (73.4 cu in)
Bore Stroke 883Cc:
76.2 mm x 96.8 mm (3.00 in x 3.81 in)
Bore Stroke 1200Cc:
88.7 mm x 96.8 mm (3.49 in x 3.81 in)
Compression Ratio 883Cc:
8.8:1
Compression Ratio 1200Cc:
9.0:1
Horsepower Estimate 883Cc:
Approx. 55 HP @ 6000 RPM
Torque Estimate 883Cc:
Approx. 58 ft-lbs @ 3200 RPM
Horsepower Estimate 1200Cc:
Approx. 65 HP @ 6000 RPM
Torque Estimate 1200Cc:
Approx. 70 ft-lbs @ 3500 RPM
Carburetor Type:
Keihin CV (Constant Velocity) 34mm
Ignition System:
Electronic Ignition
Engine Oil Type:
Harley-Davidson Genuine V-Twin Oil 20W50
Engine Oil Capacity:
3.0 US quarts (2.8 L) with filter change
Primary Chain Case Oil Type:
Harley-Davidson Genuine Primary Chain Case Oil
Primary Chain Case Oil Capacity:
26-28 oz (0.77-0.83 L)
Safety Ratings:
Not applicable in the same manner as automobiles; focus is on mechanical reliability and rider control.
Active Safety Features:
Responsive braking systems, stable chassis dynamics.
Passive Safety Features:
Robust frame construction, rider control through suspension and steering.
First Service:
1,000 miles (1,600 km) or 6 months
Subsequent Service Intervals:
Every 5,000 miles (8,000 km) or 12 months
Primary Chain Adjustment Interval:
Every 2,500 miles (4,000 km)
Fork Oil Type:
Harley-Davidson Type 'E' or 'B' (check specific model variation or manual)
Fork Oil Capacity:
Approx. 9.6 US oz (284 ml) per fork leg
Common Wear Items:
Clutch plates, brake pads, wheel bearings, and fork seals are common wear items requiring periodic inspection and replacement.
Carburetor Tuning:
Keihin CV carburetor may require periodic fine-tuning for optimal performance and emissions.
Primary Drive Tension:
Proper primary drive chain tension is critical to prevent premature wear on the chain and sprockets.
Brand Legacy:
Harley-Davidson has a rich history dating back to 1903, synonymous with American motorcycle culture.
Sportster Lineage:
The Sportster line, introduced in 1957, is one of Harley-Davidson's longest-running and most iconic model families, known for its sporty character.
Production Period:
The 2002 model is part of the Evolution Sportster generation, produced from the late 1980s through the early 2000s before significant updates.
Manufacturing Location:
United States
