🏷️ Basic Information

Make:

Harley-Davidson

Model:

Sportster XLH

Year:

2005

Product Code:

Harley Davidson Sportster XLH Models 2005 WSM Service Repair Manual

👋 Introduction

Category:

Cruiser Motorcycle

Segment:

Entry-level to mid-range cruiser, popular for customization.

Competitors:

Indian Scout, Yamaha Bolt, various Japanese metric cruisers.

Engine Type:

Air-cooled, Evolution V-Twin

Frame Type:

Steel cradle frame

Customization Potential:

High, known for its extensive aftermarket support.

📋 Manual Details

Engine:

Included

Transmission:

Included

Electrical System:

Included

Chassis Components:

Included

Bodywork:

Included

Suspension:

Included

Braking System:

Included

Fuel System:

Included

Exhaust System:

Included

Troubleshooting:

Included

Pages:

Estimated 700+ pages (typical for a WSM of this scope)

Type:

Workshop Service Manual (WSM)

Language:

English

Format:

Digital (likely PDF, though physical copies also exist)

📖 Manual Coverage

Engine Mechanical:

Detailed disassembly, inspection, and reassembly of the Evolution V-Twin engine (1200cc & 883cc variants).

Engine Electrical:

Ignition system, charging system, starting system, EFI (Electronic Fuel Injection) and ECU diagnostics.

Transmission Drivetrain:

5-speed transmission inspection, repair, and adjustment; primary drive system (clutch, chain, compensator); final drive belt maintenance.

Fuel System:

Fuel tank, fuel pump, fuel filter, injectors, and all associated lines and components for EFI models.

Suspension Steering:

Front fork (showa, potentially 39mm) disassembly, seal replacement, fluid changes; rear shock absorber service; steering head bearing inspection and adjustment.

Braking System:

Front and rear brake caliper service, pad replacement, hydraulic system bleeding, master cylinder service.

Electrical Components:

Wiring diagrams, lighting system, horn, starter solenoid, battery maintenance, fuse replacement, switchgear.

Frame Bodywork:

Frame inspection, mounting points, fender removal/installation, seat, fuel tank, and other body component service.

Routine Maintenance:

Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, chain adjustment (if applicable), brake fluid checks.

Troubleshooting Guides:

Diagnostic charts and procedures for common performance issues, electrical faults, and starting problems.

Engine Rebuild:

Complete engine teardown, piston ring replacement, valve inspection and lapping, gasket and seal replacement.

Transmission Repair:

Gear inspection, bearing replacement, shift drum and fork servicing.

Electrical Diagnostics:

Component testing, sensor diagnostics, wiring harness continuity checks, ECM troubleshooting.

Suspension Service:

Fork seal replacement, fork oil change, shock absorber damper rod inspection.

Brake System Overhaul:

Caliper piston seal replacement, master cylinder rebuild, brake line inspection.

Depth:

Comprehensive, covering both routine maintenance and in-depth mechanical and electrical repairs. Suitable for professional mechanics and experienced DIY enthusiasts.

📊 Manual Specifications

Digital Format:

PDF

Searchability:

Likely contains searchable text for quick information retrieval.

Illustrations:

High-quality diagrams, schematics, and photographs.

Binding:

N/A for digital; Original factory manuals may be bound or sectioned.

Paper:

N/A for digital; Original factory manuals are typically on durable, gloss paper.

⚙️ Engine Specifications

Engine Family:

Evolution (often referred to as 'Evo' or 'Big Twin Lite')

Engine Type:

Air-cooled, 45-degree V-twin

Displacement Options:

883cc (53.8 cu in) and 1200cc (73.7 cu in)

Bore Stroke 883:

76.2 mm x 96.8 mm (3.00 in x 3.81 in)

Bore Stroke 1200:

88.9 mm x 96.8 mm (3.50 in x 3.81 in)

Horsepower 883:

Approx. 55-60 hp (estimated, varies by specific model configuration)

Torque 883:

Approx. 67-70 ft-lbs @ 3500 rpm (estimated)

Horsepower 1200:

Approx. 65-70 hp (estimated)

Torque 1200:

Approx. 79-82 ft-lbs @ 3500 rpm (estimated)

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded gasoline, minimum 91 octane recommended

Fuel Tank Capacity:

4.5 US gallons (17.0 L) for most XLH models

Oil Type:

Harley-Davidson SYN3 (or equivalent API SG, JASO MA rated 20W50 motorcycle oil)

Oil Capacity:

Approx. 3.0 US quarts (2.8 L) with filter change

🔧 Transmission

Type:

5-speed constant mesh

Options:

N/A for this year and model line, all XLH models featured the 5-speed.

Primary Drive:

Chain drive; Duplex primary chain

Final Drive:

Belt drive

Transmission Oil:

Harley-Davidson Formula+ (or equivalent API GL-4 SAE 80W-90 gear oil)

Transmission Oil Capacity:

Approx. 24 US fluid ounces (710 ml)

📐 Dimensions

Length:

Approx. 88.2 in (2240 mm)

Wheelbase:

Approx. 60.0 in (1525 mm)

Ground Clearance:

Approx. 4.5 in (114 mm)

Dry Weight:

Approx. 500-530 lbs (227-240 kg), depending on model variant

Gvwr:

Approx. 965 lbs (438 kg)

Front Tire Size:

3.00-19 4PR BW

Rear Tire Size:

150/80B16 71H BW

Wheel Type:

Cast aluminum or spoke wheels, depending on trim (e.g., XLH1200C Custom, XLH883L Low, XLH883R Roadster)

Wheelbase Type:

Aluminum alloy or chrome-plated steel spokes

🛡️ Safety Features

Crash Test Ratings:

Motorcycles are not typically subjected to standardized automotive crash tests. Safety is primarily inherent in design and rider responsibility.

Braking System:

Hydraulic disc brakes front and rear.

Lighting:

Halogen headlamp, taillight, brake light, turn signals.

Frame Construction:

Steel cradle frame providing structural integrity.

Engine Guard Options:

Optional engine guards available for rider protection.

💡 Technology Features

Audio System:

Typically no integrated infotainment system. Audio systems (radio, CD players) were rare factory options and more common aftermarket additions.

Display:

Analog speedometer and tachometer; LCD odometer and indicator lights.

ABS:

Anti-lock Braking System (ABS) was not standard and was a rare option on these models for 2005.

Bluetooth:

Not available from the factory.

ECM:

Engine Control Module (ECM) manages EFI, ignition timing, and other engine functions. Diagnostic port (e.g., 4-pin Deutsch connector) for access with diagnostic tools.

🔧 Maintenance

First Service:

1,000 miles (1,600 km) or 12 months, whichever comes first.

Subsequent Services:

Every 5,000 miles (8,000 km) or 12 months for routine checks, oil changes, and fluid checks.

Major Service Intervals:

Spark plugs typically every 10,000 miles (16,000 km); drive belt inspection/replacement as needed (check tension at service intervals).

Engine Oil:

Harley-Davidson SYN3 20W-50 (or equivalent API SG, JASO MA)

Transmission Oil:

Harley-Davidson Formula+ (or equivalent API GL-4 SAE 80W-90)

Primary Chain Case Oil:

Harley-Davidson Formula+ (or equivalent API GL-4 SAE 80W-90, shares oil with transmission)

Brake Fluid:

DOT 4 (for hydraulic clutch if equipped, otherwise DOT 4 for brakes)

Carburetor Vs Efi:

For 2005, EFI models generally resolved the carburetor-related tuning and starting issues common on earlier models.

Idle Control Issues:

Some EFI models might experience occasional idle control valve (IAC) issues or sensor readings requiring diagnostic checks.

Belt Tension:

Proper primary and final drive belt tension is critical for longevity. The manual provides specific adjustment procedures.

Battery Maintenance:

Regular battery charging and terminal cleaning are important for reliable starting.

📚 Vehicle History

Manufacturer:

Harley-Davidson Motor Company, founded in 1903.

Sportster Lineage:

The Sportster line dates back to 1957, evolving from the K model. The XLH designation signifies the Evolution engine platform introduced in 1986.

2005 Updates:

2005 models saw refinements including updated EFI systems, revised seating, and potentially new color options across the various XLH sub-models (XL883, XL883R, XL883C, XL1200C, XL1200R, XL1200S - though 'S' was phased out earlier).

Manufacturing Location:

United States (Milwaukee, Wisconsin or Kansas City, Missouri assembly plants).

🏆 Awards & Recognition

Sportster Legacy:

The Sportster line has received numerous accolades over its history for its iconic styling and performance. Specific awards for the 2005 models are varied and depend on individual motorcycle publications and rider reviews.

Industry Perception:

Consistently regarded as a benchmark in the cruiser segment for its blend of classic Harley-Davidson character and accessible performance.