Historical Position:
The 1986 Sportster represented a blend of classic Harley-Davidson styling with evolving technology, catering to riders seeking a versatile performance cruiser.
Competitors 1986:
Competed with Japanese performance motorcycles and other American V-twin offerings, emphasizing its unique character and heritage.
Model Year Features:
Introduction of the Evolution (Evo) engine in Sportster models, offering improved reliability and performance over previous Shovelhead engines.
Manual Utility:
Essential resource for maintaining and repairing the 1986 Harley-Davidson Sportster, covering all essential technical aspects.
Engine Mechanical:
Complete overhaul, including cylinders, pistons, crankshaft, connecting rods, camshafts, valve train, and timing.
Fuel System:
Carburetor (Keihin CV type), fuel pump, fuel lines, fuel tank maintenance and repair.
Ignition System:
Electronic ignition module, spark plugs, ignition coils, wiring, troubleshooting.
Electrical System:
Wiring diagrams, charging system (stator, regulator/rectifier), lighting, horn, starter motor, battery, fuses.
Transmission:
4-speed transmission (including clutch, gearbox components, primary drive, final drive belt inspection and adjustment).
Brakes:
Front and rear hydraulic disc brake systems, including master cylinders, calipers, brake lines, pads, and fluid replacement.
Suspension:
Front fork (telescopic), rear shock absorbers, fork oil replacement, seal replacement, shock absorber adjustment.
Frame And Bodywork:
Frame inspection, mounting points, fenders, fuel tank, seat, handlebars, controls, cables.
Wheel And Tires:
Wheel bearings, tire replacement, balancing, spoke adjustment (if applicable).
Maintenance:
Oil changes, filter replacement, spark plug replacement, chain/belt adjustment, lubrication, brake fluid flush.
Troubleshooting:
Diagnostic procedures for common issues, including starting problems, engine performance issues, electrical faults.
Repair:
Detailed step-by-step instructions for component disassembly, repair, and reassembly.
Rebuilds:
Engine and transmission rebuild procedures, including torque specifications and clearances.
Depth:
Complete mechanical and electrical overhaul, suitable for professional mechanics and experienced DIY enthusiasts.
PDF Quality:
High-resolution scans, searchable text for key terms (if OCR'd).
Printable:
Yes, pages can be printed for workshop use.
Original Binding:
Likely a professional-style bound manual for workshop use (digital format simulates this).
Original Paper:
Typically printed on durable, grease-resistant paper for workshop environments.
Engine Family:
Evolution (Evo) V-twin
Engine Type:
Air-cooled, 45-degree V-twin, 4-stroke
Displacement:
1100 cc (approx. 67.3 cubic inches)
Bore X Stroke:
3.4375 in x 3.96875 in (87.3 mm x 100.8 mm)
Compression Ratio:
8.0:1 (typical)
Horsepower:
Approximately 55-60 hp @ 5000 RPM (estimated)
Torque:
Approximately 63-67 ft-lbs @ 3200 RPM (estimated)
Carburetor Model:
Keihin CV (Constant Velocity) 36mm
Fuel Type:
Unleaded gasoline, 87 octane minimum
Oil Type:
SAE 20W-50 Motorcycle Oil (API CD or better)
Oil Capacity:
Approx. 3 quarts (2.8 liters) for engine and transmission
Length:
Refer to specific model variant (approx. 88 inches)
Width:
Refer to specific model variant (approx. 36 inches)
Height:
Refer to specific model variant (approx. 47 inches)
Dry Weight:
Approximately 470-500 lbs (213-227 kg)
Gvwr:
Refer to owner's manual/VIN plate
Fuel Tank Capacity:
Approx. 3.0 gallons (11.4 liters)
Crash Test Ratings:
Not applicable (motorcycle)
Braking System:
Front and rear hydraulic disc brakes
Lighting:
Headlight, taillight, brake light, turn signals
Frame Construction:
Steel frame and swingarm designed for stability.
Initial Service:
Refer to manual (typically 500-1000 miles)
Regular Oil Change:
Every 2,500-3,000 miles or annually
Belt Inspection Tension:
Every 5,000 miles or as needed
Brake Fluid Flush:
Every 12-24 months
Engine Oil Viscosity:
SAE 20W-50
Engine Oil Standard:
API CD or better
Brake Fluid Type:
DOT 4 Hydraulic Brake Fluid
Fork Oil Type:
Refer to manual (e.g., Bel-Ray 10W, Spectro 10W)
Common Wear Items:
Clutch plates, primary chain, belt drive, wheel bearings, fork seals.
Electrical Reliability:
Early Evo models could have minor electrical gremlins, often related to wiring insulation or regulator/rectifier units.
Carburetor Tuning:
Keihin CV carburetors require periodic adjustment and cleaning for optimal performance.
Harley Davidson Legacy:
Harley-Davidson boasts a long history of motorcycle manufacturing, known for its V-twin engines and iconic styling.
Sportster Lineage:
The Sportster line has been in continuous production since 1957, evolving through various engine configurations and styling cues.
Manufacturing Location:
United States (Milwaukee, Wisconsin, and other facilities)
Year Significance:
1986 was a pivotal year with the introduction of the Evolution engine across the Sportster range, marking a significant update.
