Target Audience:
Owners and independent mechanics of 1995 Harley-Davidson Sportster XL/XLH models.
Value Proposition:
Enables users to perform dealership-level maintenance and repairs, saving time and money.
Alternatives:
Factory service manuals (FSM), other aftermarket repair guides (e.g., Clymer, Haynes - though this listing implies a more comprehensive 'full service' manual).
Comprehensiveness:
Full coverage from routine checks to major overhauls.
Detail Level:
Detailed step-by-step instructions and clear diagrams.
Troubleshooting Support:
Includes diagnostic aids for common issues.
Product Name:
Harley Davidson Sportster XL XLH 1995 Full Service Repair Manual
Description Summary:
Comprehensive guide for repair and maintenance of Harley-Davidson Sportster XL and XLH models from 1995.
Estimated Page Count:
Likely 400-600 pages (typical for full service manuals of this era)
Type:
Full Service Repair Manual
Format:
Print (typical for this product listing, PDF possible with some vendors)
Engine:
Complete engine overhaul, disassembly, assembly, tuning, performance modifications (carburetor, ignition).
Transmission:
Service and repair of the 4-speed or 5-speed gearbox, clutch assembly, primary drive.
Electrical System:
Wiring diagrams, lighting, ignition system, charging system (stator, regulator/rectifier), starter, battery maintenance.
Fuel System:
Carburetor service (Keihin CV), fuel lines, fuel tank, fuel pump (if applicable).
Brakes:
Front and rear brake system maintenance, hydraulic lines, caliper service, rotor inspection, brake fluid specifications.
Suspension:
Front fork service (oil change, seal replacement), rear shock absorber maintenance and replacement.
Chassis And Frame:
Frame inspection, steering head bearing service, swingarm and pivot bearing maintenance.
Bodywork And Trim:
Fender removal/installation, fuel tank mounting, seat service, exhaust system maintenance.
Routine Maintenance:
Oil changes, filter replacements, spark plug service, chain adjustment (if applicable), tire pressure checks.
Troubleshooting:
Diagnostic charts for common problems, electrical gremlins, engine performance issues.
Engine Rebuild:
Detailed steps for piston removal, cylinder honing, valve seat service, crankshaft inspection, and reassembly.
Clutch Replacement:
Procedure for clutch plate replacement and adjustment.
Fork Seal Replacement:
Step-by-step guide for replacing front fork seals and oil.
Wiring Diagram Interpretation:
Ability to read and understand complex electrical schematics.
Carburetor Tuning:
Jetting recommendations, idle mixture adjustment, accelerator pump settings.
Depth:
Comprehensive; covers everything from basic scheduled maintenance to complete engine and transmission overhauls.
Diagnostic Capability:
High; includes troubleshooting guides and symptomatic analysis.
Rebuild Instructions:
Detailed, component-level rebuild instructions.
Performance Enhancement Guidance:
Likely includes some basic tuning and modification advice relevant to the era.
Print Quality:
Likely original factory quality, clear text and diagrams.
Diagram Clarity:
High, with detailed exploded views and schematics.
Binding:
Typically perfect bound or saddle-stitched for print manuals.
Paper Quality:
Durable, often coated paper to resist workshop grease and oil.
Engine Type:
Air-cooled, Evolution (Evo) V-twin
Engine Displacement:
883cc (57 cubic inches) and 1200cc (74 cubic inches) variants
Bore X Stroke 883Cc:
3.00 in. x 3.8125 in. (76.2 mm x 96.8 mm)
Bore X Stroke 1200Cc:
3.499 in. x 4.25 in. (88.9 mm x 108 mm)
Compression Ratio 883Cc:
8.4:1 (typical)
Compression Ratio 1200Cc:
9.0:1 (typical)
Horsepower 883Cc:
Approx. 55 hp @ 6000 rpm
Horsepower 1200Cc:
Approx. 65 hp @ 6000 rpm
Torque 883Cc:
Approx. 59 ft-lbs @ 3500 rpm
Torque 1200Cc:
Approx. 67 ft-lbs @ 3500 rpm
Carburetor:
Keihin CV (Constant Velocity) 34mm for 883cc, 40mm for 1200cc
Fuel Requirement:
Unleaded gasoline, 87 octane minimum (refer to manual for specific recommendations)
Ignition System:
Electronic ignition, dual spark plugs per cylinder
Wheelbase 883:
Approx. 59.5 inches (1511 mm)
Wheelbase 1200:
Approx. 59.5 inches (1511 mm)
Seat Height Laden:
Approx. 26.1 inches (663 mm)
Dry Weight 883:
Approx. 477 lbs (216 kg)
Dry Weight 1200:
Approx. 489 lbs (222 kg)
Fuel Capacity:
3.6 US gallons (13.6 liters) for standard tank
Oil Capacity:
2.5 US quarts (2.4 liters) with filter change (refer to manual for exact specification)
Oil Change Interval:
Every 2,500 miles or 6 months, whichever comes first (typical for this model, always consult manual).
Primary Chain Tension Check:
Every 2,500 miles (critical for preventing premature drive failure).
Spark Plug Replacement:
Every 10,000 miles (refer to manual for correct type and gap).
Brake Fluid Flush:
Every 2 years or as needed based on condition.
Engine Oil:
Harley-Davidson 20W-50 (or equivalent API SG/SH rated) motorcycle oil.
Transmission Oil:
SAE 85W-140 Gear Oil (GL-1 rated).
Primary Chain Case Oil:
Same as transmission oil, or Harley-Davidson Primary Chain Case Lubricant.
Brake Fluid:
DOT 4 (or specified type for the system).
Rear Main Seal Leaks:
Common for Evolution engines to develop slight leaks over time; proactive replacement may be needed.
Carburetor Issues:
Keihin CV carburetors can require tuning adjustments and occasional diaphragm replacement.
Primary Chain Tensioner:
The stock tensioner can wear; upgraded kits are available and often recommended.
Electrical Connections:
Corrosion on connectors, especially in older bikes, can lead to intermittent electrical faults.
Brand Founding:
1903, Milwaukee, Wisconsin.
Iconic Status:
Harley-Davidson is an iconic American motorcycle manufacturer known for its V-twin engines and distinctive styling.
Sportster Lineage:
The Sportster line, introduced in 1957, is one of Harley-Davidson's longest-running models, evolving from the Ironhead engine to the Evolution engine in the mid-1980s.
1995 Sportster Significance:
The 1995 models featured the established Evolution engine and were part of a significant period of Harley-Davidson's resurgence and modernization.
Manufacturing Location:
United States
