Target Audience:
Harley-Davidson Sportster owners, independent repair shops, motorcycle enthusiasts.
Value Proposition:
Provides critical repair and maintenance information that replicates dealership-level expertise, saving owners significant cost.
Diagnostic Focus:
Detailed troubleshooting sections for common and uncommon issues faced by the 1999 Sportster models.
Engine Service:
Engine assembly, disassembly, tuning, troubleshooting, specific components (carburetor, ignition, exhaust).
Transmission Service:
Gearbox disassembly, inspection, repair, clutch service, maintenance.
Electrical System:
Wiring diagrams, ignition system, lighting, battery, charging system, starter, troubleshooting.
Frame And Suspension:
Front forks (shocks), rear shocks, frame inspection, steering head bearing service.
Braking System:
Front and rear brake caliper service, master cylinders, brake lines, bleeding procedures.
Fuel System:
Fuel tank, fuel lines, carburetor (e.g., Keihin CV), fuel pump (if applicable).
Cooling System:
Not applicable for air-cooled engines, but includes oil cooling system details.
Exhaust System:
Exhaust pipe and muffler removal, installation, gasket replacement.
Bodywork And Trim:
Fender removal/installation, seat, fuel tank mounting, handlebars, controls.
Preventive Maintenance:
Scheduled maintenance tasks, lubrication, fluid changes, filter replacements.
Troubleshooting Guides:
Systematic diagnosis of common problems and their solutions.
Component Overhaul:
Detailed steps for rebuilding major components like the engine and transmission.
Wiring Diagrams:
High-quality, detailed electrical schematics for accurate troubleshooting.
Torque Specifications:
Essential torque values for critical fasteners across all systems.
Depth Of Coverage:
Comprehensive, from basic routine maintenance to advanced engine rebuilds and electrical diagnostics.
Searchable Text:
Typically yes, allowing for quick information retrieval.
Print Resolution:
High-resolution scans suitable for printing.
Binding:
N/A (Digital PDF Download)
Paper Quality:
N/A (Digital PDF Download)
Engine Type:
Evolution (Evo) V-Twin, Air-Cooled
Engine Displacement:
883cc (57ci) and 1200cc (74ci) variants
Bore X Stroke 883Cc:
3.00 in x 3.81 in (76.2 mm x 96.8 mm)
Bore X Stroke 1200Cc:
3.50 in x 3.81 in (88.9 mm x 96.8 mm)
Compression Ratio 883Cc:
8.8:1 (approx.)
Compression Ratio 1200Cc:
9.0:1 (approx.)
Horsepower 883Cc:
Approximately 50-55 HP
Horsepower 1200Cc:
Approximately 65-70 HP
Carburetor:
Keihin CV (Constant Velocity) 34mm (883cc), Keihin CV 40mm (1200cc)
Fuel Type:
Unleaded gasoline, minimum 91 octane recommended
Oil Type Specification:
SAE 20W50 API SG
Oil Capacity With Filter:
Approx. 3 US quarts (2.8 Liters)
Transmission Type:
5-Speed Constant Mesh
Clutch Type:
Wet, multi-plate, diaphragm spring
Transmission Oil Specification:
Harley-Davidson Formula Plus or equivalent SAE 80W-90 GL-5 gear oil
Transmission Oil Capacity:
Approx. 26 US fluid ounces (0.77 Liters)
Safety Certification:
Meets DOT standards for motorcycles.
Braking System:
Hydraulic disc brakes front and rear.
Tire Specifications:
Front: 100/90-19 (typical), Rear: 130/90-16 (typical). Specifics vary by trim.
Lighting System:
Halogen headlight, tail light, brake light, turn signals.
Oil And Filter Change:
Every 2,500 miles or annually.
Primary Chain Tension Check:
Every 5,000 miles.
Spark Plug Replacement:
Every 10,000 miles.
Brake Fluid Flush:
Every 2 years (recommended).
Front Fork Oil Type:
Harley-Davidson Type 'E' or 'B' (specified by manual, typically a light weight fork oil like 10W or 15W)
Front Fork Oil Capacity:
Specify per leg as per manual (e.g., 7.6 US fl oz / 225 ml per leg for 883).
Rear Shock Oil:
N/A (most were gas or air charged, not user-serviceable oil fill).
Carburetor Tuning:
Keihin CV carburetors can require periodic adjustment for optimal performance, especially after modifications.
Primary Chain Tensioner:
Early Evo models had an automatic tensioner that could wear; manual adjustment or upgraded tensioners are common.
Vibration:
Characteristic V-twin vibration can lead to loose fasteners; regular inspection is recommended.
Ignition Module:
Potential for failure over time; detailed testing procedures are in the manual.
Manufacturer History:
Harley-Davidson is an iconic American motorcycle manufacturer with a rich history dating back to 1903.
Sportster Lineage:
The Sportster model line, introduced in 1957, is one of Harley-Davidson's longest-running and most recognizable platforms, known for its sporty handling and V-twin power.
1999 Production Significance:
The 1999 model year represents the continuation of the Evolution (Evo) engine platform for the Sportster line, which began in 1986, offering improved performance and reliability over previous Ironhead models.
