Harley Davidson Sportster 1999 Service Repair Manual

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Taper: Motorcycle

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UGS: 59955

Mots clés: 1999 Harley Davidson Misc Motorcycle Motorcycles Sportster

Variantes de produits

Description

Welcome to the definitive guide for your 1999 Sportster, a celebrated model from a legendary American manufacturer. Building upon a rich heritage dating back to 1903, the Sportster line, introduced in 1957, represents a cornerstone of the brand, renowned for its distinctive V-twin power and agile handling. The 1999 models, featuring the robust Evolution (Evo) engine, are available in 883cc and 1200cc variants, offering an authentic riding experience. This motorcycle is engineered for riders who appreciate classic design, reliable performance, and the open road, embodying a spirit of freedom and individuality. This comprehensive service manual provides essential information for the maintenance, repair, and troubleshooting of your 1999 Sportster. Covering a wide array of systems, including the engine, transmission, electrical system, brakes, fuel system, and bodywork, this manual is an invaluable resource for owners and technicians alike. It details routine maintenance procedures, component overhauls, and diagnostic strategies, complete with detailed wiring diagrams and critical torque specifications. By following the expert guidance within these pages, you can ensure your Sportster remains in peak condition, delivering the performance and reliability expected.

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

Sportster

Year:

Generation

Generation Code:

XL (Evo)

👋 Introduction

Market Position

Target Audience:

Harley-Davidson Sportster owners, independent repair shops, motorcycle enthusiasts.

Competitive Analysis

Value Proposition:

Provides critical repair and maintenance information that replicates dealership-level expertise, saving owners significant cost.

Key Features

Diagnostic Focus:

Detailed troubleshooting sections for common and uncommon issues faced by the 1999 Sportster models.

📋 Manual Details

Coverage Areas

General Coverage:

Comprehensive service, repair, and workshop information for 1999 Harley-Davidson Sportster models.

Page Count

Estimated Page Count:

300-500

Manual Type

Manual Type:

Service Manual / Workshop Manual / Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

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.

Procedures Included

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.

Technical Depth

Depth Of Coverage:

Comprehensive, from basic routine maintenance to advanced engine rebuilds and electrical diagnostics.

📊 Manual Specifications

File Format

File Type:

Searchable Text:

Typically yes, allowing for quick information retrieval.

Print Quality

Print Resolution:

High-resolution scans suitable for printing.

Binding Type

Binding:

N/A (Digital PDF Download)

Paper Type

Paper Quality:

N/A (Digital PDF Download)

⚙️ Engine Specifications

Primary Engine

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.)

Performance

Horsepower 883Cc:

Approximately 50-55 HP

Horsepower 1200Cc:

Approximately 65-70 HP

Fuel System

Carburetor:

Keihin CV (Constant Velocity) 34mm (883cc), Keihin CV 40mm (1200cc)

Fuel Type:

Unleaded gasoline, minimum 91 octane recommended

Engine Oil

Oil Type Specification:

SAE 20W50 API SG

Oil Capacity With Filter:

Approx. 3 US quarts (2.8 Liters)

🔧 Transmission

Standard

Transmission Type:

5-Speed Constant Mesh

Clutch Type:

Wet, multi-plate, diaphragm spring

Transmission Fluid

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)

📐 Dimensions

Exterior

Overall Length:

Variable by model (e.g., Sportster 883 Hugger, Sportster 1200 Custom)

Wheelbase:

Approx. 56.5 inches (1435 mm)

Weights

Dry Weight 883Cc:

Approx. 490 lbs (222 kg)

Dry Weight 1200Cc:

Approx. 500 lbs (227 kg)

Gross Vehicle Weight Rating Gvwr:

Approx. 930 lbs (422 kg)

🛡️ Safety Features

Ratings

Safety Certification:

Meets DOT standards for motorcycles.

Active Features

Braking System:

Hydraulic disc brakes front and rear.

Tire Specifications:

Front: 100/90-19 (typical), Rear: 130/90-16 (typical). Specifics vary by trim.

Passive Features

Lighting System:

Halogen headlight, tail light, brake light, turn signals.

💡 Technology Features

Infotainment

Infotainment System:

None (basic analogue gauges for speed, tachometer, fuel, oil pressure/voltage).

Driver Assistance

Driver Assistance Features:

None.

Connectivity

Connectivity Features:

None.

🔧 Maintenance

Service Intervals

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).

Fluid Specifications

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).

Known Issues

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.

📚 Vehicle History

Brand Heritage

Manufacturer History:

Harley-Davidson is an iconic American motorcycle manufacturer with a rich history dating back to 1903.

Model Evolution

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.

Production

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.

🏆 Awards & Recognition

Recognitions

Model Recognition:

The Harley-Davidson Sportster is consistently recognized as a foundational model in the cruiser and custom motorcycle segments.