Harley Davidson Sportster XL XLH 1986 Full Service Repair Manual

Prix habituel: $16.99
Prix soldé: $16.99
Prix habituel
Prix unitaire: par

🏷️ Basic Information Identification Make: Harley-Davidson Model: Sportster Model Variant: XL, XLH Year: 1986 👋 Introduction Market Position Motorcycle Segment: Cruiser/Standard motorcycle Competitive Analysis Competitors 1986: Other American V-twin motorcycles,...

15 people are viewing this right now

Taper: Motorcycle

Distributeur:

UGS: 524109

Mots clés: 1986 Harley Davidson Misc Motorcycle Motorcycles Sportster XL Sportster XLH

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

Sportster

Model Variant:

XL, XLH

Year:

👋 Introduction

Market Position

Motorcycle Segment:

Cruiser/Standard motorcycle

Competitive Analysis

Competitors 1986:

Other American V-twin motorcycles, Japanese inline-fours and V-twins in a similar displacement range (e.g., Yamaha Virago, Honda Shadow, Kawasaki Vulcan).

Key Features

Sportster Identity:

Known for its iconic V-twin engine, lightweight chassis relative to larger Harley-Davidson models, and customisable platform.

Value Proposition

Manual Value:

Essential for owners and mechanics to maintain, repair, and troubleshoot the 1986 Sportster, ensuring longevity and optimal performance of this classic American motorcycle.

📋 Manual Details

Coverage Areas

Covered Models:

All 1986 Harley-Davidson Sportster XL and XLH models

Page Count

Estimated Page Count:

Approximately 300-500 pages (typical for a full service manual of this era)

Manual Type

Manual Type:

Full Service Repair Manual

Language

Language:

English

Format

Format:

Likely printed (original factory manual or high-quality reproduction); digital formats like PDF may also be available from aftermarket suppliers.

📖 Manual Coverage

Systems Covered

Engine Service:

Complete overhaul, troubleshooting, carburetor tuning (e.g., Keihin butterfly, CV carbs), ignition system (points, electronic), oil system, cooling system (air-cooled), piston and cylinder reconditioning, valve train service, timing.

Transmission Service:

4-speed and 5-speed transmission (depending on specific XLH variant) overhaul, clutch service, gear inspection, bearing replacement, lubrication.

Electrical System:

Wiring diagrams, lighting systems, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), battery service, ignition system troubleshooting, instrument cluster.

Chassis And Suspension:

Frame inspection and repair, front fork service (telescopic forks, seals, oil), rear shock absorber service, wheel bearings, steering head bearings, swingarm service.

Braking System:

Front and rear brake system service (drum brakes and early disc brakes depending on model variant), hydraulic fluid flush and bleed, caliper and master cylinder overhaul, brake pad/shoe replacement.

Fuel System:

Fuel tank inspection, fuel lines, fuel petcock service, carburetor disassembly and cleaning/rebuilding.

Exhaust System:

Exhaust pipe and muffler service, gasket replacement.

Bodywork And Trim:

Fender removal and installation, seat service, minor body panel adjustments, trim piece identification.

Procedures Included

Routine Maintenance:

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

Troubleshooting Guides:

Step-by-step diagnostic procedures for common issues related to starting, running, electrical faults, and braking.

Rebuilding Procedures:

Detailed instructions for rebuilding key components such as carburetors, brake calipers, master cylinders, and potentially engine components.

Assembly And Disassembly:

Comprehensive guides for the safe and correct disassembly and reassembly of all major motorcycle systems.

Performance Tuning:

Guidance on carburetor adjustments and timing for optimal engine performance.

Technical Depth

Depth Of Coverage:

Full mechanical and electrical overhaul, detailed diagnostics, component-level repair, and performance tuning.

Diagnostic Procedures:

Detailed procedures for diagnosing electrical and mechanical faults, including common symptoms and their probable causes.

Specifications Charts:

Includes torque specifications for critical fasteners, clearances, fluid capacities, and electrical resistance values.

📊 Manual Specifications

File Format

Digital File Format:

PDF (if digital version)

Print Quality

Print Quality:

High-quality reproduction with clear diagrams and text (for printed versions)

Binding Type

Binding Type:

Likely staple-bound or perfect-bound for original; comb or spiral binding for aftermarket reproductions.

Paper Type

Paper Type:

Durable, matte finish paper suitable for workshop environments.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, 45-degree V-twin

Engine Displacement Xl:

883cc (53.9 cu in)

Engine Displacement Xlh:

1100cc (67.1 cu in)

Bore Stroke 883:

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

Bore Stroke 1100:

80.0 mm x 108.0 mm (3.15 in x 4.25 in)

Compression Ratio 883:

8.0:1

Compression Ratio 1100:

8.0:1

Engine Build:

Pushrod actuated overhead valves (OHV), 2 valves per cylinder

Performance

Horsepower 883 Approx:

48-55 hp

Horsepower 1100 Approx:

60-65 hp

Torque 883 Approx:

56-60 ft-lbs

Torque 1100 Approx:

65-70 ft-lbs

Fuel System

Carburetor Type:

Keihin butterfly or constant velocity (CV) carburetor

Carburetor Size 883:

Carburetor Size 1100:

Fuel Type:

Unleaded gasoline, minimum 87 octane (check manual for specifics)

🔧 Transmission

Standard

Transmission Type Xl:

4-speed manual constant mesh

Transmission Type Xlh:

5-speed manual constant mesh

Features

Clutch Type:

Multi-plate, wet clutch operated by cable

Primary Drive:

Duplex chain drive to clutch basket

Final Drive:

Belt drive or chain drive (depending on specific model variant)

Transmission Oil Type:

API GL-4 SAE 80W or 85W gear oil (check manual for exact specification and capacity)

📐 Dimensions

Exterior

Length Approx:

2235 mm (88.0 in)

Width Handlebars:

850 mm (33.5 in)

Wheelbase Approx:

1510 mm (59.4 in)

Seat Height Approx:

720 mm (28.3 in)

Weights

Dry Weight Xl Approx:

208 kg (459 lbs)

Dry Weight Xlh Approx:

215 kg (474 lbs)

Fuel Capacity:

13.0 L (3.3 US gal)

Oil Capacity Engine Transmission:

2.8 L (3 US qt) (check manual for exact fill)

🛡️ Safety Features

Ratings

Crash Safety Ratings:

N/A for motorcycles of this era; safety is primarily based on rider skill and vehicle design features.

Active Features

Braking System:

Front disc brake, rear drum brake (or dual disc on some later models/variants).

Lighting:

Headlight, tail/brake light, turn signals, running lights.

Passive Features

Frame Construction:

Steel frame designed for rigidity and rider support.

💡 Technology Features

Infotainment

Infotainment System:

None (classic motorcycle design focused on mechanicals).

Driver Assistance

Driver Assistance Features:

None (classic motorcycle design).

Connectivity

Connectivity Features:

None (classic motorcycle design).

Instrumentation

Instrument Cluster:

Analog speedometer, tachometer (optional on some models), odometer, indicator lights (oil pressure, neutral, turn signals, high beam).

🔧 Maintenance

Service Intervals

First Service:

1000 miles (1600 km) or 6 months, whichever comes first (includes engine oil/filter change, check primary chain tension, inspect brakes).

Subsequent Oil Changes:

Every 2500-3000 miles (4000-4800 km) or 6 months, whichever comes first.

Major Service Intervals:

Refer to manual for specific intervals for valve adjustments, transmission service, and carburetor tuning (typically around 7500-10000 miles).

Fluid Specifications

Engine Oil Type:

Harley-Davidson recommended V-Twin specific oil or equivalent API SF/SG 20W-50 motorcycle oil.

Transmission Oil Type:

API GL-4 SAE 80W or 85W gear oil.

Primary Chain Case Oil:

Harley-Davidson primary chain oil or equivalent SAE 20W-50 motorcycle oil.

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid (check manual for specific system requirement).

Known Issues

Common Wear Items:

Cam bushings, primary chain tensioner, wheel bearings, fork seals, carburetor diaphragm (on CV carbs).

Ignition System Notes:

Points-based ignition systems require regular timing checks and adjustment. Early electronic ignition systems may require testing of the ignition module and pickup coil.

Carburetor Performance:

Carburetors can be prone to gumming if not used regularly; proper cleaning and adjustment are critical for smooth operation.

Oil Leaks:

Can occur at primary cover, transmission seals, and rocker boxes; requires careful inspection and gasket replacement.

📚 Vehicle History

Brand Heritage

Harley Davidson Legacy:

Founded in 1903, Harley-Davidson is an iconic American motorcycle manufacturer renowned for its V-twin engines and classic styling.

Model Evolution

Sportster Lineage:

The Sportster line, introduced in 1957, has been a staple for Harley-Davidson, evolving from its 'K-Model' roots to become a versatile and accessible platform.

Production

1986 Updates:

The 1986 model year saw the introduction of the 1100cc engine for the XLH models, replacing the previous 1000cc. This era also saw the transition from points ignition to electronic ignition on many models.

Manufacturing Location:

🏆 Awards & Recognition

Recognitions

Sportster Iconic Status:

The Sportster line is widely recognized as a cultural icon in motorcycling, representing American freedom and style.

Ratings

Industry Recognition:

Consistently lauded for its distinctive V-twin rumble, customizable nature, and enduring appeal.