Segment:
Cruiser Motorcycle Segment
Target Audience:
Enthusiasts and owners seeking in-depth knowledge for maintenance and repair
Competitors:
Other V-twin cruiser motorcycles of the era (e.g., Indian Chief, select Japanese cruisers)
Sportster Legacy:
Iconic model known for its accessible V-twin performance and customizable nature
Manual Value:
Provides essential technical data for maintaining originality and performance
Primary Coverage:
2005 Harley-Davidson Sportster XLH Series Motorcycles
Engine Coverage:
Evolution V-Twin Engine
Chassis Coverage:
Frame, Suspension, Wheels, Brakes, Steering
Electrical Coverage:
Ignition, Lighting, Charging System, Starting System, Instruments
Body Coverage:
Fuel Tank, Fenders, Seat, Handlebars, Controls
Estimated Pages:
Extensive (Typically 400-600 pages for factory manuals)
Type:
Factory Service Repair Workshop Manual
Purpose:
Comprehensive guide for diagnosis, repair, and maintenance
Accessibility:
Instant download, accessible on multiple devices
Licensing:
No expiry dates, no extra fees
Powertrain:
Engine assembly, disassembly, tuning, lubrication, cooling, fuel delivery (carburetor), ignition system
Drivetrain:
Clutch, primary drive, transmission (gearbox), final drive (belt drive)
Chassis And Suspension:
Frame inspection and repair, front fork assembly and service, rear shock absorber replacement and adjustment, wheel bearing service
Brakes:
Front and rear brake system service (calipers, master cylinders, brake lines, fluid flush and bleed), parking brake adjustment
Steering:
Handlebar replacement, steering head bearing service and adjustment
Electrical System:
Battery maintenance, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), ignition system (ignition module, coils, spark plugs), lighting system (headlight, taillight, turn signals), instrument cluster functions and troubleshooting
Fuel System:
Carburetor overhaul and adjustment (e.g., Keihin CV carburetor), fuel tank service, fuel lines
Maintenance:
Oil change, filter replacement, spark plug replacement, chain adjustment (if applicable), tire pressure checks, brake pad inspection, battery terminal cleaning
Troubleshooting:
Diagnostic flowcharts for common starting, running, and electrical issues
Repair:
Complete engine teardown and rebuild, transmission repair, fork seal replacement, brake caliper rebuild, electrical component replacement
Specifications:
Torque specifications for all fasteners, engine timing, valve lash adjustment, electrical system voltage checks
Assembly Disassembly:
Step-by-step instructions with detailed diagrams for component removal and installation
Depth:
Comprehensive factory-level detail, suitable for professional mechanics and experienced DIY enthusiasts
Diagnostics:
Includes guidance on identifying symptoms and diagnosing root causes of mechanical and electrical problems
Illustrations:
Detailed exploded views, wiring diagrams, and repair illustrations
Engine Type:
Air-cooled, Evolution V-twin
Displacement:
88 cubic inches (1449cc)
Bore X Stroke:
3.437 in x 3.812 in (87.3 mm x 96.8 mm)
Valve Train:
Pushrod-actuated, overhead valves, two valves per cylinder
Horsepower:
Approximately 65-70 hp (estimated, varies with tuning)
Torque:
Approximately 75-80 lb-ft (estimated, varies with tuning)
Carburetor:
Keihin CV (Constant Velocity) 40mm
Fuel Type:
Unleaded gasoline, minimum 89 octane
Oil Type:
Harley-Davidson 20W-50 (or equivalent API SG rated)
Oil Capacity:
3.0 US quarts (2.8 liters) with filter change
Type:
5-speed constant mesh
Gear Ratios:
1st: 9.007, 2nd: 6.056, 3rd: 4.423, 4th: 3.432, 5th: 2.945
Primary Drive:
Duplex chain drive, 34/46T
Clutch:
Wet, multi-plate, diaphragm spring
Transmission Oil Type:
Harley-Davidson Primary Chain Lubricant (or equivalent SAE 80W)
Transmission Oil Capacity:
2.5 US quarts (2.4 liters)
Final Drive:
Belt drive, 68/29T, 1.5 inch belt width
Crash Test Results:
N/A (Motorcycles are not subjected to automotive crash testing standards)
Braking System:
Dual-action front brake (single disc), rear drum brake (standard on many XLH models, disc optional/varied)
Lighting:
Headlight, taillight, brake light, turn signals
Frame Construction:
Steel tube frame
Ergonomics:
Rider-centric controls for confident operation
Features:
Basic instrument cluster: speedometer, odometer, trip meter, neutral indicator, oil pressure light, turn signal indicators
Features:
N/A (No electronic rider aids typical for this era)
Features:
N/A (No modern connectivity features like Bluetooth or Wi-Fi)
Initial Service:
First service typically at 1,000 miles (1600 km)
Regular Oil Change:
Every 2,500-5,000 miles (4000-8000 km) or 6 months
Primary Oil Change:
Every 5,000-10,000 miles (8000-16000 km) or 12 months
Belt Drive Check:
Inspect belt tension and condition every 2,500 miles (4000 km)
Engine Oil Viscosity:
20W-50
Primary Oil Viscosity:
SAE 80W
Brake Fluid Type:
DOT 4 (or as specified by Harley-Davidson for this model year)
Carburetor Tuning:
CV carburetor can require periodic adjustment for optimal performance and idle stability
Belt Drive Wear:
Belt tension and alignment are critical to prevent premature wear
Electrical Connections:
Corrosion on connectors can lead to intermittent electrical issues
Fork Seals:
Leaking fork seals are a common maintenance item
Harley Davidson Founding:
Founded in 1903, Milwaukee, Wisconsin
Sportster Introduction:
The Sportster line was introduced in 1957, evolving significantly over decades
Evolution Engine Era:
The Evolution engine debuted in 1984, marking a significant technological advancement over the Ironhead Sportster
2005 Model Significance:
Represents a mature stage of the Evolution engine Sportster, refined with electronic ignition and a 5-speed transmission.
Manufacturing Location:
United States (primarily York, Pennsylvania and Milwaukee, Wisconsin)
