Positioning:
The 2005 Harley-Davidson Sportster XLH series represented a crucial point in the evolution of the iconic Sportster line, known for its accessible performance and customization potential, making it a popular choice for both new riders and experienced enthusiasts.
Competition:
Competed against models from brands like Indian, Triumph (Bonneville), and custom builders offering similar displacement and styling.
Features:
Evolution Engine, classic styling, customizable platform, reliable V-twin power delivery, accessible seat height for many riders.
Covered Models:
Harley-Davidson Sportster XLH Models 2005 (e.g., XL883, XL883R, XL883C, XL883L, XL1200R, XL1200C, XL1200S - specific models confirmed by VIN)
Estimated Pages:
Approx. 600-800 pages (typical for comprehensive service manuals)
Type:
Workshop Service Repair Manual
Format:
Likely PDF (digital download), potentially available in printed format
Engine:
Engine disassembly, assembly, tuning, diagnosis, internal components (pistons, rings, valves, camshafts, crankshaft), oil pump, primary drive, lubrication system.
Transmission Drivetrain:
5-speed constant mesh transmission, clutch operation and adjustment, primary chain, final drive belt, troubleshooting drivetrain issues.
Fuel System:
Carburetor tuning and overhaul (e.g., Keihin CV carburetor), fuel tank, fuel lines, fuel filters, fuel pump (if applicable to specific models).
Electrical System:
Ignition system (coil, spark plugs, ignition module), battery, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting, horn, instrumentation, wiring diagrams.
Brakes:
Front and rear brake systems (caliper service, master cylinder, brake lines, bleeding procedures), brake fluid specifications.
Suspension Steering:
Front fork (oil change, seal replacement, adjustments), rear shock absorbers, steering head bearing adjustment and replacement.
Frame Bodywork:
Frame inspection, fender replacement, seat mounting, fuel tank mounting, handlebar removal/installation, body panel adjustments.
Maintenance:
Scheduled maintenance, oil and filter changes, spark plug replacement, chain adjustment, brake pad inspection, tire pressure checks.
Troubleshooting:
Diagnostic procedures for common issues, fault finding guides, symptom-based troubleshooting.
Repair:
Step-by-step instructions for component repair, replacement of wear items, and major overhauls.
Diagnostics:
Procedures for diagnosing electrical faults, engine performance issues, and mechanical problems.
Wiring Diagrams:
Detailed electrical wiring diagrams for all systems, facilitating diagnosis and repair of electrical faults.
Torque Specifications:
Comprehensive torque specifications for all critical fasteners and components, crucial for proper assembly and safety.
Depth:
Comprehensive, covering routine maintenance to complete engine and transmission rebuilds, including detailed diagnostics and specifications.
Troubleshooting Guides:
Includes dedicated troubleshooting sections for common symptoms, providing a systematic approach to identifying and resolving issues.
Digital Format:
PDF (Searchable text, high-resolution images, printable pages)
Print Quality:
High-resolution (for digital), clear diagrams and text (for printed versions)
Binding:
Spiral or perfect bound (for printed versions), designed for workshop use
Paper Type:
Durable, coated paper to resist grease and shop dirt (for printed versions)
Engine Type:
Air-cooled, Evolution V-twin (OHV, 2 valves per cylinder)
Displacement:
883cc and 1200cc variants
Bore X Stroke:
XL883: 3.00 in x 3.50 in (76.2 mm x 88.9 mm); XL1200: 3.50 in x 3.81 in (88.9 mm x 96.8 mm)
Compression Ratio:
Typically around 9.0:1 (varies slightly by model)
Horsepower:
Approx. 50-55 HP for 883cc, 60-65 HP for 1200cc (estimated at crankshaft)
Torque:
Approx. 48-52 ft-lbs for 883cc, 65-70 ft-lbs for 1200cc (estimated at crankshaft)
Carburetor:
Keihin CV (Constant Velocity) carburetor, 38mm for 1200cc models, 34mm for 883cc models
Fuel Capacity:
Typically 3.1 US gallons (11.7 liters)
Oil Capacity:
Approx. 2.6 US quarts (2.5 liters) with filter change
Oil Type Specification:
Harley-Davidson H-D 360 SAE 20W50 or equivalent API SG or higher rated motorcycle oil.
Ignition System:
Electronic ignition with single fire coil
Wheelbase:
Approx. 59.8 inches (1519 mm) (varies slightly by model)
Length:
Approx. 87.5 inches (2223 mm) (varies slightly by model)
Seat Height:
Approx. 26.5 inches (673 mm) (unladen, varies by model)
Dry Weight:
Approx. 500-540 lbs (227-245 kg) (varies by model)
Gross Vehicle Weight Rating:
Approx. 930-970 lbs (422-440 kg) (varies by model)
Front Tire Size:
Typically MT90B16 (54H) or MH90-21 (54H)
Rear Tire Size:
Typically 150/80B16 (77H)
Wheel Type:
Spoked or cast alloy, depending on model variant
Safety Certification:
Meets DOT standards for all components.
Braking System:
Dual-piston front caliper with 11.5-inch disc, single-piston rear caliper with 10-inch disc.
Lighting:
Halogen headlight, LED taillight and brake light, amber incandescent front and rear turn signals.
Frame Construction:
Steel, mild-section, backbone, cradle frame.
Oil Change Interval:
Every 2,500 miles (4,000 km) or 6 months, whichever comes first.
Primary Chain Adjustment:
Every 2,500 miles (4,000 km) or 6 months.
Spark Plug Replacement:
Every 7,500 miles (12,000 km)
Brake Fluid Flush:
Every 2 years, regardless of mileage.
Fork Oil Type:
Harley-Davidson Tractech Type 20W or equivalent Harley-Davidson fork oil.
Transmission Oil Capacity:
Approx. 0.8 US quarts (0.75 liters)
Common Issues:
Carburetor jetting sensitivity to altitude/temperature, potential oil leaks from primary cover gasket, clutch cable adjustment, steering head bearing looseness.
Oil Filter Part Number:
Harley-Davidson part number 63731-39B (or equivalent aftermarket)
Heritage:
The Harley-Davidson Sportster line, introduced in 1957, is one of the longest continuously produced motorcycle models in history, known for its V-twin engine and customization potential.
Evolution Notes:
The 2005 models benefited from continuous evolution of the Evolution engine, introduced in 1986, bringing improved reliability, performance, and refinement over earlier Sportster generations.
Manufacturing Location:
United States (Milwaukee, Wisconsin, and other facilities).
