Harley Davidson Sportster XLH 2005 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: Sportster XLH Year: 2005 Chassis Code: XLH Codes Engine Code Prefix: XL 👋 Introduction Market Position Positioning: The Harley-Davidson Sportster line has historically...

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Taper: Motorcycle

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UGS: 438426

Mots clés: 2005 Harley Davidson Misc Motorcycle Motorcycles Sportster XLH

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

Sportster XLH

Year:

Chassis Code:

Codes

Engine Code Prefix:

👋 Introduction

Market Position

Positioning:

The Harley-Davidson Sportster line has historically been positioned as a more accessible and nimble option within the Harley-Davidson lineup, appealing to a broader range of riders.

Competitive Analysis

Competitors:

Competes with other mid-size V-twin cruisers and sportbikes from manufacturers like Indian, Triumph, and some Japanese manufacturers, depending on the specific Sportster variant.

Key Features

Engine Type:

Air-cooled, Evolution V-twin engine

Handling:

Known for its relatively lighter weight and more agile handling compared to larger Harley-Davidson models.

Customization:

Highly popular platform for customization and personalization.

📋 Manual Details

Coverage Areas

Primary Focus:

Repair and Maintenance

Scope:

Comprehensive Workshop Service

Page Count

Total Pages:

Manual Type

Type:

Workshop Service Manual

Purpose:

Detailed repair and servicing procedures

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine:

V-Twin Evolution Engine (All configurations for 2005 XLH)

Fuel System:

Carburetor (Keihin CV type), Fuel Lines, Fuel Tank, Fuel Pump (if applicable for specific sub-models)

Ignition System:

Electronic Ignition, Spark Plugs, Ignition Coils, Tacho Drive

Transmission:

5-Speed Constant Mesh Gearbox, Clutch Assembly, Primary Drive System

Drivetrain:

Belt Drive System, Rear Wheel Hub, Bearings

Suspension:

Front Fork Assembly (Telescopic), Rear Shock Absorbers, Swingarm

Brakes:

Front Disc Brake System, Rear Disc Brake System, Brake Lines, Master Cylinders, Calipers

Electrical System:

Wiring Harness, Battery, Charging System (Stator, Regulator/Rectifier), Lighting System (Headlight, Taillight, Indicators), Starter System, Switches, Fuses

Exhaust System:

Exhaust Pipes, Mufflers, Mounting Hardware

Wheels And Tires:

Wheel Bearings, Axles, Tire Specifications, Inflation Pressures

Frame And Bodywork:

Frame Structure, Sheet Metal Components, Seat, Handlebars, Controls

Lubrication System:

Oil Tank, Oil Pump, Oil Filter, Oil Lines

Procedures Included

Maintenance:

Scheduled Maintenance, Oil Changes, Filter Replacements, Chain Adjustment (if applicable), Belt Tension Adjustment

Troubleshooting:

Diagnostic Flowcharts, Fault Finding Procedures for all major systems

Repair:

Engine Overhaul, Transmission Rebuild, Fork Seal Replacement, Brake Caliper Overhaul, Electrical Component Diagnosis and Replacement

Disassembly And Assembly:

Detailed steps for component removal and reinstallation

Specifications And Tolerances:

Torque Values, Clearances, Wear Limits

Wiring Diagrams:

Complete Electrical Schematics

Technical Depth

Depth:

In-depth technical procedures suitable for professional technicians and advanced DIY mechanics.

Diagnostics:

Advanced diagnostic techniques, including troubleshooting based on symptoms and electrical test procedures.

Rebuild Procedures:

Comprehensive rebuild instructions for major components like the engine, transmission, and forks.

📊 Manual Specifications

File Format

Type:

Digital (PDF)

Searchability:

Searchable text within the PDF for quick information retrieval.

Print Quality

Quality:

High-resolution scans of original factory documentation, ensuring clarity of text and diagrams.

Binding Type

Type:

Not Applicable (Digital PDF)

Paper Type

Type:

Not Applicable (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Type:

Air-cooled, 45-degree V-twin Evolution engine

Displacement:

88 cubic inches (1450cc)

Bore X Stroke:

3.500 in x 3.812 in (88.9 mm x 96.8 mm) - Typical for 88ci Evolution

Compression Ratio:

9.0:1 (Typical for 2005 models)

Performance

Horsepower:

Approx. 60-70 HP (Engine dependent, manual will specify exact)

Torque:

Approx. 70-80 ft-lbs (Engine dependent, manual will specify exact)

Fuel System

Fuel Delivery:

Keihin 40mm CV (Constant Velocity) Carburetor

Fuel Type:

Unleaded gasoline, minimum 87 octane (refer to manual for specific recommendations)

Lubrication System

Oil Type:

Harley-Davidson Genuine V-Twin Oil, SAE 20W50 (or equivalent)

Oil Capacity:

Approx. 3 quarts (2.8 liters) with filter change (verify in manual)

Cooling

Method:

Air-cooled

🔧 Transmission

Standard

Type:

5-speed, constant mesh, helical gears

Primary Drive:

Duplex chain, 1.406:1 ratio

Final Drive:

Belt drive, 3.15:1 ratio (48/15 or similar)

Optional

Type:

None for 2005 XLH Sportster

Features

Clutch:

Wet, multi-plate

Transmission Oil Type:

Harley-Davidson Formula+ (or SAE 50 gear oil for primary/transmission)

Transmission Oil Capacity:

Approx. 2.8 pints (1.3 liters) for primary/transmission (verify in manual)

📐 Dimensions

Exterior

Length:

Approx. 87.0 in (2209.8 mm) - Varies slightly by model sub-variant (e.g., Custom, Standard)

Width:

Approx. 32.0 in (812.8 mm) - Varies

Height:

Approx. 47.0 in (1193.8 mm) - Varies

Weights

Dry Weight:

Approx. 550 lbs (249.5 kg) - Varies by model sub-variant

Gross Vehicle Weight Rating Gvwr:

Refer to VIN sticker/manual for specific GVWR

Cargo

Fuel Capacity:

Approx. 3.5 gallons (13.2 liters) - Varies by model sub-variant (e.g., 4.0 gal for custom tanks)

🛡️ Safety Features

Ratings

Crash Test Ratings:

Not applicable for motorcycles in the same way as cars; focus on structural integrity and rider protection features.

Active Features

Braking:

Dual disc front, Single disc rear (hydraulic actuation)

Lighting:

Halogen headlight, LED taillight, front/rear turn signals.

Passive Features

Frame Construction:

Steel, backbone type frame with downtubes

Rider Controls:

Handlebar mounted controls for throttle, clutch, brakes; foot-operated gear shift and rear brake.

💡 Technology Features

Infotainment

System:

Basic analog instrumentation (speedometer, tachometer optional), indicator lights for oil pressure, neutral, turn signals, and battery.

Driver Assistance

Features:

No electronic driver assistance systems (e.g., ABS, traction control) were standard on the 2005 Sportster XLH.

Connectivity

Features:

No modern connectivity features such as Bluetooth or smartphone integration.

🔧 Maintenance

Service Intervals

Initial Service:

1000 miles (1600 km) or 6 months, whichever comes first (Engine oil and filter change, inspection of primary drive, brakes, etc.)

Subsequent Service:

Every 5000 miles (8000 km) or 12 months (Engine oil and filter change, inspection of drive belt tension, brake fluid, etc.)

Spark Plug Replacement:

Refer to manual, typically around 10,000-15,000 miles.

Belt Tension Check:

Every 5,000 miles (8,000 km)

Fluid Specifications

Engine Oil:

Harley-Davidson Genuine V-Twin Oil, SAE 20W50 (or equivalent specified in manual)

Primary Chain Case Oil:

Harley-Davidson Formula+ or SAE 50 Gear Oil

Brake Fluid:

DOT 4 hydraulic fluid (ensure compatibility with seals)

Fork Oil:

Refer to manual for specific type and viscosity (e.g., Harley-Davidson Type E or Type B)

Known Issues

Clutch Slippage:

Can occur with age and mileage, often due to worn clutch plates or improper adjustment. Manual details adjustment and replacement.

Carburetor Tuning:

Keihin CV carburetor can require periodic tuning or cleaning for optimal performance. Manual provides guidance.

Rear Brake Wear:

Rear brake pads may wear faster than front, especially with aggressive riding. Manual details inspection and replacement.

Charging System Issues:

Stator or regulator/rectifier failure can lead to battery not charging. Manual provides diagnostic steps.

Oil Leaks:

Can occur at various seals (e.g., primary cover, engine cases). Manual details seal replacement procedures.

📚 Vehicle History

Brand Heritage

Heritage:

Harley-Davidson boasts a rich legacy dating back to 1903, synonymous with American motorcycle culture, freedom, and individuality.

Model Evolution

Sportster Line:

The Sportster line, introduced in 1957, has been a cornerstone of the Harley-Davidson brand, evolving from a performance-oriented motorcycle to a versatile cruiser.

2005 Updates:

The 2005 models, featuring the 88 cubic inch Evolution engine, represented a significant step in refining the Sportster platform, with improvements in chassis, ergonomics, and reliability over earlier generations.

Production

Manufacturing Location:

United States (Milwaukee, Wisconsin, and various facilities over time)

🏆 Awards & Recognition

Recognitions

Brand Recognition:

Harley-Davidson is consistently recognized as a top brand in the motorcycle industry for its iconic status and strong customer loyalty.

Ratings

Model Reputation:

The Sportster line is generally well-regarded for its blend of classic Harley-Davidson styling, manageable size, and customizability.

Certifications

Manual Quality:

Produced to meet rigorous OEM service documentation standards, ensuring accuracy and completeness for repair professionals.