Harley Davidson XLH Sportster 1200 2002 Service Manual

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

The 2002 XLH Sportster 1200 is an iconic American motorcycle, powered by a 1200cc air-cooled V-Twin Evolution engine. Known for its distinctive styling and the heritage of the Sportster lineage...

22 people are viewing this right now

Taper: Motorcycle

Distributeur:

UGS: 64655

Mots clés: 2002 Harley Davidson Motorcycle Motorcycles Sportster XLH Sportster 1200

Variantes de produits

Description

The 2002 XLH Sportster 1200 is an iconic American motorcycle, powered by a 1200cc air-cooled V-Twin Evolution engine. Known for its distinctive styling and the heritage of the Sportster lineage dating back to 1957, this model embodies a commitment to robust engineering and a classic riding experience. Designed for enthusiasts who appreciate the raw power and customization potential of a V-Twin, the XLH Sportster 1200 offers a blend of performance and enduring design, making it a sought-after machine for both cruising and personal expression. This comprehensive workshop repair service manual provides in-depth coverage for the 2002 XLH Sportster 1200, encompassing all models, engines, trims, and transmissions. It details essential service, maintenance, and troubleshooting procedures, offering step-by-step instructions, detailed illustrations, and technical specifications. This manual is an indispensable resource for owners and technicians alike, empowering them to perform diagnostics, repairs, and routine maintenance with precision, ensuring the longevity and optimal performance of their motorcycle.

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

XLH Sportster 1200

Year:

Engine Type:

V-Twin, Air-Cooled

Trim Level:

All Models/Engines/Trim/Transmissions Types

Generation

Model Generation:

Evo Sportster (XL Evolution Engine)

👋 Introduction

Market Position

Target Audience:

Harley-Davidson XLH Sportster 1200 2002 Owners and Technicians

Value Proposition:

Empowers DIY repairs, saves significant money on service costs

Competitive Analysis

Advantage Over Competitors:

Same as used in local service/repair shops; often factory manual not available in stores.

Key Features

Convenience:

Instant download, digital format protects from dirt and oil.

Completeness:

COMPLETE and INTACT, no missing/corrupt parts or pages.

📋 Manual Details

Coverage Areas

Primary Coverage:

Service, Maintenance, Troubleshooting, Repair

Comprehensive Scope:

All Models/Engines/Trim/Transmissions Types for 2002 XLH Sportster 1200

Page Count

Estimated Pages:

Hundreds (Actual number not specified, but stated as extensive)

Manual Type

Type:

Workshop Repair Service Manual

Source:

Original Manufacturer Documentation (Harley-Davidson)

Language

Language:

English

Format

File Format:

PDF Download

📖 Manual Coverage

Systems Covered

General Information:

Maintenance:

Chassis:

Fuel System:

Cooling System:

Yes (Air-Cooled)

Engine:

Clutch:

Engine Lubrication System:

Engine Removal Installation:

Drive System:

Transmission:

Wheels Tires:

Final Drive:

Brakes:

Suspension:

Steering:

Frame:

Electrical System:

Wiring Diagrams:

Procedures Included

Diagnostic Procedures:

Repair Procedures:

Yes (Step-by-step)

Maintenance Procedures:

Troubleshooting:

Disassembly:

Assembly:

Cleaning:

Reinstallation:

Tool Requirements:

Technical Depth

Depth Level:

Professional Technician Level

Detail Level:

Detailed substeps, notes, cautions, warnings

Illustrations:

Hundreds of diagrams, detailed illustrations, drawings, and photos

Information Accessibility:

Numbered table of contents for fast access

📊 Manual Specifications

File Format

Format:

Readability Features:

Zoom In/Out functionality

Print Quality

Printability:

Full Printable

Page Handling:

Print desired sections and discard after use

Binding Type

Binding:

Digital (No physical binding)

Paper Type

Paper Type Equivalence:

Equivalent to factory paper manuals (for printed sections)

Delivery

Delivery Method:

Instant Download

Requirements

Software Requirements:

Adobe PDF Reader & WinZip

Operating System Compatibility:

All Versions of Windows & Mac

⚙️ Engine Specifications

Primary Engine

Engine Code:

Evolution (Evo)

Engine Displacement:

1200cc (73.7 cubic inches)

Engine Configuration:

45-degree V-Twin

Cooling Method:

Air-Cooled

Performance

Horsepower:

Approx. 60-65 HP (Varies by specific tuning and configuration)

Torque:

Approx. 67-70 ft-lbs (Varies by specific tuning and configuration)

Fuel System

Fuel Delivery:

Carbureted (e.g., Keihin CV Carburetor) or Electronic Fuel Injection (EFI) depending on specific model variant within the 2002 lineup.

🔧 Transmission

Standard

Transmission Type:

5-Speed Manual Constant Mesh

Optional

Optional Transmission:

N/A (Standard for 2002 XLH 1200)

Features

Drive Type:

Belt Drive (Final Drive)

📐 Dimensions

Exterior

Wheelbase:

Approx. 59.5 inches (1511 mm)

Weights

Dry Weight:

Approx. 500-520 lbs (227-236 kg) (Varies by specific model)

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (Motorcycle specific safety ratings differ from automotive)

Active Features

Braking System:

Front and Rear Disc Brakes

💡 Technology Features

Infotainment

Infotainment System:

Basic instrumentation (Speedometer, Tachometer, Odometer, Fuel Gauge). No advanced infotainment.

Driver Assistance

Driver Assistance Features:

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 2,500 - 5,000 miles or annually (Refer to manual for exact specification)

Primary Chain Tension Check:

Regularly (Refer to manual for specific intervals)

Fluid Specifications

Engine Oil Type:

Viscosity recommended: 20W-50 or 10W-40 (Harley-Davidson Genuine Motor Oil or equivalent meeting Harley-Davidson specifications)

Primary Oil Type:

Harley-Davidson Genuine Primary Chaincase Lubricant or equivalent

Transmission Oil Type:

Harley-Davidson Genuine Transmission Lubricant or equivalent

Brake Fluid Type:

DOT 4 (for hydraulic clutch if equipped, and hydraulic brake systems)

Known Issues

Common Issues:

Starter solenoid issues, carburetor tuning, primary chain adjustment, potential oil leaks, rear brake wear.

📚 Vehicle History

Brand Heritage

Brand History:

Harley-Davidson, established 1903, renowned for V-twin motorcycles and custom culture.

Model Evolution

Sportster Lineage:

The Sportster line dates back to 1957, evolving from Ironhead engines to the more modern Evolution (Evo) engine.

Production

Manufacturing Location:

United States (Milwaukee, Wisconsin and Kansas City, Missouri)

🏆 Awards & Recognition

Recognitions

Awards Certifications:

N/A (Specific awards for this model year not readily available, but Sportster is a consistently popular and iconic model.)