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Harley Davidson XL883R 2009 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: XL883R Year: 2009 Chassis Code: XL Engine Family: Evolution Codes Engine Code: Dyna/Sportster 883cc 👋 Introduction Market Position Category: Sportster Motorcycle Target Audience:...
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Type: Motorcycle
Vendor:
Sku: 419837
Harley Davidson XL883R 2009 Workshop Repair Service Manual
🏷️ Basic Information
Identification
Make:
Harley-Davidson
Model:
XL883R
Year:
2009
Chassis Code:
XL
Engine Family:
Evolution
Codes
Engine Code:
Dyna/Sportster 883cc
👋 Introduction
Market Position
Category:
Sportster Motorcycle
Target Audience:
Harley-Davidson XL883R owners and technicians
Competitive Analysis
Alternatives Consideration:
Cruiser motorcycles, other Sportster variants
Key Features
Vehicle Focus:
Performance-oriented Sportster variant with racing heritage
Manual Utility:
Essential for maintenance, repairs, and performance tuning
📋 Manual Details
Coverage Areas
Coverage:
All Models/Engines/Trim/Tra...
Page Count
Estimated Page Count:
500+
Manual Type
Type:
Workshop Repair Service Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Complete overhaul, diagnosis, timing, ignition, lubrication, cooling
Transmission:
Gearbox, clutch, drive belts, chain maintenance
Fuel System:
Carburetor (Keihin CV) or EFI, fuel pump, lines, tank
Electrical System:
Wiring diagrams, battery, charging system, lighting, ignition system, starter, ECU
Suspension:
Front fork (telescopic), rear shock absorbers, adjustments
Brakes:
Hydraulic front and rear disc brakes, caliper overhaul, fluid replacement
Bodywork:
Frame, fenders, fuel tank, seat, handlebars, controls
Wheels Tires:
Wheel bearing maintenance, tire inspection and replacement, spoke tensioning
Exhaust System:
Muffler and pipe maintenance, gasket replacement
Procedures Included
Maintenance:
Scheduled maintenance intervals, oil changes, filter replacements, spark plug checks
Troubleshooting:
Diagnostic charts, common problem diagnosis for engine, electrical, and chassis issues
Repair:
Detailed step-by-step repair procedures for all major components
Rebuilds:
Engine and transmission rebuild procedures, including torque specifications and clearances
Adjustments:
Carburetor tuning, clutch adjustment, chain tensioning, suspension setup
Technical Depth
Depth:
Comprehensive, from basic service to complete engine and transmission overhauls
📊 Manual Specifications
File Format
File Type:
PDF
Searchable Text:
Yes
Print Quality
Printability:
Printable
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-cooled, Evolution V-twin
Displacement:
883 cc (53.7 cu in)
Bore X Stroke:
3.00 in x 3.75 in (76.2 mm x 95.25 mm)
Compression Ratio:
8.8:1
Performance
Horsepower:
Approx. 53 HP @ 6000 RPM (Estimate, official figures vary)
Torque:
Approx. 51 ft-lbs @ 3750 RPM (Estimate, official figures vary)
Fuel System
Fuel Delivery:
Mikuni HSR42 or Electronic Fuel Injection (EFI) depending on specific build/market
Fuel Type:
Unleaded gasoline, minimum 91 octane recommended
Lubrication
Oil Capacity:
3.0 US qt (2.8 L)
Oil Type:
Harley-Davidson SYN3 (20W50) or equivalent API SG certified lubricant
🔧 Transmission
Standard
Type:
5-speed constant mesh
Features
Clutch Type:
Wet, multi-plate
Final Drive:
Belt drive
Transmission Fluid Capacity:
2.5 US qt (2.4 L)
Transmission Fluid Type:
Harley-Davidson Formula+ or SAE 50 gear oil
📐 Dimensions
Exterior
Length:
88.5 in (2248 mm)
Width:
34.6 in (879 mm)
Height:
47.6 in (1209 mm)
Wheelbase:
60.0 in (1524 mm)
Ground Clearance:
4.7 in (119 mm)
Weights
Dry Weight:
Approx. 515 lbs (233.6 kg)
Gross Vehicle Weight Rating:
Approx. 950 lbs (431 kg)
Fuel Capacity
Fuel Tank Capacity:
4.5 US gal (17 L)
🛡️ Safety Features
Ratings
Safety Certification:
DOT, EPA, CARB (market dependent)
Active Features
Braking System:
Dual hydraulic disc brakes (front and rear)
Lighting:
Halogen headlamp, LED tail light, incandescent turn signals
Passive Features
Frame Construction:
Steel cradle frame
💡 Technology Features
Infotainment
Infotainment System:
N/A (Basic instrumentation)
Instrumentation:
Analog speedometer, tachometer (optional), odometer, trip meter, indicator lights
🔧 Maintenance
Service Intervals
First Service:
1,000 miles (1,600 km) or 6 months
Subsequent Services:
Every 5,000 miles (8,000 km) or 12 months thereafter
Fluid Specifications
Engine Oil Type:
Harley-Davidson SYN3 20W50 or equivalent
Transmission Oil Type:
Harley-Davidson Formula+ or SAE 50 Gear Oil
Primary Chain Case Oil Type:
Harley-Davidson Formula+ or SAE 50 Gear Oil
Brake Fluid Type:
DOT 4 hydraulic fluid
Known Issues
Common Wear Items:
Clutch plates, belt drive, wheel bearings, fork seals
Electrical Concerns:
Occasional voltage regulator or stator issues reported on some Harley models of this era.
Engine Considerations:
Carbon buildup in heads with extensive short-trip use; proper warm-up and occasional higher RPM operation recommended.
Fluid Capacities
Engine Oil Capacity:
3.0 US qt (2.8 L)
Primary Chain Case Capacity:
1.0 US qt (0.95 L)
Filter Part Numbers
Oil Filter P/N:
63731-37B (common for Sportster, verify with VIN)
📚 Vehicle History
Brand Heritage
Manufacturer:
Harley-Davidson Motor Company, established 1903
Model Evolution
Sportster Lineage:
The Sportster line dates back to 1957, evolving through various engine sizes and chassis designs.
Xl883R Specifics:
The 'R' designation often signifies a sportier or more performance-oriented variant, historically featuring dual front brakes and sportier suspension.
Production
Manufacturing Location:
United States (Various Harley-Davidson facilities)
🏆 Awards & Recognition
Recognitions
Industry Awards:
While specific model awards are rare, the Sportster line is consistently recognized for its iconic status and customizability.
Ratings
Owner Satisfaction:
Generally high, particularly among riders who appreciate the classic Harley-Davidson riding experience.
Certifications
Emissions Compliance:
Complies with relevant US EPA and California Air Resources Board (CARB) standards for its model year.
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