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Harley Davidson Sportster XLH Models 2005 Repair Service
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🏷️ Basic Information Identification Make: Harley-Davidson Model: Sportster XLH Year: 2005 Chassis Code: XLH Product Type: Repair Service Manual Download Availability: Instant Download 👋 Introduction Market Position Motorcycle Segment: Cruiser,...
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🏷️ Basic Information
Identification
Make:
Harley-Davidson
Model:
Sportster XLH
Year:
2005
Chassis Code:
XLH
Product Type:
Repair Service Manual
Download Availability:
Instant Download
👋 Introduction
Market Position
Motorcycle Segment:
Cruiser, Standard Motorcycle
Brand Heritage:
Harley-Davidson is renowned for its iconic cruiser motorcycles, a strong legacy of American V-twin engineering, and a passionate rider community.
Competitive Analysis
Competitors:
Competes with other American V-twins and similarly styled motorcycles from Japanese and European manufacturers in the cruiser segment.
Key Features
Sportster Identity:
The Sportster line is known for its classic styling, accessible performance, and relative affordability within the Harley-Davidson lineup.
Manual Value Proposition
Value For Buyers:
Provides essential technical data and procedures to maintain, troubleshoot, and repair the 2005 Sportster XLH models, saving time and money on professional servicing.
📋 Manual Details
Coverage Areas
Primary Coverage:
Service and Repair
Target Audience:
Professional Technicians and Experienced DIY Enthusiasts
Page Count
Estimated Page Count:
Extensive (exact count not specified, typical for comprehensive manuals)
Manual Type
Type:
Service Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Engine overhaul, top-end, bottom-end, ignition, fuel system, lubrication, cooling (air-cooled)
Transmission:
Clutch, gearbox, primary drive, final drive, lubrication
Chassis:
Frame, front suspension (forks), rear suspension (shocks), steering, wheels, tires
Electrical:
Battery, charging system, ignition system, lighting, starter, instruments, wiring diagrams, ECM
Brakes:
Front and rear brake systems, hydraulic components, adjustments
Fuel System:
Carburetor (typically Keihin CV40), fuel lines, fuel pump, fuel tank
Exhaust System:
Exhaust pipes, mufflers, mounting
Bodywork:
Fenders, fuel tank, seat, handlebars, controls, minor body component removal and installation
Procedures Included
Routine Maintenance:
Oil changes, filter replacement, chain adjustment, tire pressure, brake pad inspection
Troubleshooting:
Diagnostic charts, common problem identification, symptom analysis
Repair And Rebuild:
Complete engine disassembly and reassembly, transmission rebuilds, suspension component replacement, electrical system repairs
Diagnostics:
Component testing, electrical system diagnosis, use of diagnostic tools (where applicable)
Specifications And Tolerances:
Torque values, clearances, measurements for all major components
Technical Depth
Depth:
Comprehensive, covering all aspects from basic maintenance to complete engine and transmission overhauls.
Detail Level:
Detailed step-by-step instructions, exploded views, and diagnostic flowcharts.
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchability:
Likely text-searchable, facilitating quick information retrieval.
Print Quality
Quality:
Designed for clear digital viewing and printing. Image quality is typically high resolution for diagrams.
Binding Type
Binding:
N/A (Digital PDF format)
Paper Type
Paper Type:
N/A (Digital PDF format)
Software Requirements
Viewing Software:
Adobe Acrobat Reader or compatible PDF viewer.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-cooled, 45-degree V-twin, OHV (Overhead Valve)
Displacement:
1200cc (73.4 cubic inches) and 883cc (53.9 cubic inches) variants common for XLH models of this era.
Bore X Stroke:
1200cc: 3.50 in. x 3.81 in. (88.9 mm x 96.8 mm); 883cc: 3.00 in. x 3.81 in. (76.2 mm x 96.8 mm)
Compression Ratio:
Typically around 9.0:1 to 9.7:1 depending on the specific model variant and engine size.
Performance
Horsepower Estimate:
Around 60-70 HP for 1200cc models; 50-60 HP for 883cc models (actual figures can vary).
Torque Estimate:
Around 65-75 ft-lbs for 1200cc models; 50-60 ft-lbs for 883cc models (actual figures can vary).
Fuel System
Fuel Delivery:
Carbureted. Typically a Keihin CV40 (Constant Velocity) carburetor.
Fuel Type:
Unleaded gasoline, minimum octane rating of 91 (USA) / 95 (Europe) recommended.
Lubrication
Oil Type:
Harley-Davidson SYN3 (Full Synthetic) or equivalent SAE 20W50 motorcycle-specific oil.
Oil Capacity:
Approximately 3.0 US quarts (2.8 L) with filter change (verify specific model).
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh manual transmission.
Optional
Optional Transmission:
Not applicable for this model year.
Features
Primary Drive:
Patented Self-Contained Primary Drive System (enclosed chain drive).
Final Drive:
Enclosed final belt drive.
Fluid Specification
Transmission Fluid Type:
Harley-Davidson Transmission Fluid or SAE 80W-90 Hypoid gear lubricant.
Fluid Capacity
Transmission Fluid Capacity:
Approximately 1 US quart (0.95 L) (verify specific model).
📐 Dimensions
Exterior
Length:
Varies by model variant, typically around 88-90 inches (2235-2286 mm).
Width:
Varies by model variant, typically around 32-36 inches (813-914 mm).
Seat Height:
Varies by model variant, typically around 26-28 inches (660-711 mm).
Weights
Dry Weight:
Approximately 500-550 lbs (227-249 kg) depending on the model variant.
Gross Vehicle Weight Rating:
Typically around 900-950 lbs (408-431 kg).
Cargo
Cargo Capacity:
Minimal; reliant on optional saddlebags or luggage racks.
🛡️ Safety Features
Ratings
Safety Standards:
Meets or exceeds all applicable federal motor vehicle safety standards (FMVSS) for motorcycles.
Active Features
Braking System:
Dual-disc front brake, single-disc rear brake with hydraulic actuation.
Lighting:
Halogen headlamp, taillight, brake light, turn signals.
Passive Features
Frame Construction:
Steel tube frame designed for rigidity and rider support.
💡 Technology Features
Infotainment
Infotainment System:
Basic; typically a speedometer, odometer, tachometer (optional), and indicator lights. No integrated infotainment system.
Driver Assistance
Driver Assistance Features:
None. Focus is on rider control and mechanical engagement.
Connectivity
Connectivity Options:
None. Primarily mechanical and electrical systems.
Ignition System
Ignition Type:
Electronic Ignition (single fire).
🔧 Maintenance
Service Intervals
Initial Service:
Typically around 1,000 miles (1,600 km).
Subsequent Service:
Every 5,000 miles (8,000 km) or annually, whichever comes first (includes oil change, filter, inspection).
Major Service Intervals:
Spark plugs, drive belt inspection/adjustment typically every 10,000-15,000 miles (16,000-24,000 km).
Fluid Specifications
Engine Oil Spec:
SAE 20W50 Motorcycle Oil (Harley-Davidson SYN3 recommended).
Primary Chain Case Fluid Spec:
Harley-Davidson Primary Chain Case Lubricant or SAE 85W-140 Hypoid gear lubricant.
Transmission Fluid Spec:
Harley-Davidson Transmission Fluid or SAE 80W-90 Hypoid gear lubricant.
Brake Fluid Spec:
DOT 4 Hydraulic Fluid.
Known Issues
Common Wear Items:
Clutch plates, brake pads, wheel bearings, drive belt, spark plugs, primary chain tensioner (can wear).
Potential Electrical:
Battery charging system issues (stator/regulator), wiring harness integrity.
Carburetor Tuning:
CV carburetor can require periodic adjustments or cleaning for optimal performance and idle stability.
Filter Part Numbers
Oil Filter Part Number:
Harley-Davidson Part Number 63796-77A (and equivalents from aftermarket suppliers like K&N, Wix, etc.).
📚 Vehicle History
Brand Heritage
Founding:
Harley-Davidson Motor Company founded in 1903.
Model Evolution
Sportster Introduction:
The Sportster line was first introduced in 1957 and has evolved significantly over the decades, maintaining its core identity.
2005 Updates:
The 2005 models typically featured fuel injection becoming more common on larger displacements, but carburetor models remained prevalent, especially for XLH variants.
Production
Manufacturing Location:
United States (primarily Milwaukee, Wisconsin and York, Pennsylvania).
🏆 Awards & Recognition
Recognitions
Model Recognition:
The Sportster line is a long-standing and highly respected model in the cruiser motorcycle market, known for its enduring appeal and customization potential.
Ratings
Customer Satisfaction:
Generally high among Harley-Davidson owners, often driven by brand loyalty and the riding experience. Maintenance satisfaction is directly tied to owner involvement and quality of service.
Certifications
Technical Certification:
Manual adheres to industry standards for technical documentation and repair procedures.