Segment:
Cruiser Motorcycle
Target Audience:
Harley-Davidson owners, independent repair shops, parts suppliers, restorers.
Key Competitors:
Indian Scout, Yamaha V-Star, Honda Shadow, Suzuki Boulevard.
Manual Benefit:
Essential for accurate parts identification and ordering, crucial for maintenance, repair, and restoration projects.
Covered Models:
Sportster 883 Standard (STD), Sportster 883 Hugger (HUG), Sportster 883R (883R), Sportster 1200 (1200), Sportster 1200 Sport (1200S), Sportster 1200 Custom (1200C), Sportster 883 Custom (883C)
Estimated Pages:
Over 250 pages (typical for this era's IPLs)
Type:
Illustrated Parts List (IPL)
Format:
Digital (PDF) - Assumed for sales listing
Engine Assembly:
Cylinder heads, cylinders, pistons, crankshaft, connecting rods, camshafts, valves, oil pump, primary drive.
Fuel System:
Carburetor(s) (Keihin CV), fuel tank, fuel lines, petcock, air cleaner assembly, intake manifold.
Ignition System:
Ignition module, coils, spark plugs, wiring.
Transmission Drivetrain:
Transmission case, gears, bearings, clutch assembly, primary chain, final drive belt/chain (depending on specific model variant).
Electrical System:
Wiring harness, battery, starter motor, alternator, lighting (headlight, taillight, turn signals), switches, instrumentation.
Chassis Frame:
Frame components, steering head, swingarm, suspension components (forks, shocks).
Braking System:
Front and rear brake calipers, master cylinders, brake lines, brake discs, brake pads.
Wheels Tires:
Front and rear wheels, spokes, hubs, tires, tubes (if applicable).
Bodywork Fittings:
Fuel tank, fenders, seat, handlebars, controls, footpegs, mirrors, badges, trim.
Part Identification:
Detailed exploded diagrams for visual identification of every component and sub-assembly.
Part Number Reference:
Official Harley-Davidson part numbers for ordering replacements.
Assembly Disassembly Sequences:
Visual guidance on the order of assembly and disassembly for major components.
Interchangeability Notes:
Potential notes on part interchangeability between specific models or sub-variants, if applicable within the IPL.
Depth:
Comprehensive parts catalog with detailed visual breakdowns for all factory-supplied components. Does not contain repair procedures or torque specifications (these are found in Service Manuals).
Engine Family:
Evolution (Evo) V-Twin
Engine Displacement 883:
883 cc (53.7 cubic inches)
Engine Displacement 1200:
1200 cc (73.4 cubic inches)
Engine Type:
Air-cooled, 45-degree V-twin
Bore Stroke 883:
3.00 in x 3.8125 in (76.2 mm x 96.8 mm)
Bore Stroke 1200:
3.497 in x 4.25 in (88.8 mm x 108 mm)
Compression Ratio Typical:
8.8:1 to 9.7:1 (varies by model)
Horsepower 883 Approx:
~55 HP @ 5500 RPM
Horsepower 1200 Approx:
~65-70 HP @ 5200 RPM
Torque 883 Approx:
~65-70 lb-ft @ 3500 RPM
Torque 1200 Approx:
~75-80 lb-ft @ 3500 RPM
Carburetor:
Keihin CV (Constant Velocity) 34mm (883/1200 Standard) or 40mm (1200 Custom/Sport).
Fuel Type:
Unleaded gasoline, minimum 87 octane.
First Service:
1,000 miles (1,600 km) or 6 months, whichever comes first.
Subsequent Service:
Every 5,000 miles (8,000 km) or 12 months.
Engine Oil:
Harley-Davidson 20W50 (or equivalent) air-cooled V-twin specific oil. Capacity: ~3 quarts (2.8 L) with filter change.
Primary Chain Case Oil:
Harley-Davidson Formula+ (or equivalent SAE 50 primary lubricant). Capacity: ~2.8 pints (1.3 L).
Transmission Oil:
Harley-Davidson Formula+ (or equivalent SAE 50 primary lubricant). Shared with primary case.
Brake Fluid:
DOT 4, non-silicone base hydraulic fluid.
Fork Oil:
Harley-Davidson Type 'E' or equivalent (e.g., 10W) fork oil. Specific quantity per fork leg.
Carburetor Tuning:
Keihin CV carburetors can sometimes require fine-tuning for optimal performance, especially at altitude or after modifications.
Clutch Actuation:
Clutch cable adjustment and lubrication are critical for smooth operation.
Belt Tension:
Proper final drive belt tension is essential for longevity and smooth operation.
Electrical Connections:
Regular inspection of electrical connectors for corrosion or looseness is advised.
Founding:
Founded in 1903, Milwaukee, Wisconsin.
Sportster Introduction:
The Sportster line dates back to 1957, evolving significantly over the decades.
2002 Model Year Changes:
Minor refinements to styling, suspension, and engine tuning compared to previous years. Introduction of new color options.
Manufacturing Location:
Milwaukee, Wisconsin, USA
