HARLEY DAVIDSON SPORTSTER XLH ModelS Workshop Repair Manual 2005

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🏷️ Basic Information Identification Make: Harley-Davidson Model: Sportster XLH Model Variant: XLH Models (Implies a range of Sportster XLH variants) Year: 2005 Codes Engine Family Code: Evolution V-Twin (Commonly referred...

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类型: Motorcycle

斯库: 283606

标签: 2005 Harley Davidson Misc Motorcycle Motorcycles SPORTSTER XLH

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Description

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

Sportster XLH

Model Variant:

XLH Models (Implies a range of Sportster XLH variants)

Year:

Codes

Engine Family Code:

Evolution V-Twin (Commonly referred to as 'Evo')

👋 Introduction

Market Position

Target Audience:

Harley-Davidson Owners, Independent Repair Shops, Enthusiast Mechanics

Value Proposition:

Access to factory-level repair information, saving time and money on maintenance and repairs.

Competitive Analysis

Competitor Manuals:

Haynes, Clymer (These are generally less detailed than factory service manuals).

Key Features

Accuracy:

Official dealer-level information ensures accuracy and correct procedures.

Detail Level:

Step-by-step instructions with clear diagrams facilitate complex repairs.

Comprehensiveness:

Covers all aspects of maintenance, repair, and diagnostics for the specified model range.

📋 Manual Details

Coverage Areas

Manual Type:

Workshop Service & Repair Manual

Language:

English

Format:

Downloadable (Implied digital format, likely PDF)

Coverage Scope:

Full Workshop Procedures for Official Dealer Workshops

Page Count

Page Count Estimated:

Estimated 500+ pages (Typical for comprehensive workshop manuals)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul, internal components, lubrication, cooling, fuel delivery, ignition

Fuel System:

Carburetor (Keihin CV) or Fuel Injection (EFI) systems, fuel pump, lines, filters

Ignition System:

Spark plugs, ignition coils, electronic control module (ECM), timing

Transmission:

5-speed constant mesh gearbox, clutch operation, primary drive, final drive (belt)

Electrical System:

Wiring diagrams, battery, charging system, lighting, starter, ignition switches, fuses, relays

Brakes:

Front and rear hydraulic brake systems, calipers, master cylinders, brake lines, rotor specifications

Suspension:

Front telescopic forks (41mm stanchions), rear shock absorbers, fork oil specifications, adjustments

Chassis Frame:

Frame inspection, alignment, steering head bearing service

Body Fittings:

Fenders, fuel tank, seat, handlebars, controls, exhaust system, mounting points

Wheels Tires:

Wheel bearing service, tire pressure, specifications, spoke tension (if applicable)

Procedures Included

Routine Maintenance:

Oil changes, filter replacement, spark plug replacement, chain adjustment (if applicable), brake pad inspection

Troubleshooting:

Diagnostic charts, symptom-based troubleshooting guides, common fault identification

Component Rebuild:

Engine top-end and bottom-end rebuilds, transmission disassembly and assembly, carburetor/EFI unit overhaul

Electrical Diagnostics:

Circuit testing, component testing, wiring harness repair

Suspension Service:

Fork seal replacement, fork oil change, shock absorber servicing

Brake System Service:

Brake pad replacement, caliper servicing, bleeding procedures

Torque Specifications:

Detailed torque values for all critical fasteners

Technical Depth

Depth Level:

Comprehensive Rebuild and Diagnostic Procedures

Diagnostic Capability:

Advanced troubleshooting with detailed schematics and diagnostic flowcharts

Repair Detail:

Step-by-step instructions with detailed diagrams for all repair operations

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format - Common for digital manuals)

Searchability:

Likely text-searchable for quick information retrieval

Print Capability:

Printable pages for workshop use

Print Quality

Image Resolution:

High-resolution images and diagrams for clarity

Binding Type

Binding Type Physical Equivalent:

Spiral-bound or perfect-bound (typical for professional manuals for lay-flat use)

Paper Type

Paper Type Physical Equivalent:

Durable, high-quality paper suitable for workshop environments

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, Evolution V-Twin

Displacement Cc:

88 cubic inches (1442cc) - Standard for most 2005 Sportsters

Bore X Stroke Mm:

3.50 in x 4.47 in (88.9 mm x 113.6 mm) (Typical for 88ci Evo)

Compression Ratio:

9.0:1 (Typical)

Valve Train:

Overhead Valves (OHV), 2 valves per cylinder, pushrod actuated

Performance

Horsepower Hp Estimated:

Approximately 65-70 HP (Varies slightly by specific model variant)

Torque Ft Lbs Estimated:

Approximately 70-75 ft-lbs @ 3200 RPM (Varies slightly)

Fuel System

Fuel Delivery:

Keihin CV 40mm Carburetor or Electronic Fuel Injection (EFI) depending on specific XLH sub-model.

Fuel Type:

Unleaded gasoline, minimum 91 octane (RON+MON)/2

Fuel Tank Capacity Liters:

Typically 3.5 US gallons (13.3 liters) for standard tank, or 4.5 US gallons (17 liters) for larger tanks.

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Primary Drive:

Duplex chain in oil bath

Final Drive:

Carbon fiber reinforced belt drive

Features

Clutch Type:

Wet multi-plate

Gear Ratios:

Specific ratios are detailed within the manual, crucial for performance tuning.

📐 Dimensions

Exterior

Wheelbase Mm:

Approximately 1510 mm (59.5 inches) - Varies slightly by model

Seat Height Mm:

Approximately 720 mm (28.3 inches) - Unladen

Weights

Dry Weight Kg:

Approximately 250 kg (550 lbs) - Varies by specific model and accessories

🛡️ Safety Features

Ratings

Safety Standards:

Compliance with DOT (Department of Transportation) and EPA (Environmental Protection Agency) regulations for motorcycles.

Active Features

Braking System:

Dual-piston front caliper, single-piston rear caliper, hydraulic actuation.

Passive Features

Lighting:

Halogen headlight, taillight, brake light, turn signals.

💡 Technology Features

Infotainment

Infotainment Features:

Basic analog instrumentation (speedometer, tachometer, fuel gauge). No integrated infotainment systems in the modern sense.

Driver Assistance

Driver Assistance Features:

None typically featured on 2005 Sportster models.

Connectivity

Connectivity Features:

No electronic connectivity features like Bluetooth or USB ports.

🔧 Maintenance

Service Intervals

First Service Km Miles:

Typically 1,000 miles (1,600 km) - Oil change, filter, primary chain adjustment, general inspection.

Subsequent Services Km Miles:

Every 5,000 miles (8,000 km) or annually - Oil change, filter, spark plugs, belt inspection, brake service, general inspection.

Fluid Specifications

Engine Oil Type:

Harley-Davidson Genuine V-Twin Motorcycle Oil 20W50 or equivalent API SG certified oil. Specific part numbers are in the manual.

Engine Oil Capacity Liters:

Approximately 3.0 US quarts (2.8 liters) with filter change.

Primary Chain Case Oil Type:

Harley-Davidson Genuine Primary Chain Case Lubricant or Syn3 Fully Synthetic Motorcycle Oil.

Primary Chain Case Oil Capacity Liters:

Approximately 1.0 US quart (0.95 liters).

Transmission Oil Type:

Harley-Davidson Genuine Transmission Lubricant or Syn3 Fully Synthetic Motorcycle Oil.

Transmission Oil Capacity Liters:

Approximately 0.8 US quarts (0.76 liters).

Fork Oil Type:

Harley-Davidson Genuine Fork Oil (viscosity specified in manual, typically 10W or 15W).

Known Issues

Common Wear Items:

Clutch friction plates, belt drive, wheel bearings, fork seals, exhaust gaskets.

Carburetor Tuning:

CV carburetor tuning can be sensitive to altitude and modifications. Manual provides detailed procedures.

Electrical Connectors:

Corrosion or loose connections can cause intermittent electrical issues, which the manual helps diagnose.

📚 Vehicle History

Brand Heritage

Harley Davidson Legacy:

Founded in 1903, renowned for its V-twin engines and iconic motorcycle designs.

Model Evolution

Sportster Lineage:

The Sportster platform has been in continuous production since 1957, evolving significantly over the decades.

2005 Sportster Updates:

2005 saw continued refinement of the Evolution engine and chassis, with potential for minor aesthetic or functional updates across various XLH models.

Production

Manufacturing Location:

Milwaukee, Wisconsin, USA (Primary manufacturing location for Harley-Davidson)

🏆 Awards & Recognition

Recognitions

Harley Davidson Market Recognition:

Harley-Davidson consistently ranks high in brand loyalty and recognition within the motorcycle industry.

Ratings

Sportster Model Reputation:

The Sportster line is widely regarded as a versatile platform, suitable for customization and everyday riding.