Target Audience:
Harley-Davidson Sportster XL/XLH owners, independent repair shops, enthusiasts
Value Proposition:
Empowers owners to perform maintenance and repairs, saving money and ensuring optimal performance and longevity.
Advantage Over Others:
Offers detailed, specific information for the 2002 model year, which may be fragmented in generic manuals.
Primary Focus:
Comprehensive repair and maintenance for the 2002 Harley-Davidson Sportster XL/XLH models.
Information Source:
Based on factory service information and extensive field testing.
Engine Coverage:
Complete engine overhaul, tuning, diagnostics
Transmission Coverage:
Disassembly, assembly, troubleshooting, fluid service
Electrical System Coverage:
Wiring diagrams, component testing, troubleshooting ignition, lighting, starting systems
Chassis And Suspension Coverage:
Fork, shock absorber, wheel bearing service, frame inspection
Brake System Coverage:
Hydraulic system bleeding, component replacement, maintenance
Fuel System Coverage:
Carburetor tuning and rebuilding, fuel pump service, fuel tank maintenance
Bodywork And Trim Coverage:
Fender, tank, seat, and accessory installation and removal
Type:
Full Service & Repair Manual
Format:
Digital Download (PDF)
Engine Systems:
Cylinder heads, cylinders, pistons, crankshaft, camshafts, valve train, oil pump, primary drive
Transmission And Drivetrain:
5-speed constant mesh gearbox, clutch assembly, final drive belt
Fuel And Exhaust:
Keihin CV carburetor, intake manifold, exhaust system
Ignition And Electrical:
Electronic ignition, battery, charging system (stator, regulator/rectifier), lighting (headlight, taillight, turn signals), starter motor, instrumentation
Brakes And Wheels:
Front disc brake, rear drum brake, wheel hubs, spokes, tires, tubes
Suspension And Steering:
Telescopic front forks, rear shock absorbers, steering head bearings, triple clamps
Frame And Body:
Frame construction, fuel tank, fenders, seat, handlebars, controls
Maintenance Procedures:
Oil changes, filter replacements, chain adjustment, spark plug service, brake fluid flush, battery care, tire pressure checks
Repair Procedures:
Engine rebuilds, transmission overhauls, carburetor tuning, fork seal replacement, brake caliper rebuild, electrical component diagnosis and replacement
Troubleshooting Guides:
Systematic diagnostic steps for common and uncommon issues, fault code interpretation (if applicable)
Wiring Diagrams:
Detailed, color-coded wiring schematics for all electrical systems
Special Tool Requirements:
Identification and usage of specialized tools for specific repair tasks
Depth:
Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds
Diagnostic Capabilities:
Advanced troubleshooting with detailed explanations and diagnostic flowcharts
Specifications Detail:
Precise torque values, clearances, fluid capacities, and tolerances
Engine Type:
Air-cooled, Evolution V-twin
Displacement:
883cc (53.9 cu in) and 1200cc (73.2 cu in) variants
Bore X Stroke 883Cc:
3.00 in x 3.81 in (76.2 mm x 96.8 mm)
Bore X Stroke 1200Cc:
3.50 in x 3.81 in (88.9 mm x 96.8 mm)
Compression Ratio 883Cc:
8.8:1
Compression Ratio 1200Cc:
9.0:1
Carburetor:
Keihin CV (Constant Velocity) 34mm
Valve Train:
Overhead Valves (OHV), 2 valves per cylinder
Cooling System:
Air-cooled
Horsepower 883Cc:
Approx. 55 hp @ 6000 rpm
Torque 883Cc:
Approx. 53 ft-lbs @ 4000 rpm
Horsepower 1200Cc:
Approx. 65 hp @ 6000 rpm
Torque 1200Cc:
Approx. 70 ft-lbs @ 4000 rpm
Fuel Delivery:
Carburetor
Fuel Type:
Unleaded gasoline, minimum 89 octane recommended
Transmission Type:
5-speed, constant mesh
Optional Transmissions:
N/A (All models for this year typically came with 5-speed)
Clutch Type:
Wet, multi-plate, diaphragm spring
Primary Drive:
Duplex chain
Transmission Fluid Type:
Harley-Davidson Transmission Lubricant (or equivalent SAE 80W-90 gear oil)
Transmission Fluid Capacity:
Approx. 24 fl oz (0.7 L)
Crash Test Data:
Motorcycle safety ratings are not typically standardized like automobiles. Focus is on rider protection via apparel and safe riding practices.
Braking System:
Front: Single disc brake with 4-piston caliper. Rear: Drum brake.
Lighting:
Headlight, taillight, brake light, turn signals, license plate light.
Frame Design:
Steel tube frame providing structural integrity.
Fuel Tank Material:
Steel
Oil Change Interval:
Every 2,500 - 5,000 miles (4,000 - 8,000 km) or 6 months, whichever comes first. Refer to manual for specifics based on usage.
Primary Chain Adjustment:
Check every 2,500 miles (4,000 km)
Spark Plug Replacement:
Typically every 10,000 - 15,000 miles (16,000 - 24,000 km). Check manual for specific plug type.
Brake Fluid Flush:
Every 12-24 months
Engine Oil Type:
Harley-Davidson 20W-50 motorcycle oil (or equivalent API SG/SH/SJ rated oil)
Engine Oil Capacity:
Approx. 3 quarts (2.8 L) with filter change
Primary Chain Case Oil Type:
Harley-Davidson Primary Chain Lubricant (or equivalent SAE 80W-90 gear oil)
Primary Chain Case Oil Capacity:
Approx. 1 quart (0.95 L)
Common Wear Items:
Clutch plates, brake pads, fork seals, wheel bearings, drive belt, carburetor diaphragms.
Potential Engine Issues:
Pushrod tube leaks, valve seat wear (with high mileage), carburetor tuning sensitivity.
Electrical Considerations:
Voltage regulator failure, stator output degradation over time.
Brand Establishment:
Founded in 1903, Harley-Davidson is one of the oldest motorcycle manufacturers in the world.
Sportster Introduction:
The Sportster line debuted in 1957, evolving significantly over the decades.
2002 Model Year:
The 2002 model year represents a mature iteration of the Evolution Sportster, featuring fuel injection on some 1200 models (though this manual likely covers carbureted versions predominantly) and continued refinements.
Manufacturing Location:
United States
Model Specific Awards:
No specific awards for the 2002 model year are widely documented, but the Sportster line consistently ranks high in rider satisfaction for its class.
Reliability Perception:
Generally considered reliable with proper maintenance, though specific model years and components can have known weak points.
Certification Standards:
Meets all applicable US EPA and DOT safety and emissions standards for its production year.
