🏷️ Basic Information

Make:

Harley-Davidson

Model:

Sportster XLH

Year:

2005

Engine Code:

Evolution V-Twin (likely 883cc or 1200cc)

Generation Designation:

Sportster Evolution (XL Platform)

👋 Introduction

Vehicle Segment:

Cruiser motorcycle

Brand Legacy:

Iconic American motorcycle brand with a strong heritage in performance and customization.

Direct Competitors Era:

Other American V-twin cruisers (e.g., some Indian models, custom builds) and Japanese cruisers offering similar displacement and style.

Engine Layout:

Air-cooled Evolution V-twin

Primary Drive:

Wet, multi-plate clutch, enclosed chain drive to transmission

Rear Drive:

Belt drive

Frame Type:

Steel, cradle frame

Exhaust System:

Dual exhaust system

📋 Manual Details

Coverage Description:

Comprehensive repair and overhaul of Harley-Davidson Sportster XLH 2005 models. Assumes technician familiarity with general automotive practices.

Estimated Page Count:

Likely 400-600 pages (typical for comprehensive service manuals of this era).

Manual Type:

Service Repair Manual / Workshop Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine:

Disassembly, inspection, assembly, tuning, troubleshooting of the Evolution V-Twin engine (carbureted, likely 883cc and 1200cc variants).

Fuel System:

Carburetor (likely Keihin CV) overhaul, adjustment, troubleshooting, fuel tank, fuel lines, petcock.

Ignition System:

Spark plugs, coils, ignition module, timing, troubleshooting.

Transmission:

5-speed constant mesh gearbox overhaul, inspection, lubrication, clutch operation, primary drive.

Drive Train:

Belt drive system, rear pulley, front sprocket inspection and maintenance.

Brakes:

Front and rear brake systems, hydraulic lines, calipers, master cylinders, brake pads, rotor inspection and replacement.

Suspension:

Front forks (telescopic), rear shock absorbers, bushings, seals, troubleshooting, adjustment.

Electrical System:

Wiring diagrams, battery, charging system (stator, regulator/rectifier), lighting, starter motor, solenoids, fuses, circuit breakers.

Wheels And Tires:

Wheel bearing maintenance, tire inspection, pressure recommendations, wheel removal and installation.

Frame And Bodywork:

Frame inspection, body panel removal and installation, fenders, fuel tank, seat assembly.

Controls:

Handlebars, grips, levers, cables (throttle, clutch), foot controls, linkages.

Routine Maintenance:

Oil changes, filter replacement, spark plug replacement, chain/belt adjustment, lubrication points.

Troubleshooting:

Diagnostic procedures for common starting, running, and electrical issues.

Overhaul Procedures:

Detailed step-by-step instructions for major component rebuilds (engine, transmission).

Component Replacement:

Instructions for replacing wear items and common failure parts.

Wiring Diagrams:

Detailed electrical schematics for accurate diagnosis and repair.

Depth Of Coverage:

Expert level, covering complete diagnostics, repair, rebuilding, and specification adjustments.

📊 Manual Specifications

PDF Quality:

High resolution, searchable text, printable pages.

Print Recommendation:

Recommended for printing on standard office printers for workshop use.

Binding Type For Printed:

N/A (Digital PDF)

Paper Type For Printed:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Type:

Air-cooled, Evolution V-Twin

Displacement:

Available in 883cc (53.9 cu in) and 1200cc (73.3 cu in) variants.

Bore X Stroke 883Cc:

76.2 mm x 96.8 mm (3.00 in x 3.81 in)

Bore X Stroke 1200Cc:

88.8 mm x 96.8 mm (3.496 in x 3.81 in)

Compression Ratio 883Cc:

8.8:1 (typical)

Compression Ratio 1200Cc:

9.0:1 (typical)

Carburetion:

Keihin CV (Constant Velocity) carburetor, typically 40mm.

Horsepower 883Cc:

Approx. 53-55 hp @ 6000 rpm (estimated)

Torque 883Cc:

Approx. 57-59 lb-ft @ 3500 rpm (estimated)

Horsepower 1200Cc:

Approx. 67-69 hp @ 6000 rpm (estimated)

Torque 1200Cc:

Approx. 70-72 lb-ft @ 4000 rpm (estimated)

Fuel Type:

Unleaded gasoline, minimum 91 octane recommended

Fuel Tank Capacity:

Typically 3.1 gallons (11.7 liters) for standard tank.

🔧 Transmission

Transmission Type:

5-speed, constant mesh, sequential gearbox

Optional Transmissions:

N/A for factory 2005 XLH models.

Gear Ratios Typical:

1st: 10.33; 2nd: 7.77; 3rd: 5.74; 4th: 4.74; 5th: 3.73 (approximate, subject to variation)

Transmission Fluid Type:

Harley-Davidson transmission fluid (e.g., Formula+), or equivalent. Capacity approx. 1 quart (0.95 L).

📐 Dimensions

Length:

Approx. 88-90 inches (2235-2286 mm) depending on model variant.

Width:

Approx. 32-34 inches (813-864 mm) at handlebars.

Height:

Approx. 46-48 inches (1168-1219 mm) to top of handlebars.

Wheelbase:

Approx. 60 inches (1524 mm).

Dry Weight:

Approx. 490-510 lbs (222-231 kg) depending on configuration.

Gross Vehicle Weight Rating Gvwr:

Typically around 900-950 lbs (408-431 kg).

🛡️ Safety Features

Safety Certification:

Meets all applicable DOT and NHTSA standards for motorcycles.

Braking System:

Front and rear disc brakes with hydraulic actuation. ABS was not standard or commonly available on Sportsters in 2005.

Lighting:

Halogen headlight, LED tail light, incandescent turn signals.

Frame Construction:

Robust steel cradle frame providing structural integrity.

Ergonomics:

Designed for rider comfort and control.

💡 Technology Features

Infotainment Features:

No integrated infotainment system. Focus on mechanical performance and rider connection.

🔧 Maintenance

Oil Change Interval:

Every 2,500-5,000 miles (4,000-8,000 km) or annually, whichever comes first. Check manual for specific recommendation.

Transmission Fluid Change Interval:

Every 5,000-10,000 miles (8,000-16,000 km) or annually.

Primary Chain Case Oil Change Interval:

Every 2,500-5,000 miles (4,000-8,000 km) or annually.

Belt Drive Inspection Interval:

Every 2,500 miles (4,000 km) for tension and condition.

Spark Plug Replacement Interval:

Typically every 10,000 miles (16,000 km).

Engine Oil Type:

Harley-Davidson 20W50 (or equivalent JASO MA certified motorcycle oil).

Engine Oil Capacity:

Approx. 3 quarts (2.8 liters) with filter change.

Primary Chain Case Oil Type:

Harley-Davidson primary fluid (or equivalent primary chain case lubricant).

Primary Chain Case Oil Capacity:

Approx. 1 quart (0.95 liters).

Common Wear Items:

Clutch plates, belt drive components, fork seals, wheel bearings, brake pads.

Potential Electrical Issues:

Stator failure, voltage regulator issues, starter solenoid issues can occur with age and mileage.

Carburetor Tuning:

CV carburetors can require periodic adjustment for optimal performance and starting, especially with altitude or temperature changes.

📚 Vehicle History

Harley Davidson Founding:

Founded in 1903, Milwaukee, Wisconsin. One of the two oldest motorcycle manufacturers in the world.

Sportster Introduction:

The Sportster line was introduced in 1957, evolving through various iterations. The Evolution engine was introduced in 1986.

2005 Sportster Positioning:

Represented a mature iteration of the Evolution Sportster, a popular entry-level Harley-Davidson platform with a focus on accessible performance and customization.

Manufacturing Location:

United States (typically Milwaukee or York, Pennsylvania)

🏆 Awards & Recognition

Harley Davidson Awards:

Harley-Davidson consistently ranks high in customer satisfaction for cruiser motorcycles. Specific awards for the 2005 Sportster XLH are not typically documented in a way that translates to a simple attribute, but its enduring popularity is a testament to its design and performance.

Customer Satisfaction:

Generally high among owners for its classic styling, V-twin character, and customization potential.