🏷️ Basic Information

Make:

Harley-Davidson

Model:

Sportster XLH

Year:

2005

Product Type:

Workshop Repair Service Manual

Sportster Generation:

Evo Sportster (Evolution Engine)

👋 Introduction

Motorcycle Segment:

Cruiser / Standard Motorcycle

Target Audience:

Harley-Davidson Sportster XLH 2005 owners and independent repair shops.

Key Competitors 2005:

Cruiser models from brands like Honda (Shadow series), Yamaha (V-Star series), Kawasaki (Vulcan series), Suzuki (Boulevard series), and other Harley-Davidson models.

Sportster Philosophy:

The Sportster line is known for its relatively lightweight, nimble handling, and distinctive character within the Harley-Davidson lineup, often appealing to riders looking for a more accessible entry into the brand.

📋 Manual Details

Manual Coverage Scope:

All Models/Variants of the 2005 Harley-Davidson Sportster XLH

Estimated Page Count:

Approximately 600-800 pages (typical for comprehensive workshop manuals)

Manual Type:

Workshop Repair Service Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine Systems:

Engine assembly, disassembly, tuning, lubrication, cooling, fuel and ignition systems, carburetion (Keihin CV available), EFI (if applicable to specific XLH variants), exhaust systems.

Drivetrain Systems:

Transmission (5-speed, specifically the 'K-model' transmission evolution), clutch operation and adjustment, primary drive, final drive (belt or chain, depending on model variant), gearbox maintenance and repair.

Chassis Systems:

Frame inspection and repair, suspension (front forks, rear shock absorbers), steering system, wheel bearing maintenance, brake system (hydraulic front and rear, drum or disc), wheel and tire specifications.

Electrical Systems:

Wiring diagrams (schematics for all circuits), lighting systems (headlight, taillight, signals), ignition system (coil, module, spark plugs), battery maintenance, charging system (stator, regulator/rectifier), starter motor, instruments and controls.

Bodywork And Trim:

Fender removal and installation, fuel tank mounting and removal, seat assembly, handlebar and control lever adjustments, mounting brackets, decorative trim.

Routine Maintenance:

Oil changes, filter replacements, air filter cleaning/replacement, spark plug inspection and replacement, brake fluid flush and replacement, drive belt tensioning and inspection, chain lubrication and adjustment (if applicable).

Diagnostic Procedures:

Troubleshooting common problems, identifying symptoms, using diagnostic tools (if applicable), reading fault codes (if fuel injected), electrical system diagnostics.

Repair And Overhaul:

Engine rebuild procedures (top-end and bottom-end), transmission overhaul, brake caliper servicing, fork seal replacement, carburetor rebuilding, starter motor replacement.

Technical Specifications:

Torque specifications for all fasteners, electrical component resistance values, engine timing procedures, carburetor jetting data, valve clearance specifications.

Diagnostic Capability:

Advanced diagnostics for electrical and mechanical issues, including step-by-step troubleshooting guides.

Rebuild Capability:

Comprehensive rebuild procedures for major components like the engine, transmission, and suspension.

Customization Support:

Information relevant for understanding component replacement and compatibility for common modifications.

📊 Manual Specifications

File Format:

PDF

Searchability:

Text-searchable PDF for quick information retrieval.

Print Quality:

High-resolution, designed for clarity when printed, includes detailed diagrams and illustrations.

Binding Type:

N/A (Digital PDF Download)

Paper Type:

N/A (Digital PDF Download)

⚙️ Engine Specifications

Engine Type:

Air-cooled, Evolution V-twin (Big Twin derivative but specific to Sportster)

Displacement:

883cc (53.9 cubic inches) and 1200cc (73.9 cubic inches) variants were common for the XLH line in 2005.

Bore X Stroke 883:

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

Bore X Stroke 1200:

88.9 mm x 96.8 mm (3.50 in x 3.81 in)

Compression Ratio 883:

Approximately 8.4:1

Compression Ratio 1200:

Approximately 9.0:1

Valve Train:

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

Horsepower 883 Approx:

50-55 HP

Torque 883 Approx:

50-55 lb-ft

Horsepower 1200 Approx:

65-70 HP

Torque 1200 Approx:

70-75 lb-ft

Fuel Delivery:

Carbureted (typically Keihin CV40 on 883cc, Keihin CV40 or CV44 on 1200cc) or Electronic Fuel Injection (EFI) on select models/regions.

Fuel Type:

Unleaded gasoline, minimum 91 octane recommended.

🔧 Transmission

Transmission Type:

5-speed constant mesh, manual transmission.

Primary Drive:

Duplex chain drive, wet clutch.

Final Drive:

Belt drive (most common for 2005 models).

Clutch Type:

Wet, multi-plate.

Gear Ratios Approximate:

1st: 2.875, 2nd: 2.063, 3rd: 1.571, 4th: 1.227, 5th: 1.000

📐 Dimensions

Overall Length Approx:

2,200 mm (86.6 inches)

Wheelbase Approx:

1,520 mm (59.8 inches)

Ground Clearance Approx:

120 mm (4.7 inches)

Dry Weight Approx:

250 kg (551 lbs) for 883cc models, 255 kg (562 lbs) for 1200cc models.

Gvwr Approx:

454 kg (1000 lbs)

Fuel Capacity Approx:

12.5 liters (3.3 US gallons)

🛡️ Safety Features

Crash Test Ratings:

Motorcycles of this era were not subjected to standardized crash testing like automobiles.

Braking System:

Front: Dual-piston caliper, hydraulic disc. Rear: Dual-piston caliper, hydraulic disc (some earlier models had drum rear brakes, but 2005 typically disc).

Lighting:

Halogen headlight, taillight, brake light, front and rear turn signals.

Frame Construction:

Steel, cradle frame.

💡 Technology Features

Infotainment System:

Basic analog instrumentation; typically speedometer, tachometer (optional), odometer, trip meter, and indicator lights. No integrated infotainment systems.

Driver Assistance Features:

None standard. Relies on rider skill and attentiveness.

Connectivity Features:

None standard. Aftermarket options may exist for audio systems or GPS.

🔧 Maintenance

Initial Service:

500 miles (800 km) - typically includes oil and filter change, primary chain adjustment, chassis lubrication, and inspection.

Subsequent Service:

Every 5,000 miles (8,000 km) or annually, whichever comes first (includes oil change, filter, spark plugs, belt inspection, brake inspection, etc.). Specific intervals for other items like fork oil, transmission fluid, and differential oil are detailed in the manual.

Engine Oil Type:

Harley-Davidson Syn3 (20W-50 synthetic) or equivalent premium quality motorcycle oil meeting Harley-Davidson specifications (e.g., API SG, SH, SJ, SL).

Engine Oil Capacity:

Approximately 3 quarts (2.8 liters) with filter change.

Primary Chain Case Oil Type:

Harley-Davidson Primary Chain Lubricant, Formula +, or Syn3 (20W-50 synthetic).

Primary Chain Case Oil Capacity:

Approximately 24 US fluid ounces (0.71 liters).

Transmission Oil Type:

Harley-Davidson Transmission Lubricant, Formula + or Syn3 (20W-50 synthetic).

Transmission Oil Capacity:

Approximately 20 US fluid ounces (0.59 liters).

Brake Fluid Type:

DOT 4 hydraulic brake fluid.

Cam Chain Tensioners:

Early Evolution engines had spring-loaded cam chain tensioners prone to wear. While 2005 models might have received updates, this is a common area for inspection and potential upgrade to hydraulic tensioners for longevity.

Carburetor Adjustment:

The Keihin CV carburetor can sometimes require periodic adjustment or cleaning to maintain optimal performance and idle stability.

Belt Drive Tension:

Proper belt tension is crucial for longevity; over-tensioning can damage bearings, while under-tensioning can cause slippage.

📚 Vehicle History

Harley Davidson Legacy:

Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer renowned for its V-twin engines and cruiser/touring motorcycles.

Sportster Lineage:

The Sportster line dates back to 1957, evolving significantly over the decades. The Evolution engine was introduced in 1986, offering improved performance and reliability over earlier Ironhead engines. The 2005 models represent a mature iteration of the Evo Sportster platform.

Manufacturing Location:

United States (primarily Milwaukee, Wisconsin).

🏆 Awards & Recognition

Sportster Reputation:

The Sportster line is consistently recognized for its classic styling, character, and customization potential, often earning a dedicated following among enthusiasts.