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Harley Davidson Sportster XLH Motorcycle Complete Workshop Service Repair Manual 2005

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🏷️ Basic Information Identification Make: Harley-Davidson Model: Sportster XLH Year: 2005 Codes Platform Code: XL 👋 Introduction Market Position Category: Cruiser Motorcycle Segment: Lightweight/Entry-level Cruiser Competitive Analysis Key Competitors 2005:...
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Harley Davidson Sportster XLH Motorcycle Complete Workshop Service Repair Manual 2005
🏷️ Basic Information
Identification
Make:
Harley-Davidson
Model:
Sportster XLH
Year:
2005
Codes
Platform Code:
XL
👋 Introduction
Market Position
Category:
Cruiser Motorcycle
Segment:
Lightweight/Entry-level Cruiser
Competitive Analysis
Key Competitors 2005:
Indian Scout, Yamaha V-Star, Honda Shadow, Suzuki Boulevard S40
Key Features
Sportster Identity:
Compact, agile, classic Harley-Davidson styling, accessible for new riders
Engine Heritage:
Evolution V-Twin engine, known for torque and reliability
📋 Manual Details
Coverage Areas
Primary Coverage:
All XLH Sportster models
Engine Coverage:
Evolution V-Twin
Transmission Coverage:
5-speed
Page Count
Estimated Pages:
500+
Manual Type
Type:
Complete Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Engine:
Engine overhaul, tuning, diagnostics, carburetor, fuel injection (EFI models)
Transmission:
Clutch, gearbox, final drive, primary drive inspection and repair
Brakes:
Hydraulic brake system, caliper, master cylinder, lines, bleeding procedures
Electrical:
Wiring diagrams, ignition system, lighting, charging system, battery, starter, accessories
Suspension:
Front fork, rear shock absorbers, bearings, adjustments
Frame:
Frame inspection, steering head bearings, swingarm
Bodywork:
Body panels, fenders, seat, fuel tank, controls, exhaust system
Procedures Included
Maintenance:
Routine service, oil changes, filter replacements, lubrication, chain adjustment
Repair:
Component removal and installation, detailed disassembly and reassembly
Troubleshooting:
Diagnostic charts, common problems, symptom-based solutions
Diagnostics:
Engine tuning, ignition timing, electrical system testing
Specifications:
Torque values, clearances, fluid capacities, electrical specifications
Technical Depth
Depth:
Comprehensive, from basic maintenance to full engine rebuilds
Detail Level:
Step-by-step instructions with diagrams and illustrations
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text content
Print Quality
Printability:
Printable pages
Binding Type
Binding Style:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Harley-Davidson Evolution V-Twin
Displacement:
883cc (53.9 cu in)
Bore X Stroke:
3.00 in x 3.50 in (76.2 mm x 88.9 mm)
Compression Ratio:
8.8:1
Cooling System:
Air-cooled
Performance
Horsepower Estimated:
50-55 hp @ 5500 rpm (approximate, varies by exact model)
Torque Estimated:
55-60 ft-lbs @ 3500 rpm (approximate, varies by exact model)
Fuel System
Fuel Delivery:
Keihin CV (Constant Velocity) Carburetor (for XLH models)
Fuel Type:
Unleaded Gasoline, 91 octane (R+M)/2 minimum
Ignition System
Ignition:
Electronic, spark ignition
🔧 Transmission
Standard
Type:
5-speed constant mesh
Primary Drive:
Duplex chain, 34/49 ratio
Final Drive:
Belt drive, 32/65 ratio
Features
Clutch:
Wet, multi-plate
Transmission Fluid Type:
Harley-Davidson Formula+, SAE 20W-50 or equivalent
📐 Dimensions
Exterior
Length:
Approx. 88.4 in (2245 mm)
Width:
Approx. 30.9 in (785 mm)
Height:
Approx. 47.1 in (1196 mm)
Weights
Dry Weight:
Approx. 505 lbs (229 kg)
Gross Vehicle Weight Rating Gvwr:
Approx. 930 lbs (422 kg)
Payload Capacity:
Approx. 425 lbs (193 kg)
Cargo
Fuel Capacity:
Approx. 3.5 US gal (13.3 L)
Oil Capacity:
Approx. 3 US qt (2.8 L) (with filter change)
🛡️ Safety Features
Ratings
Safety Certification:
Meets or exceeds all applicable US DOT regulations
Active Features
Braking System:
Dual-piston front caliper, single-piston rear caliper, hydraulic disc brakes
Lighting:
Halogen headlight, LED tail light, turn signals
Passive Features
Frame Construction:
Steel tube frame, designed for stability
Tire Specifications:
Front: 100/90-19 57H; Rear: 150/80-16 71H (typical, confirm with specific model)
💡 Technology Features
Infotainment
Instrumentation:
Analog speedometer, tachometer (optional or integrated depending on specific sub-model), odometer, trip meter, indicator lamps
Driver Assistance
ABS:
Not typically available on 2005 XLH Sportster models
Connectivity
Smartphone Integration:
Not applicable for this model year
🔧 Maintenance
Service Intervals
Initial Service:
500 miles (800 km)
Subsequent Oil Change:
Every 5,000 miles (8,000 km) or annually, whichever comes first
Spark Plug Replacement:
Every 10,000 miles (16,000 km)
Belt Tension Check:
Every 2,500 miles (4,000 km)
Fluid Specifications
Engine Oil:
Harley-Davidson 20W-50 Synthetic or Conventional Motorcycle Oil (Meets Harley-Davidson Specification)
Primary Chain Case Fluid:
Harley-Davidson Formula+, SAE 50W or equivalent
Brake Fluid:
DOT 4 Hydraulic Brake Fluid
Transmission Fluid:
Harley-Davidson Formula+, SAE 50W or equivalent
Known Issues
Carburetor Tuning:
CV carburetor can require periodic adjustment for optimal performance and emissions, especially at altitude or with modifications.
Carburetor Jetting:
Jetting may need to be adjusted for aftermarket exhaust or air intake modifications.
Vibration:
Sportsters are known for their characteristic V-twin vibrations; ensuring proper engine mounting and balance is key.
Oil Leaks:
Checking and tightening oil seals and gaskets regularly can prevent minor leaks.
Brake Wear:
Regular inspection of brake pads and rotors is essential due to the bike's performance characteristics.
📚 Vehicle History
Brand Heritage
Brand Origin:
Milwaukee, Wisconsin, USA
Brand Legacy:
Iconic American motorcycle manufacturer with over a century of history
Model Evolution
Sportster Introduction:
First introduced in 1957
Xlh Variant Significance:
XLH designation typically refers to the Ironhead engine Sportster line, however, for 2005, the XLH Sportster primarily indicates the 883cc Evolution engine model.
Production
Production Location:
USA (primarily York, Pennsylvania or Kansas City, Missouri)
🏆 Awards & Recognition
Recognitions
Historical Impact:
The Sportster line is a highly influential motorcycle platform, often recognized for its customization potential and enduring appeal.
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