Segment:
Cruiser Motorcycle Segment
Target Audience:
Harley-Davidson Sportster owners seeking to perform maintenance, repairs, or modifications themselves.
Competitors:
Other V-twin cruisers, Japanese performance bikes (though often in a different segment focus).
Manual Value:
Provides critical information for maintaining the longevity and performance of a Harley-Davidson Sportster, saving costs on professional labor.
Powertrain:
Engine (Evolution V-Twin), Transmission, Drivetrain
Chassis:
Frame, Suspension (Front & Rear), Steering, Wheels, Brakes (Front & Rear), Exhaust System
Electrical:
Ignition System, Charging System, Starting System, Lighting, Gauges, Wiring Diagrams
Bodywork And Trim:
Fuel Tank, Seat, Fenders, Handlebars, Controls, Body Panels
Maintenance:
Routine checks, lubrication, filter replacement, spark plug service, brake pad inspection
Repair:
Engine disassembly/reassembly, transmission repair, carburetor/fuel injection service, electrical component replacement, brake caliper overhaul
Troubleshooting:
Diagnostic procedures, fault finding, common issue resolution
Engine Rebuild:
Complete engine disassembly, inspection, repair, and reassembly procedures, including torque specifications and clearances.
Transmission Overhaul:
Detailed steps for transmission removal, component inspection, gear replacement, and reassembly.
Carburetor Service:
Comprehensive guide to cleaning, rebuilding, and adjusting the Keihin carburetors fitted to these models.
Depth:
Comprehensive: From basic maintenance to complete engine and transmission rebuilds, including detailed specifications and diagnostic flowcharts.
Diagnostics:
Includes diagnostic flowcharts for common electrical and mechanical problems, aiding in efficient troubleshooting.
Wiring Diagrams:
Detailed, often color-coded, wiring diagrams for all electrical systems.
Engine Type:
Air-cooled, Evolution V-Twin
Displacement:
883cc (53.9 cu in) and 1200cc (73.4 cu in) variants
Bore X Stroke:
883cc: 3.00 in x 3.80 in (76.2 mm x 96.5 mm); 1200cc: 3.50 in x 3.80 in (88.9 mm x 96.5 mm)
Compression Ratio:
883cc: 8.4:1; 1200cc: 9.0:1 (approximate, varies by sub-model)
Horsepower:
Approx. 53-60 HP (varies by displacement and tuning)
Torque:
Approx. 54-67 ft-lbs (varies by displacement and tuning)
Fuel Delivery:
Carburetor (Keihin CV 40mm for 883cc, Keihin CV 40mm or 44mm for 1200cc) or Electronic Fuel Injection (EFI) on some XLH models.
Fuel Type:
Unleaded gasoline, minimum 89 octane (91 AKI)
Ignition Type:
Electronic Ignition (CDI/Distributorless on most models)
Transmission Type:
5-speed constant mesh
Optional Transmissions:
N/A for 2002 model year Sportster
Clutch Type:
Wet, multi-plate
Gear Ratios:
Detailed ratios for each gear available in the manual.
Transmission Fluid Type:
Harley-Davidson Formula+ (or equivalent API GL-4, SAE 80W-90 gear oil)
Transmission Fluid Capacity:
Approximately 2.8 U.S. quarts (2.6 Liters)
Overall Length:
Approximately 87.9 inches (2233 mm)
Wheelbase:
Approximately 60.0 inches (1524 mm)
Seat Height:
Approximately 26.0 inches (660 mm) unladen
Dry Weight:
Approximately 497 lbs (225 kg) for 883cc, 504 lbs (229 kg) for 1200cc
Gross Vehicle Weight Rating:
Approximately 935 lbs (424 kg)
Cargo Capacity:
N/A (Motorcycle)
Crash Test Results:
Motorcycle safety is primarily rider-dependent; formal crash ratings are not applicable in the same way as automobiles.
Braking System:
Front: Single disc with dual-piston caliper. Rear: Single disc with dual-piston caliper.
Lighting:
Halogen headlamp, taillight, brake light, front and rear turn signals.
Frame Construction:
Steel, rigid backbone frame.
Rider Assistance:
N/A (No electronic rider aids like ABS or traction control typically found on this model year).
Infotainment System:
N/A (Basic instrumentation: speedometer, tachometer (optional), odometer, basic indicator lights).
Electronic Aids:
None (No ABS, traction control, or other electronic rider aids).
Connectivity Features:
N/A (No Bluetooth or smartphone integration).
Initial Service:
First service typically at 1,000 miles (1,600 km) for oil change, filter replacement, primary chain adjustment, and inspection.
Regular Oil Change:
Every 2,500 miles (4,000 km) or annually, whichever comes first.
Spark Plug Service:
Inspect every 5,000 miles (8,000 km), replace as needed. Refer to manual for correct plug type and gap.
Belt Drive Tension:
Check and adjust primary drive belt tension every 5,000 miles (8,000 km).
Engine Oil Type:
Harley-Davidson 20W-50 Syn3 (Synthetic) or equivalent motorcycle-specific 20W-50 oil.
Engine Oil Capacity:
Approximately 3.0 U.S. quarts (2.8 Liters) with filter change.
Primary Chain Case Oil:
Harley-Davidson Formula+ or equivalent API GL-4, SAE 80W-90 gear oil.
Brake Fluid:
DOT 4 compatible brake fluid.
Carburetor Tuning:
Carburetors can require periodic adjustment due to wear or altitude changes. Manual provides detailed tuning procedures.
Belt Drive Wear:
Belt tension and alignment are critical for belt longevity; incorrect tension can lead to premature wear.
Electrical Connections:
Corrosion on electrical connectors can sometimes cause intermittent issues, particularly in humid environments.
Brand History:
Harley-Davidson, founded in 1903, is an iconic American motorcycle manufacturer renowned for its V-twin engines and cruiser styling.
Sportster Lineage:
The Sportster line, introduced in 1957, is Harley-Davidson's longest-running model family, characterized by its compact size and nimble handling relative to larger Harley models.
2002 Updates:
The 2002 models featured updated styling, potential for electronic fuel injection on certain XLH variants, and refinements to the Evolution engine. This year represented a mature iteration of the Sportster platform before significant electronic integration in later years.
Manufacturing Location:
United States (primarily Milwaukee, Wisconsin)
