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Harley Davidson XL883L 2009 Workshop Service Repair Manual
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Basic Information Identification Make: Harley-Davidson Model: XL883L Year: 2009 Generation Platform Generation: Sportster (Evolution Engine) Codes Engine Code: Evolution V-Twin (90 cubic inch / 883cc) Introduction Market Position Vehicle Segment:...
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| Basic Information | |
| Identification | |
| Make: | Harley-Davidson |
| Model: | XL883L |
| Year: | 2009 |
| Generation | |
| Platform Generation: | Sportster (Evolution Engine) |
| Codes | |
| Engine Code: | Evolution V-Twin (90 cubic inch / 883cc) |
| Introduction | |
| Market Position | |
| Vehicle Segment: | Entry-level cruiser motorcycle, part of the iconic Harley-Davidson Sportster family. |
| Competitive Analysis | |
| Competitors 2009: | Primarily competed with other middleweight cruisers from brands like Honda (Shadow series), Yamaha (V-Star series), and Kawasaki (Vulcan series). |
| Key Features | |
| Model Positioning: | The 'L' in XL883L signifies the 'Low' version, designed for increased accessibility with a lower seat height and often adjusted suspension. |
| Heritage: | Carries the legacy of the Sportster line, known for its V-twin rumble and classic styling. |
| Manual Details | |
| Coverage Areas | |
| General Coverage: | Complete factory service and repair for the 2009 Harley-Davidson XL883L |
| Page Count | |
| Estimated Page Count: | Hundreds of pages (printable in its entirety or specific sections) |
| Manual Type | |
| Manual Type: | Workshop Service Repair Manual |
| Language | |
| Language: | English |
| Format | |
| Format: | PDF Download |
| Manual Coverage | |
| Systems Covered | |
| Engine System: | Complete engine overhaul, including disassembly, assembly, component inspection, and specifications. |
| Fuel System: | Fuel injection system, fuel pump, injectors, throttle body, fuel tank, and lines. |
| Ignition System: | Ignition module, spark plugs, ignition coils, and troubleshooting. |
| Exhaust System: | Exhaust pipes, mufflers, catalytic converter (if applicable), and mounting hardware. |
| Transmission System: | Clutch operation, gear shifting mechanism, primary drive, and transmission fluid service. |
| Chassis Frame: | Frame inspection, welds, and component mounting points. |
| Suspension System: | Front forks (disassembly, seal replacement, oil levels), rear shock absorbers, and mounting. |
| Brake System: | Front and rear brake calipers, master cylinders, brake lines, fluid replacement, bleeding procedures, and pad replacement. |
| Wheel And Tire Assembly: | Wheel bearing service, tire mounting and balancing, spoke tensioning (if applicable). |
| Electrical System: | Battery, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting, instrumentation, and wiring diagrams. |
| Bodywork And Fittings: | Fenders, fuel tank, seat, handlebars, controls, mirrors, and associated hardware. |
| Diagnostics And Troubleshooting: | Fault finding procedures, diagnostic codes, and systematic problem-solving for various systems. |
| Procedures Included | |
| Routine Maintenance: | Oil changes, filter replacements, spark plug replacement, air filter cleaning/replacement, chain adjustment (if applicable), and lubrication. |
| Component Replacement: | Detailed step-by-step guides for replacing virtually all components. |
| Rebuild Procedures: | Comprehensive instructions for rebuilding the engine, transmission, and other major assemblies. |
| Troubleshooting Guides: | Flowcharts and step-by-step diagnostics for common and uncommon issues. |
| Wiring Diagrams: | Detailed, color-coded wiring schematics for all electrical systems. |
| Torque Specifications: | All critical fastener torque values for engine, chassis, and accessories. |
| Special Tools: | Identification and usage of specialized tools required for specific tasks. |
| Technical Depth | |
| Depth Of Information: | Factory-level diagnostic and repair procedures, suitable for professional technicians and advanced DIY mechanics. |
| Diagnostic Capabilities: | Includes guidance for using diagnostic tools and interpreting diagnostic codes. |
| Performance Tuning: | May include basic information on performance adjustments or modifications, though primarily focused on stock operation. |
| Manual Specifications | |
| File Format | |
| File Type: | Portable Document Format (PDF) |
| Print Quality | |
| Document Resolution: | High-resolution, suitable for clear printing of text and diagrams. |
| Binding Type | |
| Binding Recommendation: | Recommend professional binding or printing in sections for ease of use. |
| Paper Type | |
| Paper Recommendation: | Durable paper stock recommended for workshop environments. |
| Engine Specifications | |
| Primary Engine | |
| Engine Type: | Air-cooled, Evolution V-twin |
| Displacement: | 53.8 cu in (883 cc) |
| Bore X Stroke: | 3.00 in x 3.50 in (76.2 mm x 88.9 mm) |
| Compression Ratio: | 8.8:1 |
| Performance | |
| Horsepower Est: | Approx. 57 HP @ 6000 RPM (manufacturer claimed) |
| Torque Est: | Approx. 55 lb-ft @ 3200 RPM (manufacturer claimed) |
| Fuel System | |
| Fuel Delivery: | Electronic Sequential Port Fuel Injection (ESPFI) |
| Fuel Type: | Unleaded gasoline, minimum 91 octane (RVP 8.0) |
| Cooling System | |
| Cooling Method: | Air-cooled |
| Transmission | |
| Standard | |
| Transmission Type: | 5-speed constant mesh |
| Optional | |
| Optional Transmission: | N/A for this model year and variant |
| Features | |
| Primary Drive: | Chain, 34/46 ratio |
| Final Drive: | Belt, 32/65 ratio |
| Clutch Type: | Multiplate wet clutch |
| Dimensions | |
| Exterior | |
| Length: | 88.0 in (2235 mm) |
| Width: | 33.7 in (856 mm) |
| Height: | 47.6 in (1209 mm) |
| Seat Height Laden: | 25.5 in (648 mm) |
| Ground Clearance: | 4.3 in (109 mm) |
| Wheelbase: | 60.0 in (1524 mm) |
| Weights | |
| Dry Weight: | 545 lbs (247 kg) |
| Gross Vehicle Weight Rating Gvwr: | 926 lbs (420 kg) |
| Payload Capacity: | 381 lbs (173 kg) |
| Cargo | |
| Fuel Capacity: | 4.5 gal (17.0 L) |
| Safety Features | |
| Ratings | |
| Safety Certification: | Meets applicable EPA, DOT, and NHTSA standards for motorcycles. |
| Active Features | |
| Braking System: | Front: Dual piston caliper, 292mm disc. Rear: Single piston caliper, 292mm disc. |
| ABS: | Anti-lock Braking System (ABS) was an optional feature for the 2009 XL883L. |
| Passive Features | |
| Lighting: | Halogen headlight, LED tail light, incandescent turn signals. |
| Technology Features | |
| Infotainment | |
| Instrumentation: | Analog speedometer, tachometer (on some models/variants), odometer, trip meter, fuel gauge, and indicator lamps. |
| Driver Assistance | |
| ABS Integration: | If equipped with ABS, the system provides electronic braking assistance. |
| Connectivity | |
| Oem Connectivity: | Limited to basic vehicle diagnostics via the ECM (Electronic Control Module). No integrated Bluetooth or infotainment systems as standard. |
| Maintenance | |
| Service Intervals | |
| First Service: | 1,000 miles (1,600 km) or 12 months, whichever comes first. |
| Subsequent Service: | Every 5,000 miles (8,000 km) or 12 months, whichever comes first. |
| Fluid Specifications | |
| Engine Oil Type: | Harley-Davidson recommends its own proprietary V-Twin oil, or equivalent API CI-4 or ACEA E3/E5 rated synthetic motorcycle oil, SAE 20W50. |
| Engine Oil Capacity: | 3.0 US qt (2.8 L) with filter change. |
| Primary Chain Case Oil Type: | Harley-Davidson Primary Chain Case Lubricant or HD Syn3 Motorcycle Oil (SAE 5W-40). |
| Primary Chain Case Oil Capacity: | 1.0 US qt (0.95 L). |
| Transmission Oil Type: | Harley-Davidson Transmission Lubricant (SAE 80W-90) or suitable gear oil. |
| Transmission Oil Capacity: | 2.4 US qt (2.3 L). |
| Brake Fluid Type: | DOT 5.1 silicone-based brake fluid. |
| Fork Oil Type: | Refer to manual for specific weight; typically a light-weight fork oil (e.g., 5W or 10W). |
| Known Issues | |
| Common Wear Items: | Clutch plates, brake pads, fork seals, battery, and drive belt. |
| Potential Electrical: | Voltage regulator and stator can be prone to failure over time, affecting charging system performance. |
| Fueling System Considerations: | Ensure clean fuel and regular inspection of fuel filter. |
| Vehicle History | |
| Brand Heritage | |
| Harley Davidson Legacy: | Founded in 1903, Harley-Davidson is one of the oldest motorcycle manufacturers in the world, renowned for its V-twin engines and iconic styling. |
| Model Evolution | |
| Sportster Lineage: | The Sportster line, introduced in 1957, is Harley-Davidson's longest-running model line, evolving from its early 'K' model predecessors. |
| Production | |
| Xl883L Introduction: | The 'Low' variant of the 883cc Sportster was introduced to broaden appeal, particularly for riders seeking a more accessible riding position. |
| Manufacturing Location: | Typically assembled at the Harley-Davidson Vehicle and Powertrain Operations in York, Pennsylvania, and Milwaukee, Wisconsin. |
| Awards & Recognition | |
| Recognitions | |
| Sportster Awards: | The Sportster line has consistently received praise for its iconic styling and accessible performance, making it a popular choice for new and experienced riders. |
| Ratings | |
| Rider Satisfaction: | Often cited for its engaging ride and classic aesthetic, contributing to high rider satisfaction. |
| Certifications | |
| Manufacturer Standards: | Adheres to Harley-Davidson's rigorous internal quality and performance standards. |