Target Audience:
Harley-Davidson XLH Sportster owners, independent repair shops, professional dealership technicians.
Value Proposition:
Provides the same essential service and repair information used by authorized technicians.
Unauthorized Manuals:
This manual offers a higher degree of accuracy and completeness than generic third-party guides.
Completeness:
Covers all major systems and maintenance procedures for the 2005 XLH models.
Accuracy:
Based on official Harley-Davidson service documentation.
Engine Overhaul:
Complete disassembly, inspection, reassembly of all engine components.
Transmission Service:
Gearbox maintenance, clutch service, shift mechanism repair.
Electrical System:
Wiring diagrams, component testing, ignition system, lighting, charging system.
Fuel System:
Carburetor (Keihin CV typically) service, fuel pump, fuel lines.
Braking System:
Front and rear brake caliper service, master cylinder, hydraulic lines, pad replacement.
Suspension And Steering:
Front fork service (dampers, seals), rear shock absorber replacement, steering head bearing adjustment.
Frame And Bodywork:
Frame inspection, fender mounting, fuel tank removal/installation, seat replacement.
Wheels And Tires:
Wheel bearing inspection and replacement, tire mounting and balancing.
Routine Maintenance:
Oil changes, filter replacements, spark plug service, lubrication.
Diagnostic Troubleshooting:
Step-by-step guides for identifying and resolving common issues.
Component Repair And Rebuild:
Detailed instructions for rebuilding engine, transmission, and other major components.
Electrical Diagnostics:
Troubleshooting electrical faults using wiring diagrams and testing procedures.
Torque Specifications:
Precise torque values for critical fasteners throughout the motorcycle.
Level Of Detail:
Comprehensive, suitable for professional technicians and advanced home mechanics.
Diagnostic Charts:
Includes symptom-based diagnostic flowcharts.
Special Tools:
Identifies required specialized Harley-Davidson tools for specific procedures.
Engine Type:
Air-cooled, Evolution V-twin
Engine Displacement:
88 cubic inches (1450cc) typical for this era Sportster. Manual may also cover 1200cc variants depending on specific XLH sub-models.
Bore X Stroke:
Refer to manual for specific dimensions (e.g., 3.4375 in x 3.8125 in for 88ci).
Compression Ratio:
Refer to manual (typically around 9.0:1).
Valve Train:
Pushrod-actuated overhead valves, two valves per cylinder.
Horsepower:
Refer to manual for exact figures, typically in the 60-70 HP range.
Torque:
Refer to manual for exact figures, typically in the 70-80 lb-ft range.
Fuel Delivery:
Carbureted (Keihin CV 40mm common) or potentially early EFI on some variants. Manual will detail specific system.
Fuel Type:
Unleaded gasoline, 91 octane (R+M)/2 or higher recommended.
Oil Type:
Harley-Davidson motorcycle specific lubricant or equivalent API SG or higher, SAE 20W-50.
Oil Capacity:
Refer to manual (typically around 3 quarts).
Transmission Type:
5-speed constant mesh manual transmission.
Transmission Variants:
All 2005 XLH models utilize the 5-speed transmission.
Clutch Type:
Wet, multi-plate, diaphragm spring.
Transmission Fluid:
Refer to manual for specific fluid type and capacity, typically Harley-Davidson transmission lubricant or equivalent.
Wheelbase:
Refer to manual for exact dimensions; typically around 60 inches.
Length:
Refer to manual for exact dimensions.
Dry Weight:
Refer to manual for exact figures, typically in the 500-550 lb range depending on model variant.
Gross Vehicle Weight Rating:
Refer to manual for GVWR.
Crash Test Data:
Motorcycle safety is not typically rated by agencies like NHTSA in the same way as cars; manual focuses on mechanical integrity and safe operation.
Braking System:
Dual-piston front caliper with 292mm disc, single-piston rear caliper with 292mm disc.
Lighting:
Headlight, taillight, brake light, turn signals.
Frame Construction:
Steel tube frame designed for rider stability and protection.
First Service:
Typically at 1,000 miles or 1 month, whichever comes first (refer to manual for exact mileage).
Subsequent Service:
Scheduled every 5,000 miles or 6 months (refer to manual for detailed schedule).
Oil Change Interval:
Refer to manual; typically every 2,500-5,000 miles or annually.
Engine Oil:
SAE 20W-50 Motorcycle Oil, API SG or higher.
Transmission Fluid:
Harley-Davidson Transmission Lubricant or equivalent (refer to manual for type).
Primary Chain Case Oil:
Refer to manual for type (e.g., Harley-Davidson Primary Chaincase Lubricant).
Brake Fluid:
DOT 4 hydraulic brake fluid.
Fork Oil:
Refer to manual for viscosity and type (e.g., SAE 10W).
Clutch Adjustment:
Cable stretch can lead to stiff clutch lever; manual details adjustment procedure.
Carburetor Tuning:
Keihin CV carburetor may require periodic cleaning and adjustment for optimal performance.
Belt Drive Tension:
Proper belt tension is crucial for longevity; manual specifies adjustment.
Exhaust Leaks:
Exhaust header pipe gaskets can sometimes fail; manual covers replacement.
Harley Davidson Legacy:
Established in 1903, Harley-Davidson is an iconic American motorcycle manufacturer known for its V-twin engines and distinctive styling.
Sportster Lineage:
The Sportster model line, introduced in 1957, is one of Harley-Davidson's longest-running and most versatile platforms.
2005 Updates:
The 2005 model year represents a mature iteration of the Evolution Sportster, with refinements over previous years. Specific updates detailed in manual.
Manufacturing Location:
Typically manufactured in the United States.
Sportster Reputation:
The Sportster has consistently been recognized for its performance, customization potential, and iconic styling within the motorcycle community.
Reliability:
Harley-Davidson Evolution engines are known for their durability when properly maintained, as outlined in this manual.
Manual Standard:
Adheres to industry standards for service and repair documentation, providing factory-level accuracy.
