Repair Manual covers the following models: * Sportster XL833 (2004-2009) * XL883C Custom (2004-2010) * XL883L Super Low (2004-2013) * XL883N Iron (2009-2013) * XL883R Roadster (2004-2013) * XL1200C Custom (2004-2013) * XL1200L Super Low (2004-2011) * XL1200N Nightster (2007-2012) * XL1200R Roadster (2004-2009) * XL1200V 72 (2010-2013) * Sportster XL1200X 48 (2010-2013) Note: this manual DOES NOT include XR1200 Contents: * AMENDMENT On the 2/1 edition page X (QRD) and page 538 have been changed to note the engine oil capacity on: * 2008 – 2009 models is 2.8 qt (2.65 litre) * 2004 – 2007 models the capacity is 3.6 qt. (3.4 litre) * QUICK REFERENCE DATA * GENERAL INFORMATION Manual organization / Warnings cautions and notes / Safety / Serial numbers / Fasteners / Shop supplies / Tools / Measuring tools / Electrical system fundamentals / Basic service methods / Storage / gearshift mechanism / Transmission / Mainshaft / (2004-2005 models) / Countershaft / (2004-2005 models) / Transmission / (2006-on models) / Mainshaft / (2006-on models) / Countershaft / (2006-on models) / Main drive gear / Crankcase bearing / Transmission drive sprocket / Specifications * FUEL click
* Primary drive clutch and transmission * Fuel and exhaust systems * Ignition system * Steering suspension and final drive * Brakes wheels and tires * Frame and bodywork * Electrical system and wiring diagrams come here
(1970-1972 1978-1985) * Harley-Davidson XLCR Sportster (1977-1978) * Harley-Davidson XLX Sportster (1983-1985) * Harley-Davidson XLS Sportster (1980-1985) * Harley-Davidson XL Sportster (1973-1977) Contents: * QUICK REFERENCE DATA * GENERAL INFORMATION * TROUBLESHOOTING * PERIODIC LUBRICATION MAINTENANCE AND TUNE-UP Maintenance schedule intervals / Periodic lubrication / Engine oil and filter change / Periodic maintenance / Suspension adjustment / Breaker point ignition service / Magneto / Breakerless ignition system / Carburetor adjustments * ENGINE Removal installation / Pushrods / Valves and components / Cylinder / Oil pump / Gearcase / Tappets and guides / Crankcase / Drive sprocket and seal / Engine seals / Starter drive shaft and housing / Specifications * CLUTCH PRIMARY DRIVE KICKSTARTER AND TRANSMISSION Clutch / Primary chain / Kickstarter / Transmission / Front hub / Wheel balance / Tyre changing / Tyre repairs / Handlebar and throttle control / Steering head / Front fork / Specifications * REAR SUSPENSION Rear wheel / Rear hub / Driven sprocket assembly / Drive chain / Wheel balancing / Tyre changing / Rear swing arm / Shock absorbers / extra
and notes / Safety / Serial numbers / Fasteners / Shop supplies / Tools / Measuring tools / Electrical system fundamentals / Service methods / Storage / Specifications * TROUBLESHOOTING Starting the engine / Engine performance / Electrical component replacement / Starting system / Charging system / Ignition system (1986-1997 models) / Ignition system (1998-2003 models except 1200S models) / Ignition system (1998-2003 1200S models) / Fuel system / Engine noises / Engine smoke / Leakdown test / Engine lubrication / Clutch / Transmission / Electrical testing / Electronic speedometer/tachometer / Turn signal module (1991-1996 models) / Turn signal module (1997-2003 models) / Excessive vibration / Front suspension and steering / Brake problems / Specifications * LUBRICATION MAINTENANCE AND TUNE-UP Maintenance schedule / Oil and filter change / Tune-up / Air adjuster / Primary drive / clutch / Clutch cable / Specifications * PRIMARY DRIVE AND CLUTCH (1991-2003 MODELS) Primary drive cover (1991-1993 models) / Primary drive cover (1994-2003 models) / Clutch release mechanism (1991-1993 models) / Clutch release mechanism (1994-2003 models) / Primary come here
The town roads are dense with traffic, however it ended up being nevertheless an unforgettable ride. With misleading rate, the thin, black colored Harley-Davidson XLCR carved a swath through miles of slow-moving material. The slight twist associated with throttle sent the torquey V-twin stomping effortlessly forward. Every where the menacing black Harley XLCR Caf Racer moved, its booming bass fatigue note cleared vehicles from its road, turned pedestrians’ minds and threatened to turn structures to rubble.
Phenomenal things — and I also wasn’t also riding the Harley, just after at the rear of on a contemporary Honda whilst the XLCR’s owner led the way in which through his neighborhood with applied ease. Before i got eventually to drive they, the initial Harley-Davidson Caf Racer have charmed myself using its unique design and presence. However if that’s the V-twin’s great power, then it’s also the Hog’s fatal flaw. For if ever a motorcycle ended up being designed for image in the place of performance, this is the one.
Find out about Tony Long’s connection with riding and owning a Harley XLCR Caf Racer
Form over features
That has been not exactly that which was intended once the Harley-Davidson XLCR — pronounced “Excelsior,” one awe-struck tester commented — premiered in 1977. In the past, the ads chatted excitedly of 120mph top speeds, and exactly how it was many powerful production bicycle Harley had ever before built. But also then, it absolutely was the Caf Racer’s mean and moody all-black appearance that ready the bike aside.
The Caf Racer idea ended up being dreamt up by Harley design chief Willie G. Davidson, and he took the theory into the limit. Virtually every area of the cycle had been pure black: the bikini fairing, the gasoline container, the tapered flat-track style chair product, along side it panels and mudguards, the frame, the exhaust system and a lot of of huge 45-degree V-twin motor itself. The effect is spectacular, and unlike such a thing Harley had complete before.
Underneath the styling, though, the XLCR ended up being dramatically less unique. Their motor had been the exact same four-speed, 998cc pushrod lump utilized in the Sportster design, with not a hot cam or huge valve to be noticed. Compression proportion stayed a modest 9:1, and even the 38mm Keihin carburetor had been identical. The Caf Racer’s one novelty, its siamese black exhaust program, made no huge difference on stated peak output of 61bhp at 6,200rpm.
The XLCR’s frame is latest, consisting of a Sportster front side section paired with rear tubes and a box-section steel swing-arm predicated on those regarding the XR750 battle cycle. Rims were seven-spoke alloy by Morris, 19in front side, 18in backside. The frame geometry in addition to 58.5in wheelbase were exactly the same as those associated with inventory 1977 Sportster, although Caf Racer’s triple-disc brakes had been a notable update through the cruiser’s single front side disk and rear drum.
If it therefore the black bicycle’s racy outlines conspired to give the impression of a difficult and quick road fighter, then your riding place ended up being enough to encourage some doubts. Which was definitely true as I tossed a leg over the low seat and bent forward not to ever caf-race clip-ons, but to near-straight taverns. Although the foot pegs were rearset, they’re no greater than those from the stock Sportster. Combined with the XLCR’s inch-taller chair, that gives a generous amount of legroom by displaying standards.
Despite revealing its part-faired look and larger V-twin engine design with Ducati’s contemporary 900SS street-racer, Harley’s hot rod possess a totally different feel. On hit associated with the starter switch, those huge 81mm diameter pistons begin thudding along on their shared crankpin with a loud, deep, offbeat remember that could only result from a Harley-Davidson. And when I prod the bicycle into gear and let out the clutch, the CR draws away with all the conventional tractor-like easy a big motor that thumps out their peak torque at just 3,800rpm.
This Harley Caf Racer are well-cared-for but unrestored (besides resprayed black colored crinkle-finish engine paint). This has the typically lived-in look — several smaller chips into the paint work, somewhat tarnished pipelines and alloy — unavoidable after a lot more than 23,000 miles of good use. And apart from a Screamin’ Eagle hand support and an S&S carburetor and filter, their black housing somewhat smaller than the Harley original, the bicycle is very standard.
Contemporary path tests rated the Harley Caf Racer less stronger as compared to standard XLCH 1000 below 3,000rpm, although that unequal-length fatigue system, that has been reported to enhance mid-range power, ended up being the actual only real distinction between the two systems. It’s challenging say if the after markets carbohydrate helps, but this huge black colored Harley drawn better from below 2,500rpm, even in top equipment.
Less impressive are the bike’s unpredictable hot starting behavior as well as its unreliable tick over, which combined to produce letting run of this fat twist-grip during the lighting a risky company. The CR’s various other quite irritating trait, which was most likely due to its carb, was its habit of surge off and on the ability. At speeds under about 50mph, the tiniest action associated with throttle made the bicycle speed up or slow down momentarily.
Carburetion ended up being otherwise impressively sharp, together with Hog was very happy to chug forth hard, its low-down torque encouraging short-shifting through very slow and long-travel four-speed package. Back 1977 the Caf Racer’s top speeds had been very near the 120mph level that Harley reported, although solid-mounted, 45-degree V-twin engine’s inevitable vibration was another great reason behind concentrating on the low area of the rev number.
The Harley’s management is no great motivation to fast cruising, often, as at much over 80mph the bars started to deliver a vague think may have been provoked by the unhelpful aerodynamics of this handlebar-mounted fairing. Contemporary examinations reported a weave at rates above 90mph, aided by the spindly twin-down tube frame becoming another prime suspect.
Control ended up being nevertheless rated appropriate with its time, even though XLCR came no place near matching the poise of Italian sportsters such as Ducati’s 900SS and Moto Guzzi Le Mans. Time moves on. My most brilliant memories of this ride was of negotiating a decent flex for the first time. The Harley, with its ancient geometry and 19in front-wheel, required alot more energy than we in the beginning used, and I needed to simply take another huge haul regarding the thin bars to get the bicycle around.
When into a fold the suspension system, although hard and without damping, coped relatively really with all the task of maintaining this fairly lengthy and heavy (515lb wet) cycle on the right course. This XLCR’s blend of Michelin front and Metzeler rear tires doubtless provide considerably more hold than the earliest rubberized (generally speaking Goodyears), although i did not drive my fortune difficult enough to confirm reports your gear lever could be the very first thing to touch straight down in left-handers.
Used to do use the brake system very difficult, though, and I necessary to since the twin-disc front setup was most wooden, despite receiving praise in 1977. (Urgent stops needed the Harley rider’s standard stamp in the base pedal.) Testers in those times were considerably keen to criticize the feeble headlamp, drag-prone clutch, complete insufficient space for storing for a much-needed device kit, and leaky gas cap. This cycle ended up being built a long time before Harley’s development period improvements in quality control, plus it showed.
Those faults did not stop testers of this time enthusing about the style and class of gigantic Ebony, “the meanest, manliest, meatiest, gutsiest, hustlingest mutha” ever before built by Harley, together place it. “In an environment of mass-produced standardization,” another typed, “a bike such as this sticks out like a hooker at a convent school address time.”
But once brand new, the Harley Caf Racer is mighty high priced, costing significantly more than top Italian recreation bikes, in addition to people was not persuaded. Harley’s image then wasn’t nearly as stylish as it’s today, plus the XLCR appealed neither to genuine sports bikers nor on conventional Harley crowd with regards to cruisers and tourers. In the event that CR is significant for something, it absolutely was for appearing that there was additional to an activity bicycle than slick styling and some framework mods.
But of course all of that doesn’t matter any more. All Seventies superbikes tend to be sluggish and difficult by modern-day criteria, who cares this you’re even slower than their contemporary competitors? A great deal more importantly, Willie grams’s grand folly is still as black colored, noisy and mean as ever it absolutely was — and the undeniable fact that Harley has not yet built such a thing remotely enjoy it before or since simply increases the appeal. Every one of these many years later, the XLCR’s looks, sounds and charisma more than replace the reality that it never ever ended up being a genuine Caf Racer after all.
XL900 the original mid compression variation
XLH900 same as the standard XL but with the “H” denoting the high compression motor
XLC900 off road version of the XL, The XLC have magneto ignition and kickstart best (including some other modifications to eliminate weight).
XLCH900 off-road form of the XLH – or perhaps the XLC with all the high-compression engine! – the “CH” denoting “competition/high-compression”. after per year lighting, speedo and full roadway legal specification arrived.
XLX-61 a basic level “Ironhead” era Sportster, offered with sparse trim, in black with black fatigue and handlebars or purple with chrome exhaust and handlebars.
XLT1000 “Tourer” 1977 special model had a Superglide container, screen, bigger seat and panniers
XLCH, XLH and XT different types of the 1977 Harley-Davidson Confederate version that had commemorative paint and tank and fender decals. Really low volume production of just 45 XLCH, 229 XLH and 15 XT models.
XLCR1000 “Cafe Racer” is the Cafe Racer design, for sale in 1977 and 1978.
XR1000, two high increase level track style exhausts on left and two staggered K&N kind filters feeding Dell’Orto carburetors on the appropriate. Had a 1,000 cc motor and a mixture of XLX Sportster and changed XR-750 areas.
XLH883 “Deluxe”, double seat, tachometer, buckhorn pubs, and spoke tires (vs single chair, speedometer best, reduced taverns and cast rims for the XLH883 standard design)
XLH883 “Hugger”, with reduced solitary chair level and paid off suspension, the precursor to your “XL lower” versions
XL53C “Personalized 53” (EU) XL883C “Custom” (US) ’98–’03 (883 cc or 53.9 cu in), Forward-controls, duelseat, solid backside wheel and drag pubs attached to a riser. This became the XL883C “Custom” all over the world with all the ’04 rubbermount version
XL883 “Sportster 883” solitary chair standard model, mid-controls, 13-spoke mags or cables
XL883C “Custom” has actually wider, flatter “custom” tank, forward-controls, duelseat and 21-inch wire and 16-inch solid disc wheels
XL1200C “Personalized” framework mount products had a chunkier duelseat and typical tank, plastic supports have smoother seat and flatter wide “personalized” container, all need 21-inch line and 16-inch slotted disc rims and forward-controls
XL883L “Low”; solitary seat, very low shocks, mid-controls, 13-spoke mags or cables
XL1200L “minimum”; Dualseat, middle bumps, mid-controls, larger flatter “Custom” tank, 13-spoke mags or cables
XL1200S “Sport” — this Sportster have adjustable suspension with piggyback shox, dual disk forward brake system, hotter cams and 13-spoke mags, later on models see twin connect cylinder heads with single fire ignition
XL883R “Roadster” Frame attach versions have a 2–1 fatigue, 13-spoke mags, black motor and obtainable in orange with ‘R’ graphics, rubberized supports bring 2–2 exhaust, somewhat different dualseat, wire wheel choice and much more ‘R’ colors, all need triple discs and rev-counter. This season, the XL883R officially receives the “Roadster” suffix
XL1200R “Roadster” Black system with highlighted fins, triple discs, rev-counter, orange paint offered but no ‘R’ visuals and ’08 models have the larger slimmer “custom” container which distance it further from the 883R
XL50 1200 “50th Anniversary” 2007 restricted production of 2,000 designs
XL1200N “Nightster” to begin the black Customs, combined LED tail/brake/indicator lighting, tapered silencers (EU) and part installed LED lit licence plate, 11-inch bumps, and baloney cut silencers (US), mid-controls and wire rims
XL883N “metal 883”, blacked aside 883 similar to the Nightster with an increase of black colored and 13-spoke mags, mid-controls.
XR1200 even more sports focused “Euro” design bicycle, male-slider forks, reworked Sportster motor with XR minds, new framework, four-pot two fold discs, 120/70-18 and 180/55-17 split 3-spoke mags, rear-controls – has its own race series
XL1200X “Forty-Eight”, inside “Dark” Nightster design but has the classic 1948 style small peanut container, cable wheels, forward-controls, another 130 mm front tire, and extremely small solitary chair
XR1200X Starting as a XR1200 with piggyback/fully flexible shocks, fully flexible front end, available in either Black Denim or light Denim paint colors
XL883L “SuperLow”, new for 2011 have black colored separate 5-spoke mags with polished wheels and 120/70-18 and 150/60-17 tires, wider slimmer “Custom” container, mid-controls
XL1200C “1200 Custom” As of 2011 features a 130/90B16 front side tyre, broad forward end, 5-spoke mags (UNITED KINGDOM gets wires), latest form eyebrow, larger flatter “Personalized” tank and introduces “H-D1”.
XL1200V “72” Radical Chopper with design impressed because of the classic styling of the very early ’70s chopper/bobbers that were commonplace during this period. Cycle has the chopper bobber looks, tricky Candy Personalized (with material flake) paint is optional.
2008 XL1200N Nightster
Introduced in 2007, the XL1200N Nightster included (then) special elements eg a bobbed back fender, forward fork gaiters, and a side mount license dish. The driving position and 25.3-inch (640 mm) seat height associated with the Nightster are the same as those of the XL883L Sportster minimum – UNITED KINGDOM version (and metal 883 and Forty-Eight) has actually central number plate, 13.5-inch back bumps, tapered silencers, and combined LED indicator/tail/brake lights. The bike has actually a measured HP of 57.2 hp (42.7 kW) (backside wheel) and 64.4 lb*ft (87.3 N*m) (backside wheel) and a top speed of 107 miles per hour (172 km/h) and a wet body weight of 564 pound (256 kg).
The Harley Iron was launched during 2009 as a smaller displacement form of the Nightster. The most important variations are blacked out motor, throw rims in place of laced; narrower handlebars; and of course small system displacement.
2010 Harley-Davidson XR1200 Sportster
Into the 2008 model seasons, Harley-Davidson revealed the XR1200 Sportster in Europe, Africa, therefore the Middle East. The XR1200 had an Evolution system tuned to make 91 bhp (68 kW), four-piston dual front disk brake system, and an aluminum swing arm. Motorcyclist have the XR1200 in the address of its July 2008 concern, and is typically positive about this within their “initially Ride” story, where Harley-Davidson ended up being repeatedly asked to offer they in the United States. One possible cause for the delayed availability in the us is the truth that Harley-Davidson must receive the “XR1200” naming liberties from Storz overall performance, a Harley modifying shop in Ventura, Calif. The XR1200 was released in america last year, in a particular color plan including Mirage tangerine highlighting its dirt-tracker traditions. The very first 750 XR1200 designs in ’09 were pre-ordered and was included with several 1 tag for the front side of the bike, autographed by Kenny Coolbeth and Scott Parker and a thank you/welcome letter from Harley-Davidson, finalized by costs Davidson. The XR1200 was discontinued in the united states of america marketplace for the 2013 lineup. The bike features a measured HP of 79.26 hp (59.10 kW) (backside wheel) and 67.53 lb*ft (91.56 N*m) (rear wheel) and a premier speed of 120.7 miles per hour (194.2 km/h)and a wet weight of 580 pound (260 kg).
Harley-Davidson Sportster Forty-Eight
When you look at the 2010 design 12 months, Harley-Davidson launched the XL1200X “Forty-Eight” design. It’s just like the “Dark” Nightster style but has the classic 1948 design little peanut tank, cable tires, forward-controls, a larger front tire with a fat forward end and chopped forward fender, a slammed speedo with under mount mirrors, reduced solo single seat, and reasonable suspension.
Inside 2012 model season, Harley-Davidson launched the XL1200V “Seventy-Two” design. This has the classic styling of this early ’70s chopper/bobbers that were common during this period. It offers the peanut gas tank, wire tires, white-wall tires, forward-controls, some additional rake and a little much longer forward forks, a chopped (bobbed) rear fender, side-mounted license dish, reasonable solamente solitary chair, mini-ape hanger handlebars, and reduced suspension system. The bicycle possess a measured HP of 54.67 hp (40.77 kW) (rear wheel) and 59.81 lb*ft (81.09 N*m) (backside wheel) and a premier rate of 108 mph (174 km/h) with a wet weight of 559.5 pound (253.8 kg).
Inside 2016 design year, Harley-Davidson launched the XL1200CX “Roadster” model. This is the sporty Sportster this has caf bicycle styling and position. With mid-position pegs and a slammed drag bar provide a small lean forth operating place. A 43mm inverted cartridge hand plus in the rear preload-adjustable emulsion-type bumps assist the roadster to really have the greatest slim direction of every Sportster. Furthermore twin 300mm floating disks and a tach and speedo. The cycle have a measured HP of 65.4 hp (48.8 kW) (back wheel) and 69.7 lb*ft (94.5 N*m) (back wheel).
The Sportster exists in many different models. The 2016 designs, that are not all available in similar region, were:
SuperLow – XL883L
Metal 883 – XL883N
883 Roadster – XL883R (U.K.)
1200 Personalized – XL1200C
SuperLow 1200T – XL1200T
Forty-Eight – XL1200X
Seventy-Two – XL1200V
Roadster – XL1200CX
1999 Buell M2 Cyclone 1203cc sportster motor
Buell started with water-cooled two-stroke square-fours and concluded with a water cooled four-stroke V-Twin, nevertheless the great majority of their bicycles made use of reworked 883 and 1200 Sportster motors. With Buell-designed heads, barrels, plus in 1999 gas injection, all of these generated a increase in horse power. They even have plastic mounting and a fan that cools the rear cylinder.
Lean, nimble frame. World-famous Evolution engine torque. The Harley-Davidson Sportster line is the pure motorcycle experience from street to highway.
The Harley-Davidson Sportster is a line of motorcycles produced continuously since 1957 by Harley-Davidson. Sportster models are designated in Harley-Davidson’s …
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This is the Sportster done with the kind of custom details only Harley-Davidson brings to the street. It’s the ultimate wide-shouldered custom cruiser.
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