Harley Davidson Sportster Xl1200 Custom 96-03 Service Manual (MT044559)

Harley Davidson Sportster Xl1200 Custom 96-03 Service Manual (MT044559)

• This manual presented for you in electronic format you can just print out the page you need then dispose of it when you have completed your task. This manual has detailed illustrations as well as step by step written instructions with the necessary diagrams or pictures. These manuals are your number one source for repair and service information, specifically written for the do-it-yourself as well as the experienced mechanics worldwide used to use this factory manual to fix your vehicle. Using this repair manual is an inexpensive way to keep your car working properly. it is this level of detail, along with illustrations, that guide the reader through each service, repairs, maintenance procedure.
• Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003 Workshop Service Manual for Repair.

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  This Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003 service manual provides data, characteristics, instructions and methodology to perform repair interventions on the vehicle and its components.

  This manual includes special notes, important points, service data, precautions, etc. that are needed for the maintenance, adjustments, service, removal and installation of vehicle components for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  The most detailed, comprehensive step by step procedures, explanations, and pictorial diagrams from bumper to bumper you will ever see for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.

  Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003 Service Repair Manual meets all your information needs to repair or make some adjustments to your Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003 Service Repair Manual. This manual is intended as a handy, easy to read reference book for the mechanics and DIY persons. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order.

  Detailed illustrations, exploded diagrams, drawings and photos guide you through every service repair procedure for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003 Service Repair Manual.

  Adjustment and repair operations include reference to Service tool numbers and the associated illustration depicts the tool for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003. Where usage is not obvious the tool is shown in use.

  This Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003 service manual can be viewed on any computer, as well as zoomed and printed.
  
  This service manual has been specially prepared so that the explanation is very simple. It has been prepared so that if this manual is thoroughly read, even comparatively new personel can give satisfactory after services to the customers as well as disassemble and maintain the vehicle.

  All service and repair instructions included for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  Always use the correct special service tools or equipment specified. Under no circumstances use makeshift tools or equipment since the use of substitutes may adversely affect safe operation.
  
  Where accurate measurements are required, they can only be made using calibrated, precision instruments.
  
  Providing that the service schedules are respected, the customers can be sure of obtaining the maximum satisfaction and best result from his car. This manual provides general descriptions for accomplishing service and repair work with tested, efective tehniques. Following them will help assure reliability.
  
  Information on the construction and function are included. This part should be understood before proceeding with troubleshooting, disassembling and servicing. Information on the troubleshooting, servicing specification lists, tightening torque, checking and adjusting, disassembling and assembling and servicing which cover procedures, precautions, factory specifications and allowable limits.
  
  Information in this manual for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003 is divided into groups. These groups contain general information, diagnosis, testing, adjustments, removal, installation, disassembly, and assembly procedures for the systems and components. Appropiate service methods and correct repair procedures are esential for the safe, reliabe operation of all motor vehicles as well as the personal safety of the individual carrying out the work.

  The illustrations in this manual are used to highlight the fundamental principles and procedures of basic interventions. They may not show exactly the Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003 in your possession.

  Adjustment and repair operations also include reference to wear limits for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003. Relevant data, useful assembly details all in this SERVICE MANUAL for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  In order to perform the work efficiently and to avoid costly mistakes, read the text and thoroughly familiarise yourself with procedures before starting work.
  
  All work should be performed with great care and in a clean working area with adequate lighting.

  Please peruse and utilize this manual for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003 fully to ensurea complete repair work for satisfying you or your customers by keeping their vehicle in optimum condition.
  
  All information, illustration and specifications contained in this manual are based on the latest product information avaiable at the time of publication approval. The specification, maintenance and other information for the components are included, and diagnostic information has also been added where necessary. These torque values are intended for use in service assembly and installation procedures using the correct OEM fasteners. When replacing fasteners, always use the same type (part number) fastener as removed.
  
  This Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003 book outlines procedures for servicing and repairing vehicles using safe, effective methods. The procedures contain many NOTES, CAUTIONS and WARNINGS which should be followed along with standard safety procedures to eliminate the possibility of personal injury or improper service which could damage the vehicle or compromise its safety.

  To maximise the life of your Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003:
  
  Accurately follow the maintenance requirements of the periodic maintenance chart in the service manual.
  
  Do not allow problems to develop. Investigate unusual noises and changes in the riding characteristics of the Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003. Rectify all problems as soon as possible (immediately if safety related).
  
  Use only genuine Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003 parts as listed in the parts catalogue.
  
  Follow the procedures in this manual carefully and completely. Do not take short cuts.
  
  Keep complete records of all maintenance and repairs with dates and any new parts installed.
  
  Use only approved lubricants, as specified, in the manual of the Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.

  This manual for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003 has been issued to provide you with technical information regarding the design, function, disassembly, adjusting work and troubleshooting on the components and model of the Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  The descriptions are brief but precise and are supported by photographs, notes, drawings and schematics, as well as exploded and sectional drawings. All this information is intended to simplify any necessary repair work which can be performed on Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  This manual also contains information about adjusting work and valuable reference data for such adjustment values.
  
  For all maintenance and repair work on Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003, all accident prevention guidelines must be strictly observed. To perform all repairs listed in this manual, a complete set of standard tools, as well as the special tools and fixtures shown and listed are necessary.
  
  No special emphasis is put on replacing sealing components as we assume that these items are replaced during any repair. Unless specific values are given, all threaded connections should be tightened according to the required tightening torques listed on torque charts.
  
  When describing work, which can be dangerous, we have described the required safety measures in this manual and indicated them by special remarks DANGER, CAUTION or NOTE.

  This Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003 Service Service Repair Manual QUALITY manual is 100 percents COMPLETE and INTACT, no MISSING/CORRUPT pages/sections to freak you out!

  This Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003 Service manual is known in many names:
  
  Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003 Service service manual.
  
  Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003 Service repair manual.
  
  Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003 Service workshop manual.
  
  Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003 Service shop manual.

  This manual for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003 is designed primarily for use by trained technicians in a properly equipped workshop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. The work can only be carried out if the owner has the necessary hand and special service tools to complete the job.
  
  A basic knowledge of mechanics, including the proper use of tools and workshop procedures is necessary in order to carry out maintenance and repair work, satisfactorily.

  GENERAL TAGS FOR MOTORCYCLES:

  SPECIFICATIONS for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  VEHICLE IDENTIFICATION NUMBER (V.I.N.) for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  WHEELS for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  FRONT WHEEL for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  REAR WHEEL for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  TIRES for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  FRONT BRAKE MASTER CYLINDER AND HAND LEVER for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  FRONT BRAKE LINE for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  FRONT BRAKE CALIPER for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  BRAKE PEDAL for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  REAR BRAKE MASTER CYLINDER for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  REAR BRAKE LINE for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  REAR BRAKE CALIPER for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  FENDERS for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  FRONT FORK for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  FORK CLAMPS: UPPER AND LOWER for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  STEERING HEAD BEARINGS for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  SWINGARM AND BRACE for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  FRAME for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  REAR SHOCK ABSORBER for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  THROTTLE CONTROL for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  CLUTCH CONTROL for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  HEADLAMP ASSEMBLY AND SUPPORT BRACKET for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  FOOTPEG, HEEL GUARD AND MOUNT for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  SPROCKET COVER for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  BELT GUARDS. for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  INTAKE COVER for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  SIDESTAND for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  SEAT LOCKS for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  ENGINE for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  ENGINE REMOVAL for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  ENGINE INSTALLATION for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  CYLINDER HEAD for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  CYLINDER AND PISTON for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  LUBRICATION SYSTEM for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  OIL RESERVOIR AND OIL HOSE ROUTING for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  OIL COOLER for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  OIL PRESSURE INDICATOR SWITCH for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  CRANKCASE BREATHING SYSTEM for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  OILING SYSTEM for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  OIL PUMP for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  HYDRAULIC LIFTERS for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  GEARCASE AND CAM GEARS for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  CRANKCASE for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  AIR CLEANER ASSEMBLY for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  ELECTRONIC CONTROL MODULE (ECM) for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  THROTTLE POSITION SENSOR (TPS) for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  IGNITION COIL for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  FUEL TANK for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  FUEL PUMP for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  THROTTLE BODY for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  EXHAUST SYSTEM for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  STARTER for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  IGNITION SYSTEM for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  IGNITION/HEADLAMP KEY SWITCH for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  SPARK PLUG CABLES for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  CHARGING SYSTEM for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  BATTERY CABLES for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  VOLTAGE REGULATOR for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  ALTERNATOR for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  TURN SIGNAL FLASHER, FRONT TURN SIGNALS, REAR TURN SIGNALS for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  HEADLIGHT, TAIL LAMP for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  MAIN FUSE AND FUSES for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.
  
  WIRING DIAGRAMS for Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003.

  AND MORE…

  Harley Davidson Sportster XL1200 Custom 1996 1997 1998 1999 2000 2001 2002 2003 Workshop Service Manual for Repair.