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Online Auto Repair offers service repair manuals for your Harley-Davidson XL Sportster 883 - DOWNLOAD your manual now! Harley-Davidson XL Sportster 883 service repair manuals. Complete list of Harley-Davidson XL Sportster 883 motorcycle service repair manuals: Harley Davidson 2015 Sportster Repair Service Manual.
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This INSTANT REPAIR MANUAL DOWNLOAD for the Harley Davidson Sportster XL & XLH883 were designed primarily for factory service 1991 Sportster XLH 883 Hugger technicians in a properly equipped shop. However, enough information in this 1991 Sportster XLH 883 Hugger repair manuals is given for do-it-yourself or apprentice mechanics to correctly and safely perform repair work to their 1991 Sportster XLH 883 Hugger motorcycle and components. Individuals using this 1991 Sportster XLH 883 Hugger repair manual should possess basic knowledge of tools and mechanical theory. The 1991 Sportster XLH 883 Hugger motorcycle mechanic should carefully read the text and become familiar with the 1991 Sportster XLH 883 Hugger service manual procedures before beginning the work. Some repair procedures in this Harley 1991 Sportster XLH 883 Hugger downloadable manual may require the use of special tools. Its recommended to only use the exact tools, as specified in this 1991 Sportster XLH 883 Hugger service manual. Most tools can be rented at local parts stores. There's nothing this 1991 Sportster XLH 883 Hugger owners repair manual doesn't cover. From 1991 Sportster XLH 883 Hugger maintenance procedures, troubleshooting to complete 1991 Sportster XLH 883 Hugger engine overhaul, this Harley 1991 Sportster XLH 883 Hugger manual COVERS IT ALL! The ebook is simple to download and works on all computers. The download book is in a simple PDF format. 1. throttle cable adjustment on 1991 harley hugger
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TRANSMISSIONThis chapter covers the five-speed transmission for the 1991-2003 models, internal gearshift assemblies and shift mechanism.When the clutch is engaged, the mainshaft is driven by the clutch hub, which is driven by the primary chain sprocket/clutch outer housing. Power flows from the mainshaft through the selected gear combination to the countershaft, which drives the main drive gear and transmission sprocket. To gain access to the transmission and internal shift mechanism, it is not necessary to remove the engine or disassemble the crankcase.
The transmission components are contained behind an access door on the left crankcase half. RIGHT TRANSMISSION CASE BEARINGSThe right transmission case is equipped with the following bearings:1.
Main drive gear bearing2. Countershaft needle bearing3. Shift drum needle bearingEach of these bearings can be replaced with the engine crankcase assembled and installed in the frame.SHIFT MECHANISMTo inspect and service the shift shaft assembly, the transmission must be disassembled as described in this chapter. The shift lever can be removed by loosening the pinch bolt. Tighten the pinch bolt to 90-110 in.-lb. Drive sprocket2. Spacer (drive belt)4.
Right crankcase half8. Needle bearing10. Main drive gear11. Needle bearing12. Mainshaft second gear13. Thrust washer15. Mainshaft third gear16.
Split bearing17. Mainshaft first gear18. Mainshaft fourth gear19. Access door22.
Spring washer26. Mainshaft nut27. Countershaft needle bearing28. Shift shaft needle bearing29.
Countershaft fifth gear30. Countershaft second gear31. Countershaft third gear32. Countershaft first gear34. Countershaft fourth gear35. Beveled washer36.
Retainer collar39. ScrewShift Assembly Parts. In you repair manual and c oat the oil seal lips with transmission oil prior to installation. Slide the oil seal, with its lips facing toward the crankcase, over the spacer. Tap the oil seal into the crankcase until its outer surface is flush with or slightly below (0.030 in. 0.76 mm maximum) the oil seal bore inside surface. Insert the main drive gear into the main drive gear bearing in the transmission portion of the engine crankcase as far as it will go.
Then hold it in place and assemble the main drive gear remover and installer tool as shown in your reference manual.a. Detent nut and washer.SHIFT FORKS AND SHIFT DRUMDisassemblyInstallation1. Shift shaft assembly2. Right crankcase half5. Detent plate snap ring6.
Detent plate7. Detent screw8. Detent arm10.
Shifter drum locating plate11. Reinforcing plate12. Countershaft bearing15. Mainshaft bearing16. 4th gear shift fork17.
Shift fork pins18. Cotter pins19. 1st and 2nd gear shift fork20.
3rd and 5th gear shift fork21. Shift drum22. Pin (neutral indicator)23.
Access doorMain Drive Gear Parts Assembly1. Drive sprocket2. Spacer (drive belt)4. Right crankcase half8. Needle bearing10.
Main drive bearing (fifth gear).
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