Welcome to the definitive guide for your 1999 Sportster, a celebrated model from a legendary American manufacturer. Building upon a rich heritage dating back to 1903, the Sportster line, introduced in 1957, represents a cornerstone of the brand, renowned for its distinctive V-twin power and agile handling. The 1999 models, featuring the robust Evolution (Evo) engine, are available in 883cc and 1200cc variants, offering an authentic riding experience. This motorcycle is engineered for riders who appreciate classic design, reliable performance, and the open road, embodying a spirit of freedom and individuality. This comprehensive service manual provides essential information for the maintenance, repair, and troubleshooting of your 1999 Sportster. Covering a wide array of systems, including the engine, transmission, electrical system, brakes, fuel system, and bodywork, this manual is an invaluable resource for owners and technicians alike. It details routine maintenance procedures, component overhauls, and diagnostic strategies, complete with detailed wiring diagrams and critical torque specifications. By following the expert guidance within these pages, you can ensure your Sportster remains in peak condition, delivering the performance and reliability expected. 🏷️ Basic Information Identification Make: Harley-Davidson Model: Sportster Year: 1999 Generation Generation Code: XL (Evo) 👋 Introduction Market Position Target Audience: Harley-Davidson Sportster owners, independent repair shops, motorcycle enthusiasts. Competitive Analysis Value Proposition: Provides critical repair and maintenance information that replicates dealership-level expertise, saving owners significant cost. Key Features Diagnostic Focus: Detailed troubleshooting sections for common and uncommon issues faced by the 1999 Sportster models. 📋 Manual Details Coverage Areas General Coverage: Comprehensive service, repair, and workshop information for 1999 Harley-Davidson Sportster models. Page Count Estimated Page Count: 300-500 Manual Type Manual Type: Service Manual / Workshop Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Service: Engine assembly, disassembly, tuning, troubleshooting, specific components (carburetor, ignition, exhaust). Transmission Service: Gearbox disassembly, inspection, repair, clutch service, maintenance. Electrical System: Wiring diagrams, ignition system, lighting, battery, charging system, starter, troubleshooting. Frame And Suspension: Front forks (shocks), rear shocks, frame inspection, steering head bearing service. Braking System: Front and rear brake caliper service, master cylinders, brake lines, bleeding procedures. Fuel System: Fuel tank, fuel lines, carburetor (e.g., Keihin CV), fuel pump (if applicable). Cooling System: Not applicable for air-cooled engines, but includes oil cooling system details. Exhaust System: Exhaust pipe and muffler removal, installation, gasket replacement. Bodywork And Trim: Fender removal/installation, seat, fuel tank mounting, handlebars, controls. Procedures Included Preventive Maintenance: Scheduled maintenance tasks, lubrication, fluid changes, filter replacements. Troubleshooting Guides: Systematic diagnosis of common problems and their solutions. Component Overhaul: Detailed steps for rebuilding major components like the engine and transmission. Wiring Diagrams: High-quality, detailed electrical schematics for accurate troubleshooting. Torque Specifications: Essential torque values for critical fasteners across all systems. Technical Depth Depth Of Coverage: Comprehensive, from basic routine maintenance to advanced engine rebuilds and electrical diagnostics. 📊 Manual Specifications File Format File Type: PDF Searchable Text: Typically yes, allowing for quick information retrieval. Print Quality Print Resolution: High-resolution scans suitable for printing. Binding Type Binding: N/A (Digital PDF Download) Paper Type Paper Quality: N/A (Digital PDF Download) ⚙️ Engine Specifications Primary Engine Engine Type: Evolution (Evo) V-Twin, Air-Cooled Engine Displacement: 883cc (57ci) and 1200cc (74ci) variants Bore X Stroke 883Cc: 3.00 in x 3.81 in (76.2 mm x 96.8 mm) Bore X Stroke 1200Cc: 3.50 in x 3.81 in (88.9 mm x 96.8 mm) Compression Ratio 883Cc: 8.8:1 (approx.) Compression Ratio 1200Cc: 9.0:1 (approx.) Performance Horsepower 883Cc: Approximately 50-55 HP Horsepower 1200Cc: Approximately 65-70 HP Fuel System Carburetor: Keihin CV (Constant Velocity) 34mm (883cc), Keihin CV 40mm (1200cc) Fuel Type: Unleaded gasoline, minimum 91 octane recommended Engine Oil Oil Type Specification: SAE 20W50 API SG Oil Capacity With Filter: Approx. 3 US quarts (2.8 Liters) 🔧 Transmission Standard Transmission Type: 5-Speed Constant Mesh Clutch Type: Wet, multi-plate, diaphragm spring Transmission Fluid Transmission Oil Specification: Harley-Davidson Formula Plus or equivalent SAE 80W-90 GL-5 gear oil Transmission Oil Capacity: Approx. 26 US fluid ounces (0.77 Liters) 📐 Dimensions Exterior Overall Length: Variable by model (e.g., Sportster 883 Hugger, Sportster 1200 Custom) Wheelbase: Approx. 56.5 inches (1435 mm) Weights Dry Weight 883Cc: Approx. 490 lbs (222 kg) Dry Weight 1200Cc: Approx. 500 lbs (227 kg) Gross Vehicle Weight Rating Gvwr: Approx. 930 lbs (422 kg) 🛡️ Safety Features Ratings Safety Certification: Meets DOT standards for motorcycles. Active Features Braking System: Hydraulic disc brakes front and rear. Tire Specifications: Front: 100/90-19 (typical), Rear: 130/90-16 (typical). Specifics vary by trim. Passive Features Lighting System: Halogen headlight, tail light, brake light, turn signals. 💡 Technology Features Infotainment Infotainment System: None (basic analogue gauges for speed, tachometer, fuel, oil pressure/voltage). Driver Assistance Driver Assistance Features: None. Connectivity Connectivity Features: None. 🔧 Maintenance Service Intervals Oil And Filter Change: Every 2,500 miles or annually. Primary Chain Tension Check: Every 5,000 miles. Spark...