🏷️ Basic Information Identification Make: Harley-Davidson Model: XLH Sportster 1200 Year: 2002 Engine Type: V-Twin, Air-Cooled Trim Level: All Models/Engines/Trim/Transmissions Types Generation Model Generation: Evo Sportster (XL Evolution Engine) 👋 Introduction Market Position Target Audience: Harley-Davidson XLH Sportster 1200 2002 Owners and Technicians Value Proposition: Empowers DIY repairs, saves significant money on service costs Competitive Analysis Advantage Over Competitors: Same as used in local service/repair shops; often factory manual not available in stores. Key Features Convenience: Instant download, digital format protects from dirt and oil. Completeness: COMPLETE and INTACT, no missing/corrupt parts or pages. 📋 Manual Details Coverage Areas Primary Coverage: Service, Maintenance, Troubleshooting, Repair Comprehensive Scope: All Models/Engines/Trim/Transmissions Types for 2002 XLH Sportster 1200 Page Count Estimated Pages: Hundreds (Actual number not specified, but stated as extensive) Manual Type Type: Workshop Repair Service Manual Source: Original Manufacturer Documentation (Harley-Davidson) Language Language: English Format File Format: PDF Download 📖 Manual Coverage Systems Covered General Information: Yes Maintenance: Yes Chassis: Yes Fuel System: Yes Cooling System: Yes (Air-Cooled) Engine: Yes Clutch: Yes Engine Lubrication System: Yes Engine Removal Installation: Yes Drive System: Yes Transmission: Yes Wheels Tires: Yes Final Drive: Yes Brakes: Yes Suspension: Yes Steering: Yes Frame: Yes Electrical System: Yes Wiring Diagrams: Yes Procedures Included Diagnostic Procedures: Yes Repair Procedures: Yes (Step-by-step) Maintenance Procedures: Yes Troubleshooting: Yes Disassembly: Yes Assembly: Yes Cleaning: Yes Reinstallation: Yes Tool Requirements: Yes Technical Depth Depth Level: Professional Technician Level Detail Level: Detailed substeps, notes, cautions, warnings Illustrations: Hundreds of diagrams, detailed illustrations, drawings, and photos Information Accessibility: Numbered table of contents for fast access 📊 Manual Specifications File Format Format: PDF Readability Features: Zoom In/Out functionality Print Quality Printability: Full Printable Page Handling: Print desired sections and discard after use Binding Type Binding: Digital (No physical binding) Paper Type Paper Type Equivalence: Equivalent to factory paper manuals (for printed sections) Delivery Delivery Method: Instant Download Requirements Software Requirements: Adobe PDF Reader & WinZip Operating System Compatibility: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Code: Evolution (Evo) Engine Displacement: 1200cc (73.7 cubic inches) Engine Configuration: 45-degree V-Twin Cooling Method: Air-Cooled Performance Horsepower: Approx. 60-65 HP (Varies by specific tuning and configuration) Torque: Approx. 67-70 ft-lbs (Varies by specific tuning and configuration) Fuel System Fuel Delivery: Carbureted (e.g., Keihin CV Carburetor) or Electronic Fuel Injection (EFI) depending on specific model variant within the 2002 lineup. 🔧 Transmission Standard Transmission Type: 5-Speed Manual Constant Mesh Optional Optional Transmission: N/A (Standard for 2002 XLH 1200) Features Drive Type: Belt Drive (Final Drive) 📐 Dimensions Exterior Wheelbase: Approx. 59.5 inches (1511 mm) Weights Dry Weight: Approx. 500-520 lbs (227-236 kg) (Varies by specific model) 🛡️ Safety Features Ratings Safety Ratings: N/A (Motorcycle specific safety ratings differ from automotive) Active Features Braking System: Front and Rear Disc Brakes 💡 Technology Features Infotainment Infotainment System: Basic instrumentation (Speedometer, Tachometer, Odometer, Fuel Gauge). No advanced infotainment. Driver Assistance Driver Assistance Features: None Connectivity Connectivity Features: None 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 2,500 - 5,000 miles or annually (Refer to manual for exact specification) Primary Chain Tension Check: Regularly (Refer to manual for specific intervals) Fluid Specifications Engine Oil Type: Viscosity recommended: 20W-50 or 10W-40 (Harley-Davidson Genuine Motor Oil or equivalent meeting Harley-Davidson specifications) Primary Oil Type: Harley-Davidson Genuine Primary Chaincase Lubricant or equivalent Transmission Oil Type: Harley-Davidson Genuine Transmission Lubricant or equivalent Brake Fluid Type: DOT 4 (for hydraulic clutch if equipped, and hydraulic brake systems) Known Issues Common Issues: Starter solenoid issues, carburetor tuning, primary chain adjustment, potential oil leaks, rear brake wear. 📚 Vehicle History Brand Heritage Brand History: Harley-Davidson, established 1903, renowned for V-twin motorcycles and custom culture. Model Evolution Sportster Lineage: The Sportster line dates back to 1957, evolving from Ironhead engines to the more modern Evolution (Evo) engine. Production Manufacturing Location: United States (Milwaukee, Wisconsin and Kansas City, Missouri) 🏆 Awards & Recognition Recognitions Awards Certifications: N/A (Specific awards for this model year not readily available, but Sportster is a consistently popular and iconic model.)