The XL1200S Sportster Sport, produced in 2002, is a significant model within the legendary Sportster lineage, renowned for its performance-oriented design and the iconic Evolution V-Twin engine. This model builds upon a rich heritage, offering a blend of classic styling and enhanced capabilities that have cemented the Sportster's enduring appeal. Its engineering quality and reliability are hallmarks, providing riders with a dependable and exhilarating experience, characterized by its distinctive V-twin character and responsive handling. This comprehensive workshop service repair manual provides in-depth coverage for the 2002 XL1200S Sportster Sport, encompassing all models, engines, and trim types. It serves as an essential resource for owners and technicians alike, detailing crucial maintenance procedures, troubleshooting guidance, technical specifications, and safety information. With professional-level diagnostic and repair information, including detailed disassembly, assembly, cleaning, and reinstallation procedures, this manual empowers users to effectively maintain and repair their vehicle, ensuring optimal performance and longevity. 🏷️ Basic Information Identification Make: Harley-Davidson Model: XL1200S Sportster Sport Year: 2002 Codes Engine Family: Evolution V-Twin 👋 Introduction Market Position Target Audience: Harley-Davidson XL1200S Sportster Sport 2002 owners and independent repair shops Key Features Source Authenticity: Original Manufacturer's Workshop Repair Service Manual, same as used by local service/repair shops Content Quality: Complete and intact, without missing or corrupt parts/pages, professional quality, highly detailed User Experience: Easy-to-follow directions, pictures, diagrams, numbered instructions, bold figure numbers for quick matching Benefit To User: Saves time and money on repairs and maintenance, enables DIY repairs Delivery Method: Instant Download, no shipping costs or waiting 📋 Manual Details Coverage Areas Primary Coverage: Service, Maintenance, Troubleshooting, Repair All Models Trims Engines: All Models/Engines/Trim/Transmissions Types for 2002 XL1200S Page Count Estimated Page Count: Hundreds of pages (specific count not provided, but described as comprehensive) Manual Type Type: Workshop Service Repair Manual Language Language: English Format File Format: PDF Download 📖 Manual Coverage Systems Covered General Information: Included Maintenance: Included Chassis: Included Fuel System: Included Cooling System: Included (though Sportster models are typically air-cooled, this may refer to oil cooling components if applicable or general thermal management) Engine: Included Clutch: Included Engine Lubrication System: Included Drive: Included Transmission: Included Wheels Tires: Included Final Drive: Included Brakes: Included Suspension: Included Steering: Included Frame: Included Electrical System: Included Wiring Diagrams: Included Procedures Included Disassembly Assembly: Included Cleaning: Included Reinstalling: Included Troubleshooting: Included (with detailed wiring diagrams) Technical Depth Depth: Professional Technician Level, Diagnostic, Repair, and Maintenance Information 📊 Manual Specifications File Format File Type: PDF Print Quality Printability: Full Printable Zoom Functionality: Zoom IN/OUT supported Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Requirements Software Requirements: Adobe PDF Reader & WinZip Operating System Compatibility: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Type: Air-cooled, Evolution V-Twin Displacement: 1200cc (73.4 cu in) Bore X Stroke: 3.50 in x 3.81 in (88.9 mm x 96.8 mm) Compression Ratio: 9.0:1 (typical for XL1200S) Performance Horsepower: Approximately 65-70 HP (specific dyno figures may vary, manual will provide OEM specifications) Torque: Approximately 70-75 ft-lbs (specific dyno figures may vary, manual will provide OEM specifications) Fuel System Fuel Delivery: Carbureted (likely Keihin CV carburetor, manual will specify exact model and tuning) Fuel Type: Unleaded Gasoline, minimum 89 Octane (check manual for specific recommendations) Engine Lubrication System Oil Type: Motorcycle-specific engine oil, typically Harley-Davidson SYN3 or equivalent (manual will detail viscosity and capacity) Oil Capacity: Approximately 3 quarts (3 liters) with filter change (manual will provide exact capacity and procedure) 🔧 Transmission Standard Type: 5-speed constant mesh Clutch Type: Wet, multi-plate Features Drive Type: Primary drive: Duplex chain. Final drive: Belt Fluid Requirements Transmission Oil: Harley-Davidson Transmission Oil or equivalent (manual will specify type and capacity) 📐 Dimensions Weights Dry Weight: Approximately 525 lbs (238 kg) (varies by specific configuration) Gvwr: Not typically specified for motorcycles in the same way as cars, but manual may cover load limits 🛡️ Safety Features Active Features Brakes: Dual Disc Front, Single Disc Rear (specific caliper type and rotor size detailed in manual) Suspension: Tuning fork front fork (likely Showa), dual rear shock absorbers (XL1200S featured adjustable shocks) Passive Features Lighting: Headlight, taillight, brake light, turn signals (wiring diagrams in manual) 💡 Technology Features Infotainment Features: As a 2002 model, infotainment features are basic, typically limited to analog gauges (speedometer, tachometer, oil pressure, fuel level) and potentially a basic odometer/trip meter. The manual will detail instrument cluster functions. Driver Assistance Features: No advanced driver assistance systems typical of modern vehicles. Safety relies on rider skill and well-maintained mechanical components. Connectivity Features: No connectivity features. The manual focuses on the mechanical and electrical systems of the motorcycle. 🔧 Maintenance Service Intervals Oil Change: Typically every 2,500-5,000 miles or annually (manual will provide precise interval and procedure) Primary Chain Tension: Check at regular intervals, adjustment procedure in manual Spark Plugs: Check and replace as needed,...