The 2002 XLH Sportster 1200 is an iconic American motorcycle, powered by a 1200cc air-cooled V-Twin Evolution engine. Known for its distinctive styling and the heritage of the Sportster lineage dating back to 1957, this model embodies a commitment to robust engineering and a classic riding experience. Designed for enthusiasts who appreciate the raw power and customization potential of a V-Twin, the XLH Sportster 1200 offers a blend of performance and enduring design, making it a sought-after machine for both cruising and personal expression. This comprehensive workshop repair service manual provides in-depth coverage for the 2002 XLH Sportster 1200, encompassing all models, engines, trims, and transmissions. It details essential service, maintenance, and troubleshooting procedures, offering step-by-step instructions, detailed illustrations, and technical specifications. This manual is an indispensable resource for owners and technicians alike, empowering them to perform diagnostics, repairs, and routine maintenance with precision, ensuring the longevity and optimal performance of their motorcycle. 🏷️ 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...