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sportster_history:1991_sportster [2022/01/28 00:31] hippysmack [Vehicle Identification Number (VIN)] |
sportster_history:1991_sportster [2024/01/25 18:24] (current) hippysmack |
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====== Related Manuals and Documentation ====== | ====== Related Manuals and Documentation ====== | ||
- | |||
Below are some suggestions for manuals for your ride. \\ | Below are some suggestions for manuals for your ride. \\ | ||
__You should have, at minimum, a Factory Service Manual (FSM) and a Factory Parts Catalog for your year model__. \\ | __You should have, at minimum, a Factory Service Manual (FSM) and a Factory Parts Catalog for your year model__. \\ | ||
+ | **Note**: Updated manuals sometimes correct mistakes from the original manuals and some are updated simply to add mid year intro models. \\ | ||
**Factory Service Manuals (FSM)**; \\ | **Factory Service Manuals (FSM)**; \\ | ||
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* Written in 1991 and lists parts available in 1992 for 1991-1992 models. | * Written in 1991 and lists parts available in 1992 for 1991-1992 models. | ||
* **Factory Owners Manual**: | * **Factory Owners Manual**: | ||
- | * 1991 XLH Models Owners Manual (99466-91). | + | * 1991 (all) Models Owners Manual (99466-91). |
**Pics of Manual Covers**. \\ | **Pics of Manual Covers**. \\ | ||
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See the full list of pertinent catalogs in the links above. \\ | See the full list of pertinent catalogs in the links above. \\ | ||
Click on any pic below to enlarge: \\ | Click on any pic below to enlarge: \\ | ||
+ | |||
+ | | 1991 Owners Manual (99466-91) | | ||
+ | |{{:sportster_history:l003-om-1991_edition_cover_99466-91.jpg?direct&200|}}| | ||
| 1991 FSM (99484-91) \\ Original Manual | 1991-1992 FSM \\ Updated Manual (99484-92) | 1991 Original \\ Parts Catalog (99451-91) | 1991-1992 Updated \\ Parts Catalog (99451-92) | | | 1991 FSM (99484-91) \\ Original Manual | 1991-1992 FSM \\ Updated Manual (99484-92) | 1991 Original \\ Parts Catalog (99451-91) | 1991-1992 Updated \\ Parts Catalog (99451-92) | | ||
|{{:sportster_history:l001-fsm-1991_edition_cover_99484-91_for_1991.jpg?direct&200|}}|{{:sportster_history:l001-fsm-1992_edition_cover_99484-92_for_1991-1992.jpg?direct&200|}}|{{:sportster_history:l002-pc-1991_edition_cover_99451-91_for_1991.jpg?direct&200|}}|{{:sportster_history:l002-pc-1992_edition_cover_99451-92_for_1991-1992.jpg?direct&200|}}| | |{{:sportster_history:l001-fsm-1991_edition_cover_99484-91_for_1991.jpg?direct&200|}}|{{:sportster_history:l001-fsm-1992_edition_cover_99484-92_for_1991-1992.jpg?direct&200|}}|{{:sportster_history:l002-pc-1991_edition_cover_99451-91_for_1991.jpg?direct&200|}}|{{:sportster_history:l002-pc-1992_edition_cover_99451-92_for_1991-1992.jpg?direct&200|}}| | ||
- | ===== Engine, Drivetrain, Performance ===== | + | ====== Specifications ====== |
+ | |||
+ | ==== Model Designations ==== | ||
+ | * Model Designations: XLH-883, XLH-883 Hugger, XLH-883 Deluxe, XLH-1200 | ||
+ | |||
+ | ==== Dimensions ==== | ||
+ | * Wheelbase: ((Harley-Davidson Sportster 1991 Service Manual pg 2-1)) | ||
+ | * XLH-883 / XLH-883 Deluxe / XLH-1200, 60 in / 152.40 cm per the 1991 FSM (1991-1992 FSM says 60.2") | ||
+ | * XLH-883 Hugger, 60.5 in / 153.67 cm | ||
+ | * Overall Length: ((Harley-Davidson Sportster 1991 Service Manual pg 2-1)) | ||
+ | * XLH-883 / XLH-883 Hugger / XLH-883 Deluxe / XLH-1200, 87.5 in / 222.25 cm per the 1991 FSM (1991-1992 FSM says 87.6") | ||
+ | * Overall Width: ((Harley-Davidson Sportster 1991 Service Manual pg 2-1)) | ||
+ | * XLH-883, 32 in / 81.28 cm | ||
+ | * XLH-883 Hugger, 33 in / 83.82 cm | ||
+ | * XLH-883 Deluxe / XLH 1200 32 in / 81.28 cm per the 1991 FSM (1991-1992 FSM says 33 in / 83.82 cm) | ||
+ | * Overall Height: ((Harley-Davidson Sportster 1991 Service Manual pg 2-1)) | ||
+ | * XLH-883, 47.5 in / 120.65 cm | ||
+ | * XLH-883 Deluxe, 47.5 in / 120.65 cm per the 1991 FSM (1991-1992 FSM says 49.75 in / 126.365 cm) | ||
+ | * XLH-883 Hugger, 49.75 in / 126.365 cm | ||
+ | * XLH-1200, 49.75 in / 126.36 cm | ||
+ | * Road Clearance: ((Harley-Davidson Sportster 1991 Service Manual pg 2-1)) | ||
+ | * XLH-883 / XLH-883 Deluxe / XLH-1200, 6.75 in / 17.145 cm | ||
+ | * XLH-883 Hugger, 5.9 in / 14.986 cm | ||
+ | * Weight (as shipped from the factory): ((Harley-Davidson Sportster 1991 Service Manual pg 2-1)) | ||
+ | * XLH-883, XLH-883 Hugger, 472 lbs. | ||
+ | * XLH-883 Deluxe, 484 lbs. | ||
+ | * XLH-1200, 470 lbs. | ||
+ | |||
+ | ==== Engine ==== | ||
+ | * Engine type: 4 cycle Overhead Valves, 45 degree V2 ((Harley-Davidson Sportster 1991 Service Manual pgs 3-1,3-2, 3-3)) | ||
+ | * Displacement: | ||
+ | * 883cc: 53.9 ci | ||
+ | * 1200cc: 73.3 ci | ||
+ | * Compression Ratio: 9:1 | ||
+ | * HP @ 6000 RPM: | ||
+ | * 883cc, 52 | ||
+ | * 1200cc, 68 | ||
+ | * Torque: | ||
+ | * 883cc, 53 ft/lbs at 4250 RPM | ||
+ | * 1200cc, 72 ft/lbs at 4500 RPM | ||
+ | * Bore: | ||
+ | * 883: 3 in / 76.2 mm | ||
+ | * 1200: 3.498 in / 88.8492 mm | ||
+ | * Stroke: 3.812 in / 96.8248 mm | ||
+ | * 4 Cams | ||
+ | * [[techtalk:ih:oil03|Gerotor type oil pump]]. \\ The oil pump and engine oil routing system was redesigned in 1991. 1990 and prior gerotor oil pumps will not function properly on 91-up engines. \\ Oil pump pressure at operating temp (gauge mounted at oil pressure switch location): | ||
+ | * Minimum: 7-12 psi (idle) | ||
+ | * Normal riding conditions: 12-17 psi (2500 rpm) | ||
+ | * [[techtalk:evo:engctl01#electronic_ignition_systems|Ignition]]: Electronic Ignition System. | ||
+ | * Spark Plugs | ||
+ | * 12mm 6R12, Gap (.038"-.043"), Torque 11-18 ft-lb / 3-5 Nm | ||
+ | * [[techtalk:evo:engctl01#voes_-_vacuum-operated_electric_switch|VOES]] (vacuum-operated electric switch) for timing advance | ||
+ | * [[techtalk:evo:carb01#keihin_butterfly_non-cv_carburetor_stock_on_l1976-1987_sportsters|Fuel System]]: HD Keihin CV carburetor | ||
+ | |||
+ | ==== Capacities ===== | ||
+ | * Fuel Capacity: | ||
+ | * 2.25 gal / 8.517 l ((Harley-Davidson Sportster 1991 Service Manual pg 2-1)) \\ Reserve: .25 gal / .946 l | ||
+ | * Oil Capacity: 3 qts. / 1.419 l (quoted from -85 FSM) | ||
+ | * Transmission Capacity: 1.5 pints / .71 l | ||
+ | * Front Forks (per fork): Wet 9.0 oz, Dry 10.2 oz | ||
+ | |||
+ | ==== Clutch ==== | ||
+ | * Multi-Disc wet clutch-pack with alternate steel and fiber friction plates. | ||
+ | |||
+ | ==== Drivetrain ==== | ||
+ | * Constant Mesh ((Harley-Davidson Sportster 1991 Service Manual pg 6-1)) | ||
+ | * Left Side Shifter | ||
+ | * Speeds - 4 Forward | ||
+ | * Number of Sprocket Teeth (all) | ||
+ | * Engine: 35 | ||
+ | * Clutch: 56 | ||
+ | * Clutch Sprocket to Engine Sprocket Ratio: 1.60:1 | ||
+ | * Transmission: | ||
+ | * 883, 21 | ||
+ | * 883 Deluxe, 27 | ||
+ | * 1200, 29 | ||
+ | * Rear Wheel: | ||
+ | * 883, 48 | ||
+ | * 883 Deluxe, 61 | ||
+ | * 1200, 61 | ||
+ | * Primary Belt: | ||
+ | * | ||
+ | * 883 Deluxe, 127 (yellow) | ||
+ | * 1200, 128 (orange) | ||
+ | * Gear Ratios (XLH / XLS / XLX) ((Harley-Davidson Sportster 1991 Service Manual pg 6-1)) | ||
+ | * Internal Gear Ratios: \\ Internal gear ratios indicate number of clutch gear revolutions required to drive mainshaft sprocket one revolution. | ||
+ | * 1st: 2.78:1 | ||
+ | * 2nd: 2.03:1 | ||
+ | * 3rd: 1.49:1 | ||
+ | * 4th: 1.22:1 | ||
+ | * 5th: 1.00:1 | ||
+ | * Overall Gear Ratios: \\ Overall gear ratios indicate number of engine revolutions required to drive rear wheel one revolution. | ||
+ | * 883 | ||
+ | * 1st: 10.17 | ||
+ | * 2nd: 7.43 | ||
+ | * 3rd: 5.45 | ||
+ | * 4th: 4.47 | ||
+ | * 5th: 3.66 | ||
+ | * 883 Deluxe: | ||
+ | * 1st: 10.04 | ||
+ | * 2nd: 7.33 | ||
+ | * 3rd: 5.38 | ||
+ | * 4th: 4.4 | ||
+ | * 5th: 3.61 | ||
+ | * 1200: | ||
+ | * 1st: 9.37 | ||
+ | * 2nd: 6.84 | ||
+ | * 3rd: 5.02 | ||
+ | * 4th: 4.11 | ||
+ | * 5th: 3.37 | ||
+ | |||
+ | ==== Tires ==== | ||
+ | Rim size and contour are cast or stamped into the exterior surface of the rim. \\ | ||
+ | * All 883 and 1200 Models ((Harley-Davidson Sportster 1991 Service Manual pgs 2-2, 2-3)) | ||
+ | * Front: | ||
+ | * For tube type laced (contour T19x2.50 MTA) or tubeless cast (contour T19x2.15 MT) 19" wheels: Dunlop D401 (100/90-19). | ||
+ | * Rear: | ||
+ | * For tube type laced or tubeless cast (contour T16x3.00D) 16" wheels: Dunlop D401 (130/90-16). | ||
+ | * Tire pressure based on overall weight. | ||
+ | * Up to 300 lb load including rider, passenger and cargo: | ||
+ | * Front 30 psi / 2.06 bar | ||
+ | * Rear 36 psi / 2.48 bar | ||
+ | * Up to GVWR maximum load: | ||
+ | * Front 30 psi / 2.06 bar | ||
+ | * Rear 40 psi / 2.75 bar | ||
- | ===== Specifications ===== | + | ==== Brake Discs ==== |
+ | For all 883cc and 1200cc models; ((Harley-Davidson Sportster 1991 Service Manual pg 2-2)) \\ | ||
+ | * Diameter: | ||
+ | * Front, 11.5" | ||
+ | * Rear, 11.5" | ||
+ | * Minimum Thickness: | ||
+ | * Front, .180" | ||
+ | * Rear, .205" | ||
===== Models ===== | ===== Models ===== |