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sportster_history:1992_sportster [2016/02/03 04:57]
hippysmack [XLH 883 Hugger]
sportster_history:1992_sportster [2024/01/25 18:25] (current)
hippysmack
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 |1 |HD |1 |CA |P |1 |6 |N |Y |201624 |===== Engine, Drivetrain, Performance ===== |1 |HD |1 |CA |P |1 |6 |N |Y |201624 |===== Engine, Drivetrain, Performance =====
  
-===== Specifications =====+====== Related Manuals and Documentation ====== 
 +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__. \\ 
 +**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)**; \\ 
 +The FSM will have the most accurate information,​ procedures and specs. \\  
 +Clymer and Haynes make service manuals also for Sportsters but some of the information is in error to the factory FSMs. \\ 
 +And some of the information in the aftermarket manuals is vague in information or procedures but they may have more pictures. \\ 
 +So it is generally said you can get use from both an aftermarket manual and the factory service manuals but get the factory manual first. \\ 
 +[[techtalk:​miscres:​miscres10|Click Here]] to view the Factory Service Manual page in the Sportsterpedia. \\ 
 + 
 +**Parts Catalogs**; \\ 
 +The Parts Catalog has part numbers of course but it also has exploded parts views. \\ 
 +However, IT IS NOT INTENDED TO BE AN ASSEMBLY MANUAL. \\ 
 +And some of the exploded views are confusing or not related to each other on the same pages. \\ 
 +But, all in all, the exploded views do help finding what goes where. \\ 
 +Most of the fasteners listed in the relevant parts catalog individual pages have thread sizes and lengths also in case you need those. \\ 
 +Below is a simple list of original and "​latest edition parts catalogs. 
 +The in-between year books may show different part numbers for the same year model bike. \\ 
 +[[techtalk:​miscres:​miscres12|Click Here]] to see the Factory Parts Catalog page in the Sportsterpedia for parts catalog uses and a full list of parts catalog numbers from 1957 to present. \\ 
 +(complete list of other parts catalogs and supplement catalogs that pertain to each year model on the bottom of that page) \\ 
 +Some often acquire several year model parts catalogs and that page will help decide which ones are right for them. \\ 
 + 
 +**Suggested Manuals**: \\ 
 + 
 +  * **Factory Service Manual (FSM)**: 
 +    * **Original**:​ 1991-1992 XLH Models Service Manual (99484-92) 
 +  * **Factory Parts Catalog**:​ 
 +    * **Original**:​ 1991-1992 Five Speed Sportster Parts Catalog (99451-92) 
 +      * Written in 1991 and lists parts available in 1992 for 1991-1992 models. 
 +  * **Factory Owners Manual**: 
 +    * 1992 (all) Models Owners Manual (99466-92). 
 + 
 +**Pics of Manual Covers**. \\ 
 +Below are pics of used manual covers related to 1992 model Sportsters. \\ 
 +See the full list of pertinent catalogs in the links above. ​ \\ 
 +Click on any pic below to enlarge: \\ 
 + 
 +|  1992 Owners Manual (99466-92) ​ | 
 +|{{:​sportster_history:​l003-om-1992_edition_cover_99466-92.jpg?​direct&​200|}}| 
 + 
 +| 1991-1992 FSM \\ Original Manual (99484-92) ​ |  1991-1992 Original \\ Parts Catalog (99451-92) ​ | 
 +|{{:​sportster_history:​l001-fsm-1992_edition_cover_99484-92_for_1991-1992.jpg?​direct&​200|}}|{{:​sportster_history:​l002-pc-1992_edition_cover_99451-92_for_1991-1992.jpg?​direct&​200|}}| 
 + 
 +====== Specifications =====
 + 
 +==== Model Designations ==== 
 +  * Model Designations:​ XLH-883, XLH-883 Hugger, XLH-883 Deluxe, XLH-1200 
 + 
 +==== Dimensions ==== 
 +  * Wheelbase: ((Harley-Davidson Sportster 1992 Service Manual pg 2-1)) 
 +    * XLH-883 / XLH-883 Deluxe, 60 in / 152.40 cm 
 +    * XLH-883 Hugger, 59.0 in / 149.86 cm 
 +    * XLH-1200, 60 in / 152.40 cm 
 +  * Overall Length: ((Harley-Davidson Sportster 1992 Service Manual pg 2-1)) 
 +    * XLH-883 / XLH-883 Deluxe, 87.5 in / 222.25 cm 
 +    * XLH-883 Hugger, 87.25 in / 221.615 cm 
 +    * XLH-1200, 87.5 in / 222.25 cm 
 +  * Overall Width: ((Harley-Davidson Sportster 1992 Service Manual pg 2-1)) 
 +    * XLH-883, 32 in / 81.28 cm 
 +    * XLH-883 Deluxe / XLH-883 Hugger XLH-1200, 33 in / 83.82 cm 
 +  * Overall Height: ((Harley-Davidson Sportster 1992 Service Manual pg 2-1)) 
 +    * XLH-883, 47.5 in / 120.65 cm 
 +    * XLH-883 Hugger / XLH-883 Deluxe / XLH-1200, 49.75 in / 126.365 cm 
 +  * Road Clearance: ((Harley-Davidson Sportster 1992 Service Manual pg 2-1)) 
 +    * XLH-883 / XLH-883 Deluxe / XLH-1200, 6.75 in / 17.145 cm 
 +    * XLH-883 Hugger, 4.5 in / 11.43 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 1991-1992 Service Manual pg 3-1,3-2, 3-3)) 
 +  * Displacement:​ 
 +    * 883cc: 53.9 ci 
 +    * 1200cc: 73.3 ci 
 +  * Compression Ratio: 9:1 
 +  * HP: 
 +    * 883cc, 55 @ 6000 RPM 
 +    * 1200cc, 64 @ 5200 RPM 
 +  * Torque: 
 +    * 883cc, 55 ft/lbs at 4500 RPM 
 +    * 1200cc, 71.5 ft/lbs at 4000 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]]. \\ Oil pump pressure at operating temp (gauge mounted at oil pressure switch location):​ 
 +    * Minimum: 7-12 psi (idle, 1000 RPM)  
 +    * 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: 40 oz / 1.18 l 
 +  * Front Forks (per fork): 
 +    * XLH-883 / XLH-883 Deluxe / XLH-1200, Wet 9.0 oz, Dry 10.2 oz 
 +    * XLH-883 Hugger, Wet 10.7 oz, Dry 12.1 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 / 883 Hugger (chain drive), 21 
 +      * 883 Deluxe (belt drive), 27 
 +      * 1200 (belt drive), 29 
 +    * Rear Wheel: 
 +      * 883 / 883 Hugger (chain drive), 48 
 +      * 883 (belt drive), 61 
 +      * 1200 (belt drive), 61 
 +    * Primary Belt: 
 +      * 883 Deluxe, 128 (orange) 
 +      * 1200, 128 (orange) 
 +    * Ratios 
 +        * 883 / 883 Hugger, 2.29:1 
 +        * 883 Deluxe, 226:1 
 +        * 1200, 2.10:1 
 +  * Gear Ratios (XLH / XLS / XLX) ((Harley-Davidson Sportster 1991-1992 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 / 883 Hugger: 
 +        * 1st: 10.16 
 +        * 2nd: 7.41 
 +        * 3rd: 5.44 
 +        * 4th: 4.45 
 +        * 5th: 3.66 
 +      * 883 Deluxe: 
 +        * 1st: 10.04 
 +        * 2nd: 7.32 
 +        * 3rd: 5.38 
 +        * 4th: 4.39 
 +        * 5th: 3.61 
 +      * 1200: 
 +        * 1st: 9.35 
 +        * 2nd: 6.82 
 +        * 3rd: 5.01 
 +        * 4th: 4.09 
 +        * 5th: 3.36 
 + 
 +==== 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 
 + 
 +==== 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 =====
 ==== XLH 883 ==== ==== XLH 883 ====
 +What is the Current KBB Value? ​ ((http://​www.kbb.com/​motorcycles/​harley-davidson/​xlh-sportster-883/​1992-harley-davidson-xlh-sportster-883/​trade-in/​))
 +
   * Colors: Solid and Candy   * Colors: Solid and Candy
 +  * 
 +  * 
 +  * 
 ==== XLH 883 Deluxe ==== ==== XLH 883 Deluxe ====
 +What is the Current KBB Value? ​ ((http://​www.kbb.com/​motorcycles/​harley-davidson/​xlh-sportster-883-deluxe/​1992-harley-davidson-xlh-sportster-883-deluxe/​trade-in/​))
 +
   * Colors: Solid and Candy   * Colors: Solid and Candy
 +  * 
 +  * 
 +  * 
 ==== XLH 883 Hugger ==== ==== XLH 883 Hugger ====
 +What is the Current KBB Value? ​ ((http://​www.kbb.com/​motorcycles/​harley-davidson/​xlh-sportster-883-hugger/​1992-harley-davidson-xlh-sportster-883-hugger/​trade-in/​))
 +
   * Colors: Solid and Candy   * Colors: Solid and Candy
 +  * 
 +  * 
 +  * 
 ==== XLH 1200 ==== ==== XLH 1200 ====
 +What is the Current KBB Value? ​ ((http://​www.kbb.com/​motorcycles/​harley-davidson/​xlh-sportster-1200/​1992-harley-davidson-xlh-sportster-1200/​trade-in/​))
 +
 +  * Colors: Solid, Candy and Two Tone
 +  * 
 +  * 
 +  * 
 +
  
  
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-Back to [[:sportster_history:​start|Sportster History Index]]+Back to [[sportster_history:​99xx-01|Sportster History Index]]