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sportster_history:1992_sportster [2022/01/28 00:38]
hippysmack [Vehicle Identification Number (VIN)]
sportster_history:1992_sportster [2024/01/25 18:25] (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**:
-    * 1992 XLH Models Owners Manual (99466-91).+    * 1992 (all) Models Owners Manual (99466-92).
  
 **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: \\
 +
 +|  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) ​ | | 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|}}| |{{:​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 =====+ 
 +====== 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 =====