Example: 1HD1CAP16RY201624 appears on steering head. Abbreviated VIN appears on engine crankcase - CAP16RY201624

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.
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.
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: 1993-1994 XLH Models Service Manual (99484-94)
• Factory Parts Catalog:
  • Original: 1993-1994 Five Speed Sportster Parts Catalog (99451-94)
    • Written in 1993 and lists parts available in 1994 for 1993-1994 models.
• Factory Owners Manual:
  • 1994 original (all) Models Owners Manual (99466-94).
  • 1994 updated (all) Models Owners Manual (99466-94A).

Pics of Manual Covers.
Below are pics of used manual covers related to 1994 model Sportsters.
See the full list of pertinent catalogs in the links above.
Click on any pic below to enlarge:

1994 Owners Manual (99466-94)

1993-1994 FSM Original Manual (99484-94)	1993-1994 Original Parts Catalog (99451-94)

• Model Designations: XLH-883, XLH-883 Hugger, XLH-883 Deluxe, XLH-1200

• Wheelbase: ¹⁾
  • XLH-883 / XLH-883 Deluxe / XLH-1200, 60.2 in / 1529 mm
  • XLH-883 Hugger, 59.0 in / 149.86 cm
• Overall Length: ²⁾
  • XLH-883 / XLH-883 Deluxe / XLH-1200, 87.6 in / 2225 mm
  • XLH-883 Hugger, 87.25 in / 2216 mm
• Overall Width: ³⁾
  • XLH-883, 33 in / 838 mm
  • XLH-883 Hugger / XLH-883 Deluxe / XLH-1200, 35 in / 889 mm
• Overall Height: ⁴⁾
  • XLH-883 / XLH-883 Deluxe, 47.50 in / 1207 mm
  • XLH-883 Hugger / XLH-1200, 49.75 in / 1264 mm
• Road Clearance: ⁵⁾
  • XLH-883 / XLH-883 Deluxe / XLH-1200, 6.70 in / 170.2 mm
  • XLH-883 Hugger, 4.50 in / 114.3 mm
• Weight (as shipped from the factory): ⁶⁾
  • XLH-883, 488 lbs. / 221 kg
  • XLH-883 Hugger, 485 lbs. / 220 kg
  • XLH-883 Deluxe, 494 lbs. / 224 kg
  • XLH-1200, 490 lbs. / 222 kg

• Engine type: 4 cycle Overhead Valves, 45 degree V2 ⁷⁾
• Displacement:
  • 883cc: 53.9 ci
  • 1201cc: 73.3 ci
• Compression Ratio: 9:1
• HP:
  • 883cc, 55 @ 6000 RPM
  • 1200cc, 65 @ 5200 RPM
• Torque:
  • 883cc, 50 ft/lbs at 4600 RPM
  • 1200cc, 71 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
• 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: 10-17 psi (2500 rpm)
• Ignition: Electronic Ignition System.
• Spark Plugs
  • 12mm 6R12, Gap (.038”-.043“), Torque 11-18 ft-lb / 3-5 Nm
• VOES (vacuum-operated electric switch) for timing advance
• Fuel System: HD Keihin CV carburetor

• Fuel Capacity:
  • 2.25 gal / 8.5 l ⁸⁾
    Reserve: .25 gal / .946 l
• Oil Capacity: 3 qts. / 2.8 l
• Transmission Capacity: 32 oz / 946 ml
• Front Forks (per fork):
  • XLH-883 / XLH-883 Deluxe / XLH-1200, Wet 9.0 oz / 266 ml, Dry 10.2 oz / 302 ml
  • XLH-883 Hugger, Wet 10.7 oz / 316 ml, Dry 12.1 oz / 358 ml

• Multi-Disc wet clutch-pack with alternate steel and fiber friction plates.

• Constant Mesh ⁹⁾
• 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:
    • 883cc Engine, 27
    • 1200cc Engine, 29
  • Rear Wheel:
    • 883cc or 1200cc Engine, 61
  • Secondary Drive Belt:
    • 883cc or 1200cc Engine, 128 (orange)
  • Ratios
    • 883cc Engine, 2.26:1
    • 1200cc Engine, 2.10:1
• Overall Gear Ratios (XLH / XLS / XLX) ¹⁰⁾
  Overall gear ratios indicate number of engine revolutions required to drive rear wheel one revolution.
  • Domestic 883cc Engine:
    • 1st: 10.04
    • 2nd: 7.32
    • 3rd: 5.38
    • 4th: 4.39
    • 5th: 3.61
  • Domestic 1200cc Engine:
    • 1st: 9.35
    • 2nd: 6.82
    • 3rd: 5.01
    • 4th: 4.09
    • 5th: 3.36

Rim size and contour are cast or stamped into the exterior surface of the rim.

• All 883 and 1200 Models ¹¹⁾
  • Front:
    • For tube type laced (contour T19x2.50 TLA) or tubeless cast (contour T19x2.15 MT) 19” wheels: Dunlop D401 Elite S/T (100/90-19).
  • Rear:
    • For tube type laced or tubeless cast (contour T16x3.00D) 16“ wheels: Dunlop D401 Elite S/T (130/90-16).
• Tire pressure based on overall weight.
  • Up to 300 lb load including rider, passenger and cargo:
    • Front 30 psi / 2.1 bar
    • Rear 36 psi / 2.5 bar
  • Up to GVWR maximum load:
    • Front 30 psi / 2.1 bar
    • Rear 40 psi / 2.8 bar

For all 883cc and 1200cc models; ¹²⁾

• Diameter:
  • Front, 11.5” / 292 mm
  • Rear, 11.5“ / 292 mm
• Minimum Thickness:
  • Front, .180” / 4.57 mm
  • Rear, .205“ / 5.21 mm

What is the Current KBB Value? ¹³⁾

• Colors: Solid and Candy

What is the Current KBB Value? ¹⁴⁾

• Colors: Solid and Candy

What is the Current KBB Value? ¹⁵⁾

• Colors: Solid and Candy

What is the Current KBB Value? ¹⁶⁾

• Colors: Solid, Candy and Two Tone

Back to Sportster History Index