Other than the introduction of a new Sportster model, the 2002 line up remained basically unchanged.

In 2002 Harley-Davidson introduced the new XL 883R which is modeled after the 1970 XR-750. Unlike all other 2002 Sportster models, it came with a 2 in 1 exhaust. It was also the only 2002 883 model with dual front disc brakes.

Example: 1HD1CJM162K201624 appears on steering head. Abbreviated VIN appears on engine crankcase - CJM2201624

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: 2002 Sportster Models Service Manual (99484-02).
  • Updated Version: 2002 Sportster Models Service Manual (99484-02A).
• Factory Electrical Diagnostic Manual (EDM):
  • Original: 2002 Sportster Models Electrical Diagnostic Manual (99495-02).
• Factory Parts Catalog:
  • Original: 2002 XLH Models Parts Catalog (99451-02)
    • Written in 2001 and lists parts available in 2002 for 2002 models.
  • Updated Version: 2001 XLH Models Parts Catalog (99451-01A)
    • Also written in 2001 and lists parts available in 2002 for 2002 models.
• Factory Owners Manual:
  • 2002 Sportster Owners Manual (99468-02).

Pics of Manual Covers.
Below are pics of used manual covers related to 2002 model Sportsters.
See the full list of pertinent catalogs in the links above.
Click on any pic below to enlarge:

2002 Sportster Owners Manual (99468-02)

2002 FSM Original Manual (99484-02)	2002 FSM Updated Manual (99484-02A)	2002 EDM (99495-02)

2002 Original Parts Catalog (99451-02)

• 4 Cycle, Air Cooled, Over Head Valve, 45 degree V-twin, Evolution®
• Bore: 3.498 in / 88.85 mm
• Stroke: 3.812 in / 96.82
• Displacement: 73.3 cubic in. / 1203 cc
• Compression Ratio: 9.1:1 (10:1 - 1200 Sport)
• Fuel System: Carburetor - 40 mm constant velocity with enrichener and accelerator pump
• Carburetor Main Jet: 170 / 195 (49 State), 185 / 195 (California), 200 (HDI)
• Carburetor Slow Jet: 42
• Engine Idle Slow Speed: 1050 rpm
• Engine speed for setting ignition timing: 1050 - 1500

• Primary Drive: Chain,
• Gear Ratios (overall)
  • 1st:
  • 2nd
  • 3rd:
  • 4th:
  • 5th:

• Engine Torque Testing Method:
• Engine Torque: 72 @ 4500 (76 @ 4500 - 1200 Sport)
• Lean Angle, Right (deg.):
• Lean Angle, Left (deg.):
• Fuel Economy, Combined City/Highway:

• 4 Cycle, Air Cooled, Over Head Valve, 45 degree V-twin, Evolution®
• Bore: 3.0005 in. / 76.20 mm
• Stroke: 3.812 in / 96.82 mm
• Displacement: 53.9 cubic in. / 883 cc
• Compression Ratio:9.0:1
• Fuel System: Carburetor - 40 mm constant velocity with enrichener and accelerator pump
• Ignition: Inductive, battery-powered,V Fire III electronic breakerless with solid-state dual stage advance¹⁾
• Lubrication System Dry sump, gear drive pump with full flow spin-on disposable oil filter²⁾

• Primary Drive: Triple-row chain
• Primary Drive Front Gear: 35 tooth
• Primary Drive Rear Gear: 56 tooth
• Transmission Gear Ratio: 1.60:1
• Clutch Multi-plate with diaphragm spring in oil bath
• Five-speed,constant mesh
• Clutch Gear Ratios (overall)
  • 1st: 9.717
  • 2nd: 6.690
  • 3rd: 5.180
  • 4th: 4.267
  • 5th: 3.615
• Final Drive: Gates aramid fiber reinforced Poly Chain belt;
• Final Drive Front Gear: 27 tooth
• Final Drive Rear Gear: 61-tooth
• Final Drive Ratio: 2.259:1

• Engine Torque Testing Method:
• Engine Torque: 53 Nm @ 4500 rpm
• * Lean Angle, Right (deg.):
• Lean Angle, Left (deg.):
• Fuel Economy, Combined City/Highway:

• Gross Vehicle Weight Rating (GVWR) 948 lb / 430 kg
• Gross Axel Weight Rating - Front (GAWR-FRONT) 353 lb / 150 kg
• Gross Axel Wwight Rating - Rear (GAWR-REAR) 595 lbs / 270 kg
• Fuel Tank Capacity: 3.3 gal / 12.5 l
• Fuel Reserve Capacity: .5 gal / 1.89 l
• Oil tank Capacity: 3 qt / 2.84 l
• Transmission Capacity 32 oz / 946 ml
• Front Fork (per side)
  • Wet: 9 oz / 266 ml
  • Dry: 10.2 oz / 302 ml
• Brake Disc Diameter (Front and Rear): 11.5 in / 262 mm
• Brake Disc Minimum Thickness
  • Front: 0.200 in / 5.08 mm
  • Rear: 0.230 in / 5.84 mm
• Max Disc Runout (Front and Rear): 0.008 in / 0.20 mm

• Frame Mild steel, twin cradle
• Swing Arm Mild steel, rectangular section
• Front Fork: 39mm
• Rear Shocks Short stroke
• Brakes: Caliper Type Four-piston front and rear
• Suspension travel:
  • Front wheel: 4.1 in / 10.41 cm
  • Rear wheel: 2.1 in / 5.33 cm

• Battery Sealed 12-volt, 19 amp-hour, 270 cca
• Charging 22-amp permanent magnet alternator with solid-state regulator (275 watts @ 3,000 rpm, 285 peak)
• Starting Electric start
• Lights
  • Headlamp Quartz halogen 55-watt low beam, 60-watt high beam
  • Tail/stop lights (US) 8w/28w, International 5w/21w
  • Turn signal lights 28w self-canceling, (21w)
  • Running lights integrated in front turn signals (except International models)

• Vivid Black: $5,695 ³⁾
• What is the Current KBB Value? ⁴⁾
• Color Option:
• Two Tone Option:
• Security Option:
• California Emissions:
• Freight:

• Seat: Solo
• Foot Controls: Mid-mount
• Engine Trim: Polished
• Exhaust System: Staggered shorty duals
• Front Fender: Sport-style
• Handlebars: Low-rise stainless steel

• Length: 88.1 in / 223.8 cm
• Width: 33 in / 83.8 cm
• Height: 47.5 in / 120.7 cm
• Ground Clearance: 6.70 in / 17 cm
• Rake (steering head) (deg): 30.1⁵⁾
• Trail: .7 in. / 11.93 cm ⁶⁾
• Wheelbase:60 in / 152.4 cm
• Tires, Front: 100/90-19
• Tires, Rear: 130/90HB16
• Weight, As Shipped: 488 lb / 222 kg

Lowest seat in the 2002 Sportster line up ⁷⁾

• Vivid Black: $6,155
• Color Option:
• Two Tone Option:
• Security Option:
• California Emissions:
• Freight:

• Seat: Low profile solo
• Foot Controls: Mid-mount
• Engine Trim: Silver Powder Coated with polished rocker boxes
• Exhaust System: Staggered shorty duals
• Front Fender: Sport-style
• Handlebars: Buckhorn

• Length: 88.0 in /223.34 cm
• Seat Height, Laden: 27.1 in / 68.83 cm
• Seat Height, Unladen: 27 in / 68.7 cm
• Ground Clearance: 4.7 in / 11.93 cm
• Rake: (in deg) 30.1
• Trail: 4.7 in. / 11.93 cm
• Wheelbase 59.0 in. / 149.74 cm
• Tires: Dunlop Harley-Davidson Series S/T D401
  • Front: 100/90-19
  • Rear: 130/90HB16
• Fuel: Capacity: 3.3 gal / 12.5 l
• Reserve Fuel Capacity: 0.5 gal / 1.9 l
• Oil Capacity: 3.0 qts. / 2.8 L
• Dry Weight: 486.0 lbs / 220.6 kg
• Vehicle Weight In Running Order: 507 lbs / 230 kg
• Gross Vehicle Weight Rating: 948.0 lbs / 430.4 kg
• Wheels 19 in. front, 16 in. rear, 13-spoke aluminum cast (laced option)

• What is the Current KBB Value? ⁸⁾

• Vivid Black: $6,795 ⁹⁾
• What is the Current KBB Value? ¹⁰⁾
• Color Option:
• Two Tone Option:
• Security Option:
• California Emissions:
• Freight:

• Engine: Silver powdercoated engine with polished rocker boxes
• Steering: Tall, chromed riser with drag style handlebar
• Headlight: Chrome bullet headlight
• Wheels: Laced front wheel, disc rear wheel
• Seat: One-piece, low-profile, two-up seat
• Foot controls: Forward foot controls
• Low-profile rear shocks
• Exhaust System Staggered shorty duals

• Length: 89.0 in / 225.88 cm
• Seat Height Laden: 27.6 in / 69.95 cm
• Seat Height Unladen: 28 in / 71 cm
• Ground Clearance: 6.7 in / 17 cm
• Rake: (in deg) 29.6
• Trail: 4.6 in / 11.67 cm
• Wheelbase: 60 in / 152.28 cm
• Tires: Dunlop Harley-Davidson Series S/T D401
  • Front: 100/90-21
  • Rear: 130/90HB16
• Fuel Capacity: 3.3 gal / 12.5 l
• Reserve Fuel Capacity: 0.5 gal / 1.9 l
• Oil Capacity: 3.0 qts / 2.8 l
• Dry Weight 489.0 lbs / 222 kg
• Vehicle Weight in Running Order: 518 lbs / 235 kg
• Gross Vehicle Weight Rating 948.0 lbs / 430.4 kg

2002 Sportster XL 883C Custom

• Vivid Black:
• What is the Current KBB Value? ¹¹⁾
• Color Option:
• Two Tone Option:
• Security Option:
• California Emissions:
• Freight:

• Length:
• Seat Height, Laden:
• Seat Height, Unladen:
• Ground Clearance:
• Rake (steering head) (deg):
• Trail:
• Wheelbase:
• Tires, Front:
• Tires, Rear:
• Fuel Capacity:
• Oil Capacity(with filter):
• Weight, As Shipped:
• Weight, In Running Order:

¹²⁾

• 2002 XL883R

• What is the Current KBB Value? ¹³⁾

• Vivid Black:
• What is the Current KBB Value? ¹⁴⁾
• Color Option:
• Two Tone Option:
• Security Option:
• California Emissions:
• Freight:

• Length:
• Seat Height, Laden:
• Seat Height, Unladen:
• Ground Clearance:
• Rake (steering head) (deg):
• Trail:
• Wheelbase:
• Tires, Front:
• Tires, Rear:
• Fuel Capacity:
• Oil Capacity(with filter):
• Weight, As Shipped:
• Weight, In Running Order:

• Vivid Black:
• What is the Current KBB Value? ¹⁵⁾
• Color Option:
• Two Tone Option:
• Security Option:
• California Emissions:
• Freight:

• Length:
• Seat Height, Laden:
• Seat Height, Unladen:
• Ground Clearance:
• Rake (steering head) (deg):
• Trail:
• Wheelbase:
• Tires, Front:
• Tires, Rear:
• Fuel Capacity:
• Oil Capacity(with filter):
• Weight, As Shipped:
• Weight, In Running Order:

• Vivid Black:
• What is the Current KBB Value? ¹⁶⁾
• Color Option: Impact Blue
• Two Tone Option:
• Security Option:
• California Emissions:
• Freight:

• Length:
• Seat Height, Laden:
• Seat Height, Unladen:
• Ground Clearance:
• Rake (steering head) (deg):
• Trail:
• Wheelbase:
• Tires, Front:
• Tires, Rear:
• Fuel Capacity:
• Oil Capacity(with filter):
• Weight, As Shipped:
• Weight, In Running Order:

¹⁷⁾

• 2002 XL1200S Sport

• Vivid Black (All models)
• Luxury Rich Red Pearl (883, 883C)
• Luxury Blue Pearl (883, 883C)
• Real Teal Pearl (Hugger, 883C)
• White Pearl (Hugger, 883C)
• Concord Purple Pearl (Hugger, 883C)
• Real Red Pearl (Hugger, 883C)
• Impact Blue Pearl (Hugger, 883C)
• Racing Orange (883R)

• Laced

Back to Sportster History Index