1986 Harley Sportster Manual

The 1986 Harley Sportster is a classic American motorcycle featuring an 883cc or 1100cc V-twin engine, 4-speed transmission, chain drive, kick and electric start, dual disc front brakes, and iconic Harley-Davidson styling. This manual covers maintenance, operation, specifications, and troubleshooting for the 1986 XLH and XLCH Sportster models. Below are key sections for safety, features, maintenance, operation, and technical specifications.

1. Features at a Glance 2. Safety Information 3. Maintenance Schedule 4. Specifications 5. Controls and Operation 6. Engine Maintenance 7. Electrical System 8. Brake System 9. Troubleshooting 10. Storage & Winterization 11. Warranty Information

Features at a Glance

Key components: Evolution V-twin engine, 4-speed transmission, chain final drive, dual front disc brakes, rear drum brake, kick and electric start.

Feature	Description
Engine	883cc or 1100cc air-cooled V-twin
Transmission	4-speed constant mesh
Final Drive	Chain
Starting System	Kick and electric start
Front Brakes	Dual disc
Rear Brake	Single drum
Fuel Capacity	2.25 gallons
Weight	Approx. 480 lbs
Seat Height	29.5 inches
Wheelbase	60 inches

Safety Information

Always wear proper protective gear and inspect motorcycle before riding.

Pre-ride inspection: Check tires, brakes, lights, chain tension, fluid levels.
Protective gear: Always wear helmet, eye protection, gloves, jacket, and boots.
Riding position: Maintain proper control with both hands on handlebars.
Braking technique: Use both front and rear brakes for maximum stopping power.

WARNING! Motorcycle operation requires skill and attention. Never operate under influence of alcohol or drugs.

Maintenance Schedule

Regular maintenance ensures optimal performance and longevity.

Daily: Check tire pressure, fuel level, lights, brakes.
Every 500 miles: Check chain tension and lubrication.
Every 2,500 miles: Change engine oil and filter.
Every 5,000 miles: Check valve clearance, spark plugs, brake pads.
Every 10,000 miles: Replace air filter, check wheel bearings.

CAUTION! Use only Harley-Davidson recommended fluids and parts.

Specifications

Engine: 883cc/1100cc air-cooled 45° V-twin
Bore x Stroke: 3.0" x 3.81" (883cc) / 3.5" x 3.81" (1100cc)
Compression Ratio: 9.0:1
Carburetor: Keihin constant velocity
Ignition: Breaker point (XLH) or electronic (XLCH)
Transmission: 4-speed, constant mesh
Final Drive: #530 chain
Front Suspension: Telescopic fork
Rear Suspension: Dual shocks
Fuel Capacity: 2.25 gallons
Oil Capacity: 3 quarts with filter change

Controls and Operation

Left handlebar: Clutch lever, high/low beam, turn signals, horn. Right handlebar: Front brake lever, throttle, engine kill switch.

Instrument Cluster: Speedometer, odometer, neutral light, high beam indicator, turn signal indicators, oil pressure light.

Starting procedure: Turn fuel petcock to ON, turn ignition key ON, pull choke (cold starts), press starter button or use kick starter. Shifting pattern: 1-down, 2-up, 3-up, 4-up. Neutral between 1st and 2nd.

Engine Maintenance

Oil change: Drain plug under engine, replace filter, refill with 20W50 motorcycle oil.

Warm engine slightly, then shut off.
Place drain pan under drain plug.
Remove drain plug and oil filter.
Replace drain plug and new filter.
Refill with 3 quarts of oil.
Start engine, check for leaks, check level.

Tip: Check oil level with motorcycle upright, not on side stand.

Electrical System

12-volt system with battery, alternator, points ignition (XLH) or electronic ignition (XLCH).

Battery: 12V, maintenance required, check fluid level monthly.
Charging system: Alternator output 19 amps at 2000 RPM.
Lights: Headlight, taillight, brake light, turn signals.
Fuses: Located under seat, carry spares.

WARNING! Disconnect battery before electrical work to prevent shorts.

Brake System

Front: Dual disc brakes with hydraulic calipers. Rear: Drum brake with mechanical linkage.

Check brake fluid level in front master cylinder.
Inspect brake pads for wear (replace if less than 1/8").
Adjust rear brake pedal free play.
Bleed brakes if spongy feel or air in system.

CAUTION! Brake fluid damages paint - wipe spills immediately.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	Fuel, spark, compression	Check fuel petcock, spark plugs, battery charge.
Poor performance	Carburetor, ignition	Clean carburetor, check points gap, adjust timing.
Electrical failure	Battery, fuses, connections	Check battery voltage, fuses, clean connections.
Brakes dragging	Calipers, cables	Clean and lubricate caliper slides, adjust cables.
Chain noise	Tension, lubrication	Adjust chain tension to 3/4" play, lubricate chain.

Emergency: Carry basic tools: wrenches, screwdrivers, pliers, tire repair kit.

Storage & Winterization

Proper storage prevents damage during extended non-use.

Fill fuel tank and add fuel stabilizer.
Change oil and filter.
Remove battery and store on trickle charger.
Clean and lubricate chain.
Inflate tires to maximum pressure.
Cover motorcycle in dry, ventilated area.

CAUTION! Do not store with fuel in carburetor - drain or run until dry.

Warranty Information

1986 Harley-Davidson Sportster warranty: 12 months unlimited mileage. Coverage includes defects in materials and workmanship. Normal maintenance items, tires, and batteries excluded. For warranty service, contact authorized Harley-Davidson dealer. Keep maintenance records for warranty claims.