Harley Davidson Sportster All Models Repair Service Manuals 1959-2018

Harley Davidson Sportster All Models Repair Service Manuals 1959-2018

MANUAL LIST (13,810 pages):
99484-03 - Harley Davidson Sportster Models Service Manual 2003 + Wiring (99495-03)
99484-07 - Harley Davidson Sportster Models Service Manual 2007 + Wiring (99495-07)
99484-04 - Harley Davidson Sportster Models (XLH) Service Manual 2004 + Wiring (99495-04).pdf
99484-05 - Harley Davidson Sportster Models (XLH) Service Manual 2005 + Wiring (99495-05).pdf
99484-06 - Harley Davidson Sportster Models (XLH) Service Manual 2006 + Wiring (99495-06).pdf
99484-07 - Harley Davidson Sportster Models Service Manual 2007 + Wiring (99495-07).pdf
99484-08 - Harley Davidson Sportster Models Service Manual 2008.pdf
99484-08 - Harley Davidson Sportster Models Service Manual 2008 + Wiring (99495-08).pdf
99484-09 - Harley Davidson Sportster Models Service Manual 2009 + Wiring (99495-09).pdf
99484-10 - Harley Davidson Sportster Models Service Manual 2010 + Wiring (99495-10).pdf
99484-13 - Harley Davidson Sportster Models Service Manual 2013.pdf
99484-16 - Harley Davidson Sportster Models Service Manual 2016 + Wiring (99495-16).pdf
99484-69 - Harley Davidson Sportster Models Service Manual 1959-1969 + Wiring.pdf
99484-85 - Harley Davidson Sportster Models (XL_XR 1000cc 4-Speed) Service Manual 1979-1985 + Wiring.pdf
99495-09 - Harley Davidson Sportster Models Eletrical Diagnostic Manual 2009.pdf
99495-13 - Harley Davidson Sportster Models Eletrical Diagnostic Manual 2013.pdf
99495-18 - Harley Davidson Sportster Models Eletrical Diagnostic Manual 2018.pdf
99495-18 - Harley Davidson Sportster Models Eletrical Service Manual 2018.pdf
Harley Davidson 2018 Wiring Diagrams H.D. (Softail, FLHXSE, FLHTKSE, FLTRXSE, Sportster, Touring, Street, Police, Trike).pdf
Harley Davidson Sportster Models Repair Manual 1970-2003.pdf
Harley Davidson Sportster Models Repair Manual 1989-2003 (FR).pdf
Harley Davidson Sportster Models Service Manual 2004-2006.pdf
Harley Davidson Sportster Models (XL, XLH) Service Repair Manual 1986-2003 (EN).pdf

Complete service repair manual for Harley Davidson Sportster All Models 1959-2018, with all the shop information to maintain, diagnostic, repair, refurbish/rebuild like professional mechanics.

Harley Davidson Sportster All Models 1959-2018 Motorcycles workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

PRODUCT DETAILS:
Total Pages/Size: 13,810 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English
Delivery: instant download link displayed on page & emailed to you after checkout
Protection: DRM-free; without any restriction

TABLE OF CONTENTS
1 Chapter One General Information
2 Chapter Two Troubleshooting
3 Chapter Three Periodic Lubrication, Maintenance & Tune-up
4 Chapter Four Engine Top End
5 Chapter Five Engine Lower End
6 Chapter Six Primary Drive, Clutch & External Shift Mechanism
7 Chapter Seven Transmission & Internal Shift Mechanism
8 Chapter Eight Fuel, Emission Control & Exhaust Systems
9 Chapter Nine Electrical System
10 Chapter Ten Wheels, Tires & Drive Belt
11 Chapter Eleven Front Suspension & Steering
12 Chapter Twelve Rear Suspension
13 Chapter Thirteen Brakes
14 Chapter Fourteen Body
15 Chapter Fifteen Index
16 Chapter Sixteen Wiring Diagrams
...
1.1 GENERAL
Servicing a New Motorcycle...1-1
Safe Operating Maintenance..1-1
Shop Practices...1-1
Repair Notes...1-1
Safety..1-1
Removing Parts...1-1
Cleaning..1-1
Disassembly and Assembly..1-2
Checking Torques on Fasteners with Lock Patches...1-2
Magnetic Parts Trays...1-2
Repair and Replacement Procedures..1-2
Hardware and Threaded Parts..1-2
Threadlocking Agents..1-2
Wiring, Hoses and Lines...1-2
Instruments and Gauges...1-2
Bearings..1-2
Bushings...1-2
Gaskets...1-2
Lip Type Seals...1-2
O-Rings (Preformed Packings)..1-3
Gears..1-3
Shafts..1-3
Part Replacement..1-3
Exhaust System Leakage..1-3
Cleaning...1-3
Part Protection..1-3
Cleaning Process..1-3
Rust or Corrosion Removal...1-3
Bearings..1-3
Tool Safety..1-3
Air Tools...1-3
Wrenches..1-3
Pliers/Cutters/Pry bars..1-3
Hammers...1-4
Punches/Chisels..1-4
Screwdrivers..1-4
Ratchets and Handles...1-4
Sockets..1-4
Storage Units...1-4
Refilling Oil Tank..1-14
1.6 BRAKES
General...1-15
Inspection...1-15
Troubleshooting..1-15
1.7 BLEEDING HYDRAULIC BRAKE SYSTEM
General...1-17
Bleeding Front Brake..1-17
Bleeding Rear Brake..1-19
1.8 TIRES AND WHEELS
Tires...1-20
Tire Replacement...1-21
Inspection..1-21
When To Replace Tires...1-21
Wheel Bearings..1-21
Wheel Spokes..1-21
1.9 PRIMARY CHAIN
Inspection...1-23
Adjustment...1-23
1.10 CLUTCH
Adjustment...1-25
1.11 TRANSMISSION LUBRICANT
Transmission Lubrication: Sportster Models...1-27
Check Lubricant Level...1-27
Changing Lubricant...1-27
1.12 REAR BELT AND SPROCKETS
General...1-29
Cleaning...1-29
Inspection...1-29
Sprockets..1-29
Rear Belt...1-29
1.13 SHOCK ABSORBER ADJUSTMENT
Shock Absorber Preload Adjustment: Sportster Models...1-31
1.2 FUEL AND OIL 1.14 REAR BELT DEFLECTION
Fuel..1-5
Gasoline Blends...1-5
Engine Lubrication..1-5
Winter Lubrication..1-6 Inspection...1-32
Belt Deflection Adjustment...1-33
Wheel Alignment..1-34
Checking Wheel Alignment...1-34
Adjusting Wheel Alignment...1-35
1.3 MAINTENANCE SCHEDULE
General...1-7
1.4 BULB REQUIREMENTS
Bulb Chart..1-11
1.5 ENGINE OIL AND FILTER
Checking and Adding Oil..1-12
Removing and Replacing Oil Filler Cap..1-12
Checking Oil with Cold Engine..1-12
Checking Oil with Warm Engine..1-12
Changing Oil and Filter...1-13
General..1-13
Draining Oil Tank...1-13
Removing Oil Filter..1-13
Installing New Oil Filter..1-14
1.15 BRAKE PADS AND DISCS
Inspection...1-36
Brake Pads..1-36
Brake Disc Thickness, Lateral Runout and
Warpage..1-36
Brake Pad Replacement: Front...1-36
Brake Pad Replacement: Rear...1-39
1.16 BATTERY MAINTENANCE
General...1-43
Battery Disconnection and Removal..1-44
Cleaning and Inspection...1-45
Charging Battery..1-45
Safety Precautions..1-45
Using a Battery Charger..1-45
Battery Installation and Connection..1-46
Storage...1-47
1.17 SPARK PLUGS
General...1-49
Inspection...1-49
Spark Plug Cable Inspection..1-49
1.18 STEERING HEAD BEARINGS
Adjustment...1-51
Lubrication..1-51
1.19 REAR FORK BEARINGS
General...1-53
Procedure...1-53
1.20 FRONT FORK OIL
General...1-54
Changing Fork Oil...1-54
Filling Fork Oil: Forks Assembled, in Frame..1-54
Filling Fork Oil: Forks Disassembled, out of Frame..1-55
1.21 CABLE AND CHASSIS LUBRICATION
General...1-56
Cables and Hand Levers..1-56
Foot Shift Lever and Rear Brake Pedal..1-56
Jiffy Stand...1-56
Steering Head Bearings...1-56
1.22 AIR CLEANER AND EXHAUST SYSTEM
General...1-57
Removal...1-57
Cleaning, Inspection and Repair..1-58
Installation..1-58
Exhaust System Leak Check..1-58
1.23 THROTTLE CONTROL
Cable Inspection and Lubrication...1-59
Cable Adjustment...1-59
1.24 IDLE SPEED AND IGNITION TIMING
Idle Speed..1-60
Ignition Timing..1-60
1.25 FUEL SUPPLY FILTER
General...1-61
Fuel System Hose and Fittings...1-61
Removal...1-61
Installation..1-61
1.26 ENGINE MOUNTS AND STABILIZER
LINKS
1.28 FLUID AND LUBRICANT
REQUIREMENTS
Brake Fluid...1-65
Brake Component Grease..1-65
Front Fork Oil..1-65
Engine Oil...1-65
Primary Drive/Transmission Lubricant..1-65
1.29 CRITICAL FASTENERS
Inspection...1-66
1.30 STORAGE
General...1-67
Placing in Storage..1-67
Removal From Storage...1-67
1.31 TROUBLESHOOTING
General...1-69
Engine..1-69
Starter Motor Does Not Operate or Does Not Turn Engine
Over...1-69
Engine Turns Over But Does Not Start..1-69
Starts Hard..1-69
Starts But Runs Irregularly or Misses..1-69
Spark Plug Fouls Repeatedly..1-70
Pre-Ignition or Detonation (Knocks or Pings)..1-70
Check Engine Light Illuminates During Operation...1-70
Overheating...1-70
Valve Train Noise...1-70
Excessive Vibration...1-70
Lubrication System...1-70
Oil Does Not Return To Oil Tank..1-70
Engine Uses Too Much Oil Or Smokes Excessively...1-70
Engine Leaks Oil From Cases, Push Rods, Hoses,
Etc...1-70
Low Oil Pressure...1-70
High Oil Pressure..1-71
Electrical System..1-71
Alternator Does Not Charge..1-71
Alternator Charge Rate Is Below Normal..1-71
Speedometer Operates Erratically..1-71
Transmission...1-71
Shifts Hard..1-71
Jumps Out Of Gear...1-71
Clutch Slips...1-71
Clutch Drags Or Does Not Release..1-71
Clutch Chatters..1-71
Handling...1-71
Brakes..1-71
Brake Does Not Hold Normally...1-71
CHASSIS
Inspection...1-62
1.27 HEADLAMP ALIGNMENT
Headlamp Alignment: Sportster Models...1-63
Inspection..1-63
Adjustment (XL 883C and XL 1200C Models)..1-63
Adjustment (All Models Except XL 883C and XL
1200C)..1-63
2.1 SPECIFICATIONS
2008 Sportster Specifications...2-1
Tires...2-2
2.2 VEHICLE IDENTIFICATION NUMBER
(V.I.N.)
Vehicle Identification Number (V.I.N.): Sportster Models...2-4
General..2-4
Abbreviated V.I.N...2-4
Installing Brake Pads in Caliper..2-48
Installation..2-49
2.3 WHEELS 2.11 REAR BRAKE MASTER CYLINDER
General...2-6
Troubleshooting..2-6
Front Wheel..2-7
Removal..2-7
Disassembly: Cast Front Wheel..2-7
Disassembly: Laced Front Wheel..2-8
Cleaning and Inspection..2-8
Assembly: Cast Front Wheel...2-8
Assembly: Laced Front Wheel...2-8
Installation...2-12
Rear Wheel...2-12
Removal..2-12
Disassembly..2-13
Cleaning and Inspection..2-13
Assembly...2-13
Installation...2-16
Sealed Wheel Bearings..2-16
Inspection..2-16
Removal..2-17
Installation...2-19 General...2-51
Inspection...2-51
Removal...2-51
Disassembly...2-54
Cleaning, Inspection and Repair..2-55
Assembly..2-56
Installation..2-58
2.4 WHEEL LACING: 16 INCH RIM
General...2-20
Procedure...2-20
2.5 WHEEL LACING: 19 INCH RIM
Procedure...2-23
2.6 WHEEL LACING: 21 INCH RIM
General...2-27
Procedure...2-27
2.7 TRUING LACED WHEELS
General...2-31
Lateral Truing..2-31
Radial Truing...2-32
2.8 CHECKING CAST WHEEL RUNOUT
General...2-34
Lateral Runout..2-34
Radial Runout...2-34
2.9 FRONT BRAKE MASTER CYLINDER
General...2-35
Inspection...2-35
Removal...2-35
Disassembly...2-36
Cleaning, Inspection and Repair..2-39
Assembly..2-39
Installation..2-40
2.12 REAR BRAKE MASTER CYLINDER
RESERVOIR
General...2-59
Removal...2-59
Installation..2-60
2.13 REAR BRAKE CALIPER
Removal...2-61
Disassembly...2-63
Cleaning, Inspection and Repair..2-64
Lubricating Rear Caliper Bolt Pins and Boots..2-64
Assembly..2-65
Installation..2-66
2.14 BRAKE LINES
Front Brake Line...2-68
Removal..2-68
Installation...2-69
Rear Brake Line..2-70
Removal..2-70
Installation...2-71
2.15 TIRES
General...2-72
Removal...2-72
Cleaning, Inspection and Repair..2-72
Installation..2-73
Tube Type Tires...2-73
Tubeless Tires...2-73
Checking Tire Runout...2-74
Lateral Runout...2-74
Radial Runout...2-74
Wheel Balancing..2-74
Weights for Laced Wheels...2-74
Weights for Cast Wheels...2-75
2.16 LEFT SIDE COVER
General...2-76
Opening Left Side Cover..2-76
Closing Left Side Cover..2-77
Removing Left Side Cover..2-77
Installing Left Side Cover..2-77
2.10 FRONT BRAKE CALIPER 2.17 FRONT FORK
Removal...2-43
Disassembly...2-44
Cleaning, Inspection and Repair..2-46
Assembly..2-47
Lubricating Front Caliper Bolt Pins and Boots..2-47 General...2-78
Removal...2-78
Disassembly...2-78
Cleaning, Inspection and Repair..2-80
Assembly..2-80
Installation..2-81
2.18 FORK STEM AND BRACKET
ASSEMBLY
Removal and Disassembly...2-83
Cleaning, Inspection and Repair..2-83
Assembly and Installation...2-84
2.19 BELT GUARD AND DEBRIS
DEFLECTOR
Belt Guard..2-85
Removal..2-85
Installation...2-85
Debris Deflector..2-85
Removal..2-85
Installation...2-85
2.20 REAR FORK
Removal...2-86
Disassembly...2-86
Cleaning and Inspection...2-87
Assembly..2-87
Installation..2-87
2.21 SHOCK ABSORBERS
General...2-89
Removal...2-89
Cleaning and Inspection...2-89
Installation..2-89
2.22 STABILIZER LINKS
General...2-90
Upper Front Stabilizer Link...2-90
Removal..2-90
Installation...2-90
Lower Front Stabilizer Link...2-90
Removal..2-90
Installation...2-90
Rear Stabilizer Link..2-91
Removal..2-91
Installation...2-91
2.23 FRONT ENGINE MOUNT/ISOLATOR
Removal...2-92
Installation..2-93
2.24 REAR ENGINE MOUNT/ISOLATOR
Removal...2-94
Installation..2-95
2.25 THROTTLE CABLES
Removal and Disassembly...2-97
Cleaning, Inspection and Repair..2-98
Assembly and Installation...2-99
2.26 CLUTCH CONTROL
General...2-100
Removal and Disassembly...2-100
Clutch Cable: Lower..2-100
Clutch Lever and Clutch Cable: Upper..2-101
VI TABLE OF CONTENTS
Clutch Hand Control..2-101
Assembly and Installation...2-102
Clutch Hand Control..2-102
Clutch Lever and Clutch Cable: Upper..2-103
Clutch Cable: Lower..2-103
Finish...2-103
2.27 HANDLEBARS
Removal...2-104
All Models..2-104
XL 883C and XL 1200C..2-104
XL 1200L and XL 1200N...2-105
All Except XL 883C, XL 1200C, XL 1200L and XL
1200N..2-106
Installation..2-107
XL 883C and XL 1200C..2-107
XL 1200L and XL 1200N...2-108
All Except XL 883C, XL 1200C, XL 1200L and XL
1200N..2-108
All Models..2-109
2.28 FRONT FENDER
XL Models..2-110
Removal..2-110
Installation...2-110
2.29 REAR FENDER: ALL MODELS EXCEPT
XL 1200N
General...2-111
Removal...2-111
Installation..2-113
2.30 REAR FENDER AND LICENSE PLATE
BRACKET: XL 1200N
General...2-115
Removal and Disassembly...2-115
Assembly and Installation...2-117
2.31 JIFFY STAND
General...2-120
Jiffy Stand Interlock: International Models..2-120
Removal...2-120
Cleaning and Lubrication..2-120
Installation..2-121
2.32 SEAT
General...2-122
Seat Removal...2-122
Seat Installation..2-122
2.33 RIDER FOOT CONTROLS: ALL
MODELS EQUIPPED WITH MID-MOUNT
CONTROLS
Right Footrest and Rear Brake Pedal Assembly..2-124
Removal..2-124
Installation...2-124
Left Footrest and Shift Lever Assembly..2-124
Removal..2-124
Installation...2-124
2.34 RIDER FOOT CONTROLS: ALL
MODELS EQUIPPED WITH FORWARD
CONTROLS 3.9 BOTTOM END SERVICE
Right Footrest and Rear Brake Pedal Assembly..2-126
Removal..2-126
Installation...2-126
Left Footrest and Shift Lever Assembly..2-127
Removal..2-127
Installation...2-128
Adjusting Shift Pedal..2-129 3.10 REMOVING ENGINE FROM CHASSIS
2.35 PASSENGER FOOTRESTS
General...2-130
XL Models..2-130
Removal..2-130
Installation...2-130
2.36 FORK LOCK
Removal...2-131
Installation..2-131
ENGINE
3.1 SPECIFICATIONS
Specifications: 2008 Sportster Models...3-1
3.2 ENGINE
General...3-6
3.3 OIL PRESSURE
General...3-7
Oil Pressure Indicator Lamp..3-7
Checking Oil Pressure..3-7
3.4 CRANKCASE BREATHING SYSTEM
General...3-10
3.5 TROUBLESHOOTING
Diagnosing Valve Train Noise...3-11
Compression Test...3-11
Cylinder Leakage Test..3-11
Diagnosing Smoking Engine or High Oil Consumption...3-12
Check Prior to Cylinder Head Removal...3-12
Check After Cylinder Head Removal...3-12
Adjustment and Testing..3-12
General..3-12
Engine in Chassis...3-21
Engine Removed From Chassis...3-22
General...3-23
Procedure...3-23
3.11 INSTALLING ENGINE IN CHASSIS
General...3-28
Procedure...3-28
3.12 TOP END OVERHAUL: DISASSEMBLY
General...3-31
Stripping Motorcycle for Top End Repair..3-31
Cylinder Heads...3-32
Disassembling Rocker Covers..3-32
Removing Cylinder Head..3-34
Disassembling Push Rods and Covers...3-36
Cylinder and Piston..3-37
3.13 TOP END OVERHAUL: ASSEMBLY
General...3-39
Piston and Cylinder..3-39
Push Rods, Covers, and Retainers..3-40
Cylinder Head...3-42
Rocker Covers..3-45
Assembling Motorcycle After Top End Repair..3-47
3.14 BOTTOM END OVERHAUL:
DISASSEMBLY
General...3-48
Tappets...3-48
Oil Pump...3-48
Gearcase Cover and Cam Gears...3-48
Crankcase..3-49
Removing Piston Oil Jets..3-51
Removing Cylinder Base Studs...3-51
3.15 BOTTOM END OVERHAUL: ASSEMBLY
3.6 ENGINE LUBRICATION SYSTEM Crankcase..3-52
Installing Piston Oil Jets..3-52
Installing Pinion Shaft Bearings..3-52
Installing Left Main Bearing...3-54
Assembling Crankcase Halves..3-54
Installing Cylinder Base Studs...3-57
Cam Gears and Gearcase Cover...3-57
Tappets...3-60
Assembling Top End of Engine...3-61
General...3-13
Oil Pump...3-13 3.16 VALVE TAPPETS
3.7 HOW TO USE THIS SECTION
Typical Symptoms...3-18
Top End Repair...3-18
Bottom End Repair...3-18
3.8 TOP END SERVICE
Engine in Chassis...3-19
Engine Removed from Chassis..3-20
General...3-62
Removal...3-62
Cleaning and Inspection...3-62
Installation..3-62
3.17 GEARCASE COVER AND CAM GEARS
General...3-63
Removal and Disassembly...3-63
Cleaning, Inspection and Repair..3-63
Cam Pinion Gear Identification, Inspection and
Selection...3-63
Bushing Inspection and Removal..3-64
Bushing Installation..3-65
Cam Gear Bushings in Right Crankcase...3-65
Cam Gear Bushings (Except Rear Intake Bushing) in
Gearcase Cover..3-65
Rear Intake Cam Gear Bushing in Gearcase Cover..3-65
Pinion Shaft Bushing in Gearcase Cover..3-65
Bushing Reaming...3-66
Cam Gear Bushings in Right Crankcase...3-66
Cam Gear Bushings (Except Rear Intake Bushing) in
Gearcase Cover..3-67
Rear Intake Cam Gear Bushing in Gearcase Cover..3-67
Pinion Shaft Bushing in Gearcase Cover..3-67
Assembly and Installation...3-68
3.18 CYLINDER HEAD
Removal...3-69
Disassembly...3-69
Cleaning and Inspection...3-71
Cylinder Heads..3-71
Rocker Arm Assemblies..3-71
Valves..3-73
Valve Seats...3-73
Valve Guides...3-73
Valve Springs..3-73
Spark Plug Threads...3-74
Push Rods...3-74
Replacing Rocker Arm Bushings..3-74
Replacing Valve Guides..3-75
Removal..3-75
Installation...3-76
Refacing Valve Seats..3-79
Replacing Valve Seats...3-80
Assembly..3-80
Installation..3-83
3.19 CYLINDER AND PISTON
Removal and Disassembly...3-84
Cleaning, Inspection and Repair..3-84
Checking Gasket Surface..3-84
Measuring Cylinder Bore...3-84
Measuring Piston to Cylinder Fit...3-85
Boring and Honing Cylinder..3-86
Fitting Piston Rings...3-86
Connecting Rod Bushings..3-88
Removing Upper Connecting Rod Bushings...3-88
Installing Upper Connecting Rod Bushings...3-90
Reaming Upper Connecting Rod Bushings...3-90
Honing Upper Connecting Rod Bushings..3-91
Repair..3-91
Assembly and Installation...3-91
3.20 CRANKCASE
General...3-92
Removal...3-92
Disassembly...3-93
Fitting Pinion Bearings...3-95
Bearing Selection..3-95
Lapping Engine Main Bearing Races...3-99
Assembling Crankcase Halves...3-99
VIII TABLE OF CONTENTS
3.21 OIL PUMP
General...3-100
Removal...3-101
Disassembly...3-101
Cleaning and Inspection...3-101
Assembly..3-101
Installation..3-101
3.22 OIL FILTER MOUNT
General...3-103
Disassembly...3-103
Cleaning and Inspection...3-103
Assembly..3-103
3.23 OIL TANK
Oil Hose Routing..3-104
Removal...3-104
Installation..3-107
FUEL SYSTEM
4.1 SPECIFICATIONS: FUEL SYSTEM
Specifications: 2008 Sportster Models...4-1
4.2 ELECTRONIC FUEL INJECTION (EFI)
Troubleshooting..4-2
4.3 AIR CLEANER
Removal...4-3
Cleaning, Inspection and Repair..4-3
Installation..4-4
4.4 FUEL TANK
General...4-5
Purging and Disconnecting Fuel Supply Hose...4-6
Removing Fuel Tank...4-6
Cleaning and Inspection...4-7
Installing Fuel Tank...4-7
Reconnecting Fuel Hose and Filling Fuel Tank..4-8
Vapor Valve...4-8
Console Replacement..4-9
Removal..4-9
Installation...4-10
4.5 THROTTLE POSITION SENSOR (TPS)
General...4-12
Removal...4-12
Installation..4-12
4.6 ENGINE TEMPERATURE SENSOR (ET)
General...4-14
Removal...4-14
Installation..4-15
4.7 INDUCTION MODULE
General...4-16
Removal...4-16
Disassembly...4-18
Assembly..4-19
Installation..4-20
4.8 IDLE AIR CONTROL (IAC)
General...4-22
Removal...4-22
Installation..4-23
4.9 TEMPERATURE MANIFOLD ABSOLUTE
PRESSURE SENSOR (TMAP)
General...4-24
Removal...4-24
Installation..4-24
Charcoal Canister...4-45
Removal..4-45
Installation...4-46
Vapor Valve...4-47
Removal..4-47
Installation...4-47
Hose Routing..4-48
Induction Module...4-48
Canister Hose Routings..4-48
STARTER
4.10 OXYGEN SENSOR 5.1 SPECIFICATIONS: STARTER
General...4-26
Removal...4-26
Installation..4-26 Specifications: 2008 Sportster Models...5-1
4.11 EXHAUST SYSTEM General...5-2
Starter Relay...5-2
Wiring Diagrams..5-2
Removal...5-2
Installation..5-2
Testing..5-2
Armature...5-2
Brushes and Brush Holder..5-5
Field Coil Assembly..5-6
Disassembly..5-6
Inspection..5-6
Assembly...5-6
Drive Assembly...5-7
Disassembly..5-7
Inspection..5-7
Assembly...5-7
General...4-28
Removal...4-29
Mufflers and Exhaust Pipes...4-29
Muffler Interconnect Bracket...4-29
Installation..4-30
Muffler Interconnect Bracket...4-30
Exhaust Pipes and Mufflers...4-30
4.12 FUEL INJECTORS
General...4-32
Removal...4-32
Installation..4-33
4.13 FUEL PUMP
General...4-35
Removal...4-35
Disassembly...4-36
Pressure Regulator and Filter Housing...4-36
Fuel Pump Assembly and Pump Bracket..4-37
Low Fuel Level Sensor Assembly...4-37
Fuel Pump/Sender Harness..4-37
Assembly..4-37
Fuel Pump/Sender Harness..4-37
Low Fuel Level Sensor Assembly...4-37
Fuel Pump Assembly and Pump Bracket..4-37
Pressure Regulator and Filter Housing...4-37
Installation..4-38
4.14 FUEL PRESSURE TEST
General...4-40
Testing..4-40
5.2 STARTER
5.3 STARTER SOLENOID
Solenoid Assembly...5-8
Disassembly..5-8
Assembly...5-8
Solenoid Plunger..5-8
Disassembly..5-8
Assembly...5-8
Solenoid Contacts..5-8
Disassembly..5-8
Assembly...5-9
DRIVE/TRANSMISSION
6.1 SPECIFICATIONS: DRIVE
2008 Sportster Specifications...6-1
4.15 INTAKE LEAK TEST 6.2 PRIMARY CHAIN ADJUSTER
General...4-43
Leak Tester...4-43
Parts List...4-43
Tester Assembly..4-43
Tester Adjustment..4-43
Procedure...4-43 General...6-2
Removal...6-2
Primary Cover...6-2
Primary Chain Adjuster...6-4
Installation..6-4
Primary Chain Adjuster...6-4
Primary Cover...6-5
4.16 EVAPORATIVE EMISSIONS CONTROL
(CA MODELS) 6.3 CLUTCH RELEASE MECHANISM
General...4-45
Removal and Disassembly...6-7
Cleaning, Inspection and Repair..6-8
Assembly and Installation...6-8 6.12 TRANSMISSION LEFT CASE
BEARINGS
6.4 PRIMARY DRIVE AND CLUTCH Removal...6-44
Mainshaft and Countershaft Bearings...6-44
Shifter Drum Bushing..6-44
Installation..6-44
Mainshaft and Countershaft Bearings...6-44
Shift Drum Bushing...6-44
General...6-10
Removal...6-12
Disassembly...6-12
Inspection and Repair..6-13
Assembly..6-14
Installation..6-15
6.5 SECONDARY DRIVE BELT
6.13 TRANSMISSION INSTALLATION
6.6 TRANSMISSION General...6-45
Installation..6-45
Shifter Forks and Drum Assembly..6-46
Assembling Crankcases...6-47
Shifter Shaft Installation...6-48
General...6-20 6.14 TRANSMISSION SPROCKET
6.7 CASE DISASSEMBLY FOR
TRANSMISSION REMOVAL Removal...6-50
Installation..6-51
General...6-21
Engine Removal and Disassembly...6-21 ELECTRICAL
6.8 TRANSMISSION REMOVAL AND
DISASSEMBLY 7.1 SPECIFICATIONS: ELECTRICAL
Transmission Removal From Left Crankcase...6-25
Mainshaft/Countershaft..6-28
Mainshaft Disassembly...6-29
Cleaning and Inspection..6-30
Countershaft Disassembly..6-30
Cleaning and Inspection..6-30 7.2 VOLTAGE REGULATOR
6.9 TRANSMISSION ASSEMBLY General...7-5
Replacing Fuses...7-5
Replacing Relays..7-5
Removal...6-17
Installation..6-18
Mainshaft Assembly...6-32
Countershaft Assembly..6-32
6.10 MAIN DRIVE GEAR AND BEARING
General...6-34
Removal...6-35
Main Drive Gear..6-35
Main Drive Gear Ball Bearing..6-36
Disassembly...6-36
Assembly..6-36
Installation..6-37
Main Drive Gear Ball Bearing..6-37
Main Drive Gear..6-38
Main Drive Gear Seal..6-40
6.11 TRANSMISSION RIGHT CASE
BEARINGS
Removal...6-43
Countershaft Needle Bearing..6-43
Shifter Drum Bushing..6-43
Installation..6-43
Countershaft Needle Bearing..6-43
Shifter Drum Bushing..6-43
X TABLE OF CONTENTS
Specifications: 2008 Sportster Models...7-1
General...7-2
Removal...7-2
Installation..7-3
7.3 FUSES AND RELAYS
7.4 MAXI-FUSE HOLDER
General...7-6
Replacement..7-6
7.5 SPEEDOMETER: ALL SINGLE GAUGE
MODELS EXCEPT XL 883C/XL 1200C
Removal...7-7
Installation..7-7
7.6 SPEEDOMETER AND TACHOMETER:
ALL DUAL GAUGE MODELS
Speedometer Removal...7-9
Trip Odometer Reset Switch Replacement..7-9
Tachometer Removal..7-9
Speedometer Installation..7-10
Tachometer Installation...7-11
7.7 SPEEDOMETER: XL 883C/XL 1200C
Removal...7-12
Installation..7-13
7.8 TURN SIGNAL AND SECURITY MODULE
(TSM/TSSM/HFSM) 7.19 TAIL LAMP: ALL MODELS EXCEPT XL
1200N
General...7-14
Testing..7-14
Removal...7-14
Installation..7-15 General...7-37
Bulb Replacement..7-37
Base Replacement...7-37
7.9 BATTERY CABLES
Removal...7-16
Installation..7-17
7.10 BATTERY TRAY
General...7-18
Removal...7-18
Installation..7-19
7.11 IGNITION SYSTEM
General...7-20
Troubleshooting..7-20
7.12 IGNITION AND LIGHT SWITCH
General...7-22
Removal...7-22
Installation..7-22
7.13 ELECTRONIC CONTROL MODULE
(ECM)
General...7-24
Removal...7-24
Installation..7-24
7.20 TURN SIGNALS
General...7-40
Bulb Replacement..7-40
Front Housing Replacement...7-40
Rear Housing Replacement...7-41
Preliminary Vehicle Disassembly: All Models..7-41
Disconnect Wiring: All Models Except XL 1200N..7-41
Disconnect Wiring: XL 1200N..7-42
Remove and Disassemble Turn Signal Assembly: All
Models...7-43
Reassemble and Install Turn Signal Assembly: All
Models...7-44
Connect Wiring: All Models Except XL 1200N..7-45
Connect Wiring: XL 1200N..7-45
Final Assembly: All Models..7-45
7.21 LICENSE PLATE LAMP MODULE: XL
1200N
General...7-46
Removal (Domestic Only)...7-46
Installation (Domestic Only)..7-46
Removal (HDI Only)...7-47
Installation (HDI Only)..7-49
7.14 SPARK PLUG CABLES 7.22 REAR LIGHTING CONVERTER
MODULE: XL 1200N (DOMESTIC ONLY)
General...7-25
Removal...7-25
Installation..7-26 General...7-51
Removal...7-51
Installation..7-52
7.15 IGNITION COIL 7.23 REAR STOP LAMP SWITCH
General...7-27
Troubleshooting..7-27
Removal...7-27
Installation..7-28 General...7-53
Replacement..7-53
7.16 CHARGING SYSTEM
General...7-29
Alternator..7-29
Voltage Regulator...7-29
7.17 HEADLAMP
Replacement: XL 883C/XL 1200C...7-30
Replacement: All Models Except XL 883C/XL 1200C..7-32
7.18 INDICATOR LAMP MODULE
General...7-34
Preliminary Disassembly: All Models..7-34
Replacement: XL 1200L and XL 1200N...7-34
Replacement: XL 883C and XL 1200C..7-35
Replacement: All Other Models..7-35
Reassembling Vehicle: All Models..7-36
7.24 CRANK POSITION SENSOR (CKP)
General...7-54
Removal...7-54
Installation..7-54
7.25 ALTERNATOR
Removal and Disassembly...7-55
Rotor...7-55
Stator...7-55
Cleaning and Inspection...7-56
Assembly and Installation...7-56
Stator...7-56
Rotor...7-57
Final Assembly..7-57
7.26 VEHICLE SPEED SENSOR (VSS)
General...7-58
Removal...7-58
Installation..7-58
7.27 NEUTRAL SWITCH
General...7-59
Replacement..7-59
7.28 MAIN WIRING HARNESS
General...7-61
Removal...7-61
Installation..7-63
7.29 ELECTRICAL CADDIES
General...7-67
Voltage Regulator Caddy..7-67
Removal..7-67
Installation...7-67
Wire Harness Caddy..7-67
Removal..7-68
Installation...7-69
7.30 JIFFY STAND SWITCH:
INTERNATIONAL MODELS
General...7-71
Removal...7-71
Installation..7-72
7.31 OPTIONAL SECURITY SIREN
General...7-73
Removal...7-73
Disassembly...7-73
Battery Replacement..7-74
Assembly..7-74
Installation..7-75
7.32 OIL PRESSURE SWITCH
General...7-76
Removal...7-76
Installation..7-76
7.33 HORN
Troubleshooting..7-77
Voltage Test..7-77
Replacement: Models with Front Mounted Horn..7-77
Replacement: Models with Side Mounted Horn...7-77
7.34 MAXI-FUSE
General...7-79
Removal...7-79
Installation..7-79
7.35 HANDLEBAR SWITCH ASSEMBLIES
General...7-80
Repair Procedures...7-80
Connectors...7-81
7.36 RIGHT HANDLEBAR SWITCHES
Removal...7-82
Disassembly...7-82
Switch Repair/Replacement...7-83
Upper Housing Repair...7-83
Lower Housing Repair...7-83
Turn-Right Signal Switch...7-84
Assembly..7-84
Installation..7-85
7.37 LEFT HANDLEBAR SWITCHES
Removal...7-88
Disassembly...7-88
Switch Repair/Replacement...7-88
Upper Housing Repair...7-88
Lower Housing Repair...7-89
Turn-Left Signal Switch...7-89
Clutch Interlock Switch..7-89
Assembly..7-89
Installation..7-90
APPENDIX A CONNECTOR REPAIR
A.1 AMP 1-PLACE CONNECTORS
AMP 1-Place Connector Repair...A-1
General...A-1
Separating Pin and Socket Housings...A-1
Mating Pin and Socket Housings..A-1
Removing Socket Terminals..A-1
Installing Socket Terminal...A-1
Removing Pin Terminal...A-1
Installing Pin Terminal...A-2
A.2 AMP MULTILOCK CONNECTORS
AMP Multilock Connector Repair...A-3
General...A-3
Separating Pin and Socket Housings...A-3
Mating Pin and Socket Housings..A-3
Removing Terminals from Housing...A-3
Inserting Terminals into Housing...A-4
Preparing Wire Leads for Crimping...A-4
Crimping Terminals to Leads..A-5
Inspecting Crimped Terminals...A-6
A.3 AUTOFUSE ELECTRICAL
CONNECTORS
Autofuse Connector Repair..A-7
General...A-7
Disassembly..A-7
Assembly..A-7
A.4 DELPHI CONNECTORS
Delphi Connector Repair..A-8
General...A-8
Separating Pin and Socket Housings...A-8
Mating Pin and Socket Housings..A-8
Removing Socket Terminals..A-8
Installing Socket Terminals..A-8
A.5 DELPHI MAXI FUSE HOUSING
Delphi Maxi-Fuse Housing Repair...A-10
General...A-10
Removing Maxi-Fuse..A-10
Installing Maxi-Fuse..A-10
Removing Socket Terminals..A-10
Installing Socket Terminals..A-10
A.6 DEUTSCH ELECTRICAL CONNECTORS
Crimping Terminals...A-26
Deutsch Connector Repair...A-12
General...A-12
Separating Pin and Socket Housings...A-12
Mating Pin and Socket Housings..A-12
Removing Socket Terminals..A-12
Installing Socket Terminals..A-12
Removing Pin Terminals...A-14
Installing Pin Terminals...A-14
Crimping Terminals...A-15 A.13 PACKARD 480 METRI-PACK
CONNECTORS
A.7 DEUTSCH STANDARD TERMINAL
REPAIR A.14 PACKARD 630 METRI-PACK
CONNECTORS
Deutsch Standard Terminal Crimps...A-16
Preparing Wire Leads for Crimping...A-16
Crimping Terminal to Lead..A-16
Inspecting Crimps...A-16 630 Metri-Pack Connector Repair..A-28
General...A-28
Separating Pin and Socket Housings...A-28
Mating Pin and Socket Housings..A-28
Removing Socket Terminal...A-28
Installing Socket Terminal...A-28
A.8 DEUTSCH SOLID BARREL MINI
TERMINAL REPAIR
Deutsch Solid Barrel Terminal Crimps...A-17
Preparing Wire Leads For Crimping...A-17
Adjusting Crimper Tool..A-17
Crimping a Barrel Contact To Wire Lead...A-17
Inspecting Crimps...A-17
A.9 DEUTSCH MINI TERMINAL REPAIR
Deutsch Mini Terminal Crimps...A-19
Preparing Wire Leads for Crimping...A-19
Crimping a Mini Terminal to Wire Lead...A-19
Inspecting Crimps...A-19
A.10 MOLEX CONNECTORS
Molex Connector Repair..A-20
Separating Pin and Socket Housings...A-20
Mating Pin and Socket Housings..A-20
Removing Terminals...A-20
Installing Terminals...A-20
Crimp Terminal to Lead..A-21
Prepare Lead..A-21
Prepare Tool..A-21
Position Terminal in the Punch/Die...A-22
Insert Stripped Lead...A-22
Crimp Terminal to Lead...A-22
Inspect Crimp..A-23
A.11 PACKARD 150 METRI-PACK
CONNECTORS
150 Metri-Pack Connector Repair..A-24
General...A-24
Separating Pin and Socket Housings...A-24
Mating Pin and Socket Housings..A-24
Removing Socket Terminal...A-24
Inserting Socket Terminal..A-24
A.12 PACKARD 280 METRI-PACK RELAY
AND FUSE BLOCK CONNECTORS
Fuse Block Repair..A-26
Removing Socket Terminals..A-26
Installing Socket Terminals..A-26
480 Metri-Pack Connector Repair..A-27
General...A-27
Separating Pin and Socket Housings...A-27
Mating Pin and Socket Housings..A-27
Removing Socket Terminals..A-27
Installing Socket Terminals..A-27
A.15 PACKARD METRI-PACK TERMINALS
Metri-Pack Terminal Crimps...A-29
Matching Terminal To Crimper..A-29
Preparing Wire Lead...A-29
Crimping Wire Core..A-29
Crimping Insulation/Seal...A-29
Inspecting Crimps...A-30
A.16 PACKARD ECM CONNECTOR
Packard 100W Connector Repair...A-31
General...A-31
Separating Socket Housing From ECM..A-31
Mating Socket Housing To ECM...A-31
Removing Socket Terminal...A-31
Installing Socket Terminal...A-31
Crimping Terminals...A-31
A.17 PACKARD MICRO-64 CONNECTORS
Packard Micro-64 Connector Repair..A-33
General...A-33
Separating Pin and Socket Housings...A-33
Mating Pin and Socket Housings..A-33
Removing Terminal...A-33
Installing Terminal...A-33
Preparing Wire Leads for Crimping...A-34
Crimping Terminals...A-34
Inspecting Crimps...A-34
A.18 SEALED SPLICE CONNECTORS
Sealed Splice Connector Repair..A-36
General...A-36
Preparing Wire Leads...A-36
Splicing Wire Leads..A-36
Inspecting Seals...A-36
APPENDIX B WIRING
B.1 CONNECTORS
Connector Locations..B-1
Function/Location...B-1
Place and Color..B-1
Connector Number..B-1
Repair Instructions..B-1
B.2 WIRING DIAGRAMS
Wiring Diagram Information...B-3
Wire Color Codes..B-3
Wiring Diagram Symbols..B-3
2008 Sportster Wiring Diagrams..B-4
APPENDIX C CONVERSIONS
C.1 METRIC CONVERSION
APPENDIX D COMPENSATING
SPROCKET
D.1 COMPENSATING SPROCKET
General..D-1
Removal and Disassembly...D-1
Cleaning, Inspection and Repair..D-1
Sprocket Bearing Replacement...D-1
Removal..D-1
Installation..D-2
Assembly and Installation..D-2
Conversion Table..C-1 APPENDIX E GLOSSARY
C.2 FLUID CONVERSIONS E.1 GLOSSARY
United States System..C-2
Metric System..C-2
British Imperial System..C-2 Acronyms and Abbreviations..E-1
C.3 TORQUE CONVERSIONS
United States System..C-3
Metric System..C-3
REFERENCE MATERIAL
TOOLS...I
TORQUE VALUES..VII
INDEX..XXI