Table of Contents

Introduction
About this manual, Introduction to the Harley-Davidson Sportster, Fraction/decimal/millimeter equivalents, English/American terminology, Vehicle identification numbers, Buying parts, Maintenance techniques, tools and working facilities, Motorcycle chemicals and lubricants, Safety first!

Troubleshooting
The troubleshooting section of this book provides you with help in diagnosing problems such as Engine doesn't start or is difficult to start (Starter motor doesn't rotate, Starter motor rotates but engine doesn't turn over, Starter works but engine won't turn over (seized), No fuel flow, Engine flooded, No spark or weak spark, Compression low, Stalls after starting, Rough idle), Runs poorly at low speed (Spark weak, Fuel/air mixture incorrect, Compression low, Poor acceleration), Runs poorly or no power at high speed (Firing incorrect, Fuel/air mixture incorrect, Compression low, Knocking or pinging, Miscellaneous causes), Overheating, Firing incorrect, Fuel/air mixture incorrect, Compression too high, Engine load excessive, Lubrication inadequate, Miscellaneous causes, Clutch problems (Clutch slipping, Clutch not disengaging completely), Gear shifting problems (Doesn't go into gear or lever doesn't return, Jumps out of gear, Overshifts), Abnormal engine noise (Knocking or pinging, Piston slap or rattling, Valve noise, Other noise), Abnormal driveline noise (Clutch noise, Transmission noise), Abnormal frame and suspension noise (Front end noise, Shock absorber noise, Disc brake noise), Oil pressure indicator light comes on (Engine lubrication system, Electrical system), Excessive exhaust smoke (White smoke, Black smoke, Brown smoke), Poor handling or stability (Handlebar hard to turn, Handlebar shakes or vibrates excessively, Handlebar pulls to one side, Poor shock absorbing qualities), Braking problems (Brakes are spongy, don't hold (hydraulic disc brakes only), Brake lever or pedal pulsates, Brakes drag), Electrical problems ( Weak or dead battery, Battery overcharged, Alternator not charging, Generator not charging, Generator charging rate below normal).

Chapter 1- Tune-up and routine maintenance
Routine maintenance intervals, Introduction, Fluid levels - check, Air cleaner - servicing, Drive chain - check - adjustment and lubrication, Brake shoes/pads - wear check, Clutch - adjustment, Fuel system - check, Brake system - general check, Lubrication - general, Clutch and front brake cable - lubrication, Fasteners - check, Tires/wheels/spokes - general check, Valve clearance - adjustment (pre-Evolution engine only), Idle speed - adjustment, Automatic drive chain oiler - maintenance and adjustment, Engine oil and filter - change, Spark plugs - check and replacement, Contact breaker points (1970 through 1978) – check and replacement, Ignition timing - check and adjustment, Primary chain - adjustment, Fuel filter - cleaning and replacement, Transmission oil - change, Throttle - check and lubrication, Suspension - inspection, Steering head bearings - check, Fork oil (except 1995-on XL 1200S) - change, Wheel bearings - repack, Cylinder compression - check, Headlight aim - adjustment,, Sidestand - check and maintenance, Brake hydraulic systems - bleeding and fluid replacement, Drive belt - check and adjustment.

Chapter 2 - Engine, clutch and transmission
General information, Repair operations possible with the engine in the frame, Major engine repair - general information, Engine removal, Engine disassembly and reassembly - general information, Cylinder heads, barrels and tappets - removal, Starter motor and solenoid - removal, Clutch, primary drive sprocket and primary chain - removal, Ignition components - removal, Final drive sprocket - removal, Timing cover and camshafts - removal, Oil pump - removal, inspection and installation, Transmission components - removal and disassembly, Splitting the crankcases, Inspection and repair - general information, Crankshaft and connecting rod bearings - inspection, Cylinder barrels - inspection, Pistons - inspection, Valves, valve seats and valve guides - servicing, Cylinder head and valves - disassembly, inspection and reassembly, Rocker arms/shafts and pushrods - inspection, Camshafts, timing gears, tappets and timing case bearings - inspection, Crankcases - inspection, Transmission components - inspection, Transmission gear cluster - disassembly and reassembly, Clutch components - inspection, Primary drive components - inspection, Kickstart mechanism - inspection, Starter drive assembly - inspection, Oil seals - inspection and replacement, Engine reassembly - general information, Crankcases - reassembly, Crankcase breather - timing (1976 and earlier models only), Camshafts - installation, Ignition components - installation, Tappets - installation, Transmission gear cluster, primary drive and clutch components - installation, Starter motor - installation, Final drive sprocket - installation, Piston rings - installation, Pistons and cylinder barrels - installation, Cylinder heads - installation, Rocker boxes (pre-Evolution engine) - installation, Engine installation, Generator (early models) and primary chain cover - installation, Completing engine reassembly, Starting and running the rebuilt engine, Recommended break-in procedure.

Chapter 3 - Fuel system
Fuel system - general information, Fuel tank - removal and installation, Fuel control valve - removal and installation, Carburetor - removal and installation, Carburetor overhaul - general information, Carburetor - disassembly, inspection and reassembly, Carburetor - adjustments, Air cleaner - removal and installation, Evaporative emission control system - general information, Throttle cable - adjustment.

Chapter 4 - Ignition system
General information, Spark plugs - check and replacement, Ignition coil - check, removal and installation, Contact breaker points - check and replacement, Condenser - removal and installation, Air gap - check and adjustment, Electronic ignition system - check, Ignition components - removal and installation, Ignition timing - check and adjustment, Vacuum Operated Electric Switch (VOES) – check and replacement, Distributor (1970 models only) - removal and installation.

Chapter 5 - Frame and suspension
General information, Frame - inspection and repair, Instrument cluster - removal and installation, Shock absorbers - removal and installation, Swingarm bearings – check, Swingarm - removal, inspection and installation, Forks - removal and installation, Forks - disassembly, inspection and reassembly, Steering head bearings - maintenance, Seat - removal and installation.

Chapter 6 - Wheels, brakes and tires
General information, Wheels - inspection and repair, Front wheel - removal and installation, Front drum brake - inspection and brake shoe replacement, Front disc brake - inspection and brake pad replacement, Front brake disc - removal and installation, Front disc brake caliper - removal and installation, Front disc brake caliper - overhaul, Front disc brake master cylinder - removal, overhaul and installation, Disc brakes - bleeding, Rear wheel - removal and installation, Rear drum brake - inspection and brake shoe replacement, Rear disc brake - inspection and brake pad replacement, Rear disc brake caliper - removal, overhaul and installation, Rear disc brake master cylinder - removal, overhaul and installation, Rear brake pedal - check and adjustment, Rear wheel sprocket - removal and installation, Rear brake disc - removal and installation, Tires - removal and installation, Tubes - repair, Wheel bearings - repack.

Chapter 7 - Electrical system
General information, Electrical troubleshooting - general information, Charging system check - general information, Battery - check and maintenance, Battery - charging, Battery specific gravity - check, Headlight bulb - replacement, Taillight and turn signal bulbs - replacement, Generator/alternator - check, Generator/alternator- removal, overhaul and installation, Regulator- general information, Starter motor - removal and installation, Starter motor - disassembly, inspection and reassembly, Starter solenoid - check, Handlebar switches - removal and installation, Ignition and light switch - removal and installation, Horn - adjustment, Brake light switches - adjustment, Warning light bulbs - replacement, Evaporative emission control system - solenoid test (1992-on California models), Turn signal relay/cancel unit - location, Wiring diagrams - general information.

Wiring diagrams
This book includes complete wiring diagrams.

Conversion factors
A complete chart of popular conversions is included in this book.

Index
A full index by topic with page reference is included in this book.

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