Harley Davidson Sportster XL XLH All Models Service & Repair Manual PDF 1959-2018 (99484-04) - 99484-04 - Harley Davidson Sportster Models (XLH) Service Manual 2004 + Wiring (99495-04).pdf
**Harley Davidson Sportster Complete Repair & Service Manual Collection, 1959–2018**
MANUAL INDEX (13,810 pages total):
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