1970-1978 Harley Davidson Sportster XL XLH XLCH XLT-1000 Service Manual 99484-78 – PDF DOWNLOAD
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1970-1978 Harley Davidson Sportster XL XLH XLCH XLT-1000 Service Manual 99484-78 – PDF DOWNLOAD
Description
1970-1978 Harley Davidson Sportster XL XLH XLCH XLT-1000 Service Manual 99484-78 – PDF DOWNLOAD
FILE DETAILS:
1970-1978 Harley Davidson Sportster XL XLH XLCH XLT-1000 Service Manual 99484-78 – PDF DOWNLOAD
Language : English
Pages : 236
Downloadable : Yes
File Type : PDF
Size: 41 MB
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
1970-1978 Harley Davidson Sportster XL XLH XLCH XLT-1000 Service Manual 99484-78 – PDF DOWNLOAD
FOREWORD:
This service and repair manual has been prepared with two purposes in mind. First, it will acquaint the reader
with the construction of the Harley-Davidson product and assist him in performing basic maintenance
Π° nd repair. Secondly, it will introduce to the professional Harley-Davidson mechanic the latest field-tested
and factory-approved major repair methods. We sincerely believe that this manual will make your association
with Harley-Davidson products more pleasant and profitaΠ«e.
HOW Π’Π USE YOUR SERVICE MANUAL:
Your Service Manual is arranged for quick, easy reference. This manual is divided into numbered sections entitled “Chassis,” Β·Β·Engine” and “Transmission.” Sections are then divided into sub-sections. The Engine Section, for example, is comprised of “Cylinder” and “Crankcase” subsections. Use this manual as follows:
1. Check the Π’Π°Π«Π΅ of Contents located in the front of each
section to find subject desired.
2. Page number is listed across from subject.
3. Each section is printed with section number for quick
general location of subject. Page number consists of section
number and page numЬer.
\ lnformation is presented in Π° definite order as follows:
) Minor adjustments
” Minor maintenance or repair
Complete disassemΠ«y
Cleaning
Major maintenance ΠΎΠ³ repair
AssemΠ«y
In figure legends the number following а name of а part indicates the quantity necessary for one complete assemЬly.
AII information for servicing Π° part should Π¬Π΅ readbefore repair work is started to avoid needless disassemΠ«y.
TABLE OF CONTENTS:
1970-1978 Harley Davidson Sportster XL XLH XLCH XLT-1000 Service Manual 99484-78 – PDF DOWNLOAD
PRDDUCT
CHASSIS
ENGINE
TRANSMISSIDN
ELECTRICAL
MISCELLANEOUS
SPECIFICA TIONS
Drum Π’ΡΡΠ΅ 2-18 CYLINDER HEAD
DisassemΠ«ing and
DimeΠΏsions 1 Β· 1 AssemΠ«ing 2-18
Removing 3-11
Capacit ies 1 β’ 1 DisassemΠ«ing 3-11
Engine 1 Β· 1 FRAME 2-19 Cleaning and lnspecting 3-11
Transmission 1 β’ 1 FORKS
Repair Rocker Arm
Tire Data 1-1 Front Fork 2-21 Π°ΠΏd Bushings 3-13
SERVICE Servicing 2-21 Refacing Valves and
Servicing а New Motorcycle 1-3 DisassemЬling and Repair 2-24 Valve Seats 3-13
Recommended Operations at AssemΠ«y 2-30 AssemΠ«ing Cylinder Head 3-14
First 500 and 1,000 Miles 1-3 Rear Shock Absorber 2-31
Adjusting Tappets 3-15
Regular Service lntervals 1-4 Rear Fork 2-32 Removing and lnstalling
Push Rods Only 3-15
Lubricants 1-5 BRAKES
Π’ORQUE REQUIREMENTS Servicing 2-35
CYLINDER AND PISTON
FasteΠΏer Tightening 1-13 Adjusting Front Wheel
Removing 3-17
Brake 2-35
Cleaning and lnspecting 3-17
LOCATING TROUBLES Adjusting Rear Wheel
Refinishing Cylinders 3-17
Engine 1-15 Brake 2-35
Fitting Piston Rings 3-19
Lubrication System 1-16 Replacing Front Wheel
Connecting Rod Bushing 3-20
Electrical System 1-16 Brake Π‘Π°Π«Π΅ 2-36
Straightening Connecting
Carburetor 1-16 DisassemΠ«ing Brakes 2-36 Rods 3-20
Transmission 1-16 lnspecti ΠΏg and Repairing AssemΠ«ing Cylinder
Clutch 1-16 Brakes 2-36 and Piston Π- 21 ) ” 1-17 AssemΠ¬ling Brakes 2-37 GEARCASE
ASSIS Cross Shaft 2-37 Oil Pump 3-23
RΠ΅Π°Π³ Brake Foot Pedal Check Valve 3-23
DRIVE (1977 & Later) 2-3’8 Cleaning and lnspecting
Front Chain 2-1 Front Disc ΠΠ³Π°kΠ΅ Oil Pump 3-24
Adjustment 2-1 (1973 & Later) 2-40 AssemΠ«ing Oil Pump 3-25
Lubrication 2-2 Check List 2-41 DisassemЬling Oil Pump 3-25
Replacing 2-2 1973 Front Disc Brake 2-42 Valve Tappets and
Rear Chain 2-2 DisassemΠ«ing and Guides 3-28
Adjustment 2-2 ReassemΠ«ing 2-42 Gearcase Cover and
RΠ΅Π°Π³ Chain Oiler 2-2 1974 and LateΠ³ Front Timing Gears 3-30
Servicing Rear Chain 2-3 Disc Brake 2-43 DisassemΠ«ing 3-30
Front Brake Master Cleaning and lnspecting 3-31
WHEELS Cylinder 2-45 Bearing Replacement 3-31
Service Chart 2-5 Bleeding Hydraulic AssemΠ«ing 3-32
Removing and lnstalling System 2-46
Wheels 2-5 CRANKCASE
Hubs 2-7 FIBERGLASS BODY CARE General 3-35
Sp[()cket Replacement 2-10 AND REPAIR DisassemΠ«ing Crankcase 3-35
Spoking Wheels 2-11 General 2-47 Flywheels 3-37
Truing Wheels 2-13 Surface Finishing 2-47 AssemΠ«ing CraΠΏkcase 3-42
Truing Rim 2-13 Molded-in-Color Surface
Removing Tire and Repairs 2-48 FUEL SYSTEM
Tube from Rim 2-14 Patching of Holes, Carburetor (Tillotson) 3-45
Mounting Tire and PurΡ.tures and Breaks 2-49 Description 3-45
Tube on Rim 2-Π’4 TOOLS 2-53 Operation 3-45
Checking Tire Trueness .~
ENGINE lnspecting and Testing 3-49
)DLEΠAR Π’ΠRΠΠ’Π’LΠ, 1′ DisassemΠ«ing 3-51
GENERAL Cleaning, lnspecting,
NTROL β’ Specifications 3-1 and Repairing 3-51
Spiral Π’ΡΡΠ΅ 2-17 Description 3-1 AssemΠ«ing 3-53
DisassemΠ«ing 2-17 LubricatioΠΏ r 3-2 TrouΠ«eshooting Guide 3-53
TABLE OF CONTENTS (cont’d)
Page Page Page
Number Number Number
Carburetor (Bendix) 3-54 1970 Clutch 4-8 SWITCHES
Operation 3-54 DisassemΠ«ing 4-8 8utton 5-17
Adjusting 3-55 lnspecting and Repairing 4-8 Solenoid Switch 5-18
DisassemΠ«ing 3-56 Replacing Clutch Sprocket Stop Lamp FΠ³ont
Cleaning and lnspection 3-56 Needle Bearing and ΠΠ³Π°kΠ΅ Switch 5-18
AssemΠ«ing 3-58 Starter Clutch 4-9
5-19 Π‘Π°Π³Π¬uΠ³Π΅tΠΎΠ³ (Keihin) 3-58 AssemΠ«ing Clutch 4-9 Starter Relay Switch
Operation 3-58 1971 and Later Clutch 4-11 LAMPS
Adjusting 3-61 DisassemΠ«ing 4-11 Headlamp 5-21
DisassemΠ«ing 3-61 lnsΞΌec1i11g Π°ΠΏd RepairiΠΏg 4-11 Adjusting Beam 5-21
Cleaning and lnspecting 3-62 AssemЬling Clutch 4-14 Bulb Chart 5-21
AssemΠ«ing 3-62 Compensating Sprocket 4-15
lnstalling 3-62 GENERATOR
Checking, Testing and
TrouΠ«eshooting Chart 3-64 KICK STARTER
Air Cleaner 3-66 General 4-17 Repair 5-23
FuelTank 3-66 DisassemΠ«ing 4-17 Brushes 5-23
Fuel Supply Valve 3-66 lnspecting and Repair 4-18 Field Coils 5-23
AssemΠ«ing 4-18 Armature 5-25
TOOLS 3-69 Commutator 5-26
ELECTRIC STARTER DisassemЬling 5-27 TRANSMISSION Staгter Drive 4-21 AssemЫing 5-28
DisassemΠ«ing Solenoid 4-21
GENERAL DisassemΠ«ing Starter CIRCUIT BREAKER Specifications 4-1 Drive Shaft and Housing 4-22 Description 5-29 Description 4-1 AssemΠ«ing Starter and Operation 5-29
CLUTCH Solenoid 4-22 TrouΠ«eshooting 5-29
Diagnosis Chart 4-3 TRANSMISSION Adj11sting Points 5-29
1970 Clutch Controls 4-3 General 4-23 lgnition Timing 5-30
Adjusting Clutch Release 1975 and 1976 Shifter DisassemЬling and
‘ Mechanism 4-3 Linkage 4-23 AssemΠ«ing 5-31
Adjusting Clutch Spring Removing Transmission 4-24 lnstalling Circuit
Tension 4-3 lnspecting and Replacing Breaker 5-33
Replacing Clutch Control Parts 4-25 DisassemΠ«ing and As-
Π‘Π°Π«Π΅ and Coil 4-4 AssemΠ«ing Transmission 4-28 semΠ«ing 1971 & Later
DisassemΠ«ing Clutch Lubrication 4-30 Models 5-33
Release Mechanism 4-4
lnspecting Clutch Release Π’OOLS 4-31
IGNITION COIL
Mechanism 4-5
TrouΠ«eshooting 5-37
AssemΠ«ing Clutch ELECTRICAL Replacing Π‘Π°Π«Π΅s 5-37
Release Mechanism 4-5
1971 and Later Clutch WIRING SPARK PLUGS
Controls 4-6 Wiring Diagrams
Removing Plugs 5-39
Adjusting Clutch Release 1970-71 XLH 5-3 Cleaning, lnspecting and
Mechanism 4-6 1970-71 XLCH 5-5 Repair 5-39
Adjusti_ng Clutch Spring 1 972 XLH Std. Seat 5-5 Setting Spark Gap 5-40
Tension 4-6 1972 XLCH Std. Seat 5-6 Testing Spark Plugs 5-40
DisassemΠ«ing Clutch 1 972 XLH Low Seat 5-7 lnstalling Spark Plugs 5-40
Release Mechanism 1 972 XLCH Low Seat 5-7
and Clutch Π‘Π°Π«Π΅ 4-6 1973-74 XL 5-9 REGULATOR –
lnspecting and Repairing 1973-74 XLCH 5-9 1977 & EARLIER
Clutch Release 1975 & 1976 XL 5-11 Tests 5-41
Mechanism and Clutch 1975 & 1976 XLCH 5-11 Test Specifications 5-41
Π‘Π°Π«Π΅ 4-6 1977 XL 5-13 Testing Method 1
AssemΠ«ing Clutch 1977 XLCH 5-13 (Model XLH) 5-42
Release Mechanism 1978 XL 5-15 Testing Method 1
and Clutch Π‘Π°Π«Π΅ 4-8 1978 XLCH 5-15 (Model XLCH) 5-43
TABLE OF CONTENTS (cont’d)
) Page Page
Number Number
Testing Method 11 Testing 5.53 Starter Motors
(Model XLH) 5-44 Charging 5-54
Testing Method 11
(Model XLCH) 5-45 HORN 5-55
TOOLS
Servicing 5-47 MISCELLANEOUS
REGULATOR – 1978 STARTER MOTOR
General 5-49 TrouΠ«eshooting 5-57 INSTRUMENTS
Checking Charging System 5-49 Starter Motor and Drive 5-57 Speedometer
Prestolite Starter Motor 5-58 Tachometer
ΠΠΠ’Π’ΠRΠ£ Hitach i Sta rter Motor 5-58
Π‘Π°Π³Π΅ 5-53 Prestolite and Hitachi
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