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
а 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 profitaЫe.

HOW ТО USE YOUR SERVICE MANUAL:

Your Service Manual is arranged for quick, easy reference. This manual is divided into numbered sections entitled “Chassis,” ··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 ТаЫе 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 а definite order as follows:
) Minor adjustments
” Minor maintenance or repair
Complete disassemЫy
Cleaning
Major maintenance ог repair
AssemЫy
In figure legends the number following а name of а part indicates the quantity necessary for one complete assemЬly.
AII information for servicing а part should Ье readbefore repair work is started to avoid needless disassemЫy.

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 Туре 2-18 CYLINDER HEAD
DisassemЫing and
Dimeпsions 1 · 1 AssemЫing 2-18
Removing 3-11
Capacit ies 1 • 1 DisassemЫing 3-11
Engine 1 · 1 FRAME 2-19 Cleaning and lnspecting 3-11
Transmission 1 • 1 FORKS
Repair Rocker Arm
Tire Data 1-1 Front Fork 2-21 апd 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 AssemЫy 2-30 AssemЫing 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
ТORQUE REQUIREMENTS Servicing 2-35
CYLINDER AND PISTON
Fasteпer 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 СаЫе 2-36
Straightening Connecting
Carburetor 1-16 DisassemЫing Brakes 2-36 Rods 3-20
Transmission 1-16 lnspecti пg and Repairing AssemЫing Cylinder
Clutch 1-16 Brakes 2-36 and Piston З- 21 ) ” 1-17 AssemЬling Brakes 2-37 GEARCASE
ASSIS Cross Shaft 2-37 Oil Pump 3-23
Rеаг Brake Foot Pedal Check Valve 3-23
DRIVE (1977 & Later) 2-3’8 Cleaning and lnspecting
Front Chain 2-1 Front Disc Вгаkе Oil Pump 3-24
Adjustment 2-1 (1973 & Later) 2-40 AssemЫing 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 DisassemЫing and Guides 3-28
Adjustment 2-2 ReassemЫing 2-42 Gearcase Cover and
Rеаг Chain Oiler 2-2 1974 and Lateг Front Timing Gears 3-30
Servicing Rear Chain 2-3 Disc Brake 2-43 DisassemЫing 3-30
Front Brake Master Cleaning and lnspecting 3-31
WHEELS Cylinder 2-45 Bearing Replacement 3-31
Service Chart 2-5 Bleeding Hydraulic AssemЫing 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 DisassemЫing Crankcase 3-35
Spoking Wheels 2-11 General 2-47 Flywheels 3-37
Truing Wheels 2-13 Surface Finishing 2-47 AssemЫing Craпkcase 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 Purю.tures and Breaks 2-49 Description 3-45
Tube on Rim 2-Т4 TOOLS 2-53 Operation 3-45
Checking Tire Trueness .~
ENGINE lnspecting and Testing 3-49
)DLEВAR ТНRОТТLЕ, 1′ DisassemЫing 3-51
GENERAL Cleaning, lnspecting,
NTROL • Specifications 3-1 and Repairing 3-51
Spiral Туре 2-17 Description 3-1 AssemЫing 3-53
DisassemЫing 2-17 Lubricatioп r 3-2 TrouЫeshooting 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 DisassemЫing 4-8 8utton 5-17
Adjusting 3-55 lnspecting and Repairing 4-8 Solenoid Switch 5-18
DisassemЫing 3-56 Replacing Clutch Sprocket Stop Lamp Fгont
Cleaning and lnspection 3-56 Needle Bearing and Вгаkе Switch 5-18
AssemЫing 3-58 Starter Clutch 4-9
5-19 СагЬuгеtог (Keihin) 3-58 AssemЫing Clutch 4-9 Starter Relay Switch
Operation 3-58 1971 and Later Clutch 4-11 LAMPS
Adjusting 3-61 DisassemЫing 4-11 Headlamp 5-21
DisassemЫing 3-61 lnsμec1i11g апd Repairiпg 4-11 Adjusting Beam 5-21
Cleaning and lnspecting 3-62 AssemЬling Clutch 4-14 Bulb Chart 5-21
AssemЫing 3-62 Compensating Sprocket 4-15
lnstalling 3-62 GENERATOR
Checking, Testing and
TrouЫeshooting Chart 3-64 KICK STARTER
Air Cleaner 3-66 General 4-17 Repair 5-23
FuelTank 3-66 DisassemЫing 4-17 Brushes 5-23
Fuel Supply Valve 3-66 lnspecting and Repair 4-18 Field Coils 5-23
AssemЫing 4-18 Armature 5-25
TOOLS 3-69 Commutator 5-26
ELECTRIC STARTER DisassemЬling 5-27 TRANSMISSION Staгter Drive 4-21 AssemЫing 5-28
DisassemЫing Solenoid 4-21
GENERAL DisassemЫing Starter CIRCUIT BREAKER Specifications 4-1 Drive Shaft and Housing 4-22 Description 5-29 Description 4-1 AssemЫing Starter and Operation 5-29
CLUTCH Solenoid 4-22 TrouЫeshooting 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 AssemЫing 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 DisassemЫing and As-
СаЫе and Coil 4-4 AssemЫing Transmission 4-28 semЫing 1971 & Later
DisassemЫing Clutch Lubrication 4-30 Models 5-33
Release Mechanism 4-4
lnspecting Clutch Release ТOOLS 4-31
IGNITION COIL
Mechanism 4-5
TrouЫeshooting 5-37
AssemЫing Clutch ELECTRICAL Replacing СаЫеs 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
DisassemЫing Clutch 1 972 XLH Low Seat 5-7 lnstalling Spark Plugs 5-40
Release Mechanism 1 972 XLCH Low Seat 5-7
and Clutch СаЫе 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
СаЫе 4-6 1977 XL 5-13 Testing Method 1
AssemЫing Clutch 1977 XLCH 5-13 (Model XLH) 5-42
Release Mechanism 1978 XL 5-15 Testing Method 1
and Clutch СаЫе 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 TrouЫeshooting 5-57 INSTRUMENTS
Checking Charging System 5-49 Starter Motor and Drive 5-57 Speedometer
Prestolite Starter Motor 5-58 Tachometer
ВАТТЕRУ Hitach i Sta rter Motor 5-58
Саге 5-53 Prestolite and Hitachi

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