1998 Harley Davidson XLH Service Manual Manual PDF Download

Description

1998 Harley Davidson XLH Service Manual – PDF DOWNLOAD

DESCRIPTION:

1998 Harley Davidson XLH Service Manual – PDF DOWNLOAD

GENERAL
SERVICING А NEW MOTORCYCLE

• Service operations 10 Ье performed before customer delivery are specified in the applicable model year PREDELIVERY AND SETUP MANUAL.
• The performance of new motorcycle initial service is required to keep warranty in force and 10 ensure proper emissions systems operation.
• After а new motorcycle has Ьееn driven its first 500 miles, and again at 5000 miles, а Harley-Davidson dealer should perform the service operations listed in the Regular Maintenance intervals lаblе on the next page.

SAFE OPERATING MAINTENANCE
А careful check of certain equipment is necessary after periods of storage, and frequently between regular service intervals, 10 determine if additional maintenance is required.
Check:
1. Tires for abrasions, cuts and correct pressure.
2. Secondary drive belt for proper tension and condition.
3. Brakes, steering and throttle for responsiveness.
4 . Brake fluid level and condition. Hydraulic lines and fittings for leaks. Also, check brake pads and discs for wear.
5. Cables for fraying, crimping and free operation.
6 . Engine oil and transmission fluid levels.
7 . Wheel spoke tightness, if applicable.
8. Headlamp, tail lamp, brake lamp and directional lamp operation.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

1998 Harley Davidson XLH Service Manual – PDF DOWNLOAD

SECTION 1 – PRODUCT
General
Page No SECTION 2 – CHASSIS Page No
Servicing а New Motorcycle
Safe Operating Ma,ntenance
Regular Maintenance lntervals
Side Views
Storage
General
Removal from Storage
Fluid Requirements
General
United States System
British lmperial System
Metric System
Wheel Bearing Grease
Brake Fluid
Front Fork Oit
Engine Oit
Fuel
Primary Drive/Тransmission Lubricant
Metric Conversion ТаЫе
Fastener Torque Values
TrouЫeshooting
Engine
Engine Lubrication System
Etectrical System
Fuel
Traлsmission
Clutch
Chassis
Shop Practices
Repair Notes
Repair and Reptacement Procedures
Cleaning
Tool Safety
AirTools
Wrenches
Pliers/Cu«ers/Pryьars
Hammers
Punches/Chisels
Screwdrivers
Ratchets and Handles
Sockets
Storage Units
Tools
Specifications
T ires
Vehicle ldentification Number (V I N )
Wheels
General
1-З Troubleshooting
Front Wheel
Removal
DisassemЫy
Cleaning, lnspection, and Repair
Assembly
lnstallation
RearWheel
Removal
DisassemЫy
Cteaning lnspection and Repair
Assembly
lnstallation
Lacing Wheels
16-lnch Wheels
19-lnch Wheels
Truing Laced Wheel
Checklng Cast Rim Runout
Tires
General
Removal
Cleaning, lnspection, and Repair
lnstallation
Brakes
General
TrouЫeshooting
Front Brake Master Cylinder
Removal/DisassemЫy
Cleaning, lnspection, and Repair
AssemЫy/lnstallation
Rear Brake Master Cylinder
Adjustment
Removal/DisassemЫy
Cleaning lnspection, and Repair
AssemЫy/lnstallation
Rear Brake Linkage and
Sprocket Cover
Removal
lnstallation
Front Brake Caliper
RemovatlDisassemЫy
Cleaning, lnspection, and Repair
AssemЫy
lnstallation
Rear Brake Caliper
RemovatlDisassemЫy
Cleaning, lnspection, and Repair
AssemЫy , ,
lnstallation ,
Brake Lines
Front Brake Line ,
RearBrakeLine , ,,,,,
Bleeding Hydraulic System
General
Front Fork
General ,, ,,, ,
Removal
DisassemЫy
Cleaning, lnspection, and Repair
AssemЫy , , , ,
lnstallation
DisassemЫy XL 1200S
lnspection XL 1200S
AssemЫy XL 1200S
lnstallation XL1200S
Fork Stem and
Bracket AssemЫy
Adjustment , , , , , , 2-54
Lubrication , , , , 2-54
RemovaVDisassemЫy 2-54
Cleaning, lnspection, and Repair 2-54
AssemЫy/lnstallation 2-54
Rear Fork 2·55
RemovallDisassemЫy 2-55
Cleaning and lnspection 2·55
AssemЫy 2-55
lnstallation 2-55
Rear Shock Absorber
Adjustment
Removal
DisassemЫy , , , ,
Cleaning and lnspection
lnstallation,
Throttle Control
Adjustment
RemovaVDisassemЫy ,
Cleaning, lnspection, and Repair
AssemЫy/lnstallation
Handlebars
Removal
lnstallation
Clutch Control
Adjustment ,
Removal/DisassemЫy , ,
AssemЫy/lnstallation , , ,
Exhaust System
Removal , ,
DisassemЫy , , ,
AssemЫy
lnstallation , , , ,
Front Fender
Removal , , , , ,
lnstallation , , , ,
Rear Fender
Removal ,,,,,
lnstallation ,
Jiffy Stand
General
Removal ,
Cleaning and Lubrication
lnstallation
Seat
Removal ,,,
lnstallation
SECTION З – ENGINE
Specifications
Engine
Lэpping Engine Main Bearing Races 3-66
AssemЫy 3-67
SECTION 4 – FUEL SYSTEM
General
Adjustmentrresting
3-5 Specifications
Stripping Motorcycle for
Engine Repair
lnstalling the Engine
Cylinder Head
Removal
DisassemЫy
Cleaning, lnspection, and Repair
AssemЫy
lnstatlation ,
Cylinder and Piston
RemovaVDisassemыy , ,
Cleaning, lnspection, and Repair, ,
AssemЫy/lnstallation
Engine Lubrication System
Checking and Adding Oil
Changing Oil and Filter
Winter Lubrication , , ,
Oil Hose Routing
OilTank
Oil Pressure Signal Light Switch
Oil Pressure Signal Light
Oil Pressure
Crankcase Breathing System ,
Oiling System
OilPump
Oil Fi lter Mount , ,
Valve Tappets
General
Removal ,
Cleaning and lnspection
lnstallation , ,,
Gearcase Cover and Cam Gears
General
Removal/Disassembly
Cleaning, lnspection, and Repair
AssemЫy/lnstal lation , ,
Crankcase
General
Adjustmentffesting
D1sassemЫy
Cleaning and lnspection
Replacing Fly,vheel Washers
Lapping Connecting Rod Races
Fitting Rod Bearings ,
Fitting Sprocket Bearings
Fit1ing Pinion Bearings
Carburetor
General ,
TrouЫeshooting ,
Vacuum Piston AS$embly TrouЫeshooting ,
Operation , , ,,
Adjustment , ,
Operation Check -Vacuum Piston ,
Removal
Disassemыy
Cleaning, lnspection, and Repair , ,
AssemЫy
lnstallation ,
Air Cleaner
General
Removal
Clean,ng lnspection, and Repair
lnstallation , , ,
Fuel Supply Valve
General
Removal ,
Clean,ng, lnspection,a nd Repair ,
lnstallation ,
FuelTank
General
Removal
Cleaning, lnspection, and Repair
lnstallation , ,
Evaporative Emissions Control –
California Models
General
TrouЫeshooting ,
Solenoid Electrical Tesl$ -д;r Oeane< Bune’11y Valve
Removal ,
Cleaning, lnspection, Repair, and Lubrication
lnstallation and Adjustment ,
Hose Routing
SECTION 5 – ELECTRIC STARTER
Specificatlons
Electric Starter System
General ,
TrouЫeshooting , , ,
Starting System Oiagnosis ,
Starter System Testing
“On-Motorcycle” Tests
Starter
Removal
Testing AssemЫed Starter
Oisassembly, lnspection, and Repair
AssemЫy
lnstallation
Starter Solenoid
General 5·18
OisassemЫy 5· 18
AssemЫy 5-18
SECTION 6 – DRIVEffRANSMISSION
Specifications
Primary Chain
General
Adjustment
Removal
lnstallation
Shifter Forks and Drum
Disassembly
Cleaning,l nspection,a nd Repair
AssemЫy
Mainshaft and Countershaft
OisassemЫy
Cleaning, lnspeclion, and Repair
AssemЫy
Main Drive Gear 6-30
Removal 6-30
DisassemЫy 6-31
AssemЫy 6-31
lnstallation 6-31
Access Door Bearings
Removal
lnstallation
Right Transmission Case
Bearings
Removal
lnstallation
Transmission lnstallation and
Secondary Drive Belt 6-7 Shifter Pawl Adjustment 6 34
General
Adjustment
Cleaning
Removal and lnstal lation
Clutch
General
Trouыeshooting
Clutch Release Mechanism
Adjustment
DisassemЫy
Cleaning lnspection, and Repair
AssemЫy
Primary Drive/Clutch
Removal
Disassembly
lnspection and Repair
AssemЫy
lnstallation
Transmission
General
lubrication
Transmission Case
General
Removal
Cleaning, lnspection,a nd Repair
SECTION 7 – ELECTRICAL
Specifications
Electrical Bracket
Replace Fuse(s)
Replace Main Circuit Breaker
Replace Siarter Relay
Replace Electrical Bracket
lgnition System
General
TrouЫeshooting
Oiagnostic Charts AII Models Except 1200S
Checking forT rouЫe Codes 1200S
Check Engine Lamp
Retrieving TrouЫe Codes
Scanalyzer
Breakout Вох lnstallation
Oiagnostic Check 1200S Sport
Trouыe Code 12 МАР Sensor
TrouЫe Code 16 BatteryVoltage
TrouЫe Code 2 4 and 2 5 lgnition Со,!
TrouЫe Code 35 Tachometer
TrouЫe Code 41 Cam Sync Failure
TrouЫe Code 44 Вank Angle Sensor
Trouыe Codes 52, 54, 55 lgnition Module Failure
lgnition Тimlng
Static Тiming 1200S
Adjust T iming using Scanalyzer 1200S
Static Тiming AII except 1200S
Dynamic T iming
Bank Angle Sensor
МАР Sensor -1200S
Page No
7 47
7-48
Vacuum-Operated Electric
Switch (V O E S )
AdjustmenVТesting
Removal
lnstallation
lgnition/Light Switch
General
Removal
lnstallation
lgnition Module 1200S
General
Removal
lnstallation
Cam Position Sensor and Rotor
1200S
General
Removal
lnstallation
lgnition Module AII except 1200S
General
Aemoval
lnstallation
Spark Plugs
General
Adjustment
Cleaning and lnspectюn
lnstallat,on
Spark Plug СаЫеs
General
Aemoval
lnspection
Ins1aIIa1ion
lgnition Coil
General
Trouыeshoot,ng
Removal AII E xcept 1200S
lnstallation А/1 E xcept 1200S
Removal 1200S
lnstallation 1200S
Charging System
General
TrouЫeshooting
Adjustmenvтesting
Alternator
Removal and OisassemЫy
Cleaning, lnspection and Repair
AssemЫy and lnstallation
Voltage Regulator
General
Removal
lnstallation
Battery
General
Activat,ng and Testing New Battery
Cleaning and lnspection
Charging
Oisconnection and Removat
Storage
lnstallation and Connection
Battery СаЫе Replacement
Lamps
General
Adjustment
Removalllnstallation
Rear Brake Switch
Handlebar Switches
General
Removal
lnstallation
Switch RepairlReplaoement
Horn
General
TrouЫeshooting
Neutral lndicator Switch
General
Testing
Removal and lnstallation
Directional (Turn Signal)
Canceller
Operation
Distance Test
Тime Test (Alternate)
Aider Preference and Control
Trouыeshooting
8830nly
1200 Models
RemovaVlnstallation
Fuses and Main Circuit Breaker
General
Electronic Speedometer
How-it Works
Speedometer Removat 1200 Models
Speedometer lnstallation 1200 Models
Speedometer Removal 883 Models
Speedometer lnstallation 8ВЗ Models
Tachometer Removal
Tachometer lnsratlation
Speedometer sensor Reptacement
Odometer reset switch Replacement
883 Speedometer (цite Model}
Speedometer/Тachometer Performance Check
Troubleshooting
Deutsch Connectors
Amp Multilock Connectors
Packard Electrical Connectors 1-120
Sealed Butt Connectors 1-122
Crimp ТаЫеs 7-123
viii
Wiring Diagrams 7-127
XL 1200S Domestic and lnternationat Models –
Main Harness 7-127
XLH AII Models, Star1ing and Charging –
XL1 200S Front цimps 7-128
XL 1200S Domest,c and lnternationat – lgnition Circuit 7-129
XL 1200s Domestic and lnte rnat,onal –
Horn and lnstruments 7-130
XL 1200S Domestic and lnternationat – Ughts 7-131
AII X L Domestic and lnternational (Excepl 1200S} –
Main Harness 7-132
AII X L Domestic and lnternational (Except 1200S) –
lgnition Circuit 7-133
AII XL Domestic and lnternational (Except 1200S)
Horn and lnstruments 7 134
INDEX 1-1

1998 HARLEY DAVIDSON XLH SERVICE MANUAL – PDF DOWNLOAD:

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• This is the SAME MANUAL used by the dealerships to diagnose your vehicle
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