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2008 Harley Davidson Sportster Models Service Manual – PDF DOWNLOAD
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Description
2008 Harley Davidson Sportster Models Service Manual – PDF DOWNLOAD
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
2008 Harley Davidson Sportster Models Service Manual – PDF DOWNLOAD
GENERAL:
- This Service Manual has been prepared with two purposes in mind. First, it will acquaint the user with the construction of the Harley-Davidson product and assist in the performance of basic maintenance and repair.
- Secondly, it will introduce to the professional Harley-Davidson Technician the latest field-tested and factory-approved major repair methods. We sincerely believe that this Service Manual will make your association with Harley-Davidson products more pleasant and profitable.
HOW TO USE YOUR SERVICE MANUAL :
Refer to the table below for the content layout of this manual.
NO. CHAPTER
1 Maintenance
2 Chassis
3 Engine
4 Fuel System
5 Starter
6 Drive/Transmission
7 Electrical
A Appendix A Connector Repair
B Appendix B Wiring
C Appendix C Conversions
D Appendix D Compensating Sprocket
E Appendix E Glossary
- Use the TABLE OF CONTENTS (which follows this FOREWORD) and the INDEX (at the back of this manual) to quickly locate subjects. Sections and topics in this manual are sequentially numbered for easy navigation.
- For example, a cross-reference shown as 2.1 SPECIFICATIONS refers to chapter 2 CHASSIS, heading 2.1 SPECIFICATIONS.
- For quick and easy reference, all pages contain a section number followed by a page number. For example, page 3-5 refers to page 5 in section 3.
- A number of acronyms and abbreviations are used in this document. See the D.1 GLOSSARY for a list of acronyms, abbreviations and definitions.
TABLE OF CONTENTS:
2008 Harley Davidson Sportster Models Service Manual – PDF DOWNLOAD
COVER........................................................................ 1 FOREWORD..................................................................... 2 TABLE OF CONTENTS............................................................ 4 1. MAINTENANCE............................................................... 16 1.1 GENERAL.............................................................. 18 Servicing a New Motorcycle........................................... 18 Safe Operating Maintenance........................................... 18 Shop Practices....................................................... 18 Repair and Replacement Procedures.................................... 19 Cleaning............................................................. 20 Tool Safety.......................................................... 20 1.2 FUEL AND OIL......................................................... 22 Fuel................................................................. 22 Gasoline Blends...................................................... 22 Engine Lubrication................................................... 22 Winter Lubrication................................................... 23 1.3 MAINTENANCE SCHEDULE................................................. 24 General.............................................................. 24 1.4 BULB REQUIREMENTS.................................................... 28 Bulb Chart........................................................... 28 1.5 ENGINE OIL AND FILTER................................................ 29 Checking and Adding Oil.............................................. 29 Changing Oil and Filter.............................................. 30 1.6 BRAKES............................................................... 32 General.............................................................. 32 Inspection........................................................... 32 Troubleshooting...................................................... 32 1.7 BLEEDING HYDRAULIC BRAKE SYSTEM...................................... 34 General.............................................................. 34 Bleeding Front Brake................................................. 34 Bleeding Rear Brake.................................................. 36 1.8 TIRES AND WHEELS..................................................... 37 Tires................................................................ 37 Tire Replacement..................................................... 38 Wheel Bearings....................................................... 38 Wheel Spokes......................................................... 38 1.9 PRIMARY CHAIN........................................................ 40 Inspection........................................................... 40 Adjustment........................................................... 40 1.10 CLUTCH.............................................................. 42 Adjustment........................................................... 42 1.11 TRANSMISSION LUBRICANT.............................................. 44 Transmission Lubrication: Sportster Models........................... 44 1.12 REAR BELT AND SPROCKETS............................................. 46 General.............................................................. 46 Cleaning............................................................. 46 Inspection........................................................... 46 1.13 SHOCK ABSORBER ADJUSTMENT........................................... 48 Shock Absorber Preload Adjustment: Sportster Models.................. 48 1.14 REAR BELT DEFLECTION................................................ 49 Inspection........................................................... 49 Belt Deflection Adjustment........................................... 50 Wheel Alignment...................................................... 51 1.15 BRAKE PADS AND DISCS................................................ 53 Inspection........................................................... 53 Brake Pad Replacement: Front......................................... 53 Brake Pad Replacement: Rear.......................................... 56 1.16 BATTERY MAINTENANCE................................................. 60 General.............................................................. 60 Battery Disconnection and Removal.................................... 61 Cleaning and Inspection.............................................. 62 Charging Battery..................................................... 62 Battery Installation and Connection.................................. 63 Storage.............................................................. 64 1.17 SPARK PLUGS......................................................... 66 General.............................................................. 66 Inspection........................................................... 66 Spark Plug Cable Inspection.......................................... 66 1.18 STEERING HEAD BEARINGS.............................................. 68 Adjustment........................................................... 68 Lubrication.......................................................... 68 1.19 REAR FORK BEARINGS.................................................. 70 General.............................................................. 70 Procedure............................................................ 70 1.20 FRONT FORK OIL...................................................... 71 General.............................................................. 71 Changing Fork Oil.................................................... 71 1.21 CABLE AND CHASSIS LUBRICATION....................................... 73 General.............................................................. 73 Cables and Hand Levers............................................... 73 Foot Shift Lever and Rear Brake Pedal................................ 73 Jiffy Stand.......................................................... 73 Steering Head Bearings............................................... 73 1.22 AIR CLEANER AND EXHAUST SYSTEM...................................... 74 General.............................................................. 74 Removal.............................................................. 74 Cleaning, Inspection and Repair...................................... 75 Installation......................................................... 75 Exhaust System Leak Check............................................ 75 1.23 THROTTLE CONTROL.................................................... 76 Cable Inspection and Lubrication..................................... 76 Cable Adjustment..................................................... 76 1.24 IDLE SPEED AND IGNITION TIMING...................................... 77 Idle Speed........................................................... 77 Ignition Timing...................................................... 77 1.25 FUEL SUPPLY FILTER.................................................. 78 General.............................................................. 78 Fuel System Hose and Fittings........................................ 78 Removal.............................................................. 78 Installation......................................................... 78 1.26 ENGINE MOUNTS AND STABILIZER LINKS.................................. 79 Inspection........................................................... 79 1.27 HEADLAMP ALIGNMENT.................................................. 80 Headlamp Alignment: Sportster Models................................. 80 1.28 FLUID AND LUBRICANT REQUIREMENTS.................................... 82 Brake Fluid.......................................................... 82 Brake Component Grease............................................... 82 Front Fork Oil....................................................... 82 Engine Oil........................................................... 82 Primary Drive/Transmission Lubricant................................. 82 1.29 CRITICAL FASTENERS.................................................. 83 Inspection........................................................... 83 1.30 STORAGE............................................................. 84 General.............................................................. 84 Placing in Storage................................................... 84 Removal From Storage................................................. 84 1.31 TROUBLESHOOTING..................................................... 86 General.............................................................. 86 Engine............................................................... 86 Lubrication System................................................... 87 Electrical System.................................................... 88 Transmission......................................................... 88 Handling............................................................. 88 Brakes............................................................... 88 2. CHASSIS................................................................... 90 2.1 SPECIFICATIONS....................................................... 92 2008 Sportster Specifications........................................ 92 Tires................................................................ 93 2.2 VEHICLE IDENTIFICATION NUMBER (V.I.N.)............................... 95 Vehicle Identification Number (V.I.N.): Sportster Models............. 95 2.3 WHEELS............................................................... 97 General.............................................................. 97 Troubleshooting...................................................... 97 Front Wheel.......................................................... 98 Rear Wheel...........................................................103 Sealed Wheel Bearings................................................107 2.4 WHEEL LACING: 16 INCH RIM............................................111 General..............................................................111 Procedure............................................................111 2.5 WHEEL LACING: 19 INCH RIM............................................114 Procedure............................................................114 2.6 WHEEL LACING: 21 INCH RIM............................................118 General..............................................................118 Procedure............................................................118 2.7 TRUING LACED WHEELS..................................................122 General..............................................................122 Lateral Truing.......................................................122 Radial Truing........................................................123 2.8 CHECKING CAST WHEEL RUNOUT...........................................125 General..............................................................125 Lateral Runout.......................................................125 Radial Runout........................................................125 2.9 FRONT BRAKE MASTER CYLINDER..........................................126 General..............................................................126 Inspection...........................................................126 Removal..............................................................126 Disassembly..........................................................127 Cleaning, Inspection and Repair......................................130 Assembly.............................................................130 Installation.........................................................131 2.10 FRONT BRAKE CALIPER.................................................134 Removal..............................................................134 Disassembly..........................................................135 Cleaning, Inspection and Repair......................................137 Assembly.............................................................138 Lubricating Front Caliper Bolt Pins and Boots........................138 Installing Brake Pads in Caliper.....................................139 Installation.........................................................140 2.11 REAR BRAKE MASTER CYLINDER..........................................142 General..............................................................142 Inspection...........................................................142 Removal..............................................................142 Disassembly..........................................................145 Cleaning, Inspection and Repair......................................146 Assembly.............................................................147 Installation.........................................................149 2.12 REAR BRAKE MASTER CYLINDER RESERVOIR................................150 General..............................................................150 Removal..............................................................150 Installation.........................................................151 2.13 REAR BRAKE CALIPER..................................................152 Removal..............................................................152 Disassembly..........................................................154 Cleaning, Inspection and Repair......................................155 Lubricating Rear Caliper Bolt Pins and Boots.........................155 Assembly.............................................................156 Installation.........................................................157 2.14 BRAKE LINES.........................................................159 Front Brake Line.....................................................159 Rear Brake Line......................................................161 2.15 TIRES...............................................................163 General..............................................................163 Removal..............................................................163 Cleaning, Inspection and Repair......................................163 Installation.........................................................164 Checking Tire Runout.................................................165 Wheel Balancing......................................................165 2.16 LEFT SIDE COVER.....................................................167 General..............................................................167 Opening Left Side Cover..............................................167 Closing Left Side Cover..............................................168 Removing Left Side Cover.............................................168 Installing Left Side Cover...........................................168 2.17 FRONT FORK..........................................................169 General..............................................................169 Removal..............................................................169 Disassembly..........................................................169 Cleaning, Inspection and Repair......................................171 Assembly.............................................................171 Installation.........................................................172 2.18 FORK STEM AND BRACKET ASSEMBLY......................................174 Removal and Disassembly..............................................174 Cleaning, Inspection and Repair......................................174 Assembly and Installation............................................175 2.19 BELT GUARD AND DEBRIS DEFLECTOR.....................................176 Belt Guard...........................................................176 Debris Deflector.....................................................176 2.20 REAR FORK...........................................................177 Removal..............................................................177 Disassembly..........................................................177 Cleaning and Inspection..............................................178 Assembly.............................................................178 Installation.........................................................178 2.21 SHOCK ABSORBERS.....................................................180 General..............................................................180 Removal..............................................................180 Cleaning and Inspection..............................................180 Installation.........................................................180 2.22 STABILIZER LINKS....................................................181 General..............................................................181 Upper Front Stabilizer Link..........................................181 Lower Front Stabilizer Link..........................................181 Rear Stabilizer Link.................................................182 2.23 FRONT ENGINE MOUNT/ISOLATOR.........................................183 Removal..............................................................183 Installation.........................................................184 2.24 REAR ENGINE MOUNT/ISOLATOR..........................................185 Removal..............................................................185 Installation.........................................................186 2.25 THROTTLE CABLES.....................................................188 Removal and Disassembly..............................................188 Cleaning, Inspection and Repair......................................189 Assembly and Installation............................................190 2.26 CLUTCH CONTROL......................................................191 General..............................................................191 Removal and Disassembly..............................................191 Assembly and Installation............................................193 2.27 HANDLEBARS..........................................................195 Removal..............................................................195 Installation.........................................................198 2.28 FRONT FENDER........................................................201 XL Models............................................................201 2.29 REAR FENDER: ALL MODELS EXCEPT XL 1200N.............................202 General..............................................................202 Removal..............................................................202 Installation.........................................................204 2.30 REAR FENDER AND LICENSE PLATE BRACKET: XL 1200N.....................206 General..............................................................206 Removal and Disassembly..............................................206 Assembly and Installation............................................208 2.31 JIFFY STAND.........................................................211 General..............................................................211 Jiffy Stand Interlock: International Models..........................211 Removal..............................................................211 Cleaning and Lubrication.............................................211 Installation.........................................................212 2.32 SEAT................................................................213 General..............................................................213 Seat Removal.........................................................213 Seat Installation....................................................213 2.33 RIDER FOOT CONTROLS: ALL MODELS EQUIPPED WITH MID-MOUNT CONTROLS....215 Right Footrest and Rear Brake Pedal Assembly.........................215 Left Footrest and Shift Lever Assembly...............................215 2.34 RIDER FOOT CONTROLS: ALL MODELS EQUIPPED WITH FORWARD CONTROLS......217 Right Footrest and Rear Brake Pedal Assembly.........................217 Left Footrest and Shift Lever Assembly...............................218 Adjusting Shift Pedal................................................220 2.35 PASSENGER FOOTRESTS.................................................221 General..............................................................221 XL Models............................................................221 2.36 FORK LOCK...........................................................222 Removal..............................................................222 Installation.........................................................222 3. ENGINE....................................................................224 3.1 SPECIFICATIONS.......................................................226 Specifications: 2008 Sportster Models................................226 3.2 ENGINE...............................................................231 General..............................................................231 3.3 OIL PRESSURE.........................................................232 General..............................................................232 Checking Oil Pressure................................................232 3.4 CRANKCASE BREATHING SYSTEM...........................................235 General..............................................................235 3.5 TROUBLESHOOTING......................................................236 Diagnosing Valve Train Noise.........................................236 Compression Test.....................................................236 Cylinder Leakage Test................................................236 Diagnosing Smoking Engine or High Oil Consumption....................237 Adjustment and Testing...............................................237 3.6 ENGINE LUBRICATION SYSTEM............................................238 General..............................................................238 Oil Pump.............................................................238 3.7 HOW TO USE THIS SECTION..............................................243 Typical Symptoms.....................................................243 Top End Repair.......................................................243 Bottom End Repair....................................................243 3.8 TOP END SERVICE......................................................244 Engine in Chassis....................................................244 Engine Removed from Chassis..........................................245 3.9 BOTTOM END SERVICE...................................................246 Engine in Chassis....................................................246 Engine Removed From Chassis..........................................247 3.10 REMOVING ENGINE FROM CHASSIS........................................248 General..............................................................248 Procedure............................................................248 3.11 INSTALLING ENGINE IN CHASSIS........................................253 General..............................................................253 Procedure............................................................253 3.12 TOP END OVERHAUL: DISASSEMBLY.......................................256 General..............................................................256 Stripping Motorcycle for Top End Repair..............................256 Cylinder Heads.......................................................257 Cylinder and Piston..................................................262 3.13 TOP END OVERHAUL: ASSEMBLY..........................................264 General..............................................................264 Piston and Cylinder..................................................264 Push Rods, Covers, and Retainers.....................................265 Cylinder Head........................................................267 Rocker Covers........................................................270 Assembling Motorcycle After Top End Repair...........................272 3.14 BOTTOM END OVERHAUL: DISASSEMBLY....................................273 General..............................................................273 Tappets..............................................................273 Oil Pump.............................................................273 Gearcase Cover and Cam Gears.........................................273 Crankcase............................................................274 3.15 BOTTOM END OVERHAUL: ASSEMBLY.......................................277 Crankcase............................................................277 Cam Gears and Gearcase Cover.........................................282 Tappets..............................................................285 Assembling Top End of Engine.........................................286 3.16 VALVE TAPPETS.......................................................287 General..............................................................287 Removal..............................................................287 Cleaning and Inspection..............................................287 Installation.........................................................287 3.17 GEARCASE COVER AND CAM GEARS........................................288 General..............................................................288 Removal and Disassembly..............................................288 Cleaning, Inspection and Repair......................................288 Bushing Installation.................................................290 Bushing Reaming......................................................291 Assembly and Installation............................................293 3.18 CYLINDER HEAD.......................................................294 Removal..............................................................294 Disassembly..........................................................294 Cleaning and Inspection..............................................296 Replacing Rocker Arm Bushings........................................299 Replacing Valve Guides...............................................300 Refacing Valve Seats.................................................304 Assembly.............................................................305 Installation.........................................................308 3.19 CYLINDER AND PISTON.................................................309 Removal and Disassembly..............................................309 Cleaning, Inspection and Repair......................................309 Connecting Rod Bushings..............................................313 Assembly and Installation............................................316 3.20 CRANKCASE...........................................................317 General..............................................................317 Removal..............................................................317 Disassembly..........................................................318 Fitting Pinion Bearings..............................................320 Lapping Engine Main Bearing Races....................................324 Assembling Crankcase Halves..........................................324 3.21 OIL PUMP............................................................325 General..............................................................325 Removal..............................................................326 Disassembly..........................................................326 Cleaning and Inspection..............................................326 Assembly.............................................................326 Installation.........................................................326 3.22 OIL FILTER MOUNT....................................................328 General..............................................................328 Disassembly..........................................................328 Cleaning and Inspection..............................................328 Assembly.............................................................328 3.23 OIL TANK............................................................329 Oil Hose Routing.....................................................329 Removal..............................................................329 Installation.........................................................332 4. FUEL SYSTEM...............................................................334 4.1 SPECIFICATIONS: FUEL SYSTEM..........................................336 Specifications: 2008 Sportster Models................................336 4.2 ELECTRONIC FUEL INJECTION (EFI)......................................337 Troubleshooting......................................................337 4.3 AIR CLEANER..........................................................338 Removal..............................................................338 Cleaning, Inspection and Repair......................................338 Installation.........................................................339 4.4 FUEL TANK............................................................340 General..............................................................340 Purging and Disconnecting Fuel Supply Hose...........................341 Removing Fuel Tank...................................................341 Cleaning and Inspection..............................................342 Installing Fuel Tank.................................................342 Reconnecting Fuel Hose and Filling Fuel Tank.........................343 Vapor Valve..........................................................343 Console Replacement..................................................344 4.5 THROTTLE POSITION SENSOR (TPS).......................................347 General..............................................................347 Removal..............................................................347 Installation.........................................................347 4.6 ENGINE TEMPERATURE SENSOR (ET).......................................349 General..............................................................349 Removal..............................................................349 Installation.........................................................350 4.7 INDUCTION MODULE.....................................................351 General..............................................................351 Removal..............................................................351 Disassembly..........................................................353 Assembly.............................................................354 Installation.........................................................355 4.8 IDLE AIR CONTROL (IAC)...............................................357 General..............................................................357 Removal..............................................................357 Installation.........................................................358 4.9 TEMPERATURE MANIFOLD ABSOLUTE PRESSURE SENSOR (TMAP).................359 General..............................................................359 Removal..............................................................359 Installation.........................................................359 4.10 OXYGEN SENSOR.......................................................361 General..............................................................361 Removal..............................................................361 Installation.........................................................361 4.11 EXHAUST SYSTEM......................................................363 General..............................................................363 Removal..............................................................364 Installation.........................................................365 4.12 FUEL INJECTORS......................................................367 General..............................................................367 Removal..............................................................367 Installation.........................................................368 4.13 FUEL PUMP...........................................................370 General..............................................................370 Removal..............................................................370 Disassembly..........................................................371 Assembly.............................................................372 Installation.........................................................373 4.14 FUEL PRESSURE TEST..................................................375 General..............................................................375 Testing..............................................................375 4.15 INTAKE LEAK TEST....................................................378 General..............................................................378 Leak Tester..........................................................378 Procedure............................................................378 4.16 EVAPORATIVE EMISSIONS CONTROL (CA MODELS)...........................380 General..............................................................380 Charcoal Canister....................................................380 Vapor Valve..........................................................382 Hose Routing.........................................................383 5. STARTER...................................................................386 5.1 SPECIFICATIONS: STARTER..............................................388 Specifications: 2008 Sportster Models................................388 5.2 STARTER..............................................................389 General..............................................................389 Removal..............................................................389 Installation.........................................................389 Testing..............................................................389 Field Coil Assembly..................................................393 Drive Assembly.......................................................394 5.3 STARTER SOLENOID.....................................................395 Solenoid Assembly....................................................395 Solenoid Plunger.....................................................395 Solenoid Contacts....................................................395 6. DRIVE/TRANSMISSION........................................................398 6.1 SPECIFICATIONS: DRIVE................................................400 2008 Sportster Specifications........................................400 6.2 PRIMARY CHAIN ADJUSTER...............................................401 General..............................................................401 Removal..............................................................401 Installation.........................................................403 6.3 CLUTCH RELEASE MECHANISM.............................................406 Removal and Disassembly..............................................406 Cleaning, Inspection and Repair......................................407 Assembly and Installation............................................407 6.4 PRIMARY DRIVE AND CLUTCH.............................................409 General..............................................................409 Removal..............................................................411 Disassembly..........................................................411 Inspection and Repair................................................412 Assembly.............................................................413 Installation.........................................................414 6.5 SECONDARY DRIVE BELT.................................................416 Removal..............................................................416 Installation.........................................................417 6.6 TRANSMISSION.........................................................419 General..............................................................419 6.7 CASE DISASSEMBLY FOR TRANSMISSION REMOVAL............................420 General..............................................................420 Engine Removal and Disassembly.......................................420 6.8 TRANSMISSION REMOVAL AND DISASSEMBLY.................................424 Transmission Removal From Left Crankcase.............................424 Mainshaft/Countershaft...............................................427 Mainshaft Disassembly................................................428 Countershaft Disassembly.............................................429 6.9 TRANSMISSION ASSEMBLY................................................431 Mainshaft Assembly...................................................431 Countershaft Assembly................................................431 6.10 MAIN DRIVE GEAR AND BEARING.........................................433 General..............................................................433 Removal..............................................................434 Disassembly..........................................................435 Assembly.............................................................435 Installation.........................................................436 6.11 TRANSMISSION RIGHT CASE BEARINGS....................................442 Removal..............................................................442 Installation.........................................................442 6.12 TRANSMISSION LEFT CASE BEARINGS.....................................443 Removal..............................................................443 Installation.........................................................443 6.13 TRANSMISSION INSTALLATION...........................................444 General..............................................................444 Installation.........................................................444 Shifter Forks and Drum Assembly......................................445 Assembling Crankcases................................................446 Shifter Shaft Installation...........................................447 6.14 TRANSMISSION SPROCKET...............................................449 Removal..............................................................449 Installation.........................................................450 7. ELECTRICAL................................................................452 7.1 SPECIFICATIONS: ELECTRICAL...........................................454 Specifications: 2008 Sportster Models................................454 7.2 VOLTAGE REGULATOR....................................................455 General..............................................................455 Removal..............................................................455 Installation.........................................................456 7.3 FUSES AND RELAYS.....................................................458 General..............................................................458 Replacing Fuses......................................................458 Replacing Relays.....................................................458 7.4 MAXI-FUSE HOLDER.....................................................459 General..............................................................459 Replacement..........................................................459 7.5 SPEEDOMETER: ALL SINGLE GAUGE MODELS EXCEPT XL 883C/XL 1200C.........460 Removal..............................................................460 Installation.........................................................460 7.6 SPEEDOMETER AND TACHOMETER: ALL DUAL GAUGE MODELS....................462 Speedometer Removal..................................................462 Trip Odometer Reset Switch Replacement...............................462 Tachometer Removal...................................................462 Speedometer Installation.............................................463 Tachometer Installation..............................................464 7.7 SPEEDOMETER: XL 883C/XL 1200C........................................465 Removal..............................................................465 Installation.........................................................466 7.8 TURN SIGNAL AND SECURITY MODULE (TSM/TSSM/HFSM)......................467 General..............................................................467 Testing..............................................................467 Removal..............................................................467 Installation.........................................................468 7.9 BATTERY CABLES.......................................................469 Removal..............................................................469 Installation.........................................................470 7.10 BATTERY TRAY........................................................471 General..............................................................471 Removal..............................................................471 Installation.........................................................472 7.11 IGNITION SYSTEM.....................................................473 General..............................................................473 Troubleshooting......................................................473 7.12 IGNITION AND LIGHT SWITCH...........................................475 General..............................................................475 Removal..............................................................475 Installation.........................................................475 7.13 ELECTRONIC CONTROL MODULE (ECM).....................................477 General..............................................................477 Removal..............................................................477 Installation.........................................................477 7.14 SPARK PLUG CABLES...................................................478 General..............................................................478 Removal..............................................................478 Installation.........................................................479 7.15 IGNITION COIL.......................................................480 General..............................................................480 Troubleshooting......................................................480 Removal..............................................................480 Installation.........................................................481 7.16 CHARGING SYSTEM.....................................................482 General..............................................................482 Alternator...........................................................482 Voltage Regulator....................................................482 7.17 HEADLAMP............................................................483 Replacement: XL 883C/XL 1200C........................................483 Replacement: All Models Except XL 883C/XL 1200C......................485 7.18 INDICATOR LAMP MODULE...............................................487 General..............................................................487 Preliminary Disassembly: All Models..................................487 Replacement: XL 1200L and XL 1200N...................................487 Replacement: XL 883C and XL 1200C....................................488 Replacement: All Other Models........................................488 Reassembling Vehicle: All Models.....................................489 7.19 TAIL LAMP: ALL MODELS EXCEPT XL 1200N...............................490 General..............................................................490 Bulb Replacement.....................................................490 Base Replacement.....................................................490 7.20 TURN SIGNALS........................................................493 General..............................................................493 Bulb Replacement.....................................................493 Front Housing Replacement............................................493 Rear Housing Replacement.............................................494 7.21 LICENSE PLATE LAMP MODULE: XL 1200N.................................499 General..............................................................499 Removal (Domestic Only)..............................................499 Installation (Domestic Only).........................................499 Removal (HDI Only)...................................................500 Installation (HDI Only)..............................................502 7.22 REAR LIGHTING CONVERTER MODULE: XL 1200N (DOMESTIC ONLY)............504 General..............................................................504 Removal..............................................................504 Installation.........................................................505 7.23 REAR STOP LAMP SWITCH...............................................506 General..............................................................506 Replacement..........................................................506 7.24 CRANK POSITION SENSOR (CKP).........................................507 General..............................................................507 Removal..............................................................507 Installation.........................................................507 7.25 ALTERNATOR..........................................................508 Removal and Disassembly..............................................508 Cleaning and Inspection..............................................509 Assembly and Installation............................................509 7.26 VEHICLE SPEED SENSOR (VSS)..........................................511 General..............................................................511 Removal..............................................................511 Installation.........................................................511 7.27 NEUTRAL SWITCH......................................................512 General..............................................................512 Replacement..........................................................512 7.28 MAIN WIRING HARNESS.................................................514 General..............................................................514 Removal..............................................................514 Installation.........................................................516 7.29 ELECTRICAL CADDIES..................................................520 General..............................................................520 Voltage Regulator Caddy..............................................520 Wire Harness Caddy...................................................520 7.30 JIFFY STAND SWITCH: INTERNATIONAL MODELS............................524 General..............................................................524 Removal..............................................................524 Installation.........................................................525 7.31 OPTIONAL SECURITY SIREN.............................................526 General..............................................................526 Removal..............................................................526 Disassembly..........................................................526 Battery Replacement..................................................527 Assembly.............................................................527 Installation.........................................................528 7.32 OIL PRESSURE SWITCH.................................................529 General..............................................................529 Removal..............................................................529 Installation.........................................................529 7.33 HORN................................................................530 Troubleshooting......................................................530 Voltage Test.........................................................530 Replacement: Models with Front Mounted Horn..........................530 Replacement: Models with Side Mounted Horn...........................530 7.34 MAXI-FUSE...........................................................532 General..............................................................532 Removal..............................................................532 Installation.........................................................532 7.35 HANDLEBAR SWITCH ASSEMBLIES.........................................533 General..............................................................533 Repair Procedures....................................................533 Connectors...........................................................534 7.36 RIGHT HANDLEBAR SWITCHES............................................535 Removal..............................................................535 Disassembly..........................................................535 Switch Repair/Replacement............................................536 Assembly.............................................................537 Installation.........................................................538 7.37 LEFT HANDLEBAR SWITCHES.............................................541 Removal..............................................................541 Disassembly..........................................................541 Switch Repair/Replacement............................................541 Assembly.............................................................542 Installation.........................................................543 A. APPENDIX A CONNECTOR REPAIR...............................................546 A.1 AMP 1-PLACE CONNECTORS...............................................548 AMP 1-Place Connector Repair.........................................548 A.2 AMP MULTILOCK CONNECTORS.............................................550 AMP Multilock Connector Repair.......................................550 A.3 AUTOFUSE ELECTRICAL CONNECTORS.......................................554 Autofuse Connector Repair............................................554 A.4 DELPHI CONNECTORS....................................................555 Delphi Connector Repair..............................................555 A.5 DELPHI MAXI FUSE HOUSING.............................................557 Delphi Maxi-Fuse Housing Repair......................................557 A.6 DEUTSCH ELECTRICAL CONNECTORS........................................559 Deutsch Connector Repair.............................................559 A.7 DEUTSCH STANDARD TERMINAL REPAIR.....................................563 Deutsch Standard Terminal Crimps.....................................563 A.8 DEUTSCH SOLID BARREL MINI TERMINAL REPAIR............................564 Deutsch Solid Barrel Terminal Crimps.................................564 A.9 DEUTSCH MINI TERMINAL REPAIR.........................................566 Deutsch Mini Terminal Crimps.........................................566 A.10 MOLEX CONNECTORS....................................................567 Molex Connector Repair...............................................567 Crimp Terminal to Lead...............................................568 A.11 PACKARD 150 METRI-PACK CONNECTORS...................................571 150 Metri-Pack Connector Repair......................................571 A.12 PACKARD 280 METRI-PACK RELAY AND FUSE BLOCK CONNECTORS..............573 Fuse Block Repair....................................................573 A.13 PACKARD 480 METRI-PACK CONNECTORS...................................574 480 Metri-Pack Connector Repair......................................574 A.14 PACKARD 630 METRI-PACK CONNECTORS...................................575 630 Metri-Pack Connector Repair......................................575 A.15 PACKARD METRI-PACK TERMINALS........................................576 Metri-Pack Terminal Crimps...........................................576 A.16 PACKARD ECM CONNECTOR...............................................578 Packard 100W Connector Repair........................................578 A.17 PACKARD MICRO-64 CONNECTORS.........................................580 Packard Micro-64 Connector Repair....................................580 A.18 SEALED SPLICE CONNECTORS............................................583 Sealed Splice Connector Repair.......................................583 B. APPENDIX B WIRING.........................................................586 B.1 CONNECTORS...........................................................588 Connector Locations..................................................588 B.2 WIRING DIAGRAMS......................................................590 Wiring Diagram Information...........................................590 2008 Sportster Wiring Diagrams.......................................591 C. APPENDIX C CONVERSIONS....................................................612 C.1 METRIC CONVERSION....................................................614 Conversion Table.....................................................614 C.2 FLUID CONVERSIONS....................................................615 United States System.................................................615 Metric System........................................................615 British Imperial System..............................................615 C.3 TORQUE CONVERSIONS...................................................616 United States System.................................................616 Metric System........................................................616 D. APPENDIX D COMPENSATING SPROCKET..........................................618 D.1 COMPENSATING SPROCKET................................................620 General..............................................................620 Removal and Disassembly..............................................620 Cleaning, Inspection and Repair......................................620 Sprocket Bearing Replacement.........................................620 Assembly and Installation............................................621 E. APPENDIX E GLOSSARY.......................................................624 E.1 GLOSSARY.............................................................626 Acronyms and Abbreviations...........................................626 TOOLS........................................................................628 TORQUE VALUES................................................................634 INDEX........................................................................648
2008 HARLEY DAVIDSON SPORTSTER MODELS SERVICE MANUAL – PDF DOWNLOAD:
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
S.V
