2010 Harley-Davidson Sportster Models Service Manual – PDF DOWNLOAD

Description

2010 Harley-Davidson Sportster Models Service Manual – PDF DOWNLOAD

DESCRIPTION:

2010 Harley-Davidson Sportster Models Service Manual – PDF DOWNLOAD

ABOUT THIS MANUAL
GENERAL
This service manual has been prepared with the following purposes in mind:
• To acquaint the user with the construction of the Harley- Davidson product and assist in the performance of basic maintenance and repair.
• To introduce the professional Harley-Davidson technician to 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 Drive/Transmission
6 Electrical
A Appendix A Connector Repair
B Appendix B Wiring
C Appendix C Compensating Sprocket
D Appendix D Conversions
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. Chapters and topics in this manual are sequentially numbered for easy navigation. For example, a cross-reference shown as 2.2 SPECIFICATIONS refers to chapter 2 CHASSIS, heading 2.2 SPECIFICATIONS.
• For quick and easy reference, all pages contain a chapter number followed by a page number. For example, page 3-5 refers to page 5 in Chapter 3. A number of acronyms and abbreviations are used in this document. See the E.1 GLOSSARY for a list of acronyms, abbreviations and definitions.

TABLE OF CONTENTS:

2010 Harley-Davidson Sportster Models Service Manual – PDF DOWNLOAD

2010 HARLEY SPORTSTER MODELS COVER PAGE....................................  1
++CHAPTER 0NE MAINTENANCE.................................................. 18
Maintenance Schedules...................................................... 28
Engine Oil And Filter...................................................... 32
Brakes Inspection and Maintenance.......................................... 36
Tires And Wheels Inspection and Maintenace................................. 54
Primary Chain.............................................................. 57
Clutch..................................................................... 59
Trans Lubricant............................................................ 61
Drive Belst and Sprockets.................................................. 63
Wheel Alignment............................................................ 68
Battery Maintenance........................................................ 70
Spark Plugs................................................................ 76
Steering Head Bearings..................................................... 78
Shock Absorber Adjustment.................................................. 80
Air Cleaner:XL Models...................................................... 83
Air Cleaner : XR Models.................................................... 85
Throttle Control........................................................... 89
Fuel Supply Filter......................................................... 90
Engine Mounts and Stabilizer Links......................................... 91
Headlamp Alignment......................................................... 92
Troubleshooting............................................................ 98
++CHAPTER TWO CHASSIS......................................................101
Wheels.....................................................................115
Front Brake Master Cylinder................................................141
Front Brake Caliper: Xl Models.............................................150
XR Models..................................................................158
Rear Brake Master Cyliner: XL Models.......................................163
XR Models..................................................................171
Rear Brake Caliper: XL Models..............................................179
Front Fork: XR Models......................................................188
Rear Brake Caliper: XR Models..............................................198
brake lines................................................................204
Left Side Cover............................................................214
Front Fork : XL Models.....................................................217
XR Models..................................................................223
Belt Guard and Debris Deflector............................................242
Rear Fork..................................................................244
Shock Absorbers............................................................247
Throttle Cables: All Models................................................256
Clutch Control.............................................................260
Hadle Bars-Triple Trees....................................................264
Front Fender: XL Models....................................................270
Rear Fender: All XL Models Except XL 883N/XL 1200N.........................271
Rear Fender : XL 883N/XL 1200N.............................................275
Rear Fender: XR Models.....................................................280
Jiffy Stand................................................................281
Seat:XL Models.............................................................283
XR Models..................................................................285
Foot Controls..............................................................287
++CHAPTER THREE ENGINE.....................................................300
Oil Pressure General Troubleshooting.......................................312
Crank Case Breathing System................................................315
Engine Lubrication System..................................................320
Top and Bottom End Repair..................................................333
Cooling Systems............................................................352
Top End Overhaul Disassembly and Reassembly................................358
BottomEnd Overhaual Disassembley and reassembly............................378
Cylinder and Piston........................................................417
Crankcase..................................................................425
Oil Pump: Xl and XR Models.................................................433
Oil Filter Mount...........................................................440
++CHAPTER FOUR FUEL SYSTEMS................................................447
Fuel Tank: XL Models.......................................................455
Fuel Tank :XR Models.......................................................462
Throttle Postiion Sensor...................................................467
Engine Temperature Sensor..................................................471
Induction Modules..........................................................473
Idle Air Control...........................................................484
Temperature Manifold Absolute Pressure Sensor..............................488
Oxygen Sensor..............................................................492
Exhaust Systems............................................................494
Fuel Injectors.............................................................500
Fuel Pump..................................................................503
Evaporative Emission Control ( California Models ).........................512
++CHAPTER FIVE DRIVE/TRANSMISSIONS.........................................518
Primary Chain Adjuster.....................................................522
Clutch Release Mechanism...................................................527
Primary Drive and Clutch...................................................530
Transmission...............................................................552
Case Disassembly For Transmission Removal..................................553
Transmission Removal and Disassembly.......................................557
Transmission Assembly......................................................564
Main Drive Gear and Bearing................................................566
Transmission Right Case Bearings...........................................575
Transmission Left Case bearings............................................576
Transmission Installation..................................................577
Transmission Sprocket......................................................582
++CHAPTER 6 ELECTRICAL.....................................................585
Voltage Regulator..........................................................590
Fuses and Relays...........................................................594
Speedometers...............................................................596
Electronic Control Module..................................................603
Turn Signal Security Module (TSM/TSSM/HFSM)................................605
Battery Cables.............................................................607
Starter....................................................................611
Ignition...................................................................618
Spark Plug Cables..........................................................620
Ignition Coil..............................................................623
Headlamp...................................................................626
Indicator Lamp and Tail lamps..............................................629
Turn Signals...............................................................635
Rear Stop Lamp Switch......................................................649
Crank Position Sensor......................................................650
Alternator.................................................................651
Vehicale Speed Sensor (VSS)................................................654
Neutral Indicator Switch...................................................655
Main Wiring Harness........................................................657
Electrical Caddies and all cubbie holes they like to hide the wiring in....662
Jiffy Stand Switch International Models....................................668
Optional Security Siren....................................................670
Oil Pressure Switch........................................................673
Beep Beep..................................................................675
Main Fuse..................................................................677
Handlebar Switch Assemblies................................................678
TSSM/HFSM Maintenance......................................................690
Personal Identification Number (PIN).......................................692
H-DSSS Actuation...........................................................694
TSM/HFSM:Password Learn....................................................695
++APPENDIX A CONNECTOR REPAIR..............................................698
+++APPENDIX B WIRING.......................................................733
Wiring Diagrams............................................................736
+++APPENDIX C CONVERSIONS..................................................771
+++APPENDIX D COMPENSATING SPROCKET........................................776
+++APPENDIX E GLOSSARY.....................................................781
+++TOOLS USED IN THIS MANUAL...............................................786
+++TORQUE VALUES...........................................................794
+++INDEX...................................................................816
***THE END.................................................................825

2010 HARLEY-DAVIDSON SPORTSTER MODELS SERVICE MANUAL – PDF DOWNLOAD:

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