2011 Harley Davidson Sportster Service Manual – PDF DOWNLOAD

Description

2011 Harley Davidson Sportster Service Manual – PDF DOWNLOAD

DESCRIPTION:

2011 Harley Davidson Sportster Service Manual – PDF DOWNLOAD

ABOUT THIS MANUAL
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.

• 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:

2011 Harley Davidson Sportster Service Manual – PDF DOWNLOAD

2011 SPORTSTER SERVICE MANUAL #99484-11A.................................................  1
ABOUT THIS MANUAL........................................................................  8
	GENERAL..............................................................................  8
	HOW TO USE YOUR SERVICE MANUAL.......................................................  8
	PREPARATION FOR SERVICE..............................................................  8
	SERVICE BULLETINS....................................................................  8
	USE GENUINE REPLACEMENT PARTS........................................................  8
	WARNINGS AND CAUTIONS................................................................  8
	PRODUCT REFERENCES...................................................................  9
	PRODUCT REGISTERED MARKS.............................................................  9
	H-D MICHIGAN, INC. TRADEMARK INFORMATION.............................................  9
	CONTENTS.............................................................................  9
TABLE OF CONTENTS........................................................................ 10
1. MAINTENANCE........................................................................... 24
	FASTENER TORQUE VALUES............................................................... 26
	GENERAL.............................................................................. 28
	FUEL AND OIL......................................................................... 32
	BULB REQUIREMENTS.................................................................... 34
	MAINTENANCE SCHEDULE................................................................. 35
	ENGINE OIL AND FILTER................................................................ 39
	BRAKES............................................................................... 43
	BRAKE PADS AND DISCS: XL MODELS...................................................... 45
	BRAKE PADS AND DISCS: XR 1200X....................................................... 52
	TIRES AND WHEELS..................................................................... 57
	PRIMARY CHAIN........................................................................ 61
	CLUTCH............................................................................... 62
	TRANSMISSION LUBRICANT............................................................... 64
	DRIVE BELT AND SPROCKETS............................................................. 66
	WHEEL ALIGNMENT...................................................................... 70
	BATTERY MAINTENANCE.................................................................. 72
	SPARK PLUGS.......................................................................... 78
	STEERING HEAD BEARINGS............................................................... 80
	SUSPENSION ADJUSTMENTS............................................................... 81
	CABLE AND CHASSIS LUBRICATION........................................................ 85
	AIR FILTER........................................................................... 86
	EXHAUST SYSTEM....................................................................... 90
	THROTTLE CONTROL..................................................................... 91
	FUEL SUPPLY FILTER................................................................... 92
	ENGINE MOUNTS AND STABILIZER LINKS................................................... 93
	HEADLAMP ALIGNMENT................................................................... 94
	CRITICAL FASTENERS................................................................... 96
	STORAGE.............................................................................. 98
	TROUBLESHOOTING......................................................................100
2. CHASSIS...............................................................................104
	FASTENER TORQUE VALUES...............................................................106
	SPECIFICATIONS.......................................................................114
	VEHICLE IDENTIFICATION NUMBER (VIN)..................................................118
	WHEELS...............................................................................120
	WHEEL LACING.........................................................................133
	CHECKING AND TRUING WHEELS...........................................................137
	FRONT BRAKE MASTER CYLINDER..........................................................141
	FRONT BRAKE CALIPER: XL MODELS.......................................................150
	FRONT BRAKE CALIPER: XR 1200X........................................................158
	REAR BRAKE MASTER CYLINDER: XL MODELS................................................163
	REAR BRAKE MASTER CYLINDER: XR 1200X.................................................170
	REAR BRAKE MASTER CYLINDER RESERVOIR.................................................175
	REAR BRAKE CALIPER: XL MODELS........................................................178
	REAR BRAKE CALIPER: XR 1200X.........................................................185
	BRAKE LINES..........................................................................191
	BLEEDING BRAKES......................................................................197
	TIRES................................................................................201
	LEFT SIDE COVER......................................................................204
	FRONT FORK: XL MODELS................................................................206
	FRONT FORK: XR 1200X.................................................................213
	FORK STEM AND BRACKET ASSEMBLY.......................................................219
	BELT GUARD AND DEBRIS DEFLECTOR......................................................221
	REAR FORK............................................................................223
	SHOCK ABSORBERS......................................................................226
	STABILIZER LINKS.....................................................................228
	FRONT ENGINE MOUNT/ISOLATOR..........................................................230
	REAR ENGINE MOUNT/ISOLATOR...........................................................232
	THROTTLE CABLES: ALL MODELS..........................................................235
	CLUTCH CONTROL.......................................................................239
	HANDLEBAR............................................................................244
	FRONT FENDER.........................................................................248
	REAR FENDER: ALL XL MODELS EXCEPT XL 883N, XL 1200N/X................................249
	REAR FENDER AND LICENSE PLATE BRACKET: XL 883N, XL 1200N/X...........................255
	REAR FENDER: XR 1200X................................................................259
	JIFFY STAND..........................................................................260
	SEAT.................................................................................263
	RIDER FOOT CONTROLS: XL MID-MOUNT CONTROLS...........................................266
	RIDER FOOT CONTROLS: XL FORWARD CONTROLS.............................................268
	RIDER FOOT CONTROLS: XR 1200X........................................................272
	PASSENGER FOOTRESTS..................................................................274
	FORK LOCK............................................................................275
3. ENGINE................................................................................278
	FASTENER TORQUE VALUES...............................................................280
	SPECIFICATIONS.......................................................................284
	ENGINE...............................................................................289
	OIL PRESSURE.........................................................................290
	CRANKCASE BREATHING SYSTEM...........................................................293
	TROUBLESHOOTING......................................................................294
	ENGINE LUBRICATION SYSTEM............................................................296
	HOW TO USE THIS SECTION..............................................................306
	TOP END SERVICE......................................................................307
	BOTTOM END SERVICE...................................................................309
	REMOVING ENGINE FROM CHASSIS.........................................................311
	INSTALLING ENGINE IN CHASSIS.........................................................320
	PRECISION COOLING SYSTEM: XR 1200X...................................................325
	TOP END OVERHAUL: DISASSEMBLY........................................................331
	CYLINDER HEAD........................................................................338
	CYLINDER AND PISTON..................................................................350
	TOP END OVERHAUL: ASSEMBLY...........................................................358
	BOTTOM END OVERHAUL: DISASSEMBLY.....................................................365
	GEARCASE.............................................................................370
	CRANKCASE............................................................................374
	OIL PUMP: XL MODELS..................................................................381
	OIL PUMP: XR 1200X...................................................................384
	BOTTOM END OVERHAUL: ASSEMBLY........................................................388
	OIL FILTER MOUNT.....................................................................400
	OIL TANK.............................................................................401
4. FUEL SYSTEM...........................................................................406
	FASTENER TORQUE VALUES...............................................................408
	SPECIFICATIONS: FUEL SYSTEM..........................................................411
	AIR CLEANER: XL MODELS...............................................................412
	AIR BOX: XR 1200X....................................................................414
	FUEL TANK: XL MODELS.................................................................415
	FUEL TANK: XR 1200X..................................................................419
	THROTTLE POSITION (TP) SENSOR........................................................424
	ENGINE TEMPERATURE {ET) SENSOR.......................................................427
	INDUCTION MODULE: XL MODELS..........................................................429
	INDUCTION MODULE: XR 1200X...........................................................435
	IDLE AIR CONTROL (IAC)...............................................................439
	TEMPERATURE MANIFOLD ABSOLUTE PRESSURE (TMAP) SENSOR.................................443
	OXYGEN SENSOR........................................................................446
	EXHAUST SYSTEM: XL MODELS............................................................448
	EXHAUST SYSTEM: XR 1200X.............................................................452
	FUEL INJECTORS.......................................................................454
	FUEL PUMP............................................................................457
	FUEL PRESSURE TEST...................................................................462
	INTAKE LEAK TEST.....................................................................464
	EVAPORATIVE EMISSIONS CONTROL........................................................466
5. DRIVE/TRANSMISSION....................................................................472
	FASTENER TORQUE VALUES...............................................................474
	SPECIFICATIONS: DRIVE................................................................476
	PRIMARY COVER........................................................................477
	PRIMARY DRIVE AND CLUTCH: XL MODELS..................................................481
	PRIMARY DRIVE AND CLUTCH: XR 1200X...................................................488
	DRIVE BELT...........................................................................497
	TRANSMISSION.........................................................................501
	CASE DISASSEMBLY FOR TRANSMISSION REMOVAL............................................502
	TRANSMISSION REMOVAL AND DISASSEMBLY.................................................505
	TRANSMISSION ASSEMBLY................................................................509
	MAIN DRIVE GEAR AND BEARING..........................................................511
	TRANSMISSION RIGHT CASE BEARINGS.....................................................521
	TRANSMISSION LEFT CASE BEARINGS......................................................522
	TRANSMISSION INSTALLATION............................................................523
	TRANSMISSION SPROCKET................................................................528
6. ELECTRICAL............................................................................532
	FASTENER TORQUE VALUES...............................................................534
	SPECIFICATIONS: ELECTRICAL...........................................................537
	VOLTAGE REGULATOR....................................................................538
	FUSES AND RELAYS.....................................................................542
	MAIN FUSE HOLDER.....................................................................543
	SPEEDOMETER: XL MODELS...............................................................544
	SPEEDOMETER AND TACHOMETER: XR 1200X.................................................547
	ELECTRONIC CONTROL MODULE (ECM)......................................................549
	TURN SIGNAL AND SECURITY MODULE {TSM/TSSM/HFSM)......................................551
	BATTERY CABLES.......................................................................553
	BATTERY TRAY.........................................................................555
	STARTER..............................................................................557
	IGNITION AND LIGHT SWITCH............................................................561
	SPARK PLUG CABLES....................................................................563
	IGNITION COIL........................................................................566
	HEADLAMP.............................................................................569
	INDICATOR LAMP MODULE................................................................572
	TAIL LAMP: ALL MODELS EXCEPT XL 883N/XL 1200N/X......................................575
	LICENSE PLATE LAMP MODULE: XL 883N, XL 1200N/X.......................................579
	FRONT TURN SIGNALS...................................................................584
	REAR TURN SIGNALS....................................................................587
	REAR LIGHTING CONVERTER MODULE: XL 883N, XL 1200N/X (DOM)............................594
	REAR STOP LAMP SWITCH................................................................597
	CRANK POSITION SENSOR (CKP)..........................................................599
	ALTERNATOR...........................................................................600
	VEHICLE SPEED SENSOR (VSS)...........................................................603
	NEUTRAL INDICATOR SWITCH.............................................................604
	MAIN WIRING HARNESS..................................................................606
	ELECTRICAL CADDIES...................................................................611
	JIFFY STAND SWITCH: INTERNATIONAL MODELS.............................................617
	SECURITY SYSTEM/OPTIONAL SIREN.......................................................619
	OIL PRESSURE SWITCH..................................................................622
	HORN.................................................................................624
	MAIN FUSE............................................................................625
	HANDLEBAR SWITCH ASSEMBLIES..........................................................626
	RIGHT HANDLEBAR SWITCHES.............................................................628
	LEFT HANDLEBAR SWITCHES..............................................................634
	PERSONAL IDENTIFICATION NUMBER (PIN).................................................638
	H-DSSS ACTUATION.....................................................................640
	TSM/HFSM: PASSWORD LEARN.............................................................641
APPENDIX A - CONNECTOR REPAIR............................................................644
	AUTOFUSE UNSEALED ELECTRICAL CONNECTORS..............................................646
	DELPHI 100W MICRO-PACK SEALED CONNECTOR..............................................647
	DELPHI 150 METRl-PACK SEALED CONNECTORS..............................................649
	DELPHI 280 METRl-PACK UNSEALED CONNECTORS............................................651
	DELPHI 480 METRl-PACK UNSEALED CONNECTORS............................................652
	DELPHI 630 METRl-PACK UNSEALED CONNECTORS............................................653
	DELPHI 800 METRl-PACK SEALED MAIN FUSE HOUSING.......................................654
	DELPHI METRl-PACK TERMINAL REPAIR....................................................655
	DELPHI MICRO 64 SEALED CONNECTORS....................................................657
	DELPHI GT 150 SEALED CONNECTORS......................................................660
	DELPHI GT 280 SEALED 73-TERMINAL ECM CONNECTOR.......................................662
	DEUTSCH DT SEALED CONNECTORS.........................................................664
	DEUTSCH DT SEALED TERMINAL REPAIR....................................................668
	DEUTSCH DTM SEALED MINI TERMINAL REPAIR..............................................669
	DEUTSCH DTM SEALED SOLID BARREL MINI TERMINAL REPAIR.................................670
	JAE MX19 SEALED CONNECTORS...........................................................672
	MOLEX CMC SEALED CONNECTORS..........................................................673
	MOLEX MX 150 SEALED CONNECTORS.......................................................675
	TYCO 070 MULTILOCK UNSEALED CONNECTOR................................................679
	SEALED SPLICE CONNECTORS.............................................................683
APPENDIX B - WIRING......................................................................686
	CONNECTORS...........................................................................688
	WIRING DIAGRAMS......................................................................691
	WIRING DIAGRAM LIST..................................................................693
		Figure B-3. Battery Power........................................................694
		Figure B-4. Ignition Power.......................................................695
		Figure B-5. Accessory Power......................................................696
		Figure B-6. Chassis Grounds......................................................697
		Figure B-7. Main Harness: 2011 Sportster.........................................699
		Figure B-8. Engine Management: 2011 Sportster....................................701
		Figure B-9. Starting and Charging Circuit: 2011 Sportster........................703
		Figure B-10. Lighting (1 of 2): 2011 Sportster...................................705
		Figure B-11. Lighting (2 of 2): 2011 Sportster...................................707
		Figure B-12. Instrument, Indicators, and Hand Controls: 2011 Sportster...........709
		Figure B-13. Security Circuit: 2011 Sportster....................................711
		Figure B-14. Security Circuit with Anti-Theft Tracking Module: 2011 Sportster....713
APPENDIX C - CONVERSIONS.................................................................716
	METRIC CONVERSION....................................................................718
	FLUID CONVERSIONS....................................................................719
	TORQUE CONVERSIONS...................................................................720
APPENDIX D - COMPENSATING SPROCKET.......................................................722
	COMPENSATING SPROCKET................................................................724
APPENDIX E - GLOSSARY....................................................................728
	GLOSSARY.............................................................................730
TOOLS....................................................................................734
TORQUE VALUES............................................................................742
INDEX....................................................................................764

2011 HARLEY DAVIDSON SPORTSTER SERVICE MANUAL – PDF DOWNLOAD:

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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]

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