2018 Harley Davidson Sportster Models Service Manual – PDF DOWNLOAD

Description

2018 Harley Davidson Sportster Models Service Manual – PDF DOWNLOAD

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

2018 Harley Davidson Sportster Models Service Manual – PDF DOWNLOAD

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.

Refer to the table below for the content layout of this manual:

Generated list of chapters

• 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:

2018 Harley Davidson Sportster Models Service Manual – PDF DOWNLOAD

Foreword
Foreword
General
How To Use Your Manual
Preparation For Service
Service Bulletins
Use Genuine Replacement Parts
Warnings and Cautions
Product References
Product Registered Marks
H-D U.S.A., LLC Trademark Information
Contents
Maintenance
FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter
General
Servicing a New Motorcycle
Safe Operating Maintenance
Shop Practices
Disposal and Recycling
Repair and Replacement Procedures
Cleaning
Tool Safety
FUEL AND OIL
Fuel
Gasoline Blends
Engine Lubrication
Low Temperature Lubrication
MAINTENANCE SCHEDULE
General +[ENG, WORLD]
ENGINE OIL AND FILTER
Checking and Adding Oil
Changing Oil and Filter
AIR CLEANER AND EXHAUST SYSTEM
Air Cleaner
Cleaning Filter Element
Check Exhaust System Leakage
TIRES AND WHEELS
Air Pressure
Tire Replacement
Specified Tires
Wheel Bearings
Wheel Spokes
PRIMARY CHAIN
Free Play Adjustment
TRANSMISSION LUBRICANT
Transmission Lubrication
CLUTCH
Adjustment
BRAKES
General
Inspect Brake Lines
Fluid Level
Troubleshooting
BRAKE PADS AND DISCS
Inspection
Brake Pad Replacement: Front
Brake Pad Replacement: Rear
DRIVE BELT AND SPROCKETS
General
Cleaning
Inspection
Check Drive Belt Deflection
Adjustment
THROTTLE CONTROL
Cable Inspection and Lubrication
Cable Adjustment
CABLE AND CHASSIS LUBRICATION
General
Cables and Hand Levers
Jiffy Stand
STEERING HEAD BEARINGS
SPARK PLUGS
Remove
Inspect
Clean
Installation
Inspect Spark Plug Cables
STEERING HEAD BEARINGS
Fall-Away
Lubrication
SUSPENSION ADJUSTMENTS
Shock Absorber Preload: All except XL1200T
Shock Absorber Preload: XL1200T
ENGINE MOUNTS AND STABILIZER LINKS
Inspection
BATTERY MAINTENANCE
General
Disconnection and Removal
Cleaning and Inspection
Voltage Test
Charging Battery
Installation and Connection
Storage
WHEEL ALIGNMENT
Wheel Alignment
HEADLAMP ALIGNMENT
Headlamp Alignment
Headlamp Adjustment
STORAGE
Placing in Storage
Removal From Storage
TROUBLESHOOTING
General
Engine
Lubrication System
Electrical System
Transmission
Handling
BRAKES
Chassis
FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter
Specifications
Tables
Vehicle Identification Number (VIN)
Vehicle Identification Number (VIN)
Tires
Remove
Clean, Inspect and Repair
Installation
Check Tire Runout
Balance Wheel
WHEELS
General
Wheel Bearing End Play
FRONT WHEEL
REAR WHEEL
SEALED WHEEL BEARINGS
Wheel Lacing
Wheel Lacing: Angle Flange Hub
Wheel Lacing: Straight Flange Hub, Single Hole Circle
CHECKING AND TRUING WHEELS
Cast Wheel Runout
Laced Wheel Rim Offset
True Laced Wheels
FRONT BRAKE MASTER CYLINDER AND RESERVOIR
Inspection
Removal
Front Brake Lever
Front Master Cylinder Reservoir Cover
Front Master Cylinder
Installation
FRONT BRAKE CALIPERS
Removal
Disassembly
Cleaning and Inspection
Assembly
Installation
REAR BRAKE MASTER CYLINDER AND RESERVOIR
Inspection
Removal
Cover
Master Cylinder Rebuild Kit
Master Cylinder Mounting Bracket
Installation
REAR BRAKE CALIPER
Removal
Disassembly
Cleaning and Inspection
Installation
Assembly
Brake Lines
Front Brake Line (Non-ABS)
Front Brake Line Routing (Non-ABS)
Rear Brake Line (Non-ABS)
Front Master Cylinder to Manifold to Caliper (ABS)
Front Manifold to EHCU (ABS)
Rear Master Cylinder to EHCU (ABS)
Rear EHCU to Caliper (ABS)
Bleeding Brakes
General
Procedure
Electro Hydraulic Control Unit (EHCU)
Removal
Installation
Left Side Cover
Opening and Closing
Replacement
FRONT FORK
Check For Oil Leak
Removal
Disassembly: Right Side, All but XL1200CX
Disassembly: Left Side, All but XL1200CX
Disassembly: Left Side, XL1200CX
Clean and Inspect
Disassembly: Right Side, XL1200CX
Installation
Assembly: Right Side, All but XL1200CX
Assembly: Left Side, All but XL1200CX
Assembly: Left Side, XL1200CX
Assembly: Right Side, XL1200CX
FORK STEM AND BRACKET ASSEMBLY
Removal and Disassembly
Cleaning, Inspection and Repair
Assembly and Installation
BELT GUARD AND DEBRIS DEFLECTOR
Belt Guard
Debris Deflector
REAR FORK
Removal
Pivot Bearings
Installation
Axle Adjusters
Shock Absorbers
Removal
Cleaning and Inspection
Installation
Preload Adjustment Knob: XL1200T
STABILIZER LINKS
General
Upper Front Stabilizer Link
Lower Front Stabilizer Link
Rear Stabilizer Link
FRONT ENGINE MOUNT AND ISOLATOR
Removal
Installation
REAR ENGINE MOUNT AND ISOLATOR
Removal
Installation
THROTTLE CABLES
Removal
Throttle Adjusting Screw
Cleaning and Inspection
Installation
CLUTCH CONTROL
Removal and Disassembly
Assembly and Installation
HANDLEBAR
Removal
Installation
Left Hand Grip
SEAT
Removal
Installation
Saddlebags: XL1200T
Removal
Lockset
Reflectors and Medallions
Installation
HEADLAMP VISOR
Removal and Installation
Disassemble and Assemble
Front Fender
All Models
Front License Plate: India
Front License Plate: India
REAR FENDER: TOP MOUNT LICENSE PLATE EXCEPT XL1200T, XL1200C
Removal
Installation
Fender Preparation
Top Mount License Plate Bracket
REAR FENDER: XL1200C
Replacement
Fender Preparation
License Plate Bracket
REAR FENDER: XL1200T
Removal
Installation
Fender Preparation
License Plate Bracket: XL1200T
REAR FENDER: MODELS WITH INTEGRATED TURN SIGNAL, TAIL AND STOP
LAMPS
General
Removal and Disassembly
Assembly and Installation
Windshield: XL1200T
Windshield Removal and Installation: XL1200T
Cleaning
Windshield Replacement
Mounting Clamps
SAREE GUARD: INDIA MODELS
Saree Guard
REAR LICENSE PLATE: INDIA MODELS
Rear License Plate: India
RIDER FOOT CONTROLS: MID-MOUNT
Right Footrest and Rear Brake Pedal Assembly
Left Footrest and Shift Lever Assembly
Footboard Inserts: XL1200T
RIDER FOOT CONTROLS: FORWARD
Right Footrest and Rear Brake Pedal Assembly
Left Footrest and Shift Lever Assembly
Adjusting Shift Pedal
Passenger Footrests
Left
Right
Jiffy Stand
Removal
Cleaning and Lubrication
Installation
Fork Lock
Removal
Installation
MEDALLIONS, BADGES AND TANK EMBLEMS
Removal
Installation
Engine
FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter
Specifications
Specifications: Sportster Models
CRANKCASE BREATHING SYSTEM
Operation
Oil Pressure
Operation
Checking Oil Pressure
ENGINE LUBRICATION SYSTEM
Oil Pump Operation
Oil Flow
Troubleshooting
Diagnosing Valve Train Noise
Compression Test
Cylinder Leakage Test
Diagnosing Smoking Engine or High Oil Consumption
Adjustment and Testing
HOW TO USE THIS SECTION
Top End Repair
Bottom End Repair
Typical Symptoms
TOP END SERVICE
Engine in Chassis
Engine Removed from Chassis
TOP END OVERHAUL: DISASSEMBLY
General
Stripping Motorcycle for Top End Repair
CYLINDER HEADS
CYLINDER AND PISTON
TOP END OVERHAUL: ASSEMBLY
General
Piston and Cylinder
Tappet Covers, Pushrod Covers and Pushrods
CYLINDER HEAD
Rocker Covers
Assembling Motorcycle After Top End Repair
BOTTOM END SERVICE
Engine in Chassis
Engine Removed from Chassis
BOTTOM END OVERHAUL: DISASSEMBLY
General
Oil Pump
Tappets
Cam Gear End Play
Crankcase
GEARCASE COVER AND CAM GEARS
BOTTOM END OVERHAUL: ASSEMBLY
Crankcase
Cam and Pinion Gear Identification
Cam Gears and Gearcase Cover
Tappets
REMOVING ENGINE FROM CHASSIS
Procedure
INSTALLING ENGINE IN CHASSIS
Procedure
CYLINDER HEAD
Disassembly
Cleaning and Inspection
Replacing Rocker Arm Bushings
Refacing Valve Seats
Replacing Valve Guides
Assembly
CYLINDER AND PISTON
Cleaning, Inspection and Repair
Connecting Rod Bushings
Oil Pump
General
Removal
Cleaning and Inspection
Disassembly
Installation
Assembly
OIL FILTER MOUNT
General
Disassembly
Cleaning and Inspection
Assembly
GEARCASE
Bushing Inspection and Removal
Bushing Installation
Bushing Reaming
Crankcase
General
Disassembly
Fitting Pinion Bearings
Lapping Pinion Bearing Outer Race
OIL TANK
Pressure Relief Valve
Oil Line Routing
Crimp Clamps
Removal
Installation
Oil Tank Bracket
Fuel System
FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter
SPECIFICATIONS: FUEL SYSTEM
Specifications
Fuel Pressure Test
General
Testing
Intake Leak Test
General
Leak Tester
Procedure
AIR CLEANER ASSEMBLY
All Models
FUEL FILTER ELEMENT
General
Removal
Installation
FUEL TANK
Purging and Disconnecting Fuel Supply Line
Removing Fuel Tank
Cleaning and Inspection
Installing Fuel Tank
Connecting Fuel Hose and Filling Fuel Tank
Vapor Valve
INDUCTION MODULE
Removal
Disassembly
Installation
Assembly
Idle Air Control (IAC)
General
Removal
Installation
Throttle Position Sensor (TPS)
General
Removal
Installation
TEMPERATURE MANIFOLD ABSOLUTE PRESSURE (TMAP) SENSOR
General
Removal
Installation
HEATED OXYGEN SENSOR (HO2S)
Removal
Installation
ENGINE TEMPERATURE (ET) SENSOR
General
Removal
Installation
Fuel Injectors
Removal
Installation
FUEL PUMP
General
Removal
Disassembly
Assembly
Installation
EXHAUST SYSTEM
Unit Removal
Mufflers
Exhaust Shields
Muffler Shields
Exhaust Pipes
Exhaust Pipe Bracket
Mounting Bracket
EVAPORATIVE (EVAP) EMISSIONS CONTROL
General
Charcoal Canister
Fuel Vapor Vent Hose
Canister-to-Solenoid Hose
Solenoid-to-Induction Module Hose
Purge Solenoid
Drive and Transmission
FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter
SPECIFICATIONS: DRIVE
Sportster Specifications
PRIMARY COVER
Removal
Clutch Release Ramp
Primary Chain Adjuster
Installation
PRIMARY DRIVE AND CLUTCH
Troubleshooting
Removal
Disassembly
Inspection and Repair
Assembly
Installation
Drive Belt
Drive Belt Handling
Drive Belt
TRANSMISSION POWER FLOW
General
CASE DISASSEMBLY FOR TRANSMISSION REMOVAL
General
Engine Removal and Disassembly
TRANSMISSION REMOVAL AND DISASSEMBLY
Transmission Removal From Left Crankcase
Cleaning and Inspection
Mainshaft Disassembly
Countershaft Disassembly
TRANSMISSION ASSEMBLY
Mainshaft Assembly
Countershaft Assembly
MAIN DRIVE GEAR AND BEARING
General
Removal
Disassembly
Assembly
Installation
TRANSMISSION RIGHT CASE BEARINGS
Removal
Installation
TRANSMISSION LEFT CASE BEARINGS
Removal
Installation
TRANSMISSION INSTALLATION
General
Installation
Shifter Forks and Drum Assembly
Assembling Crankcases
Shifter Shaft Installation
TRANSMISSION SPROCKET
Removal
Installation
Electrical
FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter
SPECIFICATIONS: ELECTRICAL
Specifications
Fuses
Replacement
SPEEDOMETER
Removal
Installation
ELECTRONIC CONTROL MODULE (ECM)
Removal
Installation
BODY CONTROL MODULE (BCM)
Removal
Installation
H-DSSS
Activation
Antenna
Fob Battery
Battery Tray
Removal
Installation
BATTERY CABLES
Negative Battery Cable
Positive Battery Cable
Ignition Switch
Removal
Installation
SPARK PLUG CABLES
General
Removal
Installation
IGNITION COIL
General
Removal
Installation
STARTER
Removal
Touch-Up Paint
Installation
Solenoid
Clutch Shaft Assembly
HEADLAMP
Bulb Replacement
Headlamp Mounts
INDICATOR LAMP MODULE
Preliminary Disassembly
Replacement: XL883L, XL883N, XL1200NS, XL1200T, XL1200X, XL1200CX,
XL1200XS
Replacement: XL1200C
Assembly
TAIL LAMP: MODELS WITH TOP-MOUNT LICENSE PLATE
Bulb Replacement: XL883L, XL1200T
Base Replacement: XL883L, XL1200T
Rear Lighting Harness
LED Tail Lamp: XL1200C
LICENSE PLATE LAMP MODULE
General
Removal: Side-Mount License Plate
Installation: Side-Mount License Plate
Removal: Center-Mount License Plate
Installation: Center-Mount License Plate
Reflector Brackets
Front Turn Signals
Bulb Replacement
Front Turn Signal Wire Harness
All Except XL1200T, XL1200X, XL1200XS
XL1200X, XL1200XS
XL1200T
REAR TURN SIGNALS
General
XL883L
XL1200T
XL883N, XL1200NS, XL1200X, XL1200XS
XL1200C
XL1200CX
Rear Stop Lamp Switch
Removal
Installation
Crank Position Sensor (CKP)
General
Removal
Installation
Vehicle Speed Sensor (VSS)
Removal
Installation
Neutral Indicator Switch
General
Replacement
Oil Pressure Switch
General
Removal
Installation
VOLTAGE REGULATOR
Removal
Installation
ALTERNATOR
Removal and Disassembly
Cleaning and Inspection
Assembly and Installation
HORN
Front Mount
Side Mount
MAIN WIRING HARNESS AND ELECTRICAL CADDIES
Removal
Backbone Electrical Caddies
Replacing ECM Electrical Caddy
Installation
J-Clips: Mid-Mount Models
RIGHT HANDLEBAR CONTROL MODULE
Removal
Right Handlebar Control Key Caps
Installation
Front Stop Lamp Switch Replacement
LEFT HANDLEBAR CONTROL MODULE
Removal
Left Handlebar Control Key Caps
Clutch Switch Replacement
Installation
WHEEL SPEED SENSOR (WSS)
Front WSS
Rear WSS
Smart Siren
Replacement
Battery
Personal Identification Number (PIN)
General
Changing the PIN
JIFFY STAND SENSOR (JSS): INTERNATIONAL MODELS
Removal
Installation
Operation
Wiring
WIRING DIAGRAMS
General
Wiring Diagrams
Reference
GLOSSARY
Acronyms and Abbreviations
METRIC CONVERSION
Conversion Table
FLUID CONVERSION
United States System
Metric System
British Imperial System
TORQUE CONVERSION
United States System
Metric System
Backmatter
Backmatter
Backmatter
Backmatter

2018 HARLEY DAVIDSON SPORTSTER MODELS SERVICE MANUAL – PDF DOWNLOAD:

PLEASE NOTE:

• This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
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