Index Harley Davidson Harley Davidson Sportster models 2011. Service manual

Harley Davidson Sportster models 2011. Service manual - page 1

SUBJECT PAGE NO.

1.1 FASTENER TORQUE VALUES.................................................................................................1-1

1.2 GENERAL..................................................................................................................................1-3

1.3 FUEL AND OIL..........................................................................................................................1-7

1.4 BULB REQUIREMENTS............................................................................................................1-9

1.5 MAINTENANCE SCHEDULE..................................................................................................1-10

1.6 ENGINE OIL AND FILTER.......................................................................................................1-14

1.7 BRAKES..................................................................................................................................1-18

1.8 BRAKE PADS AND DISCS: XL MODELS...............................................................................1-20

1.9 BRAKE PADS AND DISCS: XR 1200X...................................................................................1-27

1.10 TIRES AND WHEELS............................................................................................................1-32

1.11 PRIMARY CHAIN...................................................................................................................1-36

1.12 CLUTCH................................................................................................................................1-37

1.13 TRANSMISSION LUBRICANT..............................................................................................1-39

1.14 DRIVE BELT AND SPROCKETS.........................................................................................1-41

1.15 WHEEL ALIGNMENT............................................................................................................1-45

1.16 BATTERY MAINTENANCE....................................................................................................1-47

1.17 SPARK PLUGS......................................................................................................................1-53

1.18 STEERING HEAD BEARINGS..............................................................................................1-55

1.19 SUSPENSION ADJUSTMENTS............................................................................................1-56

1.20 CABLE AND CHASSIS LUBRICATION.................................................................................1-60

1.21 AIR FILTER............................................................................................................................1-61

1.22 EXHAUST SYSTEM..............................................................................................................1-65

1.23 THROTTLE CONTROL.........................................................................................................1-66

1.24 FUEL SUPPLY FILTER..........................................................................................................1-67

1.25 ENGINE MOUNTS AND STABILIZER LINKS.......................................................................1-68

1.26 HEADLAMP ALIGNMENT.....................................................................................................1-69

1.27 CRITICAL FASTENERS........................................................................................................1-71

1.28 STORAGE..............................................................................................................................1-73

1.29 TROUBLESHOOTING...........................................................................................................1-75

SERVICING A NEW MOTORCYCLE

Perform the service and maintenance operations as indicated in the regular service interval table. Lack of regular maintenance at the recommended intervals can affect the safe operation of your motorcycle, which could result in death or serious injury. (00010a)

Service operations to be performed before customer delivery are specified in the applicable model year predelivery and setup instructions.

The performance of new motorcycle initial service is required to keep warranty in force and to verify proper emissions systems operation. See 1.5 MAINTENANCE SCHEDULE.

SAFE OPERATING MAINTENANCE

NOTES

Do not attempt to tighten engine head bolts or engine damage may result.

During the initial break-in period, use only Harley-Davidson 20W50 engine oil. Failure to use the recommended oil will result in improper break-in of the engine cylinders and piston rings.

A careful check of certain equipment is necessary after periods of storage, and frequently between regular service intervals, to determine if additional maintenance is required.

Check:

1. Tires for abrasions, cuts and correct pressure.

2. Drive belt tension and condition.

3. Brakes, steering and throttle for responsiveness.

4. Brake fluid level and condition. Hydraulic lines and fittings for leaks. Also, check brake pads and discs for wear.

5. Cables for fraying, crimping and free operation.

6. Engine oil and transmission fluid levels.

7. Headlamp, auxiliary lamp, tail lamp, brake lamp, horn and turn signal operation.

SHOP PRACTICES Repair Notes

General maintenance practices are given in this section.

NOTES

Repair = Disassembly/Assembly.

Replacement = Substitute a new part for existing component.

All special tools and torque values are noted at the point of use.

All required parts or materials can be found in the parts catalog.

Safety

Safety is always the most important consideration when performing any job. Be sure you have a complete understanding

of the task to be performed. Use common sense. Use the proper tools. Protect yourself and bystanders with approved eye protection. Don't just do the job - do the job safely.

Removing Parts

Always consider the weight of a part when lifting. Use a hoist whenever necessary. Do not lift heavy parts by hand. A hoist and adjustable lifting beam or sling are needed to remove some parts. The lengths of multiple chains or cables from the hoist to the part should be equal and parallel and should be positioned directly over the center of the part. Be sure that no obstructions will interfere with the lifting operation. Never leave a part suspended in mid-air.
Awarning
Be sure to check capacity rating and condition of hoists, slings, chains and cables before use. Exceeding capacity ratings or using lifting devices that are in poor condition can lead to an accident, which could result in death or serious injury. (00466c)

Always use blocking or proper stands to support the part that has been hoisted. If a part cannot be removed, verify that all bolts and attaching hardware have been removed. Check to see if any parts are in the way of the part being removed.

When removing hoses, wiring or tubes, always tag each part to verify proper installation.

Cleaning

If parts are to be reused, follow good shop practice and thoroughly clean the parts before assembly. Keep all dirt out of parts to promote better component operation and longer life. Seals, filters and covers are used in this vehicle to keep out extraneous dirt and dust. These items must be kept in good condition to guarantee satisfactory operation.

When instructed to clean fastener threads or threaded holes, proceed as follows: Clean all threadlocking material from fastener threads and threaded holes. Use a wire brush to clean fastener threads. Use a thread chaser or other suitable tool to clean threaded holes. Use PJ1 cleaner or equivalent to remove all traces of oil and contaminants from threads. Clean all threaded holes with low pressure compressed air.

Clean and inspect all parts as they are removed. Be sure all holes and passages are clean and open. After cleaning, cover all parts with clean lint-free cloth, paper or other material. Be sure the part is clean when it is installed.

Always clean around lines or covers before they are removed. Plug, tape or cap holes and openings to keep out dirt, dust and debris.

Always verify cleanliness of blind holes before assembly. Tightening a screw with dirt, water or oil in the hole can cause castings to crack or break.

Disassembly and Assembly

Always assemble or disassemble one part at a time. Do not work on two assemblies simultaneously. Be sure to make all necessary adjustments. Check your work when finished to be sure that everything is done.

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