1986-1994 Harley-Davidson Sportster service manual

Table of Contents

Chapter One: General Information

• Manual organization
• Notes, cautions and warnings
• Safety first
• Cleaning parts
• Handling gasoline safely
• Service hints
• Torque specifications
• Fasteners
• Lubricants
• Threadlocking compound
• RTV gasket sealant
• Expendable supplies
• Serial numbers
• Warning and information labels
• Basic hand tools
• Precision measuring tools
• Special tools
• Fabricating tools
• Mechanic's tips
• Bearing replacement
• Seals
• Storage

Chapter Two: Troubleshooting

• Operating requirements
• Troubleshooting instruments
• Starting the engine
• Starting difficulties
• Engine is difficult to start
• Engine starting system
• Charging system
• Ignition system
• Electronic throttle control
• Fuel system
• Engine overheating
• Engine
• Engine noises
• Cylinder leak down test
• Power train
• Steering
• Frame noise
• Brakes

Chapter Three: Lubrication, Maintenance and Tune-Up

• Pre-ride checklist
• Tires and wheels
• Battery
• Battery electrical cable connectors
• Periodic lubrication
• Periodic maintenance
• Unscheduled inspection and maintenance
• Engine tune-up

Chapter Four: Engine Top End

• Engine principles
• Engine cooling
• Engine lubrication
• Servicing the engine in the frame
• Exhaust system
• Cylinder head cover
• Rocker arm assembly
• Camshaft
• Cylinder head
• Valves and valve components
• Cylinder block
• Piston and piston rings
• Camshaft chain and sprockets
• Break-in procedure

Chapter Five: Engine Lower End

• Engine
• Flywheel and stator plate
• Recoil starter
• Crankcase
• Crankshaft inspection
• Balancer shaft inspection
• Shaft end float measurement and shim selection
• Oil pump
• Oil system one-way check valve
• Break-in procedure

Chapter Six: Fuel System

• Carburetor operation
• Carburetor
• Carburetor cleaning and inspection
• Carburetor tests and adjustments
• Throttle cable replacement
• Starting enrichment (choke) cable
• Fuel tank
• Fuel shutoff valve
• Air filter air box
• Fuel pump

Chapter Seven: Cooling Systems

• Polaris variable transmission (PVT) air cooling system
• Engine cooling system
• Safety precautions
• Hoses and hose clamps
• Engine gaskets/seals
• Cooling system inspection
• Radiator
• Cooling fan
• Coolant pump
• Thermostat
• Temperature sensors

Chapter Eight: Clutch/Drive Belt System

• Drive unit
• Drive pulley
• Special tools
• Driven pulley
• Drive belt
• Drive pulley
• Driven pulley
• Clutch outer and inner cover (all models)

Chapter Nine: Transmission

• Transmission
• Transmission inspection
• Shift shafts
• Front output shaft
• Transmission gearcase oil seal inspection and replacement
• Shift selector linkage

Chapter Ten: Front Drive System

• Front hub and Hillard clutch
• Front drive axle, boots and CV (constant velocity) joints
• Front drive shaft
• Front drive unit

Chapter Eleven: Electrical System

• Basic information
• Negative battery terminal
• Charging system
• Alternator stator
• Voltage regulator/rectifier
• Capacitor discharge ignition
• Ignition coil
• Ignition stator coils
• Electric starting system
• Starter drive gears
• Starter solenoid
• Lighting system
• Electrical components
• Switches
• Wiring diagrams

Chapter Twelve: Front Suspension and Steering

• Front wheel
• Front hub
• Front strut cartridge and spring
• Front strut/spindle
• Control arm
• Handlebar
• Tie rods
• Steering shaft
• Tires and wheels

Chapter Thirteen: Rear Suspension

• Rear wheels
• Tire changing and tire repairs
• Shock absorber
• Rear hub and bearing carrier
• Rear axles
• Upper control arm
• Lower control arm
• Upper and lower control arm inspection
• Stabilizer linkage
• Stabilizer support

Chapter Fourteen: Brakes

• Disc brakes
• Front brake pad replacement
• Front caliper
• Output shaft brake pad replacement (1996-1997 models)
• Output shaft brake caliper (1996-1997 models)
• Output shaft brake pad replacement (1998-on models)
• Output shaft brake caliper (1998-on models)
• Front master cylinder
• Rear master cylinder
• Brake hose replacement
• Rear brake pedal
• Rear brake lever (1996-1997 Sweden models)
• Foot brake (1998-on Sweden models)
• Brake disc
• Bleeding the system

Chapter Fifteen: Body

• Seat
• Front rack and grille
• Side panels
• Front fender
• Front bumper (models so equipped)
• Radiator guard
• Rear rack
• Rear fender
• Footwells
• Rear bumper (models so equipped)

Supplement: 2001-2003 Service Information

• Starting the engine
• Ignition system
• Periodic maintenance
• Engine tune-up
• Cylinder block
• Piston and piston rings
• Engine
• Flywheel and stator plate
• Carburetor (Sportsman 500 H.O. models)
• Cleaning and inspection
• Carburetor tests and adjustments
• Drive belt
• Driven pulley (2003 models built after 07/08/02)
• Transmission
• Lighting system
• Electrical components
• Steering shaft (2002-on models)
• Rear hub and bearing carrier (2003 models)
• Rear brake pad replacement (2003 models)
• Rear calipers (2003 models)
• Front master cylinder
• Rear master cylinder (2003 models)
• Rear brake disc (2003 models)
• Brake hose replacement (2003 models)

Index

• 470

Wiring Diagrams

• 476

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