2008 Harley-Davidson Sportster service manual

Table of Contents

Maintenance

1.1 General

• Servicing a New Motorcycle
• Safe Operating Maintenance
• Special Tools
• Shop Supplies
• Cleaning and Care
• Battery
• Fastener
• Bearings
• Removing Parts and Assembly
• Replacing Components
• Expendable Supplies
• Initial Service Operation
• Key Lubrication Points
• Primary Chaincase
• Hand and Foot Controls
• Electrical Switches
• Cables and Lubrication
• Engine Oil
• Transmission Lubricant
• Final Drive Belt
• Clutch
• Brake Fluid
• Tires and Wheels
• Spark Plugs
• Air Cleaner
• Air Suspension
• Exhaust System
• Front Suspension
• Fork Oil
• Rear Fork
• Steering Head Bearings
• Rear Shocks
• Engine Stabilizer Links
• Headlamp Alignment
• Fuel Supply Valve
• Engine Identification
• Transmission Identification
• Crankcase Numbers
• Frame Numbers

1.2 Fuel and Oil

1.3 Maintenance Schedule

1.4 Bulb Requirements

1.5 Engine Oil and Filter

• Checking Oil Level
• Changing Oil and Filter
• Checking Engine Oil Pressure
• Removing and Installing Oil Filter

1.6 Brakes

• Inspecting Brake Pads and Discs
• Brake Fluid
• Bleeding Hydraulic Brake System

1.7 Tires and Wheels

• Tires
• Wheels
• Wheel Inspection
• Wheel Bearing

1.8 Steering Head Bearings

• Lubrication
• Adjustment

1.9 Front Fork Oil

• Checking and Draining Fork Oil
• Refilling Fork Oil

1.10 Clutch

• Clutch Release Adjustment

1.11 Transmission Lubricant

• Checking Transmission Lubricant Level
• Changing Transmission Lubricant

1.12 Rear Belt and Sprockets

• Rear Belt Deflection

1.13 Shock Absorber Adjustment

• Standard Shock Absorbers
• Premium Ride Hand-Adjustable Shock Absorbers

1.14 Rear Belt Deflection

• Checking Rear Belt Deflection
• Adjusting Rear Belt Deflection

1.15 Brake Pads and Discs

• Inspecting Brake Pads and Discs
• Checking Brake Fluid
• Bleeding Hydraulic Brake System

1.16 Battery Maintenance

• Battery Inspection
• Battery Charging and Connection

1.17 Spark Plugs

• General
• Inspecting Spark Plugs
• Gapping and Replacing Spark Plugs

1.18 Steering Head Bearings

• Lubrication
• Adjustment

1.19 Rear Fork Bearings

• Lubrication

1.20 Front Fork Oil

• Checking and Draining Fork Oil
• Refilling Fork Oil

1.21 Cable and Chassis Lubrication

• Lubricating Throttle Control Cables
• Lubricating Clutch Cables
• Lubricating Rear Brake Pedal

1.22 Air Cleaner and Exhaust System

• Inspecting Air Cleaner Element
• Inspecting Exhaust System

1.23 Throttle Control

• Checking and Lubricating

1.24 Idle Speed and Ignition Timing

1.25 Fuel Supply Filter

1.26 Engine Mounts and Stabilizer Links

• Engine Mounts
• Stabilizer Links

1.27 Headlamp Alignment

• Adjusting Headlamp Alignment

1.28 Fluid and Lubricant Requirements

• Recommended Engine Oils
• Recommended Transmission Lubricants
• Recommended Primary Chaincase Lubricants
• Recommended Front Fork Oils

1.29 Critical Fasteners

1.30 Storage

• Preparing for Storage
• Returning to Service

1.31 Troubleshooting

• Troubleshooting General
• Engine Does Not Turn Over
• Engine Turns Over But Does Not Start
• Engine Misses or Runs Erratically
• Engine Lacks Power
• Engine Overheats
• Engine Knocks
• Starter Does Not Operate
• Battery Does Not Charge
• Headlamp, Tail Lamp or Signal Lamps Do Not Burn
• Lamps Burn Out Frequently
• Speedometer or Tachometer Inoperative or Inaccurate
• Engine Noise
• Excessive Vibration
• Clutch Does Not Work Properly
• Transmission Noisy or Jumps Out of Gear
• Motorcycle Pulls to Right or Left
• Motorcycle Wanders or Wobbles
• Tires Wear Rapidly or Wear Unevenly
• Rear Wheel Skids

Chassis 2.1 Specifications 2.2 Vehicle Identification Number (V.I.N.)

• Location of Vehicle Identification Number (V.I.N.)
• V.I.N. Model Designations

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