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.
HOW TO USE YOUR SERVICE MANUAL :
Refer to the table below for the content layout of this manual.
1 Maintenance
2 Chassis
3 Engine
4 Fuel System
5 Drive/Transmission
6 Electrical
A Appendix A Connector Repair
B Appendix B Wiring
c Appendix C Conversions
D Appendix D Compensating Sprocket
E Appendix E Glossary
2 Chassis
3 Engine
4 Fuel System
5 Drive/Transmission
6 Electrical
A Appendix A Connector Repair
B Appendix B Wiring
c Appendix C Conversions
D Appendix D Compensating Sprocket
E Appendix E Glossary
- 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
VIDEO PREVIEW OF THE MANUAL:
IMAGES PREVIEW OF THE MANUAL:
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]
S.V