1998 Harley Davidson XLH Service Manual – PDF DOWNLOAD
DESCRIPTION:
1998 Harley Davidson XLH Service Manual – PDF DOWNLOAD
SERVICING A NEW MOTORCYCLE :
- Service operations to be performed before customer delivery are specified in the applicable model year PREDELIVERY AND SETUP MANUAL. The performance of new motorcycle initial service is required to keep warranty in force and to ensure proper emissions systems operation.
- After a new motorcycle has been driven its first 500 miles, and again at 5000 miles, a Harley-Davidson dealer should perform the service operations fisted in the Regular Maintenance Intervals table on the next page.
SAFE OPERATING MAINTENANCE:
- 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. AcAur10N Do not attempt to retighten engine head bolts. Retightenlng can cause engine damage.
- During the initial 500 mile (800 km) 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. Do not lubricate the enrichment cable on CV carburetors.
Check:
1. Tires for abrasions, culs and correct pressure.
2. Secondary drive belt for proper tension and condilion.
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 levers.
7. Wheel spoke tightness, if applicable.
8. Headlamp, tail lamp, brake lamp and directional lamp operation
TABLE OF CONTENTS:
1998 Harley Davidson XLH Service Manual – PDF DOWNLOAD
SECTION 1 – PRODUCT
General
Servicing a New Motorcycle
Safe Operating Maintenance
Regular Maintenance Intervals
Side Views
Storage
General
Removal from Storage
Fluid Requirements
General
United States System
British Imperial System
Metric System
Wheel Bearing Grease
Brake Fluid
Front Fork Oil
Engine Oil
Fuel
Primary Drive/Transmission Lubricant
Metric Conversion Table
Fastener Torque Values
Troubleshooting
Engine
Engine Lubrication System
Electrical System
Fuel
Transmission
Clutch
Chassis
Shop Practices
Repair Notes
Repair and Replacement Procedures
Cleaning
Tool Safety
Air Tools
Wrenches
Pliers/Cutters/Prybars
Hammers
Punches/Chisels
Screwdrivers
Ratchets and Handles
Sockets
Storage Units
Tools
Specifications
Tires
Vehicle Identification Number (V I N )
Wheels
General
Troubleshooting
Front Wheel
Removal
Disassembly
Cleaning Inspection and Repair
Assembly
Installation
Rear Wheel
Removal
Disassembly
Cleaning Inspection and Repair
Assembly
Installation
Lacing Wheels
16-lnch Wheels
19-lnch Wheels
Truing Laced Wheel
Checking Cast Rim Runout
Tires
General
Removal
Cleaning Inspection and Repair
Installation
Brakes
General
Troubleshooting
Front Brake Master Cylinder
Removal/Disassembly
Cleaning Inspection and Repair
Assembly/Installation
Rear Brake Master Cylinder
Adjustment
Removal/Disassembly
Cleaning Inspection and Repair
Assembly/Installation
Rear Brake Linkage and
Sprocket Cover
Removal
Installation
Front Brake Caliper
Removal/Disassembly
Cleaning Inspection and Repair
Assembly
Installation
Rear Brake Caliper
Removal/Disassembly
Cleaning Inspection and Repair
Assembly
Installation
Brake Lines
Front Brake Line
Rear Brake Line
Bleeding Hydraulic System
General
Front Fork
General
Removal
Disassembly
Cleaning Inspection and Repair
Assembly
Installation
Disassembly XL1200S
Inspection XL1200S
Assembly· XL 1200S
Installation XL1200S
Fork Stem and
Bracket Assembly
Adjustment 2-54
Lubrication 2-54
RemovaVDisassembly 2-54
Cleaning Inspection and Repair 2-54
Assembly/Installation 2-54
Rear Fork 2·55
Removal/Disassembly 2-55
Cleaning and Inspection 2·55
Assembly 2-55
Installation 2-55
Rear Shock Absorber
Adjustment
Removal
Disassembly
Cleaning and Inspection
Installation
Throttle Control
Adjustment
RemovaVDisassembly
Cleaning Inspection and Repair
Assembly/Installation
Handlebars
Removal
Installation
Clutch Control
Adjustment
Removal/Disassembly
Assembly/Installation
Exhaust System
Removal
Disassembly
Assembly
Installation
Front Fender
Removal
Installation
Rear Fender
Removal
Installation
Jiffy Stand
General
Removal
Cleaning and Lubrication
Installation
Seat
Removal
Installation
SECTION 3 – ENGINE
Specifications
Engine
Lapping Engine Main Bearing Races 3-66
Assembly 3-67
SECTION 4 – FUEL SYSTEM
General
Adjustmentffesting
3-5 Specifications
Stripping Motorcycle for
Engine Repair
Installing the Engine
Cylinder Head
Removal
Disassembly
Cleaning Inspection and Repair
Assembly
Installation
Cylinder and Piston
Removal/Disassembly
Cleaning Inspection and Repair
Assembly/Installation
Engine Lubrication System
Checking and Adding Oil
Changing Oil and Filter
Winter Lubrication
Oil Hose Routing
Oil Tank
Oil Pressure Signal Light Switch
Oil Pressure Signal Light
Oil Pressure
Crankcase Breathing System
Oiling System
Oil Pump
Oil Filter Mount
Valve Tappets
General
Removal
Cleaning and Inspection
Installation
Gearcase Cover and Cam Gears
General
Removal/Disassembly
Cleaning Inspection and Repair
Assembly/Installation
Crankcase
General
Adjustmentffesting
Disassembly
Cleaning and Inspection
Replacing Flywheel Washers
Lapping Connecting Rod Races
Fitting Rod Bearings
Fitting Sprocket Bearings
Fitting Pinion Bearings
Carburetor
General
Troubleshooting
Vacuum Piston Assembly Troubleshooting
Operation
Adjustment
Operation Check – Vacuum Piston
Removal
Disassembly
Cleaning Inspection and Repair
Assembly
Installation
Air Cleaner
General
Removal
Cleaning Inspection and Repair
Installation
Fuel Supply Valve
General
Removal
Cleaning Inspection and Repair
Installation
Fuel Tank
General
Removal
Cleaning Inspection and Repair
Installation
Evaporative Emissions Control –
California Models
General
Troubleshooting
Solenoid Electrical Tes IS – Air Cleane< Butterlly Valve
Removal
Cleaning Inspection Repair and Lubrication
Installation and Adjustment
Hose Routing
SECTION 5 – ELECTRIC STARTER
Specifications
Electric Starter System
General
Troubleshooting
Starting System Diagnosis
Starter System Testing
“On-Motorcycle” Tests
Starter
Removal
Testing Assembled Starter
Disassembly Inspection and Repair
Assembly
Installation
Starter Solenoid
General 5·18
Disassembly 5· 18
Assembly 5-18
SECTION 6 – DRIVE/TRANSMISSION
Specifications
Primary Chain
General
Adjustment
Removal
Installation
Shifter Forks and Drum
Disassembly
Cleaning Inspection and Repair
Assembly
Mainshaft and Countershaft
Disassembly
Cleaning Inspection and Repair
Assembly
Main Drive Gear s-30
Removal 6-30
Disassembly 6-31
Assembly 6-31
Installation 6-31
Access Door Bearings
Removal
Installation
Right Transmission Case
Bearings
Removal
Installation
Transmission Installation and
Secondary Drive Belt 6-7 Shifter Pawl Adjustment 6 34
General
Adjustment
Cleaning
Removal and Installation
Clutch
General
Troubleshooting
Clutch Release Mechanism
Adjustment
Disassembly
Cleaning Inspection and Repair
Assembly
Primary Drive/Clutch
Removal
Disassembly
Inspection and Repair
Assembly
Installation
Transmission
General
l ubrication
Transmission Case
General
Removal
Cleaning Inspection and Repair
SECTION 7 – ELECTRICAL
Specifications
Electrical Bracket
Replace Fuse(s)
Replace Main Circuit Breaker
Replace Starter Relay
Replace Electrical Bracket
Ignition System
General
Troubleshooting
Diagnostic Charts All Models Except 1200S
Checking for Trouble Codes · 1200S
Check Engine Lamp
Retrieving Trouble Codes
Scanalyzer
Breakout Box Installation
Diagnostic Check 1200s Sport
Trouble Code 12 MAP Sensor
Trouble Code 16 Battery Voltage
Trouble Code 24 and 25 Ignition Coil
Trouble Code 35 Tachometer
Trouble Code 41 Cam Sync Failure
Trouble Code 44 Bank Angle Sensor
Trouble Codes 52 54 55 Ignition Module Failure
Ignition Timlng
Static Timing 1200s
Adjust Timing using Scanalyzer 1200S
Static Timing All except 1200S
Dynamic Timing
Bank Angle Sensor
MAP Sensor -1200S
Page No
7 47
7-48
Vacuum-Operated Electric
Switch (V O E S )
AdjustmenVTesting
Removal
Installation
Ignition/Light Switch
General
Removal
Installation
Ignition Module 1200S
General
Removal
Installation
Cam Position Sensor and Rotor
1200S
General
Removal
Installation
Ignition Module All except 1200S
General
Removal
Installation
Spark Plugs
General
Adjustment
Cleaning and lnspecllon
Installation
Spark Plug Cables
General
Removal
Inspection
Installation
Ignition Coil
General
Troubleshooting
Removal All Except 1200S
Installation All Except 1200S
Removal 1200S
Installation 1200S
Charging System
General
Troubleshooting
AdjustmenVTesting
Alternator
Removal and Disassembly
Cleaning Inspection and Repair
Assembly and Installation
Voltage Regulator
General
Removal
Installation
Battery
General
Activating and Testing New Battery
Cleaning and Inspection
Charging
Disconnection and Removal
Storage
Installation and Connection
Battery Cable Replacement
Lamps
General
Adjustment
Removal/Installation
Rear Brake Switch
Handlebar Switches
General
Removal
Installation
Switch Repair/Replacement
Horn
General
Troubleshooting
Neutral Indicator Switch
General
Testing
Removal and Installation
Directional (Turn Signal)
Canceller
Operation
Distance Test
Time Test (Alternate)
Aider Preference and Control
Troubleshooting
883Only
1200 Models
RemovaVlnstallation
Fuses and Main Circuit Breaker
General
Electronic Speedometer
How-it Works
Speedometer Removal 1200 Models
Speedometer Installation 1200 Models
Speedometer Removal 883 Models
Speedometer Installation 8B3 Models
Tachometer Removal
Tachometer Installation
Speedometer sensor Replacement
Odometer reset switch Replacement
883 Speedometer (Late Model}
Speedometer/Tachometer Performance Check
Troubleshooting
Deutsch Connectors
Amp Multilock Connectors
Packard Electrical Connectors 1-120
Sealed Butt Connectors 1-122
Crimp Tables 7-123
viii
Wiring Diagrams 7-127
XL 1200S Domestic and International Models –
Main Harness 7-127
XLH All Models Starl ing and Charging –
XL 1200S Front Lamps 7-128
XL 1200S Domestic and International – Ignition Circuit 7-129
XL 1200s Domestic and lnterna11onat –
Horn and Instruments 7-130
XL 1200S Domestic and International – Lights 7-131
All XL Domestic and International (Except 1200S) –
Main Harness 7-132
All XL Domestic and International (Except 1200S) –
Ignition Circuit 7-133
All XL Domestic and International (Except 1200S)
Horn and Instruments 7 134
INDEX 1-1
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PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
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