2010 Harley-Davidson Sportster Models Service Manual – PDF DOWNLOAD
DESCRIPTION:
2010 Harley-Davidson Sportster Models Service Manual – PDF DOWNLOAD
ABOUT THIS MANUAL
GENERAL
This service manual has been prepared with the following purposes in mind:
• To acquaint the user with the construction of the Harley- Davidson product and assist in the performance of basic maintenance and repair.
• To introduce the professional Harley-Davidson technician to 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.
NO. CHAPTER
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 Compensating Sprocket
D Appendix D Conversions
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:
2010 Harley-Davidson Sportster Models Service Manual – PDF DOWNLOAD
2010 HARLEY SPORTSTER MODELS COVER PAGE.................................... 1 ++CHAPTER 0NE MAINTENANCE.................................................. 18 Maintenance Schedules...................................................... 28 Engine Oil And Filter...................................................... 32 Brakes Inspection and Maintenance.......................................... 36 Tires And Wheels Inspection and Maintenace................................. 54 Primary Chain.............................................................. 57 Clutch..................................................................... 59 Trans Lubricant............................................................ 61 Drive Belst and Sprockets.................................................. 63 Wheel Alignment............................................................ 68 Battery Maintenance........................................................ 70 Spark Plugs................................................................ 76 Steering Head Bearings..................................................... 78 Shock Absorber Adjustment.................................................. 80 Air Cleaner:XL Models...................................................... 83 Air Cleaner : XR Models.................................................... 85 Throttle Control........................................................... 89 Fuel Supply Filter......................................................... 90 Engine Mounts and Stabilizer Links......................................... 91 Headlamp Alignment......................................................... 92 Troubleshooting............................................................ 98 ++CHAPTER TWO CHASSIS......................................................101 Wheels.....................................................................115 Front Brake Master Cylinder................................................141 Front Brake Caliper: Xl Models.............................................150 XR Models..................................................................158 Rear Brake Master Cyliner: XL Models.......................................163 XR Models..................................................................171 Rear Brake Caliper: XL Models..............................................179 Front Fork: XR Models......................................................188 Rear Brake Caliper: XR Models..............................................198 brake lines................................................................204 Left Side Cover............................................................214 Front Fork : XL Models.....................................................217 XR Models..................................................................223 Belt Guard and Debris Deflector............................................242 Rear Fork..................................................................244 Shock Absorbers............................................................247 Throttle Cables: All Models................................................256 Clutch Control.............................................................260 Hadle Bars-Triple Trees....................................................264 Front Fender: XL Models....................................................270 Rear Fender: All XL Models Except XL 883N/XL 1200N.........................271 Rear Fender : XL 883N/XL 1200N.............................................275 Rear Fender: XR Models.....................................................280 Jiffy Stand................................................................281 Seat:XL Models.............................................................283 XR Models..................................................................285 Foot Controls..............................................................287 ++CHAPTER THREE ENGINE.....................................................300 Oil Pressure General Troubleshooting.......................................312 Crank Case Breathing System................................................315 Engine Lubrication System..................................................320 Top and Bottom End Repair..................................................333 Cooling Systems............................................................352 Top End Overhaul Disassembly and Reassembly................................358 BottomEnd Overhaual Disassembley and reassembly............................378 Cylinder and Piston........................................................417 Crankcase..................................................................425 Oil Pump: Xl and XR Models.................................................433 Oil Filter Mount...........................................................440 ++CHAPTER FOUR FUEL SYSTEMS................................................447 Fuel Tank: XL Models.......................................................455 Fuel Tank :XR Models.......................................................462 Throttle Postiion Sensor...................................................467 Engine Temperature Sensor..................................................471 Induction Modules..........................................................473 Idle Air Control...........................................................484 Temperature Manifold Absolute Pressure Sensor..............................488 Oxygen Sensor..............................................................492 Exhaust Systems............................................................494 Fuel Injectors.............................................................500 Fuel Pump..................................................................503 Evaporative Emission Control ( California Models ).........................512 ++CHAPTER FIVE DRIVE/TRANSMISSIONS.........................................518 Primary Chain Adjuster.....................................................522 Clutch Release Mechanism...................................................527 Primary Drive and Clutch...................................................530 Transmission...............................................................552 Case Disassembly For Transmission Removal..................................553 Transmission Removal and Disassembly.......................................557 Transmission Assembly......................................................564 Main Drive Gear and Bearing................................................566 Transmission Right Case Bearings...........................................575 Transmission Left Case bearings............................................576 Transmission Installation..................................................577 Transmission Sprocket......................................................582 ++CHAPTER 6 ELECTRICAL.....................................................585 Voltage Regulator..........................................................590 Fuses and Relays...........................................................594 Speedometers...............................................................596 Electronic Control Module..................................................603 Turn Signal Security Module (TSM/TSSM/HFSM)................................605 Battery Cables.............................................................607 Starter....................................................................611 Ignition...................................................................618 Spark Plug Cables..........................................................620 Ignition Coil..............................................................623 Headlamp...................................................................626 Indicator Lamp and Tail lamps..............................................629 Turn Signals...............................................................635 Rear Stop Lamp Switch......................................................649 Crank Position Sensor......................................................650 Alternator.................................................................651 Vehicale Speed Sensor (VSS)................................................654 Neutral Indicator Switch...................................................655 Main Wiring Harness........................................................657 Electrical Caddies and all cubbie holes they like to hide the wiring in....662 Jiffy Stand Switch International Models....................................668 Optional Security Siren....................................................670 Oil Pressure Switch........................................................673 Beep Beep..................................................................675 Main Fuse..................................................................677 Handlebar Switch Assemblies................................................678 TSSM/HFSM Maintenance......................................................690 Personal Identification Number (PIN).......................................692 H-DSSS Actuation...........................................................694 TSM/HFSM:Password Learn....................................................695 ++APPENDIX A CONNECTOR REPAIR..............................................698 +++APPENDIX B WIRING.......................................................733 Wiring Diagrams............................................................736 +++APPENDIX C CONVERSIONS..................................................771 +++APPENDIX D COMPENSATING SPROCKET........................................776 +++APPENDIX E GLOSSARY.....................................................781 +++TOOLS USED IN THIS MANUAL...............................................786 +++TORQUE VALUES...........................................................794 +++INDEX...................................................................816 ***THE END.................................................................825
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