2017 Harley-Davidson Sportster Models Service Manual VISIT THE HARLEY-DAVIDSON WEB SITE htp:llwww.harley-davidson.comREADER COMMENTS ‘The Harley-Davidson Service Communications Department maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we need user feedback - your critical evaluation of this manual. Please comment on the completeness, accuracy, organization, usal y and readability of this manual. Please list the page, item, and part number(s) of any errors you find in this manual. Please tell us how we can improve this manual. Occupation: Nam Deslershi Street: Department: ity State: Zip: 2017 Harley-Davidson Sportster Models Service Manual (94000384) Please clip out and mail to: Service Communications Department Harley-Davidson Motor Company P.O. Box 653 ‘Milwaukee, WI USA 53201NOTESABOUT THIS MANUAL GENERAL Awarninc ‘The rider's safety depends upon proper motorcycle service and maintenance. If a procedure in this manual is not within your capabilities or you do not have the correct fools, have a Harley-Davidson dealer perform the pro- ‘cedure. Improper service or maintenance could result in death or serious injury. (00627b) 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. + Tointroduce the professional Harley-Davidson technician to the latest feld-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 MANUAL. Refer to the table below for the content layout ofthis manual [ No. CHAPTER 1 [Maintenance | [Chassis 2 3 [Engine 4 [Fuel System 5 [Drive and Transmission e A 8 Electrical Append A Witing “Appendix B Compensating Sprocket © |AnpendxC Reference Use the TABLE OF CONTENTS (which foliows this FORE- WORD) and the INDEX (atthe 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 C.4 GLOSSARY for a list of acronyms, abbreviations and definitions. PREPARATION FOR SERVICE TOOL NAME DIGITAL TECHNICIAN II PART NUMBER HD-48650 ENG Stop the engine when refueling or servicing the fuel system, Do not smoke or allow open flame or sparks near gasoline. Gasoline Is extremely flammable and highly explosive, which could result in death or serious injury. (000022) ‘Good preparation is very important for efficient service work. Start each job with a clean work area. Ths will allow the repair to procead as smoothly as possible. It will aso reduce the incidence of misplaced tools and parts, Clean a motorcycle thats excessively dirty before work start. Cleaning will occasionally uncover sources of trouble. Gather any tool, instruments and any parts needed for the job before ‘work begins. Interrupting a job to locate tools or pats isa dis- traction and causes needless delay. NOTES + To avoid unnecessary disassembly, carefully read all related service information before repair work begins. + In figure legends, the number which follows the name of €@ part indicates the quantity necessary for one complete assembly. + When servicing @ vehicle equipped with the Harley- Davidson Smart Security System (H-DSSS), first disarm the system. Keep the fob close to the vehicle or use DIGITAL TECHNICIAN II (Part No. HD-48650) to disable the system. Activate the system after service is completed. SERVICE BULLETINS In addition to the information presented in this manual, Harley- Davidson Motor Company will periodically issue service bul- letins to Harley-Davidson dealers. Service bulletins cover interim engineering changes and supplementary information, Consult the service bulletins to keep your product knowledge current and complete. USE GENUINE REPLACEMENT PARTS. Awarning Harley-Davidson parts and accessories are designed for Harley-Davidson motorcycles. Using non-Harley-Davidson parts or accessories can adversely affect performance, stability or handling, which could result in death or serious injury. (00001) ‘To achieve satisfactory and lasting repairs, carefully follow the service manual instructions and use only genuine Harley- Davidson replacement parts. Behind the emblem bearing the words GENUINE HARLEY-DAVIDSON stand more than 100 years of design, research, manufacturing, testing and inspecting ‘experience. This is your assurance thal the parts you are using will ft right, operate properly and last longer. FARFWOARNWARNINGS AND CAUTIONS _ ‘Statements in this manual preceded by the following words are of special significance. AWARNING WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. (001198) Oe CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. (001398) NOTICE NOTICE indicates a potentially hazardous situation which, if not avoided, may result in property damage. (00140b) NOTE Refers to important information. it is recommended that you {ake special notice ofthese items. Proper service and repair are important for the safe, reliable ‘operation ofall mechanical products. The service procedures recommended and described in this manual are effective methods for performing service operations. Always wear proper aye protection when using hammers, arbor or hydraulic presses, gear pullers, spring com- pressors, slide hammers and similar tools. Flying parts ould resultin death or serious injury. (00496b) ‘Some of these service operations require the use of tools specially designed for the purpose. These special tools should be used when and as recommended. It is important to note that some wamings against the use of specific service methods, Which could damage the motorcycle or render it unsafe, are stated inthis manuel. However, remember that these wamings. are not alincusive. Inadequate safety precautions could result in death or serious injury. Since HarleyDavidson could not possibly know, evaluate or advise the service trade of all possible ways in which service might be performed, or of the possible hazardous con- sequences ofeach method, we have not undertaken any such broad evaluation. Accordingly, anyone who uses a service procedure or tool which is not recommended by Harley- Davidson must first thoroughly satisfy himseif that neither his ‘or the operator's safety willbe jeopardized as a result. Failure to.do so could result in death or serious injury. FOREWORD PRODUCT REFERENCES Read and follow warnings and directions on all products. Failure to follow warnings and directions can result in death or serious injury. (00470b) When reference is made in this manual to a specific brand name product, too! or instrument, an equivalent product, too! or instrument may be substituted, Special Tools Alltools mentioned in this manual with a part number beginning with "HD", "J" or°B" must be ordered through your local Harley- Davidson dealer. Special tools may only be purchased, serviced or warrantied through a Harley-Davidson dealer. LOCTITE Sealing and Threadlocking Products ‘Some procedures in this manual call for the use of LOCTITE products. Ifyou have any questions regarding LOCTITE product ‘usage or retaller/wholesaler locations, contact Loctite Corp. at ww loctte.com, PRODUCT REGISTERED MARKS Apple, Alcantara S.pA., Allen, Amp Muttlock, Bluetooth Brembo, City Navigator, Delphi, Deutsch, Dunlop, Dynojet Fluke, G.E. Versilube, Garmin, Gunk, Hydroseal, Hylomar, iPhone, iPod, Kevlar, Lexan, Loctite, Lubrplate, Keps, KAN, Magnaflux, Marson Thread-Setter ToolKit, MAXI fuse, Molex, Michelin, MPZ, Muliilock, nano, NGK, Novus, Packard, Peli, Permatex, Philips, PJ1, Pozidrv, Road Tech, Robinair, $100, ‘Sems, SiriusXM, Snap-on, Teflon, Threadlocker, Torca, Torco, TORX, Tufoil, Tyco, Utratorch, Velero, X-Acto and XM Satelite Radio are among the trademarks of their respective owners. H-D U.S.A., LLC TRADEMARK INFORMATION Bar & Shield, Booml, Cross Bones, Cruise Drive, CVO, Digital Tech, Digital Technician, Digital Technician tl, Dyna, Electra Glide, Evolution, Fat Bob, Fat Boy, Forty-Eight, Glaze, Gloss, Night Rod, Nightster, Night Train, Profile, Reflex, Revolution, Road Glide, Road King, Road Tech, Rocker, Screamin’ Eagle, ‘Seventy-Two, Sofa, Sportster, Street Glide, Street Rod, Sun Ray, Sunwash, Super Glide, SuperLow, Supersmart, Switch back, SYN3, Techlink, TechLink ll, Tour-Pak, Tri Glide, Twin Cam 88, Twin Cam 888, Twin Cam 96, Twin Cam 968, Twin Cam 103, Twin Cam 1038, Twin Cam 110, Twin Cam 1108, ‘Twin-Cooied, Ultra Ciassic, V-Rod, VRSC and Harley-Davidson Genuine Motor Parts and Genuine Motor Accessories are ‘among the trademarks of H-D U.S.A., LLC.CONTENTS All photographs, illustrations and procedures may not neces- sarily depict the most current model or component, but are tased on the latest production information available atthe time cf publication Since product improvement is our continual goal, Harley. Davidson reserves the right to change specifications, equipment fr designs at any time without notice and without incurring obligation FOREWORD IllNOTES IV FOREWORDMAINTENANCE 4.1 FASTENER TORQUE VALUES Fastener Torque Values in this Chapter. 41.2 GENERAL Servicing a New Motorcycle. Safe Operating Maintenance. Disposal and Recycling ‘Shop Practices, Repair Notes. Safety. Removing Parts, Cleaning Cleaning Fastener Threads. Disassembly and Assembly. ‘Checking Torques on Fasteners. Magnetic Parts Trays. Repair and Replacement Procedures. Hardware and Threaded Parts Threadlocking Agents. Wiring, Hoses and Lines.. Instruments and Gauges. Bearings. Bushings, Gaskets, Lip-Type Seals, ‘O-Rings, Gears. Shafts. Part Replacement, Cleaning, Protecting Rubber Parts. Cleaning Process, Rust or Corrasion Removal. Bearings. ool Safety. Air Tools. Wrenches. Pliors/Cutters/Pry Bars... Hammers. PunchesiChisels. ‘Screwdrivers. Ratchets and Handles, ‘Sockets. Storage Units. 1.3 FUEL AND OIL Fehon Gasoline Blends. Engine Lubrication Low Temperature Lubrication 1.4 MAINTENANCE SCHEDULE General 1.5 ENGINE OIL AND FILTER Checking and Adding Oil Removing and Replacing Oil Filler Cap. Oil Level Cold Check. il Level Hot Check ‘Changing Oil and Filter. Draining Oil Tank... Removing Oil Fite. Installing Oi Filter. 44 413 413 443 14 444 444 145 415 Refiling Oil Tank. 416 4.6 AIR CLEANER AND EXHAUST SYSTEM Air Cleaner, Removal Installation, Cleaning Filter Element Check Exhaust System Leakage, Exhaust System Leakage, 4.7 TIRES AND WHEELS Air Pressure. Tire. Replacement. Tread Wear. Tire Damage. Specified Tires Wheel Bearings. Wheel Spokes: ‘dentfy Wheel Spoke Groups... ‘Agjust Wheel Spokes. 1.8 PRIMARY CHAIN Free Play Adjustment. 1.9 TRANSMISSION LUBRICANT ‘Transmission Lubrication, (Check Lubricant Level ‘Change Lubricant, 1.10 CLUTCH Adjustment. Release Clutch Cable Tension Clutch Adjustment. Lever Free Play. 1.11 DRIVE BELT AND SPROCKETS General Cleaning, Inspection. Sprockets... Drive Belt. ‘Check Drive Belt Deflection ‘Adjustment, 4.12 THROTTLE CONTROL Cable Inspection and Lubrication. Cable Adjustment. Operation. ‘Adjustment. 4a7 447 47 AAT 419 4.19 4.20 4-20 24-20 4-21 l-2A 4-21 4-22 rot-22, 4-22 4-24 vo-29 1-29 4-29 1-29 29 4-30 131 4-33 4-33 4-33 4-33 4.43 CABLE AND CHASSIS LUBRICATION General Cables and Hand Lovers. iffy Stand, ‘Steering Head Bearings... 1.14 BRAKES General. Inspect Brake Lines. Fluid Level Troubleshooting, 1.15 BRAKE PADS AND DISCS Inspection. Brake Pads. 4-35 4-35 4-35 4-35 41-36 1-36 437 4.37 4-39 4-39 v TABLE OF CONTENTS.TABLE OF CONTENTS Brake Disc Thickness, Lateral Runout and Warpage. Brake Pad Replacement: Front. 4.39 Removal 4.39 Installaton.. 41-40 Brake Pad Replacement: Rear. 141 Removal. 141 Installaion : AAD 1.16 SPARK PLUGS Remove, 1-43 Inspect... 1-43 Clean. 4-43 Installation, 184 Inspect Spark Plug Cables. 1.84 1.17 STEERING HEAD BEARINGS Fal- Away... 4.48, Measurement, 4-45 Adjustrrent 145 Lubrication, 4-46 1.18 ENGINE MOUNTS AND STABILIZER LINKS: Inspection. 447 1.19 BATTERY MAINTENANCE General . 1-48 Disconnection and Removal 4-49 Cleaning and Inspection, 4-49 Voltage Test. 4-49 ‘Charging Battery. 4-50 Safety Precautions... 4-50 Using a Battery Charger. 1-50 Installation and Connection... 4-51 Storage. 4-51 1.20 WHEEL ALIGNMENT ‘Wheel Alignment. 1-53 Checking Wheel Alignment. 1-53 ‘Adjusting Wheel Alignment. 1-54 1.21 SUSPENSION ADJUSTMENTS ‘Shock Absorber Preload: All except XL1200T. 1-55 Identity Shock 1-55 Identity the Pretoad Dot... 1-85 ‘Shock Adjustment. 1-58 ‘Shock Absorber Preload: XL1200T. 1-59 1.22 HEADLAMP ALIGNMENT Headlamp Aignment. 1-61 Headlamp Adjustment. 1-81 XL1200C, XL1200CB, XL1200CX, XL1200x Models. ‘ 1-61 XLB83L, XLBB3N, XL1200T Models, 4-62 1.23 STORAGE Placing in Storage. 1-63 Removal From Storage. 4-63 VI TABLE OF CONTENTS 1.24 TROUBLESHOOTING General 1-64 Engine. 1-84 Starter Motor Does Not Operate or Does Not Turn Engine Over. 41-84 Engine Tums Over But Does Not Star. 1-64 Starts Hard nA Starts But Runs irregularly or Misses. 1-64 Spark Plug Fouls Repeatedly... 1-64 Pre-lgntion or Detonation (Knocks of Pings).....9-65 CCheck Engine Light iuminates During Operation, 1-65 Overheating e 4-65 Valve Train Noise 4-85 Excessive Vibration 1-85 Lubrication System, 4-65 ll Does Not Retum To Oil Tank. 1-85 Engine Uses Too Much Oil Or Smokes Excessively. 1-65, Engine Leaks Oil From Cases, Pushrods, Hoses, Etc. 1-65 Low Oil Pressure. 4-65 High Oil Pressure. vot -68 Electrical System, 68 ‘Altemator Does Not Charge. 1-66 Altemator Charge Rate Is Below Normal 1-66 Speedometer Operates Erratcaly 1-66 Transmission. Shits Hard Jumps Out OF Gear. Cite Sips Cutch Drags Or Does Not Release 1-66 Ciuteh Chatters. 166 Hans 4-66 Brakes. = 4-66 ‘Brake Does Not Hold Normally 146 CHASSIS 2.1 FASTENER TORQUE VALUES Fastener Torque Values in this Chapt... 24 2.2 SPECIFICATIONS Tables. ; 2 Chassis 29 Wheels and Tres 21 2.3 VEHICLE IDENTIFICATION NUMBER: (vin) Vehicle ldentiicaton Number (VIN) 212 General : 242 Location 212 Abbreviated VIN. 212 2.4 TIRES Remove 244 Clean, inspect and Repair 214 instalation aren Mounting, aH4 Tube Type Tires rar) Tubeless Tires. 215 Ccheck Tre Runout 215TABLE OF CONTENTS Lateral Runout 245 Radial Runout 245 Balance Wheel. 2416 Static vs Dynamic. 2416 Weights 246 2.5 WHEELS General 247 ‘Wheel Bearing End Play, 2417 Front Wheel 248 Removals 2418 Disassembly: Cast Front Wheel... 249 ‘Assembly: Cast Front Wheel. 249 Disassembly: Laced Front Wheel. 2-20 ‘Assembly: Laced Front Wheel. (2-20 Installation 224 Rear Wheel 222 Removal 2-22 Disassembly. 2-22 Cleaning and Inspection. 2.23 Assembly 2-23 Installation, 2-24 Sealed Whee! Bearings, 2.25 Inspection. 2-25 Removal 2.25 Installation, 2-26 2.6 WHEEL LACING Wheel Lacing: Angle Flange Hub... 2.28 Wheel Lacing: Straight Flange Hub, Single Hole Circle...2-28 2.7 CHECKING AND TRUING WHEELS Cast Wheel Runout. 2-32 Wheel Stand. 2-32 Lateral Runout 2-32 Radial Runout.. (2-32 Laced Whee! Rim Offset. 233 ‘True Laced Wheels. 234 ‘Adjust Radial Runout 2-34 ‘Adjust Lateral Runout 235 2.8 FRONT BRAKE MASTER CYLINDER AND RESERVOIR Inspection. 2-36 Removal... 236 Front Brake Lever. 237 Removal. 237 Installation 237 Front Master Cylinder Reservoir Cover. 237 Removal. 237 Installation, 237 Front Master Cylinder. 2.38 Disassembly. 2-98 Cleaning and inspection. 2-38 Assembly. 2:38 Installation, 2.38 2.9 FRONT BRAKE CALIPERS Removal 2.42 Disassembly. . 2-42 leaning and Inspection. 2-43 ‘Assembly. Pistons, Brake Caliper to Mounting Bracket. Brake Pads. 2.45 Installation. 245 2.10 REAR BRAKE MASTER CYLINDER AND RESERVOIR Inspection 247 Removal 247 Cover. 2-48 Removal 2-48 installation. 2-48 Master Cyinder Rebuild Kit 2-48 Disassembly 248 Cieaning and inspection. 2-49 Assembiy. ‘248 Master Cylinder Mounting Bracke. 250 Removal 2-50 Installation. 2-50 instalation 2-50 2.11 REAR BRAKE CALIPER Removal 252 Disassembly. 2-52 Cleaning and inspection, 253 Assembly 2-53 instalation 264 2.12 BRAKE LINES Front Brak Line (Non-ABS) 2-56 Removal 2-56 Installation. 2-56 Front Brake Line Routing (Non-ABS) 2-58 XxL12006X 2-68 XLB89L, XLBAIN, XL1200G, XL1Z00T, XLTZ00X...2-58 XL120008 with Mini Ape Handlebar. 2559 Rear Brake Line (Non-ABS) 2:50 Removal 2-60 Installation "2-60 Front Master Cynder to Manifold to Caer (ABS)....21 Removal 2-61 Installation 261 Front Manifold to EHCU (ABS). 2-63 Removal 2-63 Installation, 2-63 Rear Master Cyindor to EHCU (ABS) 2-64 Romoval 2-64 installation 285 Rear EHC 1 Caipr 85) 2-65 Removal ‘2-65 instalation. 2-65 2.13 ELECTRO HYDRAULIC CONTROL UNIT (EHCU) Removal 267 instalation 2-68 2.14 BLEEDING BRAKES Gonoral 269 Procedure 2-69 ‘TABLE OF CONTENTS VIITABLE OF CONTENTS 2.15 LEFT SIDE COVER Opening and Closing. Open. Close. Replacement. Remove. Barrel Clip. Install 2.16 FRONT FORK (Check For Oil Leak. Fork Cil Seals, (Check Oil Leak. Removal — Disassembly: Right Side, All but XL12000X Drain Fork Oi Fork Cisassembly, Disassemby: Left Side, All but XL1200CX. Disassembiy: Left Side, XL1200CX. Disassembiy: Right Side, XL1200CX. ‘Clean and inspect. Assembly: Right Side, All but XL1200CX. Filling and Final Assembly ‘Assembly: Left Side, All but XL1200CX. Filling and Final Assembly ‘Assembly: Left Side, XL1200CX. ‘Assembly: Right Side, XL1200CX. Installation 2.17 FORK STEM AND BRACKET ASSEMBLY Removal and Disassembly. Cleaning, Inspection and Repair. Assembly end Installation. 2.18 BELT GUARD AND DEBRIS DEFLECTOR Belt Guard Removal. Installation, Debris Deflector. Removal Installation 2.19 REAR FORK Removal Installation Pivot Bearings, Removal Cleaning and Inspection. Installetion Axle Adjusts. Removal Installetion, 2.20 SHOCK ABSORBERS Removal Cleaning and inspection, reload Adjustment Knob: XL1200T... Installation, Vill TABLE OF CONTENTS 2m 271 271 271 27 271 27 272 272 272 272 273 273 273 275 278 2-80 281 2-82 2.83 2-83 2-84 2-86 287 2-90 291 ‘291 ‘292 294 2.94 2.94 298 2-94 2.94 2.95 2.95 2-06 2.96 2.96 2.96 287 297 297 298 2-98 2-98 2.21 STABILIZER LINKS General Upper Front Stabilizer Link. Removal Disassembly. ‘Assembly. Installation Lower Front Stabilizer Link. Removal. Disassembly. ‘Assembly. Installation Rear Stabilizer Link Removal Installation. 2.22 FRONT ENGINE MOUNT AND ISOLATOR Removal Installation, 2-400 2-100 "2-100 2-100 2-400 2-100 2-400 2-100 2-100 2-100 2-101 2-401 (2-401 2-401 2402 (2403 2.23 REAR ENGINE MOUNT AND ISOLATOR Removal Installation 2.24 THROTTLE CABLES Removal Throttle Adjusting Sorew. Removal Installation Cleaning and Inspection. Installation, 2.25 CLUTCH CONTROL Removal and Disassembly. Clutch Cable: Lower. Clutch Lever and Cable: Upper. (Clutch Hand Control ‘Assembly and Installation. ‘Clutch Hand Control, bo (Clutch Lever and Clutch Cable: Upper. Clutch Cable: Lower. 2.26 HANDLEBAR Removal All Models. XL12006, All Models except XL1200C. Installation XL1200C. ‘All Models except XL1200C. ‘All Models. Left Hand Grip. Removal Installation 2.27 FRONT FENDER: All Models 2-404 2-405 2406 2407 2-407 2-107 2-108 (2-408 2410 2-110 2411 2412 2113 2113 2413 2413 2015 ANS 2115 2415 2418 24118 24118 2419 2119 2-419 “2119 2120TABLE OF CONTENTS 2.28 FRONT LICENSE PLATE: INDIA Front License Plate: India 2422 XLB83L, XLBB3N. 2-122 XL1200X, XL12006X. 2-422 XL1200€, 2-122 2.29 SADDLEBAGS: XL1200T Removal. 2.124 Leckset 2-124 Reflectors and Medallions. 2-124 Reflectors, sn D424 Medallions. 2-124 Installation 2-124 2.30 REAR FENDER: TOP MOUNT LICENSE PLATE EXCEPT XL1200T, XL1200C, XL1200CB Removal 2425 Installation 2427 Fender Preparation. 2428 Tail Lamp Assembly. 2128 Seat Nut. 2128 Fender Extension 2428 Wire Harness and Conduit 2428 ‘ep Mount License Plate Bracket, 2428 Removal. 2-128 Installation, 2-128 2.31 REAR FENDER: XL1200C, XL1200CB Replacement. 2-129 Removal 2-129 Installation. 2-130 Fender Preparation, 2-431 Tall Lamp Assembly 2-131 ‘Seat Nut 2431 Fender Extension, 2-431 Wire Harness. 2431 License Plate Bracket: XL1200C, XL1200CB, 2-431 2.32 REAR FENDER: XL1200T Removal. Installation. Fender Preparation. Tail Lamp Assembly. Seat Nut Fender Extension Wire Harness, License Plate Bracket: XL1200T. Removal Installation, 2.33 REAR FENDER: MODELS WITH INTEGRATED TURN SIGNAL, TAIL AND STOP LAMPS General 2435 Removal and Disassembly. 2135 ‘Assembly and Installation 2437 2.34 WINDSHIELD: XL1200T Windshield Removal and Installation: XL1200T. 2-140 Removal. 2-140 Installation 2-140 Cleaning 2-140 Windshield Replacement, 2441 Disassembly. 2441 ‘Assembly. 2-142 Mounting Clamps. 2-142 Removal. 2-142 Installation, 2-142 2.35 SAREE GUARD: INDIA MODELS ‘Saree Guard. 2-144 Right and Left-Rear. 2-144 Let-Front. 2-144 2.36 REAR LICENSE PLATE: INDIA MODELS Rear License Plate: India. 2146 2.37 JIFFY STAND Removal, 2447 ‘Cleaning and Lubrication 24147 Installation, 2-148 2.38 SEAT Removal 2-149 Installation, 2-149 2.39 RIDER FOOT CONTROLS: MID-MOUNT Right Footrest and Rear Brake Pedal Assembly........2-151 Removal. 2-151 Installation 2481 Left Footrest and Shift Lever Assembly. 2-182 Removal. 2-152 Installation 2-152 Footboard Inserts: XL1200T.... 2-154 Removal. 2-154 Installation. 2-184 2.40 RIDER FOOT CONTROLS: FORWARD. Right Footrest and Rear Brake Pedal Assembly.......2-155 Removal. 2-155 Installation, 2-185 Left Footrest and Shit Lever Assembly. 2-156 Removal. 2-156 Installation 2-186 Adjusting Shift Pedal 2-458 2.41 PASSENGER FOOTRESTS: Let 2159 Removal 2-159 Installation 2-159 Right. 2-160 Removal 2-160 Installation 2-160 2.42 FORK LOCK Removal 2-461 Installation, 2461 ‘TABLE OF CONTENTS 1XTABLE OF CONTENTS 2.43 MEDALLIONS, BADGES AND TANK EMBLEMS Removal 2162 Installation, 2-162 ENGINE 3.1 FASTENER TORQUE VALUES Fastener Torque Values in this Chapter. a4 3.2 SPECIFICATIONS Specifications: Sportster Models. 33 3.3 OIL PRESSURE Operation. 37 ‘Al Models 37 il Pressure Indicator Lamp, 37 Checking Gil Pressure. 38 Preparation, 38 Connecting Gauge. 38 Testing Pressure. 38 Removing Gauge. 38 Finalize Test 38 3.4 CRANKCASE BREATHING SYSTEM Operation, 340 3.5 TROUBLESHOOTING Diagnosing Valve Train Noise..... 341 Compression Test, 341 Cylinder Leakage Test 341 Diagnosing Smoking Engine or High Oil Consumption..3-12 ‘Check Prior to Cylinder Head Removal. 342 Check After Cylinder Head Removal 342 Adjustment and Testing 342 General 342 3.6 ENGINE LUBRICATION SYSTEM il Pump Operation. 313 Oil Flow. 3415 3.7 HOW TO USE THIS SECTION ‘Typical Symptoms, 319 ‘Top End Repair. 349 Bottom Enc Repair. 349 3.8 TOP END SERVICE Engine in Chassis. 3.20 Engine Removed from Chassis. 3.21 3.9 BOTTOM END SERVICE Engine in Chassis. 322 Engine Removed From Chassis. 3.23 3.10 REMOVING ENGINE FROM CHASSIS. Procedure. 3:24 3.11 INSTALLING ENGINE IN CHASSIS. Procedure. 3.27 X TABLE OF CONTENTS 3.12 TOP END OVERHAUL: DISASSEMBLY General 3-30 Stripping Motorcycle for Top End Repair. 3.30 Cylinder Heads. os 3.30 Disassembling Rocker Covers. 3.30 Removing Cylinder Head... 332 Disassembling Pushrods and Covers, 3-33 (Cylinder and Piston, 334 3.13 CYLINDER HEAD Disassembly. 3-36 Cleaning and inspection. 3-36 Cylinder Heads. 3-36 Rocker Arm Assemblies 337 Valves. 3.38 Valve Seats 3-38 Valve Guides. 3.39 Valve Springs 3.39 Spark Plug Threads. 3.39 Pushrods. 339 Replacing Rocker Arm Bushings. 3.39 Replacing Valve Guides. 3-40 Removal 3-40 Installation. 3-41 Refacing Valve Seats. 3-44 Replacing Valve Seats, 346 ‘Assembly. 3-46 3.14 CYLINDER AND PISTON Cleaning, Inspection and Repair. 3.48 Checking Gasket Surface, 348 Measuring Cylinder Bore 348 Measuring Piston to Cylinder Fit. 349 Boring and Honing Cylinder. 349) Fitting Piston Rings. 3-60 Connecting Rod Bushings. 3-62 Removing Upper Connecting Rod Bushings. 3-52 Instaling Upper Connecting Rod Bushings. 3.53 Reaming Upper Connecting Rod Bushings. 3.54 Honing Upper Connecting Rod Bushings... 3.54 Repair. 354 3.15 TOP END OVERHAUL: ASSEMBLY General on BS Piston and Cylinder. 3-55 ‘Tappet Covers, Pushrod Covers and Pushrods. 3.56 Cylinder Head. 3.58 Rocker Covers. 350 Inner Cover. 359 Breather. 3.59 Outer Cover. 3-60 ‘Assembling Motorcycle After Top End Repair. 361 3.16 BOTTOM END OVERHAUL: DISASSEMBLY General 3-62 il Pump. 3.62 Tappets, 3-62 Cam Gear End Play. 362 Gearcase Cover and Cam Gears. BQ Crankcase, 3-63TABLE OF CONTENTS Split Crankcase... erry Piston Oil Jets 3-64 Removing Cyinder Base Studs... 3-64 3.17 GEARCASE Bushing Inspection and Removal 3-65 Bushing Installation 3-65 (Cam Gear Bushings in Right Crankcase. 3-65 Cam Gear Bushings (Except Rear Intake Bushing) in Gearcase Cover... 3-66 Rear intake Cam Gear Bushing in Gearcase Cover. 3-68 Pinion Shaft Bushing in Gearcase Cover... 3-66 Bushing Reaming, 3-66 (Cam Gear Bushings in Right Crankcase. 3-66 ‘Cam Gear Bushings (Except Rear Intake Bushing) in Gearcase Cover. 367 Rear Intake Cam Gear Bushing in Gearcase Cover..3-67 Pinion Shaft Bushing in Gearcase Cover. 3.68 3.18 CRANKCASE General 3-69 Disassembly. : — 3-69 Fiting Pinion Bearings. 371 ‘Outer and Inner Races 371 Bearing Selection, 371 Inner Bearing Finish Example. 373 Lepping Pinion Bearing Outer Race. 374 3.19 OIL PUMP. General 3-76 Removal. 3-76 Disassembly. ‘377 Cleaning and Inspection. 347 Assembly. 377 Installation 378 3.20 BOTTOM END OVERHAUL: ASSEMBLY Crankcase 379 Installing Piston Oil Jets. 379 Installing Pinion Shaft Bearings, 3-79 Installing Left Main Bearing 3-80 ‘Assembling Crankcase Halves, 381 Installing Cylinder Base Studs. 3-83 ‘Cam and Pinion Gear Identification. 3-83 Cam Gears and Gearcase Cover. 3-83 Teppets. 3-86 General : 3-86 Cleaning and Inspection 3-868 Installation 3-88 3.21 OIL FILTER MOUNT General 3-88 Disassembly. 3-88 Cleaning and Inspection. 3-88 Assembly, "3-88 3.22 OIL TANK Pressure Relif Valve. 3-89 (1 Line Routing 3-89 Crimp Clamps. 3-89 Removal. 3-89 Installation 3-89 Removal "3-88 Installation, nn 390 Oil Tank Bracket aol Removal 391 Installation, vn 391 FUEL SYSTEM 4.1 FASTENER TORQUE VALUES Fastener Torque Values in this Chapter oa 4.2 SPECIFICATIONS: FUEL SYSTEM Specifications. a2 4.3 AIR CLEANER ASSEMBLY All Models. 43 Removal 43 Installation, 43 4.4 FUEL TANK Purging and Disconnecting Fuel Supply LIN€.....nneunnandd Removing Fuel Tank a8 Cleaning and Inspection 45 Installing Fuel Tank 45 Germactng Fost Howe end Fig Pu Tot 6 Vapor Valve. aes: General nnn B Removal 48 Installation, 48 4.5 THROTTLE POSITION SENSOR (TPS) General so er) Removal. 49 Installation... senna 4.6 ENGINE TEMPERATURE (en) SENSOR General ant Removal. att Installation, 412 4.7 INDUCTION MODULE Removal. 413 Disassembly. AAS ‘Assembly... 416 Installation, AB 4.8 IDLE AIR CONTROL. L (ac) General 4-19 Removal... 419 Installation 4-20 4.9 TEMPERATURE MANIFOLD ABSOLUTE, PRESSURE (TMAP) SENSOR General 424 Removal 421 Installation, 42 4.10 HEATED OXYGEN SENSOR (HO2S) Removal... 423 ‘TABLE OF CONTENTS XITABLE OF CONTENTS Installation, 4.11 FUEL INJECTORS Removal Installation, 4.12 FUEL PUMP General Removal Disassembly Pressure Regulator and Filter Housing, Fuel Pamp Assembly and Pump Bracket... Low Fuel Level Sensor Assembly. Assembly. ‘Low Fuel Level Sensor Assembly. Fuel Pump Assembly and Pump Bracket Pressure Regulator and Filter Housing. Installation, 4.13 FUEL FILTER ELEMENT General Removal. Installation, 4.14 FUEL PRESSURE TEST General Testing Conne:t Fuel Pressure Gauge Perform Test. Return to Service, 4.15 INTAKE LEAK TEST General Leak Tester. Parts list... ‘Assemble Tester ‘Adjust Tester. Procedure. 4.16 EXHAUST SYSTEM Unit Removal Exhaust Stields Removal, Installation, Mutfler Shields, Removal. Installation, Muffore Removal. Installation Exhaust Pipes. Removal. Installation Exhaust Pipe Bracket Mounting Bracket. Removal. Installation 425 4-26 428 4-28 4-29 vn 29 429 429 4-30 4-30 430 4-30 431 433 4.33 433 4-34 4-34 34 4-34 435 437 437 437 437 437 437 439 4-40 4-40 4-40 4-40 4-40 4-40 440 4-40 4-40 441 441 441 441 442 4-42 4-42 4.17 EVAPORATIVE (EVAP) EMISSIONS CONTROL General Xil TABLE OF CONTENTS 443 Charcoal Canister. 443 Removal 4-43 Installation 444 Fuel Vapor Vent Hose. aad Removal 444 Installation ee Canister-to-Solenoid Hose. nd Removal 444 Instalation 444 Solenoid-to-Induction Module Hose. aad Removal. 448 Installation 444 Purge Solenoia. AAS Removal 4-45 Installation. 445 DRIVE AND TRANSMISSION 5.1 FASTENER TORQUE VALUES Fastener Torque Values in this Chapter. 54 5.2 SPECIFICATIONS: DRIVE ‘Sportster Specifications. 52 5.3 PRIMARY COVER Removal 53 Clutch Release Ramp. 54 Primary Chain Adjuster. 55 Installation 55 5.4 PRIMARY DRIVE AND CLUTCH Troubleshooting, ST Removal ST Disassembiy. 59 Inspection and Repair. 59 ‘Assembly. 5-10 Installation, 5-11 5.5 DRIVE BELT Drive Belt Handling, 13 Drive Belt 513 Removal 5-13 Installation 514 5.6 TRANSMISSION POWER FLOW General. 515 5.7 CASE DISASSEMBLY FOR TRANSMISSION REMOVAL General 5-16 Engine Removal and Disassembly... 516 5.8 TRANSMISSION REMOVAL AND. DISASSEMBLY ‘Transmission Removal From Left Crankcase. 519 Cleaning and Inspection. ‘520 Mainshaft Disassembly 5.20 Countershaft Disassembly. 521TABLE OF CONTENTS 5.9 TRANSMISSION ASSEMBLY Mainshaft Assembly. Countershaft Assembly. 5.10 MAIN DRIVE GEAR AND BEARING 523 523 General 5-25 Removal 5-26 Main Drive Gear. 5-26 Main Drive Gear Ball Bearing, 527 Disassembly. 5-27 ‘Assembly. 5-28 Installation. 523 Main Drive Gear Bearing 5.29 Main Drive Gear. 529 Main Drive Gear Seal 531 5.11 TRANSMISSION RIGHT CASE BEARINGS Removal CCountershaft Needle Bearing Shifter Drum Bushing, Installation CCountershaft Needle Bearing Shifter Drum Bushing, 5.12 TRANSMISSION LEFT CASE BEARINGS Removal, 5.35 Mainshaft and Countershaft Bearings. 5.35 Shifter Drum Bushing 5-35 Installation. 5-35 Mainshaft and Countershat Bearings, 5-35 Shift Drum Bushing 5-35 5.13 TRANSMISSION INSTALLATION General... 5-36 Installation 5-36 Shifter Forks and Drum Assembly.. 537 ‘Assembling Crankcases. 5-38 Shifter Shaft installation 538 5.14 TRANSMISSION SPROCKET Removal 541 Installation. 5-42 ELECTRICAL 6.1 FASTENER TORQUE VALUES Fastener Torque Values in this Chapter. 64 6.2 SPECIFICATIONS: ELECTRICAL Specifications. 65 6.3 FUSES Replacement. 66 Removal 86 Installation 66 6.4 SPEEDOMETER Removal . 7 XLB83L, XL883N, XL1200CB and XL1200T. 67 XL1200X, XL12000X 67 XL1200€, 67 Installation, nT XLB83L, XL8B3N, XL1200CB, XL1200T. 67 XL1200X, XL12006X. 67 xL1200¢ 68 6.5 ELECTRONIC CONTROL MODULE (ECM) Removal 69 Installation, 69 6.6 BODY CONTROL MODULE (BCM) Removal... 5-10 Installation, 6-10 6.7 H-DSSS Activation. 6-12 Antenna, 6-12 Fob Battery . 6-12 Battery Replacement Schedule, 6-12 Battery Replacement, 6.8 PERSONAL IDENTIFICATION NUMBER 6-12 (PIN) General... 6-13 Changing The PIN. 613 Modifying an Existing PIN. 6-13 6.9 SMART SIREN Replacement. 6-15 Removal. 615 Installation 6-15 Battery 615 Replacement Schedule. 615 Replacement 6-15 6.10 BATTERY CABLES Negative Battery Cable, 6-17 Removal. 6-17 Installation, 6-17 Positive Battery Cable. 6-17 Removal. 8-17 Installation. Son 6-18 6.11 BATTERY TRAY Removal 6-19 Installation, 619 6.12 STARTER Removal 6-20 ‘Touch-Up Paint. 6-20 Installation, 6-20 Solencia. 6-21 Remove Cover and Plunger. 621 Short Post Contact: Starter. 621 ‘Long Post Contact: Battery Positive. 621 Install Plunger and Cover. 6-22 Clutch Shaft Assembly 6-22 Removal. 6-22 Inspection. 6-22 ‘TABLE OF CONTENTS XillTABLE OF CONTENTS Installation. 6.13 IGNITION SWITCH Removal... Installation... 6.14 SPARK PLUG CABLES General Removal Installation, 6.15 IGNITION COIL General Removal, Installation, 6.16 HEADLAMP. Bulb Replacement. HilLow Beam, Position Lamp: HDI Headlamp Mounts. Mount: XL883L, XL8B3N, XL1200T. Mount: XL1200CX, XL1200X. ‘Mount: XL1200¢, XL1200¢8. Visor: XL12000, XL1200C8, 6.17 INDICATOR LAMP MODULE Preliminary Disassembly. Replacemen:: XL883L, XLB&3N, XL1200CB, XL1200T, XL1200X, XL12000x. Replacemen:: XL1200C. Assembly. 6.18 TAIL LAMP: MODELS WITH TOP-MOUNT LICENSE PLATE ‘Bulb Replacement: XL8B3L, XL1200T. Base Replacement: XL883L, XL1200T. Rear Lighting Hamess, Removal... Installation LED Tail Lamp: XL1200C, XL1200C8... Removal Installation, 6.19 LICENSE PLATE LAMP MODULE General Removal: Side-Mount License Plate. Installation: Side-Mount License Plate. Removal: Center-Mount License Plate Installation: Center-Mount License Plate. Roflector Brackets, Removal Installation, 6.20 FRONT TURN SIGNALS Bulb Replacement. Front Turn Signal Wire Hamess. Removal Installation, All Except XL1200T, XL1200X. Removal XIV TABLE OF CONTENTS 6-22 B24 B24 8-25 6-25 6-26 627 827 8-28 6.29 6.29 6.29 6-30 6-30 631 B31 631 633 6-34 6-35 6-35 6-36 6-36 6-37 6-37 6-37 6-38 6-39 6-39 6-40 6-43 6-44 ‘6-44 6-45, 6-45 6-45 6-45, 6-46 6-48 Installation anne 6-46 XL1200X, 6-46 Removal. . 6-46 Installation. 6-46 XL1200T, - 6-47 Removal. oe 6-47 Disassembly. 6-47 ‘Assembly. 6-47 Installation 6-48 6.21 REAR TURN SIGNALS General . 6-49 Bulb Replacement. 6-49 Tail and Stop Lamps. 6-49 XL8831 6-49 Removal 6-49 Installation... 6-50 XL1200T. 6-51 Removal. 651 Disassembly. 6-51 ‘Assembly. 651 Installation 6-52 XLBB3N, XL1200x. 6-53 Removal. 8-53 Installation 6-54 XL1200C, XL1200CB, 6-55 Removal 6-55 Installation 6-56 XL1200CX, 6-56 Removal 6-56 Installation 6-57 6.22 REAR STOP LAMP SWITCH Removal 6-59 ‘Stop Lamp Switch, 6-59 Wire Hamess. 6-59 Installation 6-59 Wire Hamess. . 6-59 ‘Stop Lamp Switch 6.23 CRANK POSITION SENSOR (CKP) 6-59 General 661 Removal a 661 Installation, 661 6.24 VOLTAGE REGULATOR Removal nenennsnn os : 6-62 Installation, earner 6.25 ALTERNATOR Removal and Disassembly. 6-63 Stator. 5-63 Rotor. ‘6-63 Cleaning and Inspection. on 64 Assembly and Installation. 6-64 Stator. 6-64 Rotor. 6-64 Final Assembly ve 65 6.26 VEHICLE SPEED SENSOR (VSS) Removal 6-66TABLE OF CONTENTS Installation 6.27 WHEEL SPEED SENSOR (WSS) Front WSS. Removal Installation Rear WSS. Removal Installation 6.28 NEUTRAL INDICATOR SWITCH General Replacement. 6.29 MAIN WIRING HARNESS AND ELECTRICAL CADDIES Removal, Eackbone Electrical Caddies. Preparation. ‘Small Backbone Electrical Caddy. Large Backbone Electrical Caddy. Reassembly. Replacing ECM Electrical Caddy. Removal. Installation Instaliation Clips: Mid-Mount Models. 6.30 JIFFY STAND SENSOR (JSS): INTERNATIONAL MODELS Removal Installation Operation, siffy Stand Down: Engine Non-Star. “iffy Stand Down: Engine Starts and Stalls. Jiffy Stand Drops. 6.31 OIL PRESSURE SWITCH General Removal. Installation. 6.32 HORN Front Mount Removal Installation, ‘Side Mount. Removal Installation. 6.33 RIGHT HANDLEBAR CONTROL MODULE Removal Right Handlabar Control Key Caps. ‘START/Hazard and Turn Signal (OFF/RUN. Front Stop Lamp Switch Replacement Installation 6-66 6-67 6-67 6-67 6-68 5-68 6-68 6-69 6-69 6-70 671 671 671 671 671 672 672 6-72 6-73 676 617 6-77 8-78 6-78 678 6-78 6-79 8-79 6-80 6-80 6-80 681 881 6-81 6.34 LEFT HANDLEBAR CONTROL MODULE Removal. 6-86 Left Handlebar Control Key Caps. 6-86 TRIPHORN and Tum Signal 6-86 LIGHTS. 687 Clutch Switch Replacement. 6-87 Installation. 6-87 APPENDIX A WIRING A. CONNECTORS: Connector Locations. AA Function/Location, AA Place and Coler. At ‘Connector Number. At Repair Instructions, AA A.2 WIRING DIAGRAMS Wiring Diagram Information, Ad Wire Color Codes. Ad Wiring Diagram Symbols. wh 2017 Sportster Wiring Diagrams. AS APPENDIX B COMPENSATING SPROCKET B.1 FASTENER TORQUE VALUES Fastener Torque Values in this Chapter. B+ B.2 COMPENSATING SPROCKET General. B2 Removal and Disassembly. B2 Cleaning, Inspection and Repair. B2 Sprocket Bearing. B2 Removal B2 Installation, B3 Assembly and installation, B3 APPENDIX C REFERENCE C.1 METRIC CONVERSION Conversion Table, cA C.2 FLUID CONVERSION United States System, C2 Metric: System, C2 British Imperial System. c2 C.3 TORQUE CONVERSION United States System. ca Metric. System, C3 C.4 GLOSSARY ‘Acronyms and Abbreviations, ca REFERENCE MATERIAL TOOLS. ‘TABLE OF CONTENTS XVTABLE OF CONTENTS TORQUE VALUES... M INDEX... XVI TABLE OF CONTENTS‘SUBJECT 1.1 FASTENER TORQUE VALUES. 1.2 GENERAL. 1.3 FUEL AND O1L. 1.4 MAINTENANCE SCHEDULE, 1.5 ENGINE OIL AND FILTER... 1.6 AIR CLEANER AND EXHAUST SYSTEM. “U7 TIRES AND WHEELS. 4.8 PRIMARY CHAIN... 119 TRANSMISSION LUBRICANT. 4.10 CLUTCH. 4.11 DRIVE BELT AND SPROCKETS. 4.12 THROTTLE CONTROL, 1113 CABLE AND CHASSIS LUBRICATION... 1.14 BRAKES. 41.18 BRAKE PADS AND DISCS. 4.16 SPARK PLUGS. 1117 STEERING HEAD BEARINGS... 1.18 ENGINE MOUNTS AND STABILIZER LINKS. 1.19 BATTERY MAINTENANCE, 1.20 WHEEL ALIGNMENT. 1121 SUSPENSION ADJUSTMENTS. 1122 HEADLAMP ALIGNMENT. 1123 STORAGE, 1.24 TROUBLESHOOTING... PAGE NO. a4 13 47 1-9 4-13 Aa7 20 4-25 4-27 4-29 4-33 4-35 1-36 4-39 143 145 vt AT 448 4-53 4-55 4-61 4-63 MAINTFNANCENOTESFASTENER TORQUE VALUES 1.1 FASTENER TORQUE VALUES IN THIS CHAPTER The table below lists torque values forall fasteners presented inthis chapter. FASTENER TORQUE VALUE NOTES ‘Air cleaner cover screw 36-60 nbs | 4.1-6.8Nm 1.6 AIR CLEANER AND EXHAUST SYSTEM, Air | |Cleaner Air filter element serew | 40-60imibs | 4568Nm 1.6 AIR CLEANER AND EXHAUST SYSTEM, Ar Cleaner (Axle, rear, nut 95-105 ftlbs | 129-142 Nm _|1.11 DRIVE BELT AND SPROCKETS, Adjustment) ‘Axle, rear, nut 95-105 ftlbs | 129-142Nm__|1.20 WHEEL ALIGNMENT, Wheel Alignment Battery strap fastener 72-96 intbs | 8.1-10.8Nm 1.19 BATTERY MAINTENANCE, Installation and | Connection Battery terminal screw 60.70 indbs | 68-79Nm 1.18 BATTERY MAINTENANCE, instalation and | | Connection Battery terminal scrow GOTO Ibe | 6879Nm_ [1.18 BATTERY MAINTENANCE, Istalaion and | |Connection | . eee Cee — | ‘Brake caliper, front, mounting bolt 28:36 tbs | 360-51.5 Nm | 1.18 BRAKE PADS AND DISCS, Brake Pad Roplacement: Front Brake caliper, front, pad pin 131-173 in-lbs | 14.6-19.5 Nm 1.15 BRAKE PADS AND DISCS, Brake Pad | Replacement: Front {Brake caliper, rear, mounting bolt 26-38 ftlbs | 36.0-51.5Nm 1.15 BRAKE PADS AND DISCS, Brake Pad Replacement: Rear V81 ‘Brake caliper, rear, pad pin 73 indbs | 148-195 Nm 1.18 BRAKE PADS AND DISCS, Brake Pad Replacement: Rear ‘Broke hose campo rearfortscrew | 30-40insbs | _3445Nm 1.11 DRIVE BELT ANO SPROCKETS, Adjustment Brake line, font, manfod ol 36-48 dbs | 4.15.41Nm [1.17 STEERING HEAD BEARINGS, Fall Away [Brake line P-lamp, rear, sorow 3040 indbs | 8.4-4.5Nm [1.15 BRAKE PADS AND DISCS, Brake Pad Replacement: Rear ‘Brake master ojinder, font, reservar’ | 87 indbs | 1.020NNm | 1.15 BRAKE PADS AND DISCS, Brake Pad cover screws Replacement Font Brake master finde, rear, reservar | &tTindbs | .0-20Nm | 1.18 BRAKE PADS AND DISCS, Brake Pad cover screws Replacement: Rear ‘rake master Gfnde,eservor cover | &Tindbs | .0-20Nm 1.14 BRAKES, Fluid Level screws ‘Clutch cable adjuster jamnut T20inibs | 186Nm —_|1.40 CLUTCH, Adjustment ‘Clutch inspection cover screws | B-10Bindbs | 95-12.2Nm [1.0 TRANSMISSION LUBRICANT, Transmission Lubsication |Clutch inspection cover screws 84-108 Inps | 9.5-12.2Nm_|1.9 TRANSMISSION LUBRICANT, Transmission ‘Lubrication | (Ghutch inspection cover serews 408 indbs | 9.5-122Nm |1.10 CLUTCH, Adjustment =| Fork stem pinch bot, upper 30-35 tibs | 40.7-47.5 Nm | 1.17 STEERING HEAD BEARINGS, Fal-Away \Fork stem pinch bolt, upper 7 30-35 ft-lbs 40.7-47.5Nm | 1.17 STEERING HEAD BEARINGS, Fall-Away Headlamp clamp nut: XL863L, XLBB3N,| 120-240 indbs | 13.627.1 Nm |1.22 HEADLAMP ALIGNMENT, Headlamp Ixct20or | [Adjustment ‘Headlamp horizontal adjustment: 30-35 ftbs ‘40.7-47.5.Nm |1.22 HEADLAMP ALIGNMENT, Headlamp XL1200C, XL1200CB, XL1200CX, xL1200x ‘Adjustment 2017 Sportster Service Maintenance 1-1Headlamp vrtcal adjustment XL1200C, 90-35 tube | 407-47 5m | 122 HEADLAMP ALIGNMENT, Headlamp xL120068, XL12006X, XL1200X Adjustment Lower pinch serowin lower orcbracket| 90-36 fabs | 40.747.5 Nm 1.17 STEERING HEAD BEARINGS, Fal-Away XLT200X, 9.12000 Lowe pinch scrow in ower forkbracket| 80-36 fabs | 40.7476 Nm [1.17 STEERING HEAD BEARINGS, Fal-Away XC T200K, 1.12000 Lower pinch screw in ower ockbracet:| 30-96 fabs | 40.7476 Nm 1.17 STEERING HEAD BEARINGS, Fal-Away AL 1200X, HL 12000X Oil drain hose clamp 6-10 intbs: 0.7-1.1Nm 1.5 ENGINE OIL AND FILTER, Changing Oil and iter [Primary chan editor oknut 7026 fibs | 274-008 |1.8 PRIMARY CHAN Fee Play Adusinont Primary chancase drain pug ‘430 ibs | 19.040.7 Nm 1.9 TRANSMISSION LUBRIGANT, Transmission LbratoApply LOCTITE 565 THREAD SEALANT | Primary chan inpecion cover | 100-120 nabs | 113-186 Nm [1-6 PRIMARY CHAN, Fee Pay Adusiment | Sparc 2-40 Ribs | 163-244 Nm [1.16 SPARK PLUGS, isialaion | Spoke nipple | 58 indbs: 6.2Nm 1.7 TIRES AND WHEELS, Wheel Spokes Swich hovsng screw 3645 Indbs | 40-51 Nm|1.12 THROTTLE CONTROL. Coble Inspection and Lubrication ‘Upper pinch screw in ower orkbracket:| 90-36 bs | 40.747 Nm 1.17 STEERING HEAD BEARINGS, Fal-Away XL1200X, XL1200CX (initial) | Upper pinch screw in owerorkbracket| 90-06 fabs | 40.7478 Nm | 1.17 STEERING HEAD BEARINGS, Fal-Away XL1200X, XL1200CX (initial) Upper pinch screw in ower orkbracket| 30-06 Ribs 40.747 5 Nm | .17 STEERING HEAD BEARINGS, Fal-Avay XL1200X, XL1200CX (initial) 1-2 2017 Sportster Service MaintenanceGENERAL 1.2 ——— SERVICING A NEW MOTORCYCLE WARNING Perform the service and maintenance operations as Indicated in the regular service interval table. Lack of regular maintenance at the recommended intervals can affect the safe operation of your motorcycle, which could result in death or serious injury. (00010a) Parform necessary set-up tasks before customer delivery. See applicable model year predelivery and set-up instructions. ‘The performance of new motorcycle inital service is required te keep warranty in force and to verify proper emissions sys- tems operation. See 1.4 MAINTENANCE SCHEDULE, SAFE OPERATING MAINTENANCE NOTES + Do not attempt to tighten engine head bolts or engine damage may result + During the initial breek-in period, use only GENUINE HARLEY-DAVIDSON H-D 360 MOTORCYCLE OIL. 20WS0. Failure to use the recommended oil results in improper break-in of the engine cylinders and piston rings. Inspect motorcycle regularly for more maintenance needs. Routinely check components between regular maintenance irtervals, Always inspect motorcycle after periods of storage before riding Check: 1. Tires for correct pressure, excessive wear or any signs of tire damage. 2. Drive belt tension and condition. Brakes, steering and throttle for responsiveness. Brake fluid level and condition. Hydraulic ines and fitings. for leaks. (Check brake pads and discs for wear. 5 6. Cables for fraying, crimping and free operation. 7. Engine oll and transmission fluid levels. 8 Headlamp, auxiliary/fog lamp, tail lamp, stop lamp, horn ‘and turn signal operation, DISPOSAL AND RECYCLING Help protect our environment! Many communities maintain facilities for recycling used fluids, plastics and metals. Dispose for recycle used ol, lubricants, fuel, coolant, brake fluid and batteries in accordance with local regulations. Many Harley- Davidson parts and accessories are made of plastics and ‘metals which can also be recycled SHOP PRACTICES Repair Notes General maintenance practices are given inthis section, NOTES + Repair = Disassembly/Assembly + Replacement = Substitute @ new part for existing com ponent. Al special tools and torque values are noted at the point of ‘All required parts or materials can be foundin the parts catalog. Safety Safety is always the most important consideration when pe forning any ob. + Aways have a complete understanding ofthe task + Use common sense + Use the proper tools + Protect yourself and bystanders with approved eye protec- tion Do not just do the job, do the job safely. Removing Parts "Always consider the weight of a part when iting. Use a hoist ‘whenever necessary. Do nat iftheavy pats by hand Ifa hoist and adjustabie iting beam o sling are needed to remove some parts, verify that ‘+The lengths of multiple chains or cables from the hoist to the part are equal and parallel + Slings, chains and cables are positioned directly over the center of the part. No obstructions interfere with te liting operation. + Parts are not left suspended. Gd Be sure to check capacity rating and condition of hoists, slings, chains and cables before use. Exceeding capacity ratings or using lifting devices that are in poor condition can lead to an accident, which could result in death or serious injury. (00466c) ‘Always use blocking or proper stands to support the part that ‘has been hoisted. Ifa part cannot be removed, verify that all bolts and attaching hardware have been removed. Verify that ro parts are in the way of the part being removed. When removing hoses, wiring or tubes, always tag each part to verify proper installation Cleaning ‘Always clean around lines or covers before they are removed, Pug, tape or cap holes and openings to keep out dit, dust and debris. Clean and inspect all parts as they are removed. Verify that al holes and passages are clean and open. After cleaning, cover all parts with clean lint-free cloth, paper or other material Verify that the partis clean when installed. ‘Thoroughly clean all pats tobe reused before assembly. Clean parts promote better component operation and longer life. Seals, filters and covers used in this vehicle keep out 2017 Sportster Service Maintenance 1-3‘extraneous dirt and dust. Keep these items in good condition to guarantee satisfactory operation, Cleaning Fastener Threads ‘To attain proper clamp load, always cl and threaded holes prior to assembly, NOTE Never use a thread-cutng tap or die fo clean threads. *+ Clean all threadlocking material from fastener threads and threaded holes. * Use a wire brush or thread-chasing die to clean fastener threads, + Use a thread chaser to clean threaded holes, + Use Put cleaner or equivalent to remove all traces of oi and contaminants from threads. + Clear all threaded holes with low-pressure compressed Aiways very cleanliness of blind holes before assembly. Tightening a screw with dirt, water or olin the hole can cause ‘castings to crack or break, Disassembly and Assembly ‘Always assomble or disassemble one part at a time, Do not work on two assemblies simultaneously. Make all necessary ‘adjustments. Inspect your work when finished to verify that everything is done. Operate the vehicle to perform any final check or adjustments, Halls correc, the vehicie is ready to go back to the customer. Checking Torques on Fasteners Check torque using a torque wrench set othe minimum spe ification for that fastener. f the fastener does not rotate, the fastener torque has been maintained. Ifthe fastener rotates, remove it to determine iit has a theadiocking agent. I it has a threadiocking agent, clean all material from the threaded hole, Replace the fastener with a new one or clean the original fastener threads and apply the appropriate threadlocking produc. Install and tighten the fastener to spe- ification, Ifthe fastener does not use @ threadlocking agent, install and tighten it to specification Magnetic Parts Trays ‘Magnetic parts trays are common in the service facility. They {are convenient and can keep parts from becoming lost during ‘repair procedure. However, hardened steel parts can become ‘magnetized when held in magnetic parts trays. Metal fragments from normal wear are usually trapped in the il fiter or by the magnetic drain plug. Magnetized part in the ‘engine can retain these fragments, potentially causing acceler- ated engine wear and damage. Never place parts from inside the vehicle's powertrain on a ‘magnetic pats tray. ‘1-4 2017 Sportster Service Maintenance REPAIR AND REPLACEMENT PROCEDURES 7 Hardware and Threaded Parts Install thread repair inserts when threaded holes in castings {are stripped, damaged or not capable of withstanding specified torque. Replace bolts, nuts, studs, washers, spacers and small ‘common hardware if missing or damaged. Clean up or repair ‘minor thread damage with a suitable tap or di Replace all damaged or missing lubrication fitings. Use LOCTITE 565 THREAD SEALANT on pipe fitting threads Threadlocking Agents Always follow specific service manual procedures when working ith fasteners containing preappled threadlocking agents when fastener replacementis recommended. When reusing fasteners ‘containing threadlocking agents, thoroughly clean all fasteners ‘and threaded holes. Always use the recommended thread- locking agent for the specitic procedure. Wiring, Hoses and Lines Replace hoses, clamps, electrical wiring, electical switches or fuel lines i hey do not meet specications. Instruments and Gauges Replace damaged or defective instruments and gauges. Bearings ‘Always use the proper tools and fixtures when servicing bear- ings. ‘Antistiction bearings must be handled in a special way. To keep out dit and abrasives, cover the bearings as soon as they are removed from the package. ‘When bearings are installed against shoulders, always verify that the chamfered side of the bearing faces the shoulder. Lubricate bearings and all metal contact surfaces before pressing into place. Only apply pressure on the part of the ‘bearing that makes direct contact with the mating part. Install bearings with numbered side facing out. Only remove bearings ifnecessary. Removal usually damages bearings requiring replacement with new parts. Bushings Do not remove a bushing unless damaged, excessively worn (oF loose in its bore. Press out bushings requiring replacement, ‘When pressing or driving bushings, always apply pressure in line with the bushing bore. Use a bearing/bushing driver or @ bar with a smooth, fat end, Never use a hammer to drive bushings. Verity that allo holes are property aligned during installation, Gaskets ‘Aiways discard gaskets after removal. Replace with new gas- kets. Never use the same gasket twice. Verify that gasket holes match up with holes in the mating part. Be aware that sections of a gasket may be used to seal passages,Lip-Type Seals Lip seals are used to seal ol or grease and aro usualy installed with the sealing lip facing the contained lubricant. Seal orient- ation, however, may vary under diferent applications. Do not remove seals unless necessary. Only remove seals to gain access to other parts or if seal damage or wear dictates replacement Leaking oil or grease usually means that a seal is damaged. Replace leaking seals to prevent overheated bearings. ‘Aways discard seals ater removal. Do not use the same seal Wwice O-Rings ‘Aways discard O-rings ater removal. Since many Oxings are similar in size and appearance, always use new O-rings, keeping them packaged untl use to avoid contusion. To prevent leaks, lubricate the O-ings before instalation withthe same type of lubricant as that being sealed. Verity that all gasket, O- ting and seal mating surfaces are thoroughly clean before irstallation Gears ‘Always check gears for damaged or worn teeth. Remove burrs and rough spots with a honing stone or crocus oth before installation. Lubricate mating surfaces before pressing gears on shafts, Shafts Ia shaft does not come out easily, check that all nuts, bolts of retaining rings have been removed. Check to see if other parts are in the way before using force to remove. ‘Shatts fitted to tapered splines should be very tight. If shafts ‘are not tight, disassemble and inspect tapered splines. Discard parts that are worn. Veriy that tapered splines are clean, dry {and free of burrs before pulting them in place. Press mating parts together tightly Clean all rust from the machined surfaces of new parts Part Replacement WARNING. Farley-Davidson parts and accessories are designed for Harley-Davidson motorcycles. Using non-Harley-Davidson parts or accessories can adversely affect performance, stability or handling, which could result in death or serious Injury. (00001b) ‘Always install new genuine Harley-Davidson parts and accessories. This provides best service life and maintain compliance with noise and emissions regulations. Installing non-Harley-Davidson, offroad or competition parts can void warranty or result in an unsafe vehicle. CLEANING Protecting Rubber Parts Eefore cleaning, protect rubber parts (such as hoses, boots ‘and electrical insulation) from cleaning solutions. Use a grease- proof barrier material. Remove the rubber part ift cannot be properly protected Cleaning Process ‘Any cleaning method may be used as long as it does not result in parts damage, Thorough cleaning is necessary for proper parts inspection. Strip rusted paint areas to bare metal before priming and repainting, Never use cleaners containing chlorine or ammonia on plastic parts, Chlorine causes parts to become distorted and britle resulting in cracks, Ammonia causes cloudiness and britloness in windshields and non-painted parts to form a white haze. Rust or Corrosion Removal Remove rust and corrosion with a wire brush, abrasive cloth, sand blasting, vapor blasting or rust remover. Use buffing crocus cloth on highly polished parts that are rusted. Bearings Wash bearings in a non-flammable petroleum cleaning solution, Never use a solution that contains chlorine. Knock out packed lubricant by tapping the bearing against a wooden block. Wash bearings again Awarninc Using compressed air to “spin dry" bearings can cause bearing to fly apart, which could result in death or serious injury. (005056) Cover bearings with a clean shop towel and allow to air dry. Do not spin bearings while they are drying. Never use com- pressed air to dry bearings. When dry, coat bearings with clean ol. Wrap bearings in clean Paper. TOOL SAFETY Air Tools + Always use approved eye protection equipment when performing any task using air-operated tools. + Onall power tools, use only recommended accessories with proper capacity ratings. + Donot exceed air pressure ratings of any power tools, + Placed bits against work surface before air hammers are operated, + Disconnect the air supply line to an air hammer before attaching a bit ‘+ Never point an air too! at yourself or another person. Protect yourself and bystanders with approved eye protec tion, 2017 Sportster Service Maintenance 1-5Wrenches + Never use an extension on a wrench handle, + If possible, always pull on @ wrench handle and adjust your stance to prevent a fall if something suddenly releases, + Always keep the wrench squarely installed on the fastener. + Never use_a hammer on any wrench other than a STRIKNG FACE wrench. + Discard any wrench with damaged or battered points. + Never use a pipe wrench to bend, raise oi pipe Pliers/Cutters/Pry Bars + Plastic- or vinyl-covered pliers handles are not intended to1actes insulation. Do not use them on lve electrical cir cuts. + Do not use pliers or cutters for cutting hardened wire Unless they were designed for that purpose. + Always cut at right angles. + Donotuse any pry bar as a chisel, punch or hammer. Hammers + Never strike a hammer against a hardened object, such as another hammer. + Always grasp a hammer handle firmly, close to the end. + Strike tre object with the full face of the hammer. + Never work with @ hammer which has a loose head or cracked handle, + Discard hammer if face is chipped or mushroomed, + Wear approved eye protection when using striking tools. + Protect yourself and bystanders with approved eye protec- tion Punches/Chisels + Never use a punch or chisel with a chipped or mush- roome¢ end. Dress mushroomed chisels and punches with a grinder + Hold a chisel or a punch with a tool holder if possible. + When using a chisel on a small piece, clamp the piece firmly in a vise and chip toward the stationary jaw. * Always wear approved eye protection when using these tools. + Protectyourselfand bystanders with approved eye protec- tion 1-6 2017 Sportster Service Maintenance Screwdrivers + Donot use a screwdriver for prying, punching, chiseling, ‘scoring or scraping ‘+ Use the right type of screwdriver forthe job. Match the tip of a screwdriver to the fastener. + Do not interchange POZIDRIV, PHILLIPS or REED AND PRINCE screwdrivers. + Screwdriver handles are not intended to act as insulation Do not use them on lve electrical circuits + Do not use a screwdriver with rounded edges because it will sip. Redress with a grinder. Ratchets and Handles * Periodically clean and lubricate ratchet mechanisms with a light grade ol. Do not replace parts individually. Rebuild ratchets withthe entire contents of service kit. + Never hammer on a ratchet or puta pipe extension on a ratchet handle for added leverage. + Always support the ratchet head when using socket ‘extensions, Do not put your hand on the head or you may interfere with the action ofits reversing mechanism, + When breaking a fastener loose, apply a small amount of pressure as a test to make sure that the ratchet's gear Wheel is engaged with the pawl Sockets + Never use hand sockets on power or impact wrenches. Select only impact sockets for use with air or electric impact wrenches, + Select the right size socket forthe job + Always keep the wrench or socket squarely on the fastener. + Replace sockets showing cracks or wear. + Keep sockets clean. + Always use approved eye protection when using power (or impact sockets. Storage Units + Donat open more than one loaded drawer ata time. Close ‘each drawer before opening another to prevent the cabinet from unexpectedly tipping over, * Close lids and lock drawers and doors before moving storage units. + Do not pull on a tool cabinet. Always push tool cabinets in front of you. + Setthe brakes on the locking casters after the cabinet has been rolled into position,FUEL AND OIL 1.3 FUEL - ‘Amays use a good quality unleaded gasoline, Octane ratings ‘are usually found on the pump. Refer to Table 1-1 CGN) Ayold spills. Slowly remove filler cap. Do not fill above bottom of filler neck insert, leaving air space for fuel expansion. Secure filler cap after refueling. Gasoline is, extremely flammable and highly explosive, which could result in death or serious injury. (00028a) Awarninc Use care when refueling. Pressurized air in fuel tank can force gasoline to escape through filler tube. Gasoline is ‘extremely flammable and highly explosive, which could result in death or serious injury. (00023a) Modem service station pumps dispense a high flow of gasoline into @ motorcycle fuel tank making ar entrapment and pressur- ization a possibilty. Table 1-1. Octane Rating ‘SPECIFICATION Pump Octane (R+M)2 GASOLINE BLENDS ‘Your motorcycle was designed to get the best performance ‘and efficiency using unleaded gasoline. Most gasoline is ‘blended with alcohol andlor ether to create oxygenated blends, ‘The type and amount of alcohol or ether added to the fuel is important. RATING 91 (95 RON) NOTICE Do not use gasoline that contains methanol. Doing so can result in fuel system component failure, engine damage andlor equipment malfunction. (00148a) + Gasoline/METHYL TERTIARY BUTYL ETHER (TBE) blends are a mixture of gasoline and as much as 15 per- cent MTBE. Gasoline/MTBE blends use in your motorcycle is approved, + ETHANOL fuel is a mixture of ethanol (rain alcohol) and Unleaded gasoline and can have an impact on fuel mileage. Fuels with an ethanol content of up to 10 percent may be used in your motorcycle without affecting vehicle performance. U.S. EPA regulations currently indicate that fuels with 15 percent ethanol (E15) are restricted from use in motorcycles at the time of this publication. Some ‘motorcycles are calibrated to operate with higher ethanol concentrations to meet the fuel standards in certain countries. + REFORMULATED OR OXYGENATED GASOLINES. (RFG) describes gasoline blends that are specifically designed to burn cleaner than other types of gasoline. This results in fewer talpipe emissions. They are also formulated to evaporate less when filing the tank. Refor mulated gasolines use additives to oxygenate the gas. Your motorcycle will run normally using this type of fuel Harley-Davidson recommends using it whenever possible a8 an aid to cleaner air in our environment. + Do not use racing fuel or fuel containing methanol. Use of these fuels will damage the fuel system. Using fuel additives other than those approved for use by Harley-Davidson may damage the engine, fuel system and other components. ‘Some gasoline blends might adversely affect stating, driveab- lity or fuel efficiency. If any of these problems are experienced, try a diferent brand of gasoline or gasoline witha higher octane blend. ENGINE LUBRICATION Pe Prolonged or repeated contact with used motor oll may bbe harmful to skin and could cause skin cancer. Promptly wash affected areas with soap and water. (00358b) Acaution Hengine oil is swallowed, do not induce vomiting. Contact a physician immediately. In case of contact with eyes, Immediately flush with water. Contact a physician if irita- tion persists. (003574) NOTICE Do not switch lubricant brands indiscriminately because some lubricants interact chemically when mixed. Use of inferior lubricants can damage the engine. (00184a) Engine ol is a major factor in the performance and service life Cf the engine. Use the proper grade of oil for the lowest tem- perature expected before the next oll change. Refer to Table 1-2. This motorcycle was originally equipped with GENUINE HARLEY-DAVIDSON H-D 360 MOTORCYCLE OIL 20050, H-D 360 isthe preferred oll under normal operating conditions, operation under extreme cold or heat are expected, refer to Table 1-2 for alternative choices. I H-D 360 is not available, add oil certified for diesel engines, Acceptable designations include: CH-4, Cl-4 and CJ-4. The preferred viscosities, in descending order are: 20W50, 15W40 ‘and 10040, At the first opportunity, see an authorized dealer to change back to 100 percent Harley-Davidson oil 2017 Sportster Service Maintenance 1-7Table 1-2. Recommended Engine Oils ‘Screamin’ Eagle SYNS Full Synthetic SAE 2050 | HO 360 ‘Above 30 °F (-1 °C) Excellent Motorcycle Lubricant ‘Genuine Harley-Davidson #- 360 | SAE20WS0 | HD 360 ‘Above 40 °F (4 °C) ‘Good | Motorcycle Oi - ‘Genuine Harley-Davidson H-D 360 ‘SAE 50 HD 360 ‘Above 60 °F (16 °C) Poor Motorcycle Oi ‘Genuine Harley-Davidson H-D 360 ‘SAE 60 HD 360 ‘Above 80 °F (27 °C) Poor Motorcycle Oi I LOW TEMPERATURE LUBRICATION Change engine oil often in colder climates, if motorcycle is frequently ridden less than 15 mi (24 km), in ambient temper- ‘atures below 60 "F (16°C), reduce ol change intervals to 1500 mi (2400 kr). NOTE Lower ambient temperatures require more frequent oll changes. ‘Water vaporis a normal by-product of combustion, During cold- ‘weather operation, some water vapor condenses to liquid form 18 2017 Sportster Service Maintenance ‘on the cool surfaces inside the engine. In freezing weather, this water becomes slush or ice. If the engine is not warmed to operating temperature, accumulated slush orice blocks the oil lines. and causes engine damage. Over time, water will accumulate, mix with the engine oll and form a sludge that is harmful to the engine, lt the engine is allowed to warm to normal operating temper- ‘ature, most of the water evaporates and exits through the crankcase breather.MAINTENANCE SCHEDULE 1.4 GENERAL Use the quick reference maintenance chart for torque values, ———— iubricants or cross references to maintenance procedures. ‘Ateach regular service interval, perform the required mainten- Refer to Table 1-4. ‘arce. Refer to Table 1-3 Use the lubricants, greases and sealants table to identity maintenance supplies. Refer to Table 1-5. Table 1-3. Regular Service intervals: 2017 Sportster Models TEM SERVICED 1000 mi eee] cana ioe eee nee | 35000 mi | 40000 mi | 0k | 200k | enn tan men | soa km | sno sm |Son0 tm stem |Oeacpeaimefseaa! x | x) x x | x | x | x | x | x Saar rd otces | [Cecctonmenessue, | x | x | x | x | x | x | x | x) x | x | x | 4 [cates | i (Gea tonwiecseae | | x x x aaa ‘Paws tacos Fppetkentecienzage] [Xe ee one | ink Roatan x x 5 x yas [Sree oe [sit esng headboa- | xT x 5 x x2 lias | | iia dire Pad 5 ae [omnes eet | | | [** | Chock age aaieaw| x] —X |X] x] x] ®® xe Tee ‘Check upper and lower x x x) x x sathcang ose ; pox a care: sone a resin | 4 ipo engre oor] xX |X| XX xe eae ‘Check primary chain adjust-| x x x) x x x x x x [Replace transmission iub- x Tx | x x x 7 ‘Inspect olines and brake |X x x oie eax x x x |x x x 42 ‘Soon eles conan abrasion | pects ardtings| —X |X| X[ RP Re ea Sac ran | [eck pr for stair | x x x 5 [eras exon tact | | | [esa ases tre - |Creck front isolator x | x x x yx 1.25 ee | Fpetverbatenadagn] “X [x [ x |X |e | Re eee es pry? | [rete bareomnee |X x 1 x 5 [eras Serscentoree | Imeegiaigromend fx |X XD ep RP RY RX fe pe pe [Crock front axle nut torque |X ss x x x [x 125 ‘Creck brake banjo bolt x) x x x) x yx [425] me [ | - repecndtbicamysy |X| x] KX pe x pe pe pe fe x Re na | Check ach ofeane |x| x a x] ee pas Check, guard es] x] x x x [ex] x ae onus cone | L* | het rerwnestepate |X| x X x [x ]zaa si onan | | |Gvaariee mss | x | x RRR EE pec eat 7 7 | 2017 Sportster Service Maintenance 1-9‘Table 1-3. Regular Service Intervals: 2017 Sportster Models pete Be Sostot, oat (heck rar ate nutore | x Dey 1a Irpec ents |X |X x] ]x« |x px |= ve take, ccs does imanngisows oes [thes | ‘heck i oral nd la conrecions aus a laces lg ey wo er or ev 50.000 8000 ¥ Wich se a x [ar Recs elem evany 100000 (60R00 en) 24 Fish rae sso an ples DOT rk id eyo ae 2 foadtestowitveon |X | x [| x | x | x | x | x | x | x |x | x pero anomie | {Parr anual or lspci eval, whichever comes fst 12 Shul be pertored by an aunrzed Harley-Davidson doa, unless you hav the proper ol, erce data andere mechanical ‘uation '3:Perarm spoke tenon check st 100 (160 kn, 5000 (8000), 20,000 mi (32, 000k) sercs and every 15,000 (24,000 km terval reat. Nota vehicles have spoked wheels. Consut appropatelopicin serves manual. 4: Perarmmantanance more requenit) in severe condone (suc a extra iomperature, dust envronment, mountainous ‘or ough roads, lag storage condtons, shot run, heat tpi alo por aia) 5 For torque stuns, se Shop Pracices ne service manual iat aa inspect every 3,000 (8,000 km) pct reba forks ad replace fk ot every 0,000 mi (0,00 km), NoTE Whenever a vehicle is in for maintenance: + Always check for and complete open recalls and product programs. + Always verify that the latest calibration is installed, Table 1-4. Quick Reference Maintenance and Torque Chart 'Aircleaner ‘See 1.6 AIR CLEANER AND EXHAUST SYSTEM. [Ar filter screw torque ‘Air cleaner cover screw torque a "ales Front nut torque : (60-65 fhibs (81-88 Nm) Rear nut torque i (95-105 fabs (129-142 Nm) Battery ‘Lubricant ELECTRICAL CONTACT LUBRICANT “Terminal serew torque 60-70 indbs (6.8.7.9 Nm) Brakes Brake fluid type DOT 4 BRAKE FLUID Brake fuid level ‘Above low level mark Brake line banjo bolt torque 14-18 fetbs (19.0-24.4 Nm) Reservoir cover screw torque 9-17 in-lbs (1,0-2.0 Nm) Handlebar control lever clamp screw torque | 108-132 in-Ibs (12.2-14.9 Nm) | Rear master cylinder reservoir mounting screw torque| 18-22 fi-lbs (23.1-29.9 Nm) Minimum brake pad thickness (0.04 in (1.02 mm) - Minimum brake disc thickness [See stamp on side of dso. (Clutch adjustment | Free play at adjuster screw 4 turn Free play at hand lever 1116-118 in (116-33 Handlebar control lever clamp screw torque 108-132 in-bs (122-14.8 Nm) Clutch inspection cover serew torque {90-120 inabs (10 3-13.6 Nm) 1-40 2017 Sportster Service Maintenance‘Table 1-4. Quick Reference Maintenance and Torque Chart Lubricant HARLEY LUBE Handlebar control lever clamp screw torque 108-132 insbs (12.2-14.9 Nm) ‘Switch housing screw torque 35-45 incbs (4.0-5.1 Nm) Drive belt ‘Measure belt deflection on a motorcycle thats upright| All models: ‘or on jiffy stand with rear wheel on the ground and | 1/4-5/16 in (6.35-7.94 mm) tuniaden. Check deflection when belt and sprockets are at ambient temperature. Engine idle speed _|Idle speed {950-1050 rpm ‘See 2.22 FRONT ENGINE MOUNT AND ISOLATOR, ‘and 2.21 STABILIZER LINKS. Engine mounts, isol- ‘ators and stabilizers 2.23 REAR ENGINE MOUNT AND ISOLATOR ‘Stabilizer ink, upper front, engine bracket mounting 55-65 ft-lbs (74.2-88.2 Nm) screw toraue _Engine mount, ont bot orque 65-105 Fibs (1288-142.3 Nm) Engine oil and filter Oil capacity - - 2.8 gt (2.65 L) Fiter 7 Hand-tighten one half to three quarter tur after gasket contact. Front fork of Type [TYPE "E" HYDRAULIC FORK OIL Amount Soo 216 FRONT FORK. Fuel fiter ‘Fuel pump module mounting screw torque 40-45 in-bs (4.5-5.1 Nm) Primary chain tension Deflection with hot engine 114-378 in (6.3-9.5 mm) Deflection with cold engine 6-12 in 512.7 mm) | Cain tensioner nut torque 20-25 tubs (27133. Nm) Primary chain inspection cover sorew torque [90-120 ints (10.2-13.6 Nm) Primary chain and Lubricant capacty 5202 (G46 mt) ranariason Primary cheincase dan plug torque 1430 bs (18.040.7 Ne) Lubricant FORMULA TRANSMISSION AND PRIMARY CHAINCASE LUBRICANT Spark pluos ap 01038-0043 in (0.86-1.09 mm) ‘Torque 7 12-18 f-lbs (16.3-24.4 Nm) 'Steering head bearings Lubricant 7 SPECIAL PURPOSE GREASE Tres Prossure: XLGBSL, MLT2000X, XLI200T Front: 36 psi (248 KPa) Rear. 42 psi (280 KPa) Pressure: XL883N- Front: 30 psi (207 kPa) - Rear: 40 psi (276 KPa) | Pressure: XL1200X, XL1200C, XL1200CB ‘Front: 36 psi (248 kPa) | Rear: 40 psi (275 kPa) (Wear ; Replace tire if 182 n (0.8 mm) or ess of ead pattem remains West spokes Spoke nipple Toru 55 Indbs (62 Nn) 3M 847 Adhesive Table 1-5. Lubricants, Greases, Sealants (02120-19718 3M General Purpose Adhesive Remover 15 oz aerosol Anti-Seize Lubricant '98960-97 1 oz squeeze tube | CCI #20 Brake Grease '42830-05, ‘squeeze packet 2017 Sportster Service Maintenance 1-11Table 1-5. Lubricants, Greases, Sealants OT Brake Fu eos-20n 12 obo ‘Dow Coming Moly 44 Grease |94674-99 '2 0c packet iectical Coat Lubricant 11900004 | az squeeze ube Formulas Tansmisson and Primary Chaincase 2865105 1 alot Loncart G40M Brake Grease 7 |42820-04 ‘squeeze packet 7 [Genuine Hatey-Davidon Etended Lie Aifenze 962202 1 galconiainer ond Cooler Genuine Haley Davidon FFD 80 005 ‘6616 20800007 1 tote Netreyae OF | Farley Davison Asie (Glo) a Harley-Davidson Fgh Porormance Selon ray eeesoc2 [12 oxeqonzo ibe Hafiy Davison Leather Dressing ests [6ozean Harley-Davidson Seal Grease - 17300005, oz tube aly Libe [e6e-00 1 oz aed dponser omar Genel and Tread Sealant o665085 _300zube : Loctite 222 ow StongthThveadockr and Soalntpuple) 9981197 emi ube |Locite 249 edu Seng Trealocker and Sealant) [9964.87 6 mL ube 11100005 '50 mL bottie - Loctite 246 Medium Strength/High Temperature Threadlocker (blue) | | Loctite 262 High Strength Threadlocker and Sealant (red) | 94759-99 [6 mL tube Loctite 271 High Strength Threadiocker and Sealant (red) [6 mt tube 11100006 '50 mL bottle Loctite 417 Prism instant Adhesive Loctite 420 Super Bonder Adhesive Loctite 565 Thread Sealant (99818-97 |6mL tube Loctite 770 Prism Primer — Loctite 7649 Cleaner/Primer ‘98968-99 1.75 02 bottle ‘Screamin’ Eagle Assembly Lube 11300002 ‘402 tube a ‘Screamin’ Eagle SYN3 Full Synthetic Motorcycle ‘99824-03/000T |1 qtbottie Lubricant 20W50 I |Special Purpose Grease - __(99857-97A 14 02 cartridge ‘Type "E" Hysraulic Fork Oil - |62600026 16 oz bottle Wheel Bearing Grease 99855-89 1b can |99856-92 14 02 cartridge * Not a Harley-Davidson part number 142 2017 Sportster Service MaintenanceENGINE OIL AND FILTER 1.5 CHECKING AND ADDING OIL Removing and Replacing Oil Filler Cap 1. Park motorcycle on a level surface on jiffy stand. 2, See Figure 1-1. Remove the filer cap from the ol tank ‘8, Press straight down on the filer cap and release. The cap wil pop up. . Pulluponthe filer cap while turing counterclockwise one-quarter turn as if removing the filer cap, 3. Wipe dipstick clean NoTE ‘See Figure 1-2. Align tabs on oil tank filer neck to slots (1, 2) (on dipstick 4, Install the dipstick into the tank. a. Turn the filer cap clockwise one-quarter turn as if screwing the filer cap into tank. When the filer cap stops turning, itis seated. b. Press down on the filer cap unti it snaps in place, flush with the top of the oil tank cover. Figure 1-1. Filler Cap Location Wide slot Narrow slot Figure 1-2 Filler Cap Slots Level Cold Check NOTES + Check engine oit level at each complete fuel refi + An accurate engine ail check can only be made withthe engine at operating temperature (Hot Check) 1. Park motorcycle on a level surface on jy stand. 2. Remove the filer cap and wipe the dipstick clean. Install the ol filer cap in tank 3, Remove oil filer cap again and visually check for clin the tank 4, Ifoilis not visible in the tank, install he flr cap. NOTE If the oll pressure lamp stays It after starting engine, immedi- ately shut off the engine. 5. Startandidle 6. Remove oil filer cap and visually check for olin the tank. sngine for 30 seconds. Stop the engine, NOTICE Do not overfill oil. Doing so can result in oll carryover to the air cleaner leading to equipment damage andlor ‘equipment malfunction. (00190b) NOTE Use only recommended oil. Recommended viscosity depends ‘upon ambient temperature. Refer to Table 1-2. 7. Ifthere is no oll visible in the tank, add oll unl tis present Con the bottom of the dipstick. 8. When oll is present on the bottom of the dipstick, perform hot check, 2017 Sportster Service Maintenance 1-13Oil Level Hot Check 1. Run theengine until the engine oils at operating temper- ature, 2. Idle the motorcycle on the jify stand for one to two ‘minutes Tum off engine. 3. Park mctoreycle on a level surface on jify stand, 4. Remove the filer cap. Wipe dipstick clean. Install the filer cap in the tank. NOTICE Do not allow hot oil level to fall below Add/Fill mark on dipstick. Doing so can result in equipment damage andlor ‘equipment malfunction. (00189a) NOTICE Do not overfill oil. Doing so can result in oil carryover to the air cleaner leading to equipment damage andlor ‘equipment malfunction, (001906) NOTES + Use ony recommended oil, Recommended viscosity depends upon ambient temperature. Refer to Table 1-2. + The oil tank has a built-in pressure relief valve. Ifthe oil tank is cveriled, excessive pressure is created in the oll tank. The pressure relief valve opens to relieve the pres- ‘sure and prevent damage to the oil tank. Excessive oll ‘due fo overfiling is forced out the pressure relief valve when it opens. 5, See Figure 1-3. Remove the filer cap. Check engine oil level ‘2. Below the lower mark: Add only enough oil until the level reads between the upper and lower marks. b. Between the upper and lower marks: It is safe to ‘operate the motorcycle, Above the upper mark: Drain the cil until the level reads between the upper and lower marks. 6. Install te filer cap. {foil was added, remove the filer cap to verify the engine cil level n the ol tank. Do not fil ol tank to a level above upper mark on the dipstick. Install the fler cap. 1-14 2017 Sportster Service Maintenance 4. Lower mark (FILL) 2. Upper mark (FULL) _ Figure 1-3. Dipstick CHANGING OIL AND FILTER HD-42311 HARLEY-DAVIDSON OIL FILTER WRENCH HO-44067-A HARLEY-DAVIDSON OIL FILTER | WRENCH Ol drain hose clamp 6-10 imibs | 07-11 Nm Draining Oil Tank EG Be sure that no lubricants or fluids get on tires, wheels or brakes when changing fluid. Traction can be adversely affected, which could result in loss of control of the ‘motorcycle and death or serious injury. (00047d) NOTICE Do not switch lubricant brands indiscriminately because ‘some lubricants interact chemically when mixed. Use of inferior lubricants can damage the engine. (00184a) Completely drain oll tank of used oil at scheduled service intervals. Refll with fresh oll. Refer to Table 1-3 Noes + Change oil at spectied intervals in normal service at warm (or moderate temperatures. + Change engine oll at shorter intervals in cold weather or in severe operating conditions. See 1.3 FUEL AND Ol Low Temperature Lubrication, + Change engine oil at shorter intervals if ridden extremely hhard, used in competition or driven on dusty roads. + Always change oi fiter when changing engine oi 1. Run motorcycle until engine is at normal operating temper- ature2. Remove dipstick from oil tank. NOTE ‘The drain pan must hold approximately 3.0 qt (2.8 L). 3. Place a drain pan directly under the oll tank 4, See Figure 1-4, Pull clip (1) from frame tube. 5. Direct drain hose (2 infront of bracket (8) into drain pan. 6. Loosen clamp (4). Remove plug (5) from end of hose. NOTE Completely drain engine oil from oil tank. 1. Allow oil to drain. 8. Install plug into hose. 8. Tighten clamp to 6-10 in-tbs (0.7-1.1 Nm). 40. Route drain hose along frame tube. ‘11. Clip hose to frame. ones 2 4 Figure 1-4. Drain Hose Removing Oil Filter 1. Place a drain pan under the oi fer. NOTICE Use Harley-Davidson oil filter wrench for filtor removal. This tool can prevent damage to crankshaft position sensor ‘See Figure 1-5, Tum fiter (1) counterclockwise to remove from ‘mount (2) 2, Remove oil fter using HARLEY-DAVIDSON OIL FILTER WRENCH (Part No, HD-42311) or HARLEY-DAVIDSON OIL FILTER WRENCH (Part No. HD-44067-A). 3, Drain engine oll Discard oil itor 4, Clean any ol spills off crankcase and frame, Figure 1-5. Oil Filter Installing Oil Filter Nore To build of pressure on engine startup, partial fi ol iter. 4. Pour about 4floz (120 ml) of fresh, clean engine onto new oie. ‘Allow time fo lt soak into fiter element See Figure 1-6. Wipe ol itr mount contact surface (1) with a clean cloth. Surface must be smooth and free of debris or old gasket material. 4. Apply @ thin fm of oll to contact surface of the oil fiter ‘mount and fiter gasket (2) of new oi fite. NOTE Do not use oil fiter wrench to install new oil iter. 5. Install new ol fier. ‘a. Screw fter onto adapter (3) until gasket contacts the gasket contact surface. b. Hand-tighten one-half to three-quarters turn to secure the ol fiter. 2017 Sportster Service Maintenance 1-15,1. Contact surface 2. Filter gasket 3. Adapter Figure 1-6. Installing Oil Filter Refilling Oil Tank Noe Use the proper grade of ol forthe lowest temperature expected before the next oil change. Refer to Table 1-2. 4, Pour 2.0 gt (1.9 L) of ol nto engine oil tank. 2. Install dipstick in ol tank. Seat cap. 3, See Figure 1-7. Verify oil pressure. a. Start engine, . Verity thatthe oil pressure indicator turns off at 1000 rpm or above. & Tum off engine. 4. Perform engine ol evel hot check. Start engine and carefully check for oll leaks around drain plug and oi fier. NOTICE Do not overfill oil. Doing so can result in oll carryover to the air cleaner leading to equipment damage andior ‘equipment malfunction. (001905) 1-46 2017 Sportster Service MaintenanceAIR CLEANER AND EXHAUST SYSTEM 1.6 AIR CLEANER FASTENER TORQUE VALUE {Ar fiter element screw 40-60 in-lbs | 4.5-6.8Nm_ ‘ircleaner cover screw | 36-60 indbs | 4.1-6.8Nm Removal 4. See Figure 1-8. Remove cover screws (8) and trim (7) (if necessary) from the cover (6) Remove air cleaner cover. Remove seal (5) from the cover, Remove element screws (4). Remove the fer element (3) and gasket (2) from backplate. Discard gasket 4, Remove O-rings (1). Discard O-rings. Inspect the cover seal. Replace if necessary. Clean the air cleaner backplate. Clean the inside of air cleaner cover. @. \ ‘O-ring (2) Gasket Filter element Element screw (3) Seal Cover Trim Cover screw eneeeene NOTICE Install air filter before running engine. Failure to do so can draw debris into the engine and could result in engine damage. (002072) Installation 1. See Figure 1-8. Apply a thin coat of engine oil to the new (O-rings (1). Install O-rings to breather tubes. 2. Position a new gasket (2) onthe ar fiter element (3). Line Lp the gasket holes with the backplate holes. NOTE Install the fit element with THIS SIDE OUT on top. 3. Apply a drop of LOCTITE 243 MEDIUM STRENGTH ‘THREADLOCKER AND SEALANT (blue) to each element screw (4) Install the fiter element onto the backplate. Tighten to 40-60 indbs (4.5-6.8 Nm). 4, Fit seal (6) onto cover (6). Verify alignment around cover, edge. 5. Install cover onto backplate. Do not pinch or distort seal 6. Install trim insert (7) if necessary) and cover. Install cover serews (8). Tighten to 36-60 in-bs (4.1-6.8 Nm). Figure 1-8. Air Cleaner CLEANING FILTER ELEMENT WARNING. Do not use gasoline or solvents to clean filter element. Flammable cleaning agents can cause an intake system fire, which could result in death or serious injury. (00101a) NoTE Do not tap the fiter on a hard surface. 1. Wash the filter in warm soapy water. 2. To remove soot, soak the filter in warm soapy water for 30 minutes. 2017 Sportster Service Maintenance 1-17NOTE The fiter is clean it ight i visible through iter. 3. Hold the fter upto light 1-18 2017 Sportster Service Maintenance ONT Compressed air can pierce the skin and flying debris from compressed air could cause serious eye injury. Wear safety glasses when working with compressed air. Never use your hand to check for air leaks or to determine air flow rates. (00061a) 4. Dry the fter rom the inside with low-pressure compressedCHECK EXHAUST SYSTEM LEAKAGE Check exhaust system for leaks at every scheduled service interval 1. Check entre exhaust system forloose or missing fasteners. ‘and damaged pipe clamps or brackets. Check exhaust system for obvious signs of leakage such as carbon tracks at pipe joint. 2. Check for loose or damaged exhaust shields. Replace or repair as necessary. 3. Start engine, cover muffier ends with clean, dry shop towels and listen for audible signs of exhaust leakage. 4. Corect ny leaks detected. Exhaust System Leakage Han exhaust system leakis evident at a muffler or header pipe Connection, disassemble and clean all mating surfaces. See 4.46 EXHAUST SYSTEM. + Replace any damaged components + Ifleak continues, disassemble and apply Permatex Ultra Copper, LOCTITE 5920 FLANGE SEALANT or equivalent. + Assemble components. Wipe off any excess sealant. + Follow sealant product instructions. Allow adequate curing time before operating vehicle 2017 Sportster Service Maintenance 1-19TIRES AND WHEELS 1.7 a AIR PRESSURE Awarnin Be sure tires are properly inflated, balanced, undamaged, ‘and have adequate tread. Inspect your tires regularly and ‘see a Harley-Davidson dealer for replacements. Riding with excessively worn, unbalanced, improperly inflated, ‘overloaded or damaged tires can lead to tie failure and adversely affect stability and handling, which could result in death or serious injury. (000146) ‘Always maintain proper tire pressure as specified in Table 1-6. Do not load tires beyond GAWR specified in Table 2-4. Underinflated, over-inflated or overioaded tires can fail, Check tre pressure when the tres are cold, Refer to Table 1-6. NoTE Harley-Davidson does not perform any testing with only inrogen in tres. Harley-Davidson neither recommends nor discourages the use of pure nitrogen to inflate tres. ‘Table 1-6. Tire Pressure (cold): 2017 Sportster Models" MODEL kPa XLB83L 248 290 XLB83N 207 276 248 276 [xL120008 | 248 216 XL12006X 248 290 XL1200T 248 290 XL1200X 248, 276 * Tire pressure will vary with changes in ambient and tre temperature. Check pressure with tires cold 68° F (20° C), Increase tre pressure by 1 psi (6.9 KPa) for every 10° F (5° CC) in ambient air temperature above this point. TIRE REPLACEMENT Tread Wear WARNING Replace tire immediately with a Harley-Davidson specified tire when wear bars become visible or only 1/32 in (0.8. mm) tread depth remains. Riding with a worn tire could result in death or serious injury. (00090) Harley-Davidson tires are equipped with wear bars that run horizontally across the tread. When a tir is worn to the point 1-20 2017 Sportster Service Maintenance that the wear bars are visible, or 1/32 in (0.8 mm) tread depth remains, the tire can: + Be more easily damaged leading to tir failure + Provide reduced traction + Adversely affect stabilty and handling, Replace the tires with new tires before the tread wear bars. appear: + See Figure 1-9 of Figure 1-10. Indicators (1) on the tre sidewalls point to tread wear bars (2) in the tread + Tread wear bars appear in the tread pattern when 1/32 in (0.8 mm) or less of tread remains. Ps Xu J > (2)0 ) 1. Indicator 2. Tread wear bar Figure 1-9. Tread Pattern: Michelin Tires>\\" = _ A Y-s SIGE Sf \b or ee \ = 1. Indicator 2. Tread wear bar Figure 1-10. Tread Pattern: Dunlop Tires Tire Damage Replace tres with new tres when Tire cords or fabric are visible through cracked sidewall, snags or deep cuts. ‘A bump, bulge oF splits found anywhere on the tie + A puncture, cut or other damage cannot be repaired SPECIFIED TIRES CSG) Match tires, tubes, rim strips or seals, alr valves and caps. to the correct wheel. Contact a Harley-Davidson dealer. Mismatching can lead to tire damage, allow tire slippage ‘on the wheel or cause tie failure, which could result in death or serious injury. (00023c) Awarninc Harley-Davidson recommends the use ofits specified tres. This vehicle is not designed for operation with non-spe- fied tires, including snow, moped and other special-use tires. Use of non-specified tires can adversely affect sta- bility, handling or braking and lead to loss of vehicle con- ‘tol, which could result in death or serious injury. (00024c) ‘Store new tires on a horizontal tre rack, Do not stack tires ina vertical stack + Mount only Harley-Davidson specified tires. Refer to Table 1-7. Table 1-7. Specified Tires: 2017 Sportster Models MODEL |WHEEL| SPECIFIED TIRE L883 F_|Michelin Scorcher "11F* 120/70ZR18 MIC ssw R | Michelin Scorcher "11" 150/602R17 MIC jecaean Soorcher"3i* 10090810 MIC | [Michelin Scorcher 31” 150/60B16 MIC | 77H | XL1200C, | F _ |Michelin Scorcher"31" 130/90816 M/C] 73H [Michelin Scorcher “31” 150/80816 M/C 77H XL120068 | F | Michelin Scorcher "31" 130/90816 MIC. 73H R__|Michelin Scorcher "31" 150/80B16 M/C | 77H XL12006X | F [Dunlop GTSO2F 120770R19 MIC 6OV R__ |Dunlop GT502 150/70R18 MIC 70V XL1200T | F [Michelin Scorcher "117° 120/70ZR18 MIC SW R__ Michelin Scorcher "17° 150/70ZR17_ Mic 69 ,__|_™ | XL1200X, | F [Michelin Scorcher "31" 130/90816 MIC) 73H [Michelin Scorcher "31" 150/80816 M/C 77H WHEEL BEARINGS NOTE Roplace bearings in sets only. See 2.5 WHEELS, Sealed Wheel Bearings. 1. Replace when bearings exceed end play service wear limit of 0.002 in (0.051 mm). Inspect any time the wheels are removed. ‘a, Inspect the play of the whee! bearings by finger while they are in the wheel . Rotate the inner bearing race. Listen for abnormal cc. Verify smooth bearing rotation. ‘Check wheel bearings and axle spacers for wear and corrosion. Excessive play or roughness indicates worn bearings. 2017 Sportster Service Maintenance 1-24WHEEL SPOKES [PARTIES ROOTS: HD-48985, ‘SPOKE TORQUE WRENCH H-94681.80 SPOKE NIPPLE WRENCH FASTENER ‘TORQUE VALUE Spoke ripple sSindbs | 62Nm Awarninc ‘Spokes that are too tight can draw nipples through the rim tort hub flanges. Spokes that are too loose can can adversely affect stability and handling, which could result in death or serious injury. (00286a) Munn Do not over-tighten spoke nipples. Protruding spoke nipples can damage rim seal, resulting in rapid tire def tion, which could cause death or serious injury. (00611c) NOTICE When lifting a motorcycle using a jack, be sure jack con- tacts both lower frame tubes where down tubes and lower frame tubes converge. Never lift by Jacking on cross- ‘members, oil pan, mounting brackets, components or housings. Failure to comply can cause serious damage resulting inthe need to perform major repair work. (00586d) Identify Wheel Spoke Groups Nore ‘Spokes are grouped in sets of four 1. Raise te wheel 2. See Figure 1-11. Starting at the valve stem, identify the first grcup of four spokes (1-4) 3. Using a different color for each spoke in the group, draw an alignment mark across the spoke nipple and onto the 4. Continue around the wheel marking the rest ofthe spokes the same as they were marked in the previous steps, Adjust Wheel Spokes NOTES * Do not tighten spoke more than one-quarter turn past alignment mark. If more tension is needed, labe! spoke and check after completing rest of wheel. + Do not use the spoke torque wrench to loosen spokes. Use SPOKE NIPPLE WRENCH (Part No. HD-04681-80) {0 loosen spokes. 1. See Figure 1-11. Starting with the first group of spokes, loosen spoke (1) one-quarter turn using SPOKE NIPPLE WRENCH (Part No. HD-94681-80), 1-22 2017 Sportster Service Maintenance 2. Using SPOKE TORQUE WRENCH (Part No. HD-48985) tighten spoke (1) to the value listed in Table 1-8 . While tightening, ifthe torque wrench clicks before the alignment marks align, continue to turn the spoke nipple until the marks align b. If the marks align and torque specification has not been reached, tighten the spoke nipple until the cor- rect torque is achieved. Do not tum spoke nipple more than one-quarter turn past alignment mark, 3. Repeat previous two steps for spoke (4) in the same group 4. Continue around the wheel checking spokes 1 and 4 until all groups are done. 5. Repeat procedure for spokes (2, 3) in each group. NOTE When checking any spokes that were labeled, make sure to use the original alignment mark, 6 Check spokes, if any, that were labeled as not reaching the proper torque value afer tightening one-quarter turn past alignment mark. 2. Loosen spoke one-quarter tum past orginal alignment ‘mark using SPOKE NIPPLE WRENCH (Part No, HD- 194681-80). b. While tightening, i the torque wrench clicks before the alignment marks align, continue to turn the spoke ripple unt the marks align, If the marks align and torque specification has not been reached, tighten the spoke nipple unt the cor- rect torque is achieved. Do nat tum spoke nipple more than one-quarter turn past alignment mark7. Tue the wheel, See 2.7 CHECKING AND TRUING WHEELS. Table 1-8. Spoke Nipple Torque Specification Al 55 in-bs (6.2 Nm) Figure 1-11. Tightening Laced Wheels (typical) 2017 Sportster Service Maintenance 1-23,PRIMARY CHAIN FREE PLAY ADJUSTMENT FASTENER | Toraue vatue Primary chain adjusterlocknut) 20-26 ft-lbs | 27.1-33.9 Nm Primary chan pecan cover ‘To preventaccidental vehicle start-up, which could cause death or serious injury, remove main fuse before pro- ‘ceeding. (00251b) 1. Remove main fuse. 2. See Figure 1-12. Remove inspection cover (1), NOTE Rotate the engine fo measure free play at several chain posi- tions. 3, See Figure 1-13. Through the inspection opening, measure ‘chain fee play at the tightest position. NOTICE Do not adjust the primary chain tighter than specified. Running chain too tight will result in excessive wes (00202a) NOTE Factory setting: Initial cold engine free play is 1/4-3/8 in (6.35- 9.53 mm). Vith the engine cold, measure free play on a primary chain that has never been adjusted: + Less than 1/4 in (6.35 mm): Adjust to specification. + Between 1/4 in (6.35 mm) and 3/8 in (9.53 mm): Do NOT adjust 4. If the measurement is not in specification, adjust the primary chain. Refer to Table 1-9. {See Figure 1-12. Loosen the locknut (2). b. With hex key, turn the adjuster screw (3) clockwise to reduce free play or counterclockwise to increase free play. ©. When free play is within specification, hold the duster screw with a hex key. Tighten the locknut to 20-25 flbs (27.1-33.9 Nm). 5. Ifthe primary chain cannot be adjusted to specification, replace the chain. See 5.4 PRIMARY DRIVE AND. CLUTCH, 6. Install a new gasket and the primary chain inspection cover. Tighten to 100-120 in-lbs (11.3-13.6 Nm) 7. Install main fuse 4-24 2017 Sportster Service Maintenance fH Te RSS = |. Inspection cover 2. Locknut 3._Adjuster screw Figure 1-13, Primary Chain Free Play Table 1-8. Primary Chain Free Play Specifications in mm 318-12 95-127TRANSMISSION LUBRICANT 1.9 TRANSMISSION LUBRICATION FASTENER ‘TORQUE VALUE Clutch inspection cover | 84-108 indbs | 9.5-12.2 Nm |screws | |Frimary chaincase drain plug | 14-20 tibs | 19.0-40.7 Nm [Clutch inspection cover | 84-108 indbs | 95-122 Nm | screws Check Lubricant Level 1. Runmotorcycte unti engine is at normal operating temper- ature, 2. Tum offignition switch and STOP/RUN switch, NoTE ‘Stand motorcycle upright to equalize lubricant level in the transmission and clutch compartments. 3, Stand motorcycle upright (not leaning on ify stand) on a level surface. WG ‘To prevent accidental vehicle start-up, which could cause death oF serious injury, remove main fuse before pro- ceeding. (00251b) 4, Mid-mount controls: Remove left side rider footrest and mounting bracket assembly. See 2.39 RIDER FOOT CONTROLS: MID-MOUNT. 5, Soe Figure 1-14. Remove screws and washers. Remove Clutch inspection cover (1), 6 See Figure 1-15. Verity that lubricant level is even with bottom of clutch diaphragm spring (1) NOTICE ‘When draining or adding lubricant, do not allow dirt, debris or other contaminants to enter the engine. (00198a) NOTICE Do not overfill the primary chaincase with lubricant. verfiling can cause rough clutch engagement, incomplete disengagement, clutch drag andlor difficulty in finding neutral at engine idle. (00199) 7. Ifthe level slow, add FORMULA+ TRANSMISSION AND PRIMARY CHAINCASE LUBRICANT through clutch inspection cover opening. Verify that lubricant level is even with bottom of clutch diaphragm spring 8. Install the clutch inspection cover: ‘2._Install new quad ring. Verify thatthe quad ring is fully seated in groove of primary cover, b. See Figure 1-16. Install cover and tighten screws in ‘Sequence to 84-108 in-lbs (9.5-12.2 Nm). 9. Mid-mount controls: Install left side rider footrest and ‘mounting bracket assembly. See 2.39 RIDER FOOT CONTROLS: MID-MOUNT. 10. Run engine. Check for leaks, 41. Clutch inspection cover 2. Drain plug 3._ Primary chain inspection cover Figure 1-14. Primary Cover Clutch diaphragm spring Clutch adjusting screw Quad ring Primary cover Chaincase lubricant level Figure 1-18. Chaincase Lubricant Level Change Lubricant EEGs Be sure that no lubricants or fluids get on tires, wheels or brakes when changing fluid. Traction can be adversely affected, which could result in loss of control of the motorcycle and death or serious injury. (00047d) 2017 Sportster Service Maintenance 1-2541. Run motoreycle unt engine is at normal operating temper ature 2. Park motorcycle on a level surface on jify stand. The chaincase lubricant can drain out of transmission. OSG) To preventaccidental vehicle start-up, which could cause death or serious injury, remove main fuse before pro- ‘ceeding. (0251b) 3. Tum of ignition switch and STOPIRUN switch 4. See Figure 1-14. Position a suitable container under drain plug 2. 5. Remove drain plug. Drain lubricant 6. Position the motorcycle straight up and level to allow extra fluid to drain from clutch compartment. NOTICE Do not over-tighten filler or drain plug. Doing so could result in a lubricant leak. (00200b) 7. Clean magnetic drain plug. Replace drain plug O-ring if damaged 8 Apply LOCTITE 565 THREAD SEALANT. Install drain plug. Tighten to 14-30 flbs (19.0-40.7 Nm). 9. Remove the clutch inspection cover. 10. See Figure 1-15. Add 1.00 gt (0.95 L) of FORMULA+ TRANSMISSION AND PRIMARY CHAINCASE LUB- RICANT through clutch inspection cover opening. Verity 41-26 2017 Sportster Service Maintenance that level is even with bottom of clutch diaphragm spring a), ‘11, Install the clutch inspection cover: 2, Install new quad ring. Verify that the quad ring is fully seated in groove of the primary cover. b. See Figure 1-16. Install cover and tighten screws in ‘Sequence to 84-108 inbs (9.5-12.2 Nm), 12. Run engine. Check for lubricant leaks. Figure 1-16. Clutch Inspection Cover Torque SequenceCLUTCH ADJUSTMENT ‘Clutch inspection cover | 84-108 in-Ibs | 9.5-12.2 Nm ‘screws. = Clutch cable adjuster jamnut | 120in-ibs | 13.6 Nm Release Clutch Cable Tension {AWARNING ‘To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before pro- ceeding. (00251b) 4. Remove main fuse. 2, See Figure 1-17. Remove cable retaining clips. 3, See Figure 1-18, Pull rubber boot (1) away from cable adjuster (2). 4. Loosen jamnut (3). 5. Tum adjuster to loosen clutch cable at hand lever. Figure 1-17. Cable Retaining Clips. Cable adjuster Jamnut Cable end pene Figure 1-18, Clutch Cable Adjuster Clutch Adjustment 1, Mid-mount controls: Remove clutch side rider footrest ‘and mounting bracket assembly to access clutch inspec- tion cover. See 2.39 RIDER FOOT CONTROLS: MID- MOUNT. 2, Remove clutch inspection cover. Discard quad ring. 3, See Figure 1-19. Remove hex lockplate and spring (1) {rom adjusting screw (2). 4, Tum adjusting screw counterclockwise until resistance is felt. Tum adjusting screw clockwise 1/4 tur, 5, Install hex lockpiate and spring. Turn adjusting screw ‘clockwise to fit lockplate onto flats of adjusting screw. 6. Install clutch inspection cover. ‘8, Install new quad ring in primary cover. Install inspection cover. . Install screws and tighten in a cross-wise pattern to 84-108 intbs (9.5-12.2 Nm). 7. Mid-mount controls: Install footrest and mounting bracket. See 2.39 RIDER FOOT CONTROLS: MID- MOUNT. 2017 Sportster Service Maintenance 1-275. Install rubber boot (1) over cable adjuster (2). 6. See Figure 1-17. Install cable retaining clips. 7. Install main fuse. = = TS 4. Clutch cable ferrule Figure 1-19. Clutch Adjustment Screw 2. Clutch lever bracket 3._Free play - Lever Free Play Figure 1-20. Clutch Free Play Adjustment 1. See Figure 1-18. Tum cable adjuster (2) away from jamnut (3) until there is no slack in cable at clutch lever. 2. See Figure 1-20. Pull clutch cable ferrule (1) away from ‘lutch lever bracket (2) and measure free play (3). 3. Adjust to specification. Refer to Table 1-10. Measurement 116-118 632 ‘See Figure 1-18. Tighten jamnut (3) to 120 Inds (13.6 Nm». 2._ Adjusting screw ‘Table 1-10. Clutch Lever Free Play Specifications 1-28 2017 Sportster Service MaintenanceDRIVE BELT AND SPROCKETS 1.11 GENERAL Awarninc Never bend belt forward into a loop smaller than the drive ‘sprocket diameter. Never bend belt into a reverse loop. ‘Over bending can damage belt resulting in premature failure, which could cause loss of control and death or jury. (00339a) In the case of stone damage to belt, inspect the sprockets for damage and replace as required. If replacing belt, always replace both transmission and rear sprockets. CLEANING Keep dirt, grease, oil, and debris off the drive belt and sprockets. Clean the belt with a rag slightly dampened with a Ight cleaning agent. INSPECTION Sprockets NOTE Chrome chips or large rear sprocket gouges leave a pattern on belt face. 4+. See Figure 1-21. Inspect each tooth (1) of rear sprocket for: a. Tooth damage. 'b. Large chrome chips with sharp edges, c. Gouges caused by hard objects. 4. Excessive loss of chrome plating, 2. To check if chrome is wom, drag with medium pressure a soribe across bottom of a groove (2). a. If serbe slides across groove without digging in or leaving a visible mark, chrome is stil good. bi If scribe or knife points digs in and leaves a visible mark, itis cutting bare aluminum. A knife point does rot penetrate chrome. 3. Replace rear sprocket if major tooth damage or loss of chrome exists. = igure 1-21. Rear Sprocket Drive Belt NOTE Bat teeth are coated with polyethylene lubricant. Coating will wear off overtime. Wom coating is not an indicator of belt wear. ‘See Figure 1-22. Inspect drive belt for: + Cuts or unusual wear patterns. + Outboard edge bevel wear (8). Some bevel wear is ‘common, but it indicates that sprockets are misaligned. + Stone damage (7) on outside ribbed surface. If cracksidamage exists near edge of belt, replace belt immediately. Damage to center of belt requires belt replacement. When cracks extend to edge of belt, failure is imminent + Inside (toothed portion) of belt for exposed tensile cords (normally covered by nylon layer and polyethylene layer) ‘This condition causes belt fallure.It indicates worn trans mission sprocket teeth. Replace belt and transmission sprocket. + Signs of puncture or cracking at base of belt teeth. Replace bolt if either condition exists + If-conditions 2, 3, 6 or 7 (on edge of belt) exist, replace bett NOTE Condition 1 may develop into 2 or 2 over time Condition 1 is ‘not grounds for replacing belt. Watch condition 1 closely before Condition 2 develops which requires belt replacement. 2017 Sportster Service Maintenance 1-29Table 1-11. Drive Belt Wear Analysis Inlemal tooth cracks OK to run, but monitor condi- (haiine) tion 2 [External tooth cracks| Replace belt. ~ [Missing teeth Replace belt 4 | Chipping (OK to run, but monitor condi- (not serious) tion, 5 |Fuzzyedge cord [OK torun, but monitor condi tion 6 |Heok wear Replace belt and sprocket “7 [Stone damage Replace belt if damage is on’ the edge, [OK to run, but monitor condi (outboard edge only) |tion, "See © Figure 1-22. Drive Belt Wear Patterns, CHECK DRIVE BELT DEFLECTION HD-35381-A [BELT TENSION GAUGE NOTE ‘Always use BELT TENSION GAUGE (Part No. HD-36381-A) to measure bt deflection, Failure to use tension gauge may ‘cause undertensioned belts. Loose belts can fail due to “ratcheting” jumping tooth) which causes tensile cord crimping and breakage. 41-30 2017 Sportster Service Maintenance Chock deflection: + As part of pre-ide inspection + Atevery scheduled service interval + With transmission in neutral + With motoreycle at ambient temperature. + With motorcycle upright or on jfy stand with rear wheel (on the ground. + With the vehicle unladen: no rider, ne luggage and empty saddlebags. To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before pro- ceeding. (00251b) 4. Disarm security system. Remove main fuse, See 6.3 FUSES, Replacement. 2. Shift transmission to neutral ‘See Figure 1-23. Measure belt deflection using H-D BELT TENSION GAUGE (Part No. HD-35381-A): a, Slide O-ring (4) t0 0 Ib (0 kg) mark (3) b. Models equipped with belt deflection window: Fit belt cradle (2) against bottom of drive belt inline with belt defection window. ©. All other models: Fit belt cradle (2) against bottom Of drive belt halfway between drive pulleys. 4. Press upward on knob (6) until O-ring slides down to 10 Ib (4.5 kg) mark (5) and hold steady. 4, Measure belt deflection: , Models equipped with belt deflection window: Seo Figure 1-24. Measure belt deflection as viewed through belt deflection viewing window while holding ‘gauge steady. Each deflection graduation is approx- imately 1/16 in (1.59 mm). b. Allother models: See Figure 1-25. Measure amount of deflection (4) while holding gauge steady. 5. Compare with specifications. Adjust as necessary. Refer to Table 1-12. 6. Install main fuse,of All| Belt tension gauge Belt cradle 1b (0 kg) mark ‘O-ring 10 Ib (4.5 kg) mark. Knob poaene Figure 1-23. Belt Tension Gauge 1. Drive belt 2. Deflection graduation Figure 1-24. Belt Deflection Window P| _(*) 4. ‘Transmission sprocket 2. Rear wheel sprocket 3. 10 Ib (4.5 kg) of force: Amount of deflection Figure 1-25. Checking Belt Deflection Table 1-12. Bolt Deflection Specifications” [All models 14-6116 | 647.9 * Deflection measured at 10 lb (4.5 kg) tension. ADJUSTMENT ‘Axle, rear, nut 95-105 fllbs | 129-142 Nm Brake hose clamp to rear fork| 30-40 indbs | 3.44.5 Nm NOTE Rear brake line is clamped tightly to rear fork to avoid chafing of brake fine in clamp. A small amount of slack must be main- tained in rear brake line betwoen clamp and rear caliper. 1. See Figure 1-26. Remove screw (1) from clamp (2) on rear brake line (3). 2. See Figure 1-27. Remove and discard E-clip (1) and loosen axle nut (4) NOTE Turn both adjuster nuts same number of tums in order to ‘maintain approximate alignment of rear wheel. 3. Tum axle adjuster nuts (2) clockwise to decrease belt deflection (increase tension), or counterclockwise to increase belt deflection (decrease tension). 4. Check rear whee! alignment. See 1.20 WHEEL ALIGN- MENT, Wheel Alignment. 2017 Sportster Service Maintenance 1-31Ce Do not exceed specified torque when tightening axle nut. Exceeding torque can cause wheel bearings to seize during vehicle operation, which could result in death or serious Injury. (004080) 5. Tighten axle nut (4) to 95-108 ftlbs (129-142 Nm). Install new E-clp (1), 6. See Figure 1-26. Position clamp (2) on rear brake line (3). ‘Secure clamp to rear fork with screw (1). Tighten to 30-40 Inds (3.4-4.5 Nm), E-clip Axle adjuster nut (2) ‘Axle adjuster (2) Axle nut Washer Protective cap (2) Figure 1-27. Drive Belt Adjustment 1 2 3. 4 5. 6 1. Screw 2 Clamp 3._Rear brake line Figure 1-26. Rear Brake Line 1-32 2017 Sportster Service MaintenanceTHROTTLE CONTROL 1.12 CABLE INSPECTION AND LUBRICATION [FASTENER wich housing sew ‘TORQUE VALUE 36-45 inlbs | 405.1 Nm 4. Release throttle cable tension. See 1.12 THROTTLE CONTROL, Cable Adjustment. Soe Figure 1-28. Remove screws (1) to separate upper switch housing from the lower housing 3. Unhook ferrules and cables from throttle grip. Remove throttle sleeve, 4, Inspect each cable, Replace cable assembly if cable is frayed or kinked. 5. Inspect cable outer sheath from throttle grip to induction ‘module. Replace as necessary, 6. Apply a light coating of graphite to handlebar and inside surface of housings. Replace throttle grip, 7. Pour two drops of HARLEY LUBE into cable housings. 8, Install switch housing. Tighten to 35-45 indbs (4.0-5.1 Nm. 8. Adjust tote cables CABLE ADJUSTMENT Operation WARNING. Before starting engine, be sure throttle control will snap back to idle position when released. A throttle control that prevents engine from automatically returning to idle can lead to loss of control, which could result in death or ser- Jus injury. (00390a) Awarninc Do not tighten throttle friction adjustment screw to the point where the engine will not return to idle automatically ‘Over-tightening can lead to loss of vehicle control, which ‘could result in death or serious injury. (00031b) 1. See Figure 1-28. Loosen friction screw (3). 2. Roll on and release throttle grip. f throttle does not return to closed (idle), inspect and adjust throtle cables, 3. With engine idling, turn handlebar stop to stop. f engine ‘speed changes, adjust throttle cables. Adjustment 41. See Figure 1-28. Loosen fiction screw (3). 2, Remove rubber boots from cable adjusters (6). 3, Loosen jamnuts (7). 4. Verity throttle cables are seated in cable guide. Turn cable adjusters to shorten cable housings to minimum length, 5. Point front wheel straight ahead. With engine OFF, roll thvottle grip (2) fully open, Hold in position. 6. Gently tum cable adjuster on throttle cable (4) counter- Clockwise unt throttle cam (8) touches throttle cam stop (10), Release throttle grip. Tighten jamnut on throttle cable adjuster. 7. Tum handlebar full ight lock. Turn cable adjuster on idle cable (5) to lengthen sleeve until end of cable housing touches spring (8) within cable guide (11) NoTE The throttle contro! must operate freely when front wheel is turned to right and left fork stops. 8. Check adjustment. Twist and release throttle grip two or three times. If throttle does not retum to idle, turn idle agjuster to shorten sleeve until correct. Tighten jamnuts. 9, Slide rubber boots over cable adjusters. 2017 Sportster Service Maintenance 1-33,4. Scraw (2) 7. Jamnut 2) 2. Throttle grip 8. Throttle cam 3. Friction serow 8. Spring 4. Throttle cable 410. Throttle cam stop 5. Idle cable 411. Cable guide [6 Cable adjuster (2) Figure 1-28. Throttle Cable Adjustment 1-34 2017 Sportster Service MaintenanceCABLE AND CHASSIS LUBRICATION , GENERAL Inspect and lubricate the following items according to 1.4 MAINTENANCE SCHEDULE. + Front brake hand lever + Clutch hand lever + Throttle control cables + Throtie control grip sleeve + Clutch cable + Steering head bearings + ify stand operating on muddy or dusty roads, clean and lubricate at shorter intervals, CABLES AND HAND LEVERS For throttle cables, see 2.24 THROTTLE CABLES. Use HARLEY® LUBE for clutch lever and cable. Use G40M BRAKE GREASE on front brake lever pin pivot hole ‘and on the end of piston that contacts brake lever. JIFFY STAND Clean and lubricate the jfy stand. For more information, see 2.37 JIFFY STAND. STEERING HEAD BEARINGS Lubricate the steering head bearings with SPECIAL PURPOSE GREASE. See 1.17 STEERING HEAD BEARINGS. 2017 Sportster Service Maintenance 1-35BRAKES GENERAL The front and rear brakes are fully hydraulic disc brake systems that require litle maintenance. Awarning Use denatured alcohol to clean brake system components. Do not use mineral-based solvents (such as gasoline or paint thinner), which will deteriorate rubber parts even after assembly. Deterioration of these components can cause brake failure, which could result in death or serious Oe Direct contact of D.0.T. 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention ‘Swallowing large amounts of D.0.T. 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical atten- tion. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00240a) NOTICE injury. (002918) Awarninc ‘After repairing the brake system, test brakes at low speed, brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. (00289a) D.O.T. 4 brake fluid will damage painted and body panel ‘surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is per- formed. Failure to comply can result in cosmetic damage. (002396) NOTES + IfDOT 4 brake fuid contacts painted surfaces, IMMEDI- ATELY flush area with clear water, * Cover handlebar switches with @ shop towel before adding brake fui to front master cylinder reservoir. Spiling brake fluid on handlebar switches can render them inoperative. INSPECT BRAKE LINES Inspect brake lines for leaks, contact or abrasion. Refer to Table 1-13. Table 1-13. Brake Line Inspection LINE TYPE i INSPECTION REMEDY ‘tee ines z ‘OkayiMontor | Sight marin paint orpaing? Copper colored-panpaing worn of [Siver colored base materiale noceabo fel of wear Sve colored base materia-notceabe fol of wear Replace | rake fi leak or other damage | Flexi ines No mans =< ‘Okayiontor Sigh dentin proesve cover or tring of bs Wom tough protective cover oto botiom obs Replace Brae fui leak or other damage : | [Protective caver No marks — r Okayhontor | (Stoo ruber plaster ble) Sie Join coveng? | Stitt dont or Natoning of plastic covering? | 'Worn oF et roughcoverig-exposed brake ine mater Replace Brake fluid leak or other damage * If there is Ine contact, reposition the line. if base material is visible, prevent corrosion with touch-up paint. 1-36 2017 Sportster Service MaintenanceFLUID LEVEL FASTENER ‘TORQUE VALUE [Brake master oyinder reser-| 9-17 Imdbs | 1.0:20Nm wir cover serews | NOTES + Fluid should never need to be added or removed from the ‘system during normal wear. Reservoir volume is adequate 10 provide fluid to the woar limits ofthe pads and discs. + Fluid fevel in reservoir wil decrease with brake wear. If levels below the full level, suspect worn brake pads and rotors or leakage. 4, Front brake: Check fluid level. a, Set motorcycle upright and turn handlebar to level reservoir b. See Figure 1-29. Check low-level mark on reservoir sight glass. 2, Rear brake: Check fui level a. Stand motorcycle upright (not leaning on jfy stand) on a level surface. b. See Figure 1-30. Check low-level mark on reservoir sight glass, 3, If fluid is low: . Check brake pad installation or for wear beyond specication. Replace or repair as necessary. See 1.15 BRAKE PADS AND DISCS. b. Check brake components for leaks. Repair as necessary. 4. If fluids stil low, add DOT 4 BRAKE FLUID as necessary. a Clean cover. b. Remove cover screws and cover. ©. Remove diaphragm plate and diaphragm. 4d, Add DOT 4 BRAKE FLUID to full level ridge around: top of reservoir. 2. Install diaphragm, plate and cover. {. Tighten to 9-17 indbs (1.0-2.0 Nm), 5, Test front brake lever and rear brake pedal for firm feel Bleed brakes as necessary. See 2.14 BLEEDING BRAKES. Mark TROUBLESHOOTING Use the following troubleshooting guide to help in determining probable causes of poor brake operation. Refer to Table 1-14, 2017 Sportster Service Maintenance 1-37‘Low reservoir ud level Leaks in brake system Repair as necessary. Table 1-14. Troubleshooting Brake: Bleed brake system, |Wom pads and discs Replace pads and discs, Excessive lever or pedal travel or |Alrin system Bleed brake system. spongy feel [Low reservoir fluid level | Repair leaks as necessary. Bleed brake system. [Replace pads and discs. ‘Chattering sound when brake is | Worn brake pads Replace brake pads. ‘applied |Loose mounting botts| Tighten bolts. 'Warped brake disc - Replace brake disc. Ineffective brake lever or pedal- [Low fluid level - Repair leaks as necessary ‘travels to limit Bleed brake system. Replace pads and discs. Piston cup not functioning 7 Rebuild master cylinder. [Ineffective brake lever or pedal- [Distorted or glazed brake disc Replace brake disc. ea eoreey Distorted, glazed or contaminated brake pads _|Replace brake pads. | Brake pads drag on disc - does not | Cup in master cylinder blocking relief port Inspect master cylinder. Shem Master cylinder overfiled (Correct fuid level 1-38 2017 Sportster Service MaintenanceBRAKE PADS AND DISCS 1.15 INSPECTION Brake Pads Awarninc ‘Always replace brake pads in complete sets for correct ‘and safe brake operation. Improper brake operation could result in death or serious injury. (00111a) ee Direct contact of D.0.1. 4 brake fluid with eyes can cause invitation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. ‘Swallowing large amounts of D.O.T. 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical atten- ‘len, Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (002402) NOTICE D.O.7. 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is per- formed. Failure to comply can result in cosmetic damage. (002390) ‘See Figure 1-31. Replace brake pads if pads on either front or rear are wor to 0.04 in (1.02 mm) or less above backplate ‘Always replace both pads as a set. See 1.15 BRAKE PADS. AND DISCS. Wren checking brake pads and discs, inspect brake hoses for carrect routing and any signs of damage or leakage. — 1. Front, from below 2. Rear, from above 3._Pad thickness Figure 1-31. Brake Pad Thickness Brake Disc Thickness, Lateral Runout and Warpage Minimum acceptable thickness is stamped on side of disc. Replace disc if warped, badly scored or worn beyond service lit Maximum brake disc lateral runout and warpage is 0.008 in (0.2 mm) when measured near outside diameter + To replace front brake discs, see 2.5 WHEELS, Front Wheel. + Toreplace rear brake disc, see 2.5 WHEELS, Rear Wheel BRAKE PAD REPLACEMENT: FRONT [FASTENER Brake caliper, front, mounting Brake master cylinder, front, reservoir cover screws Removal NOTICE .O.7. 4 brake fluid will damage painted and body panel ‘surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is per- formed. Failure to comply can result in cosmetic damage. (00239) NOTES + Coverhandlebar switches with a shop towel before adding brake fluid to reservoir. + IFDOT 4 brake fluid contacts painted surfaces, IMMEDI- ATELY flush area with clear water. 41. Position motorcycle to level front master cylinder reservoir. 2. Wrap a shop towel around master cylinder reservoir to contain any brake fluid spils. 3, See Figure 1-32. Remove screws (6), reservoir cover (4), diaphragm plate (8) and diaphragm (2) from master cy- inde reservoir (1). NoTE As pistons are pressed into their bores, fluid level can rise ‘above max fil level. Remove fluid as necessary. 2017 Sportster Service Maintenance 1-39Installation NOTE ‘See Figure 1-33. Verify that pad spring is installed before instaling new pads. 1. Install piston-side brake pad. | ‘Slide pad mounting tab to rear. b. Press pad against pistons, ©. See Figure 1-34. Align pad spring feet against pad spring. 2. Install whee!-side brake pad. ‘a. Fit mounting tab under retaining clip. b. Press pad against mounting bracket 3. Install pad pin. ‘a. Press piston-side pad against pad spring b. Start pad pin, Press wheel-side pad against pad spring. | 4d. Complete pad pin installation 4. Master cylinder reservoir 2. Diaphragm 3, Diaphragm plate 4. Reservoir cover Screw (2) Figure 1-32. Front Brake Master Cylinder Cover 4. Remove caliper bracket and caliper. ‘a. Loosen, but do not remove, brake pad pin, b. Remove caliper bracket mounting bolts. c. ABS models: Remove WSS wire lead clips from the brake line. 4d. Remove caliper bracket and caliper. 5. Remove old pads, a. Support caliper assembly. . Topress the pistons back into their bores, press pads apart ©. Pull pad pin part way until wheel-side pad is free. 4. Continue to pull out pad pin until piston-side pad is — fees, Figure 1-33. Caliper Pad Spring e Remove pads. 6. Inspect pad pin for grooving and wear. ‘2. Measure pad pin diameter in an unworn area, 'b, Measure pad pin diameter in an (of grooving or ©. wear exceeds 0.011 in (0.28 mm), replace pin, 1-40 2017 Sportster Service MaintenanceFigure 1-34. Pad Spring Feet Install caliper and bracket. a, ABS models: Fit WSS wire lead bracket, clip and wire to caliper mounting boss. Install mounting bolts. (c. Tighten to 28-38 fbs (38,0-51.5 Nm). 4. Tighten pad pin to 131-173 in-tbs (14.8-19.5 Nm). Awarninc Aiter servicing brakes and before moving motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which ould result in death or serious injury. (00279a) 5. Squeeze brake lever to push pistons against outside brake pad, Poel Direct contact of D.O.T. 4 brake fluid with ayes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention ‘Swallowing large amounts of D.0.1. 4 brake fluid can cause gestive discomfort. if swallowed, obtain medical atten- tion. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (002402) NOTICE D.O.7. 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is per- formed. Failure to comply can result in cosmetic damage. (c02395) NOTE MDOT 4 brake fluid contacts painted surfaces, IMMEDIATELY fush area with clear water. 6 Check fluid level in brake reservoir. Add enough DOT 4 BRAKE FLUID to reservoir to bring fluid level to max fil level 7. Install diaphragm and plate. Install reservoir cover with screws. Tighten to 9-17 indbs (1.0-2.0 Nm). Win After repairing the brake system, test brakes at low speed. brakes are not operating properly, testing at high speeds ccan cause loss of control, which could result in death or serious injury. (00289a) NOTE ‘Avoid making hard stops forthe first 100 mi (160 km) to allow the new pads to become conditioned to brake discs. 8. Test brakes. ‘a, Turn ignition on. Check operation of rear lamps. Test ride motorcycle. Repeat the bleeding procedure if brakes feel spongy. See 2.14 BLEEDING BRAKES. BRAKE PAD REPLACEMENT: REAR [FASTENER TORQUE VALUE Brake caliper, rear, mounting | 28-38 flbs | 36.0-51.5 Nm ott Brake caliper, rear, pad pin. | 131-173 | 14.8-19.5 Nm in-lbs Brake line P-clamp, rear, 30-40 in-ibs | 3.4-45Nm Brake master cylinder, rear, | 9-17 indbs | 1.0-20Nm reservoir cover screws Removal NOTES + IFDOT 4 brake fluid contacts painted surfaces, IMMEDI- ATELY flush area with clear water. + As piston is pushed back into caliper, fluid level can rise higher than max fill evel. If necessary, remove Mud. 41. Prepare motorcycle: a. Raise the motorcycle. b. XL 12007: Remove left side saddlebag. See 2.29 SADDLEBAGS: XL1200T. Remove left side lower shock bolt. Rotate shock away from caliper. See 2.20 SHOCK ABSORBERS. Position motorcycle to level master cylinder reservoir. Place container under reservoir to catch fluid overflow. Remove reservoir cover. Remove caliper. a. Remove brake line P-clamp from rear fork. Loosen, but do not remove, pad pin. ©. Remove caliper mounting bolts. d, Remove caliper from bracket 2017 Sportster Service Maintenance 1-81