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RONT FORK OIL 1.20

ENERAL

eplace front fork oil:

At scheduled service intervals as specified in 1.3 MAIN-TENANCE SCHEDULE. Refer to Table 1-1.

Prior to storage.

HANGING FORK OIL

. Have an assistant hold vehicle upright (not resting on jiffystand), with front fork pointed straight ahead.

. Place a drain pan under bottom of right fork slider. SeeFigure 1-63. Remove drain screw and washer (5) frombottom of one slider (4).

. Drain fork oil by repeatedly compressing front suspen-sion slowly.

NOTEf fork oil is emulsified, aerated or light brown in color, it haseen contaminated by water. Replace fork oil seals (see 2.17RONT FORK).

. Replace drain screw and washer. Tighten to 13-17 in-lbs(1.5-2.0 Nm).

. Repeat Steps 2 through 4 above for left side fork.

NOTEefer to Table 1-12. Fork oil amounts can be measured twoays.

Use oz/ml measurement if fork is left in frame.

Use in/mm measurement if fork is disassembled.

PART NO. SPECIALTY TOOL

HD-59000-A Pro-level oil gauge

Table 1-12. Type E Fork Oil AmountsFigure 1-63. Draining Front Fork Oil

1. Fork slider tube cap2. O-ring3. Slider tube4. Fork slider5. Fork oil drain screw w/washer

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2006 Sportster: Maintenance 1-49

MODEL OZ ML IN MM

XL 883L 12.3 364 4.80 122

All others 11.6 342 5.75 146

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Filling Fork Oil: Forks Assembled, in Frame

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1. Block motorcycle under frame so that the front wheel israised off the ground slightly; this enables front fork toextend fully and allows most of spring preload (compres-sion force) to be relieved.

1WARNING1WARNING

Wear safety glasses or goggles when servicing forkassembly. Do not remove slider tube caps without reliev-ing spring preload or caps and springs can fly out, whichcould result in death or serious injury. (00297a)

2. Unscrew fork slider tube cap (1) with O-ring (2) fromeach slider tube (3). Replace the O-ring if damaged orworn.

3. Fill each slider tube/slider assembly with 11.6 fl oz. (342ml) TYPE “E” HYDRAULIC FORK OIL.

4. Install each slider tube cap with O-ring. Tighten to 22-58ft-lbs (29.9-78.7 Nm).

5. Lower motorcycle to the ground.

Filling Fork Oil: Forks Disassembled, out of Frame1. Position fork tube assembly upright. Remove spring and

compress assembly fully.

2. Pour approximately 12 fl oz. (355 ml) TYPE “E”HYDRAULIC FORK OIL into fork.

3. See Figure 1-64. Using HARLEY-DAVIDSON PRO-LEVEL OIL GAUGE, adjust oil level:

a. 4.80 in. (122 mm) for XL 883L.

b. 5.75 in. (146 mm) for all models except XL 883L.

4. Install spring and slider tube cap with O-ring. Tighten to22-58 ft-lbs (29.9-78.7 Nm).

5. Assemble fork and install in frame.

6. Repeat this procedure for other fork tube assembly.

Figure 1-64. Refilling Front Fork Oil

1. Fork slider tube2. Pro Level Oil Gauge (Part No. HD-59000-A)3. Fork oil4. Correct fork oil level is 4.80 in (122 mm) (XL 883L)

or 5.75 in (146 mm) (all except XL 883L) below top of fork tube.

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1-50 2006 Sportster: Maintenance

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PARK PLUGS 1.21

ENERAL

arley-Davidson 6R12 spark plugs have a resistor element toeduce the radio interference which originates in the motorcy-le ignition system. Use only the resistor-type spark plugspecified.

DJUSTMENT

park plug gap is 0.038-0.043 in. (0.96-1.09 mm). Use only wire-type feeler gauge. Bend the outside electrode so alight drag on the gauge is felt when passing it between elec-rodes. Never make adjustments by bending the center elec-rode.

LEANING AND INSPECTION

nspectionxamine spark plugs as soon as they have been removed.he deposits on the spark plug base are an indication of thepark plug efficiency and are a guide to the general conditionf pistons, piston rings, valves, valve guides, valve seals, car-uretor and ignition system.

park Plug Conditionee Figure 1-65. Compare your observations of the sparklug deposits with the descriptions provided below.

a. A wet, black and shiny deposit on spark plug base,electrodes and ceramic insulator tip indicates an oilfouled spark plug. The condition may be caused byone or more of the following: worn pistons, worn pis-ton rings, worn valves, worn valve guides, wornvalve seals, a weak battery or a faulty ignition sys-tem.

b. A dry, fluffy or sooty black deposit indicates a carbu-retor air-fuel mixture that is too rich, engine idling forexcessive periods of time and/or enrichener usagefor excessive periods of time.

Cleaning

If spark plugs require cleaning between tune-ups, proceed asfollows:

1. Degrease firing end of spark plug using ELECTRICALCONTACT CLEANER. Dry spark plug with compressedair.

2. Use a thin file to flatten spark plug electrodes. A sparkplug with sharp edges on its electrodes requires 25%-40% less firing voltage than one with rounded edges.

3. Adjust spark plug gap. See ADJUSTMENT under 1.21SPARK PLUGS.

INSTALLATION

Figure 1-65. Typical Spark Plug Deposits

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c. A light brown, glassy deposit indicates an over-heated spark plug. This condition may be accompa-nied by cracks in the insulator or by erosion of theelectrodes and is caused by an air-fuel mixture thatis too lean, a hot-running engine, valves not seatingor improper ignition timing. The glassy deposit onthe spark plug is a conductor when hot and maycause high-speed misfiring. A spark plug witheroded electrodes, heavy deposits or a crackedinsulator must be replaced.

d. A spark plug with a white, yellow, tan or rusty brownpowdery deposit indicates balanced combustion.Clean off spark plug deposits at regular intervals.See Cleaning.

1. Before installing spark plugs, check condition of threadsin cylinder head and on spark plug. If necessary, softendeposits with penetrating oil and clean out with a threadchaser.

2. Apply a very light coating of ANTI-SEIZE LUBRICANT tospark plug threads. Install spark plug. Tighten spark plugto 12-18 ft-lbs (16.3-24.4 Nm).

If a torque wrench is not available, finger-tighten sparkplug and then using a spark plug wrench, tighten sparkplug an additional 1/4-turn.

3. Check engine idle speed. With engine at operatingtemperature and enrichener OFF (enrichener knobpushed all the way in), adjust idle speed as necessary.See 1.25 IDLE SPEED AND IGNITION TIMING.

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CABLE AND CHASSIS LUBRICATION 1.22

GENE

Inspect antrol cablesgrip sleevMAINTEN

If service componen

CABL

Do not enricheneresistanc

See 1.24 tle cable lu

Use SUPE

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d lubricate the front brake hand lever, throttle con-, clutch hand lever, clutch cable and throttle controle at scheduled service intervals as specified in 1.3ANCE SCHEDULE. Refer to Table 1-1.

is on muddy or dusty roads, clean and lubricatets at shorter intervals.

ES AND HAND LEVERS

CAUTION

lubricate the enrichener cable or inside ofr cable conduit. The cable must have sliding

e to work properly.

THROTTLE CABLES AND ENRICHENER for throt-bricating procedure.

R OIL for hand levers.

FOOT SHIFT LEVER AND REAR BRAKE PEDAL

Clean and lubricate the foot shift lever (XL 883C/XL 1200C)and rear brake pedal pivot with ANTI-SEIZE LUBRICANT atscheduled service intervals as specified in 1.3 MAINTE-NANCE SCHEDULE. Refer to Table 1-1.

If service is on muddy or dusty roads, clean and lubricatecomponents at shorter intervals.

JIFFY STAND

Clean and lubricate the jiffy stand at scheduled service inter-vals as specified in 1.3 MAINTENANCE SCHEDULE. Referto Table 1-1. See 2.31 JIFFY STAND for procedure.

If service is on muddy or dusty roads, clean and lubricatecomponents at shorter intervals.

STEERING HEAD BEARINGS

Lubricate the steering head bearings with HARLEY-DAVID-SON SPECIAL PURPOSE GREASE at scheduled serviceintervals as specified in 1.3 MAINTENANCE SCHEDULE.Refer to Table 1-1.

2006 Sportster: Maintenance

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IR FILTER ELEMENT 1.23

ENERAL

he air cleaner prevents foreign material from entering thearburetor and engine, trapping airborne dust and dirt in thelter element.

ervice the air cleaner:

At scheduled service intervals as specified in 1.3 MAIN-TENANCE SCHEDULE. Refer to Table 1-1.

More often if the motorcycle is operated in a dusty envi-ronment.

REMOVAL

1. See Figure 1-66. Remove two screws (1) and trim insert(2) from air cleaner cover (3).

2. Remove air cleaner cover from air cleaner backplate (9).Remove air cleaner seal (4) from cover.

3. Remove three screws (5). Remove air filter element (6)and gasket (7) from air cleaner backplate. Discard gas-ket.

CAUTION

Install air filter before running engine. Failure to do socan draw debris into the engine and could result inengine damage. (00207a)

x0502a1x1. Screw (2)2. Trim insert3. Air cleaner cover4. Air cleaner seal5. Screw (3)6. Air filter element (includes item 7)7. Gasket8. O-ring (2)9. Air cleaner backplate

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Figure 1-66. Air Cleaner Assembly

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CLEANING, INSPECTION AND

REPAIR

INSTALLATION

1. See Figure 1-66. Thoroughly clean air cleaner backplate(9) and inside of air cleaner cover (3).

2. If air filter element (6) is damaged or if filter media cannotbe adequately cleaned, replace element and proceed tostep 6.

1WARNING1WARNING

Do not use gasoline or solvents to clean filter element.Flammable cleaning agents can cause an intake systemfire, which could result in death or serious injury.(00101a)

3. Wash air filter element thoroughly in warm, soapy water.To remove soot and carbon, soak air filter element for 30minutes in warm water with mild detergent.

1WARNING1WARNING

Compressed air can pierce the skin and flying debrisfrom 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 deter-mine air flow rates. (00061a)

4. Dry air filter element using low-pressure (32 psi/221 kPamaximum) compressed air. Rotate air filter element whilemoving air nozzle up and down filter element interior. Donot tap air filter element on hard surface.

5. Hold air filter element up to strong light source. Elementcan be considered sufficiently clean if light is uniformlyvisible through filter material.

NOTEDo not use air cleaner filter oil on Harley-Davidson paper airfilter elements.

6. Examine O-rings (8). If damaged, replace with new O-ring(s).

7. Examine air cleaner seal (4). If cracked, torn or other-wise damaged, replace with new seal.

1. See Figure 1-66. Apply a thin coat of engine oil or lightgrease to O-rings (8). This will help prevent them frombeing damaged when air filter element is installed.

2. Position new gasket (7) on air cleaner backplate (9).Make sure gasket holes are lined up with backplateholes.

3. Install air filter element (6) onto backplate. The words“This Side Out” should be readable on the upper edge ofthe air filter element when installed. Secure with threescrews (5). Tighten to 40-60 in-lbs (4.5-6.8 Nm).

4. Fit air cleaner seal (4) onto air cleaner cover (3). Toensure proper sealing, make sure air cleaner seal coversentire edge of air cleaner cover.

5. Install air cleaner cover onto backplate. Make sure aircleaner seal fits inside backplate and is not pinched ordistorted.

6. Install trim insert (2) and secure cover assembly with twoscrews (1). Tighten to 36-60 in-lbs (4.1-6.8 Nm).


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HROTTLE CABLES AND ENRICHENER 1.24

ABLE INSPECTION, UBRICATION AND ADJUSTMENT

nspect, lubricate and adjust throttle control cables asescribed below.

nspection and Lubrication. See Figure 1-67. Remove two screws (1) to separate the

upper handlebar housing from the lower housing.

. Unhook each ferrule and cable from the throttle grip andremove the throttle sleeve.

. Inspect each cable. Replace cable assembly if cable isfrayed or kinked.

. Inspect entire cable outer sheath from throttle grip to car-buretor for damage. Replace if necessary.

. Apply a light coat of graphite to the handlebar andreplace throttle grip.

. Pour one or two drops of SUPER OIL into the housing ofeach cable.

. Assemble handlebar housing. Tighten both screws (1) to35-45 in-lbs (4.0-5.1 Nm).

djustment

1WARNING1WARNING

heck to ensure proper throttle control functions. Thehrottle control MUST operate freely without binding.rregular or sticking throttle response could result in lossf control of the vehicle and death or serious injury.

ee Figure 1-67. With throttle friction screw (3) backed off,arburetor throttle must return to closed (idle) position. Checkontrol cable adjustment. With engine idling, turn handlebarshrough full range of travel. If engine speed changes duringhis maneuver, adjust control cables according to the follow-g procedure.

. Loosen throttle friction screw (3).

. Slide rubber boot off each control cable adjuster (6).

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1. Screw (2)2. Throttle control grip3. Throttle friction screw4. Throttle control (pull open) cable5. Idle control (pull close) cable

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3. Loosen jam nut (7) on each cable adjuster.

4. Turn cable adjusters in direction which will shorten cablehousings to minimum length.

5. Point front wheel straight ahead. With engine OFF, turnthrottle control grip (2) to fully open position and hold.

6. Gently turn adjuster (6) on throttle control cable (4) untilthrottle cam (8) touches throttle cam stop (10). Releasethrottle control grip and turn adjuster counterclockwisean additional 0-1 turn. Tighten jam nut on throttle controlcable adjuster.

7. Turn handlebars fully to right. Turn adjuster (6) on idlecontrol cable (5), lengthening sleeve until end of cablehousing just touches spring (9) within cable guide (11).

Figure 1-67. Throttle Cable Adjustment

6. Control cable adjuster (2)7. Jam nut (2)8. Throttle cam9. Spring10. Throttle cam stop11. Cable guide

HOME

8. Check adjustment. With throttle friction screw loosened,twist and release throttle control grip two or three times.Carburetor throttle must return to idle position each time

1. Loosen hex nut (5) at backside of enrichener bracket (6).

2. Move cable assembly free of slot in mounting bracket.

throttle grip is released. If throttle does not return to idle,turn idle adjuster, shortening sleeve until correct adjust-ment is reached. Tighten jam nut.

9. Slide rubber boot over each cable adjuster. Checkengine slow idle speed. Adjust if required.

ENRICHENER ADJUSTMENT

CAUTION

Pay close attention to the vehicle's warm-up time. Eitherexcessive or insufficient use of the enrichener maycause poor performance, erratic idle, poor fuel economy,spark plug fouling and equipment damage. (00164a)

Inspect enrichener operation at every scheduled serviceinterval.

CAUTION

Do not lubricate the enrichener cable or inside ofenrichener cable conduit. The cable must have slidingresistance to work properly.

See Figure 1-68. Check fuel enrichener operation. The fuelenrichener knob (1) should open, remain open and thenclose without binding. The knurled plastic nut (2) next to theenrichener knob controls the sliding resistance of theenrichener control cable within the cable conduit.

3. Hold cable assembly at flat (3) with an adjustablewrench. Turn plastic nut by hand counterclockwise(reducing sliding resistance) until knob slides inwardunaided.

4. Turn plastic nut clockwise (increasing sliding resistance)until knob remains fully open without holding, and closeswith relative ease.

5. Position cable assembly in slot in bracket with hex nutand star washer behind bracket. Tighten hex nut (5) to20-35 in-lbs (2.3-4.0 Nm).

NOTE Star lock washer (4) is positioned between bracket and hexnut.

Figure 1-68. Enrichener Control

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1. Fuel enrichener knob2. Knurled plastic nut3. Flat4. Star lock washer5. Hex nut6. Enrichener bracket

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DLE SPEED AND IGNITION TIMING 1.25

DLE SPEED ADJUSTMENT

heck and adjust engine idle speed as described below.

NOTESThe CV carburetor enrichener circuit will cause engine toidle above the normal idle range (950-1050 RPM) withengine running at normal operating temperature andenrichener knob pulled out fully. With enrichener knobpulled out partially, and engine running at normal operat-ing temperature, engine idle speed will also increaseabove normal idle range.

The increase in idle speed is intended to alert rider thatengine is warmed up to normal operating temperatureand enrichener knob should be pushed in all the way.

Continued use of enrichener after engine is at normaloperating temperature WILL cause fouled spark plugs.

. Start motorcycle and let vehicle reach normal operatingtemperature. Push enrichener knob fully in (enrichenerclosed).

. See Figure 1-69. Adjust idle speed adjusting screw soengine idles at 950-1050 RPM.

a. Turn screw clockwise to increase idle speed.

b. Turn screw counterclockwise to decrease idlespeed.

NOTESUse CARBURETOR IDLE ADJUSTER and ADJUSTERTIP to turn idle adjusting screw if necessary.

To adjust the idle speed on models without a tachometer,use a digital engine tachometer, such as the Snap-OnSE-1100, held near a spark plug cable while the motor-cycle is idling.

PART NO. SPECIALTY TOOL

HD-33413-A Carburetor idle adjuster

HD-33413-1A Adjuster tip

Figure 1-69. Idle Speed Adjustment Screw

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MAP sensor

CKP sensor

Sensor data

Ignition Control Module (ICM)

Ignition Coil

Ignition coil control signals

Sensor data


IGNITION TIMING

See Figure 1-70. Ignition timing is controlled by the IgnitionControl Module (ICM) based on input from:

● Manifold Absolute Pressure (MAP) sensor.

● Crank Position (CKP) sensor.

No ignition timing adjustment is required, or possible. Shoulda sensor fail, the resulting diagnostic trouble code (DTC) willidentify the problem. See the SPORTSTER MODELS ELEC-TRICAL DIAGNOSTIC MANUAL for more information.

Figure 1-70. Ignition Control

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FUEL SUPPLY VALVE FILTER 1.26

INSPE

See Figur

1. Turn valve

PART

HD-2373

HD-4113

1. Fu2. G3. H4. Fu5. Va

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6.7.8.9.10.

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e 1-71. Check fuel valve filter strainer (1) as follows:

ignition OFF. See Figure 1-72. Turn fuel supply handle to OFF (horizontal) position.

1WARNING1WARNING

Stop the engine when refueling or servicing the fuel sys-tem. Do not smoke or allow open flame or sparks neargasoline. Gasoline is extremely flammable and highlyexplosive, which could result in death or serious injury.(00002a)

2. See Figure 1-71. Remove clamp (8) and fuel hose (9)from outlet nipple (7). Remove vacuum hose (10) fromvacuum nipple (5).

CAUTION

Do not allow dirt or fluids to get into the vacuum hoseassembly that connects the fuel valve to the carburetor.Contaminants could block the vacuum signal or inhibitfree motion of moving parts which could cause the fuelvalve to remain open.

3. Attach a piece of fuel hose to fuel outlet nipple and routehose into a proper, clean gasoline container.

4. See Figure 1-72. Turn valve handle to RESERVE (handleup).

NO. SPECIALTY TOOL

8-A Plastic Mity-Vac hand pump

7 Hose clamp pliers

el strainerasketex fittingel supply valve assemblycuum nipple

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Figure 1-71. Fuel Supply Valve

Fuel supply valve handleOutlet nipple (underneath)ClampFuel hoseVacuum hose Figure 1-72. Fuel Valve Operating Positions

1. OFF2. ON3. Reserve

HOME

5. See Figure 1-73. Using the appropriate hose adapter,connect the PLASTIC MITY-VAC® HAND PUMP to vac-uum nipple on fuel valve.

CAUTION

Do not apply a vacuum greater than 25 in. of Hg to thevalve at the vacuum nipple to avoid damaging the valvediaphragm.

6. Gently apply a vacuum of 1-10 in. of Mercury (Hg) or justenough vacuum to get a good flow of gasoline throughthe valve.

7. See Figure 1-71. After draining tank, turn the hex fitting(3) that attaches the fuel valve assembly (4) to the fueltank counterclockwise and remove the valve assembly,gasket (2), and fuel strainer (1). Discard gasket.

8. Clean or replace fuel strainer.

9. Coat fuel valve threads with LOCTITE PIPE SEALANTWITH TEFLON.

10. Install new gasket and fuel strainer on fuel valve assem-bly.

1WARNING1WARNING

Do not thread fitting onto valve more than two turns toavoid “bottoming” fitting on valve. This could cause a

11. Attach fuel supply valve assembly to tank.

a. Thread hex fitting (3) on right hand threads of fueltank two turns. Collar on hex fitting faces fuel tank.

b. Hold hex fitting and thread body of fuel supply valveassembly into left hand threads of hex fitting twoturns.

c. Hold fuel supply valve assembly so that handlepoints to the left, straight away from motorcycle.Tighten hex fitting (clockwise) to 15-20 ft-lbs (20.3-27.1 Nm).

12. See Figure 1-74. Connect the fuel hose to the outlet nip-ple on the fuel supply valve assembly using new clampand HOSE CLAMP PLIERS.

13. See Figure 1-71. Connect vacuum hose (10) to vacuumnipple (5) and fill tank with gasoline. Check for leaks atfitting.

14. See Figure 1-72. Turn fuel supply valve handle ON andstart engine. No special procedures are required to startfuel flow. Carefully inspect for leaks. Turn fuel supplyvalve OFF and shut off engine after inspection is com-plete.

FUEL SYSTEM LINES AND FITTINGS

Inspect the fuel system lines:

● At every scheduled service interval.

● After the fuel tank filter has been serviced.

Check fuel system lines and fittings for leaks.Figure 1-73. Mity-Vac Hand Pump

(Part No. HD-23738-A)

HD-23738A

HD-41137


gasoline leak and a fire hazard which could result indeath or serious injury.

Figure 1-74. Hose Clamp Pliers(Part No. HD-41137)

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ENGINE MOUNTS AND STABILIZER LINKS 1.27

INSPE

Check eng

1. See moun

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ine mounts and stabilizer links as follows:

Figure 1-75. Check for cracks or tears in enginet isolator rubber (17, 18).

k stabilizer links (8) for wear.

3. Check that all engine mount bolts and stabilizer linkscrews are tight. See 2.21 STABILIZER LINKS, 2.22FRONT ENGINE MOUNT/ISOLATOR, or 2.23 REARENGINE MOUNT/ISOLATOR for torque specifications.

4. Check that the mounts are supporting the weight of themotor.

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Figure 1-75. Engine Mounting Assemblies

crew @ 80-120 in-lbs (9.05-13.6 Nm) (3)crew @ 55-65 ft-lbs (74.6-88.2 Nm) (2)crew @ 25-35 ft-lbs (33.9-47.5 Nm) (3)crew @ 25-35 ft-lbs (33.9-47.5 Nm) (11)asher (4)pacerock washer (2)tabilizer link (3)ront isolator mountear isolator mount

11. Nut @ 60-70 ft-lbs (81.4-95.0 Nm) 12. Bolt13. Swing arm pivot shaft14. Rear pivot lockplate15. Stabilizer link bracket (2)16. Engine bracket17. Front mount isolator (2)18. Rear mount isolator (2)19. Grounding strap20. Swing arm pivot bolt @ 60-70 ft-lbs

(81.4-95.0 Nm) (2)

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EADLAMP ALIGNMENT 1.28

NSPECTION

1WARNING1WARNING

he automatic-on headlamp feature provides increasedisibility of the rider to other motorists. Be sure head-amp is on at all times. Poor visibility of rider to other

otorists can result in death or serious injury. (00030b)

heck headlamp beam for proper height and lateral align-ent:

When the new owner takes delivery of the motorcycle.

When there is a change in load (adding luggage, etc.).

. Verify correct front and rear tire inflation pressure. See1.11 TIRES AND WHEELS.

. Place motorcycle on level floor (or pavement) in an areawith minimum light.

. See Figure 1-76. Position motorcycle 25 ft (7.62 m) awayfrom a screen or wall. Measure distance from directlybelow front axle to base of screen/wall.

. Draw a horizontal line, on screen or wall, 35 in. (889 mm)above floor.

. Stand motorcycle upright with both tires resting on floorand with front wheel held in straight alignment (directlyforward).

. Load motorcycle with rider, passenger (if normallypresent) and any cargo normally carried. Weight willcompress vehicle suspension slightly.

. Turn ignition/light switch to IGNITION position. Set han-dlebar headlamp switch to HIGH beam position.

8. Check headlamp beam for proper height alignment:

a. Main beam of light (broad, flat pattern of light)should be centered equally above and below hori-zontal line on screen or wall.

b. Main beam of light should be directed straightahead. Properly adjusted headlamps project anequal area of light to right and left of center.

c. Adjust headlamp alignment if necessary. SeeADJUSTMENT which follows.

Figure 1-76. Headlamp Alignment

A

x0302x7x

A= 35 in. (889 mm)

25 ft. (7.62 m)


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ADJUSTMENT

XL 883C, XL 1200C

1. See Figure 1-78. To adjust headlamp horizontally,

XL 883, XL 883L, XL 883R, XL 1200R1. See Figure 1-77. Remove snap plug (1) from top of

headlamp bracket (2). Loosen headlamp clamp nut (3).

2. Tilt headlamp up or down to properly aim it in relation tothe horizontal line and, at the same time, turn it right orleft to direct headlamp beam straight ahead.

3. Tighten headlamp clamp nut to 120-240 in-lbs (13.6-27.1 Nm) after headlamp is properly positioned. Installsnap plug in headlamp bracket.

a. Loosen horizontal adjustment screw (3). Turn head-lamp right or left as necessary to direct headlampbeam straight ahead.

b. Tighten horizontal adjustment screw to 30-35 ft-lbs(40.7-47.5 Nm).

2. To adjust headlamp vertically,

a. Loosen vertical adjustment bolt (1) and nut (2). Tiltheadlamp up or down to properly aim it in relation tothe horizontal line.

b. Tighten vertical adjustment bolt and nut to 30-35 ft-lbs (40.7-47.5 Nm).

Figure 1-77. Headlamp Adjustment(Non-Custom Models)

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1. Snap plug2. Headlamp bracket3. Headlamp clamp nut

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Figure 1-78. Headlamp Adjustment(Custom Models)

1. Vertical adjustment bolt2. Nut3. Horizontal adjustment screw

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LUID/LUBRICANT REQUIREMENTS 1.29

RAKE FLUID

1WARNING1WARNING

irect contact of D.O.T. 5 brake fluid with eyes can causeye irritation, swelling, and redness. Avoid eye contact.n case of eye contact flush with large amounts of waternd get medical attention. Swallowing large amounts of.O.T. 5 brake fluid can cause digestive discomfort. Ifwallowed, obtain medical attention. Use in well venti-ated area. KEEP OUT OF REACH OF CHILDREN.00144a)

se only Harley-Davidson brand D.O.T. 5 BRAKE FLUID.

RAKE COMPONENT GREASE

se only G40M BRAKE GREASE to lubricate brake systemomponents.

RONT FORK OIL

se only HARLEY-DAVIDSON TYPE “E” HYDRAULIC FORKIL.

ENGINE OIL

Engine oil is a major factor in the performance and service lifeof the engine. Refer to Table 1-13. Always use the propergrade of oil for the lowest temperature expected before thenext scheduled oil change.

If it is necessary to add oil and Harley-Davidson oil is notavailable, use an oil certified for diesel engines. Acceptablediesel engine oil designations include CF, CF-4, CG-4 andCH-4. The preferred viscosities for the diesel engine oils, indescending order, are 20W-50, 15W-40 and 10W-40. At thefirst opportunity, see a Harley-Davidson dealer to changeback to 100 percent Harley-Davidson oil.

PRIMARY DRIVE/TRANSMISSION LUBRICANT

Use only GENUINE HARLEY-DAVIDSON FORMULA+TRANSMISSION AND PRIMARY CHAINCASELUBRICANT.

Table 1-13. Recommended Engine Oil Viscosity

HARLEY-DAVIDSON TYPE

VISCOSITYHARLEY-DAVIDSON

RATINGLOWEST AMBIENT

TEMPERATURE

COLD WEATHER STARTS BELOW 50˚F

(10˚C)

HD Multigrade SAE 10W40 HD 360 Below 40˚ F (4˚ C) Excellent

HD Multigrade SAE 20W50 HD 360 Above 40˚ F (4˚ C) Good

HD Regular Heavy SAE 50 HD 360 Above 60˚ F (16˚ C) Poor

HD Extra Heavy SAE 60 HD 360 Above 80˚ F (27˚ C) Poor


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STORAGE 1.30

GENE

If the mosuch as dwhich shopreserve varnish in

This workdealer or procedure

Do not sthome or or electrflammabldeath or

1. Prepabelow

a. Folopotinwdc

b. Dinrt

2. Fill thbottooil pupast tflywh

3. Remointo eReins

4. Grea

1-64

5. Adj

6. Cheexteund

7. Wafilm

RAL

torcycle will not be operated for several months,uring the winter season, there are several thingsuld be done to protect parts against corrosion, to

the battery and to prevent the buildup of gum and the carburetor.

should be performed by your local Harley-Davidsonother qualified technician following Service Manuals.

1WARNING1WARNING

ore motorcycle with gasoline in tank within thegarage where open flames, pilot lights, sparksic motors are present. Gasoline is extremelye and highly explosive, which could result inserious injury. (00003a)

re fuel system by one of the two methods outlined:

ill fuel tank and add a gasoline stabilizer. Use onef the commercially available gasoline stabilizers fol-wing the manufacturer’s instructions. Turn fuel sup-ly valve off. See Figure 1-79. Place end of fuelverflow/drain hose (2) into an approved fuel con-ainer. Drain all gasoline from carburetor by loosen-g fuel bowl drain screw (1) one full turn; gasolineill drain through overflow/drain hose. Retightenrain screw after all gasoline has been drained fromarburetor.

rain all gasoline from the fuel tank. Spray theside of the fuel tank with a commercially available

ust preventative. Follow the manufacturer’s instruc-ions.

e oil tank. Locate the hose leading from the oil tankm to the oil pump feed fitting. Remove and plug themp end of this hose. This prevents oil from seepinghe check ball into the oil pump and filling the engineeel compartment.

ve the spark plugs, inject a few squirts of engine oilach cylinder and crank the engine 5-6 revolutions.tall spark plugs.

se wheel bearings and install new seals.

Figure 1-79. Draining Carburetor Float Chamber

1. Carburetor drain screw2. Fuel overflow/drain hose

12

10551


ust primary chain.

ck tire inflation. If the motorcycle will be stored for annded period of time, securely support the motorcycleer the frame so that all weight is off the tires.

sh painted and chrome-plated surfaces. Apply a light of oil to exposed unpainted surfaces.

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1WARNING1WARNING

Do not apply any oil to brake discs or brake pads. Oil ondisc pads degrades braking efficiency and can result inan accident resulting in death or serious injury.

8. Remove battery from vehicle. Charge battery until thecorrect voltage is obtained. Charge the battery everyother month if it is stored at temperatures below 60˚ F(16˚ C). Charge battery once a month if it is stored attemperatures above 60˚ F (16˚ C).

1WARNING1WARNING

Unplug or turn OFF battery charger before connectingcharger cables to battery. Connecting cables withcharger ON can cause a spark and battery explosion,which could result in death or serious injury. (00066a)

1WARNING1WARNING

Unplug or turn OFF battery charger before disconnectingcharger cables from battery. Disconnecting clamps withcharger ON can cause a spark and battery explosion,which could result in death or serious injury. (00067a)

1WARNING1WARNING

Store battery out of reach of children. Battery containssulfuric acid which can cause severe burns to eyes, skinand clothing.

9. If motorcycle is to be covered, use a material that willbreathe, such as light canvas. Plastic materials that donot breathe promote the formation of condensation.

REMOVAL FROM STORAGE

1WARNING1WARNING

The clutch failing to disengage can cause loss of control,which could result in death or serious injury. Prior tostarting after extended periods of storage, place trans-mission in gear and push vehicle back and forth severaltimes to assure proper clutch disengagement. (00075a)

1. Charge and install battery.

2. Remove and inspect the spark plugs. Replace if neces-sary.

3. Clean the air cleaner element.

4. If fuel tank was drained, fill fuel tank with fresh gasoline.

5. If oil feed hose was plugged, unplug it and reconnect.

6. Start the engine and run until it reaches normal operat-ing temperature.

7. Check engine oil level. Check the transmission lubricantlevel. Fill to proper levels with correct fluids, if required.

8. Perform all of the checks in the PRE-RIDING CHECK-LIST in the Owner’s Manual.


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TROUBLESHOOTING 1.31

GENE

The troubsolely asthe approing any wto observor seriou

The followating trouvice Manu

ENGIN

StartinNot Tur1. Engin

2. Ignitio

3. Dischnoid c

4. Starte

5. Electrunni

6. TSM/switch

Engine1. Fuel

2. Fuel

3. Enginenrich

4. Vacuuor pin

5. Dischnectio

6. Foule

7. Spark

1-66

conder

RAL

1WARNING1WARNING

leshooting section of this manual is intended a guide to diagnosing problems. Carefully readpriate sections of this manual before perform-ork. Observe all cautions and warnings. Failuree cautions and warnings could result in death

s injury.

ing check list can be helpful in locating most oper-bles. Refer to the appropriate sections in this Ser-al for detailed procedures.

E

g Motor Does Not Operate or Does n Engine Overe run switch in OFF position.

n switch not ON.

arged battery, loose or corroded connections (sole-hatters).

r control circuit, relay or solenoid not functioning.

ric starter shaft pinion gear not engaging or over-ng clutch slipping.

TSSM bank angle sensor tripped and ignition not cycled OFF then ON.

Turns Over But Does Not Starttank empty or fuel valve turned off.

valve or fuel strainer clogged.

e flooded with gasoline as a result of overuse ofener.

m hose to fuel supply valve disconnected, leakingched.

arged battery, loose or broken battery terminal con-ns.

d spark plugs.

plug cables in poor condition and shorting, cable

8. Ignition timing incorrect due to faulty coil, ICM or sensors(MAP, CKP and/or TSM/TSSM).

9. Loose wire connection at coil or battery connection orplug between crank position sensor (CKP) and ignitioncontrol module (ICM).

10. Ignition coil not functioning.

11. Ignition control module (ICM) not functioning.

12. Crank position sensor (CKP) not functioning.

13. Sticking or damaged valve or valves.

14. Engine oil too heavy (winter operation).

NOTEFor cold weather starts, always disengage clutch.

Starts Hard1. Spark plugs in poor condition, have improper gap or are

partially fouled.

2. Spark plug cables in poor condition.

3. Battery nearly discharged.

4. Loose wire connection at one of the battery terminals, atcoil, or at plug between crank position sensor (CKP) andignition control module (ICM).

5. Carburetor controls not adjusted correctly.

6. Ignition coil not functioning.

7. Engine oil too heavy (winter operation).

8. Fuel tank filler cap vent plugged, or carburetor fuel lineclosed off restricting fuel flow.

9. Water or dirt in fuel system and carburetor.

10. Enrichener valve inoperative.

11. Air leak at intake manifold.

12. Valves sticking.

13. Air cleaner EVAP flapper (if equipped) stuck closed orinoperative.


nections loose or cables connected to incorrect cylin-s.

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Starts But Runs Irregularly or Misses1. Spark plugs in poor condition or partially fouled.

2. Spark plug cables in poor condition and shorting or leak-ing.

3. Spark plug gap too close or too wide.

4. Ignition coil, ignition control module (ICM) or crank posi-tion sensor (CKP) not functioning properly.

5. Battery nearly discharged.

6. Damaged wire or loose connection at battery terminalsor coil.

7. Intermittent short circuit due to damaged wire insulation.

8. Water or dirt in fuel system and carburetor or fuelstrainer.

9. Fuel tank filler cap vent plugged or carburetor float bowlvent closed off.

10. Carburetor controls improperly adjusted.

11. Air leak at intake manifold or air cleaner.

12. Damaged intake or exhaust valve.

13. Weak or broken valve springs.

14. Incorrect valve timing.

15. Air cleaner EVAP flapper (if equipped) stuck closed orinoperative.

Spark Plug Fouls Repeatedly1. Incorrect spark plug.

2. Piston rings badly worn or broken.

3. Fuel mixture too rich (see 4.3 TROUBLESHOOTING).

4. Valve guides or seals badly worn or damaged.

Pre-Ignition or Detonation(Knocks or Pings)1. Excessive carbon deposit on piston head or combustion

chamber.

2. Incorrect heat range spark plug.

3. Spark plugs not firing.

4. Ignition timing advanced. Ignition control module (ICM)or crank position sensor (CKP) defective.

5. Fuel octane rating too low.

6. Intake manifold vacuum leak.

Overheating1. Insufficient oil supply, or oil not circulating.

2. Insufficient air flow over engine.

3. Leaking valves.

4. Heavy carbon deposit.

5. Ignition timing retarded. Ignition control module (ICM) orcrank position sensor (CKP) defective.

Valve Train Noise1. Low oil pressure caused by oil feed pump not functioning

properly or oil passages obstructed.

2. Hydraulic lifter not functioning properly.

3. Bent push rod.

4. Cam, cam gears, or cam bushings worn.

5. Rocker arm binding on shaft.

6. Valve sticking in guide.

Excessive Vibration1. Stabilizer links worn or loose, or stabilizer link brackets

loose or broken.

2. Isolators worn or isolator bolts loose or broken.

3. Isolator mounting brackets (left side of vehicle) loose orbroken.

4. Broken frame.

5. Primary chain badly worn or links tight as a result ofinsufficient lubrication.

6. Wheels not aligned, rim(s) bent and/or tires worn.

7. Internal engine problem.


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ENGINE LUBRICATION SYSTEM ELECTRICAL SYSTEM

Oil Does Not Return To Oil Tank1. Oil tank empty.

2. Return pump gears damaged.

3. Oil feed pump not functioning.

4. Restricted oil lines or fittings.

5. Restricted oil filter.

Engine Uses Too Much Oil or Smokes Excessively1. Piston rings badly worn or broken.

2. Valve guides or seals worn or damaged.


Engine Leaks Oil From Cases, Push Rods, Hoses, Etc.1. Loose parts.

2. Imperfect seal at gaskets, push rod covers, washers, etc.To aid locating leaks, use BLACK LIGHT LEAK DETEC-TOR (Part No. HD-35457).

3. Restricted oil return line to tank.

4. Restricted breather passage(s) to air cleaner.


FUEL

Carburetor Floods1. Excessive “pumping” of hand throttle grip.

2. Inlet valve sticking.

3. Inlet valve and/or valve seat worn or damaged.

4. Dirt or other foreign matter between valve and its seat.

5. Float misadjusted.

6. Leaky or damaged float.

Alternator Does Not Charge1. Voltage regulator-rectifier module not functioning.

2. Voltage regulator-rectifier not grounded.

3. Engine ground wire loose or broken.

4. Loose or broken wires in charging circuit.

5. Stator and/or rotor not functioning.

Alternator Charge Rate Is Below Normal1. Voltage regulator-rectifier module not functioning.

2. Stator and/or rotor not functioning.

3. Weak or damaged battery.

4. Loose connections.

Speedometer Operates Erratically1. Contaminated speedometer sensor (remove sensor and

clean off metal particles).

2. Loose connections.

TRANSMISSION

Shifts Hard1. Clutch dragging slightly.

2. Shifter forks (inside transmission) damaged.

3. Corners worn off shifter clutch dogs (inside transmis-sion).

Jumps Out of Gear1. Shifter pawl improperly adjusted.

2. Shifter engaging parts (inside transmission) badly wornand rounded.

3. Shifter forks bent.

4. Damaged gears.


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CLUTCH

Slips1. Clutch controls improperly adjusted.

2. Worn friction plates.

3. Insufficient clutch spring tension.

Drags or Does Not Release1. Clutch controls improperly adjusted.

2. Clutch plates excessively warped.

ChattersFriction or steel plates worn, warped, or dragging.

CHASSIS

Irregular/Inadequate Brake Action1. Master cylinder reservoir low on fluid.

2. Brake system contains air bubbles.

3. Master cylinder or brake caliper piston(s) worn or partsdamaged.

4. Brake pads contaminated with grease or oil.

5. Brake pads badly worn. Minimum lining thickness is 0.04in. (1.02 mm).

6. Brake disc badly worn or warped.

7. Brake pads dragging or excessive braking (brake fadesdue to heat buildup).

8. Insufficient brake pedal or hand lever free play (brakedrags).

Handling Irregularities1. Tires improperly inflated. Check TIRE DATA Section. Do

not overinflate.

2. Loose wheel axle nuts. Tighten front nut to 50-55 ft-lbs(68-75 Nm). Tighten rear nut to 72-78 ft-lbs (98-106 Nm).

3. Excessive wheel hub bearing play.

4. Rear wheel out of alignment with frame and front wheel.

5. Rims and tires out-of-true sideways. Tire runout shouldnot be more than 5/64 in. (2.0 mm).

6. Rims and tires out-of-round or eccentric with hub. Tirerunout should not be more than 3/32 in. (2.4 mm).

7. Loose spokes (laced wheel vehicles only).

8. Irregular or peaked front tire tread wear.

9. Tire and wheel unbalanced.

10. Steering head bearings improperly adjusted. Correctadjustment, and replace pitted or worn bearings andraces. See 2.18 FORK STEM AND BRACKET ASSEM-BLY.

11. Shock absorbers not functioning normally.

12. Heavy front end loading. Non-standard equipment on thefront end (such as heavy radio receivers, extra lightingequipment, or luggage) tends to cause unstable han-dling.

13. Engine mounts and/or stabilizer links loose, worn ordamaged.


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NOTES


Sm01b

Documents

foot shift

stuck closed

slider tube

restricted

air filter

oil feed pump

fuel system

air cleaner