Diagnosis and troubleshooting of motorcycle Harley Sportster XL1200 (2012-2023)

Troubleshooting engine
Warning! The Troubleshooting section of this manual is a guide to diagnose problems. Read the appropriate sections of this manual before performing any work. Improper repair and/or maintenance could result in death or serious injury. Use the...

Troubleshooting lubrication system
PART NUMBERTOOL NAMEHD-35457BLACK LIGHT LEAK DETECTOR Oil does not return to oil tank 1. Oil tank empty. 2. Oil pump gerotors damaged. The oil pump is not functioning. 3. Restricted oil hoses or fittings. 4. Restricted oil filter. Engine uses too...

Troubleshooting electrical system
Note. For diagnostic information see the electrical diagnostic manual. Alternator does not charge 1. Voltage regulator module not grounded. 2. Engine ground wire loose or damaged. 3. Faulty voltage regulator module. 4. Loose or damaged wires in...

Troubleshooting transmission
Shifts hard 1. Clutch dragging slightly. 2. Transmission lubricant level too high. 3. Transmission lubricant too heavy (winter operation). 4. Shifter return spring (inside primary chaincase) bent or broken. 5. Bent shifter rod. 6. Shifter forks...

Troubleshooting controllability
1. Tires improperly inflated. Do not overinflate. 2. Loose wheel axle nuts. Tighten to torque specification. 3. Improper vehicle alignment: rear wheel out of alignment with frame and front wheel. 4. Rims and tires out-of-true sideways. 5. Rims and...

Troubleshooting brakes
Brake does not hold normally 1. Brake fluid reservoir low, system leaking or pads worn. 2. Brake system contains air bubbles. 3. Master cylinder/caliper piston seals worn or parts damaged. 4. Brake pads contaminated with grease or oil. 5. Brake pads...