Complete map of motorcycle repair instructions Harley

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Repair motorcycles Harley Street
Harley 750/500 (2014-2021)
Information for owner

Metric conversions table
Fluid conversion
Torque conversion
Acronyms and abbreviations
Tools used in this manual
Torque values in this manual

Maintenance

Fastener torque values
Motorcycle general maintenance
Maintenance schedule
Fuel and oil
Replace engine oil and filter
Inspect tires
Lubricate cable and chassis
Inspect brakes
Check and replace brake fluid
Check and adjust throttle cables
Check and adjust clutch
Adjust brake linkage
Adjust steering head bearings
Inspect radiator and coolant
Inspect and adjust drive belt and sprockets
Inspect rear wheel compensator
Inspect exhaust system
Inspect air filter
Inspect and adjust valve lash
Inspect battery
Replace spark plugs
Storage of maintenance
Troubleshooting of maintenance
Engine and systems

Engine repair

Fastener torque values
Specifications of engine
Engine oil flow
Breather operation
Oil pressure
Troubleshooting of engine
Front engine mount
Rear engine mount
Replace engine
Rebuild engine
Intake adapter
Cylinder head covers
Camshaft sprocket and timing chain
Cylinder heads
Rocker arms
Camshaft assembly
Removing and installing valves
Chain guide
Removing and installing cylinders
Removing and installing pistons
Alternator cover
Clutch cover
Removing and installing balancer
Crankshaft gear
Starter gear
Oil pump
Oil strainer
Crankcase assembly
Main bearings
Crankcase oil nozzles
Oil passage plugs
Crankshaft and connecting rods

Fuel system

Fastener torque values
Specifications of fuel and exhaust
Air cleaner assembly
Lift rear of fuel tank
Fuel tank
Fuel line
Fuel pressure test
Fuel pump assembly
Vent tube
Vapor valve
Idle air control (IAC)
Fuel injectors
Temperature manifold absolute pressure (TMAP) sensor
Breather hoses
Induction module
Oxygen (O2) sensor

Cooling system

Fastener torque values
Specifications of cooling system
Coolant flow
Diagnose and test
Coolant of cooling system
Thermostat housing
Coolant pump
Coolant overflow tank
Coolant hoses
Engine coolant temperature (ECT) sensor
Removing and installing radiator

Exhaust system

Removing and installing muffler
Exhaust system
Intake leak test
Purge solenoid: California emissions
Charcoal canister: California emissions
Purge lines: California emissions

Transmission

Fastener torque values
Specifications of transmission and clutch
Transmission operation
Drive belt
Output pulley
Shifter shaft
Removing and installing clutch
Drum and forks
Removing and installing the transmission
Transmission right crankcase bearings
Transmission left crankcase bearings
Running gear and frame

Frame and hinged elements

Fastener torque values
Specifications of chassis
Vehicle identification number (VIN)
Side covers
Removing and installing mirrors
Front fender
Rear fender
Saree guard
Front license plate bracket
Rear license plate bracket
Rider foot controls
Passenger footpegs
Removing and installing seat
Jiffy stand

Suspension and handlebar

Front fork
Steering head/fork stem and bracket assembly
Rear fork
Belt guards
Shock absorbers
Clutch control
Throttle control
Headlamp fairing
Hand grips
Removing and installing handlebar

Brake system

Front brake master cylinder
Front brake caliper
Rear brake master cylinder
Rear brake caliper
Brake lines
Bleed brakes

Wheels and tires

Front wheel
Rear wheel
Rear wheel compensator
Wheel runout
Sealed wheel bearings
Removing and installing tires
Wheel alignment
Electric equipment

Equipment and devices

Fastener torque values
Specifications of electrical
Fuses and relays
Power disconnect
Left handlebar switch housing
Right handlebar switch housing
Removing and installing speedometer
Oil pressure switch
Neutral indicator switch
Removing and installing horn
Electronic control module (ECM)
Removing and installing cooling fan
Vehicle speed sensor (VSS)
Bank angle sensor
Jiffy stand sensor
Battery tray
Engine ground cable
Engine wire harness
Main wiring harness
Bosch compact 1.1M connectors
Delphi GT 150 sealed connectors
Deutsch DT sealed connectors
Furukawa QLW sealed connectors
Molex MX 150 sealed connectors
Sumitomo DL sealed and MT connectors
Sumitomo MTW and MTL unsealed connectors
Tyco 070 multilock unsealed connector
Tyco get 64 unsealed connectors
Tyco junior power timer unsealed connector
Tyco sealed timer connector
Tyco super seal 1.5 sealed connector
Yazaki SSD sealed connector
Component location views
Wiring diagram information
Connector locations and functions

Starting and charging system

Removing and installing starter
Starter solenoid
Removing and installing alternator
Voltage regulator
Ignition switch
Ignition coil
Spark plug cable

Lighting and lamps

Removing and installing headlamp
Front turn signal lamps
Rear turn signal lamps
Turn signal flasher
Removing and installing tail lamp
License plate lamp

Repair motorcycles Harley Sportster
Harley XL1200 (2012-2023)
Information for owner

Maintenance

Fastener torque values in this chapter
Servicing a new motorcycle
Fuel and oil for motorcycle
Bulb requirements chart
Maintenance schedule of motorcycle
Checking and adding oil
Changing oil and filter
Air filter (XL models, except XL 1200V) — removal and installation
Air filter (XL 1200V models) — removal and installation
Air filter (XR 1200X models) — removal and installation
Cleaning air filter element
Tires and wheels — air pressure
Tire replacement
Recommended motorcycle tires
Wheel bearings
Wheel spokes
Primary chain — free play adjustment
Transmission lubrication
Clutch adjustment
Drive belt and sprockets — inspection
Throttle control — lubrication and adjustment
Cable and chassis lubrication
Brake lines maintenance
Brake pads and discs: XL models — inspection
Brake pads and discs: XR 1200X — inspection
Spark plugs maintenance — removal, installation and inspection
Steering head bearings
Checking torques on fasteners
Engine mounts and stabilizer links — inspection
Battery maintenance
Exhaust system leak check
Checking wheel alignment
Suspension adjustments
Headlamp alignment
Placing motorcycle in storage
Metric conversion table
Fluid volume conversions
Torque conversions
Acronyms and abbreviations
Tools used in this manual
All torque values for motorcycle repair

Troubleshooting

Troubleshooting engine
Troubleshooting lubrication system
Troubleshooting electrical system
Troubleshooting transmission
Troubleshooting controllability
Troubleshooting brakes
Engine and systems

Engine repair

Fastener torque values
Specifications of engine
Diagnosing valve train noise
Cylinder compression test
Cylinder leakage test
Diagnosing smoking engine or high oil consumption
How to use engine repair section
Engine top end service
Engine bottom end service
Removing engine from chassis: XL models
Removing engine from chassis: XR 1200X models
Installing engine in chassis XL models
Installing engine in chassis XR 1200X models
Engine top end overhaul: disassembly
Cylinder head — disassembly
Cylinder head — cleaning and inspection
Cylinder head — replacing rocker arm bushings
Cylinder head — replacing valve guides
Cylinder head — refacing valve seats
Cylinder head — assembly
Cylinder and piston — cleaning, inspection and repair
Cylinder and piston — connecting rod bushings
Engine top end overhaul: assembly
Engine bottom end overhaul: disassembly
Gearcase: XL models
Crankcase — disassembly and assembly
Engine bottom end overhaul: assembly

Lubrication system

Oil pressure operation
Checking oil pressure
Crankcase breathing system
Oil pump operation
Oil flow: XL models
Oil flow: XR 1200X models
Precision cooling system: XR 1200X
Return oil manifold — removal and installation
Cylinder head oil return lines — removal and installation
Cylinder head oil feed assembly
Oil pump lines — removal and installation
Oil cooler — removal and installation
Oil pump: XL models — removal, installation, disassembly and assembly
Oil pump: XR 1200X models — disassembly and assembly
Oil filter mount — disassembly and assembly
Oil tank — removal and installation

Fuel system

Transmission

Fastener torque values
Specifications of transmission
Primary cover — removal and installation
Primary drive and clutch: XL models — removal, installation, disassembly and assembly
Primary drive and clutch: XR 1200X models
Drive belt — removal and installation
Transmission power flow
Case disassembly for transmission removal
Transmission removal and disassembly
Transmission assembly
Main drive gear and bearing — removal, installation, disassembly and assembly
Transmission right case bearings — removal and installation
Transmission left case bearings — removal and installation
Transmission installation
Transmission sprocket — removal and installation
Running gear and frame

Frame and hinged elements

Front suspension and handlebar

Front fork: XL models — removal, installation, disassembly and assembly
Front fork: XR 1200X — removal, installation, disassembly and assembly
Fork stem and bracket assembly
Handlebar — removal and installation

Rear suspension

Belt guard and debris deflector
Rear fork — removal and installation
Shock absorbers — removal and installation
Rear wheel compensating sprocket

Brake system

Front brake master cylinder — removal, installation, disassembly, inspection and assembly
Front brake caliper: XL models — removal, installation, disassembly and assembly
Front brake caliper: XR 1200X — removal, installation, disassembly and assembly
Rear brake master cylinder: XL models — removal, installation, disassembly, inspection and assembly
Rear brake master cylinder: XR 1200X — removal, installation, disassembly, inspection and assembly
Rear brake master cylinder reservoir
Rear brake caliper: XL models — removal, installation, disassembly and assembly
Rear brake caliper: XR 1200X — removal, installation, disassembly and assembly
Brake lines — removal and installation
Bleeding brakes

Wheels and tires

Tires — removal and installation
Wheel service chart
Wheel bearing end play
Front wheel — removal and installation
Rear wheel — removal and installation
Sealed wheel bearings — removal and installation
Wheel lacing
Checking and truing wheels
Electric equipment

Equipment and devices

Lighting and lamps

Headlamp — removal and installation
Indicator lamp module
Tail lamp: all models except XL 883N/XL 1200X/V
License plate lamp module: XL 883N, XL 1200X/V
Front turn signals — removal and installation
Rear turn signals — removal and installation
Rear lighting converter module: XL 883N, XL 1200X/V (DOM)
Rear stop lamp switch

Starting and charging system

Battery cables — removal and installation
Battery tray — removal and installation
Starter — removal and installation
Ignition switch — removal and installation
Spark plug cables — removal and installation
Ignition coil — removal and installation
Voltage regulator — removal and installation
Alternator — removal and installation

Electrical circuits

Connector locations and functions
Wiring diagram information
Battery power diagram
Ignition power diagram
Accessory power diagram
Chassis grounds diagram
Main harness diagram
Starting and charging circuit
Motorcycle lighting diagram
Instrument, indicators, and hand controls diagram
Motorcycle security circuit
Security circuit with anti-theft tracking module

Repair motorcycles Harley V-Rod
Harley VRSCA (2002-2006)
Information for owner

Introduction to manual

Rules for the safe operation of motorcycles
Traffic Laws
Accessories and cargo
Exhaust Sound Management System
Vehicle identification number
Motorcycle labels
Motorcycle Specifications
Tire information
Catalytic converters of exhaust gases
Gasoline grades

Control devices

Controls and Indicators — General Information
Ignition switch
Electric Start Switch
Switch that turns on the motor
Throttle handle
Manual clutch lever
Sound signal switch
Headlight switch
Turn signal switches
Using the turn signal switches
Motorcycle indicator lights
Speedometer (speed indicator)
Setting the clock
Kilometers corresponding to the amount of fuel in the tank
Tachometer (engine speed indicator)
Fault indicator lamp for motorcycle electronic systems
Serial fuel injection port
Gear shift lever
Brake system
Pull-out stand
Rear view mirrors
Fuel tank cap
Fork lock
Rear shock absorbers — adjusting

Keys and alarm

Harley-Davidson Intelligent Safety System
Compliance with the standards of the US Federal Communications Commission (FCC)
Wireless control key fob
Personal identification number (PIN)
Security status indicator
Turning the security system on and off
Motorcycle alarm
Operation mode with siren signal (confirmation)
Transport mode
Storing the motorcycle and keeping it at the dealer's service center
Replacing the key fob battery
Power outage
Troubleshooting

Operation manual

Recommendations for motorcycle operation
Rules for driving a new motorcycle
Checks to be performed before driving
Extension Stand Lock — Export Models
Starting and stopping the engine
Gear shift

Maintenance

Howto use your service manual
Preparation for service
Use genuine replacement parts
Warnings and cautions
Servicing a new motorcycle
Safe operating maintenance
Shop practices
Repair and replacement procedures
Tool safety
Fuel and oil for motorcycle
Maintenance schedule
Airbox and air filter
Checking coolant level in overflow bottle
Check for coolant in system
Checking and adding oil
Changing oil and filter
Battery maintenance — general
Battery — disconnection and removal
Battery — installation and connection
Battery — storage
Brake fluid inspection
Rear brake pedal adjustment
Bleeding brakes
Brake pads and discs — inspection
Brake pad replacement
Tires and wheels
Checking clutch fluid level
Bleeding clutch fluid line
Rear belt deflection — inspection
Rear belt and sprockets — inspection
Rear shock preload — adjustment
Steering head bearings — adjustment (fall-away)
Replacing front fork oil
Spark plug/coil — removal, inspection and installation
Cable and chassis lubrication
Throttle cable inspection, lubrication and adjustment
Valve lash measurment
Verify cam timing
Valve lash adjustment
Secondary cam chain — adjustment
Headlamp alignment — inspection
Critical fasteners — inspection
Preparation for storage motorcycle
Tools for repair and maintenance motorcycle
Linear conversion table
Fastener torque values
Fluid volume conversions

Troubleshooting

Troubleshooting — general
Diagnosis of engine faults
Diagnosis of lubrication system faults
Diagnosis of electrical system faults
Diagnosis of transmission faults
Diagnosis of handling faults
Brake does not hold normally
Engine and systems

Engine repair

Engine specifications
Service wear limits
Engine torque values
Howto use this section
Diagnosing valvetrain noise
Compression test
Cylinder leakage test
Diagnosing smoking engine or high oil consumption
Stripping motorcycle for service
Engine cradle and stand
Throttle body — removal and installation
Cam drive removal
Cylinder head service — removal and disassembly
Procedure for using the Neway valve seat cutter
Cylinder head — assembly
Upper and lower crankcase — disassembly
Shift drum removal
Upper and lower crankcase — assembly
Counterbalancer bearing replacement — removal and installation
Crankshaft bearing replacement
Shift shaft and seal — removal and installation
Crankshaft, piston and cylinder liner
Cam drive — assembly
Cylinder heads — installation
Installing and timing the cams
Valve tappet shims
Valve lash calculation worksheet 1
Valve lash calculation worksheet 2

Cooling and lube system

Oil flow — general
Oil pressure indicator lamp
Checking oil pressure
Oil pump — replacement
Oil filter mount — replacement
Cooling system specifications
Coolant flow — general
Cooling system troubleshooting
Pressure cap description
Pressure cap test
Cooling system pressure test
Leak detection dye test
Tests for blown gasket
Engine coolant — replacing
Thermostat — removal and installation
Water pump — removal and installation
Coolant pipes and hoses — removal and installation
Oil line fittings — removal and installation
Radiator — removal and installation
Oil cooler — removal and installation

Fuel system

Fuel system specifications
Fuel pump, filters, fuel level sender assembly — removal
Fuel pump, filters, fuel level sender assembly — installation
Suction side fuel filter
Pressure side fuel filter — removal and installation
Fuel pump — removal and installation
Fuel level sender — removal and installation
Fuel tank — removal
Fuel tank — cleaning and inspecting
Fuel tank — installation
Vapor valve — replacement
Evaporative emissions control — California models

Fuel injection

Fuel injection specifications
Electronic fuel injection: EFI
Electronic control module: ECM — removal and installation
Throttle position sensor: TP — removal and installation
Intake air temperature sensor: IAT — removal and installation
Engine coolant temperature sensor: ECT — removal and installation
Idle air control: IAC — removal and installation
Manifold absolute pressure sensor: MAP — removal and installation
Fuel rail and fuel injectors — removal, installation, disassembly and assembly
Fuel pressure test
Intake leak test

Transmission

Clutch — removal
Clutch — disassembly
Clutch — cleaning and inspection
Clutch — assembly
Clutch — installation
Gearbox specifications
Output shaft disassembly — 2nd gear end
Output shaft assembly — 2nd gear end
Output shaft assembly — 1st gear end
Input shaft disassembly — 2nd gear end
Input shaft assembly — 2nd gear end
Running gear and frame

Frame and hinged elements

Brake and cluth systems

Clutch master cylinder and reservoir — removal, installation, disassembly and assembly
Clutch hand lever — installation
Clutch fluid line — removal and installation
Secondary clutch actuator — removal and installation
Front brake master cylinder and reservoir
Front brake calipers — removal and installation
Rear brake master cylinder and reservoir
Rear brake caliper — removal and installation

Suspension and handlebar

Handlebars — removal and installation
Sealed wheel bearings — inspection
Sealed wheel bearings — removal and installation
Front fork — removal and installation
Steering head — removal and installation
Fork lock — removal and installation
Rear shock absorbers — removal and installation
Rear fork — removal and installation

Wheels and tires

Front wheel — preliminary inspection
Front wheel — removal and installation
Rear wheel — preliminary inspection
Rear wheel — removal and installation
Disc rim runout
Tires — general information
Demountng tires
Tire cleaning and inspection
Tire replacement
Mounting tires
Tire runout
Wheel balancing
Electric equipment

Equipment and devices

Starting and charging system

Alternator — removal and installation
Voltage regulator — removal and installation
Accumulator battery — general info
Accumulator battery voltmeter testing
Accumulator battery disconnection and removal
Accumulator battery charging
Accumulator battery installation and connection
Accumulator battery storage
Battery cables replacement
Electric starter specifications
Electric starter system — general info
Starter relay — removal and installation
Starter — removal and installation
Starter solenoid — removal and installation

Electrical circuits

AMP multilock electrical connectors
Deutsch electrical connectors
Mini-Deutsch connectors
Sealed butt splice connectors — installation
Packard electrical connectors
Packard ECM connector — disassembly and assembly
Connector locations
Electrical diagrams of horn and instrument
Electrical diagrams of ignition system
Electrical diagrams of lighting system
Electrical diagrams of main wiring harness
Electrical diagrams of security system
Electrical diagrams of starting system

Repair manuals for:

Aprilia BMW Ducati Harley Honda Kawasaki Suzuki Triumph Yamaha