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Articles and news
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)
Air filter (XL 1200V models)
Air filter (XR 1200X models)
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
Throttle control — lubrication and adjustment
Cable and chassis lubrication
Brake lines maintenance
Brake pads and discs: XL models
Brake pads and discs: XR 1200X
Spark plugs maintenance
Steering head bearings
Checking torques on fasteners
Engine mounts and stabilizer links
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
Cylinder head oil feed assembly
Oil pump lines — removal and installation
Oil cooler — removal and installation
Oil pump: XL models
Oil pump: XR 1200X models
Oil filter mount — disassembly and assembly
Oil tank — removal and installation
Fuel system
Fastener torque values
Specifications of fuel system
Air cleaner assembly — removal and installation
Fuel tank: XL models
Fuel tank: XR 1200X models
Throttle position sensor (TPS)
Engine temperature sensor (ET)
Induction module: XL models
Induction module: XR 1200X models
Idle air control (IAC)
Temperature manifold absolute pressure (TMAP) sensor
Oxygen sensor (O2)
Exhaust system: XL models
Exhaust system: XR 1200X models
Fuel injectors — removal and installation
Fuel pump — removal and installation
Fuel filter element — removal and installation
Fuel pressure test
Intake leak test
Evaporative emissions control
Transmission
Fastener torque values
Specifications of transmission
Primary cover — removal and installation
Primary drive and clutch: XL models
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
Transmission right case bearings
Transmission left case bearings
Transmission installation
Transmission sprocket — removal and installation
Running gear and frame
Frame and hinged elements
Fastener torque values
Specifications of motorcycle
Vehicle identification number (VIN)
Left side cover — removal and installation
Engine stabilizer links — removal and installation
Front engine mount/isolator
Rear engine mount/isolator
Throttle cables: all models
Clutch control — removal and installation
Front fender — removal and installation
Front license plate: India models
Rear fender: all XL models except XL 883N, XL 1200X/V
Rear fender and license plate bracket: XL 883N, XL 1200X/V
Rear fender: XR 1200X
Saree guard: India models
Rear license plate: India models
Jiffy stand — removal and installation
Seat — removal and installation
Rider foot controls: XL mid-mount controls
Rider foot controls: XL forward controls
Rider foot controls: XR 1200X
Passenger footrests — removal and installation
Fork lock — removal and installation
Medallions, serialized badges and tank emblems
Front suspension and handlebar
Front fork: XL models
Front fork: XR 1200X
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
Front brake caliper: XL models
Front brake caliper: XR 1200X
Rear brake master cylinder: XL models
Rear brake master cylinder: XR 1200X
Rear brake master cylinder reservoir
Rear brake caliper: XL models
Rear brake caliper: XR 1200X
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
Fastener torque values
Specifications of electrical components
Fuses and relays
Speedometer: XL models
Speedometer and tachometer: XR 1200X
Electronic control module (ECM)
Turn signal and security module (TSM/TSSM/HFSM)
Crank position sensor (CKP)
Vehicle speed sensor (VSS)
Neutral indicator switch
Main wiring harness
Electrical caddies — removal and installation
Jiffy stand sensor (JSS): international models
Security system/optional siren
Oil pressure switch — removal and installation
Horn — removal and installation
Handlebar switch assemblies
Right handlebar switches
Left handlebar switches
Personal identification number (PIN)
H-DSSS actuation
TSM/HFSM: password learn
Autofuse unsealed electrical connector
Bosch compact 1.1M connector
Delphi 100W micro-pack sealed connector
Delphi 150 metri-pack sealed connector repair
Delphi 280 metri-pack unsealed connector
Delphi 480 metri-pack unsealed connector
Delphi 630 metri-pack unsealed connector
Delphi 800 metri-pack sealed main fuse housing
Delphi metri-pack terminal repair
Delphi micro 64 sealed connector
Delphi GT 150 sealed connector repair
Delphi GT 280 sealed 73-terminal ECM connector
Deutsch DT sealed connector repair
Deutsch DT sealed terminal repair
Deutsch DTM sealed mini terminal repair
Deutsch DTM sealed solid barrel mini terminal repair
JAE MX19 sealed connectors
Molex CMC sealed connectors
Molex MX 150 sealed connector repair
Tyco 070 multilock unsealed connector repair
Tyco GET 64 sealed connector
Tyco MCP sealed connector
Sealed splice connector repair
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
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
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
Crankshaft bearing replacement
Shift shaft and seal
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
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
Throttle position sensor: TP
Intake air temperature sensor: IAT
Engine coolant temperature sensor: ECT
Idle air control: IAC
Manifold absolute pressure sensor: MAP
Fuel rail and fuel injectors
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
Frame and chassis specifications
Frame and chassis torque values
Vehicle identification number (VIN)
Frame/lower frame rails — removal and installation
Front engine mount — replacement
Front engine mount assembly
Exhaust system — removal and installation
Rear engine mounts — removal and installation
Engine replacement — removal
Engine replacement — installation
Jiffy stand — cleaning
Jiffy stand — removal and installation
Rider footrests — removal and installation
Passenger footrests — removal and installation
Throttle cables — removal and disassembly
Throttle cables — assembly and installation
Front fender — removal and installation
Belt guard and debris deflector — removal and installation
Seat latch — removal and installation
Rear fender and supports — removal and installation
Seat — removal and installation
Brake and cluth systems
Clutch master cylinder and reservoir
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
Electrical equipment specifications
Bulb requirements
Relay and fuse block
Crank position sensor: CKP
Maxi-fuse — replacement
Ignition and light switch
Headlamp — general info
Headlamp bulb — removal and installation
Headlamp lens — removal and installation
Tail lamp — removal and installation
Turn signals and running lights
Turn signal security module: TSSM
Instrument cluster — removal and installation
Vehicle speed sensor: VSS
Neutral switch — removal and installation
Oil pressure switch — removal and installation
Stop light switch — removal and installation
Horn — removal and installation
Cooling fans — removal and installation
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
Packard electrical connectors
Packard ECM connector
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:
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Aprilia
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Buel
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...motorcycles
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...motorcycles
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Yamaha
Aprilia
:
RS-series
Shiver
(map)
BMW
:
F-series
R-series
(map)
Buel
:
(map)
Ducati
:
ST series
Monster
(map)
Harley
:
Sportster
V-Rod
(map)
Honda
:
Africa Twin
CB series
VTX series
(map)
Kawasaki
:
ZX-6R
Vulcan
(map)
Suzuki
:
DR-Z
V-Strom
(map)
Triumph
:
Rocket
Street Triple
(map)
Yamaha
:
Fazer
DragStar
R1
(map)
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