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Need help?Do you have a question about the Harley-Davidson 2005 Sportster and is the answer not in the manual?
Explains the structure of the shop manual and how to use it for easy reference and information retrieval.
Provides essential guidelines and common sense practices for safely servicing the motorcycle.
Details crucial precautions for working with gasoline to prevent accidents and hazards.
Offers guidance on safe and effective cleaning of motorcycle parts using available chemicals and solvents.
Explains the location and importance of recording serial numbers for frame, engine, and carburetor.
Discusses the systems used to specify threaded fasteners and the importance of proper selection.
Explains the necessity of using an accurate torque wrench and provides general torque specifications.
Provides an overview of essential hand tools and test equipment required for motorcycle service.
Details various measuring instruments and their proper use for accurate component measurement.
Describes the types of hammers and safety precautions when using them.
Explains the use of calipers for inside, outside, and depth measurements.
Details the design and use of micrometers for linear measurement.
Describes types of lubricants and fluids required for motorcycle service.
Explains engine oil classification standards (API and SAE) and viscosity.
Provides a critical warning about using only approved brake fluid types.
Discusses the use of sealants and specific instructions for applying RTV sealant.
Explains the purpose and application of threadlocking compounds, with a caution for plastic parts.
Outlines the three basic requirements for engine operation: air/fuel mixture, compression, and spark.
Provides troubleshooting steps for engines that fail to start, including spark tests.
Offers a starting point for diagnosing issues when the engine runs but not at peak performance.
Lists potential causes for engine overheating, such as incorrect carburetor adjustment or low oil level.
Identifies common issues leading to rough running and excessive exhaust smoke.
Lists potential causes for reduced engine power, including timing and fuel mixture issues.
Details potential causes of noise from the valve train components.
Explains the components of the starting system and common troubleshooting steps.
Describes how to perform voltage drop tests to diagnose electrical circuits and components.
Provides procedures for testing the starter and diagnosing common starter-related troubles.
Explains how to measure current draw to diagnose starter or pinion gear assembly issues.
Details procedures for testing the starter solenoid using a battery and jumper wires.
Covers the components of the charging system and troubleshooting precautions.
Describes how to test the charging system output using a load tester.
Explains how to measure the total current load of the electrical system and accessories.
Details how to test battery current draw to identify discharge sources.
Covers service and test procedures for ignition system components and precautions.
Explains how to test the ignition coil's primary and secondary resistance.
Describes the electronic diagnostic system and how diagnostic trouble codes (DTCs) may be generated.
Explains how the diagnostic system indicates normal conditions or operating problems during startup.
Details methods for retrieving diagnostic trouble codes (DTCs).
Provides steps to check speedometer operation before initiating a diagnostic sequence.
Offers guidance on troubleshooting fuel system problems, starting with the fuel tank.
Helps identify whether the engine is running lean or rich based on observed conditions.
Specifies the required fuel octane rating for different models and warnings about fuel additives.
Lists essential checks to perform before riding the motorcycle for safety and proper operation.
Covers procedures for checking tire pressure, inspecting tires, spokes, and wheels.
Details periodic lubrication tasks, including oil tank inspection and maintenance intervals.
Provides steps for checking the engine oil level using the dipstick or oil filler cap.
Explains the importance of regular oil changes and the procedure for changing engine oil and filter.
Details how to periodically inspect the transmission oil level.
Provides the recommended transmission oil change intervals and procedure.
Describes the procedure for a routine fork oil change and specifications.
Explains how to lubricate control cables to ensure proper operation and long service life.
Details the recommended lubrication intervals for the throttle control grip.
Explains how to adjust the primary chain free play to prevent premature wear and noise.
Covers inspection of drive belt deflection at specified intervals.
Describes how to verify rear wheel alignment to prevent uneven drive belt wear.
Explains how to inspect brake pads for damage and wear without removing the calipers.
Provides steps for checking the front brake fluid level using the master cylinder sight glass.
Details how to inspect the rear brake fluid level in the reservoir.
Explains how to visually inspect brake discs for scoring, cracks, or damage.
Provides procedures for adjusting the clutch free play and related components.
Covers the removal and installation of the outer rocker covers, including gaskets and breather valves.
Details the removal and installation of the inner rocker covers, including pushrods and gaskets.
Provides steps for removing, inspecting, and installing rocker arms and measuring end clearance.
Explains the procedure for replacing rocker arm bushings, including special tools required.
Covers the removal, inspection, and installation of the cylinder head.
Details the procedure for removing valves from the cylinder head, including caution for component mixing.
Explains how to clean and inspect valves, valve stems, and guides for wear or damage.
Provides instructions for replacing valve guides, including special tools and measurements.
Describes methods for checking valve seat width and position using Prussian Blue or machinist's dye.
Explains how to recondition valve seats using valve cutters and the importance of proper angles.
Details the process of valve lapping to restore valve seal without machining.
Provides steps for installing valves, seals, springs, and retainers into the cylinder head.
Covers the inspection and replacement of pushrods and their covers.
Describes the removal of cylinders and inspection of cylinder bores.
Provides instructions for installing cylinders, pistons, and rings, including timing marks.
Covers the removal, inspection, and installation of pistons and piston rings.
Details how to clean and inspect pistons for carbon deposits, wear, and damage.
Explains how to measure piston-to-cylinder clearance and purchase correct pistons.
Covers inspection of the piston pin bushing for wear and damage.
Provides instructions and special tools required for replacing piston pin bushings.
Details the correct procedure for installing piston rings, including compression and oil rings.
Covers the installation of pistons onto connecting rods and into cylinders.
Describes the removal and installation of the oil tank and associated hoses and clamps.
Provides procedures for the removal and installation of the oil tank.
Illustrates the oil tank and hoses, including their routing and connection points.
Details the removal and installation of the oil tank, including related components and procedures.
Provides essential notes and precautions before servicing the engine.
Describes the use and removal of an engine stand for service work.
Lists components that can be serviced while the engine is mounted in the frame.
Details the step-by-step procedure for removing the engine from the frame.
Provides instructions for installing the engine into the frame and related components.
Covers the removal, inspection, and installation of tappets and pushrods.
Details how to inspect tappets, including checking for wear, damage, and clearance.
Explains the removal, inspection, and installation of the gearcase cover and timing gears.
Describes how to inspect cam gear and pinion gear bushings for clearance and wear.
Covers the removal, disassembly, inspection, and assembly of the oil pump.
Details the disassembly and reassembly of the oil filter mount.
Covers service procedures for crankcase and crankshaft components.
Explains how to measure crankshaft end play to indicate component wear.
Provides steps for disassembling the crankcase, including removing internal components.
Details how to inspect connecting rods, piston pin bushings, and crankshaft components.
Covers the removal and installation of the left side main bearing assembly.
Describes the procedure for installing the crankshaft and assembling the crankcase.
Explains how to replace cylinder studs, with cautions about oil leaks and hardened materials.
Details the engine mounting system, including front and rear isolator replacement.
Covers the removal, inspection, and installation of the front isolator mounts.
Provides procedures for the replacement and inspection of the rear isolator mounts.
Covers the removal and installation of the primary drive cover, including related components.
Details the removal, inspection, and installation of the clutch release mechanism.
Covers the removal, inspection, and installation of the primary chain adjuster assembly.
Describes service precautions and procedures for clutch, primary chain, and engine sprocket removal.
Provides steps for disassembling the clutch assembly while it is mounted on the motorcycle.
Explains how to clean and inspect clutch plates, springs, and components for wear or damage.
Covers inspection of the primary chain, engine sprocket, and clutch shell for wear or damage.
Details the procedure for separating and reassembling the clutch hub and shell.
Describes the assembly of the clutch components before installation onto the motorcycle.
Covers the removal, inspection, and installation of the clutch cable.
Explains the adjustment of the shift lever height and removal/installation procedures.
Details the removal, inspection, and installation of the shift shaft.
Provides specifications for clutch components like friction plates and steel plates.
Lists torque specifications for clutch and primary drive components.
Covers removal, disassembly, inspection, and assembly of the internal gearshift mechanism.
Details removal, disassembly, inspection, and assembly of the 2006-on internal gearshift mechanism.
Provides service notes and procedures for disassembling and assembling the transmission.
Covers disassembly, inspection, and assembly of the countershaft.
Details disassembly, inspection, and assembly of the mainshaft.
Covers tools, removal, inspection, and installation of the main drive gear.
Provides procedures for removal, inspection, and replacement of the main drive gear.
Covers inspection and replacement of transmission and main drive gear bearings.
Details the removal and installation of the transmission drive sprocket.
Lists specifications for primary drive, final drive, and secondary drive belts.
Provides torque specifications for countershaft and drive sprocket components.
Covers removal and inspection of the air filter backplate, including breather bolts.
Explains carburetor operation, removal, installation, and float adjustment.
Details the removal, installation, and inspection of the intake manifold.
Covers the fuel supply hose, its clamps, and proper procedures for removal and installation.
Provides procedures for removal, inspection, installation, and adjustment of throttle and idle cables.
Explains how to replace the starting enrichment valve (choke) cable.
Covers fuel tank removal, installation, and inspection, including fuel valve and hoses.
Details the removal, installation, and inspection of the exhaust system components.
Explains the evaporative emission control system and charcoal canister inspection.
Provides instructions for inspecting the charcoal canister and its hoses.
Details the replacement procedure for the vapor valve, an integral part of the fuel pressure relief system.
Lists specifications for main jet, slow jet, float level, and idle speed.
Provides torque specifications for various fuel system components.
Lists torque specifications for exhaust system components.
Offers advice on replacing electrical components, emphasizing the return policy and careful testing.
Covers battery removal, installation, inspection, testing, charging, and replacement.
Explains how to test battery current draw to identify discharge sources when the motorcycle is not in use.
Describes the charging system components and testing procedures.
Covers rotor and stator removal, installation, testing, and inspection.
Details the voltage regulator's ground test and removal/installation procedures.
Explains the ignition system components, operation, and troubleshooting.
Provides procedures for testing the ignition coil's primary and secondary resistance.
Covers the removal and installation of the ignition control module, including reprogramming.
Details the removal and installation of the MAP sensor and related components.
Explains the removal and installation of the CKP sensor, including O-ring replacement.
Covers the starter system, including removal, installation, and disassembly.
Provides disassembly and reassembly procedures for the starter solenoid.
Describes the components of the lighting system and bulb replacement.
Details the procedure for replacing the headlight bulb, including safety warnings.
Explains how to adjust the headlight vertically and horizontally.
Covers the replacement of taillight bulbs and the taillight base assembly.
Provides instructions for replacing turn signal bulbs and front turn signal housing.
Details the removal and installation of the front turn signal housing.
Covers the removal and installation of the rear turn signal housing.
Explains how to replace indicator lights adjacent to the speedometer.
Describes how to test switches for continuity and proper operation.
Identifies the switches located in the left and right handlebar housings.
Details the procedure for replacing the front brake light switch.
Covers the removal and installation of the ignition switch, which is not repairable.
Explains the operation, testing, and replacement of the oil pressure switch.
Details the replacement procedure for the neutral indicator switch.
Covers testing and replacement of the rear brake light switch.
Provides testing and replacement procedures for the horn assembly.
Covers troubleshooting and replacement of the starter relay switch.
Details troubleshooting and removal/installation of the speedometer.
Covers troubleshooting and removal/installation of the tachometer.
Explains the VSS mounting, function, and removal/installation procedures.
Covers TSM/TSSM operation, including automatic and manual cancellation, and four-way flashing.
Explains the security system operation, arming, disarming, and modes.
Details the location and function of fuses, including the Maxi-fuse.
Provides information on inspecting and servicing electrical connectors.
Shows how to remove and install socket terminals from Deutsch connector housings.
Details the procedure for removing and installing socket and pin terminals from AMP connectors.
Explains how to remove and install electrical terminals from Packard external latch connectors.
Covers removing and installing electrical terminals from speedometer and tachometer connectors.
Describes using sealed butt connectors for replacing ignition switches.
Indicates that a color wiring diagram is located at the end of the manual.
Provides specifications for alternator, battery, and ignition coil.
Details the expected results for key fob actions and system responses.
Outlines the procedure for entering a personal code number to disarm the security system.
Explains how to select auto-arm modes and expected results.
Describes options for setting the security system for transport mode.
Details options for programming the security system for storage mode.
Lists torque specifications for various electrical system components.
Provides guidance on selecting and using stands for lifting the motorcycle.
Covers the removal, installation, and inspection of the front wheel.
Details the removal, installation, and inspection of the rear wheel.
Explains the inspection of disc and cast wheels for damage and runout.
Lists preliminary checks and notes before checking wheel runout and truing.
Covers preliminary inspection and disassembly of front and rear hubs.
Details the inspection and removal/installation of the driven sprocket.
Indicates that drive sprocket information is covered in Chapter Seven.
Provides cautions for handling drive belts and procedures for removal and installation.
Explains how to inspect wheels for damage, runout, and balance.
Covers inspection of spokes, nipples, and rims for damage or wear.
Details procedures for balancing cast or disc wheels and laced wheels.
Covers tire safety, replacement, and repairs, including warnings about inner tubes.
Provides information on tire repair kits and the applicability of plugs and patches.
Lists specifications for alloy and laced wheels, including lateral and radial runout.
Provides recommended tire inflation pressures in PSI and kPa.
Covers handlebar removal, installation, inspection, and adjustment.
Details the removal, installation, disassembly, inspection, and assembly of the front fork.
Covers removal, inspection, installation, and adjustment of the steering head and stem.
Explains how to remove and install bearing races in the steering head.
Provides a procedure for checking and adjusting steering play.
Lists fork oil capacity and oil level specifications for different models.
Provides torque specifications for front suspension components.
Covers shock absorber removal, installation, inspection, disassembly, and spring preload adjustment.
Details the removal, installation, inspection, and bearing replacement of the swing arm.
Provides procedures for removing and installing bearings in the swing arm.
Lists torque specifications for rear suspension components.
Provides critical warnings about using the correct DOT 5 brake fluid and avoiding intermixing.
Offers essential safety precautions and general advice for servicing the brake system.
Covers inspection of front brake pads for wear and damage.
Details the procedure for replacing front and rear brake pads.
Covers removal, installation, disassembly, inspection, and assembly of the front brake caliper.
Explains identification, removal, installation, disassembly, inspection, and assembly of the master cylinder.
Provides guidance on inspecting rear brake pads for wear and damage.
Covers removal, installation, disassembly, inspection, and assembly of the rear brake caliper.
Details inspection of brake discs for thickness, runout, and damage.
Explains procedures for bleeding the brake system to remove air.
Covers procedures for draining and flushing the brake fluid.
Details the procedure for bleeding the front brake lever line.
Explains the procedure for bleeding the rear brake pedal line.
Lists torque specifications for various brake system components.
Covers the removal and installation of the seat.
Details the removal and installation of the front fender.
Covers the removal and installation of the rear fender.
Provides removal and installation instructions for the left side cover.
Details the removal and installation of the right side cover.
Covers the removal and installation of the footrests.
Details the removal and installation of footrest brackets.
Covers the removal, installation, and inspection of the sidestand assembly.
Explains the replacement procedure for the fork lock.
Lists torque specifications for body components.
General| Engine Type | Air-cooled, Evolution |
|---|---|
| Compression Ratio | 8.9:1 |
| Transmission | 5-speed |
| Final Drive | Belt |
| Front Brakes | Single disc |
| Rear Brakes | Single disc |
| Front Tire | 100/90-19 |
| Rear Tire | 130/90-16 |
| Displacement | 883 cc |
| Bore x Stroke | 76.2 mm x 96.8 mm |
| Front Suspension | 39 mm fork |
| Rear Suspension | Coil-over shocks |
| Wheelbase | 60.0 in. (1524 mm) |
| Dry Weight | 540 lbs. (245 kg) |
| Fuel System | Carburetor |
| Fuel Capacity | 3.3 gallons |
