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General specifications for the Sportster motorcycle, including dimensions, capacities, engine, and transmission details.
Specifications for tire sizes and recommended pressures for various Sportster models and years.
Recommended operations for servicing a new motorcycle at 500 and 1000 mile intervals.
Chart detailing recommended engine and transmission service intervals for oil changes.
Guidelines on selecting and using appropriate Harley-Davidson oils and greases for various components.
Checklist for diagnosing issues when the engine fails to start or cranks slowly.
Checklist for diagnosing issues when the engine runs poorly, misses, or backfires.
Causes and checks for engine detonation or 'pinging' during operation.
Common causes and checks for a flooding carburetor.
Diagnosing issues related to difficult gear shifting in the transmission.
Common causes and checks for a slipping clutch.
Diagnosing and rectifying issues when brakes do not hold normally.
Procedure for checking and adjusting the front chain tension.
Information on the automatic lubrication system for the front chain.
Guidance on when and how to replace a worn front chain.
Procedure for checking and adjusting the rear chain tension.
Instructions for inspecting and adjusting the rear chain oiler.
Procedure for servicing the rear chain, including cleaning and lubrication.
Importance of tire maintenance, interchangeability, and pressure for optimal performance.
Checkpoints and remedies for common wheel service issues.
Step-by-step instructions for removing and installing the front wheel assembly.
Procedure for disassembling front wheel hubs for 1963 and earlier, and 1964 and later models.
Procedure for disassembling rear wheel hubs.
Guidelines for cleaning, inspecting, and repairing wheel hubs and bearings.
Instructions for assembling front wheel hubs for different model years.
Instructions for assembling rear wheel hubs.
Procedure for replacing a worn rear wheel sprocket.
Detailed instructions for lacing spokes in front wheels for different model years.
Detailed instructions for lacing spokes in rear wheels.
Methods for truing wheels sideways and concentrically using gauges and tools.
Using a straight edge to check and correct wheel alignment.
Procedure for removing tires and tubes from wheel rims.
Instructions for mounting tires and tubes on wheel rims, including barb preparation.
Procedure for checking and correcting lateral runout in tires.
Procedure for checking and correcting radial runout in tires.
Ensuring proper alignment of front and rear wheels on the motorcycle.
Information on servicing throttle and spark advance controls, including disassembly and assembly.
Guidelines for checking frame alignment and procedures for straightening or replacement.
Diagram showing frame dimensions for alignment checks.
Detailed instructions for servicing the front fork, including oil changes and inspection.
Step-by-step procedure for draining and refilling the front fork oil.
Steps for inspecting the front fork for proper operation and oil leakage.
Exploded view diagram of the front fork and steering head components.
Procedure for disassembling the front fork assembly.
Procedure for disassembling the front fork shock absorber units.
Instructions for replacing fork boot parts.
Guidelines and procedures for straightening bent fork tubes.
Procedures for straightening the fork stem and bracket assembly.
Procedure for removing fork slider bushings.
Procedure for installing new fork slider bushings.
Procedure for reaming fork slider bushings to the correct size.
Instructions for assembling the front fork shock absorber.
Procedure for assembling the front fork assembly.
Instructions for installing the stem, bracket assembly, and fork sides.
Information on servicing the rear shock absorber and rear fork.
Procedure for disassembling the rear shock absorber.
Procedure for disassembling the rear fork assembly.
Cleaning and inspecting all parts of the rear fork assembly.
Instructions for assembling the rear fork assembly.
Procedure for adjusting the rear shock absorber spring tension.
General information on servicing front and rear brakes, including checks and adjustments.
Procedure for adjusting the front wheel brake for proper operation.
Procedure for adjusting the rear wheel brake.
Instructions for replacing the front wheel brake cable if it is worn or damaged.
Procedure for disassembling the front wheel brake assembly.
Procedure for disassembling the rear wheel brake assembly.
Guidelines for inspecting brake shoes, linings, drums, and related components.
Instructions for assembling the front wheel brake.
Instructions for assembling the rear wheel brake.
Procedure for disassembling the rear brake cross shaft.
Inspection and repair of the rear brake cross shaft and its related components.
Procedure for assembling the rear brake cross shaft.
Instructions for disassembling, inspecting, and assembling the seat post and seat.
Procedure for disassembling the seat post and seat components.
Steps for cleaning and inspecting seat post and seat parts before reassembly.
Instructions for reassembling the seat post and seat.
Guide to caring for and repairing fiberglass body parts.
Description of gel coat finish and maintenance rules.
Description of molded-in-color finish and maintenance requirements.
Information on repairing painted fiberglass finishes.
General guidance on surface finishing techniques.
Procedure for gel coat touch-up and surface repairs.
Procedure for repairing molded-in-color fiberglass surfaces.
Instructions for patching holes, punctures, and breaks in fiberglass.
List and description of tools for wheel maintenance and repair.
List and description of tools for front fork maintenance and repair.
General overview of the Sportster engine, including specifications and description.
Detailed technical specifications for engine components.
Information on the engine's force-feed oiling system and maintenance checks.
Specific lubrication recommendations for cold weather operation.
Explanation of the oil pressure signal light function and troubleshooting.
Description of the electrically operated oil pressure signal light switch.
Diagram and explanation of the engine's oiling system.
Explanation of the engine's oiling and breather system components and functions.
Information on engine oil pressure variations and how to check it.
Procedure for cleaning and replacing the oil filter element.
Instructions for cleaning and inspecting the oil tank cap and filler opening.
General approach to engine repair, outlining common procedures.
Procedure for preparing the motorcycle for engine removal and repair.
Instructions for removing and disassembling the cylinder head assembly.
Steps for removing the cylinder head assembly from the engine.
Procedure for disassembling the cylinder head.
Cleaning and inspecting all parts of the cylinder head.
Procedure for repairing worn rocker arms and bushings.
Instructions for refacing valves and valve seats.
Procedure for replacing valve seat inserts.
Procedure for replacing valve guides.
Instructions for assembling the cylinder head.
Instructions for removing, cleaning, inspecting, and disassembling cylinders and pistons.
Procedure for removing cylinders and pistons.
Cleaning and inspecting cylinder and piston components.
Guidelines for refinishing cylinders to oversize specifications.
Instructions for fitting piston rings, including gap and clearance checks.
Information on checking and replacing connecting rod bushings.
Procedures for checking and straightening connecting rods.
Instructions for assembling the cylinder and piston.
Information on servicing the gearcase, including oil pump and breather systems.
General information on the oil pump system and troubleshooting.
Procedure for disassembling the oil pump check valve.
Cleaning and inspecting the oil pump check valve components.
Instructions for assembling the oil pump check valve.
Procedure for disassembling the oil pump.
Information on servicing tappets and tappet guides.
Procedure for disassembling tappets and tappet guides.
Cleaning and inspecting tappet and guide components.
Procedures for disassembling and reassembling the gearcase and timing gears.
Procedure for disassembling the gearcase cover and related components.
Procedure for establishing correct end play for cam gears.
Procedure for timing the breather valve.
Instructions for installing timing gears and the gearcase cover.
Instructions for replacing gearcase bushings.
Procedures for repairing the crankcase, including flywheel and bearing work.
Procedure for disassembling the flywheel assembly.
Methods for determining and fitting correct oversize rollers for rod bearings.
Procedure for fitting pinion shaft bearings.
Instructions for assembling the crankcase halves.
Overview of the Sportster transmission, including clutch, starter, and gear box.
Diagnosis chart for clutch issues and procedures for adjusting release mechanism and spring tension.
Procedure for adjusting the clutch release mechanism.
Procedure for adjusting the clutch spring tension.
Instructions for replacing the clutch control cable and coil assembly.
Procedure for disassembling the clutch release mechanism.
Inspection of clutch release parts for wear and damage.
Procedure for disassembling the clutch assembly.
Instructions for assembling the clutch release mechanism.
Instructions for assembling the clutch assembly.
Procedure for removing the compensating sprocket.
Inspection of the compensating sprocket for wear and damage.
Instructions for installing the compensating sprocket.
General information and troubleshooting for the kick starter mechanism.
Procedure for disassembling the kick starter assembly.
Inspection and repair of kick starter components.
Procedure for installing the starter crankshaft.
Information on the electric starter system, including drive assembly and solenoid.
Explanation of the starter drive mechanism and its operation.
Procedure for disassembling the starter motor.
Instructions for reassembling the starter motor.
General information and procedures for servicing the transmission gear box.
Procedure for disassembling the transmission after separating crankcases.
Procedure for removing the transmission access cover.
Procedure for disassembling the shifter mechanism.
Procedure for disassembling mainshaft and countershaft components.
Inspection and replacement of transmission gear and shaft parts.
Inspection of the mainshaft sprocket for wear and damage.
Inspection of shifter cam and pawl carrier for wear and damage.
Procedure for establishing correct end play for mainshaft and countershaft.
Information on interchangeable crankcase and access covers for Sportster models.
Instructions for assembling the transmission components.
Instructions for refilling the transmission with engine oil.
Wiring diagram key and diagrams for 1959-64 Sportster H models.
Key to color codes and conduit identification for wiring diagrams.
Wiring diagram for 1959-64 Sportster H models.
Key to wiring colors and conduit identification for 1959-62 Sportster CH models.
Wiring diagram for 1959-62 Sportster CH models.
Key to wiring colors and conduit identification for 1963-64 Sportster CH models.
Wiring diagram for 1963-64 Sportster CH models.
Key to wiring colors and conduit identification for 1965-66 Sportster H models.
Wiring diagram for 1965-66 Sportster H models.
Key to wiring colors and conduit identification for 1965 Sportster CH models.
Wiring diagram for 1965 Sportster CH models.
Key to wiring colors and conduit identification for 1967 Sportster H models.
Wiring diagram for 1967 Sportster H models.
Key to wiring colors and conduit identification for 1967-69 Sportster CH models.
Wiring diagram for 1967-69 Sportster CH models.
Key to wiring colors and conduit identification for late 1969 Sportster H models.
Wiring diagram for late 1969 Sportster CH models.
Information on servicing various switches, including ignition-light, button, and dimmer switches.
Description, disassembly, cleaning, inspection, and assembly of the ignition-light switch.
Procedure for disassembling the ignition light switch.
Cleaning, inspecting, and repairing ignition light switch components.
Information on button switches used for momentary circuit closing.
Disassembly, inspection, and repair of the combined headlamp dimmer and horn switch.
Information on the neutral switch located in the transmission top cover.
Description and function of solenoid switches used in electrical circuits.
Information on the starter relay switch for late 1967 Electra-Glide models.
Description of the mechanical, normally-closed plunger type front brake switch.
Description of the hydraulic, normally-open rear brake switch.
Tests to determine if a solenoid switch is defective.
Information on headlamps, tail lamps, stop lamps, and accessories.
Description and replacement of sealed-beam headlamp units.
Instructions for correctly adjusting the headlamp beam for optimal efficiency and law compliance.
Chart listing bulb types, candle power, and Harley-Davidson part numbers for various models.
Information on generator testing, charging rate, and removal.
Description of the standard generator and its voltage regulator function.
Steps for checking generator operation and diagnosing charging issues.
Procedure for testing the generator's output amperage.
Procedures for testing generator field coils.
Methods for testing the armature for shorts, grounds, and open circuits.
Procedures for repairing the generator commutator.
Instructions for polarizing the generator to ensure correct charging polarity.
Information on checking and setting the generator charging rate.
Procedure for disassembling the generator.
Description of the fan-cooled generator and its testing procedures.
Description of ignition system circuits and types of circuit breakers.
Description and operation of single contact point circuit breakers with manual advance.
Description and operation of single contact point circuit breakers with automatic advance.
Description and operation of double contact point circuit breakers.
Diagnostic steps for circuit breaker issues.
Procedure for checking and adjusting circuit breaker point gap.
Procedure for checking and adjusting ignition timing for manual and automatic advance.
Ignition timing procedures for manual advance circuit breakers.
Ignition timing procedures for automatic advance circuit breakers.
Description and troubleshooting of the ignition coil.
Troubleshooting steps for ignition coil issues.
Instructions for replacing spark plug cables.
Information on spark plug selection, cleaning, inspection, and installation.
General information on Harley-Davidson spark plugs and heat ranges.
Procedure for safely removing spark plugs.
Using spark plug deposits to diagnose engine condition.
Procedure for correctly setting the spark plug gap.
Methods for testing spark plug sparking ability.
Procedure for installing spark plugs correctly.
Information on testing and servicing voltage and current regulators.
Overview of regulator types and their function in controlling generator output.
Procedures for testing Bosch regulators using a VAT 26 tester.
Tests to determine if the generator or regulator is at fault.
Procedure for testing the cutout relay unit's closing voltage.
Procedures for testing voltage control unit settings under load and no load.
Service and adjustment information for Delco Remy and Bosch regulators.
General information, care, charging, and servicing of motorcycle batteries.
Battery function, importance of balance, and general maintenance tips.
Prompt and correct battery care for extending lifespan and performance.
Guidelines for charging batteries at the correct continuous rate.
Procedure for reclaiming batteries that have stood in a discharged condition.
Instructions for changing battery electrolyte if necessary.
Troubleshooting and servicing procedures for the trumpet horn.
Troubleshooting and servicing for 1964 and earlier Duo-Glide and Sportster horns.
Procedure for disassembling and reassembling the horn.
Information on starter motor function, troubleshooting, and removal.
Description of the 12-volt starter motor, its components, and operation.
Steps for troubleshooting starter motor issues.
Procedures for removing the starter motor and drive assembly.
Checking the starter motor frame and field assembly for open or grounded circuits.
Instructions for replacing field coils and brushes.
Procedures for repairing the starter motor armature.
Instructions for reassembling the starter motor.
Servicing procedures for the speedometer and tachometer.
Instructions for lubricating the speedometer cable core and servicing the speedometer head.
Instructions for lubricating the tachometer cable core and servicing the tachometer head.
General| Fuel System | Electronic Sequential Port Fuel Injection (ESPFI) |
|---|---|
| Final Drive | Belt |
| Front Brakes | Single disc |
| Rear Brakes | Single disc |
| Front Tire | Varies by model |
| Rear Tire | Varies by model |
| Dry Weight | Varies by model |
| Power | Varies by model |
| Torque | Varies by model |
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