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Align the cylinder with the cylinder studs and slide it down Fig- ure until it is over the top of the piston. In- stall the bolts Figure 7 and washers and tighten to in. Clutch spring cover Install the test hadley nesses Figure 44 between the ignition module and the module connectors. The top compression ring is not marked.

This is a common problem with connectors or joints that have loose or poor connections.

Harley Sportster Manual | eBay

Butterfly valve solenoid 2. Refer to the Evaporative Emissions Control System in this chapter to confirm the correct connection of each hose. Wiring Many electrical problems can be traced to damaged wir- spoftster are located at the end of this manual. Install the Nice bearing 3, Figurewasher 4 and handle 5. Clean the crankcase threads and the new stud with sol- 4. Left mounting plate 2.


Harley Sportster Manual

If the voltmeter reading changes or the test light blinks, there is a short-to-ground at that point in mmanual harness. Then install the ar- mature Figure 99 into the solenoid housing.

Remove the drive assembly A, Figure 83idler gear B and the idler gear bearing assembly Figure 85 from the drive housing. Other heat related problems occur when a component starts to fail as it heats up. Record this distance for each valve guide so that the guides can be installed to davkdson same dimen- sion. Ammeter Measures current flow Install the aportster head onto the cylinder dowel pins and studs.

The guides can be either driven or pressed out. Inspect the oil seal Figure 65 for excessive wear, hard- ness, cracks or other damage.

Choke cable bracket 4. Turn the wheel over and insert the remover shaft into the backside of the adapter.

Harley Sportster Manual Refine Results. Remove the drive chain as described in Chapter Thirteen.

Measure the rocker arm bushing inside diameter Fig- ure 20 and the lower rocker arm cover bore diameter where the shaft rides Figure Cleaners, Degreasers and Solvents Many chemicals are available to remove oil, grease and other residue from the motorcycle. Apply clean graphite lubricant to the threads of the pilot shaft, the flat washer and the bearing. Remove the oil seal using a seal puller or 8883 tool. Thimble is between 0.


Install the float bowl onto the carburetor. Improperly operating ignition component. This tool installs the bearing to the specified depth. Measure the rocker arm shaft outside diameter Figure 19 where it rides in the rocker arm and in the lower rocker arm cover. As these connec- tions heat up, the connection or joint expands and separates, Voltmeter causing an open circuit.

If the hub on spoke wheels is damaged, the hub can be replaced by removing the spokes and assembling a new hub. Horn bracket models 9.

Harley-Davidson XLH Sportster Service Manual

The firing of the spark plug can ignite fuel ejected through the spark plug hole. If not, replace the cover. Loosen the fuel valve nut and remove the fuel shutoff valve from the fuel tank. Remove the clutch release mechanism B, Figure 38 from the cover and disconnect the cable C from the ramp and coupling. Make sure the battery cables maual connected properly.

Tap the clutch gear shaft and bearing Figure 25 out of the access cover.