2007 Harley Sportster XL 883 & 1200 Repair Manual

2007 SPORTSTER MODELS SERVICE MANUAL Part Number 99484-07 Section 1: Maintenance Section 2: Chassis Section 3: Engine Section 4: Fuel System Section 5: Electric Starter Section 6: Drive/Transmission Section 7: Electrical Appendix ELECTRICAL DIAGNOSTICS Part Number 99495-07 Section 1: Starting & Charging Section 2: Instruments Section 3: TSM/HFSM Section 4: Engine Management Section 5: Wiring Appendix

SUBJECT PAGE NO. 1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.2 Fuel and Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 1.3 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 1.4 Critical Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 1.5 Engine Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 1.6 Left Side Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 1.7 Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 1.8 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20 1.9 Bleeding Hydraulic Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22 1.10 Brake Pads and Discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26 1.11 Tires and Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35 1.12 Primary Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37 1.13 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39 1.14 Transmission Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41 1.15 Rear Belt Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-43 1.16 Rear Belt and Sprockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-47 1.17 Shock Absorber Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-49 1.18 Steering Head Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-50 1.19 Rear Fork Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-51 1.20 Front Fork Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-52 1.21 Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-54 1.22 Cable and Chassis Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-56 1.23 Air Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-57 1.24 Throttle Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-59 1.25 Idle Speed and Ignition Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-61 1.26 Fuel Supply Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-62 1.27 Engine Mounts and Stabilizer Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-63 1.28 Headlamp Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-64 1.29 Fluid/Lubricant Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-66 1.30 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-67 1.31 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-69 MAINTENANCE 1 T ab le Of Contents

2007 Sportster: Maintenance 1-1 HOME GENERAL 1.1 SERVICING A NEW MOTORCYCLE 1WARNING Perform the service and maintenance operations as indi- cated in the regular service interval table. Lack of regular maintenance at the recommended intervals can affect the safe operation of your motorcycle, which could result in death or serious injury. (00010a) Service operations to be performed before customer delivery are specied in the applicable model year PREDELIVERY AND SETUP MANUAL. The performance of new motorcycle initial service is required to keep warranty in force and to ensure proper emissions sys- tems operation. After a new motorcycle has been driven its rst 1000 miles (1600 km), and at every 5000 mile (8000 km) interval thereaf- ter, have a Harley-Davidson dealer perform the service operations listed under 1.3 MAINTENANCE SCHEDULE. SHOP PRACTICES Repair Notes NOTES ● General maintenance practices are given in this section. ● Repair = Disassembly/Assembly. ● Replace = Removal/Installation. All special tools and torque values are noted at the point of use. All required parts or materials can be found in the appropriate PARTS CATALOG. Safety Safety is always the most important consideration when performing any job. Be sure you have a complete understanding of the task to be performed. Use common sense. Use the proper tools. Protect yourself and bystanders with approved eye protection. Dont just do the job  do the job safely. Removing Parts Always consider the weight of a part when lifting. Use a hoist whenever necessary. Do not lift heavy parts by hand. A hoist and adjustable lifting beam or sling are needed to remove some parts. The lengths of chains or cables from the hoist to the part should be equal and parallel and should be posi- tioned directly over the center of the part. Be sure that no obstructions will interfere with the lifting operation. Never leave a part suspended in mid-air. 1WARNING Always check the capacity rating and condition of hoists, slings, chains or cables before use. Failure to do so could lead to an accident which could result in death or serious injury. Always use blocking or proper stands to support the part that has been hoisted. If a part cannot be removed, verify that all bolts and attaching hardware have been removed. Check to see if any parts are in the way of the part being removed. When removing hoses, wiring or tubes, always tag each part to ensure proper installation. Cleaning If you intend to reuse parts, follow good shop practice and thoroughly clean the parts before assembly. Keep all dirt out of parts; the unit will perform better and last longer. Seals, l- ters and covers are used in this vehicle to keep out environ- mental dirt and dust. These items must be kept in good condition to ensure satisfactory operation. Clean and inspect all parts as they are removed. Be sure all holes and passages are clean and open. After cleaning, cover all parts with clean lint-free cloth, paper or other material. Be sure the part is clean when it is installed. Always clean around lines or covers before they are removed. Plug, tape or cap holes and openings to keep out dirt, dust and debris. Always verify cleanliness of blind holes before assembly. Tightening a screw with dirt, water or oil in the hole can cause castings to crack or break.

1-2 2007 Sportster: Maintenance HOME Disassembly and Assembly Always assemble or disassemble one part at a time. Do not work on two assemblies simultaneously. Be sure to make all necessary adjustments. Recheck your work when nished. Be sure that everything is done. Operate the vehicle to perform any nal check or adjustments. If all is correct, the vehicle is ready to go back to the customer. Magnetic Parts Trays Magnetic parts trays are becoming common in the service facility because they are convenient and can keep parts from becoming lost during a repair procedure. However, hardened steel parts can become magnetized when held in magnetic parts trays. Metal fragments that would ordinarily be washed away in the oil and trapped in the oil lter or magnetic drain plug during vehicle operation could be captured by magnetized parts in the engine, potentially causing accelerated engine wear and damage. Parts that will be returned to service inside the vehicles pow- ertrain such as gears, thrust washers and especially bearings should never be kept in magnetic parts trays. REPAIR AND REPLACEMENT PROCEDURES Hardware and Threaded Parts Install helical thread inserts when inside threads in castings are stripped, damaged or not capable of withstanding speci- ed torque. Replace bolts, nuts, studs, washers, spacers and small common hardware if missing or in any way damaged. Clean up or repair minor thread damage with a suitable tap or die. Replace all damaged or missing lubrication ttings. Use Teon pipe sealant on pipe tting threads. Wiring, Hoses and Lines Replace hoses, clamps, electrical wiring, electrical switches or fuel lines if they do not meet specications. Instruments and Gauges Replace broken or defective instruments and gauges. Replace dials and glass that are so scratched or discolored that reading is difcult. Bearings Anti-friction bearings must be handled in a special way. To keep out dirt and abrasives, cover the bearings as soon as they are removed from the package. Wash bearings in a non-ammable cleaning solution. Knock out packed lubricant inside by tapping the bearing against a wooden block. Wash bearings again. Cover bearings with clean material after setting them down to dry. Never use compressed air to dry bearings. Coat bearings with clean oil. Wrap bearings in clean paper. When bearings are installed against shoulders, be sure that the chamfered side of the bearing always faces the shoulder. Lubricate bearings and all metal contact surfaces before pressing into place. Only apply pressure on the part of the bearing that makes direct contact with the mating part. Always use the proper tools and xtures for removing and installing bearings. Bearings do not usually need to be removed. Only remove bearings if necessary. Bushings Do not remove a bushing unless damaged, excessively worn or loose in its bore. Press out bushings that must be replaced. When pressing or driving bushings, be sure to apply pressure in line with the bushing bore. Use a bearing/bushing driver or a bar with a smooth, at end. Never use a hammer to drive bushings. Inspect the bushing and the mated part for oil holes. Be sure all oil holes are properly aligned. Gaskets Always discard gaskets after removal. Replace with new gaskets. Never use the same gasket twice. Be sure that gasket holes match up with holes in the mating part. Lip Type Seals Lip seals are used to seal oil or grease and are usually installed with the sealing lip facing the contained lubricant. Seal orientation, however, may vary under different applica- tions. Seals should not be removed unless necessary. Only remove seals if required to gain access to other parts or if seal damage or wear dictates replacement. Leaking oil or grease usually means that a seal is damaged. Replace leaking seals to prevent overheated bearings. Always discard seals after removal. Do not use the same seal twice.

2007 Sportster: Maintenance 1-3 HOME O-Rings (Preformed Packings) Always discard o-rings after removal. Replace with new o- rings. To prevent leaks, lubricate the o-rings before installation. Apply the same type of lubricant as that being sealed. Be sure that all gasket, o-ring and seal mating surfaces are thoroughly clean before installation. Gears Always check gears for damaged or worn teeth. Lubricate mating surfaces before pressing gears on shafts. Shafts If a shaft does not come out easily, check that all nuts, bolts or retaining rings have been removed. Check to see if other parts are in the way before using force. Shafts tted to tapered splines should be very tight. If shafts are not tight, disassemble and inspect tapered splines. Dis- card parts that are worn. Be sure tapered splines are clean, dry and free of burrs before putting them in place. Press mating parts together tightly. Clean all rust from the machined surfaces of new parts. Part Replacement Always replace worn or damaged parts with new parts. Exhaust System Leakage In the event of an exhaust system leak at a mufer or header pipe connection location, disassemble and clean all mating surfaces. Replace any damaged components. If leak still exists, disassemble and repair the leak by applying a bead of Harley-Davidson High-Performance Sealant (Part No. 99650- 02). Reassemble components, wipe off any excess sealant and allow adequate curing time following sealant product instructions before operating vehicle. CLEANING Part Protection Before cleaning, protect rubber parts (such as hoses, boots and electrical insulation) from cleaning solutions. Use a grease-proof barrier material. Remove the rubber part if it cannot be properly protected. Cleaning Process Any cleaning method may be used as long as it does not result in parts damage. Thorough cleaning is necessary for proper parts inspection. Strip rusted paint areas to bare metal before repainting. Rust or Corrosion Removal Remove rust and corrosion with a wire brush, abrasive cloth, sand blasting, vapor blasting or rust remover. Use bufng cro- cus cloth on highly polished parts that are rusted. Bearings Clean open bearings by soaking them in a petroleum cleaning solution. Never use a solution that contains chlorine. Let bearings stand and dry. Do not dry with compressed air. Do not spin bearings while they are drying. TOOL SAFETY Air Tools ● Always use approved eye protection equipment when performing any task using air-operated tools. ● On all power tools, use only recommended accessories with proper capacity ratings. ● Do not exceed air pressure ratings of any power tools. ● Bits should be placed against work surface before air hammers are operated. ● Disconnect the air supply line to an air hammer before attaching a bit. ● Never point an air tool at yourself or another person. ● Protect bystanders with approved eye protection. Wrenches ● Never use an extension on a wrench handle. ● If possible, always pull on a wrench handle and adjust your stance to prevent a fall if something lets go. ● Never cock a wrench. ● Never use a hammer on any wrench other than a STRIK- ING FACE wrench. ● Discard any wrench with broken or battered points. ● Never use a pipe wrench to bend, raise or lift a pipe.

1-4 2007 Sportster: Maintenance HOME Pliers/Cutters/Prybars ● Plastic- or vinyl-covered pliers handles are not intended to act as insulation; dont use on live electrical circuits. ● Dont use pliers or cutters for cutting hardened wire unless they were designed for that purpose. ● Always cut at right angles. ● Dont use any prybar as a chisel, punch or hammer. Hammers ● Never strike a hammer against a hardened object, such as another hammer. ● Always grasp a hammer handle rmly, close to the end. ● Strike the object with the full face of the hammer. ● Never work with a hammer which has a loose head. ● Discard hammer if face is chipped or mushroomed. ● Wear approved eye protection when using striking tools. ● Protect bystanders with approved eye protection. Punches/Chisels ● Never use a punch or chisel with a chipped or mushroomed end; dress mushroomed chisels and punches with a le. ● Hold a chisel or a punch with a tool holder if possible. ● When using a chisel on a small piece, clamp the piece rmly in a vise and chip toward the stationary jaw. ● Wear approved eye protection when using these tools. ● Protect bystanders with approved eye protection. Screwdrivers ● Dont use a screwdriver for prying, punching, chiseling, scoring or scraping. ● Use the right type of screwdriver for the job; match the tip to the fastener. ● Dont interchange POZIDRIV ﬁ , PHILLIPS ﬁ or REED AND PRINCE screwdrivers. ● Screwdriver handles are not intended to act as insulation; dont use on live electrical circuits. ● Dont use a screwdriver with rounded edges because it will slip  redress with a le. Ratchets and Handles ● Periodically clean and lubricate ratchet mechanisms with a light grade oil. Do not replace parts individually; ratchets should be rebuilt with the entire contents of service kit. ● Never hammer or put a pipe extension on a ratchet or handle for added leverage. ● Always support the ratchet head when using socket extensions, but do not put your hand on the head or you may interfere with the action of its reversing mechanism. ● When breaking loose a fastener, apply a small amount of pressure as a test to be sure the ratchets gear wheel is engaged with the pawl. Sockets ● Never use hand sockets on power or impact wrenches. ● Select the right size socket for the job. ● Never cock any wrench or socket. ● Select only impact sockets for use with air or electric impact wrenches. ● Replace sockets showing cracks or wear. ● Keep sockets clean. ● Always use approved eye protection when using power or impact sockets. Storage Units ● Dont open more than one loaded drawer at a time. Close each drawer before opening up another. ● Close lids and lock drawers and doors before moving storage units. ● Dont pull on a tool cabinet; push it in front of you. ● Set the brakes on the locking casters after the cabinet has been rolled to your work.

2007 Sportster: Maintenance 1-5 HOME FUEL AND OIL 1.2 FUEL Harley-Davidson motorcycles were designed to obtain the best performance and efciency using unleaded gasoline (91 pump octane or higher for all Sportster models). Pump octane is the octane number usually shown on the gas pump. Some fuel suppliers sell gasoline/alcohol blends as a fuel. The type and amount of alcohol added to the fuel is important. 1WARNING Avoid spills. Slowly remove ller cap. Do not ll above bot- tom of ller neck insert, leaving air space for fuel expan- sion. Secure ller cap after refueling. Gasoline is extremely ammable and highly explosive, which could result in death or serious injury. (00028a) GASOLINE BLENDS CAUTION Do not use gasoline that contains methanol. Doing so can result in fuel system component failure, engine damage and/or equipment malfunction. (00148a) Harley-Davidson motorcycles are designed to give the best performance using unleaded gasoline. Some fuel suppliers sell gasoline/alcohol blends as a fuel. The type and amount of alcohol added to the fuel is important. ● DO NOT USE GASOLINES CONTAINING METHANOL. Using gasoline/methanol blends will result in starting and driveability deterioration and damage to critical fuel system components. ● ETHANOL is a mixture of 10% ethanol (Grain alcohol) and 90% unleaded gasoline. It is identied as gasohol, ethanol enhanced, or contains ethanol. Gasoline/ethanol blends can be used in your motorcycle if the ethanol content does not exceed 10%. ● REFORMULATED OR OXYGENATED GASOLINES (RFG): Reformulated gasoline is a term used to describe gasoline blends that are specically designed to burn cleaner than other types of gasoline. Your motorcycle will run normally using this type of gasoline. Because of their generally higher volatility, these blends may adversely affect the starting, driveability and fuel efciency of your motorcycle. If you experience these problems, Harley- Davidson recommends you operate your motorcycle on straight, unleaded gasoline. ENGINE OIL Use the proper grade of oil for the lowest temperature expected before the next oil change. If it is necessary to add oil and Harley-Davidson oil is not available, use an oil certied for diesel engines. Acceptable diesel engine oil designations include CF, CF-4, CG-4 and CH-4. The preferred viscosities for the diesel engine oils, in descending order, are 20W-50, 15W-40 and 10W-40. At the rst opportunity, see a Harley-Davidson dealer to change back to 100 percent Harley-Davidson oil. See 1.5 ENGINE OIL AND FILTER for all service information. WINTER LUBRICATION Normal fuel combustion in a gasoline engine produces water vapor and carbon dioxide along with other gases and particu- lates. During starting and warm-up in cold weather, especially in freezing temperatures, the vapor condenses to water before the crankcase is hot enough to exhaust it through the breather system. If the engine is driven long enough to thoroughly warm the crankcase, most of this liquid water is again vaporized and exhausted through the crankcase breather system. A moderately driven vehicle making short runs may not be able to vacate water vapors allowing liquid water to accumu- lates in the oil tank. This is especially true if the vehicle is operated in cold weather. In freezing weather, an accumula- tion of water in the engine oil may become slush or ice, which can block oil lines and lead to severe engine damage. Water remaining in the engine oil for long periods of time can form an acidic sludge that is corrosive to metal engine parts and causes accelerated wear of moving components. Always change the engine oil more often in winter. The colder the weather, the shorter the recommended oil change interval. If the engine is used for short runs, change the oil even more frequently.

1-6 2007 Sportster: Maintenance HOME MAINTENANCE SCHEDULE 1.3 GENERAL The table below lists the periodic maintenance requirements for Sportster model motorcycles. If you are familiar with the procedures, just refer to the table for the recommended service interval. If necessary, see the quick reference table (Table 1-2.) on page 1-7 for the required specications. If more detailed information is needed, turn to the sections which follow for step-by-step instructions. Also, throughout this manual, you will be instructed to use various lubricants, greases and sealants. Refer to Table 1-3. for the correct part numbers of these items. Table 1-1. Regular Service Intervals For Sportster Models ITEM SERVICED PROCEDURE 1000 MI 1600 KM 5000 MI 8000 KM 10,000 MI 16,000 KM 15,000 MI 24,000 KM 20,000 MI 32,000 KM 25,000 MI 40,000 KM NOTES Engine oil and lter Replace X X X X X X Oil lines and brake system Inspect for leaks X X X X X X 1 Air cleaner Inspect, service as required X X X X X X Tires Check pressure, inspect tread X X X X X X Wheel spokes Check tightness X X X X X X 1, 4 Transmission lubricant Replace X X X Clutch Check adjustment X X X X X X 1 Primary chain Check adjustment X X X X X X Rear belt and sprockets Inspect, adjust belt X X X X X X 1 Throttle, brake and clutch controls Check, adjust and lubricate X X X X X X 1 Jiffy stand Inspect and lubricate X X X 1 Fuel lines and ttings Inspect for leaks X X X X X X 1 Fuel tank lter element Replace X 1 Brake uid Check levels and condition X X X X X X 5 Brake pads and discs Inspect for wear X X X X X X Front brake lever pin Inspect X X X X 1, 2 Lubricate X 1, 2 Brake caliper pins Inspect X X X X 1, 2 Lubricate X 1, 2 Brake caliper boots and bushings Inspect X X X X 1, 2 Replace X 1, 2 Rear master cylinder outer boot Inspect X X X X X 1, 2 Brake components Replace brake rubber components in master cylinders and calipers X 1, 2 Lubricate master cylinder pistons X 1, 2 Spark plugs Inspect X X X X X Replace X Electrical equipment and switches Check operation X X X X X X Engine idle speed Check adjustment X X X X X X 1 Front fork oil Replace X 1 Steering head bearings Adjust X X 1 Lubricate X 1 Rear fork bearings Replace every 30,000 mi (48,000 km) 1

2007 Sportster: Maintenance 1-7 HOME Shock absorbers Inspect X X X X X X 1 Critical fasteners Check tightness X X X 1 Engine mounts and stabilizer links Inspect X X 1 Battery Check battery and clean connections 3 Road test Verify component and system functions X X X X X X NOTES 1. Should be performed by an authorized Harley-Davidson dealer, unless you have the proper tools, service data and are mechanically qualied. 2. Replace every four (4) years. 3. Perform annually. 4. Not all vehicles are equipped with spoke wheels. Consult appropriate topic in service manual. 5. Replace every two (2) years. Table 1-1. Regular Service Intervals For Sportster Models ITEM SERVICED PROCEDURE 1000 MI 1600 KM 5000 MI 8000 KM 10,000 MI 16,000 KM 15,000 MI 24,000 KM 20,000 MI 32,000 KM 25,000 MI 40,000 KM NOTES Table 1-2. Quick Reference Maintenance Chart ITEM SERVICED SPECIFICATION DATA Engine oil and lter Oil capacity 3.6 qt. (3.4 L) Filter Hand tighten 1/2-3/4 turn after gasket contact Chrome lter (XL 1200C) Part no. 63796-77A Black lter (all except XL 1200C) Part no. 63805-80A Primary chain tension Deection with hot engine 1/4-3/8 in. (6.3-9.5 mm) Deection with cold engine 3/8-1/2 in. (9.5-12.7 mm) Chain tensioner nut torque 20-25 ft-lbs (27.1-33.9 Nm) Primary chain inspection cover screw torque 40-60 in-lbs (4.5-6.8 Nm) Primary chain/ transmission lubricant Lubricant capacity 32 oz. (946 mL) Primary chaincase drain plug torque 14-30 ft-lbs (19.0-40.7 Nm) Lubricant Genuine Harley-Davidson Formula+ Transmission and Primary Chaincase Lubricant Clutch adjustment Free play at adjuster screw 1/4 turn Free play at hand lever 1/16-1/8 (1.6-3.2 mm) Clutch inspection cover screw torque 84-108 in-lbs (9.5-12.2 Nm) Tire condition and pressure Pressure for solo rider Front: 30 psi (207 kPa), Rear: 36 psi (248 kPa) Pressure for rider and passenger Front: 30 psi (207 kPa), Rear: 40 psi (276 kPa) Wear Replace tire if 1/32 in. (0.8 mm) or less of tread pattern remains Wheel spokes Spoke nipple torque 40-50 in-lbs (4.5-5.7 Nm) Steering head bearings Lubricant for neck tting SPECIAL PURPOSE GREASE

2007 Harley Sportster XL 883 & 1200 Repair Manual

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