Harley-Davidson Owners Manual Close Window Print

Maintenance and Lubrication

Safe Operating Maintenance


en Warning

Perform the service and maintenance operations as indicated 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)

Good maintenance creates a safe motorcycle. A careful check of certain equipment must be made after periods of storage. Also, frequently inspect the motorcycle between the regular service intervals to determine if additional maintenance is necessary.

Check the following items:

  1. Tires for correct pressure, abrasions or cuts.

  2. Belt and primary chain for proper tension, wear or damage.

  3. Brakes, steering and throttle for responsiveness and freedom from binding.

  4. Brake fluid level and condition. Hydraulic lines and fittings for leaks. Also, check brake pads and discs for wear.

  5. Cables for fraying or crimping and free operation.

  6. Engine oil and primary chaincase/transmission fluid levels.

  7. Headlamp, tail lamp, brake lamp and turn signals for proper operation.

NOTE:

Refer to the side view photographs in the front of this manual to locate the items discussed in this section.

Break-in Maintenance


NOTE:

The performance of new motorcycle initial service is required to keep your new motorcycle warranty in force and to assure proper emissions system operation.

Refer to Regular Service Intervals: 2006 Sportster Models. After a new motorcycle has been ridden its first 1000 miles (1600 kilometers), it should be taken to the dealer from whom it was purchased for initial service operations.

Engine Lubrication


en Caution

Do not switch lubricant brands indiscriminately because some lubricants interact chemically when mixed. Use of inferior lubricants can damage the engine. (00184a)

Engine oil is a major factor in the performance and service life of the engine. Always use the proper grade of oil for the lowest temperature expected before the next scheduled oil change. Refer to Recommended Engine Oils. Your authorized dealer has the proper oil to suit your requirements.

If it is necessary to add oil and Harley-Davidson oil is not available, use an oil certified for diesel engines. Acceptable diesel engine oil designations include: CF-4, CG-4, CH-4 and CI-4.

The preferred viscosities for the diesel engine oils in descending order are: 20W50, 15W40 and 10W40.

At the first opportunity, see an authorized dealer to change back to 100 percent Harley-Davidson oil.

Recommended Engine Oils

H-D TYPE

VISCOSITY

H-D RATING

LOWEST AMBIENT TEMPERATURE

COLD WEATHER STARTS BELOW 50° F (10° C)

H-D Multi-grade

SAE 10W40

HD 360

Below 40° F (4° C)

Excellent

H-D Multi-grade

SAE 20W50

HD 360

Above 40° F (4° C)

Good

H-D Regular Heavy

SAE 50

HD 360

Above 60° F (16° C)

Poor

H-D Extra Heavy

SAE 60

HD 360

Above 80° F (27° C)

Poor



Checking Oil Level: Sportster Models


en Caution

Oil level cannot be accurately measured on a cold engine. For pre-ride inspection, with motorcycle leaning on jiffy stand on level ground, oil should register on dipstick between arrows when engine is cold. Do not add oil to bring the level to the FULL mark on a COLD engine. (00185a)

For dipstick location, see Oil Dipstick Location: Sportster Models.

Removing and Replacing Oil Filler Cap


Position motorcycle so that it is leaning on jiffy stand on level ground.

  1. Remove filler cap from oil tank on right side of vehicle.

    1. Press straight down on filler cap and release. Cap will pop up.

    2. Pull up on filler cap while turning counterclockwise one-quarter turn as if unscrewing filler cap.

  2. Wipe attached dipstick clean.

  3. NOTE:

    See Filler Cap/Dipstick Slots: Sportster Models. Note that dipstick has a wide slot and a narrow slot and can only be inserted in oil tank one way.

  4. Insert dipstick into tank. Turn filler cap 1/4 turn as if screwing filler cap into tank. Press down on cap until flush with oil tank.

Oil Dipstick Location: Sportster Models

Oil Dipstick Location: Sportster Models

Oil Level Cold Check


  1. Position motorcycle so that it is leaning on jiffy stand on level ground.

  2. Remove filler cap. Wipe attached dipstick clean. Reinstall oil filler cap in tank.

  3. Remove oil filler cap again and check oil level on dipstick. See Filler Cap/Dipstick: Sportster Models. Dipstick has two marks. If oil level is at or below lower mark, add only enough oil to bring the level to a point between the two arrows on the dipstick. Replace filler cap.

NOTE:

Refer to Recommended Engine Oils. Use only recommended oil specified under Engine Lubrication.

Oil Level Hot Check


  1. Run engine until engine oil is at normal operating temperature. Turn engine off.

  2. Position motorcycle so that it is leaning on jiffy stand on level ground.

  3. Remove filler cap. Wipe attached dipstick clean. Reinstall oil filler cap in tank.

  4. Remove filler cap again and check warm oil level on dipstick. See Filler Cap/Dipstick: Sportster Models. Dipstick has two marks. If oil level in tank is at or below lower mark, add one quart (0.946 liter) of Harley-Davidson oil to tank. Replace filler cap.

  5. NOTE:

    Refer to Recommended Engine Oils. Use only recommended oil specified under Engine Lubrication.

  6. Place filler cap/dipstick back into oil tank.

  7. If you added oil in step 4, remove filler cap and verify correct engine oil level in oil tank. Do not fill oil tank to the level above upper mark on dipstick. Replace filler cap.

en Caution

Do not allow hot oil level to fall below Add/Fill mark on dipstick. Doing so can result in equipment damage and/or equipment malfunction. (00189a)

en Caution

Do not overfill oil tank. Doing so can result in oil carryover to the air cleaner leading to equipment damage and/or equipment malfunction. (00190a)

  • Check engine oil supply at each complete fuel refill.
  • Refer to Regular Service Intervals: 2006 Sportster Models. Oil should be changed at specified intervals in normal service at warm or moderate temperatures.
  • See Winter Lubrication. Oil change intervals should be shorter in cold weather. The same holds true if the motorcycle is ridden hard under dusty conditions.
Filler Cap/Dipstick: Sportster Models
  1. Lower mark
  2. Upper mark (full)

Filler Cap/Dipstick: Sportster Models

Filler Cap/Dipstick Slots: Sportster Models
  1. Wide slot
  2. Narrow slot

Filler Cap/Dipstick Slots: Sportster Models

Changing Oil and Oil Filter: Sportster Models


en Caution

Do not switch lubricant brands indiscriminately because some lubricants interact chemically when mixed. Use of inferior lubricants can damage the engine. (00184a)

See Oil Filter: Sportster Models. Sportster motorcycles use a chrome or black oil filter. Oil filters are located on an oil filter mount in front of the engine.

en Warning

Be sure that no lubricants or fluids get on tires, wheels or brakes when changing fluid. Traction can be adversely affected, which could result in loss of control of the motorcycle and death or serious injury. (00047d)

Removal and Draining


  1. Remove the oil filler plug/dipstick.

  2. NOTE:

    Oil will flow more quickly if the filler cap/dipstick is removed from the oil tank.

  3. Place a suitable container under the engine crankcase. The container must be able to hold approximately 4 U.S. quarts (3.8 liters).

  4. en Caution

    Use Harley-Davidson OIL FILTER WRENCH for filter removal. This tool can prevent damage to crankshaft position sensor and/or sensor cable. (00192a)

  5. See Oil Tank Drain Hose and Bracket: Sportster Models. Loosen worm drive clamp (2) and pull drain plug (3) from end of drain hose. Completely drain engine oil from oil tank. It is not necessary to drain engine crankcase.

  6. Replace drain plug into end of drain hose. Tighten worm clamp.

  7. Move drain pan beneath front of engine crankcase.

  8. Turn oil filter counterclockwise to remove from filter mount.

  9. Discard oil filter.

NOTE:

Dispose of oil and oil filter in accordance with local regulations.

Oil Filter: Sportster Models
  1. Crankcase
  2. Oil filter

Oil Filter: Sportster Models

Oil Tank Drain Hose and Bracket: Sportster Models
  1. Oil tank drain hose
  2. Worm drive clamp
  3. Drain plug

Oil Tank Drain Hose and Bracket: Sportster Models

Installation and Filling


en Caution

Do not overfill oil tank. Doing so can result in oil carryover to the air cleaner leading to equipment damage and/or equipment malfunction. (00190a)

  1. Pour about 4 fluid ounces (U.S.) (120 milliliters) of fresh, clean engine oil into new oil filter. Allow time for oil to soak into filter element.

  2. NOTE:

    Partially fill oil filter before installation to minimize the time required for buildup of oil pressure when engine is first started.

  3. See Applying Thin Oil Film. Wipe filter gasket contact surface of oil filter mount with a clean cloth. Surface should be smooth and free of any debris or old gasket material.

  4. Apply a thin film of oil to gasket contact surface on crankcase (3), gasket and new oil filter.

  5. Screw filter onto adapter until gasket contacts surface. Then apply another 1/2-3/4 turn after gasket contacts filter mounting surface.

  6. en Caution

    Detach frame clip from frame tube. Loosen worm clamp and remove drain hose from frame clip. Allow a small amount of oil to flow from hose before reconnection. This action removes air from the drain hose and reduces the possibility of oil pump cavitation. (00355a)

  7. Refer to Recommended Engine Oils. Install 3.6 quarts U.S. (3.4 liters) to engine oil tank minus the 4 fluid ounces (120 milliliters) added in step 1. Always use the proper grade of oil for the lowest expected air temperature before the next regularly scheduled oil change.

  8. Start engine. Verify that oil pressure signal light turns off when engine speed is 1000 RPM or above.

  9. Install filler cap/dipstick onto oil tank. Make sure cap is fully seated.

  10. Check for oil leaks at oil filter and oil tank drain hose. Turn engine off.

Applying Thin Oil Film
  1. Thin oil film ONLY
  2. Oil filter
  3. Mounting plate

Applying Thin Oil Film

Winter Lubrication


In colder climates, the engine oil change interval should be shorter than normal. Motorcycles used only for short runs must have the engine oil changed more frequently and have a thorough tank flush-out before new oil is put in. See an authorized dealer.

NOTE:

The further below freezing the temperature drops, the shorter the oil change interval should be.

Water vapor is a normal by-product of combustion in any engine. During cold weather operation, some of the water vapor condenses to liquid form on the cool metal surfaces inside the engine. In freezing weather this water will become slush or ice and, if allowed to accumulate too long, may block the oil lines and cause damage to the engine.

If the engine is run frequently and allowed to thoroughly warm up, most of this water will become vapor again and will be blown out through the crankcase breather.

If the engine is not run frequently and allowed to thoroughly warm up, this water will accumulate, mix with the engine oil and form a sludge that is harmful to the engine.

Transmission Lubrication: Sportster Models


Refer to Regular Service Intervals: 2006 Sportster Models. The transmission should be drained and refilled with fresh lubricant at proper intervals. For best results, drain lubricant while hot.

NOTE:

When checking the transmission lubricant level, motorcycle should be standing STRAIGHT UP, not leaning on the jiffy stand. Keep motorcycle upright for a short period of time to equalize lubricant level in the transmission compartments.

Check Lubricant Level


  1. Ride motorcycle until engine is warmed up to normal operating temperature.

  2. Position motorcycle straight up.

  3. See Primary Cover: Sportster Models. Remove screws with washers from clutch inspection cover (1). Remove clutch inspection cover from primary cover. Exercise caution to avoid damaging or dislodging quad ring in primary cover.

  4. NOTE:

    The filler access is the clutch inspection cover.

    en Caution

    When draining or adding lubricant, do not allow dirt, debris or other contaminants to enter the engine. (00198a)

    en Warning

    Be sure that no lubricants or fluids get on tires, wheels or brakes when changing fluid. Traction can be adversely affected, which could result in loss of control of the motorcycle and death or serious injury. (00047d)

    en Caution

    Do not overfill the primary chaincase with lubricant. Overfilling can cause rough clutch engagement, incomplete disengagement, clutch drag and/or difficulty in finding neutral at engine idle. (00199b)

  5. See Chaincase Lubricant Level: Sportster Models. Verify that lubricant level (5) is even with bottom of clutch diaphragm spring (1).

  6. NOTE:

    Add only enough of GENUINE Harley-Davidson FORMULA+ TRANSMISSION AND PRIMARY CHAINCASE LUBRICANT (Part No. 98851-05 quart) through clutch inspection cover opening until the lubricant reaches the bottom of clutch diaphragm spring (1).

  7. Install clutch inspection cover on primary cover using screws with washers removed in step 3. Tighten screws in a crosswise pattern to 84-108 in-lbs (9.5-12.2 Nm).

  8. Start engine. Check for any lubricant leaks.

  9. Turn engine off.

Primary Cover: Sportster Models
  1. Clutch inspection cover
  2. Drain plug

Primary Cover: Sportster Models

Changing Lubricant


  1. Ride motorcycle until engine is warmed up to normal operating temperature.

  2. When the engine reaches normal operating temperature, turn the engine off and position motorcycle on jiffy stand. This will allow the chaincase lubricant to drain out of transmission.

  3. See Primary Cover: Sportster Models. Position a suitable container under transmission drain plug (2).

  4. The drain plug is located under the clutch, on the underside of the chaincase. Remove drain plug and drain lubricant.

  5. Position the motorcycle STRAIGHT UP and LEVEL. This allows additional fluid to be drained from clutch compartment.

  6. NOTE:

    Dispose of lubricant in accordance with local regulations.

  7. Remove foreign material from magnetic drain plug. Install drain plug and tighten to 14-21 ft-lbs (19.0-28.5 Nm).

  8. en Caution

    Do not over-tighten filler or drain plug. Doing so could result in a lubricant leak. (00200b)

    en Caution

    When draining or adding lubricant, do not allow dirt, debris or other contaminants to enter the engine. (00198a)

    en Warning

    Be sure that no lubricants or fluids get on tires, wheels or brakes when changing fluid. Traction can be adversely affected, which could result in loss of control of the motorcycle and death or serious injury. (00047d)

    en Caution

    Do not overfill the primary chaincase with lubricant. Overfilling can cause rough clutch engagement, incomplete disengagement, clutch drag and/or difficulty in finding neutral at engine idle. (00199b)

  9. See Primary Cover: Sportster Models. Remove screws with washers from clutch inspection cover (1). Remove clutch inspection cover from primary cover. Exercise caution to avoid damaging or dislodging quad-ring in primary cover.

  10. NOTE:

    The filler access is the clutch inspection cover.

  11. See Chaincase Lubricant Level: Sportster Models. Add 32 fluid ounces (946 milliliters) of GENUINE Harley-Davidson FORMULA+ TRANSMISSION AND PRIMARY CHAINCASE LUBRICANT (Part No. 98851-05 quart) through clutch inspection cover opening or until the lubricant reaches the bottom of clutch diaphragm spring (1).

  12. Install clutch inspection cover on primary cover using screws with washers removed in step 7. Tighten screws in a crosswise pattern to 84-108 in-lbs (9.5-12.2 Nm).

  13. Start engine. Check for any lubricant leaks.

  14. Turn engine off.

Chaincase Lubricant Level: Sportster Models
  1. Clutch diaphragm spring
  2. Clutch adjusting screw
  3. Quad-ring
  4. Primary cover
  5. Chaincase lubricant level

Chaincase Lubricant Level: Sportster Models

Primary Chain Adjustment: Sportster Models


General


Refer to Regular Service Intervals: 2006 Sportster Models. Primary (front) chain adjustment should be checked at proper intervals and serviced as necessary. If the chain is allowed to run loose, it will cause the motorcycle to jerk when running at low speed, and chain and sprockets will wear excessively. If this happens, see a Harley-Davidson dealer or Service Manual for adjustment procedure.

Primary Chain Adjustment: Sportster Models

FREE PLAY

INCHES

MILLIMETERS

COLD engine

3/8-1/2

9.5-12.7

HOT engine

1/4-3/8

6.3-9.5



Primary Chain Vertical Free Play: Sportster Models
  1. Measurement point between sprockets
  2. Measurement value

Primary Chain Vertical Free Play: Sportster Models

Procedure


See Primary Chain Adjuster: Sportster Models. The primary chain can be adjusted without removing the primary cover (2).

en Warning

To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)

  1. Unthread nut and remove battery negative cable (black) from crankcase stud.

  2. Remove the two hex socket screws which secure primary chain inspection cover (1).

  3. Rotate sprockets to find tightest point on primary chain.

  4. en Caution

    Do not adjust the primary chain tighter than specified. Running chain too tight will result in excessive wear. (00202a)

  5. Loosen locknut. Turn chain adjuster screw clockwise (inward) to reduce free play or counterclockwise (outward) to increase free play. Vertical free play must fall within the limits specified.

  6. NOTE:

    Refer to Primary Chain Adjustment: Sportster Models. If vertical free play cannot be set within the limits specified, then primary chain and/or chain adjuster are worn beyond adjustment limits. Replace parts as necessary.

  7. See Primary Chain Adjuster: Sportster Models. When tension is set correctly, tighten locknut (6) to 20-25 ft-lbs (27-34 Nm).

  8. Install primary chain inspection cover (1). Tighten hex socket screws to 40-60 in-lbs (4.5-6.8 Nm).

Primary Chain Adjuster: Sportster Models
  1. Primary chain inspection cover
  2. Primary cover
  3. Clutch inspection cover
  4. Drain plug
  5. Chain adjuster screw
  6. Locknut

Primary Chain Adjuster: Sportster Models

Rear Drive Belt: Sportster Models


General


The inner tooth surface of the secondary belt has a thin coating of polyethylene lubricant. During initial operation, this coating will wear off as it is burnished into the belt fabric. This is a normal condition and not an indication of belt wear.

Belt deflection (tension) is set at the factory and should be checked after the first 1000 miles (1600 kilometers), at scheduled maintenance intervals and after a hard ride.

Gauging Deflection


With the rear wheel on the ground and only the rider sitting on the motorcycle, fit the BELT TENSION GAUGE (Part No. HD-35381A) approximately half-way between sprockets.

See Belt Deflection Window. Locate the belt deflection widow on the rear drive belt guard/debris deflector and note the belt position relative to the deflection graduations.

Using the BELT TENSION GAUGE, apply 10 lbs. (4.5 kg) of force at the midpoint of the bottom belt. Count the number of graduations between the original belt position and after applying the force. Multiply this number by 1/8 in. (3.2 mm).

Belt Deflection Window
  1. Rear drive belt
  2. Deflection graduations 1/8 in. (3.2 mm) apart

Belt Deflection Window

See Gauging Belt Deflection: Sportster Models and refer to Belt Deflection: 2006 Sportster Models for the recommended deflection. If belt tension adjustment is necessary, see a Harley-Davidson dealer or follow the belt deflection adjustment procedure found in the Sportster Models Service Manual.

en Warning

Be sure wheel and brake caliper are aligned. Riding with a misaligned wheel or brake caliper can cause the brake disc to bind and lead to loss of control, which could result in death or serious injury. (00050a)

When gauging deflection, check the rear brake caliper position on rear brake disc. Disc should run true within brake caliper.

Belt Deflection: 2006 Sportster Models

MODELS

INCHES

MILLIMETERS

XL 883C, XL 1200C

XL 883L, XL 1200L

1/4-5/16

6.5-7.9

XL 883, XL 883R

XL 1200R

3/8-7/16

9.5-11.1



Gauging Belt Deflection: Sportster Models
  1. Transmission sprocket
  2. Rear wheel sprocket
  3. Force of 10 lbs (4.5 kg)
  4. Deflection (refer to table)

Gauging Belt Deflection: Sportster Models

Chassis Lubrication


Refer to Regular Service Intervals: 2006 Sportster Models for all maintenance schedules.

en Caution

Do not switch lubricant brands indiscriminately because some lubricants interact chemically when mixed. Use of inferior lubricants can damage the engine. (00184a)

  1. Use recommended special purpose grease for steering head bearings. Use a multipurpose chassis grease for other applications.

  2. Remove and lubricate handlebar throttle control grip sleeve with fresh graphite at proper intervals.

  3. Lubricate throttle control cables and clutch control cable at proper intervals.

  4. Lubricate front brake hand lever and clutch control hand lever only if necessary.

  5. Inspect rear fork pivot shaft bearings.

  6. Pack the steering head bearings with fresh grease at proper intervals.

  7. Lubricate the jiffy stand mechanism with LOCTITE AEROSOL ANTI-SEIZE at proper intervals.

NOTE:

For model specific information regarding the chassis lubrication, refer to the appropriate Service Manual or see a Harley-Davidson dealer.

Oil Applications


Refer to Regular Service Intervals: 2006 Sportster Models for all control connections and parts. Vehicle should be oiled at regular intervals, particularly after washing motorcycle or driving in wet weather.

Front Fork Oil


Refer to Regular Service Intervals: 2006 Sportster Models. Drain front fork oil and refill at proper intervals. If fork does not appear to be working properly or an appreciable amount of oil leakage should develop, see a Harley-Davidson dealer. If there is insufficient oil in either side of fork, the rebound action will be incorrect.

Fuel Strainer


Carbureted Models Only


A screen type fuel strainer is located on top of the supply valve inside the fuel tank. Screen should be inspected/cleaned at proper intervals. Check the fuel valve, lines and fittings for leakage as part of the preride inspection. Refer to Regular Service Intervals: 2006 Sportster Models.

Clutch


en Caution

The clutch control cable must be oiled and adjusted periodically to compensate for lining wear. See Service Interval Table. Failure to oil and adjust the clutch control cable can result in equipment damage. (00203a)

The need for attention to clutch and controls will be indicated by the clutch slipping under load or dragging when released. In this situation, check the control cable adjustment first. See a Harley-Davidson dealer for proper service.

Hydraulic Lifters


The hydraulic lifters are self-adjusting. They automatically adjust length to compensate for engine expansion and valve mechanism wear. This keeps the valve mechanism free of lash when the engine is running.

When starting an engine which has been turned off even for a few minutes, the valve mechanism may be slightly noisy until the hydraulic units completely refill with oil. If at any time the valve mechanism becomes abnormally noisy, other than for a short period immediately after engine is started, it is an indication that one or more of the hydraulic units may not be functioning properly.

Always check the oil supply in the oil tank first since normal circulation of oil through the engine is necessary for proper operation of the hydraulic units.

If there is oil in the tank, the units may not be functioning properly because of dirt in the oil supply passages leading to the lifter units. See a Harley-Davidson dealer for service.

Front Fork Bearings


en Warning

Adjustments to front fork bearings should be performed by a Harley-Davidson dealer. Improperly adjusted bearings can adversely affect handling and stability, which could result in death or serious injury. (00051a)

Refer to Regular Service Intervals: 2006 Sportster Models. Check front fork for proper bearing adjustment and lubricate bearings at proper intervals.

With motorcycle front end raised off the floor, be sure front fork turns freely without any binding or interference and that there is no appreciable front to rear fork shake indicating excessive bearing looseness. Steering head bearings should be adjusted according to Service Manual procedure, if necessary.

Rear Fork Pivot Shaft


Refer to Regular Service Intervals: 2006 Sportster Models. Check the tightness of the rear fork pivot shaft fastener at proper intervals.

NOTE:

For model specific information regarding the rear fork pivot shaft, refer to the appropriate Service Manual or see a Harley-Davidson dealer.

Brakes: Sportster Models


en Warning

Inspect brake pads for wear at service maintenance intervals. If you ride under adverse conditions (steep hills, heavy traffic, etc.), inspect more frequently. Excessively worn brake pads can lead to brake failure, which could result in death or serious injury. (00052a)

  1. Refer to Regular Service Intervals: 2006 Sportster Models. Check brake pads and brake discs for wear at proper intervals.

  2. Check the fluid level in the master cylinder reservoirs at regular intervals.

  3. If level is low, clean dirt and debris from reservoir cover before removing.

  4. en Caution Mark

    Direct contact of D.O.T. 5 brake fluid with eyes can cause eye irritation, swelling, and redness. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 5 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00144a)

  5. Add D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID (Part No. 99902-77) if necessary.

  6. NOTE:

    Use only D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID (Part No. 99902-77) approved for brake system use and available from a Harley-Davidson dealer.

  7. Replace brake rubber components on master cylinders and calipers.

  8. Lubricate brake caliper pins at regular intervals.

en Warning

Always replace brake pads in complete sets for correct and safe brake operation. Improper brake operation could result in death or serious injury. (00111a)

Harley-Davidson has provided your new motorcycle with the optimum brake pad friction material available. It is selected to give the best performance possible under dry, wet and high operating temperature conditions. It exceeds all regulatory requirements currently in effect. However, during some braking conditions you may experience noise. This is normal for this friction material.

en Warning

Brakes are a critical safety component. Contact a Harley-Davidson dealer for brake repair or replacement. Improperly serviced brakes can adversely affect brake performance, which could result in death or serious injury. (00054a)

Visual inspection of brake pads can be made without removing the caliper. View the lower area of each caliper with a flashlight.

en Warning

Perform routine scheduled brake maintenance. Lack of maintenance at recommended intervals can adversely affect brake performance, which could result in death or serious injury. (00055a)

NOTES:
  • If the brake pad friction material is 0.04 inch (1.00 millimeter) thick or less, the pads must be replaced immediately.
  • Always replace brake pads in pairs.

The rear brake outer pad on all models can be measured from the caliper bracket side using a thin plastic 6.0 inch (152.4 millimeter) rule. Place the rule against the brake disc through the space alongside the caliper.

NOTE:

The outer surface of the brake pad backing plate should measure 0.04 inch (1.00 millimeter) or more away from the brake disc.

Tires


See Specifications: 2006 Sportster Models for tire pressures and sizes.

  • Be sure to keep tires properly inflated.
  • Follow tire data for correct cold tire inflation pressures.
  • Check before riding when tires are cold.
  • Do not over-inflate tires.
en Warning

Do not inflate tire beyond maximum pressure as specified on sidewall. Over inflated tires can blow out, which could result in death or serious injury. (00027a)

en Warning

Match tires, tubes, air valves and caps to the correct wheel rim. Contact a Harley-Davidson dealer. Mismatching can result in damage to the tire bead, allow tire slippage on the rim or cause tire failure, which could result in death or serious injury. (00023a)

Check inflation pressure and inspect tread for punctures, cuts, breaks, etc., at least weekly if in daily use. Check before each trip if used occasionally.

en Warning

Be sure tires are properly inflated, balanced and have adequate tread. Inspect your tires regularly and see a Harley-Davidson dealer for replacements. Riding with excessively worn, unbalanced or under-inflated tires can adversely affect stability and handling, which could result in death or serious injury. (00014a)

Same as original equipment tires should be used. Other tires may not fit correctly, could adversely affect handling, and may be hazardous to use.

en Warning

Tires are a critical safety component. Contact a Harley-Davidson dealer for tire repair or replacement. Improper tire service can adversely affect stability and handling, which could result in death or serious injury. (00057a)

en Warning

Replace punctured or damaged tires. In some cases, small punctures in the tread area may be repaired from within the demounted tire by a Harley-Davidson dealer. Speed should NOT exceed 50 mph (80 km/h) for the first 24 hours after repair, and the repaired tire should NEVER be used over 80 mph (130 km/h). Failure to follow this warning could result in death or serious injury. (00015a)

en Warning

Striking an object, such as a curb, can cause internal tire damage. If an object is struck, remove and inspect both the inside and outside of the tire. A damaged tire can adversely affect stability and handling, which could result in death or serious injury. (00058a)

Tire Replacement


Inspection


en Warning

Harley-Davidson tires are equipped with wear bars that run horizontally across the tread. When wear bars become visible and only 1/32 in. (0.8 mm) tread depth remains, replace tire immediately. Using a worn tire can adversely affect stability and handling, which could result in death or serious injury. Use only Dunlop Harley-Davidson replacement tires. (00090a)

See Tire Sidewall Wear Bar Locator. Arrows on tire sidewalls pinpoint location of wear bar indicators.

Tread wear indicator bars will appear on tire tread surfaces when 1/32 in. (0.8 mm) or less of tire tread remains. See Wear Bar Appearance. Always replace tires before the tread wear indicator bars appear.

When To Replace Tires


New tires are needed if any of the following conditions exist:

  1. Tread wear indicator bars become visible on the tread surfaces.

  2. Tire cords or fabric become visible through cracked sidewalls, snags or deep cuts.

  3. A bump, bulge or split in the tire.

  4. Puncture, cut or other damage to the tire that cannot be repaired.

Tire Sidewall Wear Bar Locator

Tire Sidewall Wear Bar Locator

Wear Bar Appearance

Wear Bar Appearance

Shock Absorbers


Refer to Regular Service Intervals: 2006 Sportster Models. Inspect shock absorbers and rubber bushings for leaks and bushing deterioration at proper intervals.

Spark Plugs


Refer to Regular Service Intervals: 2006 Sportster Models. Check the spark plugs at proper intervals.

en Caution Mark

Do NOT pull on any electrical wires. Pulling on electrical wires may damage the internal conductor causing high resistance, which may result in minor or moderate injury. (00168a)

Disconnect spark plug cables from plugs by pulling on the molded connector caps. To reconnect, simply snap-on spark plug cables to tops of spark plugs.

Refer to Ignition System: 2006 Sportster Models before servicing spark plugs.

  1. Check spark plug type. Only use those spark plugs specified for your model motorcycle.

  2. Check spark plug gap against table specifications.

  3. Always tighten to the proper torque. Spark plugs must be tightened to the torque specified for proper heat transfer.

NOTE:

If a torque wrench is not available, tighten plugs finger tight and then tighten an additional one quarter turn with a spark plug wrench.

Ignition


The engine in your motorcycle has been designed specifically to achieve optimum fuel economy within exhaust emission controls. Factory programmed ignition characteristics provide maximum engine performance and driveability.

Carburetor


The carburetor has been specifically designed for emissions control operation. All jets are fixed at the factory.

Carburetor controls include throttle, enrichener and idle speed adjusting screw. Operation should be checked and adjusted at proper intervals. Refer to Regular Service Intervals: 2006 Sportster Models.

en Caution

Operation at higher altitudes (approximately 4000 ft. (1200 meters) elevation) can require carburetor modifications for best engine performance. See a Harley-Davidson dealer for these adjustments. Failure to do so could result in equipment damage. (00206a)

We recommend that any carburetor service be performed by a Harley-Davidson dealer.

Air Cleaner


See Air Cleaner Assembly: Sportster Models. The engine air cleaner is a paper/wire mesh air filter element.

Refer to Regular Service Intervals: 2006 Sportster Models. Remove air cleaner cover and inspect filter element at proper intervals. Under dusty conditions, inspect more often.

The paper/wire mesh air filter element should be washed in luke warm water with a mild detergent.

en Warning

Compressed air can pierce the skin and flying debris from compressed air could cause serious eye injury. Wear safety glasses when working with compressed air. Never use your hand to check for air leaks or to determine air flow rates. (00061a)

  • Allow filter to either air dry or blow it dry, from the inside, with low pressure air.
  • Do not use an air cleaner filter oil on the Harley-Davidson paper/wire mesh air filter element.
en Caution

Install air filter before running engine. Failure to do so can draw debris into the engine and could result in engine damage. (00207a)

Air Cleaner Assembly: Sportster Models
  1. Screw
  2. Cover
  3. Filter element
  4. Gasket

Air Cleaner Assembly: Sportster Models

Headlamp


See Headlamp Assemblies: Sportster Models. The headlamp assembly uses a replaceable quartz halogen bulb.

NOTE:

Refer to Bulb Chart: 2006 Sportster Models and see a service manual for more details.

en Caution

When replacement is required, use only the specified sealed beam unit or bulb, available from a Harley-Davidson dealer. An improper wattage sealed beam or bulb, can cause charging system problems. (00209a)

en Caution

Never touch the quartz bulb. Fingerprints will etch the glass and decrease bulb life. Grab the bulb with paper or a clean, dry cloth. Failure to do so could result in bulb damage. (00210a)

en Warning

Handle bulb carefully and wear eye protection. Bulb contains gas under pressure, which, if not handled carefully, could cause serious eye injury. (00062b)

Headlamp Assemblies: Sportster Models
  1. Screw
  2. Nut
  3. Headlamp ring
  4. Lens
  5. Gasket
  6. World models only
  7. Bulb
  8. Bulb shield
  9. Rubber boot
  10. Wire clip
  11. Adapter ring
  12. Connector

Headlamp Assemblies: Sportster Models

Headlamp Alignment: Sportster Models


en Warning

The automatic-on headlamp feature provides increased visibility of the rider to other motorists. Be sure headlamp is on at all times. Poor visibility of rider to other motorists can result in death or serious injury. (00030b)

Check headlamp beam for proper height and lateral alignment:

  • When the new owner takes delivery of the motorcycle.
  • When there is a change in load (adding luggage, etc.).

Inspection


  1. Verify correct front and rear tire inflation pressure. Refer to Tire Pressures: 2006 Sportster Models.

  2. Place motorcycle on level floor (or pavement) in an area with a low light level.

  3. See Headlamp Alignment: Sportster Models. Position motorcycle 25 feet (7.62 meters) away a screen or wall. Measure distance from directly below front axle to base of screen/wall.

  4. Draw a horizontal line, on screen or wall, 35 inches (0.9 meters) above floor.

  5. Load vehicle with rider, passenger (if normally present) and any cargo normally carried. Weight will compress vehicle suspension slightly.

  6. Stand motorcycle upright with both tires resting on floor and with front wheel held in straight alignment (directly forward).

  7. Turn ignition/headlamp switch to IGNITION position. Set handlebar headlamp switch to HIGH beam position.

  8. Check light beam for proper height alignment:

    1. Main beam of light (broad, flat pattern of light) should be centered equally above and below horizontal line on screen or wall.

    2. Main beam of light should be directed straight ahead. Properly adjusted headlamps project an equal area of light to right and left of center.

  9. Adjust headlamp alignment if necessary.

Headlamp Alignment: Sportster Models
  1. 25 feet (7.6 meters)
  2. 35 inches (0.9 meters)

Headlamp Alignment: Sportster Models

Adjustment (XL 883, XL 883L, XL 883R, XL 1200L, XL 1200R Models)


  1. See Headlamp Snap Plug: Sportster Models. Remove snap plug (1) on top of headlamp bracket (2).

  2. See Headlamp Clamp Nut: Sportster Models. Loosen headlamp clamp nut.

  3. Tilt headlamp up or down to properly aim it in relation to the horizontal line and, at the same time, turn it right or left to direct light beam straight ahead.

  4. Tighten headlamp clamp nut to 120-240 in-lbs (14-27 Nm) after lamp is properly positioned. Install snap plug in headlamp bracket.

Headlamp Snap Plug: Sportster Models
  1. Snap plug
  2. Headlamp bracket

Headlamp Snap Plug: Sportster Models

Headlamp Clamp Nut: Sportster Models

Headlamp Clamp Nut: Sportster Models

Adjustment (XL 883C and XL 1200C Models)


Horizontal Adjustment:

  1. See Headlamp Clamp Nut: Sportster Models. Loosen the Allen head capscrew (3).

  2. Turn the headlamp right or left as necessary to direct the light beam straight ahead.

  3. Tighten the Allen head capscrew to 30-35 ft-lbs (40.7-47.5 Nm).

Vertical Adjustment:

  1. See Headlamp Adjustment (XL 883C and XL 1200C). Loosen the locknut (1) for the vertical adjustment bolt.

  2. Tilt headlamp up or down to properly aim it at the horizontal line on the wall.

  3. Tighten headlamp locknut to 30-35 ft-lbs (40.7-47.5 Nm).

Headlamp Adjustment (XL 883C and XL 1200C)
  1. Nut
  2. Bolt (vertical adjustment)
  3. Allen head capscrew (horizontal adjustment)

Headlamp Adjustment (XL 883C and XL 1200C)

Turn Signal Bulbs: Bullet Style


Replacement


  1. See Lens Cap Notch. To access the front or rear turn signal bulbs for replacement, locate a notch on the turn signal lens cap.

  2. Insert a coin in the lens cap notch, and carefully twist until the lens cap pops out of the lamp housing.

  3. Push in and twist the lamp bulb counterclockwise and pull lamp bulb out of the socket.

  4. Orient index pins on new lamp bulb with pin guides inside bulb socket.

  5. Push lamp bulb in and turn clockwise to lock in place.

  6. Snap lens cap back into the lamp holder.

Alignment


Refer to service manual for alignment procedure.

Lens Cap Notch

Lens Cap Notch

Alternator/Voltage Regulator


Charging Rate


The alternator output is controlled and changed to direct current by the voltage regulator.

  • The voltage regulator increases charging rate when battery is low or lamps are lit.
  • The voltage regulator decreases charging rate when battery charge is up.
en Caution

It is possible to overload your motorcycle's charging system by adding too many electrical accessories. If your combined electrical accessories operating at any one time consume more electrical current than your vehicle's charging system can produce, the electrical consumption can discharge the battery and cause vehicle electrical system damage. See a Harley-Davidson dealer for advice about the amount of current consumed by additional electrical accessories, or for necessary wiring changes. (00211b)

NOTES:
  • This unit requires no interval attention. If any electrical system trouble is experienced that might be traceable to the alternator or voltage regulator, the motorcycle should be taken to a Harley-Davidson dealer who has the necessary electrical testing equipment to give the required attention.
  • For model specific information regarding the voltage regulator, refer to the appropriate Service Manual or see a Harley-Davidson dealer.

Battery: General


Type


Your motorcycle uses a permanently sealed, maintenance-free, lead/calcium and sulfuric acid battery. All batteries are shipped precharged and ready to be put into service. Do not attempt to open the battery for any reason.

Antidotes for Battery Acid

CONTACT

TREATMENT

External

Flush with water.

Internal

Drink large quantities of milk or water, followed by milk of magnesia, vegetable oil or beaten eggs. Get immediate medical attention.

Eyes

Flush with water. Get immediate medical attention.



en Warning

Batteries contain sulfuric acid, which could cause severe burns to eyes and skin. Wear a protective face shield, rubberized gloves and protective clothing when working with batteries. KEEP BATTERIES AWAY FROM CHILDREN. (00063a)

en Warning

Explosive hydrogen gas, which escapes during charging, could cause death or serious injury. Charge battery in a well-ventilated area. Keep open flames, electrical sparks and smoking materials away from battery at all times. KEEP BATTERIES AWAY FROM CHILDREN. (00065a)

en Warning

Batteries, battery posts, terminals and related accessories contain lead and lead compounds, and other chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling. (00019d)

en Warning

Never remove warning label attached to top of battery. Failure to read and understand all precautions contained in warning, could result in death or serious injury. (00064a)

Battery Warning Label
  1. Contents are corrosive
  2. Wear safety glasses
  3. Contents are explosive
  4. Keep flames away
  5. Read instructions
  6. Keep away from children

Battery Warning Label

Battery Warning Label: Sportster Models

Battery Warning Label: Sportster Models

Voltmeter Test


Refer to Voltmeter Test. The voltmeter test provides a general indicator of battery condition. Check the voltage of the battery to verify that it is in a 100 percent fully charged condition. If the open circuit (disconnected) voltage reading is below 12.6V, charge the battery and then re-check the voltage after the battery has set for one to two hours.

Voltmeter Test

READING IN VOLTS

PERCENT OF CHARGE

12.7

100

12.6

75

12.3

50

12.0

25

11.8

0



Cleaning and Inspection


Battery top must be clean and dry. Dirt and electrolyte on top of the battery can cause battery to self-discharge.

  1. Clean battery top with a solution of baking soda (sodium bicarbonate) and water. Use 5 teaspoons baking soda per quart or liter of water.

  2. When the solution stops bubbling, rinse off the battery with clean water.

  3. Clean cable connectors and battery terminals using a wire brush or fine grit sandpaper to remove any oxidation.

  4. Inspect and clean the battery screws, clamps and cables. Check for breakage, loose connections and corrosion.

  5. Check the battery posts for melting or damage caused by overtightening.

  6. Inspect the battery for discoloration, a raised top or a warped or distorted case. This might indicate that the battery has been frozen, overheated or overcharged.

  7. Inspect the battery case for cracks or leaks.

Charging


Never charge a battery without first reviewing the instructions for the charger being used. In addition to the manufacturer's instructions, follow these general safety precautions.

Charge the battery if any of the following conditions exist:

  • Vehicle lamps appear dim.
  • Electric starter sounds weak.
  • Battery has not been used for an extended period of time.
en Warning

Explosive hydrogen gas, which escapes during charging, could cause death or serious injury. Charge battery in a well-ventilated area. Keep open flames, electrical sparks and smoking materials away from battery at all times. KEEP BATTERIES AWAY FROM CHILDREN. (00065a)

en Warning

Batteries contain sulfuric acid, which could cause severe burns to eyes and skin. Wear a protective face shield, rubberized gloves and protective clothing when working with batteries. KEEP BATTERIES AWAY FROM CHILDREN. (00063a)

  1. Perform a voltmeter test to determine the state of charge. If battery needs to be charged, proceed to the next step.

  2. en Caution

    Remove battery from motorcycle before charging. Electrolyte leakage will damage motorcycle parts. (00213a)

  3. Remove the battery from the motorcycle. See Battery: Sportster Models.

  4. Place the battery on a level surface.

  5. en Warning

    Unplug or turn OFF battery charger before connecting charger cables to battery. Connecting cables with charger ON can cause a spark and battery explosion, which could result in death or serious injury. (00066a)

    en Warning

    Connect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00068a)

    en Warning

    Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a)

    en Caution

    Do not reverse the charger connections described in the following steps or the charging system of the motorcycle could be damaged. (00214a)

    NOTES:
    • The figures listed in the Amp-hour table assume that the battery is charging at room temperature. If warmer than room temperature, use a slightly shorter charging time. If colder, use a slightly longer charging time.
    • The use of constant current chargers to charge sealed maintenance free batteries is not recommended. Any overcharge will cause dry-out and premature battery failure. If a constant current charger is the only type available, do not exceed the charge times listed in 12 Amp-Hour Battery Charging Rates and Times and do not continue charging the battery if it gets hot. When charging, never exceed 15 volts.
  6. Connect the red battery charger lead to positive (+) terminal of the battery.

  7. Connect the black battery charger lead to negative (-) terminal of the battery.

  8. NOTE:

    If the battery is still in the vehicle, connect the negative lead to the chassis ground. Make sure that the ignition and all electrical accessories are turned off.

  9. Step away from the battery and turn on the charger.

  10. en Warning

    Unplug or turn OFF battery charger before disconnecting charger cables from battery. Disconnecting clamps with charger ON can cause a spark and battery explosion, which could result in death or serious injury. (00067a)

  11. After the battery is fully charged, turn OFF the charger and disconnect the black battery charger lead to the negative (-) terminal of the battery.

  12. Disconnect the red battery charger lead to the positive (+) terminal of the battery.

  13. Mark the charging date on the battery.

12 Amp-Hour Battery Charging Rates and Times

READING

(VOLTS)

PERCENT

CHARGE

3 AMP

CHARGER

6 AMP

CHARGER

10 AMP

CHARGER

20 AMP

CHARGER

12.7

100

N/A

N/A

N/A

N/A

12.6

75

1 hour 10 minutes

34 minutes

20 minutes

10 minutes

12.3

50

2 hours 20 minutes

70 minutes

40 minutes

20 minutes

12.0

25

3 hours 20 minutes

1 hour 40 minutes

1 hour

30 minutes

11.8

0

4 hours 30 minutes

2 hours 14 minutes

1 hour 20 minutes

40 minutes



Storage


en Caution

Turn engine over a few times to be sure there is no oil in the crankcase and that all oil has been pumped back into the oil tank. Stop engine and re-check oil level. Failure to do so can result in engine damage. (00071a)

en Caution

Do not allow battery to completely discharge. The electrolyte in a discharged battery will freeze. The more discharged a battery is, the more easily it can freeze and crack the battery case. (00218a)

If the motorcycle will not be operated for several months, such as during the winter season, remove the battery from the motorcycle and fully charge.

If the motorcycle is to be stored with the battery installed, it will be necessary to connect a battery tender to maintain charge. See an authorized dealer for more information.

Self-discharge is a normal condition and occurs continuously. The rate of self-discharge depends on the ambient temperature and the battery's state of charge.

  • Batteries discharge at a faster rate at higher ambient temperatures.
  • To reduce the self-discharge rate, store battery in a cool (not freezing), dry place.
  • Charge the battery every month if stored at temperatures below 60° F. (16° C).
  • Charge the battery more frequently if stored in a warm area above 60° F. (16° C).
Effective Rate of Temperature on Battery Self-discharging Rate
  1. Capacity
  2. Months of stand
  3. Measured at 105 F (40 C)
  4. Measured at 77 F (25 C)

Effective Rate of Temperature on Battery Self-discharging Rate

Battery: Sportster Models


Disconnection and Removal


en Warning

Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a)

  1. See Negative Battery Cable and Crankcase Stud: Sportster Models. Unthread nut and remove battery negative cable (black) from crankcase stud behind starter motor assembly.

  2. Remove left side cover.

  3. Remove Maxi-Fuse and holder from battery strap by grasping holder and sliding it toward the rear of the motorcycle. Then remove Maxi-Fuse holder from its mounting pin on battery strap.

  4. Remove battery strap screw and flat washer. Unhook battery strap from battery tray mount on top of battery and remove strap.

  5. Unthread bolt and remove battery positive cables (red) from battery positive (+) terminal.

  6. Remove battery and attached negative cable as an assembly from the battery tray.

Installation and Connection


en Caution

Connect the cables to the correct battery terminals. Failure to do so could result in damage to the motorcycle electrical system. (00215a)

en Warning

Connect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00068a)

en Warning

Do not allow positive (+) battery cable to contact ground with negative (-) cable connected. Resulting sparks can cause a battery explosion, which could result in death or serious injury. (00069a)

  1. Apply a light coat of petroleum jelly or corrosion retardant material to negative (-) battery terminal before installation.

  2. Place the fully charged battery with the negative cable attached into the battery tray.

  3. See Negative Battery Cable and Crankcase Stud: Sportster Models. Route negative cable around frame downtube.

  4. en Caution

    Do not over-tighten bolts on battery terminals. Use recommended torque values. Over-tightening battery terminal bolts could result in damage to battery terminals. (00216a)

  5. With negative (-) cable disconnected from grounding point on crankcase, insert bolt through Maxi-Fuse cable first then through main battery positive cable (+) (red) and into threaded hole of battery positive (+) terminal.

  6. Tighten bolt to 45-50 in-lbs (4.5-5.7 Nm).

  7. Apply a light coat of petroleum jelly or corrosion retardant material to positive (+) battery terminal. Place protective rubber boot over terminal.

  8. en Caution

    Keep battery clean and lightly coat terminals with petroleum jelly to prevent corrosion. Failure to do so could result in damage to battery terminals. (00217a)

  9. Hook top of battery strap to battery tray mount on top of battery. Install flat washer and strap screw.

  10. Tighten the strap screw to 36-60 in-lbs (4.07-6.78 Nm).

  11. Route main positive battery cable through holders on electrical bracket.

  12. Hook Maxi-Fuse holder to pin on battery strap and slide forward until it snaps into place.

  13. Place negative battery cable end onto stud on crankcase boss behind starter motor assembly. Thread nut onto stud.

  14. Tighten nut to 55-75 in-lbs (6.2-8.5 Nm).

  15. Install left side cover.

Negative Battery Cable and Crankcase Stud: Sportster Models

Negative Battery Cable and Crankcase Stud: Sportster Models

Jump Starting


Harley-Davidson does not recommend jump-starting a motorcycle. However, there may be circumstances when it is necessary to do so. Therefore, we suggest jump-starting be performed as follows:

en Warning

Be sure jumper cables touch only appropriate battery terminals or ground. Allowing jumper cables to touch each other can result in sparks and a battery explosion, which could result in death or serious injury. (00072a)

en Warning

Explosive hydrogen gas, which escapes during charging, could cause death or serious injury. Charge battery in a well-ventilated area. Keep open flames, electrical sparks and smoking materials away from battery at all times. KEEP BATTERIES AWAY FROM CHILDREN. (00065a)

en Caution

Harley-Davidson motorcycles have a 12 Volt battery. Be sure the booster vehicle has a 12 Volt system. Failure to do so could result in vehicle damage. (00220a)

NOTE:

This procedure presumes the BOOSTER battery is in another vehicle.

  1. Turn off all unnecessary lamps and accessories.

Positive Cable


  1. See Jump Start Cable Connections. Connect one end of a jumper cable to the DISCHARGED battery positive (+) terminal (1).

  2. Connect the other end of the same cable to the BOOSTER battery positive (+) terminal (2).

Negative Cable


en Warning

Do not connect negative (-) cable to or near the discharged battery negative (-) terminal. Doing so could cause a spark and explosion, which could result in death or serious injury. (00073a)

  1. Connect one end of a jumper cable to the BOOSTER battery negative (-) terminal (3).

  2. en Caution

    Do not connect the negative (-) cable to painted or chrome parts. Doing so could result in discoloration at the attachment point. (00221a)

  3. Connect other end of the same cable (4) to a safe ground, (away from the DISCHARGED battery).

  4. Start motorcycle.

  5. Disconnect cables in reverse order of steps 2, 3, 4, 5. That is: steps 5, 4, 3, 2.

Jump Start Cable Connections
  1. Discharged battery positive (+) terminal
  2. Booster battery positive (+) terminal
  3. Booster battery negative (-) terminal
  4. Ground

Jump Start Cable Connections

Electrical Protection: Sportster Models


Fuse Replacement


  1. Turn the ignition to the OFF position.

  2. The left side cover provides access to the battery and fuses. No tools are required to remove or reinstall the side cover.

  3. The left side cover is secured to the motorcycle by two upper slots that fit into clips and a bottom slot that fits into a mounting tab on the battery tray.

NOTE:

The left side cover does not need to be completely removed from the vehicle to access the battery or fuses.

Side Cover Clips: Sportster Models

Side Cover Clips: Sportster Models

Maxi-Fuse and Battery Location
  1. Battery
  2. Positive (+) battery terminal (under protective rubber boot)
  3. Maxi-fuse and holder
  4. System fuses and starter relay
  5. Left side cover

Maxi-Fuse and Battery Location

  1. Place a shop cloth or other clean, dry cloth over rear brake master cylinder reservoir and left passenger foot peg (if equipped). This will protect left side cover from damage.

  2. Grasp left side cover at upper corners and gently pull away from plastic mounting clips on frame.

  3. While rotating top of cover out away from motorcycle, slide cover down slightly so mounting slot slides down from mounting tab on battery tray. Side cover will now rest on top of rear brake master cylinder reservoir and left passenger footpeg (if equipped) with slot hanging off bottom of mounting tab.

  4. Replace the fuse if the element is burned or broken.

  5. en Caution

    Always use replacement fuses that are of the correct type and amperage rating. Use of incorrect fuses can result in damage to electrical systems. (00222a)

    NOTE:

    Automotive type ATO fuses are used for installation and replacement.

  6. Slide fuse block into holder until latch fully engages tab on holder.

  7. Place bottom of side cover with grommet in frame and press top of side cover into clips until snug.

Left Side Cover in Open Position
  1. Side cover mounting tab (on battery tray)
  2. Mounting slot (bottom of left side cover)
  3. Left side cover

Left Side Cover in Open Position

Fuse Block: Sportster Models
  1. Relay
  2. Accessories (15 amp.)
  3. Battery (15 amp.)
  4. Lamps (15 amp.)
  5. Ignition (15 amp.)
  6. Spare (15 amp.)
  7. Instruments (15 amp.)

Fuse Block: Sportster Models

Side Cover: Sportster Models
  1. Top mounting slots
  2. Bottom mounting slot

Side Cover: Sportster Models

Replacing the Maxi-Fuse


All Sportster models have a main fuse to protect the motorcycle wiring. This 30 amp maxi-fuse provides main battery power to the motorcycle. It is located in a rubber-coated fuse holder behind the motorcycle's left side cover.

  1. Grasp the fuse holder in one hand and the plastic body of the maxi-fuse in the other. Pull the maxi-fuse straight out of the fuse holder.

  2. Insert the prongs of the new maxi-fuse in the fuse holder slots. Push the maxi-fuse firmly down into the fuse holder.

  3. Grasp top corners of side cover. While rotating top of cover up towards motorcycle, gently pull cover up so that mounting slot slides up mounting tab.

  4. Line up top slots of side cover with mounting clips on motorcycle frame, aligning with front clip first. Press top of side cover into clips until snug.

Maxi-Fuse

Maxi-Fuse

Maxi-Fuse Replacement: Sportster Models

Maxi-Fuse Replacement: Sportster Models

Seat: Sportster Models


Removal


See Seat: Sportster Models. All Sportster models have a forward tab underneath the seat on the frame back.

  1. Remove screw to detach seat from rear fender.

  2. Push seat forward to release keyhole from post on frame.

  3. Lift up on seat to release tongue from frame.

  4. If applicable, inspect passenger strap for damage or excessive wear.

NOTE:

The passenger straps are secured to the seat.

Installation


  1. See Seat: Sportster Models. Slide seat forward until the tongue (1) fits snugly in frame.

  2. Push seat forward and press firmly in center until keyhole on underside of seat locks firmly to post on frame.

  3. en Warning

    After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b)

  4. Pull up on seat to verify that it is locked in place.

  5. Install screw and fasten seat mounting bracket to top of rear fender.

  6. Tighten mounting bracket screw.

  7. Pull up on seat again to verify that it is properly secured, in all three mounting points.

Seat: Sportster Models
  1. Connection point

Seat: Sportster Models

Motorcycle Storage


Placing Motorcycle in Storage


en Caution

Proper storage is important for the trouble-free operation of your motorcycle. See your Owner's Manual for storage recommendations or see a Harley-Davidson dealer. Improper storage procedures can lead to equipment damage. (00046a)

If the motorcycle will not be operated for several months, such as during the winter season, there are several tasks which should be performed. These steps will protect parts against corrosion, preserve the battery and prevent the build-up of gum and varnish in the fuel system.

en Warning

Do not store motorcycle with gasoline in tank within the home or garage where open flames, pilot lights, sparks or electric motors are present. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00003a)

NOTE:

Make a list of everything you do and fasten it to a handgrip. When you take the motorcycle out of storage, this list will be your reference/checklist to get your motorcycle in operating condition.

  1. Fill fuel tank and add a gasoline stabilizer. Use one of the commercially available gasoline stabilizers and follow the manufacturer's instructions.

  2. Warm motorcycle to operating temperature. Change oil and turn engine over to circulate the new oil.

  3. Adjust the belt.

  4. Check tire inflation. Adjust to proper inflation pressure.

  5. To protect the vehicle's body panels, engine, chassis and wheels from corrosion, follow the cosmetic care procedures described in the Accessory Maintenance section of this owner's manual prior to storage.

  6. Prepare battery for winter storage. See Battery: General.

  7. en Warning

    Explosive hydrogen gas, which escapes during charging, could cause death or serious injury. Charge battery in a well-ventilated area. Keep open flames, electrical sparks and smoking materials away from battery at all times. KEEP BATTERIES AWAY FROM CHILDREN. (00065a)

  8. If the motorcycle is to be stored with security system armed, it will be necessary to connect a Battery Tender to maintain battery charge. If security system will not be armed and a Battery Tender is not available, either:

    1. Disconnect negative battery cable.

    2. Remove Maxi-fuse (if applicable).

  9. If motorcycle is to be covered, use a material such as light canvas that will breathe. Plastic materials that do not breathe promote the formation of condensation.

Removing Motorcycle From Storage


en Warning

The clutch failing to disengage can cause loss of control, which could result in death or serious injury. Prior to starting after extended periods of storage, place transmission in gear and push vehicle back and forth several times to assure proper clutch disengagement. (00075a)

  1. See Battery: General for proper battery care. Charge and install the battery.

  2. Remove and inspect the spark plugs. Replace if necessary.

  3. Clean the air cleaner element.

  4. Start the engine and run until it reaches normal operating temperature. Turn off engine.

  5. Check amount of oil in the oil tank.

  6. Check the transmission lubricant level.

  7. Check controls to be sure they are operating properly. Operate the front and rear brakes, throttle, clutch and shifter.

  8. Check steering for smoothness by turning the handlebars through the full operating range.

  9. en Warning

    Be sure tires are properly inflated, balanced and have adequate tread. Inspect your tires regularly and see a Harley-Davidson dealer for replacements. Riding with excessively worn, unbalanced or under-inflated tires can adversely affect stability and handling, which could result in death or serious injury. (00014a)

  10. Check tire pressure. Incorrect pressure will result in poor riding characteristics and can affect handling and stability.

  11. Check all electrical equipment and switches including the stop lamp, turn signals and horn for proper operation.

  12. Check for any fuel, oil or brake fluid leaks.

en Caution

Turn engine over a few times to be sure there is no oil in the crankcase and that all oil has been pumped back into the oil tank. Stop engine and re-check oil level. Failure to do so can result in engine damage. (00071a)