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.

Break-in Maintenance


NOTE:

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

After a new motorcycle has been ridden its first 1000 mi 1600 km , it should be taken to an authorized Harley-Davidson dealer for initial service operations. Refer to Regular Service Intervals: 2011 Sportster Models.

Engine Lubrication


en Caution Mark

Prolonged or repeated contact with used motor oil may be harmful to skin and could cause skin cancer. Promptly wash affected areas with soap and water. (00358b)

en Caution Mark

If swallowed, do not induce vomiting. Contact a physician immediately. In case of contact with eyes, immediately flush with water. Contact a physician if irritation persists. (00357c)

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. Your authorized dealer has the proper oil to suit your requirements. Refer to Recommended Engine Oils.

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: CH-4, CI-4 and CJ-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

Screamin' Eagle SYN3 Synthetic Motorcycle Lubricant

SAE 20W50

HD 360

Above 40 °F 4 °C

Excellent

Screamin' Eagle Synthetic Blend Motorcycle Engine Oil

SAE 20W50

HD 360

Above 40 °F 4 °C

Good

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 and Adding Oil


Removing and Replacing Oil Filler Cap


  1. Park the motorcycle on level ground on the jiffy stand.

  2. See Filler Cap/Dipstick Location. Remove the filler cap from the oil tank.

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

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

  3. Wipe the dipstick clean.

  4. NOTE:

    See Filler Cap/Dipstick Slots. Insert the dipstick with the wide slot (1) and the narrow slot (2) matched to the wide tab and narrow tab inside the oil tank filler neck.

  5. Insert the dipstick into the tank.

    1. Turn the filler cap clockwise one-quarter turn as if screwing the filler cap into tank. When the filler cap stops turning, it is seated.

    2. Press down on the filler cap until it snaps in place, flush with the top of the oil tank cover.

Filler Cap/Dipstick Location

Filler Cap/Dipstick Location

Filler Cap/Dipstick Slots
  1. Wide slot
  2. Narrow slot

Filler Cap/Dipstick Slots

Oil Level Cold Check


NOTES:
  • Check engine oil level at each complete fuel refill.
  • An accurate engine oil check can only be made with the engine at operating temperature (Hot Check).
  1. Park the motorcycle on level ground on the jiffy stand.

  2. Remove the filler cap and wipe the dipstick clean. Install the oil filler cap in tank.

  3. Remove oil filler cap again and visually check for oil in the tank.

  4. If oil is not visible in the tank, install the filler cap.

NOTE:

If the oil pressure lamp stays lit after starting engine, immediately shut the engine off.

  1. Start and idle the engine for 30 seconds. Stop the engine.

  2. Remove oil filler cap and visually check for oil in the tank.

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)

NOTE:

Use only recommended oil. Recommended viscosity depends upon ambient temperature. Refer to Recommended Engine Oils.

  1. If there is no oil visible in the tank, add oil until it is present on the bottom of the dipstick.

  2. When oil is present on the bottom of the dipstick, perform a hot check.

Oil Level Hot Check


  1. Run the engine until the engine oil is at operating temperature.

  2. Idle the motorcycle on the jiffy stand for one to two minutes. Turn the engine off.

  3. Park the motorcycle on level ground on the jiffy stand.

  4. Remove the filler cap. Wipe the dipstick clean and install the filler cap in the tank.

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)

NOTES:
  • Use only recommended oil. Recommended viscosity depends upon ambient temperature. Refer to Recommended Engine Oils.
  • Do not overfill the oil tank. The oil tank has a built-in pressure relief valve. If the oil tank is overfilled, excessive pressure is created in the oil tank. The pressure relief valve will open to relieve the pressure and prevent damage to the oil tank. Excessive oil due to overfilling will also be forced out the pressure relief valve when it opens.
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. See Filler Cap/Dipstick. Remove the filler cap and check the hot oil level on the dipstick.

    1. Below the Lower Mark: Add only enough oil until the level reads between the upper and lower marks.

    2. Between the Upper and Lower Marks: It is safe to operate the motorcycle.

    3. At (or above) the Upper Mark: Drain the oil until the level reads between the upper and lower marks.

  2. Install the filler cap.

  3. If oil was added, remove the filler cap and verify the engine oil level in the oil tank. Do not fill oil tank to a level above upper mark on the dipstick. Install the filler cap.

Filler Cap/Dipstick
  1. Lower mark
  2. Upper mark (full)

Filler Cap/Dipstick

Changing Oil and Filter


en Caution

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

Refer to Regular Service Intervals: 2011 Sportster Models. Completely drain oil tank of used oil at scheduled service intervals. Refill with fresh oil.

NOTES:
  • Oil should be changed at specified intervals in normal service at warm or moderate temperatures. Refer to Regular Service Intervals: 2011 Sportster Models.
  • Oil change intervals should be more frequent in cold weather or severe operating conditions. See Winter Lubrication.
  • If vehicle is driven extremely hard, used in competition, or driven on dusty roads, change engine oil at shorter intervals.
  • Always change oil filter when changing engine oil.
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)

Draining Oil Tank


  1. Run engine until engine oil has reached normal operating temperature.

  2. Remove oil filler cap/dipstick from oil tank. Oil will drain faster when filler cap/dipstick is removed.

  3. See Oil Tank Drain Hose. Place a suitable container directly under the drain hose (1) at the bottom rear of the engine crankcase. The container must be able to hold approximately 3.0 qt 2.8 L .

  4. 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.

  5. Install drain plug into end of drain hose and tighten worm drive clamp securely.

Oil Tank Drain Hose
  1. Oil tank drain hose
  2. Worm drive clamp
  3. Drain plug

Oil Tank Drain Hose

Removing Oil Filter


  1. Place a drain pan beneath front of engine crankcase.

  2. en Caution

    Use Harley-Davidson oil filter wrench for filter removal. This tool can prevent damage to crankshaft position sensor and/or sensor cable. (00192b)

  3. See Oil Filter Wrenches and Oil Filter. Remove oil filter using HARLEY-DAVIDSON OIL FILTER WRENCH HD-42311 or HARLEY-DAVIDSON OIL FILTER WRENCH HD-44067-A . Turn oil filter counterclockwise to remove from filter mount.

  4. Drain oil filter into drain pan. Discard oil filter.

  5. Clean any oil spills off crankcase and frame.

NOTE:

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

Oil Filter Wrenches

Oil Filter Wrenches

Oil Filter
  1. Oil filter mount
  2. Oil filter

Oil Filter

Installing Oil Filter


NOTE:

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

  1. Pour about 4 fl oz 120 mL of fresh, clean engine oil into new oil filter. Allow time for oil to soak into filter element.

  2. 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.

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

  4. NOTE:

    Do not use oil filter wrench to install new oil filter.

  5. Install new oil filter. Screw filter clockwise onto adapter until gasket contacts the filter mount surface. Then hand tighten an additional 1/2-3/4-turn to secure the oil filter.

Refilling Oil Tank


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)

NOTE:

Do not overfill the oil tank. The oil tank has a built-in pressure relief valve. If the oil tank is overfilled, excessive pressure is created in the oil tank.The pressure relief valve will open to relieve the pressure and prevent damage to the oil tank. Excessive oil due to overfilling will also be forced out the pressure relief valve when it opens.

  1. Refer to Recommended Engine Oils. Always use the proper grade of oil for the lowest expected air temperature before the next regularly scheduled oil change. Pour 2.0 qt 1.9 L of oil into engine oil tank.

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

Applying Thin Oil Film

  1. Install filler cap/dipstick in oil tank. Make sure cap is fully seated.

  2. See Oil Pressure Indicator Lamp. Start engine. Verify that oil pressure signal lamp turns off when engine speed is 1000 rpm or above. Turn engine off.

  3. Check for oil leaks at oil filter and oil tank drain hose. Perform oil level hot check.

Oil Pressure Indicator Lamp

Oil Pressure Indicator Lamp

Winter Lubrication


In colder climates, the engine oil should be changed often. If motorcycle is used frequently for short trips, less than 15 mi 24 km , in ambient temperatures below 60 °F 16 °C , oil change intervals should be reduced to 1500 mi 2400 km . Motorcycles used only for short runs must have a thorough tank flush-out before new oil is put in. The tank flush-out should be performed by an authorized dealer or qualified technician.

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


Refer to Regular Service Intervals: 2011 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.

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)

Check Lubricant Level


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

  2. Position motorcycle straight up.

  3. en Warning

    To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)

  4. Remove main fuse. See Fuses and Relays.

  5. XL Models with Mid-Mount Foot Controls: See Mid-Mount Rider Footrest Assembly: XL Models. Remove screws and detach the rider footrest support bracket from the left side of the vehicle.

  6. XR 1200X: See Rider Footrest Assembly (Left Side): XR 1200X. Remove screws and detach the rider footrest support bracket from the left side of the vehicle. With the shift linkage still attached, lower the footrest assembly to access the clutch inspection cover screws.

  7. See Primary Cover: XL Model. Remove screws with washers from clutch inspection cover. Remove clutch inspection cover from primary cover.

  8. NOTE:

    The filler access is the clutch inspection cover.

  9. See Chaincase Lubricant Level. Verify that lubricant level is even with bottom of clutch diaphragm spring.

  10. 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.

  11. Install new quad ring. Verify that quad ring is fully seated in groove of primary cover. Install clutch inspection cover and secure with six screws. Tighten screws in a crosswise pattern to 90-120 in-lbs (10.2-13.6 Nm).

  12. If the left footrest assembly was removed, install support bracket with two screws. Tighten screws to 45-50 ft-lbs (61.0-67.8 Nm).

  13. Install main fuse.

  14. Start engine. Check for any lubricant leaks.

  15. Turn engine off.

Primary Cover: XL Model
  1. Clutch inspection cover
  2. Drain plug
  3. Primary chain inspection cover

Primary Cover: XL Model

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

Chaincase Lubricant Level

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. en Warning

    To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)

  4. Remove main fuse. See Fuses and Relays.

  5. See Primary Cover: XL Model. Position a suitable container under transmission drain plug (2).

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

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

  8. NOTE:

    Dispose of lubricant in accordance with local regulations.

    en Caution

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

  9. Remove foreign material from magnetic drain plug. Replace the O-ring if it is damaged.

  10. Apply LOCTITE 565 THREAD SEALANT (Part No. 99818-97) and install drain plug. Tighten to 14-30 ft-lbs (19.0-40.7 Nm).

  11. See Mid-Mount Rider Footrest Assembly: XL Models. For XL models equipped with mid-mount foot controls, remove screws and detach the rider footrest support bracket from the left side of the vehicle.

  12. See Rider Footrest Assembly (Left Side): XR 1200X. For the XR 1200X, remove screws and detach the rider footrest support bracket from the left side of the vehicle. With the shift linkage still attached, lower the footrest assembly to access the clutch inspection cover screws.

  13. See Primary Cover: XL Model. Remove screws with washers from clutch inspection cover. Remove clutch inspection cover from primary cover.

  14. NOTE:

    The filler access is the clutch inspection cover.

  15. See Chaincase Lubricant Level. Add 1.00 U.S. qt 0.95 L of GENUINE Harley-Davidson FORMULA+ TRANSMISSION AND PRIMARY CHAINCASE LUBRICANT (Part No. 98851-05 qt) through clutch inspection cover opening until the lubricant reaches the bottom of clutch diaphragm spring.

  16. Install new quad ring. Verify that quad ring is fully seated in groove of primary cover. Install clutch inspection cover and secure with six screws. Tighten screws in a crosswise pattern to 90-120 in-lbs (10.2-13.6 Nm).

  17. If the left footrest assembly was removed, install support bracket with two screws. Tighten screws to 45-50 ft-lbs (61.0-67.8 Nm).

  18. Install main fuse.

  19. Start engine. Check for any lubricant leaks.

  20. Turn engine off.

Mid-Mount Rider Footrest Assembly: XL Models
  1. Support bracket
  2. Screws (2)

Mid-Mount Rider Footrest Assembly: XL Models

Rider Footrest Assembly (Left Side): XR 1200X
  1. Rider footrest support bracket
  2. Screws (2)
  3. Shift linkage

Rider Footrest Assembly (Left Side): XR 1200X

Primary Chain Adjustment


General


Refer to Regular Service Intervals: 2011 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 Freeplay Specifications

ENGINE

in

mm

Cold

3/8-1/2

9.5-12.7

Hot

1/4-3/8

6.3-9.5



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

Primary Chain Vertical Free Play: Sportster Models

Primary Chain Inspection


The primary chain can be inspected and if required, adjusted without removing the primary cover.

en Warning

To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)

  1. Remove main fuse. See Fuses and Relays.

  2. See Primary Cover: XL Model. Remove the two hex socket screws which secure primary chain inspection cover (3).

  3. See Primary Chain Vertical Free Play: Sportster Models. Check primary chain tension by measuring vertical free play.

    1. Measure vertical free play through chain inspection cover opening.

    2. Rotate engine to move primary chain to a different position on sprockets.

    3. Measure vertical free play several times, each time with primary chain moved so that the measurement is taken with sprockets rotated to the tightest chain position.

  4. The tightest measurement in previous step must be within the specifications listed in Primary Chain Freeplay Specifications. If necessary, see PRIMARY CHAIN ADJUSTMENT to adjust chain tension.

Primary Chain Adjustment


en Caution

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

  1. See Primary Chain Adjuster: Sportster Models. Loosen locknut (1).

  2. Turn chain adjuster screw (2) clockwise (inward) to reduce free play or counterclockwise (outward) to increase free play. Vertical free play must fall within the limits specified. Refer to Primary Chain Freeplay Specifications.

  3. NOTE:

    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.

  4. When tension is set correctly, hold chain adjusting screw and tighten locknut to 20-25 ft-lbs (27-34 Nm).

  5. Install primary chain inspection cover and new gasket. Tighten hex socket screws to 90-120 in-lbs (10.2-13.6 Nm).

  6. Install main fuse.

Primary Chain Adjuster: Sportster Models
  1. Locknut
  2. Chain adjuster screw
  3. Transmission chaincase drain plug

Primary Chain Adjuster: Sportster Models

Checking Drive Belt Deflection


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.

Gauging Deflection


Check belt deflection at the loosest spot in the belt with the transmission in neutral and the motorcycle at ambient temperature.

  1. With the motorcycle unladen and resting on its jiffy stand, fit the BELT TENSION GAUGE HD-35381A on the belt.

    1. XL Models: See Gauging Belt Deflection: XL Models. Position the gauge half-way between the transmission and rear wheel sprockets.

    2. XR 1200X: See Gauging Belt Deflection: XR 1200X. Fit the tension gauge half-way between the idler wheel and rear sprocket.

  2. With the BELT TENSION GAUGE set to 0 lb 0 kg , note the current belt position.

    1. XL Models: See Belt Deflection Window: XL Models. Note the belt position according to the graduations on the belt deflection window located on the drive belt guard.

    2. XR 1200X: See Belt Deflection: XR 1200X. Note the belt position according to the graduations on the front of the debris deflector.

  3. Using the BELT TENSION GAUGE, apply 10 lb 4.5 kg of force to 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 to determine the deflection.

  4. Compare the deflection to specifications. Refer to Belt Deflection.

  5. If belt tension adjustment is necessary, see a Harley-Davidson dealer or follow the belt deflection adjustment procedure in the 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)

NOTE:

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

Belt Deflection

MODELS

in

mm

XL 883R

9/16-5/8

14.3-15.9

Other XL models

1/4-5/16

6.4-7.9

XR 1200X

1/4-3/8

6.4-9.5



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

Gauging Belt Deflection: XL Models

Gauging Belt Deflection: XR 1200X
  1. Transmission sprocket
  2. Rear wheel sprocket
  3. Force of 10 lb (4.5 kg)
  4. Deflection (refer to table)
  5. Idler wheel

Gauging Belt Deflection: XR 1200X

Belt Deflection Window: XL Models
  1. Drive belt
  2. Deflection graduations 1/8 in (3.2 mm) apart

Belt Deflection Window: XL Models

Belt Deflection: XR 1200X
  1. Drive belt
  2. Deflection graduations 1/8 in (3.2 mm) apart

Belt Deflection: XR 1200X

Chassis Lubrication


Refer to Regular Service Intervals: 2011 Sportster Models for all maintenance schedules.

NOTE:

Use recommended Special Purpose Grease (Part No. 99857-97) for steering head bearings. Use a multipurpose chassis grease for other applications.

  1. Remove and lubricate handlebar throttle control grip sleeve with fresh graphite.

  2. Lubricate throttle control cables and clutch control cable.

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

  4. Inspect rear fork pivot shaft bearings.

  5. Pack the steering head bearings with Special Purpose Grease (Part No. 99857-97) at the recommended service interval of 30,000 mi 48,000 km .

  6. Lubricate the jiffy stand mechanism with SILVER GRADE ANTI-SEIZE (Part No. 98960-97).

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: 2011 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: 2011 Sportster Models. Have a Harley-Davidson dealer drain the 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.

Clutch


en Caution

The clutch control cable must be oiled and adjusted periodically to compensate for lining wear. See MAINTENANCE SCHEDULING in this manual. Failure to oil and adjust the clutch control cable can result in equipment damage. (00203b)

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 engine oil level first since normal circulation of oil through the engine is necessary for proper operation of the hydraulic lifters.

If engine oil is at the proper level, the lifters 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.

Steering Head Bearings


en Warning

Adjustments to steering head 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. (00051b)

Check for proper steering head bearing adjustment and lubricate bearings at proper intervals. Refer to Regular Service Intervals: 2011 Sportster Models.

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: 2011 Sportster Models. Check the tightness of the rear fork pivot shaft fastener and lubricate bearing and bushing at proper intervals.

NOTE:

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

Brakes


Brake Fluid


en Caution

D.O.T. 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239b)

en Caution Mark

Direct contact of D.O.T. 4 brake fluid with eyes can cause irritation. 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. 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00240a)

en Caution

Do not allow dirt or debris to enter the master cylinder reservoir. Dirt or debris in the reservoir can cause improper operation and equipment damage. (00205c)

  1. See Front Brake Fluid Sight Gauge and Rear Reservoir Level Guage. Look through the sight glass on the front brake fluid reservoir and at the marks on the side of the rear brake fluid reservoir to check the brake fluid level. If necessary, shine a flashlight on the rear brake fluid reservoir to view the level.

  • The level in the sight glass or reservoir is the brake fluid level.
  • If the fluid level is below the minimum mark or not present, see a Harley-Davidson dealer.
NOTES:
  • If the brake system is not leaking, there should never be a need to add fluid. If the fluid level is low, the pads are probably worn and need to be replaced. By replacing the pads, the fluid level will rise.
  • Use only DOT 4 HYDRAULIC BRAKE FLUID (Part No. 99953-99A) and replace the brake fluid every two years. See a Harley-Davidson dealer.
  1. Verify that the front brake lever and the rear brake pedal have a firm feel when applied. If brakes are not firm, the brake system must be bled. See a Harley-Davidson dealer.

Front Brake Fluid Sight Gauge and Rear Reservoir Level Guage
  1. Front reservoir fluid level
  2. Rear reservoir fluid level

Front Brake Fluid Sight Gauge and Rear Reservoir Level Guage

Brake Pads


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)

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)

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)

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)

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

  1. Check the rear brake disc as it spins. The disc should run true in the brake caliper.

  2. See Brake Friction Material. Using a thin plastic ruler, measure the thickness of the brake pad friction material. For rear brakes, place the ruler against the brake disc through the space alongside the caliper.

  1. If the brake pad friction material is at the minimum thickness or less, replace the pads. Always replace brake pads in pairs. See a Harley-Davidson dealer. Refer to Minimum Brake Pad Friction Material Thickness.

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)

Minimum Brake Pad Friction Material Thickness

in

mm

0.040

1.02



Brake Friction Material
  1. Front brake, viewed from below
  2. Rear brake, viewed from above

Brake Friction Material

Tires


  • 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, rim seals, 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. (00023b)

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 Harley-Davidson approved replacement tires. (00090b)

Indicators on the tire sidewalls point to tread wear bars in the tread.

See Wear Bar Location (typical). Tread wear indicator bars appear in the tread pattern when 1/32 in 0.8 mm or less of tread remains. Always replace the tires before the indicator bars appear.

Replace Tires


Replace worn tires with new tires if any of the following conditions exist:

  1. Tread wear indicator bars appear in the tread pattern.

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

  3. A bump, bulge or split is found anywhere on the tire.

  4. The tire is damaged by a puncture, cut or other damage that cannot be repaired.

Tread Wear Indicator: Michelin Tires

Tread Wear Indicator: Michelin Tires

Tread Wear Indicator: Dunlop Tires

Tread Wear Indicator: Dunlop Tires

Wear Bar Location (typical)

Wear Bar Location (typical)

Shock Absorbers


Inspect shock absorbers and rubber bushings for leaks and bushing deterioration at proper intervals.

XR 1200X Model


XR 1200X shock absorbers contain pressurized gas. Visually inspect the shock absorbers while observing the following precautions.

en Warning

Shock absorber cannot be serviced. Attempting service can cause an explosion, which could result in death or serious injury. (00602d)

  • Do not refill, disassemble, puncture or expose shock to flames.
  • Replacement and disposal should only be done by an authorized Harley-Davidson dealer.

Spark Plugs


en Warning

Disconnecting spark plug cable with engine running can result in electric shock and death or serious injury. (00464b)

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)

Check the spark plugs at proper intervals. Refer to Regular Service Intervals: 2011 Sportster Models.

  1. Disconnect spark plug cables from plugs by pulling up on the molded connector caps.

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

  3. Check spark plug gap against specifications table.

  4. NOTE:

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

  5. Always tighten to the proper torque. Spark plugs must be tightened to the torque specified for proper heat transfer. Refer to Electrical: XL Models or Electrical: XR 1200X.

  6. Connect each molded connector cap until the cap snaps firmly into place over the spark plug.

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.

Air Cleaner


XR 1200X


For XR 1200X, remove all debris from the air cleaner cover inlet. See a Harley-Davidson dealer or Service Manual at specified intervals for filter element inspection or replacement. Under dusty conditions, inspect more often. Refer to Regular Service Intervals: 2011 Sportster Models.

XL Models


For XL models, remove air cleaner cover and inspect filter element at proper intervals. Under dusty conditions, inspect more often. Refer to Regular Service Intervals: 2011 Sportster Models.

See Air Cleaner Assembly: Sportster XL Models. The paper/wire mesh air filter element should be washed in luke warm water with a mild detergent.

Install baseplate gasket, air filter element, and bracket if removed. Apply a drop of LOCTITE THREADLOCKER 243 (blue) to the threads of the bracket screws and tighten to 40-60 in-lbs (4.5-6.8 Nm).

Install air cleaner cover. Tighten screw to 36-60 in-lbs (4.1-6.8 Nm).

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 XL Models
  1. Screw
  2. Cover
  3. Filter element
  4. Gasket

Air Cleaner Assembly: Sportster XL Models

Headlamp Bulb Replacement


Removal


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 Warning

To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)

  1. Remove main fuse. See Fuses and Relays.

  2. See Headlamp Assembly. Remove screw and headlamp trim ring. Refer to Legend Headlamp Assembly.

  3. Hold headlamp reflector/lens and compress release tabs on sides of bulb connector to pull connector from spade terminals.

  4. Remove headlamp reflector/lens and metal adapter ring.

  5. Pull rubber boot from back of reflector/lens.

  6. Press ends of retaining clip to unhook from notched retaining tabs and pivot retaining clip back.

Installation


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)

en Caution

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

  1. Install replacement bulb.

  2. NOTE:

    The tab opposite the center spade connector of bulb fits the top notch in the reflector which points to the top of the reflector/lens.

  3. Pivot the retaining clip over the bulb and press the ends into the retaining post.

  4. On HDI models, replace the position lamp if necessary.

    1. Pull the spade connectors from the bulb holder.

    2. Pull the bulb holder from the reflector/lens.

    3. Quarter turn the bulb to remove and replace.

    4. Replace the bulb holder and mate connectors.

  5. Install rubber boot with word TOP over top notch.

  6. Press center ring down flush with base of bulb. Press air out of boot to seal bore of boot to bulb.

  7. NOTE:

    Air will enter the rubber boot and raise the center ring above bottom of bulb.

  8. Mate the bulb connector to the bulb.

  9. Fit the adapter ring and the reflector/lens to the headlamp shell.

  10. NOTES:
    • The two notches on the circumference of the adapter ring will fit the two bulges on rim of headlamp shell.
    • A single tab on the circumference of the reflector will fit the notch on the inside of the adapter ring.
  11. Rotate the trim ring clockwise to lock down on the reflector/lens. Install the trim ring screw and tighten.

  12. Install main fuse.

  13. en Warning

    Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury. (00316a)

  14. Turn ignition on and test for proper operation.

  15. After final assembly, align headlamp as described in Headlamp Alignment.

Headlamp Assembly

Headlamp Assembly

Legend Headlamp Assembly

LEGEND NO.

COMPONENT

1

Screw

2

Nut

3

Trim ring

4

Lens

5

Bulb shield

6

Position lamp (HDI models)

7

Wire clip

8

Bulb

9

Rubber boot

10

Adapter ring

11

Connector [5]

12

Position lamp connectors

HDI models



Headlamp Alignment


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)

NOTE:

Vehicles with multiple beam headlamps that are individually aimed should be adjusted so both lamps converge into one pattern.

  1. Verify that front and rear tire inflation pressures are correct and that suspension is adjusted to the weight of the principal rider. See Specifications.

  2. Fill fuel tank or add ballast to equal the weight of the fuel needed.

  3. NOTE:

    See Headlamp Alignment: Sportster Models. To aid in properly placing the motorcycle, a perpendicular line (1) can be drawn on the floor. For best results, choose an area with minimum light.

  4. Draw a vertical line (2) on the wall.

  5. Position motorcycle so that front axle is 25 ft 7.6 m from wall.

  6. NOTE:

    As the weight of the rider will compress the suspension slightly, have a person whose weight is approximately the same as that of the principal rider sit on the motorcycle.

  7. With the vehicle laden and upright, point the front wheel straight forward at wall and measure the distance (4) from the floor to the center of the HIGH BEAM bulb.

  8. Draw a horizontal line (5) through the vertical line on the wall that is 2.1 in 53.3 mm lower than the measured bulb centerline.

  1. Verify headlamp alignment. With the motorcycle on, set the headlamp switch to HIGH beam.

    1. The center of the hot spot (brightest area of light beam) should be centered where the two lines intersect.

    2. Adjust headlamp alignment if necessary.

Headlamp Alignment: Sportster Models
  1. Perpendicular line
  2. Vertical line
  3. 25 feet (7.6 meters)
  4. High beam bulb centerline
  5. Horizontal line 2.1 in (53.3 mm) lower than bulb centerline

Headlamp Alignment: Sportster Models

Headlamp Adjustment


Adjustment: XL 1200X/C/CP


  1. Set horizontal adjustment:

    1. See Headlamp Adjustment: XL 1200X/C/CP. Loosen the horizontal adjustment screw (3).

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

    3. Tighten the horizontal adjustment screw to 30-35 ft-lbs (40.7-47.5 Nm).

  2. Set vertical adjustment:

    1. See Headlamp Adjustment: XL 1200X/C/CP. 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 1200X/C/CP
  1. Locknut
  2. Vertical adjustment bolt
  3. Horizontal adjustment screw

Headlamp Adjustment: XL 1200X/C/CP

Adjustment: All Models except XL 1200X/C/CP


  1. See Headlamp Adjustment: Except XL 1200X/C/CP. Remove snap plug (1) on top of headlamp bracket (2).

  2. Loosen headlamp clamp nut (3).

  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 Adjustment: Except XL 1200X/C/CP
  1. Snap plug
  2. Headlamp bracket
  3. Clamp nut

Headlamp Adjustment: Except XL 1200X/C/CP

LED Rear Turn Signal/Tail Lamps: XL 883N, XL 1200N and XL 1200X Models


On International and Japanese models, the rear turn signal/tail lamps are LED assemblies with no replaceable bulbs. Caps on rear turn signals are not removable. See dealer or service manual for assembly replacement.

Due to local regulations, this feature may not be found in all destinations.

Turn Signal Bulb Replacement: Bullet Style


  1. See Lens Cap Notch. Insert a coin or the blade of a small screwdriver into the notch at the bottom of the lens cap. Carefully twist until the lens cap pops out of the lamp housing.

  2. Push bulb in and rotate counterclockwise. Pull bulb from socket.

  3. Inspect condition of electrical contacts in socket. If necessary, clean with a small wire brush and electrical contact cleaner.

  4. Coat base of new bulb with ELECTRICAL CONTACT LUBRICANT (Part No. 99861-02).

  5. Align pins on bulb with pin guides in bulb socket. Push new bulb in and turn clockwise to lock in place.

  6. Snap lens cap back into the lamp holder. Rotate lens to position notch at bottom of lamp.

  7. en Warning

    Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury. (00316a)

  8. Turn ignition on and test for proper operation.

Lens Cap Notch

Lens Cap Notch

Tail Lamp Bulb Replacement


Standard Style


  1. See Tail Lamp Assembly. Make certain ignition switch is turned off.

  2. Remove two screws and lens from base.

  3. NOTE:

    For ease of bulb removal, the 4-Pin multilock connector can be removed from circuit board.

  4. Remove (pull) bulb assembly from lens. Remove bulb from socket.

  5. Coat base of new bulb with ELECTRICAL CONTACT GREASE (Part No. 99861-02). Install new bulb in socket.

  6. Install (push) bulb assembly to lens.

  7. If removed connect 4-Pin multilock connector to circuit board.

  8. Install lens to base with two screws. Tighten screws to 20-24 in-lbs (2.3-2.7 Nm).

  9. en Warning

    Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury. (00316a)

  10. Turn ignition on and test for proper tail lamp operation.

Tail Lamp Assembly
  1. Lens
  2. Base
  3. 4-pin multilock connector
  4. Bulb socket

Tail Lamp Assembly

LED Style


XL 1200C/CP tail and stop lamp is illuminated with LED's. Replace the entire assembly upon failure. See the service manual or see a Harley-Davidson dealer.

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

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.

Left Side Cover


The left side cover provides access to the main fuse holder, battery and fuse/relay block. No tools are required to remove or install the side cover.

Opening


NOTES:
  • The left side cover does not need to be completely removed from the vehicle to access the battery or fuses.
  • Place a shop cloth or other clean, dry cloth over rear brake master cylinder reservoir and left passenger foot peg (if applicable). This will protect cover from damage.
  1. See Left Side Cover (XL model shown). Grasp left side cover at upper corners and gently pull away from frame. On XL models, disengage the rear clip first for easier opening.

  2. While rotating top of cover out away from motorcycle, slide cover down slightly so mounting slot slides down from mounting tab on battery tray.

Closing


  1. Raise the left side cover.

  2. On XL models, align the barrel clips on the cover with the socket clips on the frame. Press the cover to secure.

  3. On the XR 1200X, align the locating pins with the grommets on the frame. Press the cover to secure.

Left Side Cover (XL model shown)
  1. Barrel clips on cover
  2. Socket clips on frame

Left Side Cover (XL model shown)

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. (00019e)

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

Battery Warning Label

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 12.6 V, 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.

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

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

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

  5. 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.

  6. 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. Place the battery on a level surface.

  3. 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 in 12 Amp-Hour Battery Charging Rates/Times (Approximate) show typical charging times. Charge times may vary. When using automatic chargers, allow the charger to determine when charging is complete.
    • Do not use chargers with excessively high voltage designed for flooded batteries or excessively high current designed for much larger batteries. Charging should be limited to no more than 5 amps at no more than 14.6 volts.
  4. Connect the red battery charger lead to positive (+) terminal of the battery.

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

  6. 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.

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

  8. 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)

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

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

  11. Mark the charging date on the battery.

12 Amp-Hour Battery Charging Rates/Times (Approximate)

READING

(VOLTS)

PERCENT

OF CHARGE

5 AMP

CHARGER

2 AMP

CHARGER

1.5 AMP

CHARGER

0.75 AMP

CHARGER

12.7

100

-

-

-

-

12.6

75

1 hour 36 minutes

2 hours 30 minutes

3 hours

5 hours

12.3

50

2 hours 12 minutes

4 hours

5 hours

9 hours

12.0

25

2 hours 48 minutes

5 hours 30 minutes

7 hours

13 hours

11.8

0

3 hours 24 minutes

7 hours

9 hours

17 hours



Storage


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.

A battery that is removed from the vehicle is affected by self-discharge. A battery that is stored in the vehicle is affected by both self-discharge and, more significantly, parasitic loads. Parasitic loads occur from things like diode leakage and maintaining computer memory with the vehicle off.

  • Batteries self-discharge at a faster rate at higher ambient temperatures.
  • To reduce the self-discharge rate, store battery in a cool, dry place.
  • Charge the battery once per month if stored in the vehicle.
  • Charge the battery every three months if stored out of the vehicle.
Effective Rate of Temperature on Battery Self-discharging Rate
  1. Capacity
  2. Months of non-use
  3. Measured at 105 °F (40 °C)
  4. Measured at 77 °F (25 °C)

Effective Rate of Temperature on Battery Self-discharging Rate

Battery 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. Open left side cover.

  2. NOTE:

    If vehicle is equipped with optional security siren, verify that fob is present and turn ignition key to IGNITION before removing main fuse or disconnecting battery.

  3. See Negative (-) Battery Connection. Using a swivel socket (2), remove nut that secures the negative (-) battery cable (1) connector to ground stud (4) on crankcase boss behind starter motor assembly (3). Remove cable connector from stud.

  4. See Negative (-) Battery Cable Holder. Pull end of negative (-) cable (2) forward gently to free it from cable holder (1).

  5. See Main Fuse and Battery Location: All Models. Press main fuse holder (1) toward the rear of the motorcycle until it pops off its mounting pin on battery strap (4). Remove main fuse holder from battery strap.

  6. Press data link connector (6) toward the rear of the motorcycle until it pops off its mounting pin on battery strap. Remove the connector from battery strap.

  7. Remove battery strap screw (5). Unhook battery strap from battery tray mount on top of battery and remove strap.

  8. Lift up protective rubber boot covering battery positive (+) terminal (3). Remove screw from battery positive (+) terminal and remove positive (+) battery cable.

  9. Disconnect positive (+) battery cable from cable holder (2).

  10. Slide the battery (with attached negative cable) out from the left side of the vehicle until the negative battery cable is accessible.

  11. Disconnect the negative battery cable at the battery (-) terminal. Leave the cable on the vehicle.

  12. Remove battery from battery tray. Note routing of negative (-) battery cable around frame downtube.

  13. If battery is to be left out of vehicle (i.e. winter storage), close left side cover.

Negative (-) Battery Connection
  1. Negative (-) battery cable
  2. Swivel socket
  3. Starter motor assembly
  4. Ground stud

Negative (-) Battery Connection

Negative (-) Battery Cable Holder
  1. Cable holder
  2. Negative battery cable

Negative (-) Battery Cable Holder

Main Fuse and Battery Location: All Models
  1. Main fuse and holder
  2. Positive (+) battery cable holder
  3. Positive (+) battery terminal (under protective rubber boot)
  4. Battery strap
  5. Screw
  6. Data link connector

Main Fuse and Battery Location: All Models

Battery 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)

  1. Open left side cover.

  2. Apply a light coat of petroleum jelly or corrosion retardant material to the negative (-) battery terminal.

  3. Slide fully charged battery into battery tray.

  4. Insert screw through negative (-) battery cable and into negative (-) battery terminal. Thread screw into terminal. Tighten screw to 60-70 in-lbs (6.8-7.9 Nm).

  5. Verify that the negative (-) battery cable is disconnected from the ground stud on crankcase,

  6. Hook top of battery strap (4) to battery tray mount on top of battery. Install strap screw (5). Tighten to 36-60 in-lbs (4.1-6.8 Nm).

  7. Route main positive (+) battery cable through holders on electrical bracket.

  8. Hook main fuse holder (1) to top pin on battery strap and slide forward until it snaps into place.

  9. Hook data link connector (6) to bottom pin on battery strap and slide forward until it snaps into place.

  10. See Negative (-) Battery Cable Holder. Press negative (-) battery cable (2) into cable holder (1).

  11. 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)

  12. See Main Fuse and Battery Location: All Models. With negative (-) battery cable disconnected from grounding point on crankcase, insert screw through positive (+) battery cables: through main fuse cable first, then through main positive (+) battery cable, and into positive (+) battery terminal (3). Thread screw into terminal. Tighten to 60-70 in-lbs (6.8-7.9 Nm).

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

  14. See Negative (-) Battery Connection. Place negative (-) battery cable connector onto ground stud (4) on crankcase boss behind starter motor assembly (3). Thread nut onto stud.

  15. See Attaching Negative (-) Battery Cable to Ground Stud Crankcase: XL Models or Attaching Negative (-) Battery Cable to Ground Stud Crankcase: XR 1200X. Press negative (-) battery cable connector (1) against cable stop (2) on crankcase and tighten nut (3) to 55-75 in-lbs (6.2-8.5 Nm).

  16. Close left side cover.

Attaching Negative (-) Battery Cable to Ground Stud Crankcase: XL
        Models
  1. Negative battery cable connector
  2. Cable stop
  3. Nut

Attaching Negative (-) Battery Cable to Ground Stud Crankcase: XL Models

Attaching Negative (-) Battery Cable to Ground Stud Crankcase: XR
        1200X
  1. Negative battery cable connector
  2. Cable stop
  3. Nut

Attaching Negative (-) Battery Cable to Ground Stud Crankcase: XR 1200X

Jump Starting


Jump starting a motorcycle is typically not recommended. However, there may be circumstances when it is necessary to do so. If a jump-start is necessary, use the following procedure.

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

Be sure both vehicles have the same battery voltage when jump starting. Connecting vehicles with different system voltages can result in vehicle damage. (00220c)

NOTES:
  • This procedure presumes the BOOSTER battery is in another vehicle. DO NOT jump start from a running booster vehicle. The high output charging systems on some vehicles can damage the electrical components on the motorcycle.
  • Make sure the motorcycle and the BOOSTER vehicle are not touching one another.
  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

Fuses and Relays


Fuse Replacement


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)

See Fuse Block. The fuse block is located behind the left side cover.

If replacing a fuse does not correct the problem, or if a fuse is repeatedly blown, see a Harley-Davidson dealer to diagnose any possible electrical problems.

  1. Turn the ignition to the OFF position.

  2. Open left side cover. See Left Side Cover.

  3. See Fuse Block. Push tab to release the fuse block cover.

  4. See Relay and Fuse Locations. Remove the suspect fuse and inspect the element.

  5. If the element is burned or separated, replace the fuse with a properly rated automotive type ATO fuse.

  6. Align fuse block cover with retaining guide. Slide the fuse block cover until tab latches.

  7. Close left side cover.

Main Fuse


See Removing/Installing Main Fuse. The 30 amp main fuse can be removed to disconnect power from the motorcycle's entire electrical system (except starter motor/solenoid). The main fuse is located behind the left side cover.

To prevent the security system siren from sounding (if equipped), turn the ignition switch ON with the hands-free fob present to disarm the security system before removing the main fuse.

To remove, grasp the fuse holder in one hand and the plastic body of the main fuse in the other. Pull the main fuse straight out of the fuse holder.

Fuse Block
  1. Fuse block cover
  2. Tab
  3. Retaining guide
  4. Main fuse

Fuse Block

Relay and Fuse Locations
  1. System relay
  2. Starter relay
  3. Ignition
  4. Lights
  5. Accessory
  6. ECM
  7. Battery
  8. Spare

Relay and Fuse Locations

Removing/Installing Main Fuse
  1. Main fuse
  2. Fuse holder [5]

Removing/Installing Main Fuse

Seat Removal: XL Models


  1. See Seat Assembly: Sportster XL Models. Remove screw (1) to detach seat from rear fender.

  2. Slide seat forward and lift up slightly to detach keyhole bracket from seat post. Then slide seat rearward to detach seat tongue from rear fuel tank bracket.

  3. NOTES:
  4. Verify that tongue (1) and mounting bracket (3) are tightly secured to the seat bottom.

  5. If two-up seat, inspect passenger strap (4) for damage or excessive wear.

NOTE:

The passenger strap is not sold separately. If it is damaged, excessively worn or otherwise unusable, the entire seat assembly must be replaced.

Seat: XL Solo
  1. Tongue
  2. Keyhole
  3. Mounting bracket

Seat: XL Solo

Seat: XL Two-Up
  1. Tongue
  2. Keyhole
  3. Mounting bracket
  4. Passenger strap

Seat: XL Two-Up

Seat Post: XL Models

Seat Post: XL Models

Seat Installation: XL Models


  1. Position seat on frame with mounting bracket at rear.

  2. Slide seat forward until the tongue fits snugly under rear fuel tank bracket.

  3. Push seat forward, engage keyhole onto seat post, then pull seat back slightly.

  4. See Seat Assembly: Sportster XL Models. Install seat mounting screw with captive washer (1) to fasten seat mounting bracket to top of rear fender. Mounting bracket of solo seat uses forward hole in rear fender; dual seat uses rearward hole.

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

  6. Tighten seat mounting screw to 20-40 in-lbs (2.3-4.5 Nm).

  7. 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)

  8. Pull up on seat again to verify that it is properly secured at all three points.

Seat Assembly: Sportster XL Models
  1. Seat mounting screw with captive washer
  2. Seat assembly, two-up (typical)
  3. Seat assembly, solo (typical)
  4. Passenger strap (not sold separately)

Seat Assembly: Sportster XL Models

Seat Removal: XR 1200X


  1. See Front Seat Tabs (under tail section): XR 1200X. Reach under front end of tail section and press the two seat tabs inward.

  2. Pull front of seat upward to disengage seat from the front end of the tail section.

  3. Pull seat forward over fuel tank.

NOTES:
  • When removing the seat, verify that the mounting bracket under the seat is tightly secured to the seat bottom and that no rivets are loose or missing. Inspect passenger strap for damage or excessive wear.
  • The passenger strap is not sold separately. If it is damaged, excessively worn, or otherwise unusable, the entire seat must be replaced.
Front Seat Tabs (under tail section): XR 1200X

Front Seat Tabs (under tail section): XR 1200X

Seat Installation: XR 1200X


  1. See Seat and Pillion: XR 1200X. Place rear of seat into tail section, aligning the guides in the seat bracket with the two seat posts.

  2. Push down on front of seat until the two tabs engage the front end of tail section.

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)

Seat and Pillion: XR 1200X
  1. Seat
  2. Seat tabs
  3. Seat posts
  4. Passenger pillion
  5. Pillion tabs
  6. Pillion seat post

Seat and Pillion: XR 1200X

Passenger Pillion: XR 1200X


Removal


  1. See Passenger Pillion: XR 1200X. Lift the rear of pillion to disengage grommet from the seat post.

  2. Pull pillion out from tail section.

Installation


  1. See Passenger Pillion: XR 1200X. Insert pillion into trunk, aligning tabs on pillion with the slots in the trunk.

  2. Push down firmly on rear of pillion until grommet fully engages the seat post.

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)

Passenger Pillion: XR 1200X
  1. Pillion
  2. Tabs
  3. Seat post

Passenger Pillion: XR 1200X

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. Check and adjust belt if necessary.

  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 Care and Cleaning 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)

    NOTE:
    • If the motorcycle will be stored with the security system armed, connect a 750Ma SUPERSMART BATTERY TENDER 94654-98B to maintain battery charge.
    • If the motorcycle will be stored with the security system disarmed, turn the motorcycle on while the hands-free fob is present. This will prevent the optional siren from sounding. Disconnect the negative battery cable and prepare battery for storage. See Battery: General.
  8. 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. Do not bend or tuck antennas under the cover. Either remove the antennas (if equipped) or allow them to protrude through the cover.

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)