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Operation Refer to Safety in Chapter One prior to working on the The carburetor atomizes fuel, and mixes it in correct pro Manuao the following components on the countershaft in the following order: On high-mileage motorcycles, the starter pinion gear A, Figure 8 can jam on a worn clutch ring gear B.

Disassemble and remove the gearcase as described in this chapter.

Remove the plug on top of the headlight bracket Fig- ft. Clutch cable models 13A. Remove the top center engine mount B, Figure 29 and shim harpey used. Make sure that each pushrod is seated in the top of its respective tappet.

The drum shift shaft and countershaft should enter their respective crankcase bearings. Loosen and reposition the cable lubricator. Disconnect the butter- bles 1 and Table 2 are at the end of davidon chapter. Oil pump drive gear models 3A. Replace the accelerator pump rod if bent or worn thin at Valve fully closed any point.

Remove the top and reinstall the spring.


Harley Sportster Manual

Remove the primary drive cover C, Figure 2 and gas- drive, clutch assembly and clutch cable. Install new harleu and outer gaskets Figure 5 onto the lower rocker arm cover. Place a drain pan beside one fork tube, then remove the drain screw Figure 23 from the slider.

Remove the accelerator pump housing Figure 9 at the bottom of the float bowl. Push the chain up midway between the sprockets and measure the chain free play Figure Remove the gasket A, Figure 4. Install a new snap ring Figure 23 so that the flat side faces the bearing.


Harley Sportster Manual Refine Results. Slide the sleeve 2, Figure onto the pilot until the sleeve contacts the inner bearing race.

Drain the oil tank Chapter Three. The body bushing Figure 99 should be pressed in 0.

The bearing races are pressed into the hub and should not be removed unless they require replacement. Table 1 lists the recommended transmission oil inspec- tion intervals. Discard the check valve O-ring. Slide the shift drum Figure 21 out of the access door and remove it. Slip a piece of heat shrink tubing over each wire cut in Step 3. Install the reinforcing plate A, Figure 38 on top of the shift drum locating plate, making sure to engage the notch in the reinforcing plate with the roll pin in the access door.

The second compression ring must be installed with its dot mark facing up. Hundreds of photos and drawings guide the 5. Make sure the diaphragm Fig- ure 59 seats around the bowl groove evenly.


Harley Sportster Service Manual. Do not add water while the battery is still in the frame as any spilled water along with electrolyte will flow onto the frame and cause corrosion. Inspect the gear shaft assembly Figure for wear.

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Remove the nuts from the speedometer studs A, B and C, Figure Remove the primary chain, engine sprocket and clutch Chapter Seven. Make sure it is fully charged and the battery leads are clean and securely attached to the battery terminals. Press it in until the ring Figure is locked into both bearing race remover tools Figure Main Drive Gear Installation 1. The cable with the rounded side facing out and the ramp con- spring and lockplate shown in Figure 67 will be installed nector button facing in.

Read this procedure completely before starting disassembly. The system will pause for two psortster, and then flash the ready signal, which indicates it is ready to flash the next code. Front intake cam gear 4.

Installation is the reverse of the preceding steps while noting the following. Ignition coil bracket 7.

Connect the battery ground wire to the crankcase bolt Figure Front exhaust cam gear bushing 2. Adapter ring HDI models Screw and washer 2.