Harley Davidson Sportster Models Service Manual Repair 1979-1985 Xlch Xlh Xls
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FILE TYPE:PDF
DOWNLOADABLE:YES
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PAGES:343
DESCRIPTION:
This service and repair manual has been prepared with two purposes In mind. First, It will acquaint the reader with the construction of the Harley-Davidson product and assist him in performing basic maintenance and repair, Secondly, It will Introduce to the professional Harley-Davidson mechanic the lalest field-tested and factory-approved major repair methods. We sincerely believe thai this manual will make your association with Harley-Davidson products more pleasant and profitable. Your Service Manual Is arranged for quick, easy reference. This manual Is divided Into numbered sections. Sections are then divided Into subjects. Use this manual as follows: 1. Check the TABLE OF CONTENTS located in the Iront 01 each section to lind subject desired. 2. Page number Is listed across I rom subject. Page number consists 01 section number and page number. 3. Information Is presented In a definite order as follows: Troubleshooting Adjustments Removal Disassembly Cleaning, Inspection and Repair Assembly Installation In figure legends, the number following a name 01 a part indicates the quantity necessary lor one complete assembly.
TABLE OF CONTENTS:
- Harley Davidson Sportster Models Service Manual Repair 1979-1985 Xlch Xlh Xls
SECTION 1 PRODUCT
Service
Servicing a New Motorcycle
Sachperaling Maintenance
Storage
Removal from Storage
Fluid Requirements
Melnq ConversionTable
Torque Specifications
Troubleshooting
Engine
Lubrication Service
Electrical System
Carburetor
Transmission
Clutch
Brake
Handling
Tools
SECTION 2 CHASSIS
Dimensions
Weights
Adjustments
Torques
BrakeDIsc
Tircoala
Vehicle Identification Number
Tires
Wheels
Gcnoral
FrontWheel
HearWhuol
Lacing Wheels
LacingthcIs wm
TruingLacedWheel
ChackingCaisimRunoul
Tires
Brakes
General
Troubleshooting
FrontBrakeMasterCylinder
RoanrakoMasichyiindcr
SprocketCoverand Brake Linkage
BrakePedaiAdiusimeni
DiscBrakeCalipers
FroniCaliperFoarnTapelnstaiiaiion
FroniBrakeCalipernQBd 1985)
RearCaiipcrHQBZ 1985)
BrakeDiscs
Bleeding the Hydraulic Brake System
Stoplight FrontBrakeSwiich
StoplightHearBrakeSwiich
FrontForks
General
ChangingForkOil
ForkSices
ForkSlem
RearFork
Disassembin
Cieanlngandlnspeclion , ,
Assembly”
RearShockAbsorber
AdjustingSprrng
Removal
Disassembly
Cleaningandlnspcciron,
Assembly
Handlebar Controls and Instruments
TruoitleControi—1979 1980
ThrottleControl— 198mm! Later
CluianandConlrol
$ncedometer,Tachorneier
HandlebarSwitchAssembly
Fenders
FroniFendor
FiearFOnLicr
Specifications (XR tOOO)
0imensionstXH 1000J
WeighiiXFi tOOO)
VenicieWeigntRatingsiXRdOOO)
CapacitiestR IODO)
AdjustmenileH 1000)
Torques(XR‘1000)
BrakeDisciXFi WUD)
TircDaiatXR 1000j
Page!”
General
CneckingFlywheelEndPlay
Disassembly
Flywheels _
Assembly
Specilications(XR 1000)
Engine(XR 1000)
General intormation [XII 1000)
LubricatioanR loflo)
Stripping Motorcycle ior Engine Repair (XR iOOO)
Cylinder Head (XR 1000)
RemovinthR~tOOO)
DisassemblinngR imOi
Replacrng Rocker Arm BearingsiXRtOOOi
chlacing Valve GuideSIXR inooi
Rctacing VulchchttXR IOOD)
Replacing Valve Guide SoalsiXR iOOOl
VaiveSeatlnsertleR iOOOi
PushRodsiXR loooi r
Assembling Roaker Cover and installing (XE 1000)
lnstaliing Cylinder Head (XR tODDl
Valve Clearance AdjustmentsiXRJOOOi
Cyllnder and Pistons (XR tOOO)
Removinglei loool
Fitting Cylinder to PlstontXR~1000l
Fitting Piston Rings lira 1000)
Assembiing(XR 1000l
Gearcase(XFi 1000)
Valve Tappets and GuidesiXRJCOOl
Gearcase Cover and Cam Gears i‘XR tlmO]
Replacing Needle Bearings and Bushings lXvaOOO)
GcarcuueAnaembileR WOOJ
Crankcase(XR 1000) 9r
Fitting RodBnaringsiXR tflOO]
SECTION 4 FUEL SYSTEM
Specifications
JetSizes
FueiTankCapacity
Torques
Carburetor
General
Operation
Adjustments
Rem0val
Disassembly
Troubleshooting
Cleaning Inspection and Repair
Assembly
lnstallatlon
AirCIeaner
Genetal
Removal
Inspectionandfiepair
Installation
FuelSupplyValve
Gcneral
Rem0val,v
Cleaning Inspection and Ficpaii
Installation
FuelTank
General
Removal
Cleaning, Inspection and Repair
Ins!at|a ton
Carburetor(XR 1000)
GenerallXR IOOOI
OperationtXH tUUU)
AdjustmentMXRJOOO)
RemovaIIXR ‘IOOOJ
Disassembly/(X84000)
Cleaning Inspection and Repair (XR iooo;
AssemnyIXR IOODi
lnstallatloanH tUDD)
AirCleaner(XR 1000)
GenerallXH IDOO]
Servicing Air Cleaners (XE 100 )
lnstallalioniXR lOOO)
Fuel Supply Valve (XE 1000)
GeneralIXR IOUO]
Removal(XR 1000)
Cleaning Inspection and Repair (KR 100)
InstallationIXR IOCOJ
FuelTank(XR 1OOO)
GeneraI(XR 1000)
HemovaHXR’IOOO) r
HopalHXRJOOU) ,
lnslallaiion(XR~tOOOJ
Electric Starter System 1979 1980
Specification
Description
Troubleshootmg ,
Starlcrfielay
StarterMotor
Solenotd
SiarterDrwesnart and Housing ,
Electric Starter System 1981 ~1985
Deecriptton
Troubleshooting ,
One ration
StarterRelay
Removal
TestingAssernblcdswrier
Disassembly, Inspection Repair and Assemnty
installation
Electric Starter System (XR 1000)
HemevuliXRJOUO)
InstallationiXR IOOOI
SECTIONS
DRIVEITRANSMISSION
GenerallnIormation
Description
Specifications (1979 Early 1984)
Transmission
Prrrnarthmin
RearChain
KickStaner
Gearsex
Matnshattcmup
CountershaiiGroup
Torque—5
SerwceVrIearLimits
Chains(1979 Early1984)
antCNain
RearChain
Clutch(1979 Early1984)
General
Controls
Disassembly ,
lnspcctionanufiepair _
Assembly
Transmission (1979 Early 1984)
Paar
General
Disassembly
InspectienandFiepair
Assembly
Lubrication
KickStarter 1979XLCH
General
Disassembly
InspeclonandRepair
Asscml)ly
Specifications(Late1984 and 1985)
Transmission
Clulch
MainshaIlGroup
CountershaIiGroup
Torques
ServichcarLirnits
Chains (Late 1984 and 1985)
FrontChain
RamCIrain
Clutch (Late1984 and1985)
General
Troubleshooting
Clutcnneieaselrtecnanlsm
ClutchRemoval
Clutchlnstallaiion
Disassembly
lnspectonandficpair
Assurnbly
Transmission(Late1984 and 1985)
AccmCoverHemoval
ShlfterMechaniem Removal and Disassembly
Mainshattandcounlershalt
Cleanln9,lnspectlonand Ropalr
Aesembly
ShlfterMechanIsmAssemny
Countershalt and Meinsheft Assembly
Establishing ProperGearSpactng
Gear Engagemenl
Establishing Malnshatland CounterstratlEna Play
Installation
Lubrication
SECTION 7 ELECTRICAL
Specifications
lgnitton
Spark PIugs
General
BulbChart
Ignition System1979
description
Operation
Troubleshooting
Adiusting Sensor AIRGAP
Checking Advance Timing with StrobeTiming Light
Setting Retard Timing with CircuiITesIer
Removing Ignition Timer Components
lnapectionand Replacing Parts
Assembling Ignition Timer Compenents
Ignition System 1980 1982
Description
Troubleshooting
Click Advance TIming with SIrobeTiming Light
Selting Relarded Timing
Removing ignition Components
Inspectionantl Replacing Parts
InstallingIgnitionComponents
Ignition System 198 1985
Description
Troubleshooting
Check Advance Timing with Strobe TIming Light
vacuum Operated Electric Switch
Setting RetardedT rming
ignition Component Removal
lnspcction
lgnitioa Component Installation
Ignition Light Switch
Spark PIugs
General
Inspecting Sparer lugs
Selting Spare Gap
Installing Spark Plugs
Cleaning Spark Plugs
Ignition Coil
Description
Troubleshooting
Reptacing Spark Plug Cable
Generator(1979 Early1984)
General
Genorator Output
Removal
Disassembly
Generator Test
Cleaning, Inspection and Repair
Commutator Ftupair
Regulator(1979 Early1984)
General
Checking Charging System
Charging System (Late 1984 and 1985) me
General
Treubleshooting
Replacing ReguIalor
Battery
General
Batten/Care
BoostrngBattery
ChargingBattery
Servicing
Reclaiming Sulphated Battery
Lamp srar
Head lamp
Adjusting Beam
Bulbs
Horn 749
Specifications (XE 1000)
IgnitionTiming
SbamPIugs(XR 1000)
GeneralIXR~t000)
BulehartiXR lOOO]
Ignition System (XR 1000)
Dcscription(XR 1000)
Troubleshooling(XR IOUO)
Check Advance Timing with Strobe Timing Light
Setting Rezarcee TtrningIXFI IOC’ZI)
nernovrng ignition CornponentsthJOUU)
Inspecting and Replacing Parts [XR IOOD)
Installing Ignition ComponentleFI IGOOI
ignition Light Switch (XR 1000)
Hom(XR 1000)
Spark Plugs(XR 1000)
GeneraliXR IOOG)
Installing Spark PlugleR toflo),
Wiring Diagrams
SCREENSHOT OF THE MANUAL:
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⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
⦁ The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
⦁ Any queries / doubts regarding your purchase, please feel free to contact [email protected]