Harley Davidson 1986-2003 XL/XLH Sportster. Service Manual - page 7

b. Clean all components. Lubricate the clevis pin,

spring mounting points and sidestand with bearing
grease.

c. Check sidestand operation. The sidestand is designed

to lock when it is placed in its full down position with
the weight of the motorcycle resting on it. If the mo-
torcycle is raised momentarily while the sidestand is
in place, the sidestand may retract slightly from its
full down position. Before resting the weight of the
motorcycle on the sidestand, make sure the sidestand
is in its full down position. Make sure the sidestand
retracts fully.

FORK LOCK

Replacement

1. Disconnect the negative battery cable from the crank-
case (Chapter Twelve).
2. Remove the fuel tank (Chapter Ten or Chapter Eleven).

NOTE

Depending on the tools used, it may be neces-
sary to remove or move handlebar compo-
nents for access to the fork lock. Refer to
Chapter Fourteen.

NOTE

Align the drill bit in Step 3 so it is centered on
the lockpin. Misalignment will make lockpin
removal difficult.

3. Using a 5/64-inch drill bit, drill a hole in the center of the
lockpin (Figure 19, typical).
4. Install a screw extractor into the lockpin and pull out the
lockpin.
5. Remove the lock assembly.
6. Install the new lock so the lockpin holes in the lock and
frame are aligned.
7. Drive in a new lockpin so it is flush with the frame.
8. Check lockpin operation. Be sure the handlebar can be
moved through a full range of motion.

BODY

599

SIDESTAND

(1989-2003 MODELS)

1. Pin
2. Sidestand
3. Return spring
4. Cotter pin
5. Washer

Table 1 is on the following page.

Table 1 FRAME COMPONENT TORQUE SPECIFICATIONS

ft.-lb.

in.-lb.

N•m

Engine-mounting plate bolts

(883C and 1200C

models)

25-30

–

34-41

Front fender locknuts

–

96-156

11-18

Rear fender front mounting bolt

–

120

Shift-rod mounting bolts

(883C and 1200C

models)

–

180

Strut cover bolts

(1994-2003 models)

–

96-156

11-18

Turn signal bolts

(1994-2003 models)

–

96-156

11-18

Turn signal mounting bolt

(1986-1989 models)

–

Turn signal retaining nut

(1990-1993 models)

–

96-156

11-18

600

CHAPTER SEVENTEEN

INDEX

Air filter . . . . . . . . . . . . . . . . . . 139-140

backplate

1986-1987 models. . . . . . . . . . . . 333
1988-2003 models. . . . . . . . . . . . 350

Alternator

1986-1990 models . . . . . . . . . 403-404
1991-2003 models . . . . . . . . . 404-408

Battery

1986-1996 models . . . . . . . . . 393-398
1997-2003 models . . . . . . . . . 398-402
charging rates/times

approximate . . . . . . . . . . . . . . . . . 464

Body

fender

front . . . . . . . . . . . . . . . . . . . 590-591
rear . . . . . . . . . . . . . . . . . . . . 591-594

footrests . . . . . . . . . . . . . . . . . . . . . 594
fork lock . . . . . . . . . . . . . . . . . . . . 599
forward foot controls,

1999-2003 883C
and 1200C models . . . . . . . . 594-598

seat. . . . . . . . . . . . . . . . . . . . . . . . . 590
sidestand . . . . . . . . . . . . . . . . . 598-599
torque. . . . . . . . . . . . . . . . . . . . . . . 600

Brake

adjustment . . . . . . . . . . . . . . . . . . . 131
bleeding the system . . . . . . . . 586-588
caliper

front

1986-1999 models . . . . . . . 540-544
2000-2003 models . . . . . . . 545-548

caliper

rear

1986-early 1987 models . . 567-569
late 1987-1999 models . . . 569-572
2000-2003 models . . . . . . . 572-575

disc front and rear . . . . . . . . . . 584-586
fluid,

change . . . . . . . . . . . . . . . . . . . . . 131
draining . . . . . . . . . . . . . . . . 588-589
level inspection . . . . . . . . . . 129-130
selection . . . . . . . . . . . . . . . . . . . 533

flushing the brake system . . . . . . . . 589
front brake lever pivot pin

lubrication . . . . . . . . . . . . . . . . . . 123

hose and line replacement . . . . 581-584
inspection . . . . . . . . . . . . . . . . 129-130

light switch

front . . . . . . . . . . . . . . . . . . . 446-447

rear . . . . . . . . . . . . . . . . . . . . . . . 450

master cylinder

front

1986-1995 models . . . . . . . 548-552

1996-2003 models . . . . . . . 552-557

rear

1986-early 1987 models . . 575-577

late 1987-2003 models . . . 577-581

pads

front

1986-1999 models . . . . . . . 535-538

2000-2003 models . . . . . . . 538-540

inspection . . . . . . . . . . . . . . . . . . 129

rear

1986-early 1987 models . . 557-561

2000-2003 models . . . . . . . 565-567

late 1987-1999 models . . . 561-565

service . . . . . . . . . . . . . . . . . . 533-535

specifications . . . . . . . . . . . . . . . . . 589

torque. . . . . . . . . . . . . . . . . . . . . . . 589

troubleshooting . . . . . . . . . . . . . . . 111

Troubleshooting Preparation

1. Refer to the wiring diagrams at the end of this manual
for the specific model.
2. Check the wiring harness for visible signs of damage.
3. Make sure all connectors are properly attached to each
other and locked in place.
4. Check all electrical components for a good ground.
5. Check all wiring for short circuits or open circuits.
6. Make sure all ignition circuit breakers or fuses are in
good condition.
7. Make sure the fuel tank has an adequate supply of fresh
gasoline.
8. Check the spark plug cable routing and the connections
at the spark plugs. If there is no spark or only a weak one,
repeat the test with new spark plugs. If the condition re-
mains the same with new spark plugs and if all external wir-
ing connections are good, the problem is most likely in the
ignition system. If a strong spark is present, the problem is
probably not in the ignition system. Check the fuel system.

9. Remove the spark plugs and examine them as described
in Chapter Three.

Ignition Tests

No spark at spark plug (1986-1990 models)

1. To perform this test, the battery must be fully charged
(Chapter Twelve).
2. Make sure the black ignition module ground lead is fas-
tened securely and make sure the battery ground lead is fas-
tened and in good condition.

NOTE

When performing the following test proce-
dures, it is necessary to fabricate a test
jumper from two lengths of 16 gauge wire,
three clips and a 0.33 MFD capacitor (

Fig-

ure 30

). The test jumper should be long

enough to reach from the ignition coil to a
good engine ground.

3. Perform the following:

a. Connect the positive voltmeter lead to the white igni-

tion coil wire terminal and the negative voltmeter
lead to ground (Figure 31).

b. Turn the ignition switch on. The voltmeter should

read 11-13 volts. Turn the ignition switch off.

c. If the voltage is correct, proceed to Step 4.
d. If the voltage is incorrect, check the main and igni-

tion circuit breakers (Chapter Twelve). Also check
for loose or damaged ignition system wiring.

4. Perform the following:

a. Disconnect the blue wire from the ignition coil termi-

nal (Figure 32).

TROUBLESHOOTING

0.33 MFD capacitor

16 ga. wire

Test jumper

Voltmeter

Ignition coil

* 1986-1994 models: white

1995-1997 models: white/black

Voltmeter

1. 1986-1994 models: white

1995-1997 models: white/black

2. 1986-1990 models: blue

1991-1997 models: pink

b. Turn the ignition switch on.
c. Connect the negative voltmeter lead to ground. Con-

nect the positive voltmeter lead to the white and blue
ignition coil terminals (Figure 33). The voltmeter
should read 12 volts at both terminals. Turn the igni-
tion switch off.

d. If the voltage is correct, proceed to Step 5.
e. If the voltage is incorrect, check the ignition coil re-

sistance as described in this section. If the resistance
is within the prescribed range, proceed to Step 5.

5. Perform the following:

a. Disconnect the blue wire from the ignition coil termi-

nal (Figure 33) if not previously disconnected.

b. Remove one of the spark plugs. Then connect the spark

plug wire and connector to the spark plug and touch the
spark plug base to a good ground (Figure 34). Position
the spark plug so the electrodes are visible.

c. Turn the ignition switch on.
d. Connect the jumper wire (without the capacitor) be-

tween a good engine ground and the ignition coil blue
wire terminal as shown in Figure 33. Then momen-
tarily touch the jumper wire with the capacitor to the
ignition coil blue wire terminal (Figure 33) while ob-
serving the spark plug firing tip. The spark plug
should spark. Turn the ignition switch off and remove
the jumper wire assembly.

e. If there was spark, proceed to Step 6.
f. There was no spark, replace the ignition coil.
g. Do not reinstall the spark plug at this time.

6. Perform the following:

a. Reconnect the ignition coil blue wire to its terminal

on the ignition coil.

b. Turn the ignition switch on.
c. Disconnect the sensor plate electrical connector lo-

cated behind the sprocket cover.

d. Connect the positive voltmeter lead to the ignition

module red wire socket and the negative voltmeter
lead to the ignition module black pin as shown in Fig-
ure 35. The voltmeter should read 4.5-5.5 volts. Dis-
connect the voltmeter and turn the ignition switch off.

e. If voltage is correct, proceed to Step 7.

f. If voltage is incorrect, check the ignition module

(Figure 36) ground wire and the module for dirty or
loose-fitting terminals. If okay, proceed to Step 7.

CHAPTER TWO

Jumper wire

Ignition
coil

Voltmeter

Ignition
module
side*

1. 1986-1994 models: red

1995-1997 models: red/white

2. 1986-1994 models: green

1995-1997 models: green/white

3. 1986-1994 models: black

1995-1997 models: black/white

*NOTE: This connector is triangular on

1995-1997 models

1. 1986-1994 models: white

1995-1997 models: white/black

2. 1986-1990 models: blue

1991-1997 models: pink

7. Make sure the ignition switch on. Then momentarily
ground a screwdriver across the ignition module green and
black connector pins (Figure 37) while observing the spark
plug firing tip. There should be a strong spark at the spark
plug firing tip as the screwdriver is removed. Note the fol-
lowing:

a. If there was a spark, check the sensor resistance as

described in this section.

b. If there was no spark, check the ignition module re-

sistance as described in this section.

8. Install and reconnect all parts removed for this proce-
dure.

No spark at spark plug
(1991-1997 models)

NOTE

When performing these test procedures, it is
necessary to fabricate a test jumper from two
lengths of 16 gauge wire, three clips and a
0.33 MFD capacitor; see

Figure 30

. The test

jumper should be long enough to reach from
the ignition coil to a good engine ground.

3. Perform the following:

a. On 1991-1993 models, connect the positive voltmeter

lead to the white ignition coil wire terminal and the
negative voltmeter lead to ground (Figure 31). On
1994-1997 models, connect the positive voltmeter
lead to the white/black ignition coil wire terminal and
the negative voltmeter lead to ground (Figure 31).

b. Turn the ignition switch on. The voltmeter should

read 11-13 volts. Turn the ignition switch off.

c. If the voltage is correct, proceed to Step 4.
d. If the voltage is incorrect, check the main and igni-

tion circuit breakers or fuses (Chapter Twelve). Also
check for loose or damaged ignition system wiring.

4. Perform the following:

a. Disconnect the pink wire from the ignition coil termi-

nal (Figure 32).

b. Turn the ignition switch on.
c. Connect the negative voltmeter lead to ground. On

1991-1993 models, connect the positive voltmeter
lead to the white and pink ignition coil terminals sep-
arately. On 1994-1997 models, connect the positive
voltmeter lead to the white/black and pink ignition
coil terminals separately. The voltmeter should read
12 volts at both terminals. Turn the ignition switch
off.

d. If the voltage is correct, proceed to Step 5.
e. If the voltage is incorrect, check the ignition coil re-

sistance as described in this section. If the resistance
is within the prescribed range, proceed to Step 5.

5. Perform the following:

a. Disconnect the pink wire from the ignition coil termi-

nal if not previously disconnected.

b. Remove one of the spark plugs. Then connect the

spark plug wire and connector to the spark plug and
touch the spark plug base to a good ground (Figure
34). Position the spark plug so the electrodes are
visible.

c. Turn the ignition switch on.
d. Connect the jumper wire (without the capacitor) be-

tween a good ground and the ignition coil pink termi-
nal (Figure 33). Then momentarily touch the jumper
wire with the capacitor to the ignition coil pink termi-
nal while observing the spark plug firing tip. The
spark

plug

should

spark

when

the

wire

disconnected. Turn the ignition switch off and re-
move the jumper wire assembly.

e. If there is spark, proceed to Step 6.
f. If there is no spark, replace the ignition coil.
g. Do not reinstall the spark plug at this time.

TROUBLESHOOTING

Ignition
module
side*

Screwdriver

1. 1986-1994 models: red

1995-1997 models: red/white

2. 1986-1994 models: green

1995-1997 models: green/white

3. 1986-1994 models: black

1995-1997 models: black/white

*NOTE: This connector is triangular on

1995-1997 models

6. Perform the following:

a. Reconnect the ignition coil pink wire to its terminal

on the ignition coil.

b. Turn the ignition switch on.
c. Disconnect the sensor plate electrical connector (Fig-

ure 38).

d. On 1991-1993 models, connect the positive voltme-

ter lead to the ignition module red wire socket and the
negative voltmeter lead to the ignition module
black/white pin as shown in Figure 35. On
1994-1997 models, connect the positive voltmeter
lead to the ignition module red/white wire socket and
the negative voltmeter lead to the ignition module
black/white pin as shown in Figure 35, The voltme-
ter should read 11.5-12.5 volts. Disconnect the volt-
meter and turn the ignition switch off.

e. If the voltage is correct, proceed to Step 7.
f. If the voltage is incorrect, check the ignition module

(Figure 36) ground wire and the module for dirty or
loose-fitting terminals. If okay, proceed to Step 7.

7A. On 1991-1993 models, turn the ignition switch on.
Then momentarily ground a screwdriver across the ignition
module green and black/white connector pins (Figure 37)
while observing the spark plug firing tip. There should be a
strong spark at the spark plug firing tip as the screwdriver is
removed.

a. If there is spark, check the sensor resistance as de-

scribed in this chapter.

b. If there is no spark, check the ignition module resis-

tance as described in this chapter.

7B. On 1994-1997 models, turn the ignition switch on.
Then momentarily ground a screwdriver across the ignition
module green/white and black/white connector pins (Fig-
ure 37) while observing the spark plug firing tip. There
should be strong spark at the spark plug firing tip as the
screwdriver is removed.

a. If there is spark, check the sensor resistance as de-

scribed in this chapter.

b. If there is no spark, check the ignition module resis-

tance as described in this chapter.

8. Install and reconnect all parts removed for this proce-
dure.

Intermittent Ignition Problems

Intermittent problems are usually caused by temperature

or vibration variances. Perform the following.

Temperature test

NOTE

Perform Steps 1-3 with the engine cold.

1. Remove the outer timing cover, inner timing cover and
gasket as described in Chapter Twelve.
2. Start the engine.

3. Spray the sensor (Figure 38) with a refrigerant (avail-
able at electronic supply stores). If the engine dies, replace
the sensor as described in Chapter Twelve.
4. Allow the engine to warm to normal operating tempera-
ture. Then apply heat to the sensor with a heat gun. If the en-
gine dies, replace the sensor as described in Chapter Twelve.
5. Remove the ignition module cover from the left side of
the motorcycle. With the engine running, apply heat to the
ignition module (Figure 36) with a heat gun. If the engine
dies, replace the module as described in Chapter Twelve.
6. Install the inner timing cover, gasket and outer timing
cover as described in Chapter Twelve.

Vibration test

Read this procedure completely before starting. Refer to

Figure 39.
1. Check the battery connections. Retighten or repair as re-
quired.
2. On 1986-1993 models, check the module ground wire
connection. If necessary, remove the ground wire at the
frame and scrape all paint at the mounting point. Using a
star washer, reinstall the ground wire.
3. Start the engine and retest. If there is still an intermittent
problem, proceed to Step 4.
4A. On 1986-1993 models, disconnect the white ignition
stop switch wire terminal at the ignition coil. On 1986-1993
models, do not disconnect the white module wire at the ig-
nition coil. Refer to the wiring diagram at the end of the
manual.
4B. On 1994-1997 models, leave the white/black wire
connected.
5A. On 1986-1993 models, connect a 16 ga. jumper wire
from the positive battery terminal to the white ignition coil
terminal.
5B. On 1994-1997 models, connect a 16 ga jumper wire
from the positive battery terminal to the white/black wire
ignition coil terminal.

WARNING

Steps 4 and 5 have bypassed the ignition stop
switch. When performing Step 6, the engine

CHAPTER TWO

Content .. 5 6 7 8 ..