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

New tires provide significantly less adhesion until they

are broken in. Do not subject new tires to high speed or high
cornering forces for at least 60 mile (100 km). Be especially
careful when encountering wet conditions with new tires.

Removal

CAUTION

To avoid damage when removing the tire,
support the wheel on two wooden blocks, so
the brake disc or the driven sprocket does not
contact the floor.

NOTE

To make tire removal easier, warm the tire to
make it softer and more pliable. Place the wheel
and tire assembly in the sun. If possible, place
the wheel assembly and the new tire in a com-
pletely closed automobile parked in the sun.

Take special care with tire irons when changing a tire to

avoid scratches and gouges to the outer rim surface. Insert
pads between the tire iron and the rim to protect the run
from damage.

All original equipment cast or disc wheels are designed

for use with tubeless tires only. All laced wheels use a tube
and tire combination.

When removing a tubeless tire, take care not to damage

the tire beads, inner liner of the tire or the wheel rim
flange. Use tire levers or flat handle tire irons with
rounded heads.
1. Remove the front or rear wheel as described in this chapter.
2. If not already marked by the tire manufacturer, mark the
valve stem location on the tire, so the tire can be installed in
the same location for easier balancing.
3. Remove the valve cap and unscrew the core from the
valve stem and deflate the tire or tube.

CAUTION

The inner rim and tire bead areas are the
sealing surfaces on tubeless tires. Do not
scratch the inside of the rim or damage the
tire bead.

NOTE

Removal of tubeless tires from their rims can
be difficult because of the tight tire bead-
to-rim seal. Breaking the bead seal may re-
quire a special tool (

Figure 70

). If unable to

break the seal loose, take the wheel to a deal-
ership and have them break it loose on a tire
changing machine.

4. Press the entire bead on both sides of the tire away from
the rim and into the center of the rim. If the bead it tight, use
a bead breaker.
5. Lubricate both beads with soapy water.

CAUTION

Use rim protectors (

Figure 71

, typical) or in-

sert scraps of leather between the tire iron and
the rim to protect the rim from damage.

CAUTION

Use only tire irons without sharp edges. If
necessary, file the ends of the tire irons to re-
move rough edges.

6. Insert a tire iron under the top bead next to the valve
stem (Figure 72). Force the bead on the opposite side of the
tire into the center of the rim and pry the bead over the rim
with the tire iron.

WHEEL, TIRES AND SECONDARY DRIVE

491

Bead breaker

Rim

Tire
irons

Valve stem

Rim protectors

7. Insert a second tire iron next to the first iron to hold the
bead over the rim. Then work around the tire with the first
tire iron, prying the bead over the rim (Figure 73). On
tube-type tires, be careful not to pinch the inner tube with
the tools.
8. On tube-type tires, use a thumb and push the valve stem
from its hole in the rim to the inside of the tire. Carefully
pull the tube out of the tire and lay it aside.
9. To completely remove the tire, stand the wheel upright.
Insert a tire iron between the back bead and the side of the
rim that the top bead was pried over (Figure 74). Force the
bead on the opposite side from the tire iron into the center
of the rim. Work around the tire and pry the back bead off
the rim. On tube-type tires, remove the rim band.
10. Inspect the valve stem seal. Because rubber deteriorates
with age, replace the valve stem when replacing the tire.
11. On tubeless tires, remove the old valve stem and dis-
card it. Inspect the valve stem hole (Figure 75) in the rim.
Remove any dirt or corrosion from the hole and wipe it dry
with a clean cloth. Install a new valve stem and make sure it
is properly seated in the rim.
12. Inspect the tire and wheel rim for damage as described
in this section.

Inspection

WARNING

Carefully consider whether a tire should be
replaced. If there is any doubt about the qual-
ity of the existing tire, replace it with a new
one. Do not take a chance on a tire failure at
any speed.

1. Wipe off the inner surfaces of the wheel rim. Clean off
any rubber residue or oxidation.

WARNING

Install only original equipment tire valves
and valve caps. A valve or valve/cap combi-
nation that is too long or heavier than origi-
nal equipment parts may interfere with an
adjacent component when the motorcycle is
under way. Damage to the valve will cause
rapid tire deflation and loss of control.

2. On tubeless tires, inspect the valve stem rubber grommet
for deterioration. If replacement is necessary, install only
the original equipment valve stem assembly.
3. If any of the following conditions are observed, replace
the tire:

a. A puncture or split with a total length or diameter ex-

ceeds 0.24 in. (6 mm).

b. A scratch or split on the sidewall.
c. Any type of ply separation.
d. Tread separation or excessive abnormal wear pattern.
e. Tread depth of less than 1/16 in. (1.6 mm) on original

equipment tires. Tread depth minimum may vary on
aftermarket tires.

492

CHAPTER THIRTEEN

f. Scratches on either sealing bead.
g. The cord is cut in any place.
h. Flat spots in the tread from skidding.
i. Any abnormality in the inner liner.

Installation

1. A new tire may have balancing rubbers inside. These are
not patches. Do not remove them. Most tires are marked
with a colored spot near the bead (Figure 76) indicating a
lighter point on the tire. This should be placed next to the
valve stem.
2. On tube-type tires, install the rim band around the wheel
and align the hole in the rim band with the hole in the rim. If
installing a new rim band, make sure it is the correct diame-
ter and width for the wheel.
3. Lubricate both beads of the tire with soapy water.
4. When installing the tire on the rim, make sure the correct
tire, either front or rear, is installed on the correct wheel.
Also make sure the direction arrow points in the direction
of wheel rotation.
5. When remounting the old tire, align the mark made in
Step 2 of

Removal

with the valve stem (Figure 76).

6. Place the backside of the tire onto the rim so the lower bead
sits in the center of the rim while the upper bead remains out-
side the rim (Figure 77). Work around the tire in both direc-
tions and press the lower bead by hand into the center of the
rim. Use a tire iron for the last few inches of bead.
7. On tube-type tires, perform the following:

a. Dust the inner tube with talcum powder before in-

stalling it in the tire. The talcum powder will prevent
the tube from sticking to the tire.

b. Inflate the tube just enough to round it out. Too much

air will make installation difficult.

c. Place the tube on top of the tire, aligning the valve

stem with the matching hole in the rim. Insert the tube
into the tire.

d. Lift the upper bead away from the rim with a hand and

insert the tube’s valve stem through the rim hole. Check
to make sure the valve stem is straight up (90

), not

cocked to one side. If necessary, reposition the tube in
the tire. If the valve stem wants to slide out of the hole
and back into the tire, install the valve stem nut at the
top of the valve; do not tighten the nut at this time.

8. Press the upper bead into the rim opposite the valve
stem. Working on both sides of this initial point, pry the
bead into the rim with the tire tool, and work around the rim
to the valve stem (Figure 78). On tube-type tires, do not
pinch the inner tube during the last few inches. If the tire
wants to pull up on one side, either use another tire iron or
one knee to hold the tire in place. The last few inches are
usually the toughest to install. Continue to push the tire into
the rim by hand. Re-lubricate the bead if necessary. If the
tire bead pulls out from under the rim, use both knees to
hold the tire in place. If necessary, use a tire iron for the last
few inches (Figure 79).

WHEEL, TIRES AND SECONDARY DRIVE

493

Valve stem

Rim

Balance mark

9. On tube-type tires, check to make sure that the valve stem
is straight up (90

), not cocked to one side (Figure 80). If

necessary, slide the tire along the rim in either direction while
holding the rim securely. When the valve stem is straight up,
tighten the valve stem nut at the top of the valve; do not
tighten it against the rim at this time. Check that the tube was
not forced out so that it rests between the tire bead and the
rim. If necessary, push the tube back into the tire.
10. Bounce the wheel several times, rotating it each time.
This will force the tire bead against the rim flanges. After
the tire beads are in contact with the rim, inflate the tire to
seat the beads.
11A. On tube-type tires, perform the following:

a. Inflate the tube to it maximum tire pressure to seat the

tire beads in the rim.

b. After inflating the tire, make sure the beads are fully

seated and the rim lines are the same distance from
the rim all the way around the tire (Figure 81).

c. If the tire beads do not seat properly, release the air

pressure and re-lubricate the tire beads.

d. When the tire is seated correctly, remove the valve

core and deflate the tire allowing the tube to
straighten out within the tire.

e. Install the valve core and inflate the tire to the pres-

sure in Table 2.

f. Tighten the valve stem nut securely and install the

valve stem cap.

11B. On tubeless tires/perform the following:

a. Place an inflatable band around the circumference of

the tire. Slowly inflate the band until the tire beads
are pressed against the rim. Inflate the tire enough to
make it seat, deflate the band and remove it.

WARNING

Never exceed 40 psi (276 kPa) inflation pres-
sure as the tire could burst, causing severe in-
jury. Never stand directly over a tire while
inflating it.

b. After inflating the tire, make sure the beads are fully

seated and the rim lines are the same distance from
the rim all the way around the tire (Figure 82). If the
beads will not seat, deflate the tire and lubricate the
rim and beads with soapy water.

c. Re-inflate the tire to the pressure in Table 2. Install

the valve stem cap.

12. Check tire runout as described in this section.
13. Balance the wheel as described in this chapter.
14. Install the wheel as described in this chapter.

Tire Repairs

Tubeless

NOTE

Changing or patching on the road is very dif-
ficult. A can of pressurized tire inflator and

sealer can inflate the tire and seal the hole,
but this is only a temporary fix.

Tubeless tires have the TUBELESS molded into the side-

wall and the rims have SUITABLE FOR TUBELESS
TIRES or equivalent stamped or cast on them.

If the tire is punctured, remove it from the rim to inspect

the inside of the tire and apply a combination plug/patch
from inside the tire (Figure 83). Never attempt to repair a
tubeless motorcycle tire using a plug or cord patch applied
from outside the tire.

After repairing a tubeless tire, do not exceed 50 mph (80

km/h) for the first 24 hours.

494

CHAPTER THIRTEEN

Tire rim line

Rim
circumference

Gauge

Tire lateral
runout

WARNING

Do not install an inner tube inside a tubeless
tire. The tube will cause an abnormal heat
buildup in the tire.

1. Remove the tire from the wheel rim as described in this
section.
2. Inspect the rim inner flange. Smooth scratches on the
sealing surface with emery cloth. If a scratch is deeper than
0.020 in. (0.5 mm), replace the wheel.
3. Inspect the inside and outside of the tire. Replace a tire if
any of the following conditions are found.

a. A puncture larger than 1/8 in. (3 mm) diameter.
b. A punctured or damaged side wall.
c. More than two punctures in the tire.

4. Apply the plug/patch following the manufacturer’s in-
structions.
5. As soon as possible, replace the patched tire with a new
one.

Tube-type

Patching a motorcycle tube is only a temporary fix. A

motorcycle tire flexes too much and a patch can rub off. As
soon as possible, replace the tube with a new one.

When buying a tire repair kit, make sure it is for a motorcy-

cle tire. Kits that vulcanize the patch to the tube with heat (hot
patch) are strongest. Kits that attach the patch in place with ad-
hesive are known as cold patch types.

1. Remove the tire from the wheel rim as described in this
section.

2. Inspect the rim inner flange. Smooth scratches on the
sealing surface with emery cloth. If a scratch is deeper than
0.020 in. (0.5 mm), replace the wheel.

3. Inspect the inside and outside of the tire. Replace a tire if
any of the following conditions are found.

a. A puncture larger than 1/8 in. (3 mm) diameter.

b. A punctured or damaged side wall.

c. More than two punctures in the tire.

4. Apply the patch following the manufacturer’s instruc-
tions.

5. As soon as possible, replace the patched tire with a new
one.

Runout

Check the tires for excessive lateral and radial runout af-

ter a wheel has been mounted or if the motorcycle devel-
oped a wobbe that cannot be traced to another component.
Mount the wheels on their axles when making the follow-
ing checks:

1. Check the tire for excessive lateral runout (side-to-side)
as follows:

a. Position a fixed pointer next to the tire sidewall as

shown in Figure 82. Position the pointer tip so it is
not directly in line with the molded tire logo or any
other raised surface.

b. Rotate the tire and measure lateral runout.

c. The lateral runout should not exceed 0.080 in. (2.03

mm). If runout is excessive, remove the tire from the
wheel and recheck the wheel’s lateral runout as de-
scribed in this chapter. If the runout is excessive, the
wheel must be trued (laced wheels) or replaced (alloy
wheels). If wheel runout is correct, the tire runout is
excessive and the tire must be replaced.

2. Check

the

tire

for

excessive

radial

runout

(up-and-down) as follows:

a. Position a fixed pointer at the center bottom of the tire

tread as shown in Figure 84.

b. Rotate the tire and measure the amount of radial run-

out.

c. The radial runout should not exceed 0.090 in. (2.29

mm). If runout is excessive, remove the tire from the
wheel and recheck the wheel’s radial runout as de-
scribed in this chapter. If the runout is excessive, true
(laced wheel) or replace the wheel. If wheel runout is
correct, the tire runout is excessive and the tire must
be replaced.

WHEEL, TIRES AND SECONDARY DRIVE

495

Gauge

Tire radial runout

Table 1 FRONT AND REAR WHEEL SPECIFICATIONS

in.

Cast or disc wheel runout

Lateral

0.040

1.02

Radial

0.030

0.76

Laced wheel laterial and radial runout

0.030

0.76

Tire runout

Lateral

0.08

2.03

Radial

0.09

2.29

Wheel bearing end play

1986-early 1991*

0.004-0.018

0.10-0.46

Late 1991-1999*

0.002-0.006

0.05-0.15

2000-2003 models

Front wheel

Less than 0.002

Less than 0.05

Rear wheel

0.002-0.006

0.05-0.15

*Refer to text for early and late 1991 identification.

Table 2 TIRE INFLATION PRESSURE (COLD)

psi

kPa

Up to 300 lb. load

Front

1200 models

207

883 and 1100 models

1986-1990

179

1991-2003

207

Rear

1200 models

248

883 and 1100 models

1986-1990

207

1991-2003

248

Up to GVWR maximum load

Front

1200 Models

207

883 and XLH 1100 models

1986-1990

179

1991-2003

207

Rear

1200 Models

276

883 and XLH 1100 models

1986-1990

221

1991-2003

276

1. Tire inflation pressure is for original equipment tires and must be take when the tire is cold. Aftermarket tires may require
different inflation pressure.
2. 300 lb. load includes rider, passenger and cargo.
3. The gross vehicle weight rating (GVWR) is listed on a decal mounted on a decal mounted on the frame.

Table 3 FRONT WHEEL BEARING SPACER SLEEVES (1986-EARLY 1991 MODELS)

Length

Part No.

in. (mm)

Color code

43623-78

2.564 (65.12)

Violet

43624-78

2.550 (64.77)

Pink

43625-78

2.536 (64.41)

Gold

Table 4 FRONT WHEEL BEARING SPACER SHIMS (LATE 1991-1999 MODELS)

Length

Part No.

in. (mm)

43290-82

0.030-0.033 (0.76-0.84)

43291-82

0.015-0.017 (0.38-0.43)

43292-82

0.0075-0.0085 (0.191-0.216)

43293-82

0.0035-0.0045 (0.089-0.114)

43294-82

0.0015-0.0025 (0.038-0.064)

496

CHAPTER THIRTEEN

Table 5 REAR WHEEL BEARING SPACER SLEEVES–CAST WHEEL (1986-EARLY 1991 MODELS)

Length

Part No.

in. (mm)

Color code

43604-78

4.420 (112.27)

Orange

43605-78

4.434 (112.62)

Yellow

43606-78

4.448 (112.98)

White

Table 6 REAR WHEEL BEARING SPACER SLEEVES–LACED WHEEL (1986-EARLY 1991 MODELS)

Length

Part No.

in. (mm)

Color code

43601-78A

4.420 (112.27)

Orange

43602-78A

4.434 (112.62)

Yellow

43603-78A

4.448 (112.98)

White

Table 7 REAR WHEEL BEARING SPACER SHIMS (LATE 1991-1999 MODELS)

Length

Part No.

in. (mm)

43290-82

0.030-0.033 (0.76-0.84)

43291-82

0.015-0.017 (0.38-0.43)

43292-82

0.0075-0.0085 (0.191-0.216)

43293-82

0.0035-0.0045 (0.089-0.114)

43294-82

0.0015-0.0025 (0.038-0.064)

Table 8 TUBELESS TIRE SPECIFICATIONS (1986 MODELS)

Front tire

Type

Dunlop K181

Size

MJ90-19

Wheel diameter

19 in.

Rim width and contour

T19 × 2.15 MT

Valve stem hole diameter

0.45 in. (11.4 mm)

Rear tire

Type

Dunlop K181

Size

MT90-16

Wheel diameter

16 in.

Rim width and contour

T16 × 3.00 D

Valve stem hole diameter

0.45 in. (11.4 mm)

Table 9 TUBELESS TIRE SPECIFICATIONS (1987-1990 MODELS)

Front tire

Type

Dunlop K181 or K291

Size

MJ90-19

Wheel diameter

19 in.

Rim width and contour

T19 × 2.15 MT

Valve stem hole diameter

0.45 in. (11.4 mm)

Rear tire

Type

Dunlop K181 or K291

Size

MT90-16

Wheel diameter

16 in.

Rim width and contour

T16 × 3.00 D

Valve stem hole diameter

0.45 in. (11.4 mm)

WHEEL, TIRES AND SECONDARY DRIVE

497

WIRING DIAGRAMS

607

Neutral

indicator

switch

Oil

pressure

switch

Left
rear turn
signal

Violet

tag

Brown

tag

Battery

Rear

spark

plug

Front

spark

plug

Ground under

rear brake
line clamp

on frame

Ignition

control

module

sensor

Diagram Key

Connectors

Ground

Frame ground

No connection

(NC)

Connection

Rear

brake

switch

Stator

Starter

Vacuum

switch

Tail/
brake
light

Right
rear turn
signal

Ignition control

module

Voltage

regulator

Starter

relay

86 85

Ignition

coil

608

WIRING DIAGRAMS

Neutral

indicator

High beam

indicator

Left turn

signal

indicator

Right turn

signal

indicator

Oil press.

indicator

Headlight

Right

front turn

signal

Left

front turn

signal

Left

turn signal

switch

Emergency

stop

switch

Starter

switch

Right

turn signal

switch

Horn

switch

Front

brake

switch

Off
On

Run

Ignition

switch

Headlight

dimmer switch

Speedometer

light

Tachometer

(Models so

equipped)

Tachometer

light

Turn signal

canceller

module

High

Low

1991-1993 ALL MODELS (EXCEPT HDI MODELS)

WIRING DIAGRAMS

609

Neutral

indicator

switch

Oil

pressure

switch

Left
rear turn
signal

Battery

Spark

plugs

Ignition

control

module

sensor

Diagram Key

Connectors

Ground

Frame ground

No connection

Connection

Rear

brake

switch

Stator

Ignition

coil

Starter

Ignition control

module

Vacuum

switch

Tail/
brake
light

Right
rear turn
signal

Voltage

regulator

Starter

relay

86 85

Butterfly valve

solenoid

(CA models only)

610

WIRING DIAGRAMS

Neutral

indicator

High beam

indicator

Left turn

signal

indicator

Right turn

signal

indicator

Oil press.

indicator

Headlight

Right

front turn

signal

Left

front turn

signal

Left

turn signal

switch

Emergency

stop

switch

Starter

switch

Right

turn signal

switch

Horn

switch

Front

brake

switch

Off
On

Run

Ignition

switch

Headlight

dimmer switch

Speedometer

light

Tachometer

(Models so

equipped)

Tachometer

light

Turn signal

canceller

module

High

Low

Position

light

1991-1993 HDI MODELS

WIRING DIAGRAMS

611

Neutral

indicator

switch

Oil

pressure

switch

Left
rear turn
signal

Battery

Spark

plugs

Ignition

control

module

sensor

Diagram Key

Connectors

Ground

Frame ground

No connection

Connection

Rear

brake

switch

Stator

Ignition

coil

Starter

Ignition control

module

Vacuum

switch

Tail/
brake
light

Right
rear turn
signal

Voltage

regulator

Starter

relay

86 85

612

WIRING DIAGRAMS

Neutral

indicator

High beam

indicator

Position

light

Left turn

signal

indicator

Right turn

signal

indicator

Oil press.

indicator

Headlight

Right

front turn

signal

Left

front turn

signal

Left

turn signal

switch

Emergency

stop

switch

Starter

switch

Lights

10A

Instr

10A

Acc

15A

Ign.

15A

Right

turn signal

switch

Function/

tripmeter

reset switch

Horn

switch

Front

brake

switch

Ignition

switch

Headlight

dimmer switch

Speed

sensor

Speedometer

lights

Tachometer

(1995 1200 models only,

1996 1200 and 1200S

models only)

Turn signal

module

High

Low

Off

Acc

Ign

1994-1996 ALL MODELS (EXCEPT 1996 1200C MODELS)

WIRING DIAGRAMS

613

Neutral

indicator

switch

Oil

pressure

switch

Left
rear turn
signal

Battery

Ignition control

module sensor

(All 1995 models)

Cam position

sensor (All 1996

models except

1200C models)

Diagram Key

Connectors

Ground

Frame ground

No connection

Connection

Rear

brake

switch

Stator

Starter

Motor

Main
circuit
breaker
50A

Vacuum

operated

electrical

switch

Tail/
brake
light

Right
rear turn
signal

(HDI only)

(DOM only)

Ignition control

module

Ground,

rear engine

mount

Voltage

regulator

Starter

relay

86 85

Butterfly valve

solenoid

(CA models only)

Spark

plugs

Ignition

coil

614

WIRING DIAGRAMS

Neutral

indicator

High beam

indicator

Position

light

Left turn

signal

indicator

Right turn

signal

indicator

Oil press.

indicator

Headlight

Right

front turn

signal

Left

front turn

signal

Left

turn signal

switch

Emergency

stop

switch

Starter

switch

Lights

10A

Instr

10A

Acc

15A

Ign.

15A

Right

turn signal

switch

Function/

tripmeter

reset switch

Horn

switch

Front

brake

switch

Off

Acc

Ign

Ignition

switch

Headlight

dimmer switch

Speed

sensor

Speedometer

lights

Turn signal

module

High

Low

1996 1200C MODELS

WIRING DIAGRAMS

615

Neutral

indicator

switch

Oil

pressure

switch

Left
rear turn
signal

Battery

Ignition

control

module

sensor

Diagram Key

Connectors

Ground

Frame ground

No connection

Connection

Rear

brake

switch

Stator

Starter

Motor

Main
circuit
breaker
50A

Vacuum

operated

electrical

switch

Tail/
brake
light

Right
rear turn
signal

(HDI only)

(DOM only)

Ignition control

module

Ground,

rear engine

mount

Voltage

regulator

Starter

relay

86 85

Butterfly valve

solenoid

(CA models only)

Spark

plugs

Ignition

coil

Harley Davidson 1986-2003 XL/XLH Sportster. Service Manual - page 29