Harley Davidson Sportster 2019 Factory Workshop Service Repair Manual


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Loaded with Hi Resolution illustrations, instructions, photos, and diagrams, complete to service and repair your Harley. Read and print pages directly from the CD, or copy the entire manual to your hard drive.


Pages: 1700+


Models Covered :


2019 Harley-Davidson SuperLow
2019 Harley-Davidson Iron 883
2019 Harley-Davidson Iron 1200
2019 Harley-Davidson 1200 Custom
2019 Harley-Davidson Roadster
2019 Harley-Davidson Forty-Eight
2019 Harley-Davidson Forty-Eight Special

Manual Covers :


Service Manual:
Foreword:

Foreword

Maintenance:

Fastener Torque Values
General
Fuel and Oil
Maintenance Schedule
Engine Oil and Filter
Air Cleaner and Exhaust System
Tires and Wheels
Primary Chain
Transmission Lubricant
Clutch
Brakes
Brake Pads and Discs
Drive Belt and Sprockets
Throttle Control
Cable and Chassis Lubrication
Spark Plugs
Steering Head Bearings
Suspension Adjustments
Engine Mounts and Stabilizer Links
Battery Maintenance
Wheel Alignment
Headlamp Alignment
Storage
Troubleshooting

Chassis:

Fastener Torque Values
Specifications
VIN
Tires
Wheels
Wheel Lacing
Checking and Truing Wheels
Front Brake Master Cylinder and Reservoir
Front Brake Calipers
Rear Brake Master Cylinder and Reservoir
Rear Brake Calipers
Brake Lines
Bleeding Brakes
Electroc Hydraulic Control Unit
Left Side Cover
Front Fork
Fork Stem and Bracket Assembly
Belt Guard and Debris Deflector
Rear Fork
Shock Absorbers
Stabilizer Links
Front Engine Mount and Isolator
Throttle Cables
Clutch Control
Handlebar
Seat
Saddlebags
Headlamp Visor
Front Fender
Front License Plate
Rear Fender : Top Mount License Plate Except XL1200T, XL1200C
Rear Fender : XL1200C
Rear Fender : XL1200T
Rear Fender : Models With Integrated Turn Signal, Tail and Stop Lamps
Windshield
Saree Guard
Rear License Plate : India Models
Rider Foot Controls : Mid Mount
Rider Foot Controls : Forward
Passenger Footrests
Jiffy Stand
Fork Lock
Medallions, Badges and Tank Emblems

Engine:

Fastener Torque Values
Specifications
Crankcase Breathing System
Oil Pressure
Engine Lubrication System
Troubleshooting
How To use this Section
Top End Service
Top End Overhaul : Disassembly
Top End Overhaul : Assembly
Bottom End Service
Bottom End Overhaul : Disassembly
Bottom End Overhaul : Assembly
Removing Engine From Chassis
Installing Engine in Chassis
Cylinder Head
Cylinder and Piston
Oil Pump
Oil Filter Mount
Gearcase
Crankcase
Oil Tank

Fuel System:

Fastener Torque Values
Specifications
Fuel Pressure Test
Intake Leak Test
Air Cleaner Assembly
Fuel Filter Element
Fuel Tank
Induction Module
Idle Air Control
Throttle Position Sensor
Temperature Manifold Absolute Pressure Sensor
Heated Oxygen Sensor
Engine Temperature Sensor
Fuel Injectors
Fuel Pump
Exhaust System
Evaporative Emissions Control

Drive and Transmission:

Fastener Torque Values
Specifications
Primary Cover
Primary Drive and Clutch
Drive Belt
Transmission Power Flow
Case Disassembly for Transmission Removal
Transmission Removal and Disassembly
Transmission Assembly
Main Drive Gear and Bearing
Transmission Right Case Bearings
Transmission Left Case Bearings
Transmission Installation
Transmission Sprocket

Electrical:

Fastener Torque Values
Specifications
Fuses
Speedometer
Electronic Control Module
Body Control Module
H-DSSS
Battery Tray
Battery Cables
Ignition Switch
Spark Plug Cables
Ignition Coil
Starter
Headlamp
Indicator Lamp Module
Tail Lamp : Models with Top Mount License Plate
Tail Lamp : Models with Bottom Mount License Plate
License Plate Lamp Module
Front Turn Signals
Rear Turn Signals
Rear Stop Lamp Switch
Crank Position Sensor
Vehicle Speed Sensor
Neutral Indicator Switch
Oil Pressure Switch
Voltage Regulator
Alternator
Horn
Main Wiring Harness and Electrical Caddies
Right Handlebar Control Module
Left Handlebar Control Module
Wheel Speed Sensor
Smart Siren
Personal Identification Number
Jiffy Stand Sensor

Wiring:

Wiring Diagrams


Electrical Diagnostic Manual:
Foreword:

Foreword

Intitial Diagnostics:

Specifications
Initial Daignostics
Diagnostic Tools
Diagnostics and Troubleshooting

Serial Data:

Can Data Communication
Odometer Self Diagnostic Inoperative
No Vehicle Power or Lost Communication DTCS

Starting and Charging:

Battery Testing
Starting System
Starter Output Diagnostics
Testing Starter on Motorcycle
Testing Starter on Bench
Charging System
ABS Voltage Diagnostics
Ignition Switch Diagnostics
Engine Stop Switch Diagnostics
BCM Voltage Diagnostics

Instruments:

Instruments
Fuel Level Diagnostics
Trip Odometer Functions Inoperative
Indicator Lamps

Accessories, Horn, Lighting and Security:

ACC Circuit Diagnostics
Horn Diagnostics
Turn Signals
Front Turn Signal Diagnostics
Rear Turn Signal Diagnostics
Headlamp Diagnostics
Stop Lamp Diagnostics
Switch Diagnostics
Running Lamp Diagnostics
Security System
Key Fob
Siren
Service and Emergency Functions and Configurations
Alarm Diagnostics
Security Antenna Diagnostics
DTC B2183, B2188, B2193. B2198
Neutral Switch Diagnostics

Engine Management:

EFI System
Electronic Control Module
Sensors and Drivers
System Power Circuit Diagnostics
Map Sensor Diagnostics
Fuel Pump Diagnostics
IAT Diagnostics
TPS Diagnostics
ET Sensor Diagnostics
HO2S Diagnostics
Fuel Injector Diagnostics
CKP Sensor Diagnostics
Purge Solenoid Diagnostics
VSS Diagnostics
Idle Speed Control Diagnostics
ECM Internal Diagnostics
ECM Internal Diagnostics
DTC P0641
DTC P1009
Ignition Coil Driver Diagnostics
JSS Diagnostics
Engine Performance Diagnostics
Starts, Then Stalls
Engine Cranks But Will not Start
Misfire at Idle or Under Load

ABS:

Antilock Brake System General Information
Internal Fault Diagnostics
WSS Diagnostics
Invalid VIN Diagnostics
ABS Indicator Always on, Flashing or Inoperative

Wiring:

Wiring Diagrams
Wire Harness Connectors

Connector Repair:

Bosch Compact 1.1M Sealed Connectors
Delphi GT Sealed Connectors
Delphi Metri-Pack Sealed Connectors
Delphi Micro 64- Sealed Connectors
Deutsch DT and DTM Sealed Connectors
JAE MX19 Sealed Connector
Molex BPT Sealed Connectors
Molex CMC Sealed Connectors
Molex MX Sealed Connectors
Sealed Splice Connectors
Tyco Get 64 Sealed Connectors
Tyco MCP Sealed Connectors
Tyco Multilock Unsealed Connector
Tyco Superseal 1.5 Sealed Connectors



This manual is the same as the manual used by workshops. Service Manual contains detailed instructions and step by step diagrams for all workshop procedures.


Language: English
Format: PDF


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