Motorcycle Segment:
Cruiser, entry-level to mid-range Harley-Davidson offering.
Competitors 2010:
Indian Scout, Triumph Bonneville, Japanese cruisers (e.g., Honda Shadow, Yamaha V-Star, Kawasaki Vulcan).
Sportster Identity:
Iconic Sportster line, known for its nimble handling and classic styling compared to larger Harley-Davidson models.
Primary Use:
Empowering owners and technicians with the official factory information for maintenance, repair, and troubleshooting.
Engine Mechanical:
Complete engine overhaul, cylinder head assembly, piston and connecting rod service, crankshaft and flywheel service, lubrication system.
Fuel System:
Fuel injection system (EFI), throttle body, fuel pump, fuel filter, fuel tank, fuel lines.
Ignition System:
Ignition module, spark plugs, ignition coils, wiring.
Transmission:
5-speed gearbox, clutch assembly, primary drive, chain adjustment, gear shift mechanism.
Electrical System:
Battery, charging system (stator, regulator/rectifier), lighting (headlamp, taillight, turn signals), starter motor, horn, fuses, relays, wiring diagrams.
Brakes:
Front and rear brake systems, brake calipers, master cylinders, brake lines, brake fluid service, rotor and pad replacement.
Suspension:
Front fork (telescopic), rear shock absorbers, fork oil service, seal replacement, shock absorber adjustment and replacement.
Wheels And Tires:
Wheel bearing service, tire mounting and balancing, spoke inspection and tensioning, wheel removal and installation.
Frame And Bodywork:
Frame inspection, body panel removal and installation, seat, fenders, handlebars, controls.
Exhaust System:
Exhaust pipes, mufflers, heat shields, lambda sensors (if applicable).
Diagnostic Troubleshooting:
Diagnostic codes (DTCs), symptom-based troubleshooting guides, common fault diagnosis.
Maintenance:
Regular service checks, oil changes, filter replacements, chain lubrication and adjustment, brake inspections, tire pressure checks.
Repair:
Component disassembly, cleaning, inspection, repair, and reassembly for all covered systems.
Troubleshooting:
Step-by-step diagnostic procedures for identifying and resolving common and complex issues.
Specifications:
Torque specifications, clearances, fluid capacities, electrical test parameters, and tolerances.
Depth Of Coverage:
Comprehensive factory-level detail, suitable for both independent technicians and skilled DIY mechanics. Covers from basic maintenance to complete engine and transmission rebuilds.
File Type:
Digital Download (typically PDF)
Printability:
Designed for printing, allowing users to create physical copies of sections or the entire manual.
Binding For Printed:
Not applicable for download, but designed for professional binding if printed.
Recommended Paper For Printing:
Standard A4 or Letter size paper, suitable for workshop environments.
Engine Type:
Air-cooled, Evolution V-twin
Displacement:
883 cc (53.9 cubic inches)
Bore X Stroke:
76.2 mm x 96.8 mm (3.00 in x 3.81 in)
Horsepower Estimate:
Approx. 50-55 HP (at crankshaft, depending on tuning and specific model variant)
Torque Estimate:
Approx. 55-60 ft-lbs (at crankshaft, depending on tuning and specific model variant)
Fuel Delivery:
Electronic Sequential Port Fuel Injection (ESPFI)
Fuel Type:
Unleaded gasoline, minimum 91 octane (R+M)/2
Oil Type:
Harley-Davidson Genuine V-Twin Synthetic 20W-50 or equivalent API CI-4 rated oil
Oil Capacity:
3.0 US qt (2.8 L) with filter change
First Service:
1,000 miles (1,600 km) or 6 months
Subsequent Service:
Every 5,000 miles (8,000 km) or 12 months thereafter
Fork Oil Type:
Harley-Davidson Motorcycle Fork Oil (often a 10W or equivalent)
Common Wear Items:
Clutch plates, brake pads, fork seals, wheel bearings, drive belt.
Potential Electrical:
Intermittent issues with charging system components (regulator/rectifier), wiring harness connections.
Fuel System Maintenance:
Regular cleaning of fuel injectors and throttle body recommended for optimal performance.
Oil Filter Part Number Example:
Harley-Davidson Part Number 63796-77A (or equivalent aftermarket)
Air Filter Part Number Example:
Harley-Davidson Part Number 29062-00C (or equivalent aftermarket)
