Harley Davidson Sportster 2007 Factory Workshop Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: Sportster Year: 2007 Product Type: Factory Workshop Manual Codes Product Identifier: 99483-07 👋 Introduction Market Position Target Audience: Harley-Davidson Sportster owners seeking to...

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Type: Motorcycle

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Sku: 362916

Tags: 2007 Harley Davidson Misc Motorcycle Motorcycles Sportster

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Description

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

Sportster

Year:

Product Type:

Factory Workshop Manual

Codes

Product Identifier:

99483-07

👋 Introduction

Market Position

Target Audience:

Harley-Davidson Sportster owners seeking to perform maintenance and repairs, independent motorcycle repair shops, and enthusiasts aiming for factory-correct procedures.

Value Proposition:

Provides dealership-level diagnostic and repair information, ensuring accuracy and completeness for effective vehicle maintenance and restoration.

Competitive Analysis

Vs Aftermarket Manuals:

Significantly more detailed and accurate than generic aftermarket manuals, reflecting factory engineering specifications and procedures.

Key Features

Illustrations:

Features numerous step-by-step photographic illustrations and clear technical drawings.

Dealer Equivalence:

Identical information used by authorized Harley-Davidson service centers.

📋 Manual Details

Coverage Areas

Primary Coverage:

All Harley-Davidson Sportster models for the 2007 model year.

Engine Variants Covered:

XL883, XL883R, XL883C (Custom), XL883L (Low), XL1200N (Nightster), XL1200R (Roadster), XL1200C (Custom), XL1200L (Low).

Page Count

Estimated Page Count:

Approximately 600-700 pages (typical for this era's factory manuals).

Manual Type

Manual Classification:

Factory Service Manual / Workshop Manual.

Language

Language:

English

Format

Format:

Printed physical book. (Note: Digital versions may exist but original is print).

📖 Manual Coverage

Systems Covered

Engine And Powertrain:

Detailed coverage of the Evolution (Evo) V-twin engine, including disassembly, assembly, inspection, and repair of top-end (cylinders, heads, valves) and bottom-end (crankshaft, connecting rods, bearings).

Fuel System:

Carburetor (Keihin CV) and fuel injection (EFI) system diagnostics, adjustment, and repair. Includes fuel pump, lines, injectors, and sensors.

Ignition System:

Ignition module, coil, spark plugs, wiring, and troubleshooting for proper spark timing and delivery.

Electrical System:

Comprehensive coverage of the entire electrical system: battery, charging system (stator, regulator/rectifier), starter motor, lighting, switches, fuses, relays, and accessory circuits. Includes wiring diagrams.

Transmission And Drivetrain:

5-speed constant mesh transmission service, clutch operation and adjustment, primary drive, and final belt drive system maintenance and inspection.

Suspension:

Front fork (41mm conventional) and rear shock absorber service, including fluid changes, seal replacement, and adjustments. Specific details for different suspension variants.

Brakes:

Front and rear brake system diagnostics, caliper service, master cylinder overhaul, brake pad replacement, fluid bleeding, and hydraulic system inspection.

Frame And Bodywork:

Frame inspection, body panel removal and installation, mounting hardware, and related components. Includes fuel tank, fenders, seat, and handlebars.

Wheels And Tires:

Wheel bearing service, tire mounting and balancing, spoke tension (if applicable), and general wheel assembly inspection.

Exhaust System:

Exhaust pipe and muffler removal, installation, and gasket replacement.

Procedures Included

Routine Maintenance:

Oil and filter changes, primary chain adjustment, spark plug replacement, air filter cleaning/replacement, brake fluid checks and changes, and tire pressure checks.

Troubleshooting Guides:

Systematic diagnostic procedures for common and uncommon problems, including electrical faults, engine performance issues, and braking system concerns.

Component Overhaul:

Detailed step-by-step instructions for rebuilding or overhauling major components like carburetors, fuel injectors, brake calipers, and engine internal components.

Diagnostic Procedures:

Procedures for using diagnostic tools (e.g., for EFI models), checking sensor data, and interpreting error codes.

Torque Specifications:

Precise torque values for all critical fasteners, essential for proper assembly and safety.

Wiring Diagrams:

Full-color, detailed electrical wiring diagrams for all circuits, facilitating diagnosis and repair of electrical issues.

Technical Depth

Depth Of Coverage:

Comprehensive. Covers everything from basic rider maintenance to complete engine teardowns and rebuilds, suitable for professional technicians and experienced DIY enthusiasts.

Diagnostic Capability:

High. Includes troubleshooting flowcharts and detailed symptom-to-cause analysis.

Special Tool Requirements:

Identifies necessary specialized tools for specific repair procedures.

📊 Manual Specifications

File Format

Digital Format Availability:

Original is printed. Digital PDF versions often available from third-party sellers, ensuring searchability and easy navigation.

Print Quality

Print Quality:

High-quality paper stock with clear, detailed illustrations and diagrams.

Binding Type

Binding Style:

Professionally bound, designed for durability in a workshop environment (typically saddle-stitched or perfect bound).

Paper Type

Paper Quality:

Durable, often glossy paper to withstand workshop use and highlight photographic illustrations.

⚙️ Engine Specifications

Primary Engine

Engine Family:

Harley-Davidson Evolution (Evo) V-twin.

Engine Configurations:

Air-cooled, pushrod-actuated, overhead valve V-twin.

Displacement Options:

883cc (53.9 cu in) and 1200cc (73.2 cu in).

Performance

Horsepower 883Cc:

Approx. 53 HP @ 6000 RPM (Stock).

Torque 883Cc:

Approx. 54 ft-lbs @ 3500 RPM (Stock).

Horsepower 1200Cc:

Approx. 66 HP @ 6000 RPM (Stock).

Torque 1200Cc:

Approx. 70 ft-lbs @ 3500 RPM (Stock).

Fuel System

Carbureted Models:

Keihin CV 40mm (Constant Velocity) carburetor.

Fuel Injected Models:

Electronic Sequential Fuel Injection (ESFI) with Delphi ECU.

Fuel Type:

Unleaded gasoline, minimum 91 octane recommended.

🔧 Transmission

Standard

Transmission Type:

5-speed, constant mesh.

Primary Drive:

Duplex chain, wet clutch.

Final Drive:

Belt drive.

Features

Clutch Type:

Wet, multi-plate, diaphragm spring.

Transmission Fluid Type:

Harley-Davidson Syn3 (or equivalent SAE 20W-50 engine oil in primary/transmission). Consult manual for specific recommendations.

📐 Dimensions

Exterior

Wheelbase:

Varies by model, approx. 56.0 - 57.5 inches (1422.4 - 1460.5 mm).

Weights

Dry Weight:

Varies by model, approx. 522 - 566 lbs (237 - 257 kg).

Gvwr:

Approx. 930 lbs (422 kg).

🛡️ Safety Features

Ratings

Safety Standards Compliance:

Designed and manufactured to meet all applicable federal motor vehicle safety standards (FMVSS) for motorcycles.

Active Features

Braking System:

Dual-piston front caliper with 292mm disc; single-piston rear caliper with 292mm disc. Available ABS on some specific models/trims.

Passive Features

Lighting:

Halogen headlamp, LED tail/brake light, incandescent turn signals.

💡 Technology Features

Infotainment

Audio System:

Base models typically have no factory audio. Some models may have provisions for dealer-installed audio systems.

Driver Assistance

ABS Availability:

Anti-lock Braking System (ABS) was an optional feature on select 2007 Sportster models.

Connectivity

Diagnostic Port:

Proprietary diagnostic connector for use with Harley-Davidson's Digital Technician tool on EFI models.

🔧 Maintenance

Service Intervals

First Service:

1000 miles (1600 km) or 6 months.

Subsequent Service:

Every 5000 miles (8000 km) or 12 months thereafter.

Oil Change Interval:

Every 2500 miles (4000 km) or 6 months, whichever comes first (for standard oil). Syn3 may extend interval per manual. Consult manual for exact recommendations based on oil used.

Fluid Specifications

Engine Oil:

SAE 20W-50 Harley-Davidson recommended (e.g., Syn3 or conventional). Check oil level via dipstick or sight glass.

Primary/Transmission Oil:

Harley-Davidson Primary Chaincase Lubricant or SAE 20W-50 engine oil. Capacity: approx. 2.8 US qt (2.6 L).

Brake Fluid:

DOT 4 brake fluid (for both front and rear hydraulic systems). Check reservoir levels regularly.

Fork Oil:

Typically SAE 10W fork oil. Capacity varies by model. Consult manual for precise volume.

Known Issues

Common Wear Items:

Belt drive wear, clutch cable adjustment, carburetor jetting (on CV models), wheel bearings, and fork seals.

Efi Considerations:

Potential for sensor issues (e.g., IAC, TPS, MAP) or injector clogging on EFI models, though generally reliable.

📚 Vehicle History

Brand Heritage

Harley Davidson Legacy:

Part of Harley-Davidson's longest-running model line, dating back to 1957, renowned for its customizable platform and distinctive V-twin character.

Model Evolution

Sportster Development:

The 2007 Sportster represents a mature iteration of the platform, incorporating electronic fuel injection on some models and continued refinement of the Evolution engine.

Production

Manufacturing Location:

United States (primarily Milwaukee, Wisconsin, and Kansas City, Missouri).

🏆 Awards & Recognition

Recognitions

Model Reputation:

The Sportster line is consistently recognized for its rider engagement, customization potential, and iconic status in the motorcycle world.