Harley Davidson Sportster 2010 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Harley-Davidson Model: Sportster Model Year: 2010 Product Type: Workshop Service Repair Manual Codes Vin Decoder Prefix: 1HD1 👋 Introduction Market Position Category: Mid-size cruiser/custom motorcycle....

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Type: Motorcycle

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Sku: 564651

Tags: 2010 Harley Davidson Misc Motorcycle Motorcycles Sportster

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Description

🏷️ Basic Information

Identification

Make:

Harley-Davidson

Model:

Sportster

Model Year:

Product Type:

Workshop Service Repair Manual

Codes

Vin Decoder Prefix:

👋 Introduction

Market Position

Category:

Mid-size cruiser/custom motorcycle.

Target Audience:

Enthusiasts seeking to perform their own maintenance and repairs.

Competitive Analysis

Competitors:

Cruiser motorcycles from brands like Indian, Triumph, Yamaha (Star), Honda (Shadow), Kawasaki (Vulcan).

Key Features Vehicle

Platform:

Long-standing, versatile Sportster platform known for customization and rider engagement.

Engine Configuration:

Air-cooled, Evolution V-twin engine.

Key Features Manual

Benefit:

Cost savings on dealership maintenance, increased understanding of vehicle mechanics.

Value Proposition:

Empowers owners to maintain and repair their Harley-Davidson Sportster with confidence.

📋 Manual Details

Coverage Areas

Primary Coverage:

Complete service and repair for 2010 Harley-Davidson Sportster models.

Specific Models Covered:

Sportster 883, Sportster 1200 variants (e.g., Iron 883, Nightster, 1200 Custom, 1200 Low, XR1200X).

Page Count

Estimated Pages:

Approximately 600+

Manual Type

Type:

Factory Authorized Service Manual / Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine:

Disassembly, assembly, inspection, tuning, diagnostics for Evolution V-Twin engines (883cc, 1200cc).

Fuel System:

EFI (Electronic Fuel Injection) system diagnostics, fuel pump, injectors, throttle body, sensors.

Ignition System:

Ignition module, spark plugs, coils, timing.

Transmission:

5-speed gearbox, clutch, primary drive, final drive belt maintenance.

Brakes:

Front and rear brake system inspection, service, fluid replacement, caliper maintenance.

Electrical System:

Wiring diagrams, battery, charging system (stator, regulator/rectifier), lighting, starter, switches, ECU diagnostics.

Suspension:

Front fork service, rear shock absorber replacement and adjustment.

Chassis And Frame:

Frame inspection, wheel bearing service, steering head bearing maintenance.

Bodywork And Trim:

Fender, tank, seat, fairing (if applicable) removal and installation.

Exhaust System:

Inspection and component replacement.

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, lubrication, chain/belt adjustment.

Troubleshooting:

Diagnostic procedures for common starting, running, and electrical issues.

Repair:

Detailed step-by-step instructions for component replacement and repair.

Overhaul:

Engine and transmission overhaul procedures.

Diagnostics:

Diagnostic trouble codes (DTCs) and fault finding for EFI system.

Specifications:

Torque specifications for all fasteners, clearances, and adjustments.

Technical Depth

Depth:

Comprehensive, suitable for professional technicians and advanced DIY enthusiasts.

Diagnostics Level:

Advanced electronic diagnostics with troubleshooting flowcharts.

Rebuild Capability:

Full engine and transmission rebuild procedures.

📊 Manual Specifications

File Format

Format:

Searchable PDF

Searchable Text:

Print Quality

Quality:

High-resolution scans for clear diagrams and text.

Binding Type

Binding:

N/A (Digital)

Paper Type

Paper:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine

Engine Family:

Evolution (Evo) V-Twin

Displacement Options:

883cc (53.8 cu in), 1200cc (73.4 cu in)

Configuration:

Air-cooled, 45-degree V-twin

Bore Stroke 883:

3.00 in x 3.00 in (76.2 mm x 76.2 mm)

Bore Stroke 1200:

3.497 in x 3.969 in (88.8 mm x 100.8 mm)

Valvetrain:

Overhead valves (OHV), 2 valves per cylinder

Compression Ratio 883:

8.4:1

Compression Ratio 1200:

9.7:1

Performance

Horsepower 883 Est:

Approx. 57 hp @ 6000 rpm

Torque 883 Est:

Approx. 67 lb-ft @ 3500 rpm

Horsepower 1200 Est:

Approx. 67 hp @ 6000 rpm

Torque 1200 Est:

Approx. 79 lb-ft @ 3500 rpm

Fuel System

Fuel Delivery:

Electronic Sequential Port Fuel Injection (ESPFI)

Fuel Type:

Unleaded gasoline, minimum 91 octane (95 RON) recommended.

🔧 Transmission

Standard

Type:

5-speed constant mesh

Gear Ratios Approx:

1st: 2.79, 2nd: 1.92, 3rd: 1.37, 4th: 1.00, 5th: 0.78

Clutch Type:

Clutch: Wet, multi-plate, diaphragm spring

Primary Drive:

Chain, 34/49 ratio

Final Drive:

Belt drive, 32/65 ratio

Features

Transmission Fluid:

Harley-Davidson transmission lubricant or equivalent (refer to manual for specific part number).

Primary Chain Tension:

Automatic tensioner

📐 Dimensions

Exterior

Length Approx Varies:

Approx. 87.7 in (2228 mm) depending on model.

Wheelbase Approx:

Approx. 59.6 in (1514 mm) depending on model.

Weights

Dry Weight Approx Varies:

Approx. 548 lbs (248 kg) to 575 lbs (261 kg) depending on model.

Gross Vehicle Weight Rating Gvwr Est:

Approx. 932 lbs (423 kg)

Fuel Capacity:

3.3 US gal (12.5 L)

Oil Capacity:

3.0 US qt (2.8 L) for engine/transmission combined (dry fill).

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Motorcycle safety ratings differ from automotive; focus is on design and components).

Active Features

Braking System:

Dual front disc brakes (on some models) and single rear disc brake.

Lighting:

Halogen headlamp, LED tail lamp and brake light, incandescent turn signals.

Passive Features

Frame Construction:

Steel frame and swingarm.

Tire Specifications:

Front: 100/90-19 57H, Rear: 150/80B16 71H (typical; varies by model).

Wheel Type:

Cast aluminum or wire-spoked wheels.

💡 Technology Features

Infotainment

Audio System:

Base models typically do not feature integrated audio systems; aftermarket solutions common.

Driver Assistance

Anti-lock Braking System (ABS) was an optional feature for 2010 models.

Connectivity

Diagnostic Tools:

Requires a Harley-Davidson Digital Technician (or compatible aftermarket scan tool) for advanced EFI diagnostics and programming.

🔧 Maintenance

Service Intervals

Initial Service:

First service typically at 1,000 miles (1,600 km) or 12 months.

Subsequent Service:

Subsequent services every 5,000 miles (8,000 km) or 12 months, whichever comes first.

Oil Change Interval:

Every 5,000 miles (8,000 km) or 12 months.

Fluid Specifications

Engine Oil Type:

Harley-Davidson 20W-50 Synthetic Motor Oil (or equivalent JASO MA certified oil).

Brake Fluid Type:

DOT 4 Hydraulic Brake Fluid.

Primary Chain Case Oil:

Harley-Davidson Primary Fluid or equivalent (e.g., primary lubricant, some use engine oil).

Known Issues

Common Wear Items:

Clutch wear, brake pad wear, belt drive wear, fork seal leaks, battery replacement.

Efi System:

Occasional sensor issues (e.g., MAP, O2 sensors), but generally robust.

Ignition Timing:

While electronically controlled, older spark plug condition can affect performance.

📚 Vehicle History

Brand Heritage

Brand Establishment:

Harley-Davidson Motor Company founded in 1903.

Brand Philosophy:

American motorcycle manufacturing, emphasis on V-twin engines and rider lifestyle.

Model Evolution

Sportster Introduction:

Sportster line introduced in 1957.

2010 Updates:

2010 saw continued refinement of the Evolution engine and chassis, including potential updates to EFI mapping and suspension components.

Engine Evolution Context:

The Evolution engine, introduced in 1984, is a key element of the Sportster's longevity.

Production

Manufacturing Location:

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

🏆 Awards & Recognition

Recognitions

Award Category:

Harley-Davidson Sportster has historically been recognized for its iconic styling and customization potential.

Ratings

Consumer Ratings:

Consistently popular in customer satisfaction surveys within its segment.

Certifications

Emission Standards:

Meets US EPA and CARB emission standards for the model year.