🏷️ Basic Information

Make:

Harley-Davidson

Model:

Sportster

Year:

2019

Product Name:

Harley Davidson Sportster 2019 Factory Service Repair Manual

Product Description:

Harley Davidson Sportster 2019 Factory Workshop Service Repair Manual

👋 Introduction

Target Audience:

Harley-Davidson Sportster owners, independent repair shops, and motorcycle technicians.

Manual Type Advantage:

Factory-produced manual ensures accuracy and completeness, identical to what official Harley-Davidson workshops use.

Features:

Comprehensive coverage, high-quality visuals, detailed diagnostic procedures, electrical system focus with wiring diagrams, connector repair guides, extensive troubleshooting sections.

📋 Manual Details

Models Covered:

Total Pages:

1700+

Type:

Factory Service Repair Manual / Workshop Manual

Language:

English

Format:

PDF

Accessibility:

Downloadable or Shippable CD

Compatibility:

All Windows & Mac Computers (Windows 10, 8, 7, Vista 32/64, XP, ME, 98, NT, 2000), Windows/Mac/Tablet/Phone Friendly, 32/64 bit

Readability:

Print pages directly from CD or copy to hard drive for offline access, enhancing usability.

📖 Manual Coverage

Engine:

Engine lubrication, crankcase breathing, oil pressure, top end service (cylinder head, cylinder, piston), bottom end service (gearcase, crankcase, oil tank), engine removal/installation, oil pump, oil filter mount.

Fuel System:

Fuel pressure testing, intake leak testing, air cleaner assembly, fuel filter, fuel tank, induction module, idle air control, throttle position sensor, manifold absolute pressure sensor, heated oxygen sensor, engine temperature sensor, fuel injectors, fuel pump, exhaust system, evaporative emissions control.

Drive Transmission:

Primary cover, primary drive, clutch, drive belt, transmission power flow, transmission case disassembly, transmission removal/disassembly/assembly, main drive gear and bearing, transmission case bearings, transmission sprocket.

Chassis Suspension:

Fastener torque values, specifications, VIN, tires, wheels, wheel lacing, wheel truing, front and rear brake master cylinders and calipers, brake lines, bleeding brakes, electro-hydraulic control unit, side covers, front forks, fork stem, belt guards, rear shocks, stabilizer links, engine mounts, throttle cables, clutch control, handlebars, seats, saddlebags, fenders, windshields, foot controls, jiffy stand, fork lock, badges, emblems.

Electrical Electronics:

Fuses, speedometer, electronic control module (ECM), body control module (BCM), H-DSSS, battery tray and cables, ignition switch, spark plug cables, ignition coil, starter, headlamp, indicator lamps, tail lamps, license plate lamps, turn signals, stop lamp switch, crank position sensor, vehicle speed sensor, neutral indicator switch, oil pressure switch, voltage regulator, alternator, horn, main wiring harness, handlebar control modules, wheel speed sensor, smart siren, personal identification number (PIN), jiffy stand sensor.

Diagnostics:

Initial diagnostics, diagnostic tools, troubleshooting guides for various systems, ABS diagnostics (voltage diagnostics, WSS, invalid VIN, indicator status), instrument diagnostics (fuel level, trip odometer, indicator lamps), accessories/horn/lighting/security diagnostics (ACC circuits, horn, turn signals, headlamp, stop lamp, switches, security system, key fob, siren, alarm, antenna, DTCs), engine management diagnostics (EFI system, ECM, sensors, drivers, map sensor, fuel pump, IAT, TPS, ET, HO2S, injectors, CKP, purge solenoid, VSS, idle speed control, ignition coil driver, JSS, engine performance issues like starts/stalls, cranks/no start, misfires).

Wiring:

Complete wiring diagrams for all models covered, wiring harness connectors, connector repair guides for various types (Bosch, Delphi, Deutsch, JAE, Molex, Tyco).

Bodywork:

Fenders (front and rear), side covers, fuel tank, seat, saddlebags, windshield, battery tray, headlamp visor, tank emblems, saree guards (for India models).

Maintenance:

Fastener torque values, general maintenance, fuel and oil checks, maintenance schedules, engine oil and filter replacement, air cleaner and exhaust system service, tire and wheel maintenance, primary chain adjustment, transmission lubricant service, clutch adjustment, brake system maintenance, brake pad and disc replacement, drive belt and sprocket inspection/replacement, throttle cable adjustment, chassis lubrication, spark plug replacement, steering head bearing service, suspension adjustments, engine mount inspection, battery maintenance, wheel alignment, headlamp alignment, storage procedures, troubleshooting.

Repair Rebuild:

Detailed overhaul procedures for top end (disassembly/assembly), bottom end (disassembly/assembly), engine removal from chassis, engine installation into chassis, cylinder head repair, cylinder and piston service, oil pump overhaul, gearcase disassembly/assembly, crankcase disassembly/assembly, oil tank service, transmission disassembly/assembly, clutch service, brake caliper overhaul, fork overhaul, handlebar assembly, fender replacement, windshield installation, seat removal/installation.

Diagnostics Troubleshooting:

Comprehensive diagnostic strategies for electrical and mechanical systems, specific troubleshooting steps for common issues, DTC code explanations and solutions, ABS system diagnostics.

Chassis Maintenance:

Wheel bearing inspection, steering head bearing adjustment, jiffy stand service, rider and passenger foot controls, handlebar installation and alignment, chassis lubrication points.

Depth:

Complete workshop level, including detailed step-by-step instructions, high-resolution illustrations, diagrams, and photos for all service and repair procedures. Covers basic maintenance to complete engine and transmission rebuilds, as well as advanced electrical diagnostics.

Wiring Repair:

Detailed procedures for repairing various connector types and troubleshooting wiring harness issues, including specific pinouts and wire colors in diagrams.

📊 Manual Specifications

Format:

PDF

Searchability:

Likely searchable text within the PDF, common for factory manuals.

Quality:

High Resolution Illustrations, Photos, and Diagrams

Binding:

N/A (Digital Format)

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Type:

Air-cooled Evolution V-Twin (specific displacement depends on model covered within the Sportster range, e.g., 883cc or 1200cc).

Horsepower Torque:

Specific figures vary by model (e.g., Iron 883 typically ~67 hp / ~54 lb-ft torque; Iron 1200/1200 Custom typically ~70 hp / ~73 lb-ft torque). Refer to specific model sections within the manual for precise data.

Induction:

Electronic Sequential Port Fuel Injection (ESPFI).

Oil Type:

Harley-Davidson recommends specific V-Twin motorcycle oils. Manual will specify API service classification and viscosity grade (e.g., SAE 20W-50).

Oil Capacity:

Typically around 2.8-3.0 quarts (2.6-2.8 liters) for Sportster models. Manual will provide exact capacities.

🔧 Transmission

Type:

5-speed constant mesh.

Gearbox:

N/A (standard 5-speed).

Drive Type:

Belt drive (primary and final).

Transmission Oil Type:

Harley-Davidson requires specific transmission lubricant. Manual will specify grade and type (e.g., Formula+ or equivalent primary chain lubricant).

📐 Dimensions

Wheelbase:

Varies by model. For example, Iron 883 is approximately 59.6 inches (1514 mm), Iron 1200/1200 Custom around 59.6-60.0 inches (1515-1525 mm).

Dry Weight:

Varies by model. For example, Iron 883 is around 562 lbs (255 kg), Iron 1200 around 567 lbs (257 kg), Forty-Eight around 562 lbs (255 kg).

🛡️ Safety Features

Crash Safety:

N/A (Motorcycle safety ratings are typically focused on rider protection features and operational safety, not crash test ratings like cars).

Braking System:

Dual-piston front caliper, single-piston rear caliper. Some models may offer optional ABS. Manual covers brake bleeding and component service.

Lighting:

Halogen headlamp, LED tail lamp/stop lamp, incandescent or LED turn signals depending on model. Manual details lighting system diagnostics and replacement.

💡 Technology Features

Instrumentation:

Analog speedometer with integrated digital tachometer and gear indicator on most models. Fuel gauge may be digital or indicated by a light. Manual covers instrument diagnostics.

ABS:

Anti-lock Braking System (ABS) was optional on many 2019 Sportster models. The manual includes ABS system diagnostics.

Security:

Factory security system (H-D Smart Security System) with immobilizer and siren is often standard or optional. Manual details its operation and diagnostics.

OBD Interface:

Diagnostic Trouble Codes (DTCs) can be retrieved via the motorcycle's onboard diagnostics system, accessible through specific button sequences or diagnostic tools. The manual details DTC retrieval and interpretation.

🔧 Maintenance

Oil Change Interval:

Typically every 5,000 miles (8,000 km) or annually, whichever comes first. Refer to the manual's maintenance schedule for precise intervals and checks.

Primary Chain Tension:

Check and adjust as needed, typically around 1,000-2,500 miles (1,600-4,000 km). Manual details the procedure.

Spark Plug Replacement:

Recommended at intervals often around 10,000-15,000 miles (16,000-24,000 km). Manual will specify the exact plug type and gap.

Fork Oil Type:

Manual will specify the type and viscosity of fork oil required for front suspension servicing.

Brake Fluid Type:

DOT 4 brake fluid is typically used. Manual will confirm the specification.

Common Wear Items:

Clutch plates, drive belts, brake pads, tires, and suspension components are common wear items that require periodic inspection and replacement. Electrical connectors and wiring can also be a focus for diagnosis due to vibration.

Engine Mounts:

Specific torque values for engine mounts are critical and detailed in the manual's 'Fastener Torque Values' section.

Wheel Axles:

Precise torque specifications for front and rear wheel axles are provided for safety and proper function.

📚 Vehicle History

Legacy:

Harley-Davidson has a long-standing heritage of V-twin motorcycles, with the Sportster line being one of its most iconic and enduring platforms since its introduction in 1957.

Evolution Platform:

The Sportster platform has seen continuous evolution, with the 2019 models representing a modern iteration featuring fuel injection, updated suspension, and chassis improvements, while retaining classic styling cues.

Manufacturing Location:

Harley-Davidson motorcycles are primarily manufactured in the United States (e.g., Milwaukee, Wisconsin; Kansas City, Missouri).

🏆 Awards & Recognition

Model Specific Awards:

While specific awards for the 2019 Sportster models are not universally cataloged here, the Sportster line is consistently recognized for its accessible performance and customization potential within the cruiser segment.