Harley Davidson Sportster 2019 Factory Service Manual + Wiring

The Sportster’s underlying foundations go right back to the 1952 flathead-controlled K-Model. Harley went to an over-head cam motor in ’57 and slapped the XL designator on the family. Tried and true way of thinking holds that the letters originate from “Exploratory modeL” since that is actually what it was at that point, a market concentrate to perceive how well a littler, sportier item would act in a market commanded by bigger and heavier cruiser-style bicycles. I guess you could call the “Investigation” a triumph given that we are as yet observing XL models here in 2019.

One issue you run into with such a seemingly perpetual family is that you can come up short on new intentions for keep it new, and the Sportster 1200 Custom shows that Harley isn’t exactly out of thoughts yet. For 2018, the processing plant gave the 1200 Custom a dark and-chrome treatment with dark features in chrome, dark haggles designs.

The 1200 Custom games the typical restricted “L” casing and thin “X” front end (these designators came to mirror these parts after the first XL was named) one ordinarily connects with the Sportster look. Disregarding that, the general look of the Custom is totally different from the standard.

 

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

Electric 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

 

Intiial Diagnostics:

 

Specifications

Initial Diagnostics

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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