Harley Davidson Sportster Models (2008) - Service Repair Manual - Wiring Diagrams

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HARLEY DAVIDSON SPORTSTER MODELS (2008) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS

- English Service Manual and Wiring Diagrams, to motorcycles Harley Davidson Sportster Models (2008).


MODELS COVERED

- Harley-Davidson XL 883 Sportster 883
- Harley-Davidson XL 883C Sportster 883 Custom
- Harley-Davidson XL 883L Sportster 883 Low
- Harley-Davidson XL 883R Sportster 883R
- Harley-Davidson XL 1200C Sportster 1200 Custom
- Harley-Davidson XL 1200R Sportster 1200 Roadster
- Harley-Davidson XL 1200L Sportster 1200 Low
- Harley-Davidson XL 1200N Sportster 1200 Nightster


CONTENTS:

SERVICE MANUAL

Cover
Foreword
Table Of Contents
1. Maintenance
- 1.1 General
- 1.2 Fuel And Oil
- 1.3 Maintenance Schedule
- 1.4 Bulb Requirements
- 1.5 Engine Oil And Filter
- 1.6 Brakes
- 1.7 Bleeding Hydraulic Brake System
- 1.8 Tires And Wheels
- 1.9 Primary Chain
- 1.10 Clutch
- 1.11 Transmission Lubricant
- 1.12 Rear Belt And Sprockets
- 1.13 Shock Absorber Adjustment
- 1.14 Rear Belt Deflection
- 1.15 Brake Pads And Discs
- 1.16 Battery Maintenance
- 1.17 Spark Plugs
- 1.18 Steering Head Bearings
- 1.19 Rear Fork Bearings
- 1.20 Front Fork Oil
- 1.21 Cable And Chassis Lubrication
- 1.22 Air Cleaner And Exhaust System
- 1.23 Throttle Control
- 1.24 Idle Speed And Ignition Timing
- 1.25 Fuel Supply Filter
- 1.26 Engine Mounts And Stabilizer Links
- 1.27 Headlamp Alignment
- 1.28 Fluid And Lubricant Requirements
- 1.29 Critical Fasteners
- 1.30 Storage
- 1.31 Troubleshooting
2. Chassis
- 2.1 Specifications
- 2.2 Vehicle Identification Number (V.I.N.)
- 2.3 Wheels
- 2.4 Wheel Lacing: 16 Inch Rim
- 2.5 Wheel Lacing: 19 Inch Rim
- 2.6 Wheel Lacing: 21 Inch Rim
- 2.7 Truing Laced Wheels
- 2.8 Checking Cast Wheel Runout
- 2.9 Front Brake Master Cylinder
- 2.10 Front Brake Caliper
- 2.11 Rear Brake Master Cylinder
- 2.12 Rear Brake Master Cylinder Reservoir
- 2.13 Rear Brake Caliper
- 2.14 Brake Lines
- 2.15 Tires
- 2.16 Left Side Cover
- 2.17 Front Fork
- 2.18 Fork Stem And Bracket Assembly
- 2.19 Belt Guard And Debris Deflector
- 2.20 Rear Fork
- 2.21 Shock Absorbers
- 2.22 Stabilizer Links
- 2.23 Front Engine Mount/Isolator
- 2.24 Rear Engine Mount/Isolator
- 2.25 Throttle Cables
- 2.26 Clutch Control
- 2.27 Handlebars
- 2.28 Front Fender
- 2.29 Rear Fender: All Models Except Xl 1200n
- 2.30 Rear Fender And License Plate Bracket: Xl 1200n
- 2.31 Jiffy Stand
- 2.32 Seat
- 2.33 Rider Foot Controls: All Models Equipped With Mid-Mount Controls
- 2.34 Rider Foot Controls: All Models Equipped With Forward Controls
- 2.35 Passenger Footrests
- 2.36 Fork Lock
3. Engine
- 3.1 Specifications
- 3.2 Engine
- 3.3 Oil Pressure
- 3.4 Crankcase Breathing System
- 3.5 Troubleshooting
- 3.6 Engine Lubrication System
- 3.7 How To Use This Section
- 3.8 Top End Service
- 3.9 Bottom End Service
- 3.10 Removing Engine From Chassis
- 3.11 Installing Engine In Chassis
- 3.12 Top End Overhaul: Disassembly
- 3.13 Top End Overhaul: Assembly
- 3.14 Bottom End Overhaul: Disassembly
- 3.15 Bottom End Overhaul: Assembly
- 3.16 Valve Tappets
- 3.17 Gearcase Cover And Cam Gears
- 3.18 Cylinder Head
- 3.19 Cylinder And Piston
- 3.20 Crankcase
- 3.21 Oil Pump
- 3.22 Oil Filter Mount
- 3.23 Oil Tank
4. Fuel System
- 4.1 Specifications: Fuel System
- 4.2 Electronic Fuel Injection (Efi)
- 4.3 Air Cleaner
- 4.4 Fuel Tank
- 4.5 Throttle Position Sensor (Tps)
- 4.6 Engine Temperature Sensor (Et)
- 4.7 Induction Module
- 4.8 Idle Air Control (Iac)
- 4.9 Temperature Manifold Absolute Pressure Sensor (Tmap)
- 4.10 Oxygen Sensor
- 4.11 Exhaust System
- 4.12 Fuel Injectors
- 4.13 Fuel Pump
- 4.14 Fuel Pressure Test
- 4.15 Intake Leak Test
- 4.16 Evaporative Emissions Control (Ca Models)
5. Starter
- 5.1 Specifications: Starter
- 5.2 Starter
- 5.3 Starter Solenoid
6. Drive/Transmission
- 6.1 Specifications: Drive
- 6.2 Primary Chain Adjuster
- 6.3 Clutch Release Mechanism
- 6.4 Primary Drive And Clutch
- 6.5 Secondary Drive Belt
- 6.6 Transmission
- 6.7 Case Disassembly For Transmission Removal
- 6.8 Transmission Removal And Disassembly
- 6.9 Transmission Assembly
- 6.10 Main Drive Gear And Bearing
- 6.11 Transmission Right Case Bearings
- 6.12 Transmission Left Case Bearings
- 6.13 Transmission Installation
- 6.14 Transmission Sprocket
7. Electrical
- 7.1 Specifications: Electrical
- 7.2 Voltage Regulator
- 7.3 Fuses And Relays
- 7.4 Maxi-Fuse Holder
- 7.5 Speedometer: All Single Gauge Models Except Xl 883c/Xl 1200c
- 7.6 Speedometer And Tachometer: All Dual Gauge Models
- 7.7 Speedometer: Xl 883c/Xl 1200c
- 7.8 Turn Signal And Security Module (Tsm/Tssm/Hfsm)
- 7.9 Battery Cables
- 7.10 Battery Tray
- 7.11 Ignition System
- 7.12 Ignition And Light Switch
- 7.13 Electronic Control Module (Ecm)
- 7.14 Spark Plug Cables
- 7.15 Ignition Coil
- 7.16 Charging System
- 7.17 Headlamp
- 7.18 Indicator Lamp Module
- 7.19 Tail Lamp: All Models Except Xl 1200n
- 7.20 Turn Signals
- 7.21 License Plate Lamp Module: Xl 1200n
- 7.22 Rear Lighting Converter Module: Xl 1200n (Domestic Only)
- 7.23 Rear Stop Lamp Switch
- 7.24 Crank Position Sensor (Ckp)
- 7.25 Alternator
- 7.26 Vehicle Speed Sensor (Vss)
- 7.27 Neutral Switch
- 7.28 Main Wiring Harness
- 7.29 Electrical Caddies
- 7.30 Jiffy Stand Switch: International Models
- 7.31 Optional Security Siren
- 7.32 Oil Pressure Switch
- 7.33 Horn
- 7.34 Maxi-Fuse
- 7.35 Handlebar Switch Assemblies
- 7.36 Right Handlebar Switches
- 7.37 Left Handlebar Switches
A. Appendix A Connector Repair
- A.1 Amp 1-Place Connectors
- A.2 Amp Multilock Connectors
- A.3 Autofuse Electrical Connectors
- A.4 Delphi Connectors
- A.5 Delphi Maxi Fuse Housing
- A.6 Deutsch Electrical Connectors
- A.7 Deutsch Standard Terminal Repair
- A.8 Deutsch Solid Barrel Mini Terminal Repair
- A.9 Deutsch Mini Terminal Repair
- A.10 Molex Connectors
- A.11 Packard 150 Metri-Pack Connectors
- A.12 Packard 280 Metri-Pack Relay And Fuse Block Connectors
- A.13 Packard 480 Metri-Pack Connectors
- A.14 Packard 630 Metri-Pack Connectors
- A.15 Packard Metri-Pack Terminals
- A.16 Packard Ecm Connector
- A.17 Packard Micro-64 Connectors
- A.18 Sealed Splice Connectors
B. Appendix B Wiring
- B.1 Connectors
- B.2 Wiring Diagrams
C. Appendix C Conversions
- C.1 Metric Conversion
- C.2 Fluid Conversions
- C.3 Torque Conversions
D. Appendix D Compensating Sprocket
- D.1 Compensating Sprocket
E. Appendix E Glossary
- E.1 Glossary
Tools
Torque Values
Index


ELECTRICAL DIAGNOSTIC MANUAL

Cover
Foreword
Table Of Contents
1. Starting / Charging
- 1.1 Starter Troubleshooting
- 1.2 Starting System Diagnosis
- 1.3 Starter Activation Circuits
- 1.4 Diagnostics/Troubleshooting
- 1.5 Testing Starter On Motorcycle
- 1.6 Testing Starter On Bench
- 1.7 Charging System
- 1.8 Battery Testing
2. Instruments
- 2.1 Checking For Diagnostic Trouble Codes
- 2.2 Initial Diagnostic Check: Speedometer
- 2.3 Speedometer Self Diagnostics
- 2.4 Speedometer/Tachometer
- 2.5 Breakout Box: Speedometer/Tachometer
- 2.6 Indicator Lamps
- 2.7 Dtc B1004, B1005
- 2.8 Dtc B1006, B1007
- 2.9 Dtc B1008
- 2.10 Dtc U1016, U1255
- 2.11 Dtc U1064, U1255
- 2.12 Dtc U1300, U1301 Or Bus Er
3. Tsm/Hfsm
- 3.1 Turn Signal Overview
- 3.2 Harley-Davidson Smart Security System
- 3.3 H-Dsss Actuation
- 3.4 Personal Identification Number (Pin)
- 3.5 Arming/Disarming Security System
- 3.6 Warnings And Alarms
- 3.7 Service/Emergency Functions
- 3.8 Troubleshooting
- 3.9 Checking For Diagnostic Trouble Codes
- 3.10 Initial Diagnostic Check: Tsm/Hfsm
- 3.11 Speedometer Self Diagnostics
- 3.12 Breakout Box: Tsm/Hfsm
- 3.13 Fails To Disarm (Hfsm Only)
- 3.14 Dtc B0563
- 3.15 Tsm/Hfsm: Turn Signal Errors And Dtcs
- 3.16 Dtc B1131, B1132 (Hfsm Only)
- 3.17 Dtc B1134
- 3.18 Dtc B1135
- 3.19 Dtc B1136, B1142 (Hfsm Only)
- 3.20 Dtc B1141 (Hfsm Only)
- 3.21 Dtc B1143, B1144, B1145 (Hfsm Only)
- 3.22 Dtc B1154, B1155
- 3.23 Dtc U1016, U1255
- 3.24 Dtc U1300, U1301 Or Bus Er
- 3.25 Tsm/Hfsm: Password Learn
- 3.26 Hfsm Maintenance
4. Engine Management
- 4.1 Specifications
- 4.2 Efi System
- 4.3 Efi Diagnostic Introduction
- 4.4 Checking For Diagnostic Trouble Codes: Efi
- 4.5 Initial Diagnostic Check: Efi
- 4.6 Speedometer Self Diagnostics
- 4.7 Breakout Box: Efi
- 4.8 Wiggle Test
- 4.9 Intake Leak Test
- 4.10 Engine Cranks, But Will Not Start
- 4.11 No Ecm Power
- 4.12 Starts, Then Stalls
- 4.13 Fuel System Electrical Test
- 4.14 System Relay Check
- 4.15 Fuel Pressure Test
- 4.16 Idle Air Control
- 4.17 Misfire At Idle Or Under Load
- 4.18 Dtc P0107, P0108, P0112, P0113
- 4.19 Dtc P0117, P0118
- 4.20 Dtc P0122, P0123
- 4.21 Dtc P0131, P0132, P0134, P0151, P0152, P0154
- 4.22 Dtc P0261, P0262, P0263, P0264
- 4.23 Dtc P0373, P0374
- 4.24 Dtc P0501, P0502
- 4.25 Dtc P0562, P0563
- 4.26 Dtc P0603, P0605
- 4.27 Dtc P1009, P1010
- 4.28 Dtc P1351, P1352, P1354, P1355
- 4.29 Dtc P1501, P1502
- 4.30 Dtc U1064, U1255
- 4.31 Dtc U1097, U1255
A. Appendix A Connector Repair
- A.1 Amp 1-Place Connectors
- A.2 Amp Multilock Connectors
- A.3 Delphi Connectors
- A.4 Deutsch 1-Place Electrical Connectors
- A.5 Deusch Electrical Connectors
- A.6 Deutsch Standard Terminals
- A.7 Deutsch Mini-Terminal Crimps
- A.8 Deutsch Solid Barrel Terminals
- A.9 Relay And Fuse Blocks
- A.10 150 Metri-Pack Connectors
- A.11 280 Metri-Pack Connectors
- A.12 480 Metri-Pack Connectors
- A.13 630 Metri-Pack Connectors
- A.14 800 Metri-Pack Connectors
- A.15 Metri-Pack Terminals
- A.16 Molex Connectors
- A.17 Packard Ecm Connector
- A.18 Packard Micro-64 Connectors
- A.19 Sealed Splice Connectors
B. Appendix B Wiring
- B.1 Connectors
- B.2 Wiring Diagrams
C. Appendix C Conversions
- C.1 Metric Conversion
- C.2 Fluid Conversions
- C.3 Torque Conversions
D. Appendix D Glossary
- D.1 Glossary
E. Appendix E Tsm/Tssm (Japan/Korea)
- E.1 Tsm/Tssm (Japan/Korea) Overview
- E.2 Tsm/Tssm Features
- E.3 Vehicle Delivery
- E.4 Turn Signal Functions
- E.5 Bank Angle Function
- E.6 Security System Functions (Tssm Only)
- E.7 Arming/Disarming (Tssm Only)
- E.8 Diagnostic Trouble Codes (Dtc)
- E.9 Initial Diagnostic Check: Tsm/Tssm
- E.10 Speedometer Self Diagnostics
- E.11 Breakout Box: Tsm/Tssm
- E.12 Fails To Disarm (Tssm Only)
- E.13 Turn Signal Errors: B1121, B1122, B1141
- E.14 Dtc B0563
- E.15 Dtc B1131, B1132
- E.16 Dtc B1134
- E.17 Dtc B1135
- E.18 Dtc B1154, B1155
- E.19 Dtc U1016, U1255
- E.20 Dtc U1300, U1301 Or Bus Er
- E.21 Tsm/Tssm: Password Learn
- E.22 Tssm Maintenance
Tools
Torque Values
Index