Harley Davidson Motorcycle workshop manuals

In 1981, AMF sold the organization to a group of 13 investors led by Vaughn Beals and Willie G. In the early eighties, Harley-Davidson reported that Japanese makers are importing motorcycles to the people in such volume as to hurt or

Tags: Harley-Davidson Sportster XL883, XL1200 2004 - 2013Clymer Owners Service and Repair Manual


Softcover - 616 pages - Harley-Davidson Sportster XL883 XL1200 2004 - 2013 Clymer Owners Service Repair Manual covers the following models: Sportster XL833 (2004-2009) XL883C Custom (2004-2010) XL883L Super Low (2004-2013) XL883N Iron (2009-2013) XL883R Roadster (2004-2013) XL1200C Custom (2004-2013) XL1200L Super Low (2004-2011) XL1200N Nightster (2007-2012) XL1200R Roadster (2004-2009) XL1200V 72 (2010-2013) Sportster XL1200X 48 (2010-2013)Note: this manual DOES NOT include XR1200Contents: AMENDMENTOn the 2/1 edition page X (QRD) and page 538 have been changed to note the engine oil capacity on: 2008 - 2009 models is 2.8 qt (2.65 litre) 2004 - 2007 models the capacity is 3.6 qt. (3.4 litre) QUICK REFERENCE DATA GENERAL INFORMATIONManual organization / Warnings cautions and notes / Safety / Serial numbers / Fasteners / Shop supplies / Tools / Measuring tools / Electrical system fundamentals / Basic service methods / Storage / Specifications TROUBLESHOOTINGEngine operating requirements / Engine starting / Engine performance / Sta

Tags: Harley-Davidson Sportsters 1959 - 1985 Clymer Owners Service and Repair Manual


Softcover - 376 pages - Harley-Davidson Sportsters 1959 - 1985 Clymer Owners Service Repair Manual Covers the following Models: Harley-Davidson H Sportster (1959-1969) Harley-Davidson CH Sportster (1959-1969) Harley-Davidson XLCH Sportster (1970-1980) Harley-Davidson XLH Sportster (1970-1972 1978-1985) Harley-Davidson XLCR Sportster (1977-1978) Harley-Davidson XLX Sportster (1983-1985) Harley-Davidson XLS Sportster (1980-1985) Harley-Davidson XL Sportster (1973-1977)Contents: QUICK REFERENCE DATA GENERAL INFORMATION TROUBLESHOOTING PERIODIC LUBRICATION MAINTENANCE AND TUNE-UPMaintenance schedule intervals / Periodic lubrication / Engine oil and filter change / Periodic maintenance / Suspension adjustment / Breaker point ignition service / Magneto / Breakerless ignition system / Carburetor adjustments ENGINERemoval installation / Pushrods / Valves and components / Cylinder / Oil pump / Gearcase / Tappets and guides / Crankcase / Drive sprocket and seal / Engine seals / Starter drive shaft an

Tags: Harley Davidson Sportsters 1970 - 2010 Haynes Owners Service and Repair Manual


Hardcover - 228 pages - Harley Davidson Sportsters 1970 - 2010 Haynes Owners Service Repair Manual Covers the following Models: XL XLH XLCH 883 Hugger Sportster Deluxe Custom Low Roadster 1970 - 1971 1986 - 2010 XL XLX-61 XLH XLCH XLS 1000 Sportster Roadster Anniversary 1972 - 1985 XL XLH 1100 Sportster. 1986 - 1987 XL XLH 1200 1200C 1200S 1200N 1200L 1200R Sportster 1998 - 2010DOES NOT include XR-1000 engine information or 2009-on XR models.Contents Living With Your Harley Davidson- Introduction- Milwaukee Magic- Ackowledgements- About this Manual- Identification Numbers- Buying Spare Parts- Decoding the Vehicle Identification Number (VIN)- Safety First! Daily (Pre-Ride) Checks- Engine Oil Level Check- Suspension Steering and Final Drive Checks- Legal and Safety Checks- Tyre Checks Maintenance- Routine Maintenance and Servicing- Specifications- Recommended Lubricants and Fluids- Component Locations- Maintenance Schedule- Maintenance Procedures Repairs and Overhaul- Engine Transmissi

Tags: Harley Davidson XL XLH Sportster 1986-2003 Clymer Owners Service and Repair Manual


Softcover - 640 pages - Harley Davidson XL XLH Sportster 1986 - 2003 Clymer Owners Service Repair Manual covers the following Sportster XL and XLH models: XLH883 (1986 - 2003) XLH883 Custom (1999 - 2003) XLH883 Deluxe (1986 - 1995) XLH883 Hugger (1987 - 2003) XL883R (2002 - 2003) XLH1100 (1986 - 1987) XLH1200 (1988 - 2003) XL1200 Custom (1996 - 2003) XL1200 Sport (1996 - 2003)Contents: QUICK REFERENCE DATA GENERAL INFORMATIONManual organization / Warnings cautions and notes / Safety / Serial numbers / Fasteners / Shop supplies / Tools / Measuring tools / Electrical system fundamentals / Service methods / Storage / Specifications TROUBLESHOOTINGStarting the engine / Engine performance / Electrical component replacement / Starting system / Charging system / Igni

In 1981, AMF sold the organization to a group of 13 investors led by Vaughn Beals and Willie G. Davidson for $80 million. Stock is strictly managed utilising the just-in-time system.

In the early eighties, Harley-Davidson reported that Japanese makers are importing motorcycles to the people in such volume as to hurt or threaten to harm domestic producers. After a study because of the U.S. International Trade percentage, President Reagan enforced in 1983 a 45 percentage tariff on imported bikes with motor capacities more than 700 cc. Harley-Davidson subsequently denied offers of the help of Japanese motorcycle producers. But the organization performed offer to fall the obtain the tariff in exchange for loan guarantees from Japanese.

Versus attempting to fit the Japanese, this new management intentionally exploited the "retro" benefit of the devices, creating motorbikes that intentionally followed the appearance and feel of their previous machines and the subsequent customizations of owners of that age. Numerous equipment such as for instance brake system, forks, shocks, carburetors, electrics and rims had been outsourced from foreign providers and quality increased, technical modifications are made, and buyers gradually came back.

Harley-Davidson purchased the "Sub surprise" cantilever-swingarm rear suspension system build from Missouri engineer costs Davis and created they into its Softail series of motorbikes, launched in 1984 with the FXST Softail.

In reaction to feasible motorcycle markets loss because of the ageing of baby-boomers, Harley-Davidson purchased deluxe motorhome manufacturer Holiday Rambler in 1986. In 1996, the company marketed getaway Rambler toward Monaco advisor firm.

The "Sturgis" model, offering a dual belt-drive, ended up being launched in the beginning in 1980 and was made for three years. This bike was then brought back as a commemorative model in 1991. By 1990, because of the introduction of the "Fat Boy", Harley once more became the purchases commander in heavyweight markets. During the time of unwanted fat kid design introduction, an account quickly spread that their silver paint tasks along with other qualities are motivated because of the B-29; and Fat Boy ended up being a variety of the names of the atomic bombs Fat Man and Little Boy. However, the Urban Legend guide Pages details this tale as an urban legend.

1993 and 1994 spotted the substitution of FXR models because of the Dyna, which became the only real plastic mount FX gigantic Twin framework in 1994. The FXR was revived briefly from 1999 to 2000 for unique restricted editions.

Construction started in the $75 million, 130,000 square-foot Harley-Davidson Museum when you look at the Menomonee area on June 1, 2006. It started in 2008 and houses their big number of historic motorbikes and corporate archives, along side a restaurant, café and meeting area.

Harley-Davidson, Inc., or Harley, try an United states motorcycle producer, created in Milwaukee, Wisconsin in 1903.

Among two biggest United states bike brands to endure the fantastic despair, the business has survived many ownership arrangements, subsidiary arrangements, times of bad economic health insurance and goods high quality, also intense worldwide competitors — to become among the world's biggest bike makers and an iconic brand name widely known for the loyal following — with holder groups and activities worldwide as well as a business sponsored brand-focused museum.

Noted for a method of customization that gave rise on chopper motorcycle style, Harley-Davidson traditionally marketed heavyweight, air-cooled cruiser motorbikes with engine displacements more than 700 cm³ — and has broadened their choices to incorporate their more sophisticated VRSC and middle-weight road platforms.

Harley-Davidson manufactures its motorbikes at factories in York, Pennsylvania; Milwaukee, Wisconsin; Kansas town, Missouri; Manaus, Brazil; and Bawal, Asia — and markets their services and products global.

Besides motorcycles, the company licenses and areas merchandise in Harley-Davidson brand name, one of them becoming apparel, decor in your home and ornaments, add-ons, toys, and scale figures of the motorcycles, and game titles considering their motorcycle range and neighborhood.
The expression softail describes motorbikes and bicycles that function a concealed rear suspension program with springs or surprise absorbers to soak up lumps. Softail motorbikes give the appearance of experiencing a hard-tail or rigid frame, ordinarily with the shock absorbers or springs under the motorcycle and regarding see.

The phrase "softail" was a registered trademark of Harley-Davidson motorcycles, coined aided by the release of the FXST Softail in 1984. Since that time, the word possess broadened to add other motorbikes with hidden back suspensions plus bicycles integrating a rear suspension. Its in addition said Softail means crusty old Harley bikers and their particular inability to keep erection quality.

In Harley-Davidson motorbikes, the softail frame was created to look like the rigid-frame bikes of history, while nevertheless offering the comfort of rear suspension. The shock absorbers are positioned over the axis of the bike, tucked away in transmission.
2011 Harley-Davidson FLSTFB Softail Fat Man Lo
2008 Harley Davidson FXSTC Softail Personalized

There are lots of Harley-Davidson systems because of the Softail frame, like the Softail traditional, Customized, Springer Softail, traditions Softail, Heritage Springer, evening Train, Deluxe, Deuce, Fat child, Softail Slim, the Dark Personalized Cross Bones, the Dark Personalized Blackline and Breakout. With the exception of the Deuce, which includes a 2 ins anchor stretch, these motorbikes have the same engine, transmission and frame and vary primarily when you look at the selection of fork, wheels and accessories.
Front forks

The Softail model range have included a number of selection right in front fork designs. Historically, they have furthermore supplied the Springer leading link forks that are similar to the sprung front-ends that have been put prior to the introduction of the Hydra-Glide in 1949. The FXST designation is used for 21" Front Wheel bicycles or whenever Springer fork is used with a 21 inch wheel, even though the FLST designation can be used for 16" Front Wheel Bikes or if the Springer hand can be used with a 16 inch wheel.
Engines

The Softail products do not have rubber-mounted machines. This resulted in even more vibration in Evolution-engined Softails than in rubber-mounted Touring or Dyna products with advancement motors. To compensate because of this, existing Softail designs need a counterbalanced type of the Twin Cam motor instead of the regular Twin Cam motor found in the Touring and Dyna systems.
History

Costs Davis, an enthusiastic Harley driver and professional from St. Louis, Mo. created the softail in the mid-1970s. Their first design, which he labored on in 1974 and 1975, had a cantilever swingarm pivoted at the bottom and sprung at the top using springs and surprise absorber concealed underneath the chair. Upon training his design, Davis built a prototype predicated on his 1972 Super Glide. Davis branded his build and called Willie G. Davidson, organizing a meeting in August 1976. Davidson ended up being impressed, but made no obligations. Davidson replied 6 months later on, stating your team wouldn't be able to use the style at that time but had been still interested in it.

Davis carried on to produce the design, changing the pivot and also the springing guidelines around so that the springs and shock absorber are beneath the framework therefore the pivot aim was at the top the triangular swingarm. This let the standard Harley-Davidson oils container to be placed directly under the seat. Davis attemptedto produce this new design on their own due to the fact path Worx Sub-Shock, nevertheless the relationship he previously put together for this purpose folded. Harley-Davidson exec Jeffrey Bleustein called Davis shortly afterward and began negotiations to get Davis's build. Davis sold his patents, prototype, and tooling to Harley-Davidson in January 1982. After additional evaluating and developing, Davis's build was introduced in June 1983 since the 1984 Harley-Davidson FXST Softail.

In April 1980 Harley-Davidson going work with a unique rear suspension system build that will have the appearance of a hard-tail bike. The task was presented with a low priority until later on around it had been utilized in Jim Haubert Engineering, a firm that Harley-Davidson contracted annual to custom-designed build motorcycles and prototypes. Haubert built a prototype making use of his very own back suspension build that closely observed the look of the earlier Harley rigid frames. This version ended up being complete enough for assessment by Harley-Davidson in January 1981.
Sportster motorcycles were running on a four-stroke, 45° V-twin engine which both connecting rods, associated with the "fork and blade" or "knife & fork" build, share a common crank pin. The initial Sportster engine ended up being the Ironhead system, that has been replaced aided by the advancement engine in 1986. Sportster motors, the 45 cubic inches R, D, G & W products 1929 side-valve motors, and the 'Big Twin' side-valve motors, that have been: the flathead 74.0 cu in designs V, VL etc., Models U and UL, and the 80.0 cu in designs VH and VLH, models UH and ULH has four split webcams, sporting one lobe per cam.

The cam followers found in Sportster motors, K designs, huge double side-valve brands, plus the side-valve W model series had been a somewhat smaller version of the supporters found in the larger motors, but with the exact same 0.731-inch diameter human body and 0.855-inch diameter roller follower since 1929. The organization put similar cam supporters for many years with lesser changes, from 1929 to the Eighties.
An average 5-gear, foot-shift transmission on an HD Sportster

Sportster machines retained the K/KH design crankcase build, where the transmission is within the exact same casting due to the fact motor, and driven by the engine with a triple-row #35 string main drive and a multi-plate cable-operated clutch. Designs since 1991 has five speeds; 1990 and earlier brands have four rates.

The system ended up being mounted straight to the frame from 1957 through 2003 model season. Although this program allows the bicycle becoming notably light with an increase of accurate management, additionally transmits engine vibration directly to the driver. Sportsters circulated in 2004 and later make use of rubber separation supports and connect links to restrict system movement to a single jet, which significantly decrease vibration felt by the rider. Buell motorcycles built with variations of Sportster engine used a rubber mount system since 1987.

The design K, from which the Sportster evolved, is 1st civil bike created by Harley-Davidson with hydraulic shock absorbers on both tires. Common use calls this a K design.
Model K series

That is developed from the earlier 45 W design, but with the revised flat-head system and latest 4-speed transmission included in the exact same castings as would become the Sportster. The connecting rods is inherited because of the Sportster along with other build elements and measurements.

Design K and KK 1952–1953: 750 cc side-valve motors, utilizing the 45 design bore and stroke of 2.75" x 3.8125"
Model KR 1953–1969: 750 cc side-valve machines
Model KH and KHK 1954–1956: 888 cc side-valve machines, utilising the 45 model bore, however with the swing risen to 4.5625". Here is the best small twin with an extended stroke than 3.8125". The reduced stroke are otherwise universal towards the entire 45/K/Sportster range from 1929 to the present.

XL show Sportsters

XL, Ironhead, 1957–1985: 883 cc and 1,000 cc Ironhead overhead-valve motors with cast iron minds, K series framework
XLCH, Ironhead, 1958–1971: 883 cc, and 1,000 cc 1972 & up
XR-750 1970–1971: 750 cc overhead-valve motor, metal minds
XR-750 1972–1985: 750 cc overhead-valve system, alloy minds
XLCR 1977–1978-1979: Cafe racer 1,000 cc overhead-valve system, metal minds, 2000 manufactured in 77, 1200 in 78, and 9 in 1979
XR-1000 1983–1984: 1,000 cc street model making use of XR racing cylinder head also XR system components
XLR: 883 cc overhead-valve engines, iron minds

XLS Roadster 1979-1982 1000cc ironhead / 4 rate, stock equipment—2" much longer forks, 2 up seat, sissy bar, highway pegs, 3.3 gallon tank

XLS Roadster, 1983-1985, 1,000 cc ironhead, 4 gallon gasoline tank with system
XL, advancement, since 1986: 883 cc, 1,100 cc and 1,200 cc Evolution overhead-valve system, alloy heads

Harley’s Softail might have been produced in a factory in ’84, but, like some strippers I’ve understood, it was conceived in a biker’s garage during the early ’70s. A mechanical engineer and avid rider known as Bill Davis invented the prequel to your Softail in his storage in Missouri. He adored the appearance of a hardtail rigid but disliked the continual pounding on their human body that rigids are known for on long-distance trips. He had beenn’t alone. A few staff provided hardtail-style frames with plunger suspensions, but that has beenn’t sufficient for Bill. Just the back axle had a spring, he discovered all of them to-be ineffective, and they lacked the look of a genuine rigid. Davis believed he could do better and go about to show they. Experiments begun on his ’72 Super Glide in 1974.

Involved in his storage, he created the triangular swingarm-pivot arrangement that marks all Harley Softails from the period for this. Conceptually, Davis’ design drew from the old Vincent Black Shadows regarding the ’40s. The greatest difference being the double springs and snowmobile surprise concealed underneath the seat. You could even result in the argument that concept impressed all the other hidden tech tactics customizers embraced down the road down the road. Davis instituted two other big changes that carried up to initial certified H-D Softies: an oil container similar to the older Knuckle can and flexing the framework rails to align with the swingarm to raised offer the look of a rigid.

Most handcrafting gone into Bill’s guinea-pig of a Softail—not simply all framework work in their garage. The AMF decals must run. Davis also-ran 10-inch over forks with custom trees, as well. All of the sweat equity he poured to the change paid off with a bike that checked the chopper role without the chopper backache.

Bikers whom knew Harleys liked it enough that Bill recorded United States Patent 4087109 in March 1976 so he will make and offer the stealthy brand-new framework and suspension for them. On top of that, he soon figured, you will want to use the concept to Harley-Davidson directly and determine should they desired in? A phone telephone call to Willie G. later, he'd a gathering setup in Milwaukee to show Harley’s designers exactly what he’d done.

H-D’s Louie Netz welcomed Davis and somebody if they rode over, Davis on his chopperized Glide and the friend by himself cycle. Harley’s designers were impressed; Willie G. arrived on the scene from their company to generally meet with Davis to check out the cycle. Insufficient to dedicate at that moment, though. Harley’s manufacturing queue had been chock-full of projects at the time. The Softail would have to wait.

Davis lead back once again to Missouri. He didn’t remain idle, though. Figuring he might make the frames himself, Davis developed the jigs along with other accessories needed seriously to render newer chassis kits by himself. When he isn’t creating the 10 or more Softail structures he sold to neighborhood customers, he had been both focusing on other bikes to pay the expense or refining the Softail’s design. By switching over to twin shocks instead of the earliest snowmobile setup, Davis finally decreased the chair level closer to in which he wanted it. He also conjured up a Sportster type of their frame!

Worx for me personally

In the center of all of this, a guy strolled into Bill’s go shopping for some focus on a Knucklehead. Davis never ever divulges the guy’s title. It’s not even all that crucial anymore. What's important may be the role he played at this time. This Mr. X had business mind to Davis’ manufacturing intellect. Together they established roadway Worx—the initially Softail manufacturing business to offer that frame once we discover it. Mr. X conducted advertising and marketing surveys, guaranteed money, and have the basketball rolling. Harley hadn’t lost desire for the Softail, though. Harley’s VP of engineering, Jeff Bleustein, championed the framework, and H-D made Davis an offer for this, however the provide was only a little light for their preference.

Costs went back to focus, looking for ways to make the framework better. There was a never-ending struggle between your chair height as well as the shocks. Put the chair too low, plus the springs scraped their cooking pan. Set it greater, and he’d lose the chopper lines he wished. Desperation triggered inspiration—precisely, moving the bumps to in tranny. Solve one difficulties, though, and often write new ones. Just like this idea performed.

The room beneath the transmission wasn’t precisely spacious; normal-sized bumps would bottom out on pavement. There was furthermore the minor matter of surprise build. Costs needed a shock that done stress; all of those other your he knew of relied on compression. Polyurethane becoming self-damping, he solved both problems with a concise brand-new shock cylinder manufactured from the items. After energetic road testing, their new “Sub Shock” Softail was prepared when it comes to cost Sturgis.

About, that’s what Bill thought. When he and Mr. X hit the road, they knew the Sub surprise might take a pounding. Whatever they performedn’t know, and found call at a bad ways, is that heat buildup smashed down the polyurethane with time until it rode more like an actual rigid rather. Bill’s anonymous business lover ultimately rode the latest Softail homes while Davis continuing to Deadwood. Misfortune struck here, too. Some jackass paid him the courtesy of robbing their saddlebags while Davis was at city. That has been adequate. He have on the bike, lead house, and got back towards drawing board. Back into steel springs and oils dampers.

Super-heavy-duty industrial springs had been smaller adequate to easily fit into the damper housing. That took proper care of the room problem. Operating the absorbers on stress in place of compression suggested designing his very own valves and pistons for the job.

At this stage, Mr. X strike the crushed operating. Path Worx became a proper company, and purchases began coming in… while the shit hit the lover. Davis along with his business lover butted minds bad. Real bad. Like, destroying-the-company bad. Left holding for loans after the separate, Davis revisited selling the style on guidance of their solicitors.

Aftermarket companies had been contemplating the style. They just desired it at scandalously low prices. Davis fundamentally turned-back to Harley-Davidson. Now Bleustein got your a far greater offer: royalties, albeit with a very long time cap. Meaning, for each product marketed Davis have a bit of the action until said cap had been fulfilled. He wasn’t delighted utilizing the notion of the money capping aside in the long run, but he took the deal anyhow. On January 6, 1982, he offered the patents, prototype, and tooling for their Sub Shock design toward engine Company. In Summer of 1983, society in particular found his eyesight in the shape of the 1984 Harley-Davidson FXST Softail.

Dangerous Business

I’d wager any sum of money Harley was considerably eager the next time around because of the AMF buyout. When those 15 execs bought H-D back once again from AMF during the early ’80s, tomorrow seemed brilliant. And bleak. Tossing off the overlord’s yoke freed Harley to go in a new way. Which was the good news. The bad development is Harley-Davidson had a need to reinvent it self if it was planning to live, not as thrive, facing foreign metal gobbling share of the market. Harley required a hero, and it needed they now.

Buying out an aftermarket design tryn’t precisely SOP at most of the motorcycle manufacturers. Harley-Davidson isn’t precisely an exception compared to that, either. It was surely a desperate time for company, therefore possibly a desperate measure had been warranted. Lookin back, those first couple of post-buyout years spotted some quite big modifications: the Evo motor, the Evo-esque Sportster twin, the FXR, and, obviously, the Softail. On top, buying the Sub surprise build might appear to be high-risk business; nobody understood for certain how large market there’d feel for a non-hardtail hardtail. Exactly what everybody else did understand ended up being that individuals liked the older rigid look, and Davis’ cycle packaged they in a fashion that might just be a large vendor. More over, he’d already finished nearly all of manufacturing design onto it. All Harley truly needed to manage is adjust they into exactly what it desired. Mainly, that meant installing the framework into the brand new development engine and creating the appearance. That’s the reason why they best took 6 months for H-D to obtain the Softail from prototype to production.

The FXST ended up being an immediate hit that boosted product sales. By 1988, Harley receive a straight better niche for it aided by the nostalgic Springer Softail.

In three decades since Harley place the earliest Softails on their showroom flooring, their framework have actuallyn’t altered much. Yeah, there’ve been large back tire kits, air suspensions, and Harley adjustment the trappings regarding the stockers, but the reason why mess with an icon? They’ve best gotten considerably nostalgic over time—mostly compliment of Davis along with his early Sub surprise variation a lot more than three decades right back.