Harley Davidson Sportster 1970-2003. Owner's Manual — page 4

Contents
Drive belt - removal, inspection and installation. . . . . . ... 10

Drive chain - removal, cleaning, inspection and installation. . . . ..9

Forks - disassembly, inspection and reassembly. . . . . . . . . . . . ..4

Forks - removal and installation. . . . . . . . . . . . . . . . . . . . . . . . . . 3

General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Handlebars - removal and installation. . . . . . . . . . . . . . . . . . . . . 2

Rear shock absorbers - removal and installation. . . . . . . . . . . . ..6

Sprockets - check and replacement. . . . . . . . . . . . 11

Steering head bearings - adjustment, removal, inspection

and installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Swingarm - removal, inspection and installation. . . . . . . . . . . . . 8

Swingarm bearings - check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Specifications

Fork oil capacity See Chapter 1
Torque specifications
Handlebar clamp bolts (1999 and later) 12 to 15 ft-lbs (16 to 20 Nm)
Steering stem pinch bolt
1970 through 1978 20 to 25 ft-lbs (27 to 34 Nm)
1979 through 1985 21 to 27 ft-lbs (28 to 37 Nm)
1986 through 1989 25 to 30 ft-lbs (34 to 41 Nm)
1999 and later 30 to 35 ft-lbs (41 to 47 Nm)
Upper triple clamp pinch bolts
1970 through 1985
1986 and 1987 21 to 27 ft-lbs (28 to 37 Nm)
1988 through 1990 25 to 30 ft-lbs (34 to 41 Nm)
1991 and later 30 to 35 ft-lbs (41 to 47 Nm)
Lower triple clamp pinch bolts
1970 through 1978 35 ft-lbs (47 Nm)
1979 through 1987 30 to 35 ft-lbs (41 to 47 Nm)
1988 and later 883 models 30 to 35 ft-lbs (41 to 47 Nm)
1988 through 1990 1200 models 25 to 30 ft-lbs (34 to 41 Nm)
1991 and later 1200 models 30 to 35 ft-lbs (41 to 47 Nm)
Swingarm pivot shaft (1979 through 1985) 50 ft-lbs (68 Nm)
Swingarm Allen bolts (1986 and later) 50 ft-lbs (68 Nm)

Chapter 6

Brakes, wheels and tires

Contents

Disc brakes - bleeding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Front brake disc - removal and installation. . . . . . . . . . . . . . . . . 6

Front disc brake caliper - overhaul. . . . . . . . . . . . . . . . . . . . . . . ..8

Front disc brake caliper - removal and installation. . . . . . . . . . . ..7

Front disc brake master cylinder - removal and installation. . . . ..9

Front disc brake pad replacement. . . . . . . . . . . . . . . . . . . . . . . . 5

Front drum brake - inspection and brake shoe replacement. . . ..4

Front wheel - removal and installation. . . . . . . . . . . . . . . . . . . . . 3

General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Rear brake disc - removal and installation. . . . . . . . . . . . . . . . . ..16

Rear disc brake - brake pad replacement. . . . . . . . . . . . . . . . . . 13

Rear disc brake caliper - removal, overhaul and installation. . . . 14

Rear disc brake master cylinder - removal and installation. . . . . 15

Rear drum brake - inspection and brake shoe replacement. . . . 12

Rear wheel - removal and installation. . . . . . . . . . . . . . . . . . . . . ..11

Tube tires - removal and installation. . . . . . . . . . . . . . . . . . . . . . ..18

Tubeless tires - general information. . . . . . . . . . . . . . . . . . . . . . ..17

Tubes-repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Wheels - inspection and repair. . . . . . . . . . . . . . . . . . . . . . . . . . ..2

Wheel bearings - inspection and maintenance. . . . . . . 20

Specifications

Wheels

Size (diameter)

1970 through 1979

Front. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 inches

Rear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 inches

1980 and later

Front. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 or 21 inches

Rear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 inches

Wheel bearing end play

1970 through mid-1991. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.004 to 0.018 inch (0.10 to 0.46 mm)

Mid-1991 through 1999. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002 to 0.006 inch (0.05 to 0.15 mm)

2000 and later. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002 inch (0.05 mm) or less

Rim runout (front and rear)

Spoke wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1/32 inch (0.79 mm)

Cast wheel

Lateral (axial). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..3/64 inch (1.19 mm)

Radial. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/32 inch (0.79 mm)

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