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Remove the O-ring Figure 12 from the accelerator pump housing cover. Install a new O-ring at the top of each pushrod cover. Secondary locking wedge NOTE With the exception of the 3-pin Deutsch con- nector, all of the secondary locking wedges are symmetrical.

Pinion shaft bearing outer race 9. If the charging system output exceeds the current demand and the battery continues to not hold a charge, perform the Battery Current Draw Test as described in this section. Using a suitable mandrel, press in the inner end bearing sporfster a sportater of 0. Determine the valve guide inner diameter as follows: To help approximate ignition timing when installing the ignition module, mark the position of the mounting screws on the ignition module timing plate.


Disconnect the butter- bles 1 and Table 2 are at the end of the chapter.

Harley-Davidson XLH Sportster Service Manual

Screw Rear Shock Absorbers these bolts incorrectly can cause oil leaks or cylinder head warp. Frame downtube alternator stator 4. Lower oil ring 9.

Remove the shift fork Figure To install close ratio gears in a model, refer to Close Ratio Gear Installation in this section. Disconnect the ignition timer plate wires from the wir- ing harness Figure 16, typical.


Feeler Gauge The feeler or thickness gauge Figure 25 is used manal measuring the distance between two surfaces. Felt seal late models models Disconnect the electrical connector from the neutral in- dicator switch Figure Turn the clutch adjusting screw clockwise to move the ramp assem- bly forward.

Inspect the spring plate C, Figure 24 for cracks or damage. When the ignition switch is turned on and the start button 0.

On the socket housing side, the tangs are located at spprtster top of each chamber. Spring seat flat 8. On models, disconnect the VOES vac- uum hose from the carburetor Figure 92 with the engine idling at rpm. Inspection Inspect the wheels regularly for lateral side-to-side and radial up-and-down runout, even spoke tension and visi- ble rim damage.

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Harley-Davidson Sportster 883 Owner’s Manual

Repeat until all of the clutch plates have been in- stalled. Turn the ignition on. NOTE If the tappet is tight in the guide, tap it lightly with a rubber-faced hammer and re- move it. Cam gear bushing Pull the string back through the frame, routing the new cable through the same path as the old cable.

Clutch and primary drive assembly. Do not use a wire brush to clean the ring grooves or piston sides. Do not remove the bearing assemblies unless they require re- placement.

Install the sensor plate gasket, inner cover and outer cover. Then install the ar- mature Figure 99 into the solenoid housing.

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