07 Harley Davidson 50th Anniversary Sportster Motorcycle Owners Manual
07 Harley Davidson 50th Anniversary Sportster Motorcycle Owners Manual
07 Harley Davidson 50th Anniversary Sportster Motorcycle Owners Manual
Safety First
Before operating your new motorcycle it is your responsibility to read and follow the operating and
maintenance instructions in this manual, and follow these basic rules for your personal safety.
Know and respect the rules of the road (see RULES OF THE ROAD section). Carefully read
and observe the rules contained in the RIDING TIPS booklet accompanying this Owner's
Manual. Read and familiarize yourself with the contents of the MOTORCYCLE HANDBOOK
for your state.
Before starting engine, check for proper operation of brake, clutch, shifter, throttle controls,
correct fuel and oil supply.
Use only HarleyDavidson approved parts and accessories. Use of certain other
manufacturer's performance parts will void your new motorcycle warranty. See your Harley
Davidson dealer for details.
The jiffy stand locks when placed in the full forward (down)
position with vehicle weight on it. If the jiffy stand is not in
the full forward (down) position with vehicle weight on it,
the vehicle can fall over which could result in death or
serious injury. (00006a)
A new motorcycle must be operated according to the special breakin procedure. See
Breakin Riding Rules.
Operate motorcycle only at moderate speed and out of traffic until you have become
thoroughly familiar with its operation and handling characteristics under all conditions.
NOTE:
We recommend that you obtain information and formal training in the correct motorcycle riding
technique. The Motorcycle Safety Foundation® offers beginning and advanced rider safety
courses. Call (949)7273227 for information.
Do not exceed the legal speed limit or drive too fast for existing conditions. Always reduce
speed when poor driving conditions exist. High speed increases the influence of any other
condition affecting stability and increases the possibility of loss of control.
Pay strict attention to road surfaces and wind conditions. Any two wheeled vehicle may be
subject to upsetting forces such as wind blasts from passing trucks, holes in the pavement,
rough road surfaces, rider control error, etc. These forces may influence the handling
characteristics of your motorcycle. If this happens, reduce speed and guide the motorcycle
with a relaxed grip to a controlled condition. Do not brake abruptly or force the handlebar.
This may aggravate an unstable condition.
Keep cargo weight concentrated close to the motorcycle and as low as possible to minimize
the change in the motorcycle's center of gravity. Distribute weight evenly on both sides of
the vehicle and do not load bulky items too far behind the rider or add weight to the
handlebars or front forks. Do not exceed maximum specified load in each saddlebag.
NOTE:
New riders should gain experience under various conditions while driving at moderate speeds.
Operate your motorcycle defensively. Remember, a motorcycle does not afford the same
protection as an automobile in an accident. One of the most common accident situations
occurs when the driver of the other vehicle fails to see or recognize a motorcycle and turns
left into the oncoming motorcyclist. Operate only with headlamp on.
Wear an approved helmet, clothing, and foot gear suited for motorcycle riding. Bright or light
colors are best for greater visibility in traffic, especially at night. Avoid loose, flowing
garments and scarves.
Do not allow other individuals, under any circumstances, to operate your motorcycle unless
you know they are experienced, licensed riders and are thoroughly familiar with the
operation of your particular motorcycle.
Protect your motorcycle against theft. After parking your motorcycle, lock the steering head
and remove ignition key from switch. Set security alarm if present.
Safe motorcycle operation requires alert mental judgment combined with a defensive driving
attitude. Do not allow fatigue, alcohol or drugs to endanger your safety or that of others.
Vehicles equipped with a sound system should have the volume adjusted to a nondistracting
level before operating vehicle.
Maintain your motorcycle in proper operating condition in accordance with Regular Service
Intervals: 2007 Sportster Models. Particularly important to motorcycle stability is proper
tire inflation pressure, tread condition, and proper adjustment of wheel bearings and steering
head bearings.
GVWR is the sum of the weight of the motorcycle, accessories, and the maximum weight of
the rider, passenger and cargo that can be safely carried.
GAWR is the maximum amount of weight that can be safely carried on each axle.
The GVWR and GAWR are shown on the information plate which is located on the frame
down tube.
Be sure all equipment required by federal, state and local law is installed and in good
operating condition.
Keep to the right side of the road centerline when meeting other vehicles coming in the
opposite direction. Ride to left of center of your lane to avoid oily pavement ahead.
Always sound your horn, actuate your turn signals, and exercise caution when passing other
vehicles going in the same direction. Never try to pass another vehicle going in the same
direction at street intersections, on curves, or when going up or down a hill.
At street intersections give the rightofway to the vehicle on your right. Do not presume you
have the rightofway, as the other driver may not know it is your turn.
Always signal when preparing to stop, turn or pass.
All traffic signs, including those used for the control of traffic at intersections, should be
obeyed promptly. SLOW DOWN signs near schools and CAUTION signs at railroad
crossings should always be observed and your actions governed accordingly.
When intending to turn to the left, signal at least 100 feet (30.5 meters) before reaching the
turning point. Move over to the centerline of the street (unless local rules require otherwise),
slow down, enter the intersection of the street and then turn carefully to the left.
Never anticipate a traffic light. When a change is indicated from GO to STOP (or vice versa)
in the traffic control systems at intersections, slow down and wait for the light to change.
Never run through a yellow or red traffic light.
While turning either right or left, watch for pedestrians, animals, as well as vehicles.
Do not leave the curb or parking area without signaling. Be sure your way is clear to enter
moving traffic. A moving line of traffic always has the rightofway.
Be sure your license plate is installed in the position specified by law and is clearly visible at
all times. Keep the plate clean.
Ride at a safe speed that is consistent with the type of highway you are on. Pay strict
attention to whether the road is dry, oily, icy or wet.
Watch for debris such as leaves or loose gravel.
Weather and traffic conditions on the highway dictate adjusting your speed and driving
habits accordingly.
HarleyDavidson Motor Company cannot test and make specific recommendations concerning
every accessory or combination of accessories sold. Therefore, the rider must be responsible for
safe operation of the motorcycle when installing accessories or carrying additional weight.
See the Accessory and Cargo section in your Owner's
Manual. Improper loading of cargo or installation of
accessories can affect motorcycle stability and handling,
which could result in death or serious injury. (00021a)
GVWR is the sum of the weight of the motorcycle, accessories, and the maximum weight of
the rider, passenger and cargo that can be safely carried.
GAWR is the maximum amount of weight that can be safely carried on each axle.
The GVWR and GAWR are shown on the information plate which is located on the frame
down tube.
The following guidelines should be used when equipping a motorcycle, carrying passengers
and/or cargo.
Do not exceed the legal speed limit or drive too fast for existing conditions. Always reduce
speed when poor driving conditions exist. High speed increases the influence of any other
condition affecting stability and increases the possibility of loss of control.
Pay strict attention to road surfaces and wind conditions. Any two wheeled vehicle may be
subject to upsetting forces such as wind blasts from passing trucks, holes in the pavement,
rough road surfaces, rider control error, etc. These forces may influence the handling
characteristics of your motorcycle. If this happens, reduce speed and guide the motorcycle
with a relaxed grip to a controlled condition. Do not brake abruptly or force the handlebar.
This may aggravate an unstable condition.
Keep cargo weight concentrated close to the motorcycle and as low as possible. This
minimizes the change in the motorcycle's center of gravity.
Distribute weight evenly on both sides of the vehicle.
Do not load bulky items too far behind the rider or add weight to the handlebars or front
forks.
Do not exceed maximum specified load in each saddlebag.
Luggage racks are designed for lightweight items. Do not overload racks.
Be sure cargo is secure and will not shift while riding and recheck the cargo periodically.
Accessories that change the operator's riding position may increase reaction time and affect
handling of the motorcycle.
Additional electrical equipment may overload the motorcycle's electrical system possibly
resulting in electrical system and/or component failure.
The front and/or rear guard(s) can provide limited leg and
cosmetic vehicle protection under unique circumstances.
(Fall over while stopped, very slow speed slide.) It is not
made or intended to provide protection from bodily injury
in a collision with another vehicle or any other object.
(00022a)
Large surfaces such as fairings, windshields, back rests, and luggage racks can adversely affect
handling. Only genuine HarleyDavidson items designed specifically for the motorcycle model
should be used with proper installation.
Tampering
Owners are warned that removal or replacement of any noise control system component may be
prohibited by law. This prohibition applies prior to vehicle sale or delivery to the ultimate
purchaser. Use of a vehicle on which noise control system components have been removed or
rendered inoperative may also be prohibited by law.
Identification
Vehicle Identification Number (VIN): Sportster Models
General
See Typical HarleyDavidson VIN: 2007 Sportster. A unique 17digit serial or Vehicle
Identification Number (VIN) is found on each motorcycle. For a description of each item in the
VIN, refer to HarleyDavidson VIN Breakdown: 2007 Sportster Models.
Location
See VIN Locations: Sportster Models. The full 17digit VIN is stamped on the steering head
and printed on a label located on the right front frame down tube.
Abbreviated VIN
An abbreviated VIN is stamped on the left side of the crankcase between the front and rear
cylinders.
Example: CV37111000
See Typical HarleyDavidson VIN: 2007 Sportster for the complete VIN for the same
motorcycle as it appears on the steering head.
NOTE:
Always give the full 17digit Vehicle Identification Number when ordering parts or making any
inquiry about your motorcycle.
2=Midyear
3=California/regular
4=Cosmetic changes
5=California/cosmetic changes
6=California/midyear
7 VIN check digit Can be 09 or X
8 Model year 7=2007
9 Assembly plant K=Kansas City, MO USA
10 Sequential number Varies
1. Stamped VIN
2. VIN label
VIN Locations: Sportster Models
Labels
Refer to Labels: Sportster Models for safety and maintenance labels which were on the vehicle
when new. If removed, replacement labels may be purchased for your motorcycle.
Specifications
NOTES:
The XL 50 50th Anniversary Sportster® has a 1200cc engine. All XL 1200R specifications will
apply to the XL 50 unless otherwise noted.
Specifications in this publication may not match those of official certification in some markets due
to timing of publication printing, variance in testing methods, and/or vehicle differences.
Customers seeking officially recognized regulatory specifications for their vehicle should refer to
certification documents and/or contact their respective dealer or distributor.
COMPONENT SPECIFICATION
Ignition timing not adjustable
Ignition timing not adjustable
Transmission Specifications
TRANSMISSION SPECIFICATION
Type Constant mesh, foot shift
Speeds 5 forward
MODELS MODELS
Number of cylinders 2
Type 4cycle, 45 degree
(total)
Oil tank with filter 3.6 qt. 3.4 3.6 qt. 3.4 3.6 qt. 3.4
Transmission 32 oz. 0.95 32 oz 0.95 32 oz. 0.95
(approximate)
Low fuel warning 0.8 gal 3.0 1.0 gal 3.8 0.8 gal 3.0
light on
(total)
Oil tank 3.6 qt. 3.4 3.6 qt. 3.4 3.6 qt. 3.4 3.6 qt. 3.4
with filter
Transmission 32 oz. 0.95 32 oz. 0.95 32 oz. 0.95 32 oz. 0.95
(approximate)
Low fuel warning 1.2 gal. 4.5 0.9 gal. 3.4 1.2 gal. 4.5 0.9 gal. 3.4
light on
CUSTOM LOW
LB. KG LB. KG LB. KG LB. KG
Weight 563 255 565 256 563 255 568 258
Tire Data
Match tires, tubes, air valves and caps to the correct wheel
rim. Contact a HarleyDavidson dealer. Mismatching can
result in damage to the tire bead, allow tire slippage on the
rim or cause tire failure, which could result in death or
serious injury. (00023a)
Tubeless tires fitted with the correct size inner tubes may be used on all HarleyDavidson laced
(wire spoked) wheels. Protective rubber rim strips must be used with tubeless tires (fitted with
correct size inner tubes) when mounted on laced (wire spoked) wheels.
Tubeless tires are used on all HarleyDavidson cast and disc wheels.
Tire sizes are molded on the tire sidewall. Inner tube sizes are printed on the tube.
HarleyDavidson front and rear tires are not the same.
Interchanging front and rear tires can cause tire failure,
which could result in death or serious injury. (00026a)
See Specifications: 2007 Sportster Models for tire pressures and sizes.
Gasoline Blends
Your motorcycle was designed to get the best performance and efficiency using unleaded
gasoline. Most gasoline is blended with alcohol and/or ether to create oxygenated blends. The
type and amount of alcohol or ether added to the fuel is important.
Fuel
Refer to Octane Ratings: 2007 Sportster Models. Always use a good quality unleaded
gasoline. Octane ratings are usually found on the pump.
Modern service station pumps dispense a high flow of gasoline into a motorcycle fuel tank making
air entrapment and pressurization a possibility.
(R + M)/2
All Models 91 (95 RON)
Catalytic Converters
All international (HDI) and destination Japan model motorcycles are equipped with catalytic
converters.
Some features explained are unique to certain models. These features may be available as
accessories for your HarleyDavidson motorcycle. See a HarleyDavidson dealer for a complete
list of accessories that will fit your specific motorcycle.
See Sportster XL 1200N Model. Unlike all other Sportster models, the XL 1200N is equipped
with a convertible sidemounted license plate assembly, which includes an LEDilluminated
license plate lamp module. See a HarleyDavidson dealer for LED replacement.
The license plate assembly must be in the extended position during operation. Due to local
regulations, this feature may not be found in all destinations.
The standard rear fendermounted tail lamp assembly common to all other Sportster models is not
present on the XL 1200N. Instead, the rear turn signals also function as tail lamps and brake
lamps.
See Ignition/Headlamp Key Switch: Sportster Models. The ignition/headlamp key switch
controls electrical functions of the motorcycle.
See the YOUR OWNER'S MANUAL section at the front of this book. Be sure to record all your
key numbers in the space provided.
Turn key counterclockwise to remove from the ignition. Refer to Ignition/Headlamp Switch
Positions: 2007 Sportster Models for all key switch functions.
NOTES:
ACCAccessories and hazard warning flasher can be turned on. Instrument lamps are on.
Brake lamp and horn can be activated. Key may not be removed.
The lamps work when the switch is in the IGNITION position, as required by law in some
localities.
1. Ignition off
2. Accessory ON (ACC.)
3. Ignition ON
Ignition/Headlamp Key Switch: Sportster
Models
NOTE:
See Handlebar Controls. The electric starter switch is located on the right handlebar control
group. See Starting the Engine: Sportster Models for detailed operation procedures.
1. Put the engine off/run switch in the RUN position and the transmission in neutral. Neutral
(green) indicator lamp should be illuminated.
See Handlebar Controls. The engine off/run switch (7) turns the ignition power ON or OFF. The
engine off/run switch is located on the right handlebar control. Push the top portion of the engine
off/run switch to turn off ignition power and shut the engine off. Push the bottom portion of the
engine off/run switch to turn on ignition power.
NOTES:
The engine off/run switch must be in the RUN position to start or operate the engine.
The engine off/run switch should be used to shut the engine off.
1. To shut the engine off, push the top of the off/run switch to the ignition OFF position.
2. See Ignition/Headlamp Key Switch: Sportster Models. Turn the ignition key to the
OFF position to turn the ignition power completely OFF.
See Handlebar Controls. The throttle control grip (9) is located on the right handlebar control
and is operated with the right hand.
To reduce rider fatigue on long trips, a spring loaded throttle friction adjustment screw (10) is
located at the bottom of the throttle grip clamp on noncruise equipped models.
1. Slowly turn throttle control grip clockwise (toward the front of the bike) to close the throttle
(decelerate).
2. Slowly turn throttle control grip counterclockwise (toward rear of bike) to open the throttle
(accelerate).
3. Unscrew the throttle friction adjustment screw so the throttle returns to the idle position
when the hand is removed from the grip.
4. Screw the throttle adjustment screw in to increase friction on grip. This provides a damping
effect on throttle motion.
NOTE:
The throttle friction adjustment screw should not be used under normal stop and go operating
conditions.
See Handlebar Controls. The clutch hand lever (1) is located on the left handlebar and is
operated with the fingers of the left hand.
1. Slowly pull clutch hand lever in against handlebar grip to fully disengage clutch.
2. Shift to first gear using the gear shifter lever. See Shifting Gears.
A clutch switch is incorporated into the left handlebar switch assembly. It enables the rider to start
the vehicle in any gear (or in neutral) as long as the clutch lever is pulled in. If the clutch is not
disengaged, the vehicle will not start.
Horn Switch
See Handlebar Controls. The horn is operated by pushing on the horn switch (2) located on the
left handlebar control group.
See Handlebar Controls. The headlamp dimmer switch (3) is located on the left handlebar. The
switch has two positions to activate the headlamps high or low beams.
Press the top of the headlamp dimmer beam switch to activate the high beam.
Press the bottom of the headlamp dimmer switch to return to the low beam.
See Indicator Lamps. The (blue) high beam indicator lamp will illuminate when the high beam is
on.
See Handlebar Controls. Each handlebar control group contains a turn signal switch.
The right turn signal switch (11) operates the right front and right rear flashing lamps.
The left turn signal switch (4) operates the left front and left rear flashing lamps.
NOTE:
Front turn signal lamps also function as running lamps (except International models).
The turn signal switches are used by the turn signal module to control turn signal operation based
on vehicle speed, vehicle acceleration and turn completion.
Momentarily depress the desired turn signal switch. The turn signal lamps will begin and continue
flashing until they are manually or automatically cancelled. As long as the motorcycle is
stationary, the signals will flash.
NOTES:
If you are signaling to turn in one direction and you depress the switch for the opposite turn
signal, the first signal is cancelled and the opposite side begins flashing.
If you want to stop the lamps from flashing, briefly depress the turn signal switch a second
time. The turn signal lamps will stop flashing.
1. With the ignition key ON and security system disarmed (models with security only), press
the left and right turn signal switches at the same time.
2. Turn the ignition key OFF and arm the security system if present and desired. The fourway
flashers will continue for two hours.
3. To cancel fourway flashing, disarm the security system if necessary, turn the ignition key
ON and press the left and right turn signal switches at the same time.
This system allows a stranded vehicle to be left in the fourway flashing mode and secured until
help is found.
Indicator Lamps
The green TURN indicators will flash when turn signals are activated; therefore, flashing
indicates the chosen turn direction. When the 4way hazard flashers are operating, both turn
indicators will flash simultaneously.
The blue BEAM indicator lamp, when lit, signals high beam headlamp operation.
The green NEUTRAL lamp, when lit, signals the transmission is in neutral gear.
The red OIL indicator lamp, when lit, signals that oil is not circulating through the engine.
NOTE:
The OIL indicator lamp will glow when the ignition is turned on prior to starting engine. With
engine running, lamp should be off when engine speed is above idle.
Several other circumstances that could cause the red oil indicator lamp to signal, include the
following:
If the oil pressure indicator lamp does not go off at speeds above idling, it is usually because
of an empty oil tank or diluted oil.
In freezing weather the oil feed may clog with ice and sludge, preventing oil circulation.
A grounded oil signal switch wire.
A faulty signal switch.
A damaged or improperly installed check valve.
Trouble with the pump.
Speedometer
Odometer
Trip odometers A and B
12 or 24 hour clock
The speedometer has a single display window for the above functions.
3. To reset or zero trip odometers, have desired (A or B) odometer in display window. Press
function switch (on back of speedometer) and hold button for 23 seconds. The trip
odometer will be reset to zero.
4. Repeat the previous step if you wish to zero both trip odometers.
Setting Clock
3. Press and release the function switch (on back of speedometer) once to advance to a
blinking 24HR military style time display. Each time you press and release the button, the
display will switch between 12HR and 24HR.
4. When the desired time style is displayed, press and hold the function switch (on back of
speedometer) for five seconds. The display will switch to the time display with the hours
blinking.
5. Press and release the button repeatedly to advance the hours. Each time you press and
release the button, the display will advance one hour.
NOTE:
No AM or PM time setting is required. When the correct hour is reached, press and hold
function switch to advance to minute setting.
6. When the correct hour is displayed, press and hold the button for five seconds. The minutes
display will start blinking.
7. Press and release the button repeatedly to advance the minutes display. Each time you
press and release the button, the display will advance one minute.
8. When the correct minutes are displayed, press and hold the button for five seconds. The
minutes display will stop blinking, indicating that the clock has been set.
Tachometer
The tachometer (if applicable) registers the engine speed in revolutions per minute (RPM).
Should motorcycle be tipped over, the word "tip" will appear in the odometer window. Engine will
not start until reset. To reset, cycle ignition/headlamp key switch ONOFFON.
1. Speedometer
2. Function switch (back of gauge)
3. Security system lamp
4. Odometer/trip odometer
5. Battery lamp
6. Low fuel indicator
7. Check engine lamp
Speedometer/Odometer: 2007 XL 1200C
Sportster 1200 Custom
1. Speedometer
2. Function switch (back of gauge)
3. Tachometer
4. Security system lamp
5. Odometer/trip odometer
6. Battery lamp
7. Low fuel indicator
8. Check engine lamp
Speedometer/Odometer and Tachometer:
2007 XL 1200R Sportster 1200 Roadster
See Shift Pattern: Sportster Models. The gear shift lever is located on the left side of the
motorcycle and is operated with the left foot. The transmission is a five speed sequential gear
box.
1. Push the gear shift lever all the way down (full stroke) to shift the transmission to the next
lower gear.
2. Lift the gear shift lever all the way up (full stroke) to shift the transmission to the next higher
gear.
NOTES:
Release the gear shift lever after each gear change.
The lever must return to its central position before another gear change can be made.
First gear is the last gear position that can be found by pushing the gear shift lever full stroke
downward.
Neutral is located between first and second gear. The green neutral indicator lamp on the dash
will illuminate when the transmission is in neutral.
To shift from first gear to neutral, lift the gear shift lever 1/2 of its full stroke.
When the motorcycle is standing still and the engine is not running, shifting gears requires a
different technique. Before shifting in this condition, move the motorcycle backward and forward
with the clutch fully disengaged (clutch lever pulled in). While maintaining slight pressure on the
shift lever, shift from one gear to another.
Even with the engine running and the motorcycle standing still, difficulty may be experienced in
shifting gears. This difficulty occurs because transmission gears are not turning and shifting parts
are not lined up to permit engagement.
Brake System
The front brake hand lever controls the front wheel brake and is located on the right handlebar.
Operate the hand lever with the fingers of the right hand.
Brakes should be applied uniformly and evenly to prevent wheels from locking up. A balance
between rear and front braking is generally best.
Jiffy Stand
The jiffy stand is located on the left side of the motorcycle and swings outward to support the
motorcycle for parking.
The jiffy stand locks when placed in the full forward (down)
position with vehicle weight on it. If the jiffy stand is not in
the full forward (down) position with vehicle weight on it,
the vehicle can fall over which could result in death or
serious injury. (00006a)
This type of mirror is designed to give a much wider view to the rear than a flat mirror. However,
cars and other objects seen in this type of mirror will look smaller and farther away than they
actually are.
Use caution when judging the size or relative distance of objects seen in rear view mirrors.
Always adjust the rear view mirrors to clearly reflect the area behind the motorcycle before
riding.
NOTE:
Adjust mirrors so you can see a small portion of your shoulders in each mirror. This will help you
establish the relative distance of vehicles to the rear of your motorcycle.
See Fuel Filler Cap: Sportster Models. To open, turn fuel filler cap counterclockwise and lift
up. To close, turn fuel filler cap clockwise until it clicks. The ratchet action of the cap prevents
overtightening.
NOTE:
Fuel filler cap turns approximately a 3/4 turn before it starts unscrewing.
See SAFE OPERATING RULES section and review safety procedures listed below.
See Fork Lock Location: 2007 Sportster Models. Sportster models have the fork lock located
on the steering head just above the ignition/headlamp key switch. Using the fork lock immediately
after parking your motorcycle will discourage unauthorized use or theft when parking your
motorcycle.
Do not operate vehicle with forks locked. Locking the forks
restricts the vehicle's turning ability, which could result in
death or serious injury. (00035a)
See Rear Shock Absorber Adjustment: Sportster Models. The Sportster models feature
rear shock absorbers that can be adjusted for carrying the weight of a rider and/or passenger.
NOTES:
XL 883C, XL 883L Low, XL 1200C Custom, XL 1200L Low, XL 1200N Nightster, and XL 50
models have five preload positions.
XL 883 and XL 1200R Roadster models have three preload positions.
See Spanner Wrench and Preload Adjustment: Sportster Models. To adjust the rear shock
spring preload, turn spring adjusting cam to the desired position with a spanner wrench. When
reducing preload, cams should be rotated in opposite direction. A SPANNER WRENCH HD
9482075A is available from your HarleyDavidson dealer.
The 883 Low and 1200N are designed for solo operation. If
The 883 Low and 1200N are designed for solo operation. If
you choose to add an adult passenger and/or cargo to the
vehicle, the ride quality will be compromised. See a Harley
Davidson dealer for high capacity rear suspension
options. (00487e)
Components
See Smart Security System Module w/Antenna. The HarleyDavidson Smart Security
System (HDSSS) consists of a HandsFree Security Module (HFSM) (1) and a HandsFree
Antenna (2) mounted on the motorcycle, and a HandsFree Fob carried by the rider/passenger.
After parking the motorcycle, turn the ignition key to OFF and the Smart Security System will
automatically arm within five seconds. While armed, the starter and ignition are disabled and the
rider may leave the motorcycle knowing that the module will activate an alarm if someone tampers
with the ignition or attempts to move the motorcycle.
If the fob is present, the module will automatically disarm when the ignition key is turned to
IGNITION or ACCESS.
NOTE:
Options
Several options are available for the HarleyDavidson Smart Security System from the Harley
Davidson Genuine Motor Accessories and Motor Parts catalog. Options include:
FCC Regulations
This device complies with Part 15 of the FCC Rules and with RSS210 of Industry Canada rules.
Operation is subject to the following two conditions:
(1) This device may not cause harmful interference, and (2) This device must accept any
interference received, including interference that may cause undesired operation.
WARNING: Changes or modifications not expressively approved by the party responsible for
compliance could void the user's authority to operate the equipment.
The term "IC:" before the radio certification number only signifies that Industry Canada technical
specifications were met.
HandsFree Fob
Fob Assignment
See Key Fob: Smart Security System. HandsFree Fobs are electronically assigned to the
HarleyDavidson Smart Security System by a HarleyDavidson dealer so that the module can
recognize a fob's unique signal. Only two fobs can be assigned to the module at any one time.
Replacement fobs can be purchased from a dealership but can only be assigned to the
motorcycle by a trained HarleyDavidson technician.
NOTES:
The reusable label found on the fob packaging lists the serial number of the fob. For
reference, fix the label to a blank "NOTES" page in the Owner's Manual.
The serial number of the fob is also found on the inside of the fob. See Fob Battery.
The module will arm only if the fob has been assigned by a HarleyDavidson dealer and a
Personal Identification Number (PIN) has been entered in the system. The PIN should be
recorded on the Personal Information page in the front of this Owner's Manual and on the
removable wallet card.
Should the rider misplace the fob or if the fob fails, the rider can refer to the wallet card and
use the PIN to manually disarm the system. Refer to Arming and Disarming and Fob
Battery.
The PIN can easily be changed by the rider at any time. Refer to Personal Identification
Number (PIN).
Always carry the fob when riding, loading, fueling, moving, parking or servicing the
motorcycle. Carry the fob in a convenient pocket.
Do not leave the fob attached to the handlebars or store the fob in a saddlebag or Tour
Pak®. Unintentionally leaving the fob with the motorcycle when it's parked prevents the
system from activating the alarm.
Do not ride with the fob stored in a metal case or with the fob closer than 3.0 in. (76 mm) to
a cell phone, PDA, display or other electronic device. Any electromagnetic interference may
prevent the fob from disarming the system.
For added security, always lock the fork and remove the ignition key when parked. If the fob
is within range and the motorcycle is unlocked, tampering with the motorcycle will not
activate the alarm.
The Personal Identification Number (PIN) is a number that can be used to disarm the Harley
Davidson Smart Security System in case an assigned fob is misplaced, fails or if the fob and
module cannot communicate because of electromagnetic interference.
To maintain security, the rider can change the PIN at any time. Refer to Changing the PIN.
NO.
1 Select a 5digit (1 thru 9) PIN
and record on the wallet card
from Owner's Manual.
2 With an assigned fob present,
turn IGN key IGNITIONOFF
IGNITIONOFFIGNITION.
3 Press left turn signal switch 3
times.
4 Press right turn signal switch Turn signals will flash 3 times. See figure showing the
1 time and release. Current PIN will appear in odometer window with
odometer. The first digit will be PIN display.
flashing.
5 Enter first digit (a) of new PIN
by pressing left turn signal
switch a times.
6 Press right turn signal switch The new digit (a) will replace the
1 time and release. current in odometer window.
7 Enter second digit (b) of new
PIN by pressing left turn
signal switch b times.
8 Press right turn signal switch The new digit (b) will replace the
1 time and release. current in odometer window.
9 Enter third digit (c) of new PIN
by pressing left turn signal
switch c times.
10 Press right turn switch 1 time The new digit (c) will replace the
and release. current in odometer window.
11 Enter fourth digit (d) of new
PIN by pressing left turn
signal switch d times.
12 Press right turn switch 1 time The new digit (d) will replace the
and release. current in odometer window.
13 Enter fifth digit (e) of new PIN
by pressing left turn signal
switch e times.
14 Press right turn switch 1 time The new digit (e) will replace the
and release. current in odometer window.
15 Before the module rearms, The odometer will return to Turning the ignition
turn the ignition key to OFF . mileage. key to OFF stores the
new PIN in the module
See Security Status Indicator. The illuminated key icon in the speedometer face indicates the
status of the HarleyDavidson Smart Security System.
Armed: A key icon that blinks approximately every 3 seconds indicates that the system is
armed.
Disarmed: After the ignition/headlamp switch is turned to IGNITION and the system
disarms, the key icon will remain illuminated for approximately four seconds and then turn
off.
Service: A key icon that remains illuminated longer than four seconds indicates that service
of the module is required.
Arming
When the motorcycle is parked and the ignition key is turned to OFF, the HarleyDavidson Smart
Security System arms automatically within five seconds if no motion is detected. Even when the
fob is present, the system will arm.
On arming, the turn signals will flash twice and the optional siren will chirp twice. While armed, the
key icon in the speedometer face will flash every three seconds.
NOTE:
International Models: The HFSM must be in the Chirp Mode for the siren to chirp on arming or
on disarming. See Siren Chirpless/Chirp Modes: International Models.
Disarming
Once disarmed, the rider may ride or move the motorcycle for parking, storage or service without
setting off the alarm.
Fob: An armed Smart Security System is automatically disarmed when the ignition key is turned
to IGNITION with the fob present.
When the module disarms, the optional siren will chirp once and the key icon will illuminate for a
solid four seconds and then turn off.
NOTE:
Any motion, like lifting the motorcycle up off of its jiffy stand, or turning the ignition key to
IGNITION and the module will electronically "poll" for the presence of the fob. If the fob is present,
the system disarms.
Personal Identification Number (PIN): If the fob is misplaced or if the present fob fails to
communicate with the module, the system can be disarmed with the Personal Identification
Number (PIN).
Do not turn handlebars, straddle seat or lift motorcycle off the jiffy stand. During a PIN disarm, if
the Smart Security System detects motorcycle motion the system will activate the alarm.
NO.
1 If necessary, verify the Should be recorded on wallet
current 5digit PIN. card.
2 Turn ignition key to
IGNITION.
3 Quickly (within 2 seconds Key icon flashes at fast rate. See figure showing the
of turning ignition key) hold In the odometer window, a odometer window with PIN
both turn signal switches in flashing dash will be followed display. Five dashes will
until confirmation. by four more dashes. appear in the odometer
window.
4 Enter first digit (a) in the The first digit (a) in the
PIN by pressing left turn odometer will be the first digit
switch a times. in the PIN.
5 Press right turn switch 1 The first digit is stored and Serves as enter key.
time. the dash will flash.
6 Enter second digit (b) in the The second digit (b) in the
PIN by pressing left turn odometer will be the second
switch b times. digit in the PIN.
7 Press right turn switch 1 The second digit is stored Serves as enter key.
time. and the next dash will flash.
8 Enter third digit (c) in the The third digit (c) in the
PIN by pressing left turn odometer will be the third
switch c times. digit in the PIN.
9 Press right turn switch 1 The third digit is stored and Serves as enter key.
time. the next dash will flash.
10 Enter fourth digit (d) in the The fourth digit (d) in the
PIN by pressing left turn odometer will be the fourth
switch d times. digit in the PIN.
11 Press right turn switch 1 The fourth digit is stored and Serves as enter key.
time. the next dash will flash.
12 Enter fifth digit (e) in the The fifth digit (e) in the
PIN by pressing left turn odometer will be the fifth digit
switch e times. in the PIN.
13 Press right turn switch 1 The fifth digit is stored. The Smart Security System is
time. key icon stops blinking. disarmed.
NOTES:
At any time during a PIN disarm, if the fob is brought within range of the motorcycle, the
Smart Security System will disarm when the module receives the coded signal from the fob.
If a mistake is made while entering PIN, wait two minutes before another disarming attempt.
The Smart Security System will remain disarmed until the ignition key is turned to OFF.
If it should be necessary to leave a motorcycle parked along side a roadway, the hazard warning
fourway flashers can be turned ON and the Smart Security System armed.
2. Simultaneously press both left and right turn signal switches to turn the fourway flashers
ON.
3. Turn the ignition key to OFF to arm the Smart Security System.
To turn hazard warning flashers OFF, turn the ignition key to IGNITION and simultaneously press
the left and right turn signal switches.
Alarm
Warnings
Once armed, if the motorcycle is moved or lifted up off of its jiffy stand or if the ignition key is
turned to IGNITION and the fob is not present, the alarm will warn the operator with three
alternate flashes of the turn signals and a chirp of the optional siren.
Within four seconds, if the motorcycle is back on its jiffy stand and no further motion is detected
and/or the ignition key is turned to OFF, the module will remain armed without activating the
alarm.
If the motorcycle motion continues or the ignition key is not turned back to OFF, the module will
issue a second warning four seconds after the first.
NOTE:
During warnings and alarms, the starter motor and the ignition circuits are disabled.
The Alarm
If the Smart Security System is still detecting motion and/or if the ignition key has not been turned
back to OFF after a second warning, the system will activate the alarm.
Duration: The alarm will stop within 30 seconds and if no motion is detected, the alarm will not
restart.
However, if motorcycle motion continues the system will repeat the 30 second alarm and recheck
for motion. The alarm will repeat this 30 second alarm cycle for five minutes (10 cycles) or until
the alarm is deactivated.
NOTE:
The alarm will also activate the LED, vibration or audible modes of a HarleyDavidson Security
Pager. A pager can operate either in silent or in combination with an optional Smart Siren. The
range of a pager can be up to 0.5 mile (0.8 km). See a HarleyDavidson dealer for details.
Key Fob: Bring the fob to the motorcycle. After the module identifies that the fob is present, the
system will terminate the alarm.
Chirpless Mode
In the Chirpless Mode, the siren does not chirp on arming or disarming.
NOTE:
Even when armed in the chirpless mode, the siren still chirps warnings on movement and will
activate the alarm through all alarm cycles.
Chirp Mode
On arming in the Chirp Mode, the siren responds with two chirps. When disarming, the siren
responds with a single chirp.
Switching Modes
Cycling quickly through arming and disarming twice will switch the system from either the
chirpless or the chirp mode to its opposite.
1. With the fob present, the ignition key ON and the system disarmed, turn the ignition key
OFF.
2. When the system arms (2 flashes of turn signals), immediately turn the ignition key back
ON.
3. When the system disarms (1 flash of the turn signals), immediately turn the ignition key
OFF.
4. When the system arms (2 flashes of turn signals), immediately turn the ignition key ON and
wait for the system to arm.
Transport Mode
In the transport mode, the HarleyDavidson Smart Security System is armed but the motion
detectors are inactive. The motorcycle can be transported on a trailer or moved in storage without
activating the alarm while the starter and ignition remain disabled.
3. With an assigned fob within range, turn the ignition key from OFF to ACCESS.
4. Simultaneously press both the left and right turn signal switches. The turn signals will flash
once.
5. Turn the ignition key to OFF to arm the system. The turn signals will flash three times as the
system arms in the transport mode.
With a fob present, turn the ignition key to IGNITION and the engine OFF/RUN switch to RUN.
The system exits the transport mode when the OFF/RUN switch is in RUN.
Storage and Service Departments
To maintain arming, store the fob beyond the range of the module. If the motorcycle is to be
moved while parked, have the fob present.
If the motorcycle will not be operated for several months, such as during the winter season, follow
the Owner's Manual instructions for storage. Refer to Motorcycle Storage.
Service Departments
When the motorcycle is to be left at a HarleyDavidson dealer, there are two options:
2. To maintain possession of the fob, ask the dealer to disable the module for service (service
mode) before leaving the dealership.
Fob Battery
1. See Key Fob Battery. Slowly turn a thin blade in the thumbnail slot (1) on the side of the
fob to separate the two halves.
3. Install a new battery (Panasonic 2032 or equivalent) with the positive (+) side down.
Power Disconnects
Optional Siren
On a power disconnect, to prevent the module from actuating the optional siren:
Troubleshooting
Key Icon
If the system key icon stays illuminated while riding, see a HarleyDavidson dealer.
Fob
With the fob present, if the Smart Security System continues to actuate warnings and alarms, one
of the following can be the cause:
a. Verify that the fob is not in a metal enclosure or within 3.0 in. (76 mm) of any other
electronic devices.
b. Place the fob on the seat and turn the ignition key to IGNITION. After the module
disarms, return the fob to a convenient location.
2. Discharged Fob Battery: Use the PIN to disarm the module. Replace the battery. Refer to
Fob Battery.
3. A Damaged Fob: Use the PIN to disarm the motorcycle. Replacement fobs are available for
purchase from a HarleyDavidson dealer.
Siren
If the siren does not chirp two or three times on a valid arming command from the security
module, the siren is either in the Chirpless Mode, not connected, not working, or the siren
wiring was opened or shorted while the siren was disarmed.
If the siren is armed and the internal siren battery is dead, shorted, disconnected, or has
been charging for a period longer than 24 hours, the siren will respond with three chirps on
arming instead of two.
The internal siren battery may not charge if the vehicle's battery is less than 12.5 volts.
If the siren enters the selfdriven mode where it is powered from the siren's internal 9 volt
battery, the turn signal lamps may or may not alternately flash. If the security module
activates the siren, the turn signal lamps will alternately flash. If the siren has been armed
and a security event occurs, and the siren is in selfdriven mode, the siren will alarm for 20
to 30 seconds and then turn off for 5 to 10 seconds. This alarm cycle will be repeated ten
times if the siren is in the selfdriven mode.
Operation
If motorcycle will not be ridden for a period of three weeks or more with security system armed, it
is recommended to connect a Battery Tender to maintain battery charge. If security system will
not be armed, it is recommended that the 30 amp maxifuse be removed. See Electrical
Protection: Sportster Models.
An engine running long distances at high speed must be given closer than ordinary attention to
avoid overheating and possible engine damage.
NOTE:
When descending upon a long, steep grade, downshift and use engine compression together with
intermittent application of both brakes to slow the motorcycle.
Do not coast for long distances with the engine off. The
transmission is properly lubricated only when the engine
is running. Coasting long distances can result in
transmission damage. (00180a)
The sound design, quality materials, and workmanship that are built into your new Harley
Davidson will give you optimum performance right from the start.
To allow your engine to wear in its critical parts, we recommend that you observe the riding rules
provided below for the first 500 miles (800 kilometers). Adherence to these suggestions will help
to assure good future durability and performance.
1. During the first 50 miles (80 kilometers) of riding, keep the engine speed below 4000 RPM in
any gear. Do not lug the engine by running or accelerating at very low RPM, or by running at
high RPM longer than needed for shifting or passing.
2. Up to 500 miles (800 kilometers), vary the engine speed and avoid operating at any steady
engine speed for long periods. Engine speed up to 5000 RPM in any gear is permissible.
3. Drive slowly and avoid fast starts at wide open throttle until the engine has warmed up.
4. Avoid lugging the engine by not running the engine at very low speeds in higher gears.
5. Avoid hard braking. New brakes need to be brokenin by moderate use for the first 200
miles (300 kilometers).
PreRiding Checklist
Before riding your motorcycle at any time, make a general inspection to be sure it is in safe riding
condition.
4. Check controls to make sure they operate properly. Operate the front and rear brakes,
throttle, clutch and shifter. All controls should operate freely without binding.
5. Check steering for proper operation by turning the handlebars through the full operating
range. Handlebars should turn smoothly without binding.
6. Check tire condition and pressure. Incorrect pressure will result in poor riding characteristics
and can affect handling and stability. Refer to tire specifications for correct inflation pressure
to use.
Be sure headlamp, tail and stop lamp and turn signals are
operating properly before riding. Poor visibility of rider to
other motorists can result in death or serious injury.
(00478b)
7. Check all electrical equipment and switches including the headlamp, stop lamp, turn signals
and horn for proper operation.
Do not roll the throttle before starting. Rolling the throttle before starting the motorcycle is
unnecessary. The engine management system handles starting and running the engine at all
temperatures and conditions.
Starting
1. Turn ignition/headlamp key switch to IGNITION position. Do not roll the throttle.
NOTE:
The engine lamp will light for approximately 4 seconds and you will hear the fuel pump purr
for approximately 2 seconds as it operates to fill the fuel lines with gasoline.
2. See Right Handlebar Controls. Rock the OFF/RUN switch to the RUN position.
5. When the engine has started, you can operate your motorcycle as you normally would after
raising the jiffy stand.
NOTE:
If the fuel tank becomes completely dry, it may take a few seconds longer to start the motorcycle
after filling the tank. It will not be necessary to take any extraordinary measures before starting the
motorcycle.
1. Engine off/run switch
2. Engine start switch
Right Handlebar Controls
1. Stop the engine by turning OFF the engine stop switch on right handlebar.
2. Turn OFF the ignition/headlamp key switch. If the engine should be stalled or stopped in any
way, turn off the ignition/headlamp key switch at once to prevent battery discharge.
Shifting Gears
Getting Started
The shift pattern is first gear down, next four gears up.
NOTE:
Always start engine with transmission in neutral. Always start motorcycle forward motion in first
gear.
1. With motorcycle engine running and jiffy stand retracted, pull the clutch hand lever in against
handlebar grip to fully disengage clutch.
2. Press the foot shift lever down to end of its travel and release. The transmission is now in
first gear.
3. To start forward motion, ease out the clutch lever slowly and at the same time, open throttle
gradually.
Upshift (Acceleration)
Refer to Upshift (Acceleration) Gear Speeds. Engage second gear after the motorcycle has
reached at the appropriate shifting speed.
3. See Upshift Sequence: Sportster Models. Lift the gear shift lever up to the end of its
travel and release.
4. Ease out the clutch lever and gradually open the throttle.
5. Repeat the previous steps to engage third, fourth, and fifth gears.
NOTES:
Downshift (Deceleration)
Gear shift pattern is first gear down; next four gears up. Refer to Downshift (Deceleration)
Gear Speeds for shifting speeds.
NOTE:
The shifting points shown in the tables are recommendations. Vehicle owners may determine that
their own individual shifting patterns may differ than those stated and are additionally appropriate
for individual riding styles.
See Downshift Sequence: Sportster Models. When engine speed decreases, as in climbing a
hill or running at a reduced speed, shift to the next lower gear while partially closing the throttle so
the engine accelerates as soon as the clutch lever is released.
NOTES:
The gear shifter mechanism permits shifting the transmission to neutral from either first or second
gear.
Good maintenance creates a safe motorcycle. A careful check of certain equipment must be
made after periods of storage. Also, frequently inspect the motorcycle between the regular service
intervals to determine if additional maintenance is necessary.
3. Brakes, steering and throttle for responsiveness and freedom from binding.
4. Brake fluid level and condition. Hydraulic lines and fittings for leaks. Also, check brake pads
and discs for wear.
7. Headlamp, tail lamp, brake lamp and turn signals for proper operation.
Breakin Maintenance
NOTE:
The performance of new motorcycle initial service is required to keep your new motorcycle
warranty in force and to assure proper emissions system operation.
Refer to Regular Service Intervals: 2007 Sportster Models. After a new motorcycle has
been ridden its first 1000 miles (1600 kilometers), it should be taken to an authorized Harley
Davidson dealer for initial service operations.
Engine Lubrication
Engine oil is a major factor in the performance and service life of the engine. Always use the
proper grade of oil for the lowest temperature expected before the next scheduled oil change.
Refer to Recommended Engine Oils. Your authorized dealer has the proper oil to suit your
requirements.
If it is necessary to add oil and HarleyDavidson oil is not available, use an oil certified for diesel
engines. Acceptable diesel engine oil designations include: CF4, CG4, CH4 and CI4.
The preferred viscosities for the diesel engine oils in descending order are: 20W50, 15W40 and
10W40.
At the first opportunity, see an authorized dealer to change back to 100 percent HarleyDavidson
oil.
a. Press straight down on filler cap and release. Cap will pop up.
See Filler Cap/Dipstick Slots: Sportster Models. Note that dipstick has a wide slot and
a narrow slot and can only be inserted in oil tank one way.
3. Insert dipstick into tank. Turn filler cap 1/4 turn as if screwing filler cap into tank. Press down
on cap until flush with oil tank.
Oil Dipstick Location: Sportster Models
2. Remove filler cap. Wipe attached dipstick clean. Reinstall oil filler cap in tank.
3. Remove oil filler cap again and check oil level on dipstick. See Filler Cap/Dipstick:
Sportster Models. Dipstick has two marks. If oil level is at or below lower mark, add only
enough oil to bring the level to a point between the two arrows on the dipstick. Replace filler
cap.
NOTE:
Refer to Recommended Engine Oils. Use only recommended oil specified under Engine
Lubrication.
1. Run engine until engine oil is at normal operating temperature. Turn engine off.
3. Remove filler cap. Wipe attached dipstick clean. Reinstall oil filler cap in tank.
4. Remove filler cap again and check warm oil level on dipstick. See Filler Cap/Dipstick:
Sportster Models. Dipstick has two marks. If oil level in tank is at or below lower mark, add
one quart (0.946 liter) of HarleyDavidson oil to tank. Replace filler cap.
NOTE:
Refer to Recommended Engine Oils. Use only recommended oil specified under Engine
Lubrication.
6. If you added oil in step 4, remove filler cap and verify correct engine oil level in oil tank. Do
not fill oil tank to the level above upper mark on dipstick. Replace filler cap.
1. Wide slot
2. Narrow slot
Filler Cap/Dipstick Slots: Sportster Models
See Oil Filter: Sportster Models. Sportster motorcycles use a chrome or black oil filter. Oil
filters are located on an oil filter mount in front of the engine.
Oil will flow more quickly if the filler cap/dipstick is removed from the oil tank.
2. Place a suitable container under the engine crankcase. The container must be able to hold
approximately 4 U.S. quarts (3.8 liters).
3. See Oil Tank Drain Hose and Bracket: Sportster Models. Loosen worm drive clamp
(2) and pull drain plug (3) from end of drain hose. Completely drain engine oil from oil tank.
It is not necessary to drain engine crankcase.
4. Replace drain plug into end of drain hose. Tighten worm clamp.
1. Pour about 4 fluid ounces (U.S.) (120 milliliters) of fresh, clean engine oil into new oil filter.
Allow time for oil to soak into filter element.
NOTE:
Partially fill oil filter before installation to minimize the time required for buildup of oil
pressure when engine is first started.
2. See Applying Thin Oil Film. Wipe filter gasket contact surface of oil filter mount with a
clean cloth. Surface should be smooth and free of any debris or old gasket material.
3. Apply a thin film of oil to gasket contact surface on crankcase (3), gasket and new oil filter.
4. Screw filter onto adapter until gasket contacts surface. Then apply another 1/23/4 turn after
gasket contacts filter mounting surface.
5. Refer to Recommended Engine Oils. Install 3.6 quarts U.S. (3.4 liters) to engine oil tank
minus the 4 fluid ounces (120 milliliters) added in step 1. Always use the proper grade of oil
for the lowest expected air temperature before the next regularly scheduled oil change.
6. Start engine. Verify that oil pressure signal light turns off when engine speed is 1000 RPM
or above.
7. Install filler cap/dipstick onto oil tank. Make sure cap is fully seated.
8. Check for oil leaks at oil filter and oil tank drain hose. Turn engine off.
1. Thin oil film ONLY
2. Oil filter
3. Mounting plate
Applying Thin Oil Film
Winter Lubrication
In colder climates, the engine oil should be changed often. If motorcycle is used frequently for
short trips, less than 15 miles (24 kilometers), in ambient temperatures below 60° F (16° C), oil
change intervals should be reduced to 1500 miles (2400 kilometers). Motorcycles used only for
short runs must have a thorough tank flushout before new oil is put in. See an authorized dealer.
NOTE:
The further below freezing the temperature drops, the shorter the oil change interval should be.
Water vapor is a normal byproduct of combustion in any engine. During cold weather operation,
some of the water vapor condenses to liquid form on the cool metal surfaces inside the engine. In
freezing weather this water will become slush or ice and, if allowed to accumulate too long, may
block the oil lines and cause damage to the engine.
If the engine is run frequently and allowed to thoroughly warm up, most of this water will become
vapor again and will be blown out through the crankcase breather.
If the engine is not run frequently and allowed to thoroughly warm up, this water will accumulate,
mix with the engine oil and form a sludge that is harmful to the engine.
Refer to Regular Service Intervals: 2007 Sportster Models. The transmission should be
drained and refilled with fresh lubricant at proper intervals. For best results, drain lubricant while
hot.
NOTE:
When checking the transmission lubricant level, motorcycle should be standing STRAIGHT UP,
not leaning on the jiffy stand. Keep motorcycle upright for a short period of time to equalize
lubricant level in the transmission compartments.
3. See Primary Cover: 2007 Sportster Models. Remove screws with washers from clutch
inspection cover (1). Remove clutch inspection cover from primary cover. Exercise caution
to avoid damaging or dislodging quad ring in primary cover.
NOTE:
4. Verify that lubricant level is even with bottom of clutch diaphragm spring.
NOTE:
5. Install clutch inspection cover on primary cover using screws with washers removed in step
3. Tighten screws in a crosswise pattern to 84108 inlbs (9.512.2 Nm).
6. Start engine. Check for any lubricant leaks.
Changing Lubricant
2. When the engine reaches normal operating temperature, turn the engine off and position
motorcycle on jiffy stand. This will allow the chaincase lubricant to drain out of transmission.
3. See Primary Cover: 2007 Sportster Models. Position a suitable container under
transmission drain plug (2).
4. The drain plug is located under the clutch, on the underside of the chaincase. Remove drain
plug and drain lubricant.
5. Position the motorcycle STRAIGHT UP and LEVEL. This allows additional fluid to be
drained from clutch compartment.
NOTE:
6. Remove foreign material from magnetic drain plug. Install drain plug and tighten to 1421 ft
lbs (19.028.5 Nm).
7. See Primary Cover: 2007 Sportster Models. Remove screws with washers from clutch
inspection cover (1). Remove clutch inspection cover from primary cover. Exercise caution
to avoid damaging or dislodging quadring in primary cover.
NOTE:
9. Install clutch inspection cover on primary cover. Tighten screws in a crosswise pattern to 84
108 inlbs (9.512.2 Nm).
General
Refer to Regular Service Intervals: 2007 Sportster Models. Primary (front) chain
adjustment should be checked at proper intervals and serviced as necessary. If the chain is
allowed to run loose, it will cause the motorcycle to jerk when running at low speed, and chain and
sprockets will wear excessively. If this happens, see a HarleyDavidson dealer or Service Manual
for adjustment procedure.
Procedure
The primary chain can be adjusted without removing the primary cover.
1. Unthread nut and remove battery negative cable (black) from crankcase stud.
2. See Primary Cover: 2007 Sportster Models. Remove the two hex socket screws which
secure primary chain inspection cover (3).
5. Turn chain adjuster screw (2) clockwise (inward) to reduce free play or counterclockwise
(outward) to increase free play. Vertical free play must fall within the limits specified. Refer
to Primary Chain Adjustment: Sportster Models.
NOTE:
If vertical free play cannot be set within the limits specified, then primary chain and/or chain
adjuster are worn beyond adjustment limits. Replace parts as necessary.
6. When tension is set correctly, tighten locknut to 2025 ftlbs (2734 Nm).
7. Install primary chain inspection cover. Tighten hex socket screws to 4060 inlbs (4.56.8
Nm).
1. Locknut
2. Chain adjuster screw
3. Transmission chaincase drain plug
Primary Chain Adjuster: 2007 Sportster Models
General
The inner tooth surface of the secondary belt has a thin coating of polyethylene lubricant. During
initial operation, this coating will wear off as it is burnished into the belt fabric. This is a normal
condition and not an indication of belt wear.
Belt tension is set at the factory and should be checked after the first 1000 miles (1600
kilometers), at scheduled maintenance intervals, and after a hard ride.
Gauging Deflection
Check belt deflection at the loosest spot in the belt with the transmission in neutral and the
motorcycle at ambient temperature. With the motorcycle unladen and resting on its jiffy stand, fit
the BELT TENSION GAUGE (Part No. HD35381A) approximately halfway between sprockets.
See Belt Deflection Window. Locate the belt deflection window on the rear drive belt
guard/debris deflector and note the belt position relative to the deflection graduations.
Using the BELT TENSION GAUGE, apply 10 lbs. (4.5 kg) of force at the midpoint of the bottom
belt. Count the number of graduations between the original belt position and after applying the
force. Multiply this number by 1/8 in. (3.2 mm).
See Gauging Belt Deflection: Sportster Models and refer to Belt Deflection: 2007
Sportster Models for the recommended deflection. If belt tension adjustment is necessary, see a
HarleyDavidson dealer or follow the belt deflection adjustment procedure found in the Sportster
Models Service Manual.
When gauging deflection, check the rear brake caliper position on rear brake disc. Disc should run
true within brake caliper.
XL 1200C, XL 1200L,
XL1200N
XL 883, XL 883R, 9/165/8 14.315.9
XL 1200R, XL 50
1. Rear drive belt
2. Deflection graduations 1/8 in. (3.2 mm) apart
Belt Deflection Window
1. Transmission sprocket
2. Rear wheel sprocket
3. Force of 10 lbs (4.5 kg)
4. Deflection (refer to table)
Gauging Belt Deflection: Sportster Models
Chassis Lubrication
Refer to Regular Service Intervals: 2007 Sportster Models for all maintenance schedules.
1. Use recommended special purpose grease for steering head bearings. Use a multipurpose
chassis grease for other applications.
2. Remove and lubricate handlebar throttle control grip sleeve with fresh graphite at proper
intervals.
3. Lubricate throttle control cables and clutch control cable at proper intervals.
4. Lubricate front brake hand lever and clutch control hand lever only if necessary.
6. Pack the steering head bearings with fresh grease at proper intervals.
7. Lubricate the jiffy stand mechanism with LOCTITE AEROSOL ANTISEIZE at proper
intervals.
NOTE:
For model specific information regarding the chassis lubrication, refer to the appropriate Service
Manual or see a HarleyDavidson dealer.
Oil Applications
Refer to Regular Service Intervals: 2007 Sportster Models for all control connections and
parts. Vehicle should be oiled at regular intervals, particularly after washing motorcycle or driving
in wet weather.
Refer to Regular Service Intervals: 2007 Sportster Models. Have a HarleyDavidson dealer
drain the front fork oil and refill at proper intervals. If fork does not appear to be working properly
or an appreciable amount of oil leakage should develop, see a HarleyDavidson dealer. If there is
insufficient oil in either side of fork, the rebound action will be incorrect.
Clutch
The need for attention to clutch and controls will be indicated by the clutch slipping under load or
dragging when released. In this situation, check the control cable adjustment first. See a Harley
Davidson dealer for proper service.
Hydraulic Lifters
The hydraulic lifters are selfadjusting. They automatically adjust length to compensate for engine
expansion and valve mechanism wear. This keeps the valve mechanism free of lash when the
engine is running.
When starting an engine which has been turned off even for a few minutes, the valve mechanism
may be slightly noisy until the hydraulic units completely refill with oil. If at any time the valve
mechanism becomes abnormally noisy, other than for a short period immediately after engine is
started, it is an indication that one or more of the hydraulic units may not be functioning properly.
Always check the oil supply in the oil tank first since normal circulation of oil through the engine is
necessary for proper operation of the hydraulic units.
If there is oil in the tank, the units may not be functioning properly because of dirt in the oil supply
passages leading to the lifter units. See a HarleyDavidson dealer for service.
Refer to Regular Service Intervals: 2007 Sportster Models. Check front fork for proper
bearing adjustment and lubricate bearings at proper intervals.
With motorcycle front end raised off the floor, be sure front fork turns freely without any binding or
interference and that there is no appreciable front to rear fork shake indicating excessive bearing
looseness. Steering head bearings should be adjusted according to Service Manual procedure, if
necessary.
Refer to Regular Service Intervals: 2007 Sportster Models. Check the tightness of the rear
fork pivot shaft fastener at proper intervals.
NOTE:
For model specific information regarding the rear fork pivot shaft, refer to the appropriate Service
Manual or see a HarleyDavidson dealer.
1. Refer to Regular Service Intervals: 2007 Sportster Models. Check brake pads and
brake discs for wear at proper intervals.
2. Check the fluid level in the master cylinder reservoirs at regular intervals.
3. If level is low, clean dirt and debris from reservoir cover before removing.
HarleyDavidson has provided your new motorcycle with the optimum brake pad friction material
available. It is selected to give the best performance possible under dry, wet and high operating
temperature conditions. It exceeds all regulatory requirements currently in effect. However, during
some braking conditions you may experience noise. This is normal for this friction material.
Visual inspection of brake pads can be made without removing the caliper. View the lower area of
each caliper with a flashlight.
NOTES:
If the brake pad friction material is 0.04 inch (1.00 millimeter) thick or less, the pads must be
replaced immediately.
Always replace brake pads in pairs.
The rear brake outer pad on all models can be measured from the caliper bracket side using a
thin plastic 6.0 inch (152.4 millimeter) rule. Place the rule against the brake disc through the
space alongside the caliper.
NOTE:
The outer surface of the brake pad backing plate should measure 0.04 inch (1.00 millimeter) or
more away from the brake disc.
Tires
See Specifications: 2007 Sportster Models for tire pressures and sizes.
Match tires, tubes, air valves and caps to the correct wheel
rim. Contact a HarleyDavidson dealer. Mismatching can
result in damage to the tire bead, allow tire slippage on the
rim or cause tire failure, which could result in death or
serious injury. (00023a)
Check inflation pressure and inspect tread for punctures, cuts, breaks, etc., at least weekly if in
daily use. Check before each trip if used occasionally.
Same as original equipment tires should be used. Other tires may not fit correctly, could adversely
affect handling, and may be hazardous to use.
Tire Replacement
Inspection
See Tire Sidewall Wear Bar Locator. Arrows on tire sidewalls pinpoint location of wear bar
indicators.
Tread wear indicator bars will appear on tire tread surfaces when 1/32 in. (0.8 mm) or less of tire
tread remains. See Wear Bar Appearance. Always replace tires before the tread wear indicator
bars appear.
2. Tire cords or fabric become visible through cracked sidewalls, snags or deep cuts.
Refer to Regular Service Intervals: 2007 Sportster Models. Inspect shock absorbers and
rubber bushings for leaks and bushing deterioration at proper intervals.
Spark Plugs
Refer to Regular Service Intervals: 2007 Sportster Models. Check the spark plugs at
proper intervals.
Disconnect spark plug cables from plugs by pulling on the molded connector caps. To reconnect,
simply snapon spark plug cables to tops of spark plugs.
Refer to Ignition System: 2007 Sportster Models before servicing spark plugs.
1. Check spark plug type. Only use those spark plugs specified for your model motorcycle.
3. Always tighten to the proper torque. Spark plugs must be tightened to the torque specified
for proper heat transfer.
NOTE:
If a torque wrench is not available, tighten plugs finger tight and then tighten an additional one
quarter turn with a spark plug wrench.
Ignition
The engine in your motorcycle has been designed specifically to achieve optimum fuel economy
within exhaust emission controls. Factory programmed ignition characteristics provide maximum
engine performance and driveability.
Air Cleaner
See Air Cleaner Assembly: Sportster Models. The engine air cleaner is a paper/wire mesh
air filter element.
Refer to Regular Service Intervals: 2007 Sportster Models. Remove air cleaner cover and
inspect filter element at proper intervals. Under dusty conditions, inspect more often.
The paper/wire mesh air filter element should be washed in luke warm water with a mild
detergent.
Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)
Allow filter to either air dry or blow it dry, from the inside, with low pressure air.
Do not use an air cleaner filter oil on the HarleyDavidson paper/wire mesh air filter element.
1. Screw
2. Cover
3. Filter element
4. Gasket
Air Cleaner Assembly: Sportster Models
Headlamp
See Headlamp Assemblies: Sportster Models. The headlamp assembly uses replaceable
quartz halogen bulb(s).
NOTE:
Refer to Bulb Chart: 2007 Sportster Models and see a service manual for more details.
Inspection
1. Verify correct front and rear tire inflation pressure. Refer to Tire Pressures: 2007
Sportster Models.
2. Place motorcycle on level floor (or pavement) in an area with a low light level.
3. See Headlamp Alignment: Sportster Models. Position motorcycle 25 feet (7.62 meters)
away a screen or wall. Measure distance from directly below front axle to base of
screen/wall.
4. Draw a horizontal line, on screen or wall, 35 inches (0.9 meters) above floor.
5. Load vehicle with rider, passenger (if normally present) and any cargo normally carried.
Weight will compress vehicle suspension slightly.
6. Stand motorcycle upright with both tires resting on floor and with front wheel held in straight
alignment (directly forward).
a. Main beam of light (broad, flat pattern of light) should be centered equally above and
below horizontal line on screen or wall.
b. Main beam of light should be directed straight ahead. Properly adjusted headlamps
project an equal area of light to right and left of center.
1. See Headlamp Snap Plug: Sportster Models. Remove snap plug (1) on top of
headlamp bracket (2).
2. See Headlamp Clamp Nut: Sportster Models. Loosen headlamp clamp nut.
3. Tilt headlamp up or down to properly aim it in relation to the horizontal line and, at the same
time, turn it right or left to direct light beam straight ahead.
4. Tighten headlamp clamp nut to 120240 inlbs (1427 Nm) after lamp is properly positioned.
Install snap plug in headlamp bracket.
1. Snap plug
2. Headlamp bracket
Headlamp Snap Plug: Sportster Models
Horizontal Adjustment:
1. See Headlamp Adjustment (XL 883C and XL 1200C). Loosen the Allen head
capscrew (3).
2. Turn the headlamp right or left as necessary to direct the light beam straight ahead.
Vertical Adjustment:
1. See Headlamp Adjustment (XL 883C and XL 1200C). Loosen the locknut (1) for the
vertical adjustment bolt.
2. Tilt headlamp up or down to properly aim it at the horizontal line on the wall.
1. Nut
2. Bolt (vertical adjustment)
3. Allen head capscrew (horizontal adjustment)
Headlamp Adjustment (XL 883C and XL 1200C)
Replacement
1. See Lens Cap Notch. To access the front or rear turn signal bulbs for replacement, locate
a notch on the turn signal lens cap.
2. Insert a coin in the lens cap notch, and carefully twist until the lens cap pops out of the lamp
housing.
3. Push in and twist the lamp bulb counterclockwise and pull lamp bulb out of the socket.
4. Orient index pins on new lamp bulb with pin guides inside bulb socket.
Alignment
Alternator/Voltage Regulator
Charging Rate
The alternator output is controlled and changed to direct current by the voltage regulator.
The voltage regulator increases charging rate when battery is low or lamps are lit.
The voltage regulator decreases charging rate when battery charge is up.
NOTES:
This unit requires no interval attention. If any electrical system trouble is experienced that
might be traceable to the alternator or voltage regulator, the motorcycle should be taken to a
HarleyDavidson dealer who has the necessary electrical testing equipment to give the
required attention.
For model specific information regarding the voltage regulator, refer to the appropriate
Service Manual or see a HarleyDavidson dealer.
Battery: General
Type
Your motorcycle uses a permanently sealed, maintenancefree, lead/calcium and sulfuric acid
battery. All batteries are shipped precharged and ready to be put into service. Do not attempt to
open the battery for any reason.
CONTACT TREATMENT
External Flush with water.
Internal Drink large quantities of milk or water,
followed by milk of magnesia, vegetable oil
or beaten eggs. Get immediate medical
attention.
Eyes Flush with water. Get immediate medical
attention.
Voltmeter Test
Refer to Voltmeter Test. The voltmeter test provides a general indicator of battery condition.
Check the voltage of the battery to verify that it is in a 100 percent fully charged condition. If the
open circuit (disconnected) voltage reading is below 12.6V, charge the battery and then recheck
the voltage after the battery has set for one to two hours.
Voltmeter Test
Battery top must be clean and dry. Dirt and electrolyte on top of the battery can cause battery to
selfdischarge.
3. Inspect and clean the battery screws, clamps and cables. Check for breakage, loose
connections and corrosion.
5. Inspect the battery for discoloration, a raised top or a warped or distorted case. This might
indicate that the battery has been frozen, overheated or overcharged.
Charging
Never charge a battery without first reviewing the instructions for the charger being used. In
addition to the manufacturer's instructions, follow these general safety precautions.
1. Perform a voltmeter test to determine the state of charge. If battery needs to be charged,
proceed to the next step.
2. Remove the battery from the motorcycle. See Battery: Sportster Models.
NOTES:
The figures listed in the Amphour table assume that the battery is charging at room
temperature. If warmer than room temperature, use a slightly shorter charging time. If
colder, use a slightly longer charging time.
The use of constant current chargers to charge sealed maintenance free batteries is
not recommended. Any overcharge will cause dryout and premature battery failure. If
a constant current charger is the only type available, do not exceed the charge times
listed in 12 AmpHour Battery Charging Rates and Times and do not continue
charging the battery if it gets hot. When charging, never exceed 15 volts.
4. Connect the red battery charger lead to positive (+) terminal of the battery.
5. Connect the black battery charger lead to negative () terminal of the battery.
NOTE:
If the battery is still in the vehicle, connect the negative lead to the chassis ground. Make
sure that the ignition and all electrical accessories are turned off.
7. After the battery is fully charged, turn OFF the charger and disconnect the black battery
charger lead to the negative () terminal of the battery.
8. Disconnect the red battery charger lead to the positive (+) terminal of the battery.
Storage
If the motorcycle will not be operated for several months, such as during the winter season,
remove the battery from the motorcycle and fully charge.
If the motorcycle is to be stored with the battery installed, it will be necessary to connect a battery
tender to maintain charge. See an authorized dealer for more information.
Selfdischarge is a normal condition and occurs continuously. The rate of selfdischarge depends
on the ambient temperature and the battery's state of charge.
1. Capacity
2. Months of stand
3. Measured at 105 F (40 C)
4. Measured at 77 F (25 C)
Effective Rate of Temperature on Battery
Selfdischarging Rate
1. See Negative Battery Cable and Crankcase Stud: Sportster Models. Unthread nut
and remove battery negative cable (black) from crankcase stud behind starter motor
assembly.
3. Remove MaxiFuse and holder from battery strap by grasping holder and sliding it toward
the rear of the motorcycle. Then remove MaxiFuse holder from its mounting pin on battery
strap.
5. Remove battery strap screw and flat washer. Unhook battery strap from battery tray mount
on top of battery and remove strap.
6. Unthread bolt and remove battery positive cables (red) from battery positive (+) terminal.
7. Remove battery and attached negative cable as an assembly from the battery tray.
1. Apply a light coat of petroleum jelly or corrosion retardant material to negative () battery
terminal before installation.
2. Place the fully charged battery with the negative cable attached into the battery tray.
3. See Negative Battery Cable and Crankcase Stud: Sportster Models. Route negative
cable around frame downtube.
4. With negative () cable disconnected from grounding point on crankcase, insert bolt through
MaxiFuse cable first then through main battery positive cable (+) (red) and into threaded
hole of battery positive (+) terminal.
6. Apply a light coat of petroleum jelly or corrosion retardant material to positive (+) battery
terminal. Place protective rubber boot over terminal.
7. Hook top of battery strap to battery tray mount on top of battery. Install flat washer and strap
screw.
10. Hook MaxiFuse holder to pin on battery strap and slide forward until it snaps into place.
12. Place negative battery cable end onto stud on crankcase boss behind starter motor
assembly. Thread nut onto stud.
Jump Starting
NOTE:
Positive Cable
2. See Jump Start Cable Connections. Connect one end of a jumper cable to the
DISCHARGED battery positive (+) terminal (1).
3. Connect the other end of the same cable to the BOOSTER battery positive (+) terminal (2).
Negative Cable
4. Connect one end of a jumper cable to the BOOSTER battery negative () terminal (3).
5. Connect other end of the same cable (4) to a safe ground, (away from the DISCHARGED
battery).
6. Start motorcycle.
Fuse Replacement
2. See Left Side Cover: 2007 Sportster Models. The left side cover (1) provides access to
the maxifuse holder (5), battery (6) and fuse/relay block (4). No tools are required to
remove or reinstall the side cover.
3. The left side cover is secured to the motorcycle by two upper slots that fit into upper clips (2)
and a bottom slot (3) that fits into a mounting tab on the battery tray.
NOTE:
The left side cover does not need to be completely removed from the vehicle to access the battery
or fuses.
4. Place a shop cloth or other clean, dry cloth over rear brake master cylinder reservoir and left
passenger foot peg (if equipped). This will protect left side cover from damage.
5. Grasp left side cover at upper corners and gently pull away from plastic mounting clips on
frame.
6. While rotating top of cover out away from motorcycle, slide cover down slightly so mounting
slot slides down from mounting tab on battery tray. Side cover will now rest on top of rear
brake master cylinder reservoir and left passenger footpeg (if equipped) with slot hanging off
bottom of mounting tab.
7. Locate and replace any fuse in the fuse/relay block with a burned or broken element. See
Fuse Block: 2007 Sportster Models, Fuse Block Label: 2007 Sportster Models, and
Fuse/Relay Legend to identify which fuse protects an inoperative circuit.
NOTE:
Automotive type ATO fuses are used for installation and replacement.
8. Place bottom of side cover with grommet in frame and press top of side cover into clips until
snug.
1. Side cover
2. Upper cover clips
3. Bottom slot
4. Fuse/relay block
5. Maxifuse holder
6. Battery
7. Data link connector
Left Side Cover: 2007 Sportster Models
Fuse Block: 2007 Sportster Models
Fuse/Relay Legend
All Sportster models have a main fuse to protect the motorcycle wiring. This 30 amp maxifuse
provides main battery power to the motorcycle. It is located in a rubbercoated fuse holder behind
the motorcycle's left side cover.
1. Grasp the fuse holder in one hand and the plastic body of the maxifuse in the other. Pull the
maxifuse straight out of the fuse holder.
2. Insert the prongs of the new maxifuse in the fuse holder slots. Push the maxifuse firmly
down into the fuse holder.
3. Grasp top corners of side cover. While rotating top of cover up towards motorcycle, gently
pull cover up so that mounting slot slides up mounting tab.
4. Line up top slots of side cover with mounting clips on motorcycle frame, aligning with front
clip first. Press top of side cover into clips until snug.
MaxiFuse
Removal
See Seat: Sportster Models. All Sportster models have a forward tab underneath the seat on
the frame back.
1. Remove screw to detach seat from rear fender.
Installation
1. See Seat: Sportster Models. Slide seat forward until the tongue (1) fits snugly in frame.
2. Push seat forward and press firmly in center until keyhole on underside of seat locks firmly
to post on frame.
4. Install screw and fasten seat mounting bracket to top of rear fender.
6. Pull up on seat again to verify that it is properly secured, in all three mounting points.
1. Connection point
2. Keyhole
Seat: Sportster Models
Motorcycle Storage
If the motorcycle will not be operated for several months, such as during the winter season, there
are several tasks which should be performed. These steps will protect parts against corrosion,
preserve the battery and prevent the buildup of gum and varnish in the fuel system.
NOTE:
Make a list of everything you do and fasten it to a handgrip. When you take the motorcycle out of
storage, this list will be your reference/checklist to get your motorcycle in operating condition.
1. Fill fuel tank and add a gasoline stabilizer. Use one of the commercially available gasoline
stabilizers and follow the manufacturer's instructions.
2. Warm motorcycle to operating temperature. Change oil and turn engine over to circulate the
new oil.
5. To protect the vehicle's body panels, engine, chassis and wheels from corrosion, follow the
cosmetic care procedures described in the Accessory Maintenance section of this owner's
manual prior to storage.
7. If the motorcycle is to be stored with security system armed, it will be necessary to connect
a Battery Tender to maintain battery charge. If security system will not be armed and a
Battery Tender is not available, either:
8. If motorcycle is to be covered, use a material such as light canvas that will breathe. Plastic
materials that do not breathe promote the formation of condensation.
1. See Battery: General for proper battery care. Charge and install the battery.
4. Start the engine and run until it reaches normal operating temperature. Turn off engine.
5. Check amount of oil in the oil tank.
7. Check controls to be sure they are operating properly. Operate the front and rear brakes,
throttle, clutch and shifter.
8. Check steering for smoothness by turning the handlebars through the full operating range.
9. Check tire pressure. Incorrect pressure will result in poor riding characteristics and can
affect handling and stability.
10. Check all electrical equipment and switches including the stop lamp, turn signals and horn
for proper operation.
Accessories Maintenance
Clean and protect the cosmetic surfaces on your motorcycle as often as possible to inhibit rust
and corrosion. To aid you in keeping your motorcycle clean, see your HarleyDavidson dealer for
surface care products.
Leather Care
NOTE:
Many HarleyDavidson accessories and seats are either made of leather or have leather inserts.
Natural materials age differently and require different care than manmade materials. Seat covers
and panels made of leather will gain "character", such as wrinkles, with age. Leather is porous
and organic and each leather product will settle into its own distinct form with use. Your leather
product will mature into its own custom shape and style from the sun, rain and the miles. This
maturing is natural and will enhance the custom quality of your HarleyDavidson motorcycle.
Leather must be periodically cleaned and treated to maintain its appearance and extend its life.
Clean and treat leather once a season or more frequently under adverse conditions.
Do not use ordinary soap to clean leather or fur. It could dry or remove the oils from the
leather.
Use ONLY a good quality saddle soap to clean leather. Be sure you rinse saddle soap off
thoroughly before treating leather.
Never try to dry leather quickly, using artificial means. Always let leather dry naturally, at
room temperature.
2. Thoroughly clean leather with a good quality saddle soap, following manufacturer's
directions. Rinse thoroughly with clean sponge or cloth and water. Allow leather to dry.
3. Once leather is dry, treat with a good quality leather treatment, such as LEATHERCARE
(Part No. 9826191).
Whitewall Tires
Use a good quality, commercial whitewall cleaner and follow the manufacturer's directions.
Wheel Care
Some vehicle's wheels are aluminum and do not have a protective coating. Other vehicles have
laced wheels with chrome plated rims and zinc or chrome plated spokes. Damage from harsh
chemicals, acid based wheel cleaners, brake dust and lack of maintenance can occur. Regular
washing and the use of a corrosion protectant will help to maintain their original appearance.
HarleyDavidson WHEEL AND TIRE CLEANER (Part No. 9465898) is recommended for
cleaning wheels and tires. Then use HARLEY GLOSS (Part No. 9462798) to protect the wheel
surfaces.
NOTES:
It is imperative that the wheels are cared for weekly to guard against pitting and corrosion.
Corrosion of these components is not considered to be a defect in materials or
workmanship.
WHEEL AND TIRE CLEANER (Part No. 9465898): cleaner/degreaser for wheels, tires and
engine.
HARLEY GLOSS (Part No. 9462798): all purpose surface protection the provides UV
protection and a gloss finish.
Windshields
NOTES:
To remove minor surface scratches use NOVUS® No. 2 SCRATCH REMOVER (Part No.
9983694T).
Covering the windshield with a clean, wet cloth for approximately 1520 minutes before
washing will make dried bug removal easier.
To treat your Lexan windshield with water repellent use WINDSHIELD WATER REPELLENT
TREATMENT (Part No. 9984102).
Troubleshooting
Troubleshooting: General
The following checklist of possible operating troubles and their probable causes will be helpful in
keeping your motorcycle in good operating condition. More than one of these conditions may be
causing trouble and should be carefully checked.
5. Blown fuse.
Engine Turns Over But Does Not Start
9. Blown fuse.
Starts Hard
1. Spark plugs in bad condition, have improper gap, or are partially fouled.
6. Fuel tank vent plugged or fuel line closed off, restricting fuel flow.
1. Incorrect fuel.
Overheats
3. Insufficient air flow over cylinder heads during extended periods of idling or parade duty.
Excessive Vibration
4. Front chain or links tight as a result of insufficient lubrication or belt badly worn.
Electrical System
Transmission
Clutch Slips
Clutch Chatters
Brakes
7. Brake fades because of heat build up. Excessive braking or brake pads dragging. See
dealer.
It is the owner's responsibility to follow the scheduled mileage intervals as specified; all of the
specified maintenance services must be performed to keep your warranty valid.
1. Make an appointment with a HarleyDavidson dealer for inspection and service just before
you have ridden 1000 miles (1600 kilometers).
2. Bring this Owner's Manual with you when you visit your dealer to have your motorcycle
inspected and serviced.
3. Have the dealer technician sign at the proper mileage interval. The records should be
retained by the owner as proof of proper maintenance.
4. Keep receipts covering any parts, service or maintenance performed. These records should
be transferred to each subsequent owner.
HarleyDavidson dealerships are independently owned and operated and may sell parts and
accessories that are not manufactured or approved by HarleyDavidson. Therefore, you should
understand that we are not and cannot be responsible for the quality, suitability, or safety of any
nonHarleyDavidson part, accessory or design modification, including labor, which may be sold
and/or installed by our dealers.
2. Insist that your dealer uses only Genuine replacement parts to keep your HarleyDavidson
motorcycle and its warranty intact.
Exacting design and stringent testing ensure performance and warranty coverage. Again, insist on
Genuine parts for your genuine HarleyDavidson motorcycle.
NOTE:
Installing offroad or competition parts to enhance performance may void all or part of your new
motorcycle warranty. See the HarleyDavidson Limited Warranty in this manual or a Harley
Davidson dealer for details.
If you move from your present address, or sell your motorcycle, please fill out and mail the post
card at the back of this manual. This is necessary in the event that the Company needs to contact
the owner concerning information that could affect the safe operation of this motorcycle.
All new model year 2007 HarleyDavidson motorcycles sold in the State of California are
equipped with an evaporative emission control system. This system is designed to meet the
CARB regulations in effect at the time of manufacture.
The system requires a small amount of maintenance. Periodic inspection is required to make sure
hoses are properly routed, not kinked or blocked and that all fittings are secure. Mounting
hardware should also be checked periodically for tightness.
EPA noise regulations require that the following statements be included in the Owner's Manual.
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the
following acts or the causing thereof: (1) The removal or rendering inoperative by any person
other than for purposes of maintenance, repair, or replacement of any device or element of design
incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the
ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of
design has been removed or rendered inoperative by any person.
AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED
BELOW.
1. Replacing the muffler(s) and/or the entire exhaust system with parts not certified to be noise
legal for street use.
3. Replacing the air intake/cleaner assembly with one not certified to be noise legal for street
use.
4. Modifying the air intake/cleaner assembly in such a way as to make the vehicle no longer
noise legal for street use.
HarleyDavidson recommends that any and all noise related maintenance be done by an
authorized HarleyDavidson dealer using genuine HarleyDavidson parts.
Warranty/Service Information
Any authorized HarleyDavidson dealer is responsible for providing the warranty repair work on
your motorcycle. If you have any questions regarding warranty obligations contact your selling
dealer.
For normal service work or warranty work under the above conditions, you may obtain the name
and location of your nearest U.S. HarleyDavidson dealer by calling 18004909635 (toll free), in
any state except Alaska and Hawaii.
NOTE:
Safety defects must be reported to the National Highway Traffic Safety Administration (NHTSA)
and HarleyDavidson.
NHTSA Statement
If you believe that your vehicle has a defect which could cause a crash or could cause injury or
death, you should immediately inform the National Highway Traffic Safety Administration
(NHTSA) in addition to notifying HarleyDavidson.
If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety
defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA
cannot become involved in individual problems between you, your dealer, or HarleyDavidson.
NHTSA Contacts
ITEM DATA
Phone Call the Auto Safety Hot Line tollfree at 1888
DASH2DOT
Mail U.S. Department of Transportation, National
Highway Traffic Safety Administration, Office of
Defects Investigation, NVS210, 400 7th Street
S.W., Washington, D.C. 20590
Web www.nhtsa.dot.gov
Web www.nhtsa.dot.gov
site
You can also obtain other information about motor vehicle safety from the hot line.
24 Months/Unlimited Miles
Some states do not allow limitations on how long an implied warranty lasts, so the above limitation
may not apply to you.
Duration
1. The duration of this limited warranty is twenty four months, starting from the earlier of (a) the
date of initial retail purchase and delivery from an authorized HarleyDavidson dealer, or (b)
the third anniversary of the last day of the model year of the motorcycle/sidecar. Your dealer
will submit an electronic Sales and Warranty Registration form to initiate your warranty.
2. Any unexpired portion of this limited warranty will be transferred to subsequent owners,
upon the resale of the motorcycle/sidecar during the warranty period.
Owner's Obligations
To obtain warranty service, return your motorcycle/sidecar at your expense within the warranty
period to an authorized dealer. Our dealer should be able to provide warranty service during
normal business hours and as soon as possible, depending upon the workload of the dealer's
service department and the availability of necessary parts.
HarleyDavidson Motor Company, P.O. Box 653, Milwaukee, Wisconsin 53201, U.S.A.
Exclusions
1. Which has not been operated or maintained as specified in the Owner's Manual.
2. Which has been abused, misused, improperly stored, used "off the highway," or used for
racing or competition of any kind.
3. Which is not manufactured to comply with the laws of the market in which it is registered.
4. Installing offroad or competition parts to enhance performance may void all or part of your
new motorcycle warranty. See a HarleyDavidson dealer for details.
Other Limitations
1. Parts and labor for normal maintenance as recommended in the Owner's Manual, or the
replacement of parts due to normal wear and tear including such items as the following:
tires, lubrication, oil and filter change, fuel system cleaning, battery maintenance, engine
tuneup, spark plugs, brake, clutch and chain/belt adjustment (including chain replacement).
2. Cosmetic concerns that arise as a result of owner abuse, lack of proper maintenance or
environmental conditions (except concerns that result from defects in material or
workmanship, which are covered by this warranty for the duration of the warranty period).
3. Any cosmetic condition existing at the time of retail delivery that has not been documented
by the selling dealer prior to retail delivery.
2. This warranty is a contract between you and the manufacturer. It is separate and apart from
any warranty you may receive or purchase from the dealer. The dealer is not authorized to
alter, modify, or in any way change the terms and conditions of this warranty.
3. Any warranty work or parts replacement authorized by the manufacturer will not preclude
the manufacturer from later relying on any exclusion where applicable.
The following warranty applies to the noise control system, is in addition to the MOTORCYCLE
LIMITED WARRANTY and EMISSION CONTROL SYSTEM LIMITED WARRANTY, and applies
only to motorcycles sold in the U.S.
HarleyDavidson Motor Company warrants that this vehicle is designed and built so as to conform
at the time of sale with applicable regulations of the U.S. Environmental Protection Agency (as
tested following F76 DriveBy test procedure) and that it is free from defects in materials and
workmanship which would cause this motorcycle not to meet U.S. Environmental Protection
Agency Standards within 1 year or 3,730 miles (6,000 kilometers) whichever expires first. Any
unexpired portion of this limited warranty will be transferred to subsequent owners, upon the
resale of the motorcycle during the warranty period.
Some states do not allow limitations on how long an implied warranty lasts, so the above limitation
may not apply to you.
The warranty period shall begin on the date the motorcycle is delivered to the first retail purchaser
or, if the motorcycle is placed in service as a demonstrator or company vehicle prior to sale at
retail, on the date it is first placed in service.
THE FOLLOWING ITEMS ARE NOT COVERED BY THE NOISE CONTROL SYSTEM
WARRANTY
Some states do not allow the exclusion or limitation of incidental or consequential damages, so
the above limitation or exclusion may not apply to you.
Other Rights
This warranty gives you specific legal rights, and you may have other rights which vary from state
to state.
HarleyDavidson Motor Company, P.O. Box 653, Milwaukee, Wisconsin 53201, U.S.A.
The following warranty applies to the emission control system, is in addition to the LIMITED
MOTORCYCLE WARRANTY and NOISE CONTROL SYSTEM LIMITED WARRANTY, and
applies only to motorcycles sold in the U.S.
HarleyDavidson Motor Company warrants that this vehicle is designed and built so as to conform
at the time of sale with applicable regulations of the U.S. Federal Environmental Protection
Agency, and that it is free from defects in materials and workmanship which would cause this
motorcycle not to meet U.S. Environmental Protection Agency Standards within 5 years or 18,641
miles (30,000 kilometers) whichever expires first. Any unexpired portion of this limited warranty
will be transferred to subsequent owners, upon the resale of the motorcycle during the warranty
period.
Some states do not allow limitations on how long an implied warranty lasts, so the above limitation
may not apply to you.
The warranty period shall begin on the date the motorcycle is delivered to the first retail purchaser
or, if the motorcycle is placed in service as a demonstrator or company vehicle prior to sale at
retail, on the date it is first placed in service.
THE FOLLOWING ITEMS ARE NOT COVERED BY THE EMISSION CONTROL SYSTEM
WARRANTY
2. The replacement of parts (such as spark plugs, fuel and oil filters, etc.) used in required
maintenance.
3. Any motorcycle on which the odometer mileage has been changed so that the mileage
cannot be determined.
Some states do not allow the exclusion or limitation of incidental or consequential damages, so
the above limitation or exclusion may not apply to you.
Other Rights
This warranty gives you specific legal rights, and you may have other rights which vary from state
to state.
HarleyDavidson Motor Company, P.O. Box 653, Milwaukee, Wisconsin 53201, U.S.A.
Maintenance Scheduling
Regular lubrication and maintenance will help keep your new HarleyDavidson operating at peak
performance. Your HarleyDavidson dealer knows best how to service your motorcycle with
factory approved methods and equipment assuring you of thorough and competent workmanship.
NOTES:
3. Perform annually.
4. Not all vehicles are equipped with spoke wheels. Consult appropriate topic in
service manual.
Service Literature
Refer to Service Literature: 2007 Sportster Models. Visit any HarleyDavidson dealer or go
to www.harleydavidson.com to purchase a service or parts manual for your motorcycle. Factory
authorized manuals are the most complete and detailed source of information outside of your
HarleyDavidson dealer.