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Sportster Models 883, 883 Custom, 1200 Custom, 883L, 1200L, 1200S, 1200 Roadster, XR1200, and the Nightster.
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  #1  
Old 06-18-2008, 12:00 AM
BluePotato BluePotato is offline
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Default Poor Man's Sportster Service Maintenance Guide

Poor Mans Sportster Service Maintenance Guide:


Tools Needed for Sportster Maintenance:
Fix My Hog Sportster Tools Video (Need to complete free registration on site before you can watch the video)
-What Wrench Fits What- Tool List

Sportster Maintenance Log:
Excel Spreadsheet 2004 Sportster Maintenance Log
My Service Sheet (The site has a few demo service sheets that can be downloaded as PDFs. One of the sample bikes is a Sportster 883. Instructions for logging in to the demo account are on the site.)

Beginners Maintenance:
Bikernet Sportster Maintenance (not too detailed, but a good simple overview of Sportster maintenance with photos)

Oil Change:
Frequency = 1,000 miles, 5,000 miles, and every 5,000 miles thereafter
Oil Change Instructions with Photos
Oil Filter Removal Milk Jug Trick Photos
Expert Village Harley Oil Change Video (not Sportster specific)

Primary Chain Adjustment:
Frequency = 1,000 miles, 5,000 miles, and every 5,000 miles thereafter
Expert Village Harley Primary Chain Adjustment Video (not Sportster specific)
Audible Whine Primary Chain Adjustment Method Instructions / Audible Method Summary
Visual Primary Chain Adjustment Method Instructions
Classic Primary Chain Adjustment Method Instructions

Clutch Adjustment:
Frequency = 1,000 miles, 5,000 miles, and every 5,000 miles thereafter
Clutch Adjustment Instructions With Photos
Expert Village Harley Clutch Pack Adjustment Video (not Sportster specific)
Expert Village Harley Clutch Cable Adjustment Video (not Sportster specific)

Primary/Transmission Fluid Change:
Frequency = 1,000 miles, 5,000 miles, and every 5,000 miles thereafter
Primary/Transmission Fluid Change Instructions
Expert Village Harley Primary Fluid Change Video (not Sportster specific)

Clutch/Throttle/Idle Cable Lubrication:
Frequency = 1,000 miles, 5,000 miles, and every 5,000 miles thereafter
Plastic Bag Method Cable Lubrication Instructions (not Sportster specific) (scroll down 6/10ths of the page)
Traditional Method Cable Lubrication Video Part 1 Part 2 (not Sportster specific)

Change Brake Pads:
Inspection Frequency = 1,000 miles, 5,000 miles, and every 5,000 miles thereafter
Replacement Frequency = When thickness is 1/16╙

Brake Pad Replacement Instructions

Brake bleeding:
Frequency = When brake fluid shows compressible bubbles or when brakes start to feel squishy
Brake Bleeding Instructions
Brake Bleeding Video (not Sportster specific)
Further Information on Motorcycle Brakes (not Sportster specific)

Throttle/Idle cable adjustment:
Frequency = 1,000 miles, 5,000 miles, and every 5,000 miles thereafter
Throttle/Idle Cable Adjustment Instructions
Expert Village Harley Throttle/Idle Cable Adjustment Video (not Sportster specific)

Spark plugs:
Inspection Frequency = 1,000 miles, 5,000 miles, and every 5,000 miles thereafter
Replacement Frequency = 10,000 miles and every 10,000 miles thereafter

Expert Village Harley Spark Plug Replacement Video (not Sportster specific)
Reading Spark Plug Instructions (not Sportster specific)

Engine Idle Speed Adjustment:
Frequency = 1,000 miles, 5,000 miles, and every 5,000 miles thereafter
Engine Idle Speed Adjustment Instructions

Air Cleaner Inspection/Cleaning:
Frequency = 1,000 miles, 5,000 miles, and every 5,000 miles thereafter
Expert Village Air Cleaner Inspection Video (not Sportster specific)

Steering Head Bearing Lubrication:
Frequency = 20,000 miles and every 20,000 miles thereafter
Steering Head Bearing Lubrication Instructions with Photos

Battery:
Expert Village Harley Battery Check Video (not Sportster specific)
Fix My Hog Battery Voltage Testing Video (not Sportster specific) (Need to complete free registration on site before you can watch the video, then click to view the Softail sample video. The same procedure applies to Sportsters.)

Front Fork Oil Change:
Frequency = 20,000 miles and every 20,000 miles thereafter
Front Fork Oil Change Instructions

Progressive Fork Springs Installation:
Progressive Fork Springs Installation Instructions
Progressive Fork Springs Installation Instructions with Photos

Progressive 412 Rear Shock Installation:
Progressive 412 Rear Shock Installation Instructions

Carburetor Rejetting:
Rejetting the CV Carburetor Instructions
Sportster CV Carburetor Rejetting Instructions

Torque specs for common fasteners:
[ul][*] Spark plugs = 12-18 ft.-lb[*] Clutch inspection cover = 84-108 in.-lb[*] Primary chain inspection cover = 40-60 in.-lb[*] Primary chain adjustment locknut = 20-25 ft.-lb[*] Transmission drain plug = 14-30 ft.-lb[*] Fork drain screw = 13-17 in.-lb[*] Fork cap nut = 22-58 ft.-lb[*] Air filter cover screw = 36-60 in.-lb[*] Air filter element screws = 40-60 in.-lb[*] Rear shock bolt = 45-50 ft.-lb
[/ul]
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  #2  
Old 06-18-2008, 12:04 AM
BluePotato BluePotato is offline
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Default RE: Poor Man's Sportster Service Maintenance Guide

The above is a collection of information and instructions I have found on the internet for my personal use and for educating myself on how to perform basic maintenance on my Sportster. I am happy to update this as a living document and will edit my post to include any additions, corrections, or suggestions you may have. With respect to torque specs or maintenance frequency, everybody has their own opinion, but I used the factory recommendations and I don’t intend on editing those. My goal here isn’t to create a replacement for the service manual or even to provide instruction, but to maintain a collection of links to well-written and useful instructions on recurring maintenance tasks, Sportster-specific if available.

I own a 2006 1200C, so there may be a bias toward that model and year in the links but most of this information can be used for frame-mount, carbureted, or EFI Sportsters.

I am not responsible for the content of the links or how the information is used and I claim none of it as my own original writing. I’m grateful for the people who actually can write good instructions for the rest of us. If anybody is aware of good detailed instruction available on the web for other maintenance requirements, or better links for the items above, please let me know.
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  #3  
Old 06-18-2008, 03:45 AM
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Hawg295 Hawg295 is offline
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Default RE: Poor Man's Sportster Service Maintenance Guide

Some good info there BP.&nbsp\\; Thanks for posting it.
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2007 1200C
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  #4  
Old 06-18-2008, 12:00 PM
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hogsport hogsport is offline
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Default RE: Poor Man's Sportster Service Maintenance Guide

Thanks for the post - Maybe Shu will make it&nbsp\\; a sticky
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  #5  
Old 06-18-2008, 12:06 PM
zonplyr zonplyr is offline
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Default RE: Poor Man's Sportster Service Maintenance Guide

good post, should be sticky'd
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  #6  
Old 06-18-2008, 02:39 PM
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nevets61 nevets61 is offline
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Default RE: Poor Man's Sportster Service Maintenance Guide

Good post.&nbsp\\; Some great info there to follow.
Thanks
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  #7  
Old 06-18-2008, 02:48 PM
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Default RE: Poor Man's Sportster Service Maintenance Guide

I too, vote for this becoming a sticky!
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  #8  
Old 06-18-2008, 02:52 PM
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thomasf59 thomasf59 is offline
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Default RE: Poor Man'

Some of that instruction is generic, I would never adjust my primary chain (bike running in gear)as some suggested, after following some of that advice you would be a poor man, after the F**k ups were repaired.

Didn't bother to look at the other tips,seen enough after the primary and clutch and throttle calbe instruction.
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Old 06-18-2008, 05:24 PM
Drodd8 Drodd8 is offline
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Default RE: Poor Man's Sportster Service Maintenance Guide

This is sweet stuff.&nbsp\\; I smell a sticky&nbsp\\; Thanks for the post man.
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  #10  
Old 06-18-2008, 10:18 PM
BluePotato BluePotato is offline
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Default RE: Poor Man's Sportster Service Maintenance Guide

Thanks a lot for the encouragement, fellas. I hope somebody can find it helpful.
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Old 06-18-2008, 10:18 PM
 
 
 
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