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Rubber Mount Sportster Motorcycle Talk (2004-2006) This area is to discuss issues, problems and anything else unique to the 2004 and above Sportster motorcycles

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  #1  
Old 1st July 2008
BluePotato's Avatar
BluePotato BluePotato is offline
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Join Date: Sep 2007
Location: Cincinnasti
Posts: 48
Sportster/Buell Model: Sportster 1200 Custom
Sportster/Buell Year: 2006
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Lightbulb Sportster Service Maintenance Link Collection

Sportster Service Maintenance Link Collection:


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
Clutch Adjustment Instructions (The Easy Way) (not Sportster specific)
Clutch Adjustment Instructions (By the Book) (not Sportster specific)
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 (not Sportster specific)
Traditional Method Cable Lubrication Video Part 1
Part 2 (not Sportster specific)
Part 2


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)
Brake Bleeding Video
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:
  • 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
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2006 Sportster 1200 Custom Chopper Blue / Brilliant Silver

Last edited by BluePotato; 8th July 2008 at 16:40.. Reason: Added clutch adjustment links
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  #2  
Old 1st July 2008
BluePotato's Avatar
BluePotato BluePotato is offline
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Join Date: Sep 2007
Location: Cincinnasti
Posts: 48
Sportster/Buell Model: Sportster 1200 Custom
Sportster/Buell Year: 2006
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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 1st July 2008
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shotgun46 shotgun46 is offline
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Very good ! and thank you for taking the time to set this up for us !
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  #4  
Old 1st July 2008
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wandrur wandrur is online now
Thx for the help, jackass
 
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Looks pretty sweet to me!
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  #5  
Old 2nd July 2008
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SportySarge SportySarge is offline
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I recently purchased an 06 1200L and now have approx 10,000 miles. I will be performing the service myself and this site is invaluable. Thanks
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  #6  
Old 3rd July 2008
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warhog78 warhog78 is offline
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Nice man, I appreciate the time and effort this took!
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  #7  
Old 3rd July 2008
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Blaze Blaze is offline
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Join Date: May 2006
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Sportster/Buell Model: 1200C
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Nice post dude! Thanks for sharing! I know it had to have been time consuming.
This should be a sticky!
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  #8  
Old 14th July 2008
lunloon lunloon is offline
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WOW!

This is a very helpful thread!

Kudos to Bluepotato
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  #9  
Old 19th July 2008
TrashCanMan TrashCanMan is offline
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Blue Potato
Thanks for all of this information, great post.
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Old 19th July 2008
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donnieray donnieray is offline
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Very cool indeed...just added the link to my favorites list.
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