Sportster Maintenance Spread Sheets

 These are based on Owner's Manual maintenance schedule. Hope you find these usefull

2003-Earlier Sportster Maintenance Spreadsheet - Furnished by Coasty and not edited in any way

2004 Sportster Maintenance Spreadsheet - Furnished by Coasty and edited by myself for 2004

2007 Sportster Maintenance Spreadsheet - Furnished by Coasty and not edited in any way

Useful Alternative Parts for the Sportster

Here are some alternatives to the HD parts for your Sportster.

Spark plugs

Autolite 4164 - Works just as well as the HD spark plug, but costs $1.50/each or so and is widely available in most auto parts stores.  Set the gap between 0.038" and 0.040".  The wrench for these spark plugs is not one of two standard spark plug wrenches.  It is either 13/16" or 18mm.  I am not sure if it is metric or SAE, but in this particular size either metric or SAE will work just fine.  Remember, you do not need a socket wrench for the Sportster!  A box wrench will work fine.

Champion RA8HC with '810' on the end of the box is most like the HD plug according to many posts on Sportster.org. The gap is .039" - .040".  Use a .038" dia. and a .040" dia. wires from a plug gap tool.  Set the gap so the .038" dia. gage goes thru easy and the .040"dia. gage will not go through.

Oil Filter

Pure One by Purolator PL10241
Pure One by Purolator PL25230 longer if you can use it
Mobil M1-102
Bosch 3330
Wix (& NAPA) equivalents of #51348 and 51315 (longer).
NAPA 1215
Ford (Autocraft) F1A or FL-1A

Air Filter

K&N replacement for the stock air box: HD-8834
K&N replacement for the HD Screaming Eagle air box: HD-0900 
K&N High flow air box kit with filter: RK-3929
Drag Specialties replacementfor the HD Screaming Eagle air box: 1011-0783

Stock Sportster Clutch Cable Chart

Stock Sportster Clutch Cable Chart from HD website can be found here.

Diagnostic Trouble Codes for '04 and later Sportsters

Be advised this only applies to the full serial data bikes, ie 04 and 05's

The IM (instrument module) is capable of displaying DTC's (diagnostic trouble codes).

Speedometer Self Diagnostics: The speedometer is capable of displaying and clearing speedometer, tachometer, TSM/TSSM and ICM/ECM Diagnostic Trouble Codes (DTC).

1. 
   
   
   Turn Ignition switch to OFF & Run/Stop switch is to Run.
2. 
   
   
   Push odometer reset button in & hold.
3. 
   
   
   Turn ignition switch to Ignition and release odometer reset button. Background lighting sould illuminate, speedometer needle should sweep its full range and indicator lamps (battery, security, low fuel, check engine and cruise) should illuminate. The word “diag” should then appear.
4. 
   
   
   Push the odometer reset button once and you will see the selection menu "PSSPt" with the first P flashing.
5. 
   
   
   Each letter represents an area of the diagnostics module. The module that is flashing is the one you are going to check. To move from one letter (module) to the next, you push the odometer reset button one time. (from P to S to SP to t and back to P, etc.)
   
   P = ECM/ICM (Electronic Control Module (EFI) / (Ignition Control Module, 'Carbureted')
   S = TSM/TSSM (Turn Signal/ Turn Signal Security Module)
   SP = speedometer
   T = tachometer
6. 
   
   
   To get the DTC within an area of diagnostics, push and hold the odometer reset button in for 5 seconds and release. If there are any DTC’s the code will be displayed or the word “none” will appear if there are no DTC’s. Push the odometer reset button again to view additional codes if they exist.
7. 
   
   
   Record the codes.
8. 
   
   
   If DTC’s are not to be cleared, Press and release the odometer reset button. Part number of module will be displayed.
   NOTE: To determine if a code is current or historic, clear the displayed code by pushing in and holding the odometer reset button ( longer than 5 seconds) until 'clear' comes up. Release the odometer reset button. Turn OFF the ignition switch. Run
   your bike and shut it down then recheck the DTC’s again by repeating steps 1 to 9. If the code is current it will reappear.
9. 
   
   
   Press and release the odometer reset button to continue to the next module.
10. 
    
    
    Turn Ignition switch to OFF.
    

DTC FAULT CONDITION MODULE

B0563 Battery Voltage High TSM/TSSM
B1004 Fuel Level Sending Unit Low Instruments
B1005 Fuel Level Sending Unit High/Open Instruments
B1006 Accessory Line Overvoltage Instruments
B1007 Ignition Line Overvoltage Instruments
B1008 Reset Switch Closed Instruments
B1131 Alarm Output Low TSM/TSSM
B1132 Alarm Output High TSM/TSSM
B1134 Starter Output High TSM/TSSM
B1135 Accelerometer Fault TSM/TSSM
B1151 Sidecar BAS Low TSM/TSSM
B1152 Sidecar BAS High TSM/TSSM
B1153 Sidecar BAS Out of Range TSM/TSSM
P0106 MAP Sensor Rate of Range Error Carb
P0107 Map Sensor Failed Open/Low Carb
P0107 Map Sensor Open/Low EFI
P0108 Map Sensor Failed High Carb
P0108 Map Sensor High EFI
P0112 IAT Sensor Voltage Low EFI
P0113 IAT Sensor Voltage Open/High EFI
P0117 ET Sensor Voltage Low EFI
P0118 ET Sensor Voltage Open/High EFI
P0122 TP Sensor Open/Low EFI
P0123 TP Sensor High EFI
P0261 Front Injector Open/Low EFI
P0262 Front Injector High EFI
P0263 Rear Injector Open/Low EFI
P0264 Rear Injector High EFI
P0373 CKP Sensor Intermittent Carb
P0373 CKP Sensor Intermittent EFI
P0374 CKP Sensor Not Detected Carb
P0374 CKP Sensor Synch Error EFI
P0501 VSS Low Carb
P0501 VSS Low EFI
P0502 VSS High/Open Carb
P0502 VSS High/Open EFI
P0505 Loss of Idle Sped Control EFI
P0562 Battery Voltage Low Carb
P0562 Battery Voltage Low EFI
P0563 Battery Voltage High Carb
P0563 Battery Voltage High EFI
P0602 Calibration Memory Error Carb
P0603 EEPROM Failure Carb
P0603 ECM EEPROM Error EFI
P0604 RAM Failure Carb
P0605 Program Memory Error Carb
P0605 ECM Flash Error EFI
P0607 Converter Error Carb
P1001 System Relay Coil Open/Low EFI
P1002 System relay Coil High/Shorted EFI
P1003 System relay Contacts Open EFI
P1004 System Relay Contacts Closed EFI
P1009 Incorrect Password Carb
P1009 Incorrect Password EFI
P1010 Missing Password Carb
P1010 Missing Password EFI
P1351 Front Ignition Open/Low Carb
P1351 Front Ignition Open/Low EFI
P1352 Front Ignition Coil High/Shorted Carb
P1352 Front Ignition Coil High/Shorted EFI
P1353 Front Cylinder No Combustion EFI
P1354 Rear Ignition Coil Open/Low Carb
P1354 Rear Ignition Coil Open/Low EFI
P1355 Rear Ignition Coil High/Shorted Carb
P1355 Rear Ignition Coil High/Shorted EFI
P1356 Rear Cylinder No Combustion EFI
P1357 Intermittent Secondary Front EFI
P1358 Intermittent Secondary Rear EFI
U1016 Loss of ICM/ECM Serial Data Instruments
U1016 Loss of ECM Serial Data, Vehicle Speed, Vehicle Inhibit Motion or

Powertrain Security Status TSM/TSSM
U1064 Loss of TSM/TSSM Serial Data Carb
U1064 Loss of TSM/TSSM Serial Data EFI
U1064 Loss of TSM/TSSM Serial Data Instruments
U1097 Loss of Speedometer Serial data Carb
U1097 Loss of Speedometer Serial data EFI
U1097 Loss of Speedometer Serial data TSM/TSSM
U1255 Missing Message at Speedometer EFI
U1255 Serial Data Error/Missing Message EFI
U1255 Serial Data Error/Missing Message Instruments
U1255 Serial Data Error/Missing Message TSM/TSSM
U1300 Serial Data Low Carb
U1300 Serial Data Low EFI
U1300 Serial Data Low Instruments
U1300 Serial Data Low TSM/TSSM
U1301 Serial Data Open/High Carb
U1301 Serial Data Open/High EFI
U1301 Serial Data Open/High Instruments
U1301 Serial Data Open/High TSM/TSSM

-----------------------

AFR – Air Fuel Ratio

ATS – Air Temperature Sensor

BAS – Bank Angle Sensor

CCM – Cruise Control Module

CKP – Crank Position Sensor. The CKP generates an “AC signal” which is sent to the ECM where it is used to reference engine position (TDC) and speed.

DTC – Diagnostic Trouble Codes

ECM – Electronic Control Module. (The Computer) Computes the spark advance for proper ignition timing and fuel control based on sensor inputs (from CKP, MAP & TP sensors) and controls the low-voltage circuits for the ignition coils and injectors. The dwell time for the ignition coil is also calculated in the microprocessor and is dependent upon battery voltage. The programmed dwell feature gives adequate spark at all speeds.

ECT – Engine Coolant Temperature. Sensor also controls the cooling fan relay that provides 12 Vdc to the fans.

EFI – Electronic Fuel Injection

EFP – Electronic Fuel Pump

ET – Engine Temperature sensor

FI – Fuel Injectors

FPR – Fuel Pressure regulator

IAC – Idle Air Control actuator

IAT – Intake Air Temperature sensor

ISS – Ion Sensing System…detonation detection

MAP – manifold Absolute Pressure sensor. The MAP sensor monitors the intake manifold pressure (vacuum) and sends the information to the ECM. The EMC then adjusts the spark and fuel-timing advance curves for optimum performance.

TP – Throttle Position Sensor

TSM/TSSM (Turn Signal/ Turn Signal Security Module)

VE – Volume Efficiency

VSS – Vehicle Speed Sensor. Used as an input for idle speed control

============================================================

Here is another and possibly more up to date version

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04-07 HD DTC Codes and Activation

---

These will also work on the 07 & 08 bikes. There are additional codes for the 08 bikes not listed here but are listed in this same section in another post.

These apply to 04 and later bikes with the serial bus.

The IM (instrument module) is capable of displaying DTC's (diagnostic trouble codes).
Speedometer Self Diagnostics: The speedometer is capable of displaying and clearing speedometer, tachometer, TSM/TSSM and ICM/ECM Diagnostic Trouble Codes (DTC).

1- Turn Ignition switch to OFF & Run/Stop switch is to Run.

2- Push odometer reset button in & hold.

3- Turn ignition switch to Ignition and release odometer reset button. Background lighting should illuminate, speedometer needle should sweep its full range and indicator lamps (battery, security, low fuel, check engine and cruise) should illuminate. The word “diag” should then appear.

4 - Push the odometer reset button once and you will see the selection menu "PSSPt" with the first P flashing.

5 - Each letter represents an area of the diagnostics module. The module that is flashing is the one you are going to check. To move from one letter (module) to the next, you push the odometer reset button one time. (from P to S to SP to t and back to P, etc.)
P = ECM/ICM (Electronic Control Module [EFI] / Ignition Control Module [Carbureted)
S = TSM/TSSM (Turn Signal/ Turn Signal Security Module)
SP = speedometer
T = tachometer

6 - To get the DTC within an area of diagnostics, push and hold the odometer reset button in for 5 seconds and release. If there are any DTC’s the code will be displayed or the word “none” will appear if there are no DTC’s. Push the odometer reset button again to view additional codes if they exist.

7 - Record the codes.

8 - If DTC’s are not to be cleared, Press and release the odometer reset button. Part number of module will be displayed.
NOTE: To determine if a code is current or historic, clear the displayed code by pushing in and holding the odometer reset button ( longer than 5 seconds) until 'clear' comes up. Release the odometer reset button. Turn OFF the ignition switch. Run your bike and shut it down then recheck the DTC’s again by repeating steps 1 to 9. If the code is current it will reappear.

9 – Press and release the odometer reset button to continue to the next module.

10 – Turn Ignition switch to OFF.

On models not equipped with a tachometer "No Rsp" will appear when the tachometer identifier is selected.

"No Rsp" will also appear if the run/off switch is in the off position when doing this procedure.

Also if the code set is a historic code (not a constant light) after 50 start and run cycles of at least 30 seconds each in duration, the light will extinguish itself as long as the error hasn't occurred again.
If it were a current code, the light would remain lit while running.

--------------------------

DTC FAULT CONDITION MODULE

"BUS Er" Serial data bus shorted/low/open/high
B0563 Battery Voltage High TSM/TSSM
B1004 Fuel Level Sending Unit Low Instruments
B1005 Fuel Level Sending Unit High/Open Instruments
B1006 Accessory Line Over voltage Instruments
B1007 Ignition Line Over voltage Instruments
B1008 Reset Switch Closed Instruments
B1122 Right turn output fault
B1131 Alarm Output Low TSM/TSSM
B1132 Alarm Output High TSM/TSSM
B1134 Starter Output High TSM/TSSM
B1135 Accelerometer Fault TSM/TSSM
B1141 Ignition switch open/low
B1151 Sidecar BAS Low TSM/TSSM
B1152 Sidecar BAS High TSM/TSSM
B1153 Sidecar BAS Out of Range TSM/TSSM
P0106 MAP Sensor Rate of Range Error Carb
P0107 Map Sensor Failed Open/Low Carb
P0107 Map Sensor Open/Low EFI
P0108 Map Sensor Failed High Carb
P0108 Map Sensor High EFI
P0112 IAT Sensor Voltage Low EFI
P0113 IAT Sensor Voltage Open/High EFI
P0117 ET Sensor Voltage Low EFI
P0118 ET Sensor Voltage Open/High EFI
P0122 TP Sensor Open/Low EFI
P0123 TP Sensor High EFI
P0131 Front 02 sensor low (lean)
P0132 Engine running rich
P0134 Front 02 sensor open/not responding
P0151 Rear 02 sensor low (lean)
P0152 Rear 02 sensor high (rich)
P0154 Rear 02 sensor open/not responding
P0261 Front Injector Open/Low EFI
P0262 Front Injector High EFI
P0263 Rear Injector Open/Low EFI
P0264 Rear Injector High EFI
P0373 CKP Sensor Intermittent Carb
P0373 CKP Sensor Intermittent EFI
P0374 CKP Sensor Not Detected Carb
P0374 CKP Sensor Sync Error EFI
P0501 VSS Low Carb
P0501 VSS Low EFI
P0502 VSS High/Open Carb
P0502 VSS High/Open EFI
P0505 Loss of Idle Sped Control EFI
P0562 Battery Voltage Low Carb
P0562 Battery Voltage Low EFI
P0563 Battery Voltage High Carb
P0563 Battery Voltage High EFI
P0602 Calibration Memory Error Carb
P0603 EEPROM Failure Carb
P0603 ECM EEPROM Error EFI
P0604 RAM Failure Carb
P0605 Program Memory Error Carb
P0605 ECM Flash Error EFI
P0607 Converter Error Carb
P0661 Intake solenoid low/open
P0662 Intake solenoid high/shorted
P1001 System Relay Coil Open/Low EFI
P1002 System relay Coil High/Shorted EFI
P1003 System relay Contacts Open EFI
P1004 System Relay Contacts Closed EFI
P1009 Incorrect Password Carb
P1009 Incorrect Password EFI
P1010 Missing Password Carb
P1010 Missing Password EFI
P1351 Front Ignition Open/Low Carb
P1351 Front Ignition Open/Low EFI
P1352 Front Ignition Coil High/Shorted Carb
P1352 Front Ignition Coil High/Shorted EFI
P1353 Front Cylinder No Combustion EFI
P1354 Rear Ignition Coil Open/Low Carb
P1354 Rear Ignition Coil Open/Low EFI
P1355 Rear Ignition Coil High/Shorted Carb
P1355 Rear Ignition Coil High/Shorted EFI
P1356 Rear Cylinder No Combustion EFI
P1357 Intermittent Secondary Front EFI
P1358 Intermittent Secondary Rear EFI
U1016 Loss of ICM/ECM Serial Data Instruments
U1016 Loss of ECM Serial Data, Vehicle Speed, Vehicle Inhibit Motion or Power train Security Status TSM/TSSM
U1064 Loss of TSM/TSSM Serial Data Carb
U1064 Loss of TSM/TSSM Serial Data EFI
U1064 Loss of TSM/TSSM Serial Data Instruments
U1097 Loss of Speedometer Serial data Carb
U1097 Loss of Speedometer Serial data EFI
U1097 Loss of Speedometer Serial data TSM/TSSM
U1255 Missing Message at Speedometer EFI
U1255 Serial Data Error/Missing Message EFI
U1255 Serial Data Error/Missing Message Instruments
U1255 Serial Data Error/Missing Message TSM/TSSM
U1300 Serial Data Low Carb
U1300 Serial Data Low EFI
U1300 Serial Data Low Instruments
U1300 Serial Data Low TSM/TSSM
U1301 Serial Data Open/High Carb
U1301 Serial Data Open/High EFI
U1301 Serial Data Open/High Instruments
U1301 Serial Data Open/High TSM/TSSM


2006 models with 02 sensors (Dynas)

P0131 Front 02 sensor lean for any length of time
P0151 Rear 02 sensor lean for any length of time
Above codes can also be set if 02 sensor fails.


-----------------------

AFR – Air Fuel Ratio

ATS – Air Temperature Sensor

BAS – Bank Angle Sensor

CCM – Cruise Control Module

CKP – Crank Position Sensor. The CKP generates an “AC signal” which is sent to the ECM where it is used to reference engine position (TDC) and speed. Home position established by taking readings off the 22 teeth on the alternator rotor.

DTC – Diagnostic Trouble Codes

ECM – Electronic Control Module. (The Computer) Computes the spark advance for proper ignition timing and fuel control based on sensor inputs (from CKP, MAP & TP sensors) and controls the low-voltage circuits for the ignition coils and injectors. The dwell time for the ignition coil is also calculated in the microprocessor and is dependent upon battery voltage. The programmed dwell feature gives adequate spark at all speeds.

ECT – Engine Coolant Temperature. Sensor also controls the cooling fan relay that provides 12 Vdc to the fans.

EFI – Electronic Fuel Injection

EFP – Electronic Fuel Pump

ET – Engine Temperature sensor

FI – Fuel Injectors

FPR – Fuel Pressure regulator

IAC – Idle Air Control actuator

IAT – Intake Air Temperature sensor

ISS – Ion Sensing System…detonation detection

MAP – manifold Absolute Pressure sensor. The MAP sensor monitors the intake manifold pressure (vacuum) and sends the information to the ECM. The EMC then adjusts the spark and fuel-timing advance curves for optimum performance.

TP – Throttle Position Sensor

TSM/TSSM (Turn Signal/ Turn Signal Security Module)

VE – Volume Efficiency

VSS – Vehicle Speed Sensor. Used as an input for idle speed control

Carburetor Jet Sizes and Part NumbersCarburetor Jet Sizes and Part Numbers

Needles

N65C needle: 27094-88 - This is the stock needle in the 1988 1200 Sportster and is a popular replacement for the stock needles in rigid mount Sportsters.

N9EY needle: 28027-04 - this is the stock needle in 2004-2006 Sportster (US 49 state models)


Pilot Jets

pilot jet 48: 27165-90
pilot jet 45: 27170-89

pilot jet 44: NOT an HD P/N Can be ordered from Drag Specialties DS-289317 Custom Chrome also
handles 44 jets in lots of five, #640763

pilot jet 42: 27171-89
pilot jet 40: 27281-92
pilot jet 35: 27117-88

Main Jets

main jet 200: 27105-88
main jet 185: 27185-90
main jet 180: 27114-88
main jet 175: 27090-89
main jet 170: 27115-88
main jet 165: 27116-88
main jet 160: 27152-89
main jet 155: 27154-89

Idle Speed Adjustment on a Harley-Davidson Sportster

Before you do this you may need to remove the plug covering the idle mixture screw. You can find the directions on how to do that here.

Here's my version of the idle mixture adjustment procedure. It may be slightly different than others, but I believe the idea is the same.

Procedure

1. warm up the bike to operating temperature. This is very important!
2. leave the bike running and turn the idle speed screw up so the engine idles fairly fast. It is not important how many RPM at this point, this is just to prepare for the next step.
3. turn the idle mixture screw in all the way until is seats (be gentle do not tighten the screw down. It is not a fastener, it is an adjustment needle, really). If the bike stalled while doing that go back to previous step and raise the idle speed a bit more. The idea here is to have the bike idling with the mixture screw turned all the way in.
4. now slowly turn the idle speed screw in until the engine just barely runs almost stalling. You can go to the point of stalling and back off slightly from that. Now you have your idle speed set in a pretty good place. Leave it be.
5. Shut off the engine and turn the idle mixture screw out about 3 or 4 turns out. Restart the engine. It should be running just fine now. Now turn the mixture screw in slowly while listening to the engine speed. As soon as you hear the speed change (slow down) ever so slightly stop and back off a quarter turn for colder weather and half a turn for warm weather. I tend to set it at somewhere in between and forget about it.
6. If you have a tachometer, check the idle speed against it. The specification is 1,050 RPM. It is really important to idle the bike around that speed as the oil pump does not produce enough flow to protect the engine at lower speeds.
7. Test ride and enjoy!

Note: I know I am omitting the part of finding the rich stumble, but the reality is that many times there will be no rich stumble and people will go increasing their pilot jets, which is wrong. You choose your pilot jet based on other things. Once the pilot jet is chosen you adjust the idle mixture as described above and all will be well.