2010 Harley-Davidson Sportster P/N 99484-10 Complete Service Manual

The document is a 2010 Harley-Davidson Sportster Models Service Manual. It provides detailed maintenance, troubleshooting, and repair instructions for various components, including the engine, transmission, brakes, electrical system, and chassis. It includes safety warnings, torque values, specifications, and procedures for servicing the motorcycle.

Summary of the 2010 Harley-Davidson Sportster Service Manual
General Information
•    The manual provides maintenance and repair guidelines for Harley-Davidson Sportster models.
•    It includes field-tested repair methods for professional technicians.
•    Warnings and cautions highlight potential hazards and safety precautions.
•    Genuine replacement parts are recommended for optimal performance and safety.
Maintenance & Troubleshooting
•    Covers oil changes, brake maintenance, and tire inspections.
•    Provides troubleshooting guides for engine, transmission, and electrical issues.
•    Includes wheel alignment and drive belt adjustments.
Chassis & Brakes
•    Vehicle Identification Number (V.I.N.) location and breakdown.
•    Brake system maintenance, including bleeding, pad replacement, and master cylinder servicing.
•    Front and rear suspension adjustments for different Sportster models.
Engine & Transmission
•    Engine lubrication and oil pressure testing procedures.
•    Top-end and bottom-end overhaul instructions.
•    Transmission removal, assembly, and sprocket installation.
Electrical System
•    Battery maintenance, charging, and replacement.
•    Starter motor and ignition system servicing.
•    Turn signal, lighting, and control module troubleshooting.
Fuel System
•    Fuel pump, pressure testing, and intake leak diagnosis.
•    Evaporative emissions control system maintenance for California models.
Appendices
•    Connector repair guides for AMP, Delphi, and Deutsch connectors.
•    Wiring diagrams and electrical troubleshooting.

•    Harley-Davidson Sportster Models Service Manual (2010) provides detailed maintenance and repair procedures for Sportster motorcycles.
•    Covers maintenance, chassis, electrical, fuel system, and drive/transmission with step-by-step instructions.
•    Includes safety warnings and cautions for handling fuel, electrical components, and mechanical parts.
•    Provides troubleshooting guides for engine, transmission, brakes, and electrical systems.
•    Contains torque values, specifications, and diagrams for various motorcycle components.
•    Explains vehicle identification number (V.I.N.) structure and location for identification purposes.
•    Lists required tools and special equipment for servicing Sportster models.
•    Covers wheel alignment, brake system maintenance, and clutch adjustments for different models.

Full Chapters Index - 2010 Harley-Davidson Sportster Service Manual
1. Maintenance
•    1.1 Fastener Torque Values
•    1.2 General
•    1.3 Fuel and Oil
•    1.4 Bulb Requirements
•    1.5 Maintenance Schedule
•    1.6 Engine Oil and Filter
•    1.7 Brakes
•    1.8 Bleeding Hydraulic Brake System
•    1.9 Brake Pads and Discs: XL Models
•    1.10 Brake Pads and Discs: XR Models
•    1.11 Tires and Wheels
•    1.12 Primary Chain
•    1.13 Clutch
•    1.14 Transmission Lubricant
•    1.15 Drive Belt and Sprockets
•    1.16 Wheel Alignment
•    1.17 Battery Maintenance
•    1.18 Spark Plugs
•    1.19 Steering Head Bearings
•    1.20 Shock Absorber Adjustment
•    1.21 Cable and Chassis Lubrication
•    1.22 Air Cleaner: XL Models
•    1.23 Air Cleaner: XR Models
•    1.24 Exhaust System
•    1.25 Throttle Control
•    1.26 Fuel Supply Filter
•    1.27 Engine Mounts and Stabilizer Links
•    1.28 Headlamp Alignment
•    1.29 Critical Fasteners
•    1.30 Storage
•    1.31 Troubleshooting
2. Chassis
•    2.1 Specifications
•    2.2 Front Fork
•    2.3 Steering Head Bearings
•    2.4 Rear Fork
•    2.5 Shock Absorbers
•    2.6 Stabilizer Links
•    2.7 Engine Mounts
•    2.8 Throttle Cables
•    2.9 Clutch Control
•    2.10 Handlebars
•    2.11 Rider Foot Controls
•    2.12 Passenger Footrests
•    2.13 Fork Lock
•    2.14 Rear Fender
•    2.15 Jiffy Stand
•    2.16 Seat
3. Engine
•    3.1 Fastener Torque Values
•    3.2 Specifications
•    3.3 Engine Overview
•    3.4 Oil Pressure
•    3.5 Crankcase Breathing System: XL Models
•    3.6 Crankcase Breathing System: XR Models
•    3.7 Troubleshooting
•    3.8 Engine Lubrication System
•    3.9 Top End Service
•    3.10 Bottom End Service
•    3.11 Removing Engine from Chassis
•    3.12 Installing Engine in Chassis
•    3.13 Precision Cooling System: XR Models
•    3.14 Top End Overhaul: Disassembly
•    3.15 Top End Overhaul: Assembly
•    3.16 Bottom End Overhaul: Disassembly
•    3.17 Bottom End Overhaul: Assembly
•    3.18 Valve Tappets
•    3.19 Gearcase Cover and Cam Gears
•    3.20 Cylinder Head
•    3.21 Cylinder and Piston
•    3.22 Crankcase
•    3.23 Oil Pump: XL Models
•    3.24 Oil Pump: XR Models
•    3.25 Oil Filter Mount
•    3.26 Oil Tank
4. Fuel System
•    4.1 Fastener Torque Values
•    4.2 Specifications
•    4.3 Air Cleaner: XL Models
•    4.4 Air Cleaner: XR Models
•    4.5 Fuel Tank: XL Models
•    4.6 Fuel Tank: XR Models
•    4.7 Throttle Position Sensor
•    4.8 Engine Temperature Sensor
•    4.9 Induction Module: XL Models
•    4.10 Induction Module: XR Models
•    4.11 Idle Air Control
•    4.12 Temperature Manifold Absolute Pressure Sensor
•    4.13 Oxygen Sensor
•    4.14 Exhaust System: XL Models
•    4.15 Exhaust System: XR Models
•    4.16 Fuel Injectors
•    4.17 Fuel Pump
•    4.18 Fuel Pressure Test
•    4.19 Intake Leak Test
•    4.20 Evaporative Emissions Control (CA Models)
5. Drive/Transmission
•    5.1 Fastener Torque Values
•    5.2 Specifications
•    5.3 Primary Chain Adjuster
•    5.4 Clutch Release Mechanism
•    5.5 Primary Drive and Clutch: XL Models
•    5.6 Primary Drive and Clutch: XR Models
•    5.7 Drive Belt
•    5.8 Transmission
•    5.9 Case Disassembly for Transmission Removal
•    5.10 Transmission Removal and Disassembly
•    5.11 Transmission Assembly
•    5.12 Main Drive Gear and Bearing
•    5.13 Transmission Right Case Bearings
•    5.14 Transmission Left Case Bearings
•    5.15 Transmission Installation
•    5.16 Transmission Sprocket
6. Electrical
•    6.1 Fastener Torque Values
•    6.2 Specifications
•    6.3 Voltage Regulator
•    6.4 Fuses and Relays
•    6.5 Main Fuse Holder
•    6.6 Speedometer: XL Single Gauge Models
•    6.7 Speedometer: XL 883C/XL 1200C
•    6.8 Speedometer and Tachometer
•    6.9 Electronic Control Module (ECM)
•    6.10 Turn Signal and Security Module (TSM/TSSM/HFSM)
•    6.11 Battery Cables
•    6.12 Battery Tray
•    6.13 Starter
•    6.14 Starter Solenoid
•    6.15 Ignition and Light Switch
•    6.16 Spark Plug Cables
•    6.17 Ignition Coil
•    6.18 Headlamp
•    6.19 Indicator Lamp Module
•    6.20 Tail Lamp
•    6.21 Turn Signals
•    6.22 License Plate Lamp Module
•    6.23 Rear Lighting Converter Module
•    6.24 Rear Stop Lamp Switch
•    6.25 Crank Position Sensor
•    6.26 Alternator
•    6.27 Vehicle Speed Sensor
•    6.28 Neutral Indicator Switch
•    6.29 Main Wiring Harness
•    6.30 Electrical Caddies
•    6.31 Jiffy Stand Switch
•    6.32 Optional Security Siren
•    6.33 Oil Pressure Switch
•    6.34 Horn
•    6.35 Main Fuse
•    6.36 Handlebar Switch Assemblies
•    6.37 TSSM/HFSM Maintenance
•    6.38 Personal Identification Number (PIN)
•    6.39 H-DSSS Actuation
•    6.40 TSM/HFSM Password Learn
Appendices
•    Appendix A: Connector Repair
•    Appendix B: Wiring
•    Appendix C: Conversions
•    Appendix D: Compensating Sprocket
•    Appendix E: Glossary
This index provides a structured overview of the manual’s contents, covering all major aspects of maintenance, chassis, engine, fuel system, drive/transmission, electrical components, and additional appendices.

Here are the top 10 questions that are answered in the 2010 Harley-Davidson Sportster Service Manual:
1.    How do I perform routine maintenance on my Sportster?
    •    The manual includes a maintenance schedule, oil changes, brake inspections, and other essential upkeep tasks.
2.    How do I remove and install the left side cover on my Sportster?
    •    Step-by-step instructions for removing and installing the left side cover on both XL and XR models are provided.
3.    How do I adjust the clutch on my Sportster?
    •    The manual explains clutch cable adjustments, primary chain adjustments, and clutch inspection cover removal.
4.    How do I troubleshoot electrical issues, including fuses and relays?
    •    The manual provides fuse and relay locations, instructions for replacing fuses, and checking electrical connections.
5.    How do I remove and install the battery?
    •    The battery removal and installation procedure, including safety precautions, is covered.
6.    How do I replace the air filter on my Sportster?
    •    The manual provides detailed steps for removing, cleaning, and replacing the air filter for XL and XR models.
7.    How do I service the primary drive and clutch?
    •    The manual includes instructions for removing the primary cover, adjusting the primary chain, and replacing clutch components.
8.    How do I troubleshoot and replace the horn?
    •    The manual explains horn troubleshooting, voltage testing, and replacement procedures for side-mounted and front-mounted horns.
9.    How do I replace the rear brake pads and caliper?
    •    The manual provides steps for removing and installing the rear brake caliper, replacing brake pads, and handling brake fluid safely.
10.    How do I replace the voltage regulator?
•    The manual includes removal and installation procedures, wiring connections, and torque specifications for the voltage regulator.
These topics cover essential maintenance, troubleshooting, and repairs commonly performed on the 2010 Harley-Davidson Sportster models.

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Maintenance & Repairs:
•    Sportster maintenance schedule
•    Harley-Davidson oil change guide
•    Sportster brake pad replacement
•    Harley-Davidson clutch adjustment
•    Sportster battery maintenance
Engine & Transmission:
•    Sportster engine rebuild
•    Harley-Davidson top end overhaul
•    Sportster transmission repair
•    Harley-Davidson crankcase assembly
•    Sportster valve tappet adjustment
Fuel & Electrical System:
•    Sportster fuel system troubleshooting
•    Harley-Davidson fuel injector cleaning
•    Sportster wiring diagram
•    Harley-Davidson ignition system repair
•    Sportster starter motor replacement
Chassis & Suspension:
•    Sportster front fork service
•    Harley-Davidson rear suspension adjustment
•    Sportster wheel alignment
•    Harley-Davidson jiffy stand installation
•    Sportster frame and bodywork
Brakes & Safety:
•    Sportster brake fluid replacement
•    Harley-Davidson ABS troubleshooting
•    Sportster master cylinder repair
•    Harley-Davidson brake rotor replacement
•    Sportster brake lever adjustment
Additional Keywords:
•    Sportster air cleaner replacement
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•    Sportster headlamp alignment
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•    Sportster electrical diagnostics
These keywords will help improve SEO visibility for content related to the 2010 Harley-Davidson Sportster Service Manual.

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