Harley Davidson Forums

Harley Davidson Sportster: General Information and Recommended Maintenance Schedule

Here you will learn everything you need to know about your Sportster and how to maintain it.

By David Weitz - January 12, 2016

This article applies to the Harley Davidson Sportster (1991-2015).

One of the most important things you can do to ensure many years of carefree fun and trouble-free riding is to make sure you Sportster is taken care of with tender-loving care and maintained properly at the correct mileage intervals. No matter what year your Sportster is, the maintenance schedule is the same. Basically, you will need to get it serviced every 5,000 miles, either by a knowledgeable and reliable service tech, or yourself. If you have a brand new Sportster, congratulations! You will need to get its first service and checkup at 1,000 miles, then again at 5,000 miles, and then at every 5,000 miles after that.

General Information

Like many Harley Davidsons, the Sporster does not change radically from year to year, so you don't need to buy the latest model to get a good bike that you will enjoy. Since 1991, nearly every Sportster has been belt driven with a five speed transmission, and available with 883cc or 1200cc V-twin motors. In 1994, the electrical system was modernized with sealed connectors for more trouble-free riding no matter what the weather. As the Sportster entered the 21st century, the brakes were upgraded to four piston calipers and the wheels got maintenance-free sealed bearings. The year 2004 saw big changes as the frame and engine were redesigned slightly to accommodate rubber mounting for a smoother rider experience, and the battery and oil tank now are more integrated for a cleaner look. Finally, in 2007 every Sportster got standard electronic fuel injection for a fully modern, though still classic looking bike.

2016 Harley Davidson Sportster Forty-Eight
Figure 1. 2016 Harley Davidson Sportster Forty-Eight.

Common Issues

The Harley Davidson Sportster is a generally trouble-free bike for most riders, but there are a few known issues you should keep your eyes peeled for. Of course, the experts on the forums have come up with solutions for these already, so any used bike you by may already have them solved for you.

Oil Leaking at the Air Cleaner

Like most modern cars and bikes, the Sportster directs the oil vapor from inside the engine into the intake to be burned off and not pollute the atmosphere. Because the Sportster has such a simple, short intake tract, this vapor can sometimes collect and drip out of your air cleaner housing, especially if you have modified your bike with a higher flow filter. There are several solutions for this, with the most basic being under filling the motor with oil, so it reads about 1/2 way between fill and add on the dipstick. The other solution is to direct the breather tubes directly into the throat of the throttle body/carburetor, so the oil has no chance to go anywhere but back into the motor.

  • Oil dripping from air cleaner and making a mess
    Figure 2. Oil dripping from air cleaner and making a mess.
  • Oil breathers routed back to throttle body
    Figure 3. Oil breathers routed back to throttle body.

Technical Service Bulletins

There are some issues covered by various factory TSBs over the years. One of the most common is for water getting into the fuse box and causing a relay to short out, which will drain the battery while the bike is off. Another common one is for a bad fuel pump in fuel injected bike, which doesn't deliver enough pressure to allow the bike to develop full power and sometimes causes rough running. You can read all the bulletins for you bike by entering the VIN on the Harley Davidson web site linked to at the bottom of the page.

Maintenance Schedule

First 1,000 Mile Service for New Bikes

  1. Replace the engine oil and filter
  2. Inspect the oil lines and brake system for any leaks
  3. Inspect the air cleaner and service it if necessary
  4. Check the air pressure and inspect the tread of your tires
  5. Check the tightness and torque of your wheel spokes (if equipped)
  6. Replace the transmission lubricant
  7. Check and adjust your clutch
  8. Check and adjust your primary chain
  9. Inspect as well as adjust your rear belt and check your sprockets
  10. Check, adjust as well as lubricate your throttle, brake and clutch controls
  11. Inspect and lubricate your Jiffy stand
  12. Inspect your fuel lines and fittings for any leaks
  13. Check the levels and condition of your brake fluid
  14. Inspect your brake pads and discs for any wear
  15. Inspect your spark plugs
  16. Check the operation of all your electrical equipment and switches
  17. Check and adjust your engine's idle speed
  18. Inspect your shock absorbers
  19. Check the tightness of all your bike's critical fasteners
  20. Adjust steering head bearings
  21. Check your battery and make sure the connections are clean
  22. Inspect your exhaust system, looking for any leaks, cracks or missing fasteners or heat shields
  23. Adjust steering head bearings

If this is done by a dealer or certified technician, he or she will also want to take it on a road test to verify all component and systems are functioning properly.

Please Note: Everything except numbers 1, 3, 4, 6, 8, 14, 15, 16, 21 and 22 above should be done by an authorized Harley Davidson dealer or certified technician, unless you have the proper tools, data and are mechanically qualified to perform the service.

1999 Harley Davidson Sportster Sport
Figure 4. 1999 Harley Davidson Sportster Sport.

5,000 Mile Service

  1. Replace the engine oil and filter
  2. Inspect the oil lines and brake system for any leaks
  3. Inspect the air cleaner and service it if necessary
  4. Check the air pressure and inspect the tread of your tires
  5. Check and adjust your clutch
  6. Check and adjust your primary chain
  7. Inspect and adjust your rear belt and check your sprockets
  8. Check, adjust as well as lubricate your throttle, brake and clutch controls
  9. Inspect your fuel lines and fittings for any leaks
  10. Check the levels and condition of your brake fluid
  11. Inspect your brake pads and discs for any wear
  12. Check the operation of all your electrical equipment and switches
  13. Check and adjust your engine's idle speed
  14. Inspect your shock absorbers
  15. Check the tightness of all your bike's critical fasteners
  16. Inspect your engine mounts and stabilizer links
  17. Check your battery and make sure the connections are clean
  18. Inspect your exhaust system, looking for any leaks, cracks or missing fasteners or heat shields

Please Note: Numbers 2, 9, 14, 16, and 18 above should be done by an authorized Harley Davidson dealer or certified technician, unless you have the proper tools, data and are mechanically qualified to perform the service, especially if the bike is still under warranty.

If the service is done by a dealer or certified technician, he or she will also want to take it on a road test to verify all component and systems are functioning properly.

2015 Harley Davidson Sportster 72
Figure 5. 2015 Harley Davidson Sportster 72.

Special Variations to Above Schedule

  1. After 5,000 miles, checking tightness of the wheel spokes is not done until 20,000 miles.
  2. After 10,000 miles, the transmission lubricant is replaced after every 10,000 miles.
  3. After 10,000 miles, the Jiffy stand is inspected and lubricated every 10,000 miles.
  4. The fuel tank filter screen is replaced at 25,000 miles.
  5. After 5,000 miles, the front brake lever pin is inspected every 5,000 miles and lubricated at 25,000 miles.
  6. After 5,000 miles, the brake caliper pins are inspected every 5,000 miles and lubricated at 25,000 miles.
  7. After 5,000 miles, the brake caliper boots and bushings are inspected every 5,000 miles and replaced at 25,000 miles.
  8. The rubber brake components in the master cylinders and calipers are replaced at 25,000 miles.
  9. The brake's master cylinder pistons are lubricated at 25,000 miles.
  10. After 5,000 miles, the spark plugs are inspected at 15,000 and 25,000 miles, as well as replaced at 20,000 miles.
  11. After 1,000 miles, the steering head bearings are adjusted at 20,000 miles.
  12. The rear fork bearings are inspected every 30,000 miles.
  13. After 1,000 miles, the critical fasteners are checked for tightness every 10,000 miles.
  14. The engine mounts and stabilizer links are inspected every 10,000 miles.

Related Discussions and Sites

When you click on links to various merchants on this site and make a purchase, this can result in this site earning a commission. Affiliate programs and affiliations include, but are not limited to, the eBay Partner Network.