2000 Harley Davidson FLT Service Manual – PDF DOWNLOAD

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2000 Harley Davidson FLT Service Manual – PDF DOWNLOAD

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DESCRIPTION:

2000 Harley Davidson FLT Service Manual – PDF DOWNLOAD

FOREWORD :

• This service and repair manual has Ьееп prepared with two purposes in mind. First, it will acquaint the reader with the construction of the Harley-Davidson motorcycle and assist him/her in performing basic maintenance and repair work.
• Secondly, it will introduce the professional Harley-Davidson technician to the latest field-tested and factory-approved repair methods. We hope that this manual makes your association with Harley-Davidson products both pleasant and profitaЫe.

HOWTO USE THIS MANUAL:

This manual is divided into nine sections, as identified оп the first page of this book. For quick and easy reference, all page numbers are peceded Ьу the section number. Therefore, if looking for the electrical section, simply ореп up the book to those pages preceded Ьу “8-“. lf referencing the engine section, flip to those pages begining with “3-,” and so оп.

PREPARATION FOR SERVICE :

• Proper preparation is very important for efficient service work. А clean work area at the start of each job will allow you to perform the repair as easily and quickly as possiЫe, and reduce the incidence of misplaced tools and parts.
• А motorcycle that is excessively dirty should Ье cleaned before work is begun. Cleaning will often uncover trouЫe spots or areas that need attention.
• Gather tools, instruments and parts before work is started. lnterrupting а job to collect these items results in needless delay and distraction. Special tools made availaЫe for service work are listed in Section 1.

TABLE OF CONTENTS:

2000 Harley Davidson FLT Service Manual – PDF DOWNLOAD

Harley-Davidson FLT Models - Service Manual - 99483-00
.............................................  1
	SECTIONS........................................................................................  3
	FOREWORD
.......................................................................................  5
	Table of Contents...............................................................................  7
		Suite... 1..................................................................................  8
		Suite... 2..................................................................................  9
		Suite... 3.................................................................................. 10
		Suite... 4.................................................................................. 11
		Suite... 5.................................................................................. 12
		Suite... 6.................................................................................. 13
		Suite... 7.................................................................................. 14
	MAINTENANCE..................................................................................... 15
		1. Service Intervals........................................................................ 16
		2. Storage.................................................................................. 16
		3. Fluid Requirements....................................................................... 18
		4. Fastener Torque Values................................................................... 19
		5. Metric Conversion Table.................................................................. 20
		6. Troubleshooting.......................................................................... 21
		7. Shop Practices........................................................................... 24
		8. Tool Safety.............................................................................. 26
		9. Tools.................................................................................... 28
		10. Scheduled Maintenance Table............................................................. 43
		11. Scheduled Maintenance Procedure......................................................... 48
	CHASSIS......................................................................................... 64
		1. Specifications........................................................................... 65
		2. Vehicle Identification Number (VIN)...................................................... 67
		3. Front Wheel.............................................................................. 68
		4. Rear Wheel............................................................................... 73
		5. Checking Cast Rim Runout................................................................. 78
		6. Wheel Lacing - 16 Inch Rim............................................................... 79
		7. Truing Lacing Wheel...................................................................... 82
		8. Tires and Tubes.......................................................................... 84
		9. Vehicle Alignment........................................................................ 88
		10. Front Brake Master Cylinder............................................................. 91
		11. Rear Brake Master Cylinder.............................................................. 95
		12. Front Brake Caliper.....................................................................103
		13. Rear Brake Caliper......................................................................109
		14. Bleeding Hydraulic Brake System.........................................................115
		15. Front Forks.............................................................................116
		16. Fork Stem and Bracket Assembly..........................................................120
		17. Front/Rear Air Suspension...............................................................123
		18. Rear Shcok Absorbers....................................................................128
		19. Rear Swing Arm..........................................................................130
		20. Throttle  Cables (Non-Ultra)............................................................134
		21. Clutch Cables...........................................................................139
		22. Seat....................................................................................142
		23. Saddlebags..............................................................................145
		24. Tour-Pak................................................................................148
		25. Tour-Pak Lights/Backrest/Fairing Cap (FLHT/C/U).........................................150
		26. Lower Fairing/Glove Boxes (FLHTCU)......................................................153
		27. Upper Fairing/Windshield/Fairing Cap (FLHT/C/U).........................................154
		28. Upper Fairing/Windshield/Instruments Nacelle (FLHR/C)...................................161
		29. Windshield/Headlamp Nacelle (FLHR/C)....................................................171
		30. Front Fender............................................................................173
		31. Rear Fender.............................................................................175
		32. Jiffy Stand.............................................................................178
		33. Exhaust System..........................................................................180
	ENGINE..........................................................................................183
		1. Specifications...........................................................................184
		2. Serviced Wear Limits.....................................................................186
		3. General Information......................................................................187
		4. How to Use this Section..................................................................196
		5. Stripping Motorcycle for Service.........................................................198
		6. Assembling Motorcycle After Stripping....................................................199
		7. Removing Engine From Chassis.............................................................202
		8. Installing Engine in Chassis.............................................................207
		9. Special Tools (for Servicing of the Twin Cam 88 Engine)..................................213
		10. Top End Overhaul........................................................................217
			Disassembly.............................................................................217
			Assembly................................................................................221
		11. Bottom End Overhaul.....................................................................229
			Disassembly.............................................................................229
			Assembly................................................................................231
		12. Subassembly Service and Repair..........................................................237
			Top End.................................................................................237
			Breather Assembly.......................................................................237
			Rocker Arm Assembly.....................................................................238
			Push Rods/Lifters/Covers................................................................240
			Cylinder Head...........................................................................243
				Valve Guide Replacement.............................................................245
				Valve and Seat Refacing.............................................................248
		Cylinder....................................................................................253
		Piston......................................................................................255
		Upper Connecting Rod........................................................................258
			Upper Connecting Rod Bushing............................................................258
			Reaming Upper Rod Bushing...............................................................259
			Honing Upper Rod Bushing................................................................260
		Bottom End..................................................................................263
		Cam Support Plate...........................................................................263
			Crankshaft Bushing......................................................................263
			Reaming Crankshaft Bushing..............................................................264
			Camshafts/Camshaft Bearings.............................................................265
			Cam Chain Tensioners....................................................................269
			Oil Pressure Relief Valve...............................................................269
			Cam Needle Bearings.....................................................................270
		Oil Pump....................................................................................273
		Crankcase...................................................................................275
			Crankshaft (Roller) Bearing.............................................................275
				Piston Jets.........................................................................276
			Sprocket Shaft (Timken) Bearing.........................................................276
				Cylinder Studs......................................................................282
				Pipe Plug and Oil Fittings..........................................................282
		Flywheel/Connectiong Rod Assembly...........................................................284
	FUEL SYSTEM.....................................................................................285
		1. Specifications...........................................................................286
		2. Carburetor...............................................................................287
		3. Air Cleaner (Carbureted Models)..........................................................298
		4. Vacuum Operated Fule Valve (Carbureted Models)...........................................300
		5. Fuel Tank................................................................................303
		6. Evaporative Emissions Control System - California Models Only............................308
	ELECTRIC STARTER................................................................................312
		1. Specifications...........................................................................313
		2. Starter System...........................................................................314
		3. Starting System Diagnosis (FLow Chart)...................................................316
		4. Diagnostics/Troubleshooting..............................................................318
			Starting Activation Circuits............................................................319
		5. Starter Relay............................................................................322
		6. Starter..................................................................................324
		7. Starter Solenoid.........................................................................332
		8. Starter Jackshaft........................................................................333
	DRIVE...........................................................................................335
		1. Specifications...........................................................................336
		2. Primary Chain and Sprockets..............................................................337
		3. Clutch...................................................................................340
		4. Secondary Drive Belt and Sprockets.......................................................345
		5. Primary Chaincase........................................................................352
	TRANSMISSION....................................................................................364
		Transmission Power Flow Diagram.............................................................365
		1. Specifications...........................................................................366
		2. Shifter Linkage..........................................................................368
		3. Shifter Cam Assembly/Shifter Forks.......................................................370
		4. Clutch Release Cover.....................................................................375
		5. Mainshaft/Countershaft...................................................................377
		6. Main Drive Gear..........................................................................383
		7. Transmission Case/Oil Pan................................................................388
	ELECTRICAL......................................................................................394
		1. Specifications...........................................................................395
		2. Bulb Chart...............................................................................396
		3. Ignition System (Carbureted).............................................................397
			Checking for Trouble Codes..............................................................399
			Diagnostic Check........................................................................404
		4. Ignition Module..........................................................................434
		5. Engine Sensors...........................................................................434
		6. Spark Plugs/Spark Plug Cables............................................................436
		7. Ignition Coil............................................................................437
		8. Charging System..........................................................................439
		9. Alternator/Stator........................................................................444
		10. Voltage Regulator.......................................................................448
		11. Battery.................................................................................451
		12. Headlamp (FLHR/C, FLHT/C/U).............................................................456
		13. Headlamp (FLTR).........................................................................459
		14. Passing Lamps...........................................................................462
		15. Tail Lamp Asssembly.....................................................................465
		16. Fender Tip Lamps........................................................................467
		17. Turn Signal Lamps.......................................................................472
		18. Turn Signal Module......................................................................476
		19. Ignition/Light Key Switch and Fork Lock.................................................482
		20. Fairing Cap Switches (FLHTC/U)..........................................................486
		21. Instrument Nacelle Switches (FLTR)......................................................489
		22. Handlebar Switches......................................................................494
		23. Stoplight Switches......................................................................510
		24. Neutral Switch..........................................................................511
		25. Horn....................................................................................512
		26. Cigarette Lighter (FLHTCU, FLTR)........................................................513
		27. Gauges/Instruments......................................................................514
		28. Electronic Speedometer Diagnostics......................................................523
		29. Electronic Speedometer Performance Check................................................528
		30. Fuel Level Sender (Carbureted)..........................................................531
		31. Cruise Control (FLHTC/U,FLTR)...........................................................534
			Premium Sound System (FLHTC/U, FLTR)....................................................557
		32. Wiring Harnesses and Cables (FLHT/C/U)..................................................604
	FUEL INJECTION..................................................................................621
		SECTION 9A : INTRODUCTION...................................................................623
			Sequential Port Fuel Injection System...................................................625
			General Information.....................................................................625
			Component Descriptions..................................................................625
			EFI Component Schematic.................................................................626
			EFI Pictorial Schematic.................................................................627
		SECTION 9B : SYSTEM DIAGNOSTICS.............................................................631
			Introdcution............................................................................632
			9B-1 Checking for Trouble Codes.........................................................633
			9B-2 Retrieving Troubles Codes..........................................................635
			9B-3 Tools..............................................................................639
			9B-4 Diagnosing System Problems.........................................................642
			Diagnostic Check........................................................................646
			Chart A-1, No Check Engine Lamp at Key ON...............................................648
			Chart A-2, Check Engine Lamp ON Continuously............................................650
			Chart A-3, Engine Cranks but will Not Start.............................................652
			Chart A-4, No ECM Power.................................................................656
			Chart B-1, Fuel System Electrical Test..................................................659
			Chart B-2, Fuel Pressure Test...........................................................664
			Chart C-1, Idle Speed Control...........................................................668
			Chart C-2, Misfire at Idle or Under Load................................................670
			Trouble Code 11, Throttle Position Sensor...............................................672
			Trouble Code 12, barometric Pressure Sensor.............................................674
			Trouble Code 14, Engine Temerature Sensor...............................................676
			Trouble Code 15, Intake Air Temperature Sensor..........................................678
			Trouble Code 16, Battery Voltage........................................................680
			Trouble Codes 23 and 32, Fuel Injector..................................................682
			Trouble Code 24 and 25, Ignition Coil...................................................685
			Trouble Code 33, Fuel Pump Relay........................................................688
			Trouble Code 35, Tachometer - Except FLHR/C-I...........................................690
			Trouble Code 41, Crankshaft Position Sensor.............................................692
			Trouble Code 42, Camshaft Position Sensor...............................................694
			Trouble Code 44, Bank Angle Sensor......................................................696
			Trouble Codes 52, 53, 54 and 55, ECM Failure............................................697
			Trouble Code 56, Crank Position Sensor and Cam Position Sensor Timing...................697
		SECTION 9C : REMOVAL/REPLACEMENT............................................................699
			9C-1 Electrical Bracket Assembly........................................................701
				Side Cover..........................................................................701
				Data Link Connector.................................................................702
				Electrical Relays...................................................................702
				Fuses...............................................................................702
				Electronic Control Module (ECM).....................................................703
				Barometric Pressure Sensor..........................................................703
				EFI Wire Harness....................................................................704
				EFI Wire Harness Connector Terminal Repair..........................................707
			9C-2 Sensors............................................................................708
				Barometric Pressure Sensor..........................................................708
				Throttle Position Sensor............................................................708
				Intake Air Temperature Sensor.......................................................708
				Camshaft Position Sensor............................................................708
				Crankshaft Position Sensor..........................................................710
				Engine Temperature Sensor...........................................................711
				Bank Angle Sensor...................................................................711
			9C-3 Fuel Tank Assembly.................................................................713
				Fuel tank, Complete Removal.........................................................713
					FLHTC/U-I, FLTR-I...............................................................713
					FLHR/C-I........................................................................715
				Fuel Tank, Partial Removal..........................................................717
					FLHTC/U-I, FLTR-I...............................................................717
					FLHR/C-I........................................................................718
				Console Pod/Canopy, FLHTC/U-I, FLTR-I...............................................720
				Instrument Console/Canopy, FLHR/C-I.................................................721
				Fuel Filter Canister................................................................724
				Fuel Pump...........................................................................724
				Fuel Pump Wiring....................................................................725
				Fuel Level Sender...................................................................726
				Canopy Connector/O-Ring Seal........................................................726
				Fuel Supply/Return Check Valves.....................................................727
			9C-4 Air Cleaner Assembly...............................................................729
				Air Cleaner.........................................................................729
				Warm-Slow Idle Speed Adjustment.....................................................730
				Cold Idle Speed Adjustment..........................................................730
				Charcoal Canister (California Models Only)..........................................731
			9C-5 Induction Module Assembly..........................................................733
				Induction Module....................................................................733
				Fuel Supply/Return Lines............................................................735
				Fuel Injectors......................................................................736
				Fuel Pressure Regulator.............................................................737
				Intake Air Temperature Sensor.......................................................738
				Throttle Position sensor............................................................738
				Idle Speed Control Actuator.........................................................740
				Idle Speed Control Actuator - Adjustment............................................741
				Cam Lever Assembly..................................................................741
			9C-6 Ignition System....................................................................744
				Igniton Coil........................................................................744
	ELECTRICAL CONNECTOR............................................................................745
		A. Electrical Connector Service and Repair..................................................745
			Deutsch Electrical Connectors...........................................................747
			AMP Multilock Electrical Connectors.....................................................753
			Packard Electrical Connectors...........................................................758
			Sealed Butt Splice Connectors...........................................................763
			Amp Electrical Connectors...............................................................764
		B. Electrical Connector Locations...........................................................767
			FLHT, FLHTC, FLHTC-I, FLHTCU-I..........................................................769
			FLHR, FLHRC-I...........................................................................775
			FLTR, FLTR-I............................................................................777
		C. 2000 Wiring Diagrams.....................................................................781
			Main Harness............................................................................783
			Interconnect Harness....................................................................787
			Ignition Harness, Engine Sensor Harness and Engine MAnagement Circuitry.................791
			Ignition Switch, Tail Lamps, Fender Tip Lamps and Tour-Pak Lights.......................795
			Starting and Charging...................................................................799
			Handlebar Controls, Speedometer, Tachometer, Indicator Lamps and Dash Panel Switches....803
			Radio, CB/Intercom, Rear Speakers and Cruise............................................807
			Main Harness............................................................................811
			Ignition Harness, Engine Sensor Harness and Engine Management Circuitry.................815
			Starting and Charging...................................................................819
			Handlebar Controls, Indocator Lamps, Tail Lamp, Passing Lamps and Directional Lamps.....823
			Chassis and Audio Harness...............................................................827
	INDEX...........................................................................................831
		A to E......................................................................................832
		F to M......................................................................................833
		N to T......................................................................................834
		T to W......................................................................................835

2000 HARLEY DAVIDSON FLT SERVICE MANUAL – PDF DOWNLOAD:

PLEASE NOTE:

• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
• You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
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