2002 Harley Davidson Touring FLT Models Electrical Diagnostics + Service Manual – PDF DOWNLOAD
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2002 Harley Davidson Touring FLT Models Electrical Diagnostics + Service Manual – PDF DOWNLOAD2002 Harley Davidson Touring FLT Models Electrical Diagnostics + Service Manual – PDF DOWNLOAD
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2002 Harley Davidson Touring FLT Models Electrical Diagnostics + Service Manual – PDF DOWNLOAD
REPAIR NOTES
General maintenance practices are given in this section. All special tools and torque values are noted at the point of use and all required parts or materials can be found in the appropriate PARTS CATALOG:
Safety Safety is always the most important consideration when performing any job. Be sure you have a complete understanding of the task to be performed. Use common sense. Use the proper tools. Don’t just do the job – do the job safely.
Removing Parts:
Always consider the weight of a part when lifting. Use a hoist whenever necessary. Do not lift heavy parts by hand. A hoist and adjustable lifting beam or sling are needed to remove some parts. The lengths of chains or cables from the hoist to the part should be equal and parallel, and should be positioned directly over the center of the part.
Be sure that no obstructions will interfere with the lifting operation. Never leave a part suspended in mid-air. Always use blocking or proper stands to support the part that has been hoisted.
If a part cannot be removed, verify that all bolts and attaching hardware have been removed. Check to see if any parts are in the way of the part being removed. When removing hoses, wiring or tubes, always tag each part to ensure proper installation.
Cleaning :
If you intend to reuse parts, follow good shop practice and thoroughly clean the parts before assembly. Keep all dirt out of parts; the unit will perform better and last longer. Seals, filters and covers are used in this vehicle to keep out environmental dirt and dust.
These items must be kept in good condition to ensure satisfactory operation. Clean and inspect all parts as they are removed. Be sure all holes and passages are clean and open. After cleaning, cover all parts with clean lint-free cloth, paper or other material. Be sure the part is clean when it is installed.
TABLE OF CONTENTS:
2002 Harley Davidson Touring FLT Models Electrical Diagnostics + Service Manual – PDF DOWNLOAD
KEYWORD SEARCH................................................................................. 0
CONTENTS....................................................................................... 1
MAIN SERVICE MANUAL............................................................................ 2
1 - MAINTENANCE............................................................................ 2
TROUBLESHOOTING 1.1.................................................................... 4
GENERAL............................................................................ 4
ENGINE............................................................................. 4
Starter Motor Does Not Operate or Does Not Turn Engine Over.................... 4
Engine Turns Over But Does Not Start........................................... 4
Starts Hard.................................................................... 4
Starts But Runs Irregularly or Misses.......................................... 4
A Spark Plug Fouls Repeatedly.................................................. 5
Pre-Ignition or Detonation (Knocks or Pings)................................... 5
Overheating.................................................................... 5
Valve Train Noise.............................................................. 5
Excessive Vibration............................................................ 5
Check Engine Lamp Illuminates During Operation................................. 5
LUBRICATION SYSTEM................................................................. 5
Oil Does Not Return To Oil Pan................................................. 5
Engine Uses Too Much Oil Or Smokes Excessively................................. 5
Engine Leaks Oil From Case, Push Rods, Hoses, Etc.............................. 5
Low Oil Pressure............................................................... 5
High Oil Pressure.............................................................. 6
ELECTRICAL SYSTEM.................................................................. 6
Alternator Does Not Charge..................................................... 6
Alternator Charge Rate Is Below Normal......................................... 6
Speedometer Operates Erratically............................................... 6
CARBURETOR......................................................................... 6
Carburetor Floods.............................................................. 6
TRANSMISSION....................................................................... 6
Transmission Shifts Hard....................................................... 6
Jumps Out Of Gear.............................................................. 6
Clutch Slips................................................................... 6
Clutch Drags Or Does Not Release............................................... 6
Clutch Chatters................................................................ 6
BRAKES............................................................................. 6
Brake Does Not Hold Normally................................................... 6
HANDLING........................................................................... 6
Irregularities................................................................. 6
SHOP PRACTICES 1.2..................................................................... 8
REPAIR NOTES....................................................................... 8
Safety......................................................................... 8
Removing Parts................................................................. 8
Cleaning....................................................................... 8
Disassembly and Assembly....................................................... 8
Checking Torques on Fasteners with Lock Patches................................ 8
REPAIR AND REPLACEMENT PROCEDURES.................................................. 8
Hardware and Threaded Parts.................................................... 8
Wiring, Hoses and Lines........................................................ 8
Instruments and Gauges......................................................... 8
Bearings....................................................................... 8
Bushings....................................................................... 9
Gaskets........................................................................ 9
Lip Type Seals................................................................. 9
O-Rings (Preformed Packings)................................................... 9
Gears.......................................................................... 9
Shafts......................................................................... 9
Part Replacement............................................................... 9
CLEANING........................................................................... 9
Part Protection................................................................ 9
Cleaning Process............................................................... 9
Rust or Corrosion Removal...................................................... 9
Bearings....................................................................... 9
TOOL SAFETY 1.3........................................................................ 10
AIR TOOLS.......................................................................... 10
WRENCHES........................................................................... 10
PLIERS/CUTTERS/PRYBARS............................................................. 10
HAMMERS............................................................................ 10
PUNCHES/CHISELS.................................................................... 10
SCREWDRIVERS....................................................................... 10
RATCHETS AND HANDLES............................................................... 10
SOCKETS............................................................................ 10
STORAGE UNITS...................................................................... 11
SCHEDULED MAINTENANCE TABLE 1.4........................................................ 12
SCHEDULED MAINTENANCE PROCEDURES 1.5................................................... 17
BATTERY............................................................................ 17
ENGINE OIL/ENGINE OIL FILTER....................................................... 17
PRIMARY CHAIN...................................................................... 18
PRIMARY CHAIN LUBRICANT............................................................ 19
CLUTCH ADJUSTMENT.................................................................. 20
TRANSMISSION LUBRICANT............................................................. 21
TIRES.............................................................................. 21
WHEEL SPOKES....................................................................... 22
STEERING HEAD BEARINGS............................................................. 22
BRAKE FLUID........................................................................ 22
BRAKE PAD LININGS AND DISCS........................................................ 23
DRIVE BELT......................................................................... 23
REAR SHOCK ABSORBERS............................................................... 25
AIR CLEANER........................................................................ 25
FUEL SYSTEM LINES AND FITTINGS..................................................... 26
FUEL TANK FILTER (Carbureted)...................................................... 26
ENRICHENER CONTROL................................................................. 27
THROTTLE CABLES.................................................................... 28
Lubrication.................................................................... 28
Adjustment..................................................................... 30
SPARK PLUGS........................................................................ 30
ELECTRICAL COMPONENTS.............................................................. 31
ENGINE IDLE SPEED.................................................................. 31
REAR SWING ARM PIVOT SHAFT NUT..................................................... 32
FASTENERS.......................................................................... 32
ENGINE MOUNTS...................................................................... 32
Top............................................................................ 32
Bottom......................................................................... 32
FRONT FORK OIL..................................................................... 33
ROAD TEST.......................................................................... 33
2 - CHASSIS................................................................................ 34
SPECIFICATIONS 2.1..................................................................... 36
DIMENSIONS (in.)................................................................... 36
WEIGHT (lbs.)...................................................................... 36
CAPACITIES (U.S.).................................................................. 36
DIMENSIONS (mm).................................................................... 36
WEIGHT (kg)........................................................................ 36
CAPACITIES (Metric)................................................................ 36
TIRE DATA.......................................................................... 37
REAR WHEEL SPROCKET................................................................ 37
TORQUE VALUES...................................................................... 37
TORQUE VALUES (CONT.’D)........................................................ 38
VEHICLE IDENTIFICATION NUMBER (VIN)................................................ 40
FRONT WHEEL 2.2........................................................................ 41
GENERAL............................................................................ 41
PRELIMINARY INSPECTION............................................................. 41
REMOVAL............................................................................ 41
DISASSEMBLY........................................................................ 41
CLEANING AND INSPECTION............................................................ 42
ASSEMBLY........................................................................... 43
INSTALLATION....................................................................... 44
REAR WHEEL 2.3......................................................................... 46
GENERAL............................................................................ 46
PRELIMINARY INSPECTION............................................................. 46
REMOVAL............................................................................ 46
DISASSEMBLY........................................................................ 46
CLEANING AND INSPECTION............................................................ 47
ASSEMBLY........................................................................... 48
INSTALLATION....................................................................... 49
CHECKING CAST RIM RUNOUT 2.4........................................................... 52
INSPECTION......................................................................... 52
WHEEL LACING - 16 INCH RIM 2.5......................................................... 53
GENERAL............................................................................ 53
WHEEL LACING....................................................................... 53
SPOKE TIGHTNESS.................................................................... 55
TRUING LACED WHEEL 2.6................................................................. 56
PROCEDURE.......................................................................... 56
TIRES AND TUBES 2.7.................................................................... 58
GENERAL............................................................................ 58
REMOVAL............................................................................ 58
CLEANING AND INSPECTION............................................................ 58
INSTALLATION....................................................................... 59
Checking Tire Radial Runout.................................................... 60
Checking Tire Lateral Runout................................................... 60
Wheel Balancing................................................................ 61
VEHICLE ALIGNMENT 2.8.................................................................. 62
PROCEDURE.......................................................................... 62
FRONT BRAKE MASTER CYLINDER 2.9........................................................ 65
GENERAL............................................................................ 65
REMOVAL/DISASSEMBLY................................................................ 65
CLEANING AND INSPECTION............................................................ 66
ASSEMBLY/INSTALLATION.............................................................. 66
REAR BRAKE MASTER CYLINDER 2.10........................................................ 70
REMOVAL............................................................................ 70
PRELIMINARY INSTRUCTIONS....................................................... 70
BRAKE PEDAL/MASTER CYLINDER ASSEMBLY, REMOVAL.................................. 70
BRAKE PEDAL/MASTER CYLINDER ASSEMBLY, INSTALLATION............................. 71
REAR BRAKE LINE, REMOVAL....................................................... 71
REAR BRAKE LINE, INSTALLATION.................................................. 72
INSTALLATION....................................................................... 72
FINAL INSTRUCTIONS............................................................. 72
MASTER CYLINDER.................................................................... 74
DISASSEMBLY.................................................................... 74
CLEANING AND INSPECTION........................................................ 75
ASSEMBLY....................................................................... 76
FRONT BRAKE CALIPER 2.11............................................................... 78
INSPECTION......................................................................... 78
BRAKE PADS..................................................................... 78
BRAKE LINE/HOSE INSPECTION..................................................... 78
FRONT BRAKE PAD REPLACEMENT........................................................ 78
PAD INSTALLATION............................................................... 79
CALIPER REMOVAL.................................................................... 80
CALIPER DISASSEMBLY................................................................ 81
CLEANING AND INSPECTION............................................................ 82
CALIPER ASSEMBLY................................................................... 82
CALIPER INSTALLATION............................................................... 83
REAR BRAKE CALIPER 2.12................................................................ 84
INSPECTION......................................................................... 84
BRAKE DISC THICKNESS/WARPAGE................................................... 84
BRAKE PADS..................................................................... 84
BRAKE LINE/HOSE INSPECTION..................................................... 84
REAR BRAKE PAD REPLACEMENT......................................................... 84
PAD INSTALLATION............................................................... 85
CALIPER REMOVAL.................................................................... 86
CALIPER DISASSEMBLY................................................................ 86
CLEANING AND INSPECTION............................................................ 88
CALIPER ASSEMBLY................................................................... 88
CALIPER INSTALLATION............................................................... 89
BLEEDING HYDRAULIC BRAKES 2.13......................................................... 90
GENERAL............................................................................ 90
FRONT FORKS 2.14....................................................................... 91
CHANGING FORK OIL.................................................................. 91
REMOVAL............................................................................ 91
DISASSEMBLY........................................................................ 92
LEFT FORK...................................................................... 92
RIGHT FORK..................................................................... 94
CLEANING AND INSPECTION............................................................ 94
ASSEMBLY........................................................................... 95
LEFT FORK...................................................................... 95
RIGHT FORK..................................................................... 97
INSTALLATION....................................................................... 99
STEERING HEAD BEARINGS 2.15............................................................ 100
LUBRICATION........................................................................ 100
CHECKING........................................................................... 100
ADJUSTMENT......................................................................... 100
REMOVAL............................................................................ 101
INSPECTION......................................................................... 102
ASSEMBLY........................................................................... 103
INSTALLATION....................................................................... 103
REAR AIR SUSPENSION 2.16............................................................... 104
GENERAL............................................................................ 104
REAR AIR SUSPENSION................................................................ 104
REMOVAL/INSTALLATION............................................................... 104
REAR SHOCK ABSORBERS 2.17.............................................................. 108
ADJUSTMENT......................................................................... 108
REMOVAL............................................................................ 108
DISASSEMBLY........................................................................ 108
CLEANING AND INSPECTION............................................................ 108
ASSEMBLY........................................................................... 108
INSTALLATION....................................................................... 109
REAR SWINGARM 2.18..................................................................... 110
REMOVAL............................................................................ 110
DISASSEMBLY/ASSEMBLY............................................................... 111
Bearing Removal................................................................ 111
Bearing Installation........................................................... 112
Pivot Shaft Disassembly........................................................ 112
Pivot Shaft Assembly........................................................... 112
INSTALLATION....................................................................... 113
THROTTLE CABLES (NON-CRUISE) 2.19...................................................... 118
ADJUSTMENT......................................................................... 118
REMOVAL............................................................................ 119
THROTTLE SIDE.................................................................. 119
CARBURETOR/INDUCTION MODULE SIDE............................................... 120
CLEANING AND INSPECTION............................................................ 120
INSTALLATION....................................................................... 120
THROTTLE SIDE.................................................................. 120
CARBURETOR/INDUCTION MODULE SIDE............................................... 121
LUBRICATION........................................................................ 122
CLUTCH CABLE 2.20...................................................................... 123
ADJUSTMENT......................................................................... 123
REMOVAL............................................................................ 123
INSTALLATION....................................................................... 124
SEAT 2.21.............................................................................. 126
FLHT............................................................................... 126
REMOVAL........................................................................ 126
INSTALLATION................................................................... 126
FLHTC/U............................................................................ 126
REMOVAL........................................................................ 126
INSTALLATION................................................................... 126
FLHR............................................................................... 127
REMOVAL........................................................................ 127
INSTALLATION................................................................... 127
FLHRC.............................................................................. 128
REMOVAL........................................................................ 128
INSTALLATION................................................................... 128
FLTR............................................................................... 128
REMOVAL........................................................................ 128
INSTALLATION................................................................... 128
SEAT RETENTION NUT REPLACEMENT................................................. 129
SADDLEBAG 2.22......................................................................... 130
OPENING............................................................................ 130
CLOSING............................................................................ 130
REMOVAL............................................................................ 130
INSTALLATION....................................................................... 131
INSPECTION AND REPAIR.............................................................. 131
TOUR-PAK 2.23.......................................................................... 133
FLHTC.............................................................................. 133
REMOVAL........................................................................ 133
INSTALLATION................................................................... 133
FLHTCU............................................................................. 134
REMOVAL........................................................................ 134
INSTALLATION................................................................... 135
TOUR-PAK LIGHTS/BACKREST/SPEAKER BOX 2.24.............................................. 136
GENERAL............................................................................ 136
SIDE MARKER LIGHTS FLHTC/U......................................................... 136
BULB/LENSE REPLACEMENT......................................................... 136
REMOVAL........................................................................ 136
INSTALLATION................................................................... 136
WRAP-AROUND LIGHT ASSEMBLY FLHTCU.................................................. 137
BULB REPLACEMENT............................................................... 137
REMOVAL........................................................................ 137
INSTALLATION................................................................... 138
PASSENGER BACKREST FLHTCU.......................................................... 138
REMOVAL........................................................................ 138
INSTALLATION................................................................... 139
SPEAKER BOX FLHTCU................................................................. 139
REMOVAL........................................................................ 139
INSTALLATION................................................................... 139
LOWER FAIRING/GLOVE BOXES (FLHTCU) 2.25................................................ 140
REMOVAL............................................................................ 140
INSTALLATION....................................................................... 140
UPPER FAIRING/WINDSHIELD (FLHT/C/U) 2.26............................................... 141
OUTER FAIRING/WINDSHIELD........................................................... 141
REMOVAL........................................................................ 141
INSTALLATION................................................................... 141
FAIRING CAP........................................................................ 142
REMOVAL........................................................................ 142
INSTALLATION................................................................... 142
INNER FAIRING...................................................................... 143
REMOVAL........................................................................ 143
INSTALLATION................................................................... 146
UPPER FAIRING/WINDSHIELD (FLTR) 2.27................................................... 149
WINDSHIELD ONLY.................................................................... 149
REMOVAL........................................................................ 149
INSTALLATION................................................................... 149
OUTER FAIRING...................................................................... 149
REMOVAL........................................................................ 149
INSTALLATION................................................................... 150
BEZEL.............................................................................. 151
REMOVAL........................................................................ 151
INSTALLATION................................................................... 151
INSTRUMENT NACELLE................................................................. 152
REMOVAL........................................................................ 152
INSTALLATION................................................................... 153
INNER FAIRING...................................................................... 155
REMOVAL........................................................................ 155
INSTALLATION................................................................... 156
GLOVE BOX DOOR/HINGE............................................................... 158
REMOVAL........................................................................ 158
INSTALLATION................................................................... 158
WINDSHIELD/HEADLAMP NACELLE (FLHR/C) 2.28.............................................. 159
WINDSHIELD REMOVAL................................................................. 159
WINDSHIELD INSTALLATION............................................................ 159
NACELLE REMOVAL.................................................................... 159
NACELLE INSTALLATION............................................................... 160
FRONT FENDER 2.29...................................................................... 162
REMOVAL............................................................................ 162
INSTALLATION....................................................................... 162
REAR FENDER 2.30....................................................................... 164
REMOVAL............................................................................ 164
INSTALLATION....................................................................... 165
JIFFY STAND 2.31....................................................................... 167
GENERAL............................................................................ 167
REMOVAL............................................................................ 167
INSTALLATION....................................................................... 168
EXHAUST SYSTEM 2.32.................................................................... 169
REMOVAL............................................................................ 169
INSTALLATION....................................................................... 169
3 - ENGINE................................................................................. 172
SPECIFICATIONS 3.1..................................................................... 174
MANUFACTURING TOLERANCES........................................................... 174
MANUFACTURING TOLERANCES (CONT.)............................................... 175
TORQUE VALUES...................................................................... 175
SERVICE WEAR LIMITS 3.2................................................................ 176
GENERAL............................................................................ 176
GENERAL INFORMATION 3.3................................................................ 178
FUEL............................................................................... 178
GASOLINE/ALCOHOL BLENDS........................................................ 178
LUBRICATION........................................................................ 178
CHECKING ENGINE OIL LEVEL...................................................... 178
CHANGING ENGINE OIL AND FILTER................................................. 179
WINTER LUBRICATION............................................................. 180
OIL PRESSURE INDICATOR LAMP.................................................... 180
ENGINE OIL FLOW................................................................ 181
Oil Feed (Figures 3-6, 3-7).................................................... 181
Top End (Figures 3-6, 3-7)..................................................... 181
Bottom End (Figures 3-6, 3-7, 3-8)............................................. 183
Oil Return (Figures 3-6, 3-8).................................................. 183
Oil Pump Operation............................................................. 183
Breather Operation............................................................. 186
HOW TO USE THIS SECTION 3.4............................................................ 187
GENERAL............................................................................ 187
Top End Overhaul............................................................... 187
Bottom End Overhaul............................................................ 187
Subassembly Service and Repair................................................. 188
STRIPPING MOTORCYCLE FOR SERVICE 3.5................................................... 189
PROCEDURE.......................................................................... 189
ASSEMBLING MOTORCYCLE AFTER STRIPPING 3.6.............................................. 191
PROCEDURE.......................................................................... 191
REMOVING ENGINE FROM CHASSIS 3.7....................................................... 194
PROCEDURE.......................................................................... 194
INSTALLING ENGINE IN CHASSIS 3.8....................................................... 199
PROCEDURE.......................................................................... 199
SPECIAL TOOLS (for Servicing of the Twin Cam 88 Engine) 3.9............................ 206
SPECIAL TOOLS...................................................................... 208
TOP END OVERHAUL 3.10.................................................................. 210
DISASSEMBLY........................................................................ 210
ASSEMBLY........................................................................... 214
BOTTOM END OVERHAUL 3.11............................................................... 222
DISASSEMBLY........................................................................ 222
ASSEMBLY........................................................................... 224
SUBASSEMBLY SERVICE AND REPAIR 3.12.................................................... 232
TOP END............................................................................ 232
BREATHER ASSEMBLY.................................................................. 232
Removal........................................................................ 232
Disassembly.................................................................... 232
Cleaning and Inspection........................................................ 232
Assembly....................................................................... 232
Installation................................................................... 232
ROCKER ARM ASSEMBLY................................................................ 233
Removal........................................................................ 233
Disassembly.................................................................... 233
Cleaning and Inspection........................................................ 233
Assembly....................................................................... 234
Installation................................................................... 235
PUSH RODS/LIFTERS/COVERS........................................................... 236
Removal........................................................................ 236
Disassembly.................................................................... 236
Cleaning and Inspection........................................................ 236
Assembly....................................................................... 236
Installation................................................................... 237
CYLINDER HEAD...................................................................... 240
Removal........................................................................ 240
Disassembly.................................................................... 240
Cleaning and Inspection........................................................ 241
VALVE GUIDE REPLACEMENT........................................................ 242
VALVE AND SEAT REFACING........................................................ 245
Assembly....................................................................... 248
Installation................................................................... 250
CYLINDER........................................................................... 251
Removal........................................................................ 251
Cleaning and Inspection........................................................ 251
Installation................................................................... 253
PISTON................................................................................. 254
Removal............................................................................ 254
Disassembly........................................................................ 254
Piston Rings....................................................................... 254
Cleaning and Inspection............................................................ 254
Assembly........................................................................... 255
Piston Rings....................................................................... 255
Installation....................................................................... 256
UPPER CONNECTING ROD................................................................... 257
Removal............................................................................ 257
Disassembly/Assembly............................................................... 257
Upper Connecting Rod Bushing....................................................... 257
Reaming Upper Rod Bushing.......................................................... 258
Honing Upper Rod Bushing........................................................... 259
Installation....................................................................... 260
BOTTOM END............................................................................. 262
CAM SUPPORT PLATE...................................................................... 262
Removal............................................................................ 262
Disassembly/Assembly............................................................... 262
Crankshaft Bushing................................................................. 262
Reaming Crankshaft Bushing......................................................... 263
Camshafts/Camshaft Bearings........................................................ 264
Cam Chain Tensioners............................................................... 270
Oil Pressure Relief Valve.......................................................... 271
Cam Needle Bearings................................................................ 271
Cleaning and Inspection............................................................ 273
Installation....................................................................... 273
OIL PUMP............................................................................... 274
Removal............................................................................ 274
Cleaning and Inspection............................................................ 274
Installation....................................................................... 274
CRANKCASE.............................................................................. 276
Removal............................................................................ 276
Disassembly/Assembly............................................................... 276
RIGHT CRANKCASE HALF............................................................... 276
Crankshaft (Roller) Bearing........................................................ 276
Piston Jets........................................................................ 277
LEFT CRANKCASE HALF................................................................ 277
Sprocket Shaft (Timken) Bearing.................................................... 277
Cylinder Studs..................................................................... 284
Pipe Plug and Oil Fittings......................................................... 284
Cleaning and Inspection............................................................ 284
Installation....................................................................... 284
FLYWHEEL/CONNECTING ROD ASSEMBLY....................................................... 285
Removal............................................................................ 285
Inspection......................................................................... 285
Installation....................................................................... 285
4 - FUEL SYSTEM............................................................................ 286
SPECIFICATIONS 4.1..................................................................... 288
CVH CARBURETOR JET SIZES........................................................... 288
FUEL TANK CAPACITY................................................................. 288
TORQUE VALUES...................................................................... 288
FUEL SYSTEM TROUBLESHOOTING (CARBURETED) 4.2........................................... 289
ENRICHENER (CARBURETED) 4.3............................................................ 292
GENERAL............................................................................ 292
OPERATION.......................................................................... 292
Enrichener..................................................................... 292
Cool Engine.................................................................... 293
Warm Climate Or Hot Engine..................................................... 293
ADJUSTMENTS........................................................................ 293
Slow Idle...................................................................... 293
Enrichener Control............................................................. 294
CARBURETOR 4.4......................................................................... 296
REMOVAL............................................................................ 296
INSTALLATION....................................................................... 296
DISASSEMBLY - TOP END.............................................................. 297
DISASSEMBLY - BOTTOM END........................................................... 297
CLEANING AND INSPECTION............................................................ 299
Carburetor Housing............................................................. 299
Top End Components............................................................. 299
Bottom End Components.......................................................... 300
ASSEMBLY - TOP END................................................................. 300
ASSEMBLY - BOTTOM END.............................................................. 301
AIR CLEANER 4.5........................................................................ 303
GENERAL............................................................................ 303
REMOVAL............................................................................ 303
CLEANING AND INSPECTION............................................................ 303
INSTALLATION....................................................................... 304
VACUUM OPERATED FUEL VALVE (CARBURETED) 4.6............................................ 305
GENERAL............................................................................ 305
TROUBLESHOOTING.................................................................... 305
REMOVAL........................................................................ 305
CLEANING AND INSPECTION........................................................ 306
INSTALLATION................................................................... 306
FUEL TANK (CARBURETED) 4.7............................................................. 308
COMPLETE REMOVAL................................................................... 308
FLHT/C, FLTR................................................................... 308
FLHR........................................................................... 309
CLEANING AND INSPECTION............................................................ 309
INSTALLATION (AFTER COMPLETE REMOVAL).............................................. 310
FLHT/C, FLTR................................................................... 310
FLHR........................................................................... 311
PARTIAL REMOVAL.................................................................... 311
FLHT/C, FLTR................................................................... 311
FLHR........................................................................... 312
INSTALLATION (AFTER PARTIAL REMOVAL)............................................... 312
FLHT/C, FLTR................................................................... 312
FLHR........................................................................... 313
EVAPORATIVE EMISSIONS CONTROL SYSTEM 4.8............................................... 314
CALIFORNIA MODELS ONLY............................................................. 314
TROUBLESHOOTING.................................................................... 315
VAPOR VALVE........................................................................ 315
REMOVAL........................................................................ 315
INSTALLATION................................................................... 315
CHARCOAL CANISTER.................................................................. 316
REMOVAL........................................................................ 316
INSTALLATION................................................................... 316
Charcoal Canister Hose Routing................................................. 317
Purge Tube:.................................................................... 317
Fuel Vapor Vent Tube:.......................................................... 317
Clean Air Inlet Tube:.......................................................... 317
5 - ELECTRIC STARTER....................................................................... 318
SPECIFICATIONS 5.1..................................................................... 320
STARTER............................................................................ 320
SERVICE WEAR LIMITS................................................................ 320
TORQUE VALUES...................................................................... 320
STARTER SYSTEM 5.2..................................................................... 321
GENERAL............................................................................ 321
Operation (Figure 5-1)......................................................... 321
STARTER RELAY 5.3...................................................................... 323
REMOVAL............................................................................ 323
FLHR/C......................................................................... 323
FLTR, FLHT/C/U................................................................. 323
INSTALLATION....................................................................... 323
FLHR/C......................................................................... 323
FLTR, FLHT/C/U................................................................. 323
STARTER 5.4............................................................................ 324
REMOVAL............................................................................ 324
INSTALLATION....................................................................... 324
DISASSEMBLY, TESTING AND REPAIR.................................................... 326
ASSEMBLY........................................................................... 330
STARTER SOLENOID 5.5................................................................... 331
GENERAL............................................................................ 331
DISASSEMBLY........................................................................ 331
ASSEMBLY........................................................................... 331
STARTER JACKSHAFT 5.6.................................................................. 332
REMOVAL/DISASSEMBLY................................................................ 332
ASSEMBLY/INSTALLATION.............................................................. 333
6 - DRIVE.................................................................................. 334
SPECIFICATIONS 6.1..................................................................... 336
OVERALL GEAR RATIOS................................................................ 336
CHAINS AND BELTS................................................................... 336
SPROCKETS.......................................................................... 336
CLUTCH............................................................................. 336
TORQUE VALUES...................................................................... 336
PRIMARY CHAIN AND SPROCKETS 6.2........................................................ 338
PRIMARY CHAIN ADJUSTMENT........................................................... 338
ADJUSTER SHOE REPLACEMENT.......................................................... 338
DISASSEMBLY........................................................................ 340
CLEANING AND INSPECTION............................................................ 340
Sprocket Alignment (Figure 6-3, 6-4)........................................... 340
ASSEMBLY........................................................................... 341
CLUTCH 6.3............................................................................. 342
ADJUSTMENT......................................................................... 342
REMOVAL/INSTALLATION............................................................... 343
PARTIAL DISASSEMBLY............................................................ 343
ASSEMBLY....................................................................... 343
CLEANING AND INSPECTION............................................................ 345
COMPLETE DISASSEMBLY........................................................... 345
ASSEMBLY....................................................................... 346
SECONDARY DRIVE BELT AND SPROCKETS 6.4................................................. 348
ADJUSTMENT......................................................................... 348
INSPECTION......................................................................... 349
REPLACEMENT........................................................................ 350
Removal........................................................................ 350
Installation................................................................... 350
TRANSMISSION SPROCKET.............................................................. 350
Removal........................................................................ 350
Cleaning and Inspection........................................................ 351
Installation................................................................... 351
REAR WHEEL SPROCKET................................................................ 353
Removal........................................................................ 353
Cleaning and Inspection........................................................ 353
Installation................................................................... 353
PRIMARY CHAINCASE 6.5.................................................................. 354
GENERAL............................................................................ 354
LUBRICATION........................................................................ 354
REMOVAL............................................................................ 354
INSPECTION AND REPAIR.............................................................. 357
DISASSEMBLY........................................................................ 357
MAINSHAFT BEARING AND LIP SEAL................................................. 357
MAINSHAFT BEARING INNER RACE................................................... 358
STARTER JACKSHAFT BUSHING AND LIP SEAL - PRIMARY CHAINCASE..................... 359
STARTER JACKSHAFT BUSHING - PRIMARY CHAINCASE COVER............................ 359
SHIFTER BRACKET BUSHINGS....................................................... 360
INSTALLATION....................................................................... 361
7 - TRANSMISSION........................................................................... 366
SPECIFICATIONS 7.1..................................................................... 368
TRANSMISSION DATA.................................................................. 368
SERVICE WEAR LIMITS................................................................ 368
SERVICE WEAR LIMITS (CONT.’D).................................................. 369
TORQUE VALUES...................................................................... 369
TRANSMISSION POWER FLOW 7.2............................................................ 370
GENERAL............................................................................ 370
Neutral........................................................................ 370
1st Gear....................................................................... 370
2nd Gear....................................................................... 370
3rd Gear....................................................................... 370
4th Gear....................................................................... 370
5th Gear....................................................................... 370
SHIFTER LINKAGE 7.3.................................................................... 372
ADJUSTMENT......................................................................... 372
Shifter Linkage................................................................ 372
SHIFTER CAM ASSEMBLY/SHIFTER FORKS 7.4................................................. 373
DISASSEMBLY........................................................................ 373
CLEANING AND INSPECTION............................................................ 374
ASSEMBLY........................................................................... 375
CLUTCH RELEASE COVER 7.5............................................................... 379
REMOVAL/DISASSEMBLY................................................................ 379
CLEANING AND INSPECTION............................................................ 379
ASSEMBLY/INSTALLATION.............................................................. 380
MAINSHAFT/COUNTERSHAFT 7.6............................................................. 382
REMOVAL............................................................................ 382
DISASSEMBLY........................................................................ 382
CLEANING AND INSPECTION............................................................ 383
ASSEMBLY........................................................................... 385
INSTALLATION....................................................................... 388
MAIN DRIVE GEAR 7.7.................................................................... 389
REMOVAL............................................................................ 389
CLEANING AND INSPECTION............................................................ 389
Needle Bearing Replacement..................................................... 390
INSTALLATION....................................................................... 391
Countershaft Needle Bearing Replacement........................................ 394
TRANSMISSION CASE/OIL PAN 7.8.......................................................... 395
GENERAL............................................................................ 395
REMOVAL............................................................................ 395
Transmission Case and Oil Pan.................................................. 395
Oil Pan Only................................................................... 396
CLEANING AND INSPECTION............................................................ 397
INSTALLATION....................................................................... 397
Oil Pan Only................................................................... 397
Transmission Case and Oil Pan.................................................. 397
NOTES.................................................................................. 399
8 - ELECTRICAL............................................................................. 400
SPECIFICATIONS 8.1..................................................................... 402
IGNITION TIMING.................................................................... 402
ALTERNATOR SYSTEM.................................................................. 402
BATTERY............................................................................ 402
FUSES.............................................................................. 402
SPARK PLUG......................................................................... 403
TORQUE VALUES...................................................................... 403
BULB CHART 8.2......................................................................... 404
IGNITION MODULE 8.3.................................................................... 406
REMOVAL............................................................................ 406
INSTALLATION....................................................................... 406
ENGINE SENSORS 8.4..................................................................... 407
MANIFOLD ABSOLUTE PRESSURE SENSOR.................................................. 407
Removal........................................................................ 407
Installation................................................................... 407
CRANKSHAFT POSITION SENSOR......................................................... 407
IGNITION COIL 8.5...................................................................... 408
REMOVAL............................................................................ 408
INSTALLATION....................................................................... 408
SPARK PLUGS/SPARK PLUG CABLES 8.6...................................................... 409
SPARK PLUGS........................................................................ 409
REMOVAL........................................................................ 409
INSPECTION..................................................................... 409
CLEANING....................................................................... 409
ADJUSTMENT..................................................................... 409
INSTALLATION................................................................... 409
SPARK PLUG CABLES.................................................................. 410
REMOVAL........................................................................ 410
INSPECTION..................................................................... 410
INSTALLATION................................................................... 410
ALTERNATOR/STATOR 8.7.................................................................. 411
REMOVAL............................................................................ 411
CLEANING AND INSPECTION............................................................ 412
INSTALLATION....................................................................... 413
VOLTAGE REGULATOR 8.8.................................................................. 416
REMOVAL............................................................................ 416
INSTALLATION....................................................................... 416
BATTERY 8.9............................................................................ 420
GENERAL............................................................................ 420
VOLTMETER TEST..................................................................... 420
DISCONNECTION AND REMOVAL.......................................................... 421
CLEANING AND INSPECTION............................................................ 421
BATTERY CHARGING................................................................... 421
SAFETY PRECAUTIONS............................................................. 421
CHARGING BATTERY............................................................... 421
LOAD TEST.......................................................................... 422
BATTERY CABLE ROUTING.............................................................. 423
INSTALLATION AND CONNECTION........................................................ 423
STORAGE............................................................................ 424
HEADLAMP (FLHR/C, FLHT/C/U) 8.10....................................................... 425
HEADLAMP ASSEMBLY.................................................................. 425
REMOVAL........................................................................ 425
INSTALLATION................................................................... 425
HEADLAMP BULB REPLACEMENT.......................................................... 425
HEADLAMP ADJUSTMENT................................................................ 426
HEADLAMP (FLTR) 8.11................................................................... 428
HEADLAMP ASSEMBLY.................................................................. 428
REMOVAL........................................................................ 428
INSTALLATION................................................................... 428
HEADLAMP BULB REPLACEMENT.......................................................... 428
REMOVAL........................................................................ 428
INSTALLATION................................................................... 429
HEADLAMP ADJUSTMENT................................................................ 429
PASSING LAMPS 8.12..................................................................... 431
ADJUSTMENT......................................................................... 431
PASSING LAMP BULB.................................................................. 431
REMOVAL........................................................................ 431
INSTALLATION................................................................... 431
PASSING LAMP BRACKET............................................................... 431
REMOVAL........................................................................ 431
INSTALLATION................................................................... 432
PASSING LAMP....................................................................... 433
REMOVAL........................................................................ 433
INSTALLATION................................................................... 433
TAIL LAMP ASSEMBLY 8.13................................................................ 434
TAIL LAMP.......................................................................... 434
REMOVAL........................................................................ 434
INSTALLATION................................................................... 434
CIRCUIT BOARD/TAIL LAMP BRACKET ASSEMBLY........................................... 434
REMOVAL........................................................................ 434
INSTALLATION................................................................... 435
FENDER TIP LAMPS 8.14.................................................................. 437
FRONT FENDER TIP LAMP.............................................................. 437
REMOVAL........................................................................ 437
INSTALLATION................................................................... 437
FRONT FENDER TIP LAMP JUMPER HARNESS............................................... 437
REMOVAL........................................................................ 437
INSTALLATION................................................................... 439
REAR FENDER TIP LAMP............................................................... 439
REMOVAL........................................................................ 439
INSTALLATION................................................................... 440
TURN SIGNAL LAMPS 8.15................................................................. 442
GENERAL............................................................................ 442
FLHT/C/U, FLHR/C............................................................... 442
BULB REPLACEMENT................................................................... 442
FRONT TURN SIGNAL LAMP............................................................. 442
REMOVAL........................................................................ 442
INSTALLATION................................................................... 443
REAR TURN SIGNAL LAMP.............................................................. 444
REMOVAL........................................................................ 444
INSTALLATION................................................................... 444
TURN SIGNAL/SECURITY MODULE 8.16....................................................... 446
REMOVAL............................................................................ 446
INSTALLATION....................................................................... 446
IGNITION/LIGHT KEY SWITCH AND FORK LOCK 8.17........................................... 448
FLHT/C/U (Domestic)................................................................ 448
REMOVAL........................................................................ 448
INSTALLATION................................................................... 449
FLHT/C/U (International)........................................................... 449
REMOVAL........................................................................ 449
INSTALLATION................................................................... 450
FAIRING CAP SWITCHES (FLHTC/U) 8.18.................................................... 452
REMOVAL............................................................................ 452
INSTALLATION....................................................................... 452
INSTRUMENT NACELLE SWITCHES (FLTR) 8.19................................................ 455
REMOVAL............................................................................ 455
LEFT SIDE SWITCH............................................................... 455
RIGHT SIDE SWITCH.............................................................. 456
INSTALLATION....................................................................... 457
LEFT SIDE SWITCH............................................................... 457
RIGHT SIDE SWITCH.............................................................. 458
HANDLEBAR SWITCHES 8.20................................................................ 460
GENERAL............................................................................ 460
REMOVAL............................................................................ 460
RIGHT HANDLEBAR CONTROLS....................................................... 460
LEFT HANDLEBAR CONTROLS........................................................ 461
INSTALLATION....................................................................... 461
RIGHT HANDLEBAR CONTROLS....................................................... 461
LEFT HANDLEBAR CONTROLS........................................................ 463
SWITCH REPAIR/REPLACEMENT.......................................................... 466
RIGHT SIDE HANDLEBAR SWITCHES.................................................. 466
LEFT SIDE HANDLEBAR SWITCHES................................................... 466
SPECIFIC REPAIR PROCEDURES......................................................... 466
UPPER SWITCH HOUSINGS.......................................................... 466
LOWER SWITCH HOUSINGS.......................................................... 468
GENERAL REPAIR PROCEDURES.......................................................... 475
RIGHT SIDE HANDLEBAR SWITCHES.................................................. 476
LEFT SIDE HANDLEBAR SWITCHES................................................... 477
STOPLIGHT SWITCHES 8.21................................................................ 478
FRONT STOPLIGHT SWITCH............................................................. 478
REAR STOPLIGHT SWITCH.............................................................. 478
NEUTRAL SWITCH 8.22.................................................................... 479
GENERAL............................................................................ 479
REMOVAL............................................................................ 479
INSTALLATION....................................................................... 479
HORN 8.23.............................................................................. 480
TROUBLESHOOTING.................................................................... 480
REMOVAL............................................................................ 480
INSTALLATION....................................................................... 480
CIGARETTE LIGHTER (FLHTCU, FLTR) 8.24.................................................. 481
GENERAL............................................................................ 481
TROUBLESHOOTING.................................................................... 481
REMOVAL............................................................................ 481
INSTALLATION....................................................................... 481
GAUGES/INSTRUMENTS (FLHT/C/U, FLTR) 8.25............................................... 482
GAUGES- 2 INCH DIAMETER............................................................ 482
REMOVAL........................................................................ 482
INSTALLATION................................................................... 482
GAUGES- 4 INCH DIAMETER............................................................ 482
TACHOMETER..................................................................... 482
REMOVAL........................................................................ 482
INSTALLATION................................................................... 482
SPEEDOMETER SPEED SENSOR........................................................... 483
REMOVAL........................................................................ 483
INSTALLATION................................................................... 483
SPEEDOMETER........................................................................ 483
REMOVAL........................................................................ 483
INSTALLATION................................................................... 483
INDICATOR LAMPS.................................................................... 484
REMOVAL........................................................................ 484
INSTALLATION................................................................... 484
GAUGES/INSTRUMENTS (FLHR/C) 8.26....................................................... 485
FUEL GAUGE......................................................................... 485
REMOVAL........................................................................ 485
INSTALLATION................................................................... 485
SPEEDOMETER SPEED SENSOR........................................................... 486
REMOVAL........................................................................ 486
INSTALLATION................................................................... 486
SPEEDOMETER........................................................................ 486
REMOVAL........................................................................ 486
INSTALLATION................................................................... 487
INDICATOR LIGHTS................................................................... 487
REMOVAL........................................................................ 487
INSTALLATION................................................................... 488
FUEL LEVEL SENDER (Carbureted) 8.27.................................................... 489
ALL MODELS (EXCEPT FLHR)........................................................... 489
REMOVAL........................................................................ 489
INSTALLATION................................................................... 489
FLHR ONLY.......................................................................... 490
REMOVAL........................................................................ 490
INSTALLATION................................................................... 491
CRUISE CONTROL (FLHRC, FLTR, FLHTCU) 8.28.............................................. 492
GENERAL............................................................................ 492
SYSTEM OPERATION................................................................... 492
CABLE ADJUSTMENT................................................................... 493
THROTTLE CABLE................................................................. 493
IDLE CABLE..................................................................... 494
CABLE LASH INITIALIZATION...................................................... 494
THROTTLE/IDLE CABLES............................................................... 494
REMOVAL........................................................................ 494
INSTALLATION................................................................... 495
CRUISE CABLE....................................................................... 497
REMOVAL........................................................................ 497
INSTALLATION................................................................... 497
CRUISE CONTROL MODULE.............................................................. 498
REMOVAL........................................................................ 498
INSTALLATION................................................................... 498
AUDIO HARNESS...................................................................... 499
CRUISE CONTROL SWITCHES............................................................ 499
FAIRING CAP.................................................................... 499
HANDLEBAR...................................................................... 499
PREMIUM SOUND SYSTEM (FLHTC/U, FLTR) 8.29.............................................. 500
RADIO (FLHTC/U).................................................................... 500
REMOVAL........................................................................ 500
INSTALLATION................................................................... 501
FRONT FAIRING SPEAKERS............................................................. 501
REMOVAL........................................................................ 501
INSTALLATION................................................................... 501
CONSOLE POD ASSEMBLY............................................................... 502
REMOVAL........................................................................ 502
INSTALLATION................................................................... 502
INTERCOM/CB SWITCHES............................................................... 503
REMOVAL........................................................................ 503
INSTALLATION................................................................... 503
FRONT HEADSET RECEPTACLE........................................................... 504
REMOVAL........................................................................ 504
INSTALLATION................................................................... 504
REAR HEADSET RECEPTACLE............................................................ 504
REAR PASSENGER SWITCHES............................................................ 505
REMOVAL........................................................................ 505
INSTALLATION................................................................... 505
REAR SPEAKERS...................................................................... 507
REMOVAL........................................................................ 507
INSTALLATION................................................................... 507
FUSE BLOCKS........................................................................ 507
REMOVAL........................................................................ 507
INSTALLATION................................................................... 508
CB LOADING COIL.................................................................... 508
REMOVAL........................................................................ 508
INSTALLATION................................................................... 508
AUDIO HARNESS.................................................................. 509
RADIO ANTENNA CABLE............................................................ 509
CB ANTENNA CABLE............................................................... 509
WIRING HARNESSES AND CABLES (FLHT/C/U) 8.30............................................ 510
MAIN HARNESS....................................................................... 510
REMOVAL........................................................................ 510
INSTALLATION................................................................... 513
INTERCONNECT HARNESS............................................................... 517
REMOVAL........................................................................ 517
INSTALLATION................................................................... 517
AUDIO HARNESS...................................................................... 521
REMOVAL........................................................................ 521
INSTALLATION................................................................... 522
RADIO ANTENNA CABLE................................................................ 524
REMOVAL........................................................................ 524
INSTALLATION................................................................... 525
CB ANTENNA CABLE................................................................... 526
REMOVAL........................................................................ 526
INSTALLATION................................................................... 526
9 - FUEL INJECTION......................................................................... 528
SPECIFICATIONS 9.1..................................................................... 530
EFI FUSES.......................................................................... 530
TORQUE VALUES...................................................................... 530
ELECTRICAL BRACKET ASSEMBLY 9.2........................................................ 532
GENERAL............................................................................ 532
DATA LINK CONNECTOR................................................................ 532
SETTING ENGINE IDLE SPEED...................................................... 532
EFI SYSTEM RELAY................................................................... 533
REMOVAL........................................................................ 533
INSTALLATION................................................................... 533
EFI FUSES.......................................................................... 533
REMOVAL........................................................................ 533
INSTALLATION................................................................... 533
ELECTRONIC CONTROL MODULE.......................................................... 534
REMOVAL........................................................................ 534
INSTALLATION................................................................... 534
SIREN CONNECTOR.................................................................... 534
REMOVAL........................................................................ 534
INSTALLATION................................................................... 534
EFI WIRE HARNESS................................................................... 534
REMOVAL........................................................................ 534
INSTALLATION................................................................... 536
SENSORS 9.3............................................................................ 539
GENERAL............................................................................ 539
INTAKE AIR TEMPERATURE SENSOR.................................................. 539
THROTTLE POSITION SENSOR....................................................... 539
MANIFOLD ABSOLUTE PRESSURE SENSOR.............................................. 539
BANK ANGLE SENSOR.............................................................. 539
CRANKSHAFT POSITION SENSOR......................................................... 539
REMOVAL........................................................................ 539
INSTALLATION................................................................... 540
ENGINE TEMPERATURE SENSOR.......................................................... 541
REMOVAL........................................................................ 541
INSTALLATION................................................................... 541
FUEL TANK (FUEL INJECTED) 9.4.......................................................... 543
GENERAL............................................................................ 543
COMPLETE REMOVAL................................................................... 543
FLHTC/U-I, FLTR-I.............................................................. 543
FLHR/C-I....................................................................... 545
INSTALLATION (AFTER COMPLETE REMOVAL).............................................. 545
FLHTC/U-I, FLTR-I.............................................................. 545
FLHR/C-I....................................................................... 547
PARTIAL REMOVAL.................................................................... 547
FLHTC/U-I, FLTR-I.............................................................. 547
FLHR/C-I....................................................................... 548
INSTALLATION (AFTER PARTIAL REMOVAL)............................................... 549
FLHTC/U-I, FLTR-I.............................................................. 549
FLHR/C-I....................................................................... 549
CONSOLE POD/CANOPY................................................................. 550
FLHTC/U-I, FLTR-I.............................................................. 550
REMOVAL........................................................................ 550
INSTALLATION................................................................... 551
INSTRUMENT CONSOLE/CANOPY.......................................................... 552
FLHR/C-I....................................................................... 552
REMOVAL........................................................................ 552
INSTALLATION................................................................... 553
FUEL FILTER CANISTER............................................................... 554
REMOVAL........................................................................ 554
INSTALLATION................................................................... 555
FUEL PRESSURE REGULATOR............................................................ 555
REMOVAL........................................................................ 555
INSTALLATION................................................................... 556
FUEL PUMP.......................................................................... 556
REMOVAL........................................................................ 556
INSTALLATION................................................................... 556
FUEL PUMP/FUEL LEVEL SENDER WIRING................................................. 556
FUEL LEVEL SENDER.................................................................. 557
REMOVAL........................................................................ 557
INSTALLATION................................................................... 557
CANOPY CONNECTOR/O-RING............................................................ 558
REMOVAL........................................................................ 558
INSTALLATION................................................................... 558
FUEL SUPPLY CHECK VALVE/TUBE....................................................... 558
REMOVAL........................................................................ 558
INSTALLATION................................................................... 558
INDUCTION MODULE ASSEMBLY 9.5.......................................................... 560
GENERAL............................................................................ 560
INDUCTION MODULE................................................................... 560
REMOVAL........................................................................ 560
INSTALLATION................................................................... 561
FUEL SUPPLY LINE................................................................... 562
REMOVAL........................................................................ 562
INSTALLATION................................................................... 563
FUEL RAIL/FUEL SUPPLY TUBE......................................................... 563
REMOVAL........................................................................ 563
INSTALLATION................................................................... 563
FUEL INJECTORS..................................................................... 564
REMOVAL........................................................................ 564
INSTALLATION................................................................... 564
INTAKE AIR TEMPERATURE SENSOR...................................................... 565
REMOVAL........................................................................ 565
INSTALLATION................................................................... 565
THROTTLE POSITION SENSOR........................................................... 565
REMOVAL........................................................................ 565
INSTALLATION................................................................... 566
MANIFOLD ABSOLUTE PRESSURE SENSOR.................................................. 566
REMOVAL........................................................................ 566
INSTALLATION................................................................... 566
IDLE AIR CONTROL................................................................... 567
REMOVAL........................................................................ 567
INSTALLATION................................................................... 567
NOTES.................................................................................. 569
APPENDIX A - TOOLS......................................................................... 572
TOOLS A.1.............................................................................. 572
APPENDIX B - DEUTSCH ELECTRICAL CONNECTORS................................................. 590
DEUTSCH ELECTRICAL CONNECTORS B.1...................................................... 590
GENERAL............................................................................ 590
REMOVING/DISASSEMBLING............................................................. 590
REMOVING/INSTALLING SOCKETS........................................................ 590
REMOVING/INSTALLING PINS........................................................... 593
ASSEMBLING/INSTALLING.............................................................. 593
CRIMPING INSTRUCTIONS.............................................................. 593
SOLID BARREL CONTACT CRIMPING INSTRUCTIONS......................................... 595
For Size 20, 16 and 12 Contacts Wire Range 26-12 AWG........................... 595
AMP MULTILOCK ELECTRICAL CONNECTORS B.2................................................ 598
REMOVING SOCKET/PIN TERMINALS...................................................... 598
INSTALLING SOCKET/PIN TERMINALS.................................................... 598
CRIMPING INSTRUCTIONS.............................................................. 602
PACKARD ELECTRICAL CONNECTORS B.3...................................................... 603
GENERAL............................................................................ 603
PULL-TO-SEAT TERMINALS............................................................. 603
Removing Pull-to-seat Terminals External Latch Type............................ 603
Installing Pull-to-seat Terminals External Latch Type.......................... 604
Removing Pull-to-seat Terminals Wireform Type.................................. 605
Installing Pull-to-seat Terminals Wireform Type................................ 605
PUSH-TO-SEAT TERMINALS............................................................. 606
Removing Push-to-seat Terminals................................................ 606
Installing Push-to-seat Terminals.............................................. 606
CRIMPING INSTRUCTIONS.............................................................. 606
SEALED BUTT SPLICE CONNECTORS B.4...................................................... 608
PROCEDURE.......................................................................... 608
AMP ELECTRICAL CONNECTORS B.5.......................................................... 610
1-PLACE CONNECTOR.................................................................. 610
SOCKET TERMINAL................................................................ 610
PIN TERMINAL................................................................... 611
ELECTRICAL CONNECTOR LOCATIONS B.6..................................................... 612
WIRING DIAGRAMS B.7.................................................................... 624
APPENDIX C - METRIC CONVERSIONS............................................................ 638
METRIC CONVERSIONS C.1................................................................. 638
FASTENER TORQUE VALUES C.2............................................................. 639
GENERAL............................................................................ 639
FLUID CONVERSIONS C.3.................................................................. 640
UNITED STATES SYSTEM............................................................... 640
METRIC SYSTEM...................................................................... 640
BRITISH IMPERIAL SYSTEM............................................................ 640
ELECTRICAL DIAGNOSTICS MANUAL.................................................................. 642
1 - STARTING / CHARGING.................................................................... 642
STARTER TROUBLESHOOTING 1.1............................................................ 644
STARTING SYSTEM DIAGNOSIS 1.2.......................................................... 646
DIAGNOSTICS........................................................................ 646
Diagnostic Notes............................................................... 646
Starter Testing 1.............................................................. 646
Starter Testing 2: Solenoid Clicks............................................. 647
Starter Testing 3: Relay Clicks................................................ 647
Starter Testing 4: Nothing Clicks.............................................. 648
Starter Testing 5: Starter Spins, But Does Not Engage.......................... 649
Starter Testing 6: Starter Stalls or Spins Too Slowly.......................... 649
STARTER ACTIVATION CIRCUITS 1.3........................................................ 650
DIAGNOSTICS/TROUBLESHOOTING 1.4........................................................ 651
GENERAL............................................................................ 651
VOLTAGE DROPS...................................................................... 651
STARTER SYSTEM TESTING 1.5............................................................. 652
GENERAL............................................................................ 652
STARTER RELAY TEST 1............................................................... 652
STARTER RELAY TEST 2............................................................... 652
STARTER CURRENT DRAW TEST.......................................................... 653
TESTING ASSEMBLED STARTER 1.6.......................................................... 654
STARTER SOLENOID................................................................... 654
SOLENOID PULL-IN TEST.............................................................. 654
SOLENOID HOLD-IN TEST.............................................................. 654
SOLENOID RETURN TEST............................................................... 655
FREE RUNNING CURRENT DRAW TEST..................................................... 655
CHARGING SYSTEM 1.7.................................................................... 656
GENERAL............................................................................ 656
Alternator..................................................................... 656
Voltage Regulator.............................................................. 656
TROUBLESHOOTING.................................................................... 656
Battery........................................................................ 656
Wiring......................................................................... 656
Voltage Regulator Inspection................................................... 656
Test 1.7 (Part 1 of 2)......................................................... 657
Test 1.7 (Part 2 of 2)......................................................... 658
TESTING............................................................................ 659
REGULATOR BLEED TEST........................................................... 659
MILLIAMP DRAW TEST............................................................. 659
TOTAL CURRENT DRAW TEST........................................................ 659
CURRENT OUTPUT TEST............................................................ 660
VOLTAGE OUTPUT TEST............................................................ 660
STATOR CHECK................................................................... 660
AC OUTPUT CHECK................................................................ 661
BATTERY LOAD TEST 1.8.................................................................. 662
VOLTMETER TEST..................................................................... 662
LOAD TEST.......................................................................... 662
2 - INSTRUMENTS............................................................................ 664
GAUGES AND INSTRUMENTS 2.1............................................................. 666
GENERAL............................................................................ 666
DIAGNOSTICS........................................................................ 666
Fuel Level Gauge............................................................... 666
Fuel Level Sender Test......................................................... 666
Fuel Gauge: FLHR/C............................................................. 667
Low Fuel Level Lamp: FLHTCU, FLTR.............................................. 667
Low Fuel Level Lamp: FLHR/C.................................................... 667
Oil Pressure Gauge and Indicator Light......................................... 668
Ambient Air Temperature Gauge.................................................. 668
Voltmeter...................................................................... 669
Indicator Lights: FLHR/C....................................................... 669
SPEEDOMETER 2.2........................................................................ 670
GENERAL............................................................................ 670
Reset Switch................................................................... 670
Diagnostic Mode................................................................ 670
DIAGNOSTICS........................................................................ 671
Diagnostic Notes............................................................... 671
Speedometer Test 1............................................................. 672
Speedometer Test 2A............................................................ 673
Speedometer Test 2B............................................................ 674
SPEEDOMETER PERFORMANCE CHECK 2.3...................................................... 676
GENERAL............................................................................ 676
TESTING............................................................................ 676
Frequency Input Test........................................................... 676
Needle Sweep Test.............................................................. 677
Speedometer Sensor Test........................................................ 677
Tachometer Testing............................................................. 677
3 - TSM / TSSM............................................................................. 678
TSM/TSSM OVERVIEW 3.1.................................................................. 680
GENERAL............................................................................ 680
TROUBLESHOOTING.................................................................... 680
TSM/TSSM FEATURES 3.2.................................................................. 682
GENERAL............................................................................ 682
TURN SIGNAL FUNCTIONS.............................................................. 682
TSM/TSSM Features.............................................................. 682
BANK ANGLE FUNCTIONS............................................................... 682
TSM/TSSM Features.............................................................. 682
SECURITY ALARM AND IMMOBILIZATION FUNCTIONS........................................ 682
TSSM Only Feature.............................................................. 682
TSM/TSSM VEHICLE DELIVERY 3.3.......................................................... 684
GENERAL............................................................................ 684
USING SCANALYZER ON EFI MODELS..................................................... 684
SIDECAR CONFIGURATION.............................................................. 684
POWER DISRUPTION AND CONFIGURING................................................... 684
KEY FOB ASSIGNMENT................................................................. 685
PERSONAL CODE ENTRY................................................................ 685
First Time Code Entry: TSSM Only............................................... 685
Modifying Existing Codes: TSSM Only............................................ 685
TSM/TSSM TURN SIGNAL FUNCTIONS 3.4..................................................... 689
GENERAL............................................................................ 689
AUTOMATIC CANCELLATION............................................................. 689
MANUAL CANCELLATION................................................................ 689
FOUR-WAY FLASHING.................................................................. 689
DIAGNOSTICS MODE................................................................... 689
TSM/TSSM BANK ANGLE FUNCTION 3.5....................................................... 691
GENERAL............................................................................ 691
OPERATION.......................................................................... 691
SECURITY SYSTEM (TSSM) FUNCTIONS 3.6................................................... 692
GENERAL............................................................................ 692
Security System Operation...................................................... 692
Security System Options........................................................ 692
Differences By Market Specifications........................................... 692
ALARM SENSITIVITY.................................................................. 692
Sensitivity.................................................................... 692
Transport Mode................................................................. 692
AUTO-ARMING FUNCTION............................................................... 693
STORAGE MODE....................................................................... 693
ARMING/DISARMING SECURITY SYSTEM (TSSM) 3.7............................................ 696
GENERAL............................................................................ 696
SECURITY LAMP...................................................................... 696
USING KEY FOB...................................................................... 696
General........................................................................ 696
Arming the System.............................................................. 696
Disarming the System........................................................... 696
Troubleshooting................................................................ 696
USING THE PERSONAL CODE............................................................ 697
General........................................................................ 697
Disarming the System........................................................... 697
CHECKING FOR TROUBLE CODES: TSM/TSSM 3.8............................................... 698
GENERAL............................................................................ 698
CODE TYPES......................................................................... 698
Current........................................................................ 698
Historic....................................................................... 698
TURN SIGNAL DIAGNOSTICS............................................................ 698
CHECKING FOR TROUBLE CODES: TSSM ONLY 3.9.............................................. 700
SECURITY LAMP...................................................................... 700
BREAKOUT BOX: TSM/TSSM 3.10............................................................ 702
GENERAL............................................................................ 702
INSTALLATION....................................................................... 702
REMOVAL............................................................................ 702
SCANALYZER: EFI ONLY 3.11.............................................................. 703
SCANALYZER DIAGNOSTICS............................................................. 703
General........................................................................ 703
Data Link Connector............................................................ 703
Scanalyzer Cartridge........................................................... 703
INSTALLATION....................................................................... 703
USAGE.............................................................................. 705
Checking Codes................................................................. 705
Clearing Codes................................................................. 705
REMOVAL............................................................................ 705
INITIAL DIAGNOSTIC CHECK: TSM/TSSM 3.12................................................ 706
GENERAL............................................................................ 706
Diagnostic Notes............................................................... 706
Scanalyzer Icon................................................................ 706
Circuit Diagram/Wire Harness Connector Table................................... 706
Job/Time Code Values........................................................... 706
INITIAL DIAGNOSTICS................................................................ 706
Diagnostic Tips................................................................ 706
Diagnostic Notes............................................................... 707
Multiple Trouble Codes......................................................... 707
Diagnostic Check (Part 1 of 2)................................................. 709
Diagnostic Check (Part 2 of 2)................................................. 710
NO SECURITY LAMP AT KEY ON 3.13........................................................ 712
GENERAL............................................................................ 712
No TSSM Power.................................................................. 712
DIAGNOSTICS........................................................................ 712
Diagnostic Tips................................................................ 712
Diagnostic Notes............................................................... 712
Test 3.13 (Part 1 of 3)........................................................ 714
Test 3.13 (Part 2 of 3)........................................................ 715
Test 3.13 (Part 3 of 3)........................................................ 716
SECURITY LAMP ON CONTINUOUSLY 3.14..................................................... 717
GENERAL............................................................................ 717
DIAGNOSTICS........................................................................ 717
Diagnostic Notes............................................................... 717
Test 3.14...................................................................... 719
KEY FOB SIGNAL TO TSSM WEAK OR FAILS 3.15.............................................. 720
GENERAL............................................................................ 720
DIAGNOSTICS........................................................................ 720
Diagnostic Tips................................................................ 720
Diagnostic Notes............................................................... 720
Test 3.15...................................................................... 722
TURN SIGNAL ERRORS 3.16................................................................ 723
GENERAL............................................................................ 723
DIAGNOSTICS........................................................................ 723
Diagnostic Tips................................................................ 723
Diagnostic Notes: All Turn Signal Flow Charts.................................. 726
Turn Signal Error 1A........................................................... 727
Turn Signal Error 1B........................................................... 728
Turn Signal Error 1C........................................................... 729
Turn Signal Error 2A........................................................... 730
Turn Signal Error 2B........................................................... 731
Turn Signal Error 2C........................................................... 732
Turn Signal Error 3A........................................................... 733
Turn Signal Error 3B........................................................... 734
Turn Signal Error 3C........................................................... 735
Turn Signal Error 3D........................................................... 736
Turn Signal Error 4A........................................................... 737
DTC B0563 (EFI), DTC 11 (CARB) 3.17.................................................... 738
GENERAL............................................................................ 738
Battery Voltage High........................................................... 738
DIAGNOSTICS........................................................................ 738
Diagnostic Tips................................................................ 738
Diagnostic Notes............................................................... 738
DTC 25 (CARB ONLY) 3.18................................................................ 739
GENERAL............................................................................ 739
Ignition Enable Output High.................................................... 739
DIAGNOSTICS........................................................................ 739
Diagnostic Tips................................................................ 739
Diagnostic Notes............................................................... 739
Test 3.18...................................................................... 741
DTC B1131/ B1132 (EFI), DTC 31/32 (CARB) 3.19.......................................... 742
GENERAL............................................................................ 742
Alarm Output Low (DTC B1131/DTC 31) or Alarm Output High (DTC B1132/DTC 32).... 742
DIAGNOSTICS........................................................................ 742
Diagnostic Tips................................................................ 742
Diagnostic Notes............................................................... 742
Test 3.19...................................................................... 744
DTC B1134 (EFI), DTC 34 (CARB) 3.20.................................................... 745
GENERAL............................................................................ 745
Starter Output High............................................................ 745
DIAGNOSTICS........................................................................ 745
Diagnostic Notes............................................................... 745
Test 3.20...................................................................... 747
DTC B1135 (EFI), DTC 35 (CARB) 3.21.................................................... 748
GENERAL............................................................................ 748
Accelerometer Fault............................................................ 748
DTC U1016 (EFI), DTC 14, 24, 33, 43 (CARB) 3.22........................................ 749
GENERAL............................................................................ 749
Loss of ECM Serial Data........................................................ 749
DIAGNOSTICS........................................................................ 749
Diagnostic Notes............................................................... 749
Test 3.22...................................................................... 751
TSM/TSSM 3.23.......................................................................... 752
REMOVAL/INSTALLATION............................................................... 752
PASSWORD LEARNING.................................................................. 752
Using Scanalyzer............................................................... 752
Without Scanalyzer............................................................. 752
TSSM MAINTENANCE 3.24.................................................................. 755
GENERAL............................................................................ 755
KEY FOB............................................................................ 755
Schedule....................................................................... 755
Battery Replacement............................................................ 755
SIREN (IF INSTALLED)............................................................... 756
Schedule....................................................................... 756
Battery Replacement............................................................ 756
4 - ENGINE MANAGEMENT (CARB)............................................................... 758
SPECIFICATIONS 4.1..................................................................... 760
DIAGNOSTIC INTRODUCTION 4.2............................................................ 761
SYSTEM PROBLEMS.................................................................... 761
No Start....................................................................... 761
Poor Performance............................................................... 761
Check Engine Lamp.............................................................. 761
RESOLVING PROBLEMS................................................................. 761
CHECKING FOR TROUBLE CODES 4.3......................................................... 762
CHECK ENGINE LAMP.................................................................. 762
CODE TYPES......................................................................... 763
Current........................................................................ 763
Historic....................................................................... 763
Functional..................................................................... 763
RETRIEVING TROUBLE CODES........................................................... 763
MULTIPLE TROUBLE CODES............................................................. 763
SCANALYZER: CARB 4.4................................................................... 764
SCANALYZER DIAGNOSTICS............................................................. 764
Scanalyzer Cartridge........................................................... 764
INSTALLATION....................................................................... 764
USAGE.............................................................................. 766
Checking/Clearing Trouble Codes................................................ 766
REMOVAL............................................................................ 766
CHECK ENGINE LAMP DIAGNOSTICS: CARB 4.5................................................ 767
ACTIVATION......................................................................... 767
BREAKOUT BOX: CARB 4.6................................................................. 769
GENERAL............................................................................ 769
INSTALLATION....................................................................... 769
REMOVAL............................................................................ 769
WIGGLE TEST 4.7........................................................................ 770
GENERAL............................................................................ 770
PROCEDURE.......................................................................... 770
Using Scanalyzer (Part No. HD-41325)........................................... 770
Using DVOM (Part No. HD-39978)................................................. 770
INITIAL DIAGNOSTIC CHECK 4.8........................................................... 771
GENERAL............................................................................ 771
Diagnostic Notes............................................................... 771
Scanalyzer Icon................................................................ 771
Circuit Diagram/Connector Location Table....................................... 771
Job/Time Code Values........................................................... 771
INITIAL DIAGNOSTICS................................................................ 771
General........................................................................ 771
Diagnostic Tips................................................................ 771
Diagnostic Notes............................................................... 771
Diagnostic Check (Part 1 of 2)................................................. 774
Diagnostic Check (Part 2 of 2)................................................. 775
NO CHECK ENGINE LAMP AT KEY ON 4.9..................................................... 776
GENERAL............................................................................ 776
DIAGNOSTICS........................................................................ 776
Diagnostic Tips................................................................ 776
Diagnostic Notes............................................................... 776
Test 4.9....................................................................... 778
CHECK ENGINE LAMP ON CONTINUOUSLY 4.10................................................. 779
GENERAL............................................................................ 779
DIAGNOSTICS........................................................................ 779
Diagnostic Notes............................................................... 779
Test 4.10...................................................................... 781
ENGINE CRANKS, BUT WILL NOT START 4.11................................................. 782
GENERAL............................................................................ 782
DIAGNOSTICS........................................................................ 782
Diagnostic Notes............................................................... 782
Test 4.11 (Part 1 of 3)........................................................ 784
Test 4.11 (Part 2 of 3)........................................................ 785
Test 4.11 (Part 3 of 3)........................................................ 786
NO IGNITION MODULE POWER 4.12.......................................................... 787
GENERAL............................................................................ 787
No Spark/No Check Engine Lamp At Key ON........................................ 787
DIAGNOSTICS........................................................................ 787
Diagnostic Notes............................................................... 787
Test 4.12...................................................................... 788
MISFIRE 4.13........................................................................... 789
GENERAL............................................................................ 789
Misfire at Idle or Under Load.................................................. 789
DIAGNOSTICS........................................................................ 789
Diagnostic Notes............................................................... 789
Test 4.13...................................................................... 791
DTC 12 4.14............................................................................ 792
GENERAL............................................................................ 792
MAP Sensor..................................................................... 792
DIAGNOSTICS........................................................................ 792
Diagnostic Tips................................................................ 792
Diagnostic Notes............................................................... 792
Scanalyzer Notes............................................................... 792
Test 4.14...................................................................... 794
DTC 16 4.15............................................................................ 795
GENERAL............................................................................ 795
Battery Voltage................................................................ 795
DIAGNOSTICS........................................................................ 795
Scanalyzer Notes............................................................... 795
Diagnostic Notes............................................................... 795
Test 4.15 (Part 1 of 2)........................................................ 797
Test 4.15 (Part 2 of 2)........................................................ 798
DTC 24, 25 4.16........................................................................ 799
GENERAL............................................................................ 799
Front Ignition Coil (DTC 24) and Rear Ignition Coil (DTC 25)................... 799
DIAGNOSTICS........................................................................ 799
Diagnostic Notes............................................................... 799
Scanalyzer Notes............................................................... 799
Test 4.16...................................................................... 801
DTC 35 4.17............................................................................ 802
GENERAL............................................................................ 802
Tachometer: All Except FLHR.................................................... 802
DIAGNOSTICS........................................................................ 802
Diagnostic Notes............................................................... 802
Test 4.17...................................................................... 803
DTC 41 4.18............................................................................ 804
GENERAL............................................................................ 804
Crank Position Sensor.......................................................... 804
DIAGNOSTICS........................................................................ 804
Diagnostic Notes............................................................... 804
Test 4.18...................................................................... 806
DTC 44 4.19............................................................................ 807
GENERAL............................................................................ 807
TSM/TSSM....................................................................... 807
DIAGNOSTICS........................................................................ 807
Diagnostic Notes............................................................... 807
Test 4.19 (Part 1 of 2)........................................................ 808
Test 4.19 (Part 2 of 2)........................................................ 809
DTC 52, 53, 54, 55 4.20................................................................ 810
GENERAL............................................................................ 810
Ignition Module Failure........................................................ 810
IGNITION COIL 4.21..................................................................... 811
TROUBLESHOOTING.................................................................... 811
Ignition Coil Primary Circuit Test............................................. 811
Ignition Coil Secondary Circuit Test........................................... 811
Test Results................................................................... 811
Ignition Coil Substitution..................................................... 811
5 - ENGINE MANAGEMENT (EFI)................................................................ 812
SPECIFICATIONS 5.1..................................................................... 814
EFI SYSTEM 5.2......................................................................... 816
GENERAL............................................................................ 816
TROUBLESHOOTING.................................................................... 816
EFI DIAGNOSTIC INTRODUCTION 5.3........................................................ 818
SYSTEM PROBLEMS.................................................................... 818
No Start....................................................................... 818
Poor Performance............................................................... 818
Check Engine Lamp.............................................................. 818
RESOLVING PROBLEMS................................................................. 818
CHECKING FOR TROUBLE CODES: EFI 5.4.................................................... 819
CHECK ENGINE LAMP.................................................................. 819
CODE TYPES......................................................................... 820
Current........................................................................ 820
Historic....................................................................... 820
RETRIEVING TROUBLE CODES........................................................... 820
MULTIPLE TROUBLE CODES............................................................. 820
SCANALYZER: EFI 5.5.................................................................... 821
SCANALYZER DIAGNOSTICS............................................................. 821
Scanalyzer Cartridge........................................................... 821
INSTALLATION....................................................................... 821
USAGE.............................................................................. 823
Checking/Clearing Trouble Codes................................................ 823
REMOVAL............................................................................ 823
CHECK ENGINE LAMP DIAGNOSTICS: EFI 5.6................................................. 824
GENERAL............................................................................ 824
ACTIVATION......................................................................... 824
BREAKOUT BOX: EFI 5.7.................................................................. 826
GENERAL............................................................................ 826
INSTALLATION....................................................................... 826
REMOVAL............................................................................ 826
WIGGLE TEST 5.8........................................................................ 827
GENERAL............................................................................ 827
PROCEDURE.......................................................................... 827
Using Scanalyzer (HD-41325).................................................... 827
Using DVOM (HD-39978).......................................................... 827
INITIAL DIAGNOSTIC CHECK: EFI 5.9...................................................... 828
GENERAL............................................................................ 828
Diagnostic Notes............................................................... 828
Scanalyzer Icon................................................................ 828
Circuit Diagram/Connector Location Table....................................... 828
Job/Time Code Values........................................................... 828
INITIAL DIAGNOSTICS................................................................ 828
General........................................................................ 828
Diagnostic Tips................................................................ 828
Diagnostic Notes............................................................... 828
Other Codes.................................................................... 828
Diagnostic Check (Part 1 of 2)................................................. 834
Diagnostic Check (Part 2 of 2)................................................. 835
NO CHECK ENGINE LAMP AT KEY ON 5.10.................................................... 836
GENERAL............................................................................ 836
Diagnostic Trouble Codes P1652, P1651.......................................... 836
DIAGNOSTICS........................................................................ 836
Diagnostic Tips................................................................ 836
Diagnostic Notes............................................................... 836
Test 5.10...................................................................... 838
CHECK ENGINE LAMP ON CONTINUOUSLY 5.11................................................. 839
GENERAL............................................................................ 839
Diagnostic Trouble Code P1651.................................................. 839
DIAGNOSTICS........................................................................ 839
Diagnostic Notes............................................................... 839
Test 5.11...................................................................... 841
ENGINE CRANKS, BUT WILL NOT START 5.12................................................. 842
GENERAL............................................................................ 842
DIAGNOSTICS........................................................................ 842
Diagnostic Notes............................................................... 842
Diagnostic Tip................................................................. 842
Test 5.12 (Part 1 of 4)........................................................ 844
Test 5.12 (Part 2 of 4)........................................................ 845
Test 5.12 (Part 3 of 4)........................................................ 846
Test 5.12 (Part 4 of 4)........................................................ 847
NO ECM POWER 5.13...................................................................... 848
GENERAL............................................................................ 848
No Spark/No Check Engine Lamp at Key ON........................................ 848
DIAGNOSTICS........................................................................ 848
Diagnostic Notes............................................................... 848
Diagnostic Tip................................................................. 848
Test 5.13 (Part 1 of 2)........................................................ 851
Test 5.13 (Part 2 of 2)........................................................ 852
STARTS, THEN STALLS 5.14............................................................... 853
GENERAL............................................................................ 853
Diagnostic Trouble Codes U1300, U1301: Serial Data Failure..................... 853
DIAGNOSTICS........................................................................ 853
Diagnostic Tips................................................................ 853
Diagnostic Notes............................................................... 853
Test 5.14 (Part 1 of 2)........................................................ 855
Test 5.14 (Part 2 of 2)........................................................ 856
FUEL SYSTEM ELECTRICAL TEST 5.15....................................................... 857
GENERAL............................................................................ 857
DIAGNOSTICS........................................................................ 857
Diagnostic Notes............................................................... 857
Test 5.15 (Part 1 of 4)........................................................ 859
Test 5.15 (Part 2 of 4)........................................................ 860
Test 5.15 (Part 3 of 4)........................................................ 861
Test 5.15 (Part 4 of 4)........................................................ 861
SYSTEM RELAY CHECK 5.16................................................................ 862
GENERAL............................................................................ 862
System Relay................................................................... 862
DIAGNOSTICS........................................................................ 862
Diagnostic Notes............................................................... 862
Test 5.16 (Part 1 of 3)........................................................ 865
Test 5.16 (Part 2 of 3)........................................................ 866
Test 5.16 (Part 3 of 3)........................................................ 866
FUEL PRESSURE TEST 5.17................................................................ 867
GENERAL............................................................................ 867
TESTING............................................................................ 867
DIAGNOSTICS........................................................................ 869
Diagnostic Notes............................................................... 869
Scanalyzer Notes............................................................... 869
Test 5.17...................................................................... 870
IDLE AIR CONTROL 5.18.................................................................. 871
GENERAL............................................................................ 871
IAC Operation.................................................................. 871
Diagnostic Trouble Code P0505: Loss of Idle Speed Control...................... 871
DIAGNOSTICS........................................................................ 871
Diagnostic Tips................................................................ 871
Diagnostic Notes............................................................... 872
Test 5.18 (Part 1 of 2)........................................................ 874
Test 5.18 (Part 2 of 2)........................................................ 875
MISFIRE AT IDLE OR UNDER LOAD 5.19..................................................... 876
GENERAL............................................................................ 876
Misfire at Idle or Under Load.................................................. 876
DIAGNOSTICS........................................................................ 876
Diagnostic Notes............................................................... 876
Test 5.19 (Part 1 of 3)........................................................ 878
Test 5.19 (Part 2 of 3)........................................................ 879
Test 5.19 (Part 3 of 3)........................................................ 880
COMBUSTION ABSENT/INTERMITTENT 5.20.................................................... 881
GENERAL............................................................................ 881
Diagnostic Trouble Codes P1353, P1356, P1357, P1358: No Combustion............. 881
DIAGNOSTICS........................................................................ 881
Diagnostic Notes............................................................... 881
Test 5.20 (Part 1 of 2)........................................................ 884
Test 5.20 (Part 2 of 2)........................................................ 885
DTC P0107, P0108 5.21.................................................................. 886
GENERAL............................................................................ 886
MAP Sensor..................................................................... 886
DIAGNOSTICS........................................................................ 886
Diagnostic Tips................................................................ 886
Diagnostic Notes............................................................... 886
Scanalyzer Notes............................................................... 886
Test 5.21 (Part 1 of 2)........................................................ 888
Test 5.21 (Part 2 of 2)........................................................ 889
DTC P0112, P0113 5.22.................................................................. 890
GENERAL............................................................................ 890
IAT Sensor..................................................................... 890
DIAGNOSTICS........................................................................ 890
Diagnostic Tips................................................................ 890
Diagnostic Notes............................................................... 890
Scanalyzer Notes............................................................... 890
Test 5.22 (Part 1 of 2)........................................................ 892
Test 5.22 (Part 2 of 2)........................................................ 893
DTC P0117, P0118 5.23.................................................................. 894
GENERAL............................................................................ 894
ET Sensor...................................................................... 894
DIAGNOSTICS........................................................................ 894
Diagnostic Tips................................................................ 894
Diagnostic Notes............................................................... 894
Scanalyzer Notes............................................................... 894
Test 5.23 (Part 1 of 2)........................................................ 896
Test 5.23 (Part 2 of 2)........................................................ 897
DTC P0122, P0123 5.24.................................................................. 898
GENERAL............................................................................ 898
TP Sensor...................................................................... 898
DIAGNOSTICS........................................................................ 898
Diagnostic Tips................................................................ 898
Diagnostic Notes............................................................... 898
Scanalyzer Notes............................................................... 898
Test 5.24 (Part 1 of 2)........................................................ 900
Test 5.24 (Part 2 of 2)........................................................ 901
DTC P0261, P0262, P0263, P0264 5.25.................................................... 902
GENERAL............................................................................ 902
Fuel Injectors................................................................. 902
DIAGNOSTICS........................................................................ 902
Diagnostic Notes............................................................... 902
Test 5.25 (Part 1 of 3)........................................................ 905
Test 5.25 (Part 2 of 3)........................................................ 906
Test 5.25 (Part 3 of 3)........................................................ 907
DTC P0373, P0374 5.26.................................................................. 908
GENERAL............................................................................ 908
CKP Sensor..................................................................... 908
DIAGNOSTICS........................................................................ 908
Diagnostic Tips................................................................ 908
Diagnostic Notes............................................................... 908
Test 5.26...................................................................... 910
DTC P0501, P0502 5.27.................................................................. 911
GENERAL............................................................................ 911
Vehicle Speed Sensor........................................................... 911
DIAGNOSTICS........................................................................ 911
Diagnostic Notes............................................................... 911
Test 5.27 (Part 1 of 2)........................................................ 914
Test 5.27 (Part 2 of 2)........................................................ 915
DTC P0562, P0563 5.28.................................................................. 916
GENERAL............................................................................ 916
Battery Voltage................................................................ 916
DIAGNOSTICS........................................................................ 916
Diagnostic Tips................................................................ 916
Scanalyzer Notes............................................................... 916
Diagnostic Notes............................................................... 916
Test 5.28 (Part 1 of 2)........................................................ 919
Test 5.28 (Part 2 of 2)........................................................ 920
DTC P0603, P0605 5.29.................................................................. 921
GENERAL............................................................................ 921
ECM Failure.................................................................... 921
DIAGNOSTICS........................................................................ 921
DTC P0603 Test................................................................. 921
DTC P0605 Test................................................................. 921
DTC P1009, P1010 5.30.................................................................. 922
GENERAL............................................................................ 922
Password Problem............................................................... 922
DIAGNOSTICS........................................................................ 922
Diagnostic Notes............................................................... 922
Test 5.30...................................................................... 924
DTC P1351, P1352, P1354, P1355 5.31.................................................... 925
GENERAL............................................................................ 925
Ignition Coil.................................................................. 925
DIAGNOSTICS........................................................................ 925
Diagnostic Notes............................................................... 925
Test 5.31 (Part 1 of 2)........................................................ 928
Test 5.31 (Part 2 of 2)........................................................ 929
DTC P1653, P1654 5.32.................................................................. 930
GENERAL............................................................................ 930
Tachometer..................................................................... 930
DIAGNOSTICS........................................................................ 930
Diagnostic Notes............................................................... 930
Test 5.32...................................................................... 932
DTC U1016, U1064, U1255 5.33........................................................... 933
GENERAL............................................................................ 933
Loss of TSM/TSSM or ECM Serial Data............................................ 933
DIAGNOSTICS........................................................................ 933
Diagnostic Notes............................................................... 933
Test 5.33 (Part 1 of 2)........................................................ 935
Test 5.33 (Part 2 of 2)........................................................ 936
6 - PREMIUM SOUND.......................................................................... 938
DIAGNOSTIC INTRODUCTION 6.1............................................................ 940
GENERAL............................................................................ 940
DIAGNOSTIC MODE OVERVIEW 6.2........................................................... 941
GENERAL............................................................................ 941
DIAGNOSTIC MODE GROUP 1............................................................ 942
GENERAL........................................................................ 942
SAMPLE DIAGNOSTIC.............................................................. 942
DIAGNOSTIC MODE GROUP 2............................................................ 943
GENERAL........................................................................ 943
SAMPLE DIAGNOSTIC.............................................................. 943
BREAKOUT BOX 6.3....................................................................... 944
GENERAL............................................................................ 944
INSTALLATION....................................................................... 944
REMOVAL............................................................................ 944
RADIO SYMPTOM 1 6.4.................................................................... 945
GENERAL............................................................................ 945
Problem........................................................................ 945
Setup.......................................................................... 945
Functionality.................................................................. 945
DIAGNOSTICS........................................................................ 945
Diagnostic Notes............................................................... 945
Test 6.4 (Part 1 of 2)......................................................... 946
Test 6.4 (Part 2 of 2)......................................................... 947
RADIO SYMPTOM 2 6.5.................................................................... 948
GENERAL............................................................................ 948
Problem........................................................................ 948
Setup.......................................................................... 948
Functionality.................................................................. 948
DIAGNOSTICS........................................................................ 948
Diagnostic Notes............................................................... 948
Test 6.5 (Part 1 of 4)......................................................... 949
Test 6.5 (Part 2 of 4)......................................................... 950
Test 6.5 (Part 3 of 4)......................................................... 951
Test 6.5 (Part 4 of 4)......................................................... 952
RADIO SYMPTOM 3 6.6.................................................................... 953
GENERAL............................................................................ 953
Problem........................................................................ 953
Setup.......................................................................... 953
Functionality.................................................................. 953
DIAGNOSTICS........................................................................ 953
Diagnostic Notes............................................................... 953
Test 6.6 (Part 1 of 3)......................................................... 954
Test 6.6 (Part 2 of 3)......................................................... 955
Test 6.6 (Part 3 of 3)......................................................... 956
RADIO SYMPTOM 4 6.7.................................................................... 957
GENERAL............................................................................ 957
Problem........................................................................ 957
Setup.......................................................................... 957
Functionality.................................................................. 957
DIAGNOSTICS........................................................................ 957
Automatic Volume Control (AVC) Adjustment...................................... 957
Diagnostic Notes............................................................... 958
Test 6.7 (Part 1 of 2)......................................................... 958
Test 6.7 (Part 2 of 2)......................................................... 959
RADIO SYMPTOM 5 6.8.................................................................... 960
GENERAL............................................................................ 960
Problem........................................................................ 960
Setup.......................................................................... 960
Functionality.................................................................. 960
DIAGNOSTICS........................................................................ 960
Radio Antenna Test............................................................. 960
Test 6.8....................................................................... 960
RADIO SYMPTOM 6 6.9.................................................................... 961
GENERAL............................................................................ 961
Problem........................................................................ 961
Setup.......................................................................... 961
Functionality.................................................................. 961
DIAGNOSTICS........................................................................ 961
Diagnostic Notes............................................................... 961
Test 6.9 (Part 1 of 2)......................................................... 962
Test 6.9 (Part 2 of 2)......................................................... 963
RADIO SYMPTOM 7 6.10................................................................... 964
GENERAL............................................................................ 964
Problem........................................................................ 964
Setup.......................................................................... 964
Functionality.................................................................. 964
DIAGNOSTICS........................................................................ 964
Diagnostic Notes............................................................... 964
Test 6.10 (Part 1 of 2)........................................................ 965
Test 6.10 (Part 2 of 2)........................................................ 966
RADIO SYMPTOM 8 6.11................................................................... 967
GENERAL............................................................................ 967
Problem........................................................................ 967
Setup.......................................................................... 967
Functionality.................................................................. 967
DIAGNOSTICS........................................................................ 967
Diagnostic Notes............................................................... 967
Test 6.11 (Part 1 of 2)........................................................ 968
Test 6.11 (Part 2 of 2)........................................................ 969
RADIO SYMPTOM 9 6.12................................................................... 970
GENERAL............................................................................ 970
Problem........................................................................ 970
Setup.......................................................................... 970
Functionality.................................................................. 970
DIAGNOSTICS........................................................................ 970
Diagnostic Notes............................................................... 970
Test 6.12 (Part 1 of 3)........................................................ 971
Test 6.12 (Part 2 of 3)........................................................ 972
Test 6.12 (Part 3 of 3)........................................................ 973
RADIO SYMPTOM 10 6.13.................................................................. 974
GENERAL............................................................................ 974
Problem........................................................................ 974
Setup.......................................................................... 974
Functionality.................................................................. 974
DIAGNOSTICS........................................................................ 974
Diagnostic Notes............................................................... 974
Test 6.13 (Part 1 of 2)........................................................ 975
Test 6.13 (Part 2 of 2)........................................................ 976
RADIO SYMPTOM 11 6.14.................................................................. 977
GENERAL............................................................................ 977
Problem........................................................................ 977
Setup.......................................................................... 977
Functionality.................................................................. 977
DIAGNOSTICS........................................................................ 977
Diagnostic Notes............................................................... 977
Test 6.14 (Part 1 of 2)........................................................ 978
Test 6.14 (Part 2 of 2)........................................................ 979
RADIO SYMPTOM 12 6.15.................................................................. 980
GENERAL............................................................................ 980
Problem........................................................................ 980
Setup.......................................................................... 980
Functionality.................................................................. 980
DIAGNOSTICS........................................................................ 980
Diagnostic Notes............................................................... 980
Test 6.15 (Part 1 of 2)........................................................ 981
Test 6.15 (Part 2 of 2)........................................................ 982
CB Antenna Test................................................................ 982
SWR Adjustment................................................................. 982
RADIO SYMPTOM 13 6.16.................................................................. 984
GENERAL............................................................................ 984
Problem........................................................................ 984
Setup.......................................................................... 984
Functionality.................................................................. 984
DIAGNOSTICS........................................................................ 984
Diagnostic Notes............................................................... 984
Test 6.16 (Part 1 of 2)........................................................ 985
Test 6.16 (Part 2 of 2)........................................................ 986
RADIO SYMPTOM 14 6.17.................................................................. 987
GENERAL............................................................................ 987
Problem........................................................................ 987
Setup.......................................................................... 987
Functionality.................................................................. 987
DIAGNOSTICS........................................................................ 987
Diagnostic Notes............................................................... 987
Test 6.17 (Part 1 of 2)........................................................ 988
Test 6.17 (Part 2 of 2)........................................................ 989
RADIO SYMPTOM 15 6.18.................................................................. 990
GENERAL............................................................................ 990
Problem........................................................................ 990
Setup.......................................................................... 990
Functionality.................................................................. 990
DIAGNOSTICS........................................................................ 990
Diagnostic Notes............................................................... 990
Test 6.18...................................................................... 990
7 - CRUISE CONTROL......................................................................... 992
CRUISE CONTROL 7.1..................................................................... 994
GENERAL............................................................................ 994
OPERATION.......................................................................... 994
TROUBLESHOOTING.................................................................... 995
CRUISE INOPERATIVE DIAGNOSTICS 7.2..................................................... 996
GENERAL............................................................................ 996
INOPERATIVE DIAGNOSTICS............................................................ 996
Diagnostic Notes............................................................... 996
CRUISE DROPOUT DIAGNOSTICS 7.3......................................................... 999
GENERAL............................................................................ 999
DROPOUT DIAGNOSTICS................................................................ 999
CRUISE CHART A: INITIAL DIAGNOSTICS 7.4................................................1002
DIAGNOSTICS........................................................................1002
Test 7.4 (Part 1 of 2).........................................................1002
Test 7.4 (Part 2 of 2).........................................................1003
CRUISE CHART B: RESUME SWITCH 7.5......................................................1004
DIAGNOSTICS........................................................................1004
Test 7.5.......................................................................1004
CRUISE CHART C: CRUISE ENGAGED LAMP 7.6................................................1005
DIAGNOSTICS........................................................................1005
Test 7.6.......................................................................1005
CRUISE CHART D: CRUISE POWER 7.7.......................................................1006
DIAGNOSTICS........................................................................1006
Test 7.7.......................................................................1006
CRUISE CHART E: CRUISE ENABLE 7.8......................................................1008
DIAGNOSTICS........................................................................1008
Test 7.8.......................................................................1008
Diagnostic Notes...............................................................1008
CRUISE CHART F-1: BRAKE LIGHTS ON 7.9..................................................1009
DIAGNOSTICS........................................................................1009
Test 7.9.......................................................................1009
CRUISE CHART F-2: BRAKE LIGHTS OFF 7.10................................................1010
DIAGNOSTICS........................................................................1010
Test 7.10 (Part 1 of 2)........................................................1010
Test 7.10 (Part 2 of 2)........................................................1011
Diagnostic Notes...............................................................1011
CRUISE CHART G: THROTTLE SWITCH 7.11...................................................1012
DIAGNOSTICS........................................................................1012
Test 7.11......................................................................1012
CRUISE CHART H: SPEEDOMETER INPUT 7.12.................................................1013
DIAGNOSTICS........................................................................1013
Diagnostic Notes...............................................................1013
Test 7.12 (Part 1 of 2)........................................................1013
Test 7.12 (Part 2 of 2)........................................................1014
CRUISE CHART I: TACHOMETER INPUT 7.13..................................................1015
DIAGNOSTICS........................................................................1015
Test 7.13......................................................................1015
8 - WIRING.................................................................................1016
ELECTRICAL CONNECTOR LOCATIONS 8.1.....................................................1018
WIRING DIAGRAMS 8.2....................................................................1030
FLHRSEI SUPPLEMENT MANUAL...................................................................... 0
1 - MAINTENANCE............................................................................1044
2 - CHASSIS................................................................................1046
3 - ENGINE.................................................................................1080
4 - FUEL SYSTEM............................................................................1088
5 - ELECTRIC STARTER.......................................................................1090
6 - DRIVE..................................................................................1092
7 - TRANSMISSION...........................................................................1093
8 - ELECTRICAL.............................................................................1094
9 - FUEL INJECTION.........................................................................1106
