Description
2003 Harley-Davidson FLT Touring Service & Electrical Diagnostics Manuals 99483-03A / 99497-03
This 2003 Harley-Davidson FLT Touring Service & Electrical Diagnostics Manuals 99483-03A / 99497-03 PDF combines the 2003 FLT Models Service Manual with the companion Electrical Diagnostics manual in one extensive technical reference. The service material covers maintenance, chassis, engine, fuel system, electric starter, primary and secondary drive, transmission, electrical equipment and fuel injection, while the diagnostics material adds starting and charging tests, instruments, TSM/TSSM functions, carbureted and EFI engine-management diagnostics, premium sound, cruise control and wiring diagrams. The manual identifies both carbureted and fuel-injected Touring configurations and provides model-specific procedures throughout.
File Details
- Manual type: Service Manual and Electrical Diagnostics Manual, with FLHRSEI2-specific supplement material included in the PDF
- Brand/model: Harley-Davidson 2003 FLT Models / Touring models
- Language: English
- Page count: 1192 PDF pages
- File format: PDF
- Service Manual part number: 99483-03A
- Electrical Diagnostics part number: 99497-03
Touring Models and Systems Covered
The service manual’s VIN identification material lists Touring model designations including FLHT, FLHTC, FLHRI, FLHTCUI, FLHR, FLHTCI, FLHTCUI W/SC, FLHPI, FLHTCI Shrine, FLHTCUI Shrine, FLHTPI, FLTR, FLHRCI, FLTRI, FLHPEI, FLHTI and FLHRI Shrine. The PDF also contains sections identified for FLHRSEI2; those pages state that information not unique to that model should be taken from the Touring Models Service Manual. This distinction makes the collection useful both for broad 2003 FLT Touring service work and for the additional FLHRSEI2-specific procedures and specifications included later in the file.
The main engine specifications describe a two-cylinder, 4-cycle, 45-degree V2, air-cooled engine with 3.75 in. bore, 4.00 in. stroke, approximately 88 cu. in. (1450 cc) displacement and 9.0:1 compression ratio. The engine section goes beyond basic specifications into manufacturing tolerances, service wear limits, top-end and bottom-end overhaul, cam support plate, oil pump, crankcase, flywheel and connecting-rod work. Chassis data covers dimensions, weights and capacities by FLHT/C/U, FLHR/C and FLTR group, while maintenance tables provide service intervals, lubricant information, adjustment values and critical fastener torques.
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “2003 Harley-Davidson FLT Touring Service & Electrical Diagnostics Manuals 99483-03A / 99497-03” are as follows:
KEYWORD SEARCH
CONTENTSp. 1
+MAIN SERVICE MANUALp. 2
+1 – MAINTENANCEp. 2
+TROUBLESHOOTING 1.1p. 4
GENERALp. 4
+ENGINEp. 4
Starter Motor Does Not Operate or Does Not Turn Engine Overp. 4
Engine Turns Over But Does Not Startp. 4
Starts Hardp. 4
Starts But Runs Irregularly or Missesp. 4
A Spark Plug Fouls Repeatedlyp. 5
Pre-Ignition or Detonation (Knocks or Pings)p. 5
Overheatingp. 5
Valve Train Noisep. 5
Excessive Vibrationp. 5
Check Engine Lamp Illuminates During Operationp. 5
+LUBRICATION SYSTEMp. 5
Oil Does Not Return To Oil Panp. 5
Engine Uses Too Much Oil Or Smokes Excessivelyp. 5
Engine Leaks Oil From Case, Push Rods, Hoses, Etc.p. 5
Low Oil Pressurep. 6
High Oil Pressurep. 6
+ELECTRICAL SYSTEMp. 6
Alternator Does Not Chargep. 6
Alternator Charge Rate Is Below Normalp. 6
Speedometer Operates Erraticallyp. 6
+CARBURETORp. 6
+TRANSMISSIONp. 6
Transmission Shifts Hardp. 6
Jumps Out Of Gearp. 6
Clutch Slipsp. 6
Clutch Drags Or Does Not Releasep. 6
Clutch Chattersp. 6
+BRAKESp. 7
Brake Does Not Hold Normallyp. 7
+HANDLINGp. 7
+SHOP PRACTICES 1.2p. 8
+REPAIR NOTESp. 8
Safetyp. 8
Removing Partsp. 8
Cleaningp. 8
Disassembly and Assemblyp. 8
Checking Torques on Fasteners with Lock Patchesp. 8
+REPAIR AND REPLACEMENT PROCEDURESp. 8
Hardware and Threaded Partsp. 8
Wiring, Hoses and Linesp. 8
Instruments and Gaugesp. 8
Bearingsp. 9
Bushingsp. 9
Gasketsp. 9
Lip Type Sealsp. 9
O-Rings (Preformed Packings)p. 9
Gearsp. 9
Shaftsp. 9
Part Replacementp. 9
+CLEANINGp. 9
Part Protectionp. 9
Cleaning Processp. 9
Rust or Corrosion Removalp. 10
Bearingsp. 10
+TOOL SAFETY 1.3p. 11
AIR TOOLSp. 11
WRENCHESp. 11
PLIERS/CUTTERS/PRYBARSp. 11
HAMMERSp. 11
PUNCHES/CHISELSp. 11
SCREWDRIVERSp. 11
RATCHETS AND HANDLESp. 11
SOCKETSp. 11
STORAGE UNITSp. 12
SCHEDULED MAINTENANCE TABLE 1.4p. 13
+SCHEDULED MAINTENANCE PROCEDURES 1.5p. 17
BATTERYp. 17
ENGINE OIL/ENGINE OIL FILTERp. 17
PRIMARY CHAINp. 18
PRIMARY CHAIN LUBRICANTp. 19
CLUTCH ADJUSTMENTp. 20
TRANSMISSION LUBRICANTp. 21
TIRESp. 21
WHEEL SPOKESp. 22
STEERING HEAD BEARINGSp. 22
BRAKE FLUIDp. 23
BRAKE PAD LININGS AND DISCSp. 23
DRIVE BELTp. 23
REAR SHOCK ABSORBERSp. 25
AIR CLEANERp. 25
FUEL SYSTEM LINES AND FITTINGSp. 26
FUEL TANK FILTER (Carbureted)p. 26
ENRICHENER CONTROLp. 28
+THROTTLE CABLESp. 28
Lubricationp. 28
Adjustmentp. 30
SPARK PLUGSp. 30
ELECTRICAL COMPONENTSp. 31
ENGINE IDLE SPEEDp. 31
+critical fastenersp. 32
REAR SWING ARM PIVOT SHAFTp. 32
ENGINE MOUNTSp. 33
Topp. 33
Bottomp. 33
FRONT FORK OILp. 33
ROAD TESTp. 33
+2 – CHASSISp. 36
+SPECIFICATIONS 2.1p. 38
DIMENSIONS (in.)p. 38
WEIGHT (lbs.)p. 38
CAPACITIES (U.S.)p. 38
DIMENSIONS (mm)p. 38
WEIGHT (kg)p. 38
CAPACITIES (Metric)p. 38
TIRE DATAp. 39
REAR WHEEL SPROCKETp. 39
+TORQUE VALUESp. 39
TORQUE VALUES (CONT.’D)p. 40
VEHICLE IDENTIFICATION NUMBER (VIN)p. 42
+FRONT WHEEL 2.2p. 43
GENERALp. 43
PRELIMINARY INSPECTIONp. 43
REMOVALp. 43
DISASSEMBLYp. 43
CLEANING AND INSPECTIONp. 44
ASSEMBLYp. 45
INSTALLATIONp. 46
+REAR WHEEL 2.3p. 48
GENERALp. 48
PRELIMINARY INSPECTIONp. 48
REMOVALp. 48
DISASSEMBLYp. 48
CLEANING AND INSPECTIONp. 49
ASSEMBLYp. 50
INSTALLATIONp. 51
+CHECKING RIM RUNOUT 2.4p. 54
+WHEEL LACING – 16 INCH RIM 2.5p. 55
GENERALp. 55
WHEEL LACINGp. 55
SPOKE TIGHTNESSp. 57
+TRUING LACED WHEEL 2.6p. 58
+TIRES AND TUBES 2.7p. 60
GENERALp. 60
REMOVALp. 60
CLEANING AND INSPECTIONp. 60
+INSTALLATIONp. 61
Checking Tire Radial Runoutp. 62
Checking Tire Lateral Runoutp. 62
Wheel Balancingp. 63
+VEHICLE ALIGNMENT 2.8p. 64
METHOD Ap. 64
METHOD Bp. 67
+INSPECTIONp. 69
Front Rubber Mountp. 69
Rear Swingarm Mountsp. 69
Engine Stabilizer Linksp. 69
+FRONT BRAKE MASTER CYLINDER 2.9p. 70
GENERALp. 70
REMOVAL/DISASSEMBLYp. 70
CLEANING AND INSPECTIONp. 71
ASSEMBLY/INSTALLATIONp. 71
+REAR BRAKE MASTER CYLINDER 2.10p. 75
+REMOVALp. 75
PRELIMINARY INSTRUCTIONSp. 75
BRAKE PEDAL/MASTER CYLINDER ASSEMBLY, REMOVALp. 75
BRAKE PEDAL/MASTER CYLINDER ASSEMBLY, INSTALLATIONp. 76
REAR BRAKE LINE, REMOVALp. 76
REAR BRAKE LINE, INSTALLATIONp. 77
+INSTALLATIONp. 77
+MASTER CYLINDERp. 79
DISASSEMBLYp. 79
CLEANING AND INSPECTIONp. 80
ASSEMBLYp. 81
+FRONT BRAKE CALIPER 2.11p. 83
+INSPECTIONp. 83
BRAKE PADSp. 83
BRAKE LINE/HOSE INSPECTIONp. 83
+FRONT BRAKE PAD REPLACEMENTp. 83
CALIPER REMOVALp. 85
CALIPER DISASSEMBLYp. 86
CLEANING AND INSPECTIONp. 87
CALIPER ASSEMBLYp. 87
CALIPER INSTALLATIONp. 88
+REAR BRAKE CALIPER 2.12p. 89
+INSPECTIONp. 89
BRAKE DISC THICKNESS/WARPAGEp. 89
BRAKE PADSp. 89
BRAKE LINE/HOSE INSPECTIONp. 89
REAR BRAKE PAD REPLACEMENTp. 89
CALIPER REMOVALp. 91
CALIPER DISASSEMBLYp. 91
CLEANING AND INSPECTIONp. 93
CALIPER ASSEMBLYp. 93
CALIPER INSTALLATIONp. 94
+BLEEDING HYDRAULIC BRAKES 2.13p. 95
+FRONT FORKS 2.14p. 96
+CHANGING FORK OILp. 96
FLHT/C/U, FLTRp. 96
FLHR/Cp. 96
REMOVALp. 97
+DISASSEMBLYp. 97
LEFT FORKp. 97
RIGHT FORKp. 99
CLEANING AND INSPECTIONp. 100
+ASSEMBLYp. 100
LEFT FORKp. 100
RIGHT FORKp. 103
INSTALLATIONp. 105
+STEERING HEAD BEARINGS 2.15p. 106
LUBRICATIONp. 106
CHECKINGp. 106
ADJUSTMENTp. 106
REMOVALp. 107
INSPECTIONp. 108
ASSEMBLYp. 109
INSTALLATIONp. 109
+REAR AIR SUSPENSION 2.16p. 110
GENERALp. 110
REAR AIR SUSPENSIONp. 110
REMOVAL/INSTALLATIONp. 112
+REAR SHOCK ABSORBERS 2.17p. 114
ADJUSTMENTp. 114
REMOVALp. 114
DISASSEMBLYp. 114
CLEANING AND INSPECTIONp. 115
ASSEMBLYp. 115
INSTALLATIONp. 115
+REAR SWINGARM 2.18p. 116
REMOVALp. 116
+DISASSEMBLY/ASSEMBLYp. 117
Bearing Removalp. 117
Bearing Installationp. 118
Pivot Shaft Disassemblyp. 118
Pivot Shaft Assemblyp. 118
INSTALLATIONp. 119
+THROTTLE CABLES (NON-CRUISE) 2.19p. 124
ADJUSTMENTp. 124
+REMOVALp. 125
THROTTLE SIDEp. 125
CARBURETOR/INDUCTION MODULE SIDEp. 126
CLEANING AND INSPECTIONp. 126
+INSTALLATIONp. 126
THROTTLE SIDEp. 126
CARBURETOR/INDUCTION MODULE SIDEp. 127
LUBRICATIONp. 128
+CLUTCH CABLE 2.20p. 129
ADJUSTMENTp. 129
REMOVALp. 129
INSTALLATIONp. 130
+HANDLEBARS 2.21p. 132
HANDLEBAR ADJUSTMENTp. 132
HANDLEBAR REMOVALp. 132
HANDLEBAR INSTALLATIONp. 133
+LEFT HAND GRIPp. 134
REMOVALp. 134
INSTALLATIONp. 134
+RUBBER MOUNTSp. 134
REMOVALp. 134
INSTALLATIONp. 135
+SEAT 2.22p. 136
+FLHTp. 136
REMOVALp. 136
INSTALLATIONp. 136
+FLHTC/Up. 136
REMOVALp. 136
INSTALLATIONp. 136
+FLHRp. 137
REMOVALp. 137
INSTALLATIONp. 137
+FLHRCp. 138
REMOVALp. 138
INSTALLATIONp. 138
+FLTRp. 138
REMOVALp. 138
INSTALLATIONp. 138
SEAT RETENTION NUT REPLACEMENTp. 139
+SADDLEBAG 2.23p. 140
OPENINGp. 140
CLOSINGp. 140
REMOVALp. 140
+INSTALLATIONp. 141
LATCH SPRING REPLACEMENTp. 141
+TOUR-PAK 2.24p. 143
+FLHTCp. 143
REMOVALp. 143
INSTALLATIONp. 143
+FLHTCUp. 144
REMOVALp. 144
INSTALLATIONp. 145
+TOUR-PAK LIGHTS/BACKREST/SPEAKER BOX 2.25p. 146
GENERALp. 146
+SIDE MARKER LIGHTS FLHTC/Up. 146
BULB/LENSE REPLACEMENTp. 146
REMOVALp. 146
INSTALLATIONp. 146
+WRAP-AROUND LIGHT ASSEMBLY FLHTCUp. 147
BULB REPLACEMENTp. 147
REMOVALp. 147
INSTALLATIONp. 148
+PASSENGER BACKREST FLHTCUp. 148
REMOVALp. 148
INSTALLATIONp. 149
+SPEAKER BOX FLHTCUp. 149
REMOVALp. 149
INSTALLATIONp. 149
+LOWER FAIRING/ENGINE GUARD 2.26p. 150
+LOWER FAIRINGp. 150
REMOVALp. 150
INSTALLATIONp. 150
+ENGINE GUARDp. 150
REMOVALp. 150
INSTALLATIONp. 150
+UPPER FAIRING/WINDSHIELD (FLHT/C/U) 2.27p. 151
+OUTER FAIRING/WINDSHIELDp. 151
REMOVALp. 151
INSTALLATIONp. 151
+FAIRING CAPp. 152
REMOVALp. 152
INSTALLATIONp. 152
+INNER FAIRINGp. 153
REMOVALp. 153
INSTALLATIONp. 156
+UPPER FAIRING/WINDSHIELD (FLTR) 2.28p. 159
+WINDSHIELD ONLYp. 159
REMOVALp. 159
INSTALLATIONp. 159
+OUTER FAIRINGp. 159
REMOVALp. 159
INSTALLATIONp. 160
+BEZELp. 161
REMOVALp. 161
INSTALLATIONp. 161
+INSTRUMENT NACELLEp. 162
REMOVALp. 162
INSTALLATIONp. 163
+INNER FAIRINGp. 166
REMOVALp. 166
INSTALLATIONp. 167
+GLOVE BOX DOOR/HINGEp. 168
REMOVALp. 168
INSTALLATIONp. 168
+WINDSHIELD/HEADLAMP NACELLE (FLHR/C) 2.29p. 170
WINDSHIELD REMOVALp. 170
WINDSHIELD INSTALLATIONp. 170
NACELLE REMOVALp. 170
NACELLE INSTALLATIONp. 171
+FRONT FENDER 2.30p. 173
REMOVALp. 173
INSTALLATIONp. 173
+REAR FENDER 2.31p. 175
REMOVALp. 175
INSTALLATIONp. 176
+JIFFY STAND 2.32p. 178
GENERALp. 178
REMOVALp. 178
INSTALLATIONp. 179
+EXHAUST SYSTEM 2.33p. 180
REMOVALp. 180
INSTALLATIONp. 180
+3 – ENGINEp. 184
+SPECIFICATIONS 3.1p. 186
+MANUFACTURING TOLERANCESp. 186
MANUFACTURING TOLERANCES (CONT.)p. 187
TORQUE VALUESp. 187
+SERVICE WEAR LIMITS 3.2p. 188
+GENERAL INFORMATION 3.3p. 190
+FUELp. 190
GASOLINE/ALCOHOL BLENDSp. 190
+LUBRICATIONp. 190
CHECKING ENGINE OIL LEVELp. 190
CHANGING ENGINE OIL AND FILTERp. 191
WINTER LUBRICATIONp. 192
OIL PRESSURE INDICATOR LAMPp. 192
ENGINE OIL FLOWp. 193
Oil Feed (Figures 3-6, 3-7)p. 193
Top End (Figures 3-6, 3-7)p. 193
Bottom End (Figures 3-6, 3-7, 3-8)p. 195
Oil Return (Figures 3-6, 3-8)p. 195
Oil Pump Operationp. 195
Breather Operationp. 198
+HOW TO USE THIS SECTION 3.4p. 199
+GENERALp. 199
Top End Overhaulp. 199
Bottom End Overhaulp. 199
Subassembly Service and Repairp. 200
+STRIPPING MOTORCYCLE FOR SERVICE 3.5p. 201
+ASSEMBLING MOTORCYCLE AFTER STRIPPING 3.6p. 203
+REMOVING ENGINE FROM CHASSIS 3.7p. 206
+INSTALLING ENGINE IN CHASSIS 3.8p. 211
+TOP END OVERHAUL 3.9p. 218
DISASSEMBLYp. 218
ASSEMBLYp. 222
+BOTTOM END OVERHAUL 3.10p. 230
DISASSEMBLYp. 230
ASSEMBLYp. 232
+SUBASSEMBLY SERVICE AND REPAIR 3.11p. 240
TOP ENDp. 240
+BREATHER ASSEMBLYp. 240
Removalp. 240
Disassemblyp. 240
Cleaning and Inspectionp. 240
Assemblyp. 240
Installationp. 240
+ROCKER ARM ASSEMBLYp. 241
Removalp. 241
Disassemblyp. 241
Cleaning and Inspectionp. 241
Assemblyp. 242
Installationp. 243
+PUSH RODS/LIFTERS/COVERSp. 244
Removalp. 244
Disassemblyp. 244
Cleaning and Inspectionp. 244
Assemblyp. 244
Installationp. 245
+CYLINDER HEADp. 248
Removalp. 248
Disassemblyp. 248
Cleaning and Inspectionp. 249
VALVE GUIDE REPLACEMENTp. 250
VALVE AND SEAT REFACINGp. 253
Assemblyp. 255
Installationp. 258
+CYLINDERp. 259
Removalp. 259
Cleaning and Inspectionp. 259
Installationp. 261
+PISTONp. 262
Removalp. 262
Disassemblyp. 262
Piston Rings, Removalp. 262
Cleaning and Inspectionp. 262
Assemblyp. 264
Piston Rings, Installationp. 264
Installationp. 265
+UPPER CONNECTING RODp. 267
Removalp. 267
Disassembly/Assemblyp. 267
Upper Connecting Rod Bushingp. 267
Reaming Upper Rod Bushingp. 268
Honing Upper Rod Bushingp. 269
Installationp. 270
BOTTOM ENDp. 272
+CAM SUPPORT PLATEp. 272
Removalp. 272
Disassembly/Assemblyp. 272
Crankshaft Bushingp. 272
Reaming Crankshaft Bushingp. 273
Camshafts/Camshaft Bearingsp. 274
Cam Chain Tensionersp. 280
Oil Pressure Relief Valvep. 281
Cam Needle Bearingsp. 281
Cleaning and Inspectionp. 283
Installationp. 283
+OIL PUMPp. 284
Removalp. 284
Cleaning and Inspectionp. 284
Installationp. 284
+CRANKCASEp. 286
Removalp. 286
Disassembly/Assemblyp. 286
RIGHT CRANKCASE HALFp. 286
Crankshaft Bearingp. 286
Piston Jetsp. 287
LEFT CRANKCASE HALFp. 287
Sprocket Shaft Bearingp. 287
Sprocket Shaft Bearing Inner Racep. 289
Cylinder Studsp. 291
Pipe Plug and Oil Fittingsp. 291
Cleaning and Inspectionp. 291
Installationp. 291
+FLYWHEEL/CONNECTING ROD ASSEMBLYp. 292
Removalp. 292
Inspectionp. 292
Installationp. 292
+4 – FUEL SYSTEMp. 294
+SPECIFICATIONS 4.1p. 296
CVH CARBURETOR JET SIZESp. 296
FUEL TANK CAPACITYp. 296
TORQUE VALUESp. 296
FUEL SYSTEM TROUBLESHOOTING (CARBURETED) 4.2p. 297
+ENRICHENER (CARBURETED) 4.3p. 300
GENERALp. 300
+OPERATIONp. 300
Enrichenerp. 300
Cool Enginep. 301
Warm Climate Or Hot Enginep. 301
+ADJUSTMENTSp. 301
Slow Idlep. 301
Enrichener Controlp. 302
+CARBURETOR 4.4p. 304
REMOVALp. 304
INSTALLATIONp. 304
DISASSEMBLYp. 305
+CLEANING AND INSPECTIONp. 307
ASSEMBLYp. 308
+AIR CLEANER 4.5p. 311
GENERALp. 311
REMOVALp. 311
CLEANING AND INSPECTIONp. 311
INSTALLATIONp. 312
+VACUUM OPERATED FUEL VALVE (CARBURETED) 4.6p. 313
GENERALp. 313
TROUBLESHOOTINGp. 313
REMOVALp. 313
CLEANING AND INSPECTIONp. 314
INSTALLATIONp. 314
FUEL TANK ADAPTERp. 315
+FUEL TANK (CARBURETED) 4.7p. 316
+COMPLETE REMOVALp. 316
FLHT/C, FLTRp. 316
FLHRp. 316
CLEANING AND INSPECTIONp. 317
+INSTALLATION (AFTER COMPLETE REMOVAL)p. 318
FLHT/C, FLTRp. 318
FLHRp. 319
+PARTIAL REMOVALp. 319
FLHT/C, FLTRp. 319
FLHRp. 320
+INSTALLATION (AFTER PARTIAL REMOVAL)p. 320
FLHT/C, FLTRp. 320
FLHRp. 321
+EVAPORATIVE EMISSIONS CONTROL SYSTEM 4.8p. 322
CALIFORNIA MODELS ONLYp. 322
TROUBLESHOOTINGp. 323
+VAPOR VALVEp. 323
REMOVALp. 323
INSTALLATIONp. 323
+CHARCOAL CANISTERp. 324
REMOVALp. 324
INSTALLATIONp. 324
Charcoal Canister Hose Routingp. 325
Purge Tube:p. 325
Fuel Vapor Vent Tube:p. 325
Clean Air Inlet Tube:p. 325
+5 – ELECTRIC STARTERp. 326
+SPECIFICATIONS 5.1p. 327
STARTERp. 327
SERVICE WEAR LIMITSp. 327
TORQUE VALUESp. 327
+STARTER SYSTEM 5.2p. 328
+GENERALp. 328
Operation (Figure 5-1)p. 328
+STARTER RELAY 5.3p. 330
+REMOVALp. 330
FLHR/Cp. 330
FLTR, FLHT/C/Up. 330
+INSTALLATIONp. 330
FLHR/Cp. 330
FLTR, FLHT/C/Up. 330
+STARTER 5.4p. 331
REMOVALp. 331
INSTALLATIONp. 331
DISASSEMBLY, TESTING AND REPAIRp. 333
ASSEMBLYp. 337
+STARTER SOLENOID 5.5p. 338
GENERALp. 338
DISASSEMBLYp. 338
ASSEMBLYp. 338
+STARTER JACKSHAFT 5.6p. 339
REMOVAL/DISASSEMBLYp. 339
ASSEMBLY/INSTALLATIONp. 340
+6 – DRIVEp. 341
+SPECIFICATIONS 6.1p. 343
OVERALL GEAR RATIOSp. 343
CHAINS AND BELTSp. 343
SPROCKETSp. 343
CLUTCHp. 343
TORQUE VALUESp. 343
+PRIMARY CHAIN AND SPROCKETS 6.2p. 345
PRIMARY CHAIN ADJUSTMENTp. 345
ADJUSTER SHOE REPLACEMENTp. 345
DISASSEMBLYp. 347
+CLEANING AND INSPECTIONp. 347
Sprocket Alignment (Figure 6-3, 6-4)p. 347
ASSEMBLYp. 348
+CLUTCH 6.3p. 349
ADJUSTMENTp. 349
+REMOVAL/INSTALLATIONp. 350
PARTIAL DISASSEMBLYp. 350
ASSEMBLYp. 350
+CLEANING AND INSPECTIONp. 352
COMPLETE DISASSEMBLYp. 352
ASSEMBLYp. 353
+SECONDARY DRIVE BELT AND SPROCKETS 6.4p. 355
ADJUSTMENTp. 355
CLEANING AND INSPECTIONp. 356
+REPLACEMENTp. 357
Removalp. 357
Installationp. 357
+TRANSMISSION SPROCKETp. 357
Removalp. 357
Cleaning and Inspectionp. 358
Installationp. 358
+REAR WHEEL SPROCKETp. 360
Removalp. 360
Cleaning and Inspectionp. 361
Installationp. 361
+PRIMARY CHAINCASE 6.5p. 362
GENERALp. 362
LUBRICATIONp. 362
REMOVALp. 362
INSPECTION AND REPAIRp. 365
+DISASSEMBLYp. 365
MAINSHAFT BEARING AND LIP SEALp. 365
MAINSHAFT BEARING INNER RACEp. 366
STARTER JACKSHAFT BUSHING AND LIP SEAL – PRIMARY CHAINCASEp. 367
STARTER JACKSHAFT BUSHING – PRIMARY CHAINCASE COVERp. 367
SHIFTER BRACKET BUSHINGSp. 368
INSTALLATIONp. 369
+7 – TRANSMISSIONp. 375
+SPECIFICATIONS 7.1p. 377
TRANSMISSION DATAp. 377
+SERVICE WEAR LIMITSp. 377
SERVICE WEAR LIMITS (CONT.’D)p. 378
TORQUE VALUESp. 378
+TRANSMISSION POWER FLOW 7.2p. 379
+GENERALp. 379
Neutralp. 379
1st Gearp. 379
2nd Gearp. 379
3rd Gearp. 379
4th Gearp. 379
5th Gearp. 379
+SHIFTER LINKAGE 7.3p. 381
+SHIFTER CAM ASSEMBLY/SHIFTER FORKS 7.4p. 382
DISASSEMBLYp. 382
CLEANING AND INSPECTIONp. 383
ASSEMBLYp. 384
+CLUTCH RELEASE COVER 7.5p. 388
REMOVAL/DISASSEMBLYp. 388
CLEANING AND INSPECTIONp. 388
ASSEMBLY/INSTALLATIONp. 389
+MAINSHAFT/COUNTERSHAFT 7.6p. 391
REMOVALp. 391
DISASSEMBLYp. 391
CLEANING AND INSPECTIONp. 392
ASSEMBLYp. 394
INSTALLATIONp. 397
+MAIN DRIVE GEAR 7.7p. 398
REMOVALp. 398
+CLEANING AND INSPECTIONp. 398
Needle Bearing Replacementp. 399
+INSTALLATIONp. 400
Countershaft Needle Bearing Replacementp. 403
+TRANSMISSION CASE/OIL PAN 7.8p. 404
GENERALp. 404
+REMOVALp. 404
Transmission Case and Oil Panp. 404
Oil Pan Onlyp. 405
CLEANING AND INSPECTIONp. 406
+INSTALLATIONp. 406
Oil Pan Onlyp. 406
Transmission Case and Oil Panp. 406
+8 – ELECTRICALp. 409
+SPECIFICATIONS 8.1p. 411
IGNITION TIMINGp. 411
ALTERNATOR SYSTEMp. 411
BATTERYp. 411
FUSESp. 411
SPARK PLUGp. 412
TORQUE VALUESp. 412
BULB CHART 8.2p. 413
+IGNITION MODULE 8.3p. 415
REMOVALp. 415
INSTALLATIONp. 415
+ENGINE SENSORS 8.4p. 416
+MANIFOLD ABSOLUTE PRESSURE SENSORp. 416
Removalp. 416
Installationp. 416
CRANKSHAFT POSITION SENSORp. 416
+IGNITION COIL 8.5p. 417
REMOVALp. 417
INSTALLATIONp. 417
+SPARK PLUGS/SPARK PLUG CABLES 8.6p. 418
+SPARK PLUGSp. 418
REMOVALp. 418
INSPECTIONp. 418
CLEANINGp. 418
ADJUSTMENTp. 418
INSTALLATIONp. 418
+SPARK PLUG CABLESp. 419
REMOVALp. 419
INSPECTIONp. 419
INSTALLATIONp. 419
+ALTERNATOR/STATOR 8.7p. 420
REMOVALp. 420
CLEANING AND INSPECTIONp. 421
INSTALLATIONp. 422
+VOLTAGE REGULATOR 8.8p. 425
REMOVALp. 425
INSTALLATIONp. 425
+BATTERY 8.9p. 429
GENERALp. 429
VOLTMETER TESTp. 429
DISCONNECTION AND REMOVALp. 430
CLEANING AND INSPECTIONp. 430
+BATTERY CHARGINGp. 430
SAFETY PRECAUTIONSp. 430
CHARGING BATTERYp. 430
LOAD TESTp. 431
BATTERY CABLE ROUTINGp. 432
INSTALLATION AND CONNECTIONp. 432
STORAGEp. 433
+HEADLAMP (FLHR/C, FLHT/C/U) 8.10p. 434
+HEADLAMP ASSEMBLYp. 434
REMOVALp. 434
INSTALLATIONp. 434
HEADLAMP BULB REPLACEMENTp. 434
HEADLAMP ADJUSTMENTp. 435
+HEADLAMP (FLTR) 8.11p. 437
+HEADLAMP ASSEMBLYp. 437
REMOVALp. 437
INSTALLATIONp. 437
+HEADLAMP BULB REPLACEMENTp. 437
REMOVALp. 437
INSTALLATIONp. 438
HEADLAMP ADJUSTMENTp. 438
+PASSING LAMPS 8.12p. 440
ADJUSTMENTp. 440
+PASSING LAMP BULBp. 440
REMOVALp. 440
INSTALLATIONp. 440
+PASSING LAMP BRACKETp. 441
REMOVALp. 441
INSTALLATIONp. 442
+PASSING LAMPp. 442
REMOVALp. 442
INSTALLATIONp. 442
+TAIL LAMP ASSEMBLY 8.13p. 443
+TAIL LAMPp. 443
REMOVALp. 443
INSTALLATIONp. 443
+CIRCUIT BOARD/TAIL LAMP BRACKET ASSEMBLYp. 443
REMOVALp. 443
INSTALLATIONp. 444
+FENDER TIP LAMPS 8.14p. 446
+FRONT FENDER TIP LAMPp. 446
REMOVALp. 446
INSTALLATIONp. 446
+FRONT FENDER TIP LAMP JUMPER HARNESSp. 446
REMOVALp. 446
INSTALLATIONp. 448
+REAR FENDER TIP LAMPp. 449
REMOVALp. 449
INSTALLATIONp. 450
+TURN SIGNAL LAMPS 8.15p. 451
+GENERALp. 451
BULB REPLACEMENTp. 451
+FRONT TURN SIGNAL LAMPp. 451
REMOVALp. 451
INSTALLATIONp. 452
+REAR TURN SIGNAL LAMPp. 453
REMOVALp. 453
INSTALLATIONp. 453
+TURN SIGNAL/SECURITY MODULE 8.16p. 455
REMOVALp. 455
INSTALLATIONp. 455
+IGNITION/LIGHT KEY SWITCH AND FORK LOCK 8.17p. 457
+FLHT/C/U, FLTR (DOMESTIC)p. 457
REMOVALp. 457
INSTALLATIONp. 458
+FLHT/C/U, FLTR (INTERNATIONAL)p. 459
REMOVALp. 459
INSTALLATIONp. 460
+FLHR/Cp. 462
IGNITION/LIGHT KEY SWITCHp. 462
FORK LOCKp. 462
+FAIRING CAP SWITCHES (FLHTC/U) 8.18p. 464
REMOVALp. 464
INSTALLATIONp. 464
+INSTRUMENT NACELLE SWITCHES (FLTR) 8.19p. 467
+REMOVALp. 467
LEFT SIDE SWITCHp. 468
RIGHT SIDE SWITCHp. 468
+INSTALLATIONp. 469
LEFT SIDE SWITCHp. 469
RIGHT SIDE SWITCHp. 470
+HANDLEBAR SWITCHES 8.20p. 472
GENERALp. 472
+REMOVALp. 472
RIGHT HANDLEBAR CONTROLSp. 472
LEFT HANDLEBAR CONTROLSp. 473
+INSTALLATIONp. 473
RIGHT HANDLEBAR CONTROLSp. 473
LEFT HANDLEBAR CONTROLSp. 475
+SWITCH REPAIR/REPLACEMENTp. 478
RIGHT SIDE HANDLEBAR SWITCHESp. 478
LEFT SIDE HANDLEBAR SWITCHESp. 478
+SPECIFIC REPAIR PROCEDURESp. 478
UPPER SWITCH HOUSINGSp. 478
LOWER SWITCH HOUSINGSp. 480
+GENERAL REPAIR PROCEDURESp. 487
RIGHT SIDE HANDLEBAR SWITCHESp. 488
LEFT SIDE HANDLEBAR SWITCHESp. 489
+STOPLIGHT SWITCHES 8.21p. 490
FRONT STOPLIGHT SWITCHp. 490
REAR STOPLIGHT SWITCHp. 490
+NEUTRAL SWITCH 8.22p. 491
GENERALp. 491
REMOVALp. 491
INSTALLATIONp. 491
+HORN 8.23p. 492
TROUBLESHOOTINGp. 492
REMOVALp. 492
INSTALLATIONp. 492
+CIGARETTE LIGHTER (FLHTCU, FLTR) 8.24p. 493
GENERALp. 493
TROUBLESHOOTINGp. 493
REMOVALp. 493
INSTALLATIONp. 493
+GAUGES/INSTRUMENTS (FLHT/C/U, FLTR) 8.25p. 494
+GAUGES- 2 INCH DIAMETERp. 494
REMOVALp. 494
INSTALLATIONp. 494
+GAUGES- 4 INCH DIAMETERp. 494
TACHOMETERp. 494
REMOVALp. 494
INSTALLATIONp. 494
+SPEEDOMETER SPEED SENSORp. 495
REMOVALp. 495
INSTALLATIONp. 495
+SPEEDOMETERp. 495
REMOVALp. 495
INSTALLATIONp. 495
+INDICATOR LAMPSp. 496
REMOVALp. 496
INSTALLATIONp. 496
+GAUGES/INSTRUMENTS (FLHR/C) 8.26p. 497
+FUEL GAUGEp. 497
REMOVALp. 497
INSTALLATIONp. 497
+SPEEDOMETER SPEED SENSORp. 498
REMOVALp. 498
INSTALLATIONp. 498
+SPEEDOMETERp. 498
REMOVALp. 498
INSTALLATIONp. 499
+INDICATOR LIGHTSp. 499
REMOVALp. 499
INSTALLATIONp. 500
IGNITION SWITCHp. 500
+FUEL LEVEL SENDER (CARBURETED) 8.27p. 501
+FLHT/C, FLTR CANOPYp. 501
REMOVALp. 501
INSTALLATIONp. 501
+FLHR CANOPYp. 502
REMOVALp. 502
INSTALLATIONp. 503
+FUEL LEVEL SENDERp. 503
REMOVALp. 503
INSTALLATIONp. 504
+CANOPY CONNECTOR/O-RINGp. 505
REMOVALp. 505
INSTALLATIONp. 505
+CRUISE CONTROL (FLHRC, FLTR, FLHTCU) 8.28p. 507
GENERALp. 507
SYSTEM OPERATIONp. 507
+CABLE ADJUSTMENTp. 508
THROTTLE CABLEp. 508
IDLE CABLEp. 509
CABLE LASH INITIALIZATIONp. 509
+THROTTLE/IDLE CABLESp. 509
REMOVALp. 509
INSTALLATIONp. 510
+CRUISE CABLEp. 512
REMOVALp. 512
INSTALLATIONp. 512
+CRUISE CONTROL MODULEp. 513
REMOVALp. 513
INSTALLATIONp. 513
AUDIO HARNESSp. 514
+CRUISE CONTROL SWITCHESp. 514
FAIRING CAPp. 514
HANDLEBARp. 514
+PREMIUM SOUND SYSTEM (FLHTC/U, FLTR) 8.29p. 515
+RADIO (FLHTC/U)p. 515
REMOVALp. 515
INSTALLATIONp. 516
+FRONT FAIRING SPEAKERSp. 516
REMOVALp. 516
INSTALLATIONp. 516
+CONSOLE POD ASSEMBLYp. 517
REMOVALp. 517
INSTALLATIONp. 517
+FRONT HEADSET RECEPTACLEp. 518
REMOVALp. 518
INSTALLATIONp. 519
REAR HEADSET RECEPTACLEp. 519
+REAR PASSENGER SWITCHESp. 520
REMOVALp. 520
INSTALLATIONp. 520
+REAR SPEAKERSp. 522
REMOVALp. 522
INSTALLATIONp. 522
+FUSE BLOCKSp. 522
REMOVALp. 522
INSTALLATIONp. 523
+CB LOADING COILp. 524
REMOVALp. 524
INSTALLATIONp. 524
AUDIO HARNESSp. 524
RADIO ANTENNA CABLEp. 524
CB ANTENNA CABLEp. 524
+WIRING HARNESSES AND CABLES (FLHT/C/U) 8.30p. 525
+MAIN HARNESSp. 525
REMOVALp. 525
INSTALLATIONp. 528
+INTERCONNECT HARNESSp. 532
REMOVALp. 532
INSTALLATIONp. 532
+AUDIO HARNESSp. 536
REMOVALp. 536
INSTALLATIONp. 537
+RADIO ANTENNA CABLEp. 539
REMOVALp. 539
INSTALLATIONp. 540
+CB ANTENNA CABLEp. 541
REMOVALp. 541
INSTALLATIONp. 541
+9 – FUEL INJECTIONp. 543
+SPECIFICATIONS 9.1p. 545
EFI FUSESp. 545
TORQUE VALUESp. 545
+ELECTRICAL BRACKET ASSEMBLY 9.2p. 547
GENERALp. 547
+DATA LINK CONNECTORp. 547
SETTING ENGINE IDLE SPEEDp. 547
+EFI SYSTEM RELAYp. 548
REMOVALp. 548
INSTALLATIONp. 548
+EFI FUSESp. 548
REMOVALp. 548
INSTALLATIONp. 548
+ELECTRONIC CONTROL MODULEp. 549
REMOVALp. 549
INSTALLATIONp. 549
+SIREN CONNECTORp. 549
REMOVALp. 549
INSTALLATIONp. 549
+EFI WIRE HARNESSp. 549
REMOVALp. 549
INSTALLATIONp. 551
+SENSORS 9.3p. 554
+GENERALp. 554
INTAKE AIR TEMPERATURE SENSORp. 554
THROTTLE POSITION SENSORp. 554
MANIFOLD ABSOLUTE PRESSURE SENSORp. 554
BANK ANGLE SENSORp. 554
+CRANKSHAFT POSITION SENSORp. 554
REMOVALp. 554
INSTALLATIONp. 555
+ENGINE TEMPERATURE SENSORp. 556
REMOVALp. 556
INSTALLATIONp. 556
+FUEL TANK (FUEL INJECTED) 9.4p. 558
GENERALp. 558
+COMPLETE REMOVALp. 558
FLHT/C/U/I, FLTRIp. 558
FLHR/C/Ip. 560
+INSTALLATION (AFTER COMPLETE REMOVAL)p. 560
FLHT/C/U/I, FLTRIp. 560
FLHR/C/Ip. 562
+PARTIAL REMOVALp. 562
FLHT/C/U/I, FLTRIp. 562
FLHR/C/Ip. 563
+INSTALLATION (AFTER PARTIAL REMOVAL)p. 564
FLHT/C/U/I, FLTRIp. 564
FLHR/C/Ip. 564
+CONSOLE POD/CANOPYp. 565
FLHT/C/U/I, FLTRIp. 565
REMOVALp. 565
INSTALLATIONp. 566
+INSTRUMENT CONSOLE/CANOPYp. 567
FLHR/C/Ip. 567
REMOVALp. 567
INSTALLATIONp. 568
+FUEL FILTER CANISTERp. 569
REMOVALp. 569
INSTALLATIONp. 570
+FUEL PRESSURE REGULATORp. 570
REMOVALp. 570
INSTALLATIONp. 570
+FUEL PUMPp. 571
REMOVALp. 571
INSTALLATIONp. 571
FUEL PUMP/FUEL LEVEL SENDER WIRINGp. 571
+FUEL LEVEL SENDERp. 571
REMOVALp. 571
INSTALLATIONp. 572
+CANOPY CONNECTOR/O-RINGp. 573
REMOVALp. 573
INSTALLATIONp. 573
+FUEL SUPPLY CHECK VALVE/TUBEp. 573
REMOVALp. 573
INSTALLATIONp. 573
+INDUCTION MODULE ASSEMBLY 9.5p. 575
GENERALp. 575
+INDUCTION MODULEp. 575
REMOVALp. 575
INSTALLATIONp. 576
+FUEL SUPPLY LINEp. 577
REMOVALp. 577
INSTALLATIONp. 578
+FUEL RAIL/FUEL SUPPLY TUBEp. 578
REMOVALp. 578
INSTALLATIONp. 579
+FUEL INJECTORSp. 579
REMOVALp. 579
INSTALLATIONp. 580
+INTAKE AIR TEMPERATURE SENSORp. 580
REMOVALp. 580
INSTALLATIONp. 580
+THROTTLE POSITION SENSORp. 581
REMOVALp. 581
INSTALLATIONp. 581
+MANIFOLD ABSOLUTE PRESSURE SENSORp. 581
REMOVALp. 581
INSTALLATIONp. 582
+IDLE AIR CONTROLp. 582
REMOVALp. 582
INSTALLATIONp. 583
+APPENDIX A – TOOLSp. 585
+APPENDIX B – DEUTSCH ELECTRICAL CONNECTORSp. 603
+DEUTSCH ELECTRICAL CONNECTORS B.1p. 603
GENERALp. 603
REMOVING/DISASSEMBLINGp. 603
REMOVING/INSTALLING SOCKETSp. 603
REMOVING/INSTALLING PINSp. 606
ASSEMBLING/INSTALLINGp. 606
+CRIMPING INSTRUCTIONSp. 606
STANDARD TERMINALSp. 606
MINI TERMINALSp. 608
SOLID BARREL CONTACTSp. 608
+AMP MULTILOCK ELECTRICAL CONNECTORS B.2p. 611
REMOVING SOCKET/PIN TERMINALSp. 611
INSTALLING SOCKET/PIN TERMINALSp. 611
CRIMPING INSTRUCTIONSp. 615
+PACKARD ELECTRICAL CONNECTORS B.3p. 616
GENERALp. 616
+PULL-TO-SEAT TERMINALSp. 616
Removing Pull-to-seat Terminals External Latch Typep. 616
Installing Pull-to-seat Terminals External Latch Typep. 617
Removing Pull-to-Seat Socket Terminals Wireform Typep. 618
Installing Pull-to-Seat Socket Terminals Wireform Typep. 618
+PUSH-TO-SEAT TERMINALSp. 619
Ignition Switch and Main Powerp. 619
HDI Ignition Switch Jumper Harnessp. 619
Fuse Blocksp. 619
+PACKARD ECM CONNECTORp. 620
Disassemblyp. 620
Assemblyp. 620
CRIMPING INSTRUCTIONSp. 621
+SEALED BUTT SPLICE CONNECTORS B.4p. 622
+AMP ELECTRICAL CONNECTORS B.5p. 624
+1-PLACE CONNECTORp. 624
SOCKET TERMINALp. 624
PIN TERMINALp. 624
ELECTRICAL CONNECTOR LOCATIONS B.6p. 626
WIRING DIAGRAMS B.7p. 637
+APPENDIX C – METRIC CONVERSIONSp. 651
METRIC CONVERSIONS C.1p. 651
+FASTENER TORQUE VALUES C.2p. 652
+FLUID CONVERSIONS C.3p. 653
UNITED STATES SYSTEMp. 653
METRIC SYSTEMp. 653
BRITISH IMPERIAL SYSTEMp. 653
+ELECTRICAL DIAGNOSTICS MANUALp. 655
+1 – STARTING / CHARGINGp. 655
STARTER TROUBLESHOOTING 1.1p. 657
+STARTING SYSTEM DIAGNOSIS 1.2p. 659
+DIAGNOSTICSp. 659
Diagnostic Notesp. 659
Starter Testing 1p. 659
Starter Testing 2: Solenoid Clicksp. 660
Starter Testing 3: Relay Clicksp. 660
Starter Testing 4: Nothing Clicksp. 661
Starter Testing 5: Starter Spins, But Does Not Engagep. 662
Starter Testing 6: Starter Stalls or Spins Too Slowlyp. 662
STARTER ACTIVATION CIRCUITS 1.3p. 663
+DIAGNOSTICS/TROUBLESHOOTING 1.4p. 664
GENERALp. 664
VOLTAGE DROPSp. 664
+STARTER SYSTEM TESTING 1.5p. 665
GENERALp. 665
STARTER RELAY TEST 1p. 665
STARTER RELAY TEST 2p. 665
STARTER CURRENT DRAW TESTp. 666
+TESTING ASSEMBLED STARTER 1.6p. 667
STARTER SOLENOIDp. 667
SOLENOID PULL-IN TESTp. 667
SOLENOID HOLD-IN TESTp. 667
SOLENOID RETURN TESTp. 668
FREE RUNNING CURRENT DRAW TESTp. 668
+CHARGING SYSTEM 1.7p. 669
+GENERALp. 669
Alternatorp. 669
Voltage Regulatorp. 669
+TROUBLESHOOTINGp. 669
Batteryp. 669
Wiringp. 669
Voltage Regulator Inspectionp. 669
Test 1.7 (Part 1 of 2)p. 670
Test 1.7 (Part 2 of 2)p. 671
+TESTINGp. 672
REGULATOR BLEED TESTp. 672
MILLIAMP DRAW TESTp. 672
TOTAL CURRENT DRAW TESTp. 672
CURRENT OUTPUT TESTp. 673
VOLTAGE OUTPUT TESTp. 673
STATOR CHECKp. 673
AC OUTPUT CHECKp. 674
+BATTERY LOAD TEST 1.8p. 675
VOLTMETER TESTp. 675
LOAD TESTp. 675
+2 – INSTRUMENTSp. 677
+GAUGES AND INSTRUMENTS 2.1p. 679
GENERALp. 679
+DIAGNOSTICSp. 679
Fuel Level Gaugep. 679
Fuel Level Sender Testp. 679
Fuel Gauge: FLHR/Cp. 680
Low Fuel Level Lamp: FLHTCU, FLTRp. 680
Low Fuel Level Lamp: FLHR/Cp. 680
Oil Pressure Gauge and Indicator Lightp. 681
Ambient Air Temperature Gaugep. 681
Voltmeterp. 682
Indicator Lights: FLHR/Cp. 682
+SPEEDOMETER 2.2p. 683
+GENERALp. 683
Reset Switchp. 683
Diagnostic Modep. 683
+DIAGNOSTICSp. 684
Diagnostic Notesp. 684
Speedometer Test 1p. 685
Speedometer Test 2Ap. 686
Speedometer Test 2Bp. 687
+SPEEDOMETER PERFORMANCE CHECK 2.3p. 689
GENERALp. 689
+TESTINGp. 689
Frequency Input Testp. 689
Needle Sweep Testp. 690
Speedometer Sensor Testp. 690
Tachometer Testingp. 690
+3 – TSM / TSSMp. 691
+TSM/TSSM OVERVIEW 3.1p. 693
GENERALp. 693
TROUBLESHOOTINGp. 693
+TSM/TSSM FEATURES 3.2p. 695
GENERALp. 695
+TURN SIGNAL FUNCTIONSp. 695
+BANK ANGLE FUNCTIONSp. 695
+SECURITY ALARM AND IMMOBILIZATION FUNCTIONSp. 695
+TSM/TSSM VEHICLE DELIVERY 3.3p. 697
GENERALp. 697
USING SCANALYZER ON EFI MODELSp. 697
SIDECAR CONFIGURATIONp. 697
POWER DISRUPTION/CONFIGURING WITHOUT DIAGNOSTIC TOOLp. 697
KEY FOB ASSIGNMENTp. 698
+PERSONAL CODE ENTRYp. 698
First Time Code Entry: TSSM Onlyp. 698
Modifying Existing Codes: TSSM Onlyp. 698
+TSM/TSSM TURN SIGNAL FUNCTIONS 3.4p. 702
GENERALp. 702
AUTOMATIC CANCELLATIONp. 702
MANUAL CANCELLATIONp. 702
FOUR-WAY FLASHINGp. 702
DIAGNOSTICS MODEp. 702
+TSM/TSSM BANK ANGLE FUNCTION 3.5p. 704
GENERALp. 704
OPERATIONp. 704
+SECURITY SYSTEM (TSSM) FUNCTIONS 3.6p. 705
+GENERALp. 705
Security System Operationp. 705
Security System Optionsp. 705
Differences By Market Specificationsp. 705
+ALARM SENSITIVITYp. 705
Sensitivityp. 705
Transport Modep. 705
AUTO-ARMING FUNCTIONp. 706
STORAGE MODEp. 706
+ARMING/DISARMING SECURITY SYSTEM (TSSM) 3.7p. 709
GENERALp. 709
SECURITY LAMPp. 709
+USING KEY FOBp. 709
Generalp. 709
Arming the Systemp. 709
Disarming the Systemp. 709
Troubleshootingp. 709
+USING THE PERSONAL CODEp. 710
Generalp. 710
Disarming the Systemp. 710
+CHECKING FOR TROUBLE CODES: TSM/TSSM 3.8p. 711
GENERALp. 711
+CODE TYPESp. 711
Currentp. 711
Historicp. 711
TURN SIGNAL DIAGNOSTICSp. 711
+CHECKING FOR TROUBLE CODES: TSSM ONLY 3.9p. 713
+BREAKOUT BOX: TSM/TSSM 3.10p. 715
GENERALp. 715
INSTALLATIONp. 715
REMOVALp. 715
+SCANALYZER: EFI ONLY 3.11p. 716
+SCANALYZER DIAGNOSTICSp. 716
Generalp. 716
Data Link Connectorp. 716
Scanalyzer Cartridgep. 716
INSTALLATIONp. 716
+USAGEp. 718
Checking Codesp. 718
Clearing Codesp. 718
REMOVALp. 718
+INITIAL DIAGNOSTIC CHECK: TSM/TSSM 3.12p. 719
+GENERALp. 719
Diagnostic Notesp. 719
Scanalyzer Iconp. 719
Circuit Diagram/Wire Harness Connector Tablep. 719
Job/Time Code Valuesp. 719
+INITIAL DIAGNOSTICSp. 719
Diagnostic Tipsp. 719
Diagnostic Notesp. 720
Multiple Trouble Codesp. 720
Diagnostic Check (Part 1 of 2)p. 722
Diagnostic Check (Part 2 of 2)p. 723
+NO SECURITY LAMP AT KEY ON 3.13p. 725
+GENERALp. 725
+DIAGNOSTICSp. 725
Diagnostic Tipsp. 725
Diagnostic Notesp. 725
Test 3.13 (Part 1 of 3)p. 727
Test 3.13 (Part 2 of 3)p. 728
Test 3.13 (Part 3 of 3)p. 729
+SECURITY LAMP ON CONTINUOUSLY 3.14p. 730
GENERALp. 730
+DIAGNOSTICSp. 730
Diagnostic Notesp. 730
Test 3.14p. 732
+KEY FOB SIGNAL TO TSSM WEAK OR FAILS 3.15p. 733
GENERALp. 733
+DIAGNOSTICSp. 733
Diagnostic Tipsp. 733
Diagnostic Notesp. 733
Test 3.15p. 735
+TURN SIGNAL ERRORS 3.16p. 736
GENERALp. 736
+DIAGNOSTICSp. 736
Diagnostic Tipsp. 736
Diagnostic Notes: All Turn Signal Flow Chartsp. 739
Turn Signal Error 1Ap. 740
Turn Signal Error 1Bp. 741
Turn Signal Error 1Cp. 742
Turn Signal Error 2Ap. 743
Turn Signal Error 2Bp. 744
Turn Signal Error 2Cp. 745
Turn Signal Error 3Ap. 746
Turn Signal Error 3Bp. 747
Turn Signal Error 3Cp. 748
Turn Signal Error 3Dp. 749
Turn Signal Error 4Ap. 750
+DTC B0563 (EFI), DTC 11 (CARB) 3.17p. 751
+GENERALp. 751
Battery Voltage Highp. 751
+DIAGNOSTICSp. 751
Diagnostic Tipsp. 751
Diagnostic Notesp. 751
+DTC 25 (CARB ONLY) 3.18p. 752
+GENERALp. 752
Ignition Enable Output Highp. 752
+DIAGNOSTICSp. 752
Diagnostic Tipsp. 752
Diagnostic Notesp. 752
Test 3.18p. 754
+DTC B1131/ B1132 (EFI), DTC 31/32 (CARB) 3.19p. 755
+GENERALp. 755
Alarm Output Low (DTC B1131/DTC 31) or Alarm Output High (DTC B1132/DTC 32)p. 755
+DIAGNOSTICSp. 755
Diagnostic Tipsp. 755
Diagnostic Notesp. 755
Test 3.19p. 757
+DTC B1134 (EFI), DTC 34 (CARB) 3.20p. 758
+GENERALp. 758
Starter Output Highp. 758
+DIAGNOSTICSp. 758
Diagnostic Notesp. 758
Test 3.20p. 760
+DTC B1151/ B1152/ B1153 (EFI), DTC 51/52/53 (CARB) 3.21p. 761
+GENERALp. 761
Sidecar BAS Low (DTC B1151/DTC 51), High (DTC B1152/DTC 52) or Out of Range (DTC B1153/DTC 53)p. 761
+DIAGNOSTICSp. 761
Diagnostic Tipsp. 761
Diagnostic Notesp. 761
Test 3.21p. 763
+DTC B1135 (EFI), DTC 35 (CARB) 3.22p. 765
+GENERALp. 765
Accelerometer Faultp. 765
+DTC U1016 (EFI), DTC 14/24/33/43 (CARB) 3.23p. 766
+GENERALp. 766
Loss of ECM Serial Datap. 766
+DIAGNOSTICSp. 766
Diagnostic Notesp. 766
Test 3.23p. 768
+TSM/TSSM 3.24p. 769
REMOVAL/INSTALLATIONp. 769
+PASSWORD LEARNINGp. 769
Using Scanalyzerp. 769
Without Scanalyzerp. 769
+TSSM MAINTENANCE 3.25p. 772
GENERALp. 772
+KEY FOBp. 772
Schedulep. 772
Battery Replacementp. 772
+SIREN (IF INSTALLED)p. 773
Schedulep. 773
Battery Replacementp. 773
+4 – ENGINE MANAGEMENT (CARB)p. 775
SPECIFICATIONS 4.1p. 777
+DIAGNOSTIC INTRODUCTION 4.2p. 778
+SYSTEM PROBLEMSp. 778
No Startp. 778
Poor Performancep. 778
Check Engine Lampp. 778
RESOLVING PROBLEMSp. 778
+CHECKING FOR TROUBLE CODES 4.3p. 779
CHECK ENGINE LAMPp. 779
+CODE TYPESp. 780
Currentp. 780
Historicp. 780
Functionalp. 780
RETRIEVING TROUBLE CODESp. 780
MULTIPLE TROUBLE CODESp. 780
+SCANALYZER: CARB 4.4p. 781
+SCANALYZER DIAGNOSTICSp. 781
Scanalyzer Cartridgep. 781
INSTALLATIONp. 781
+USAGEp. 783
Checking/Clearing Trouble Codesp. 783
REMOVALp. 783
+CHECK ENGINE LAMP DIAGNOSTICS: CARB 4.5p. 784
+BREAKOUT BOX: CARB 4.6p. 786
GENERALp. 786
INSTALLATIONp. 786
REMOVALp. 786
+WIGGLE TEST 4.7p. 787
GENERALp. 787
+PROCEDUREp. 787
Using Scanalyzer (Part No. HD-41325)p. 787
Using DVOM (Part No. HD-39978)p. 787
+INITIAL DIAGNOSTIC CHECK 4.8p. 788
+GENERALp. 788
Diagnostic Notesp. 788
Scanalyzer Iconp. 788
Circuit Diagram/Connector Location Tablep. 788
Job/Time Code Valuesp. 788
+INITIAL DIAGNOSTICSp. 788
Generalp. 788
Diagnostic Tipsp. 788
Diagnostic Notesp. 788
Diagnostic Check (Part 1 of 2)p. 791
Diagnostic Check (Part 2 of 2)p. 792
+NO CHECK ENGINE LAMP AT KEY ON 4.9p. 793
GENERALp. 793
+DIAGNOSTICSp. 793
Diagnostic Tipsp. 793
Diagnostic Notesp. 793
Test 4.9p. 795
+CHECK ENGINE LAMP ON CONTINUOUSLY 4.10p. 796
GENERALp. 796
+DIAGNOSTICSp. 796
Diagnostic Notesp. 796
Test 4.10p. 798
+ENGINE CRANKS, BUT WILL NOT START 4.11p. 799
GENERALp. 799
+DIAGNOSTICSp. 799
Diagnostic Notesp. 799
Test 4.11 (Part 1 of 3)p. 801
Test 4.11 (Part 2 of 3)p. 802
Test 4.11 (Part 3 of 3)p. 803
+NO IGNITION MODULE POWER 4.12p. 804
+GENERALp. 804
No Spark/No Check Engine Lamp At Key ONp. 804
+DIAGNOSTICSp. 804
Diagnostic Notesp. 804
Test 4.12p. 805
+MISFIRE 4.13p. 806
+GENERALp. 806
Misfire at Idle or Under Loadp. 806
+DIAGNOSTICSp. 806
Diagnostic Notesp. 806
Test 4.13p. 808
+DTC 12 4.14p. 809
+GENERALp. 809
+DIAGNOSTICSp. 809
Diagnostic Tipsp. 809
Diagnostic Notesp. 809
Scanalyzer Notesp. 809
Test 4.14p. 811
+DTC 16 4.15p. 812
+GENERALp. 812
+DIAGNOSTICSp. 812
Scanalyzer Notesp. 812
Diagnostic Notesp. 812
Test 4.15 (Part 1 of 2)p. 814
Test 4.15 (Part 2 of 2)p. 815
+DTC 24, 25 4.16p. 816
+GENERALp. 816
Front Ignition Coil (DTC 24) and Rear Ignition Coil (DTC 25)p. 816
+DIAGNOSTICSp. 816
Diagnostic Notesp. 816
Scanalyzer Notesp. 816
Test 4.16p. 818
+DTC 35 4.17p. 819
+GENERALp. 819
Tachometer: All Except FLHRp. 819
+DIAGNOSTICSp. 819
Diagnostic Notesp. 819
Test 4.17p. 820
+DTC 41 4.18p. 821
+GENERALp. 821
Crank Position Sensorp. 821
+DIAGNOSTICSp. 821
Diagnostic Notesp. 821
Test 4.18p. 823
+DTC 44 4.19p. 824
+GENERALp. 824
+DIAGNOSTICSp. 824
Diagnostic Notesp. 824
Test 4.19 (Part 1 of 2)p. 825
Test 4.19 (Part 2 of 2)p. 826
+DTC 52, 53, 54, 55 4.20p. 827
+GENERALp. 827
Ignition Module Failurep. 827
+IGNITION COIL 4.21p. 828
+TROUBLESHOOTINGp. 828
Ignition Coil Primary Circuit Testp. 828
Ignition Coil Secondary Circuit Testp. 828
Test Resultsp. 828
Ignition Coil Substitutionp. 828
+5 – ENGINE MANAGEMENT (EFI)p. 829
SPECIFICATIONS 5.1p. 831
+EFI SYSTEM 5.2p. 833
GENERALp. 833
TROUBLESHOOTINGp. 833
+EFI DIAGNOSTIC INTRODUCTION 5.3p. 835
+SYSTEM PROBLEMSp. 835
No Startp. 835
Poor Performancep. 835
Check Engine Lampp. 835
RESOLVING PROBLEMSp. 835
+CHECKING FOR TROUBLE CODES: EFI 5.4p. 836
CHECK ENGINE LAMPp. 836
+CODE TYPESp. 837
Currentp. 837
Historicp. 837
RETRIEVING TROUBLE CODESp. 837
MULTIPLE TROUBLE CODESp. 837
+SCANALYZER: EFI 5.5p. 838
+SCANALYZER DIAGNOSTICSp. 838
Scanalyzer Cartridgep. 838
INSTALLATIONp. 838
+USAGEp. 840
Checking/Clearing Trouble Codesp. 840
REMOVALp. 840
+CHECK ENGINE LAMP DIAGNOSTICS: EFI 5.6p. 841
GENERALp. 841
ACTIVATIONp. 841
+BREAKOUT BOX: EFI 5.7p. 843
GENERALp. 843
INSTALLATIONp. 843
REMOVALp. 843
+WIGGLE TEST 5.8p. 844
GENERALp. 844
+PROCEDUREp. 844
Using Scanalyzer (HD-41325)p. 844
Using DVOM (HD-39978)p. 844
+INITIAL DIAGNOSTIC CHECK: EFI 5.9p. 845
+GENERALp. 845
Diagnostic Notesp. 845
Scanalyzer Iconp. 845
Circuit Diagram/Connector Location Tablep. 845
Job/Time Code Valuesp. 845
+INITIAL DIAGNOSTICSp. 845
Generalp. 845
Diagnostic Tipsp. 845
Diagnostic Notesp. 845
Other Codesp. 845
Diagnostic Check (Part 1 of 2)p. 851
Diagnostic Check (Part 2 of 2)p. 852
+NO CHECK ENGINE LAMP AT KEY ON 5.10p. 853
+GENERALp. 853
Diagnostic Trouble Codes P1652, P1651p. 853
+DIAGNOSTICSp. 853
Diagnostic Tipsp. 853
Diagnostic Notesp. 853
Test 5.10p. 855
+CHECK ENGINE LAMP ON CONTINUOUSLY 5.11p. 856
+GENERALp. 856
Diagnostic Trouble Code P1651p. 856
+DIAGNOSTICSp. 856
Diagnostic Notesp. 856
Test 5.11p. 858
+ENGINE CRANKS, BUT WILL NOT START 5.12p. 859
GENERALp. 859
+DIAGNOSTICSp. 859
Diagnostic Notesp. 859
Diagnostic Tipp. 859
Test 5.12 (Part 1 of 4)p. 861
Test 5.12 (Part 2 of 4)p. 862
Test 5.12 (Part 3 of 4)p. 863
Test 5.12 (Part 4 of 4)p. 864
+NO ECM POWER 5.13p. 865
+GENERALp. 865
No Spark/No Check Engine Lamp at Key ONp. 865
+DIAGNOSTICSp. 865
Diagnostic Notesp. 865
Diagnostic Tipp. 865
Test 5.13 (Part 1 of 2)p. 868
Test 5.13 (Part 2 of 2)p. 869
+STARTS, THEN STALLS 5.14p. 870
+GENERALp. 870
Diagnostic Trouble Codes U1300, U1301: Serial Data Failurep. 870
+DIAGNOSTICSp. 870
Diagnostic Tipsp. 870
Diagnostic Notesp. 870
Test 5.14 (Part 1 of 2)p. 872
Test 5.14 (Part 2 of 2)p. 873
+FUEL SYSTEM ELECTRICAL TEST 5.15p. 874
GENERALp. 874
+DIAGNOSTICSp. 874
Diagnostic Notesp. 874
Test 5.15 (Part 1 of 4)p. 876
Test 5.15 (Part 2 of 4)p. 877
Test 5.15 (Part 3 of 4)p. 878
Test 5.15 (Part 4 of 4)p. 878
+SYSTEM RELAY CHECK 5.16p. 879
+GENERALp. 879
+DIAGNOSTICSp. 879
Diagnostic Notesp. 879
Test 5.16 (Part 1 of 3)p. 882
Test 5.16 (Part 2 of 3)p. 883
Test 5.16 (Part 3 of 3)p. 883
+FUEL PRESSURE TEST 5.17p. 884
GENERALp. 884
TESTINGp. 884
+DIAGNOSTICSp. 886
Diagnostic Notesp. 886
Scanalyzer Notesp. 886
Test 5.17p. 887
+IDLE AIR CONTROL 5.18p. 888
+GENERALp. 888
IAC Operationp. 888
Diagnostic Trouble Code P0505: Loss of Idle Speed Controlp. 888
+DIAGNOSTICSp. 888
Diagnostic Tipsp. 888
Diagnostic Notesp. 889
Test 5.18 (Part 1 of 2)p. 891
Test 5.18 (Part 2 of 2)p. 892
+MISFIRE AT IDLE OR UNDER LOAD 5.19p. 893
+GENERALp. 893
Misfire at Idle or Under Loadp. 893
+DIAGNOSTICSp. 893
Diagnostic Notesp. 893
Test 5.19 (Part 1 of 3)p. 895
Test 5.19 (Part 2 of 3)p. 896
Test 5.19 (Part 3 of 3)p. 897
+COMBUSTION ABSENT/INTERMITTENT 5.20p. 898
+GENERALp. 898
Diagnostic Trouble Codes P1353, P1356, P1357, P1358: No Combustionp. 898
+DIAGNOSTICSp. 898
Diagnostic Notesp. 898
Test 5.20 (Part 1 of 2)p. 901
Test 5.20 (Part 2 of 2)p. 902
+DTC P0107, P0108 5.21p. 903
+GENERALp. 903
+DIAGNOSTICSp. 903
Diagnostic Tipsp. 903
Diagnostic Notesp. 903
Scanalyzer Notesp. 903
Test 5.21 (Part 1 of 2)p. 905
Test 5.21 (Part 2 of 2)p. 906
+DTC P0112, P0113 5.22p. 907
+GENERALp. 907
+DIAGNOSTICSp. 907
Diagnostic Tipsp. 907
Diagnostic Notesp. 907
Scanalyzer Notesp. 907
Test 5.22 (Part 1 of 2)p. 909
Test 5.22 (Part 2 of 2)p. 910
+DTC P0117, P0118 5.23p. 911
+GENERALp. 911
+DIAGNOSTICSp. 911
Diagnostic Tipsp. 911
Diagnostic Notesp. 911
Scanalyzer Notesp. 911
Test 5.23 (Part 1 of 2)p. 913
Test 5.23 (Part 2 of 2)p. 914
+DTC P0122, P0123 5.24p. 915
+GENERALp. 915
+DIAGNOSTICSp. 915
Diagnostic Tipsp. 915
Diagnostic Notesp. 915
Scanalyzer Notesp. 915
Test 5.24 (Part 1 of 2)p. 917
Test 5.24 (Part 2 of 2)p. 918
+DTC P0261, P0262, P0263, P0264 5.25p. 919
+GENERALp. 919
+DIAGNOSTICSp. 919
Diagnostic Notesp. 919
Test 5.25 (Part 1 of 3)p. 922
Test 5.25 (Part 2 of 3)p. 923
Test 5.25 (Part 3 of 3)p. 924
+DTC P0373, P0374 5.26p. 925
+GENERALp. 925
+DIAGNOSTICSp. 925
Diagnostic Tipsp. 925
Diagnostic Notesp. 925
Test 5.26p. 927
+DTC P0501, P0502 5.27p. 928
+GENERALp. 928
Vehicle Speed Sensorp. 928
+DIAGNOSTICSp. 928
Diagnostic Notesp. 928
Test 5.27 (Part 1 of 2)p. 931
Test 5.27 (Part 2 of 2)p. 932
+DTC P0562, P0563 5.28p. 933
+GENERALp. 933
+DIAGNOSTICSp. 933
Diagnostic Tipsp. 933
Scanalyzer Notesp. 933
Diagnostic Notesp. 933
Test 5.28 (Part 1 of 2)p. 936
Test 5.28 (Part 2 of 2)p. 937
+DTC P0603, P0605 5.29p. 938
+GENERALp. 938
+DIAGNOSTICSp. 938
DTC P0603 Testp. 938
DTC P0605 Testp. 938
+DTC P1009, P1010 5.30p. 939
+GENERALp. 939
+DIAGNOSTICSp. 939
Diagnostic Notesp. 939
Test 5.30p. 941
+DTC P1351, P1352, P1354, P1355 5.31p. 942
+GENERALp. 942
+DIAGNOSTICSp. 942
Diagnostic Notesp. 942
Test 5.31 (Part 1 of 2)p. 945
Test 5.31 (Part 2 of 2)p. 946
+DTC P1653, P1654 5.32p. 947
+GENERALp. 947
+DIAGNOSTICSp. 947
Diagnostic Notesp. 947
Test 5.32p. 949
+DTC U1016, U1064, U1255 5.33p. 950
+GENERALp. 950
Loss of TSM/TSSM or ECM Serial Datap. 950
+DIAGNOSTICSp. 950
Diagnostic Notesp. 950
Test 5.33 (Part 1 of 2)p. 952
Test 5.33 (Part 2 of 2)p. 953
+6 – PREMIUM SOUNDp. 955
+DIAGNOSTIC INTRODUCTION 6.1p. 957
+DIAGNOSTIC MODE OVERVIEW 6.2p. 958
GENERALp. 958
+DIAGNOSTIC MODE GROUP 1p. 959
GENERALp. 959
SAMPLE DIAGNOSTICp. 959
+DIAGNOSTIC MODE GROUP 2p. 960
GENERALp. 960
SAMPLE DIAGNOSTICp. 960
+BREAKOUT BOX 6.3p. 961
GENERALp. 961
INSTALLATIONp. 961
REMOVALp. 961
+RADIO SYMPTOM 1 6.4p. 962
+GENERALp. 962
Problemp. 962
Setupp. 962
Functionalityp. 962
+DIAGNOSTICSp. 962
Diagnostic Notesp. 962
Test 6.4 (Part 1 of 2)p. 963
Test 6.4 (Part 2 of 2)p. 964
+RADIO SYMPTOM 2 6.5p. 965
+GENERALp. 965
Problemp. 965
Setupp. 965
Functionalityp. 965
+DIAGNOSTICSp. 965
Diagnostic Notesp. 965
Test 6.5 (Part 1 of 4)p. 966
Test 6.5 (Part 2 of 4)p. 967
Test 6.5 (Part 3 of 4)p. 968
Test 6.5 (Part 4 of 4)p. 969
+RADIO SYMPTOM 3 6.6p. 970
+GENERALp. 970
Problemp. 970
Setupp. 970
Functionalityp. 970
+DIAGNOSTICSp. 970
Diagnostic Notesp. 970
Test 6.6 (Part 1 of 3)p. 971
Test 6.6 (Part 2 of 3)p. 972
Test 6.6 (Part 3 of 3)p. 973
+RADIO SYMPTOM 4 6.7p. 974
+GENERALp. 974
Problemp. 974
Setupp. 974
Functionalityp. 974
+DIAGNOSTICSp. 974
Automatic Volume Control (AVC) Adjustmentp. 974
Diagnostic Notesp. 975
Test 6.7 (Part 1 of 2)p. 975
Test 6.7 (Part 2 of 2)p. 976
+RADIO SYMPTOM 5 6.8p. 977
+GENERALp. 977
Problemp. 977
Setupp. 977
Functionalityp. 977
+DIAGNOSTICSp. 977
Radio Antenna Testp. 977
Test 6.8p. 977
+RADIO SYMPTOM 6 6.9p. 978
+GENERALp. 978
Problemp. 978
Setupp. 978
Functionalityp. 978
+DIAGNOSTICSp. 978
Diagnostic Notesp. 978
Test 6.9 (Part 1 of 2)p. 979
Test 6.9 (Part 2 of 2)p. 980
+RADIO SYMPTOM 7 6.10p. 981
+GENERALp. 981
Problemp. 981
Setupp. 981
Functionalityp. 981
+DIAGNOSTICSp. 981
Diagnostic Notesp. 981
Test 6.10 (Part 1 of 2)p. 982
Test 6.10 (Part 2 of 2)p. 983
+RADIO SYMPTOM 8 6.11p. 984
+GENERALp. 984
Problemp. 984
Setupp. 984
Functionalityp. 984
+DIAGNOSTICSp. 984
Diagnostic Notesp. 984
Test 6.11 (Part 1 of 2)p. 985
Test 6.11 (Part 2 of 2)p. 986
+RADIO SYMPTOM 9 6.12p. 987
+GENERALp. 987
Problemp. 987
Setupp. 987
Functionalityp. 987
+DIAGNOSTICSp. 987
Diagnostic Notesp. 987
Test 6.12 (Part 1 of 3)p. 988
Test 6.12 (Part 2 of 3)p. 989
Test 6.12 (Part 3 of 3)p. 990
+RADIO SYMPTOM 10 6.13p. 992
+GENERALp. 992
Problemp. 992
Setupp. 992
Functionalityp. 992
+DIAGNOSTICSp. 992
+RADIO SYMPTOM 11 6.14p. 994
+GENERALp. 994
Problemp. 994
Setupp. 994
Functionalityp. 994
+DIAGNOSTICSp. 994
Diagnostic Notesp. 994
Test 6.14p. 995
+RADIO SYMPTOM 12 6.15p. 997
+GENERALp. 997
Problemp. 997
Setupp. 997
Functionalityp. 997
+DIAGNOSTICSp. 997
Diagnostic Notesp. 997
Test 6.15 (Part 1 of 2)p. 998
Test 6.15 (Part 2 of 2)p. 999
CB Antenna Testp. 999
SWR Adjustmentp. 999
+RADIO SYMPTOM 13 6.16p. 1001
+GENERALp. 1001
Problemp. 1001
Setupp. 1001
Functionalityp. 1001
+DIAGNOSTICSp. 1001
Diagnostic Notesp. 1001
Test 6.16 (Part 1 of 2)p. 1002
Test 6.16 (Part 2 of 2)p. 1003
+RADIO SYMPTOM 14 6.17p. 1004
+GENERALp. 1004
Problemp. 1004
Setupp. 1004
Functionalityp. 1004
+DIAGNOSTICSp. 1004
Diagnostic Notesp. 1004
Test 6.17 (Part 1 of 2)p. 1005
Test 6.17 (Part 2 of 2)p. 1006
+RADIO SYMPTOM 15 6.18p. 1007
+GENERALp. 1007
Problemp. 1007
Setupp. 1007
Functionalityp. 1007
+DIAGNOSTICSp. 1007
Diagnostic Notesp. 1007
Test 6.18p. 1007
+7 – CRUISE CONTROLp. 1009
+CRUISE CONTROL 7.1p. 1011
GENERALp. 1011
OPERATIONp. 1011
TROUBLESHOOTINGp. 1012
+CRUISE INOPERATIVE DIAGNOSTICS 7.2p. 1013
GENERALp. 1013
+INOPERATIVE DIAGNOSTICSp. 1013
+CRUISE DROPOUT DIAGNOSTICS 7.3p. 1016
GENERALp. 1016
DROPOUT DIAGNOSTICSp. 1016
+CRUISE CHART A: INITIAL DIAGNOSTICS 7.4p. 1019
+DIAGNOSTICSp. 1019
Test 7.4 (Part 1 of 2)p. 1019
Test 7.4 (Part 2 of 2)p. 1020
+CRUISE CHART B: RESUME SWITCH 7.5p. 1021
+CRUISE CHART C: CRUISE ENGAGED LAMP 7.6p. 1022
+CRUISE CHART D: CRUISE POWER 7.7p. 1023
+CRUISE CHART E: CRUISE ENABLE 7.8p. 1025
+DIAGNOSTICSp. 1025
Test 7.8p. 1025
Diagnostic Notesp. 1025
+CRUISE CHART F-1: BRAKE LIGHTS ON 7.9p. 1026
+CRUISE CHART F-2: BRAKE LIGHTS OFF 7.10p. 1027
+DIAGNOSTICSp. 1027
Test 7.10 (Part 1 of 2)p. 1027
Test 7.10 (Part 2 of 2)p. 1028
Diagnostic Notesp. 1028
+CRUISE CHART G: THROTTLE SWITCH 7.11p. 1029
+CRUISE CHART H: SPEEDOMETER INPUT 7.12p. 1030
+DIAGNOSTICSp. 1030
Diagnostic Notesp. 1030
Test 7.12 (Part 1 of 2)p. 1030
Test 7.12 (Part 2 of 2)p. 1031
+CRUISE CHART I: TACHOMETER INPUT 7.13p. 1032
+8 – WIRINGp. 1033
ELECTRICAL CONNECTOR LOCATIONS 8.1p. 1035
WIRING DIAGRAMS 8.2p. 1047
+FLHRSEI2 SUPPLEMENT MANUALp. 1061
+1 – MAINTENANCEp. 1061
+SCHEDULED MAINTENANCE 1.1p. 1063
+SCHEDULED MAINTENANCE PROCEDURES 1.2p. 1068
CLUTCHp. 1068
CHECKING CLUTCH FLUID LEVELp. 1068
+ENGINE OIL FILTER 1.3p. 1069
+CRITICAL FASTENERS 1.4p. 1070
+2 – CHASSISp. 1073
SPECIFICATIONS 2.1p. 1075
TORQUE VALUES 2.2p. 1076
+VEHICLE IDENTIFICATION NUMBER (V.I.N.) 2.3p. 1078
+REAR WHEEL 2.4p. 1079
REMOVALp. 1079
Installationp. 1079
+REAR BRAKE PADS 2.5p. 1080
GENERALp. 1080
REPLACEMENTp. 1080
+FOOTBOARDS AND CONTROLS 2.6p. 1082
+RIDER FOOTBOARDSp. 1082
Removalp. 1082
Installationp. 1082
+SHIFT LEVERp. 1084
+REAR BRAKE PEDALp. 1084
+PASSENGER FOOTRESTSp. 1084
Removalp. 1084
Installationp. 1084
+FRONT AXLE COVERS 2.7p. 1085
+HEADLAMP NACELLE 2.8p. 1086
REMOVALp. 1086
FORK LOCKp. 1086
INSTALLATIONp. 1087
+LOWER TRIPLE CLAMP COVER 2.9p. 1088
+HANDLEBARS 2.10p. 1089
REMOVAL/REPLACEMENTp. 1089
HANDGRIPSp. 1092
ASSEMBLY/INSTALLATIONp. 1093
+THROTTLE CABLE 2.11p. 1097
+FRONT BRAKE LINE 2.12p. 1098
REMOVALp. 1098
INSTALLATIONp. 1098
+CLUTCH MASTER CYLINDER/RESERVOIR 2.13p. 1100
GENERALp. 1100
REMOVALp. 1101
DISASSEMBLYp. 1102
ASSEMBLYp. 1103
INSTALLATIONp. 1104
+CLUTCH HAND LEVER 2.14p. 1105
+CLUTCH FLUID LINE 2.15p. 1106
REPLACEMENTp. 1106
CLUTCH FLUID LINE ROUTINGp. 1108
BLEEDING CLUTCH FLUID LINEp. 1109
+REAR AIR SUSPENSION 2.16p. 1110
Generalp. 1110
ADJUSTMENTp. 1110
+WIND DEFLECTOR 2.17p. 1111
REMOVALp. 1111
DISASSEMBLY/CLEANINGp. 1111
ASSEMBLYp. 1111
INSTALLATIONp. 1111
+SEAT 2.18p. 1113
REMOVALp. 1113
CLEANING AND INSPECTIONp. 1113
INSTALLATIONp. 1113
+RIDER BACKREST 2.19p. 1114
ADJUSTMENTp. 1114
REMOVALp. 1114
INSTALLATIONp. 1114
+RELEASE HANDLE CABLEp. 1115
Removalp. 1115
Installationp. 1115
+BACKREST ASSEMBLYp. 1116
Removalp. 1116
Installationp. 1116
+PASSENGER BACKREST 2.20p. 1117
REMOVALp. 1117
INSTALLATIONp. 1118
+SADDLEBAG SUPPORTS 2.21p. 1119
REMOVALp. 1119
INSTALLATIONp. 1121
+REAR FENDER 2.22p. 1122
REMOVALp. 1122
INSTALLATIONp. 1123
+CLOISONNE 2.23p. 1124
Removalp. 1124
Installationp. 1124
+MUFFLER END CAP 2.24p. 1125
+3 – ENGINEp. 1127
SPECIFICATIONS 3.1p. 1129
MANUFACTURING TOLERANCES 3.2p. 1130
SERVICE WEAR LIMITS 3.3p. 1131
TORQUE VALUES 3.4p. 1133
+BREATHER ASSEMBLY 3.5p. 1134
REMOVALp. 1134
DISASSEMBLYp. 1134
CLEANING AND INSPECTIONp. 1134
ASSEMBLYp. 1134
INSTALLATIONp. 1134
+ROCKER HOUSING 3.6p. 1135
VALVE SPRING TO ROCKER HOUSING CLEARANCEp. 1135
+HEAD BOLT COVERS 3.7p. 1138
+CYLINDER HEADS 3.8p. 1139
+PISTONS 3.9p. 1140
+BORING AND HONING CYLINDERS 3.10p. 1141
CYLINDER BORE FINISHED SIZEp. 1141
+CAMS AND TIMING MARKS 3.11p. 1142
+FLYWHEEL/CONNECTING ROD ASSEMBLY 3.12p. 1143
Generalp. 1143
Sprocket Shaft Bearing Inner Race Replacementp. 1143
+OIL VENT LINE 3.13p. 1146
+OIL COOLER OPERATION 3.14p. 1147
+GENERALp. 1147
Partially Open Thermostatp. 1149
Fully Open Thermostatp. 1149
+OIL COOLER 3.15p. 1150
REMOVALp. 1150
INSTALLATIONp. 1150
+OIL FILTER MOUNT 3.16p. 1151
REMOVALp. 1151
DISASSEMBLYp. 1151
ASSEMBLYp. 1152
INSTALLATIONp. 1152
+THERMOSTAT 3.17p. 1153
TEST PROCEDUREp. 1153
REMOVALp. 1153
INSTALLATIONp. 1153
4 – FUEL SYSTEMp. 1155
+5 – ELECTRIC STARTERp. 1157
SPECIFICATIONS 5.1p. 1159
TORQUE VALUES 5.2p. 1160
+6 – DRIVEp. 1163
SPECIFICATIONS 6.1p. 1165
TORQUE VALUES 6.2p. 1166
+CLUTCH RELEASE BEARING 6.3p. 1167
REMOVALp. 1167
INSTALLATIONp. 1167
+7 – TRANSMISSIONp. 1169
SPECIFICATIONS 7.1p. 1171
SERVICE WEAR LIMITS 7.2p. 1172
TORQUE VALUES 7.3p. 1173
+CLUTCH RELEASE COVER 7.4p. 1174
REMOVALp. 1174
INSTALLATIONp. 1175
+SECONDARY CLUTCH ACTUATOR 7.5p. 1176
+8 – ELECTRICALp. 1177
TORQUE VALUES 8.1p. 1179
+INSTRUMENT CONSOLE 8.2p. 1180
REMOVALp. 1180
INSTALLATIONp. 1180
SPEEDOMETERp. 1182
IGNITION SWITCHp. 1182
LED INDICATOR LIGHTSp. 1182
+FUEL GAUGE WIRE ROUTINGp. 1183
Pulling Gauge Wiresp. 1183
Threading Gauge Wiresp. 1183
+TURN SIGNALS 8.3p. 1184
BULB REPLACEMENTp. 1184
+FRONT TURN SIGNAL LAMPSp. 1184
Removalp. 1184
Installationp. 1186
+REAR TURN SIGNAL BARp. 1187
Removalp. 1187
Installationp. 1187
+TACHOMETER 8.4p. 1188
REMOVALp. 1188
INSTALLATIONp. 1189
9 – FUEL INJECTIONp. 1191
Chapters Covered
- Service Manual – Maintenance: troubleshooting, shop practices, tool safety, scheduled maintenance table and scheduled maintenance procedures.
- Service Manual – Chassis: specifications; front and rear wheels; rim runout, wheel lacing and truing; tires and tubes; vehicle alignment; front and rear brake master cylinders and calipers; hydraulic brake bleeding; front forks; steering head bearings; rear air suspension and shock absorbers; swingarm; cables and handlebars; seat, saddlebags, Tour-Pak, fairings, fenders, jiffy stand and exhaust system.
- Service Manual – Engine: specifications and manufacturing tolerances; service wear limits; service preparation; engine removal and installation; top-end overhaul; bottom-end overhaul; breather, rocker arms, push rods, lifters, cylinder head, cylinder, piston, connecting rod, cam support plate, oil pump, crankcase and flywheel/connecting-rod assembly.
- Service Manual – Fuel System: specifications, fuel-system troubleshooting, enrichener, carburetor, air cleaner, vacuum-operated fuel valve, fuel tank and evaporative-emissions control system.
- Service Manual – Electric Starter: specifications, starter system, starter relay, starter, starter solenoid and starter jackshaft.
- Service Manual – Drive: specifications, primary chain and sprockets, clutch, secondary drive belt and sprockets and primary chaincase.
- Service Manual – Transmission: specifications, transmission power flow, shifter linkage, shifter cam and forks, clutch release cover, mainshaft/countershaft, main drive gear and transmission case/oil pan.
- Service Manual – Electrical: electrical specifications and bulb chart; ignition module, engine sensors, ignition coil, spark plugs and cables; alternator/stator, voltage regulator and battery; headlamps and other lighting; turn-signal/security module; ignition switch, fairing and handlebar switches; stoplight and neutral switches; horn, gauges and instruments; cruise control; premium sound; wiring harnesses and cables.
- Service Manual – Fuel Injection: EFI specifications, electrical bracket assembly, sensors, fuel-injected fuel tank and induction module assembly.
- Electrical Diagnostics – Starting/Charging: starter troubleshooting, starting-system diagnosis, starter activation circuits, diagnostic tests, assembled-starter testing, charging-system diagnosis and battery load testing.
- Electrical Diagnostics – Instruments: gauges and instruments, speedometer diagnosis and speedometer performance checks.
- Electrical Diagnostics – TSM/TSSM: module overview and features, vehicle delivery, turn-signal and bank-angle functions, security-system operation, arming/disarming, trouble-code checks, breakout-box and Scanalyzer procedures, initial diagnostic checks, security-lamp faults, key-fob signal issues, turn-signal errors and TSSM maintenance.
- Electrical Diagnostics – Engine Management (Carb): specifications, diagnostic introduction, trouble-code retrieval, Scanalyzer, check-engine-lamp diagnosis, breakout box, wiggle test, initial checks, no-start and misfire diagnosis, ignition-module power checks, DTC procedures and ignition-coil testing.
- Electrical Diagnostics – Engine Management (EFI): EFI system overview, diagnostic introduction, trouble codes, Scanalyzer, check-engine-lamp diagnosis, breakout box and wiggle test, initial checks, no-start and no-ECM-power conditions, starts-then-stalls, fuel-system electrical testing, system relay, fuel pressure, idle air control, misfire/combustion diagnosis and extensive P- and U-code procedures.
- Electrical Diagnostics – Premium Sound: diagnostic mode, breakout-box use and symptom-driven diagnosis for audio controls, mode control, speakers, AVC, stereo reception, power, CD eject, headsets, microphone, intercom, CB receiver/transmitter and PTT/squelch functions.
- Electrical Diagnostics – Cruise Control: system operation, cruise-inoperative and cruise-dropout diagnosis, plus diagnostic charts for resume, engaged lamp, power, enable, brake-light inputs, throttle switch, speedometer input and tachometer input.
- Electrical Diagnostics – Wiring: electrical connector locations and wiring diagrams for main and interconnect harnesses, ignition and engine-sensor circuits, engine management, lighting, starting/charging, handlebar controls, instruments, radio/audio and applicable sidecar circuits.
- FLHRSEI2-specific material: dedicated maintenance, chassis, engine, fuel-system, starter, drive, transmission and electrical sections that identify information unique to FLHRSEI2 and refer back to the Touring Models Service Manual where the standard procedure applies.
Together, these chapters provide a working path from routine service through major mechanical repair and electrical fault isolation. Mechanical procedures are supported by exploded views, assembly sequences, torque values, clearances, service limits and special-tool references. The electrical diagnostics portion is organized around symptoms, circuit checks and trouble codes, with flow-chart style procedures for starting, charging, security, carbureted ignition management and EFI operation. The wiring section adds full harness schematics and connector-location information, allowing circuit tracing to be performed alongside the diagnostic procedures rather than treating wiring as a separate reference.
Maintenance, Mechanical Repair and Adjustment Data
The maintenance material includes engine oil and filter service, primary-chain inspection and lubrication, clutch adjustment, transmission lubricant service, tire and wheel checks, steering-head service, brake fluid and brake-pad inspection, drive-belt adjustment, air-cleaner service, carbureted fuel-tank filter work, throttle cable procedures, spark-plug service, idle-speed checks, critical fastener inspection and road-test guidance. Numeric data is given at the point of use: for example, primary-chain free play is separated into hot and cold values, transmission and primary-chaincase capacities are stated, and critical fastener tables collect chassis and engine-mount torques.
For larger repairs, the chassis and engine chapters show removal, inspection, disassembly, assembly and installation sequences for systems such as wheels and bearings, brake master cylinders and calipers, forks, steering, rear suspension, swingarm, engine assemblies, cylinder heads, pistons, cam drive, oil pump and crankcase. Transmission and drive chapters cover the clutch, primary drive, belt drive, shifter system, shafts, gears and transmission case. The 2003 Harley-Davidson FLT Touring Service & Electrical Diagnostics Manuals 99483-03A / 99497-03 therefore supports both scheduled service and component-level overhaul work rather than functioning as a simple owner’s maintenance guide.
Electrical Diagnosis, DTCs and Wiring
The companion Electrical Diagnostics manual is especially valuable when a problem cannot be solved by visual inspection alone. It includes starter and charging tests, instrument checks, TSM/TSSM security and turn-signal diagnosis, carbureted engine-management fault procedures, EFI sensor and actuator diagnosis, premium-sound troubleshooting and cruise-control charts. EFI coverage includes check-engine-lamp procedures, fuel-pressure testing, relay checks, idle-air-control diagnosis and numerous DTC-specific test paths. The wiring chapter then identifies connector locations and supplies model-group schematics for the main harness, interconnect harness, ignition harness, engine-sensor harness, engine-management circuitry, lighting, starting and charging, controls, instruments and audio systems.
Instant PDF Reference for 2003 FLT Touring Service Work
Use this manual set when you need to maintain, diagnose, adjust, disassemble or rebuild the systems covered on 2003 Harley-Davidson FLT Touring models using the procedures, specifications, service limits, torque values, diagnostic charts and wiring information contained in the document. Correct values and ordered procedures matter on jobs ranging from routine fluid service and belt adjustment to engine overhaul, brake repair, EFI diagnosis and harness fault tracing. The 2003 Harley-Davidson FLT Touring Service & Electrical Diagnostics Manuals 99483-03A / 99497-03 is delivered as an instant PDF after payment, with no physical shipping required; it can be viewed on compatible phones, tablets and computers and printed as needed for workshop reference.
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