2003 Harley Davidson Softail Models Electrical Diagnostics + Service Manual – PDF DOWNLOAD
IMAGES PREVIEW OF THE MANUAL:
2003 Harley Davidson Softail Models Electrical Diagnostics + Service Manual2003 Harley Davidson Softail Models Electrical Diagnostics + Service Manual
DESCRIPTION:
2003 Harley Davidson Softail Models Electrical Diagnostics + Service Manual – PDF DOWNLOAD
SERVICE MANUAL
Part Number 99482-03
ELECTRICAL DIAGNOSTICS
Part Number 99498-03
GENERAL SERVICING A NEW MOTORCYCLE
Service operations to be performed before customer delivery are specified in the applicable model year PREDELIVERY AND SETUP MANUAL.
The performance of new motorcycle initial service is required to keep warranty in force and to ensure proper emissions systems operation. See FIRST SCHEDULED MAINTENANCE under 1.3 MAINTENANCE SCHEDULE for details.
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. Protect yourself and bystanders with approved eye protection. 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.
TABLE OF CONTENTS:
2003 Harley Davidson Softail Models Electrical Diagnostics + Service Manual – PDF DOWNLOAD
KEYWORD SEARCH................................................................................. 0
CONTENTS....................................................................................... 1
MAIN SERVICE MANUAL............................................................................ 2
1 - MAINTENANCE............................................................................ 2
GENERAL 1.1............................................................................ 4
SERVICING A NEW MOTORCYCLE......................................................... 4
SAFE OPERATING MAINTENANCE......................................................... 4
SHOP PRACTICES..................................................................... 4
Repair Notes................................................................... 4
Safety......................................................................... 4
Removing Parts................................................................. 4
Cleaning....................................................................... 4
Disassembly and Assembly....................................................... 5
REPAIR AND REPLACEMENT PROCEDURES.................................................. 5
Hardware and Threaded Parts.................................................... 5
Wiring, Hoses and Lines........................................................ 5
Instruments and Gauges......................................................... 5
Bearings....................................................................... 5
Bushings....................................................................... 5
Gaskets........................................................................ 5
Lip Type Seals................................................................. 5
O-Rings (Preformed Packings)................................................... 5
Gears.......................................................................... 5
Shafts......................................................................... 5
Part Replacement............................................................... 5
CLEANING........................................................................... 6
Part Protection................................................................ 6
Cleaning Process............................................................... 6
Rust or Corrosion Removal...................................................... 6
TOOL SAFETY........................................................................ 6
Air Tools...................................................................... 6
Wrenches....................................................................... 6
Pliers/cutters/prybars......................................................... 6
Hammers........................................................................ 6
Punches/chisels................................................................ 6
Screwdrivers................................................................... 6
Ratchets and Handles........................................................... 7
Sockets........................................................................ 7
Storage Units.................................................................. 7
FUEL AND OIL 1.2....................................................................... 8
FUEL............................................................................... 8
GASOLINE BLENDS.................................................................... 8
ENGINE OIL......................................................................... 8
WINTER LUBRICATION................................................................. 8
MAINTENANCE SCHEDULE 1.3............................................................... 9
FIRST SCHEDULED MAINTENANCE........................................................ 9
ENGINE OIL AND FILTER 1.4.............................................................. 14
CHECKING AND ADDING OIL............................................................ 14
Type of Oil.................................................................... 14
Checking Oil Level............................................................. 14
CHANGING OIL AND FILTER............................................................ 15
BATTERY MAINTENANCE 1.5................................................................ 16
GENERAL............................................................................ 16
DISCONNECTION AND REMOVAL.......................................................... 17
INSTALLATION AND CONNECTION........................................................ 17
INSPECTION......................................................................... 18
STORAGE............................................................................ 18
BRAKES 1.6............................................................................. 19
FLUID INSPECTION................................................................... 19
REAR BRAKE PEDAL................................................................... 20
Pedal Height................................................................... 20
Pedal Lubrication.............................................................. 20
BLEEDING BRAKES 1.7.................................................................... 21
GENERAL............................................................................ 21
PROCEDURE.......................................................................... 21
BRAKE PADS AND DISCS 1.8............................................................... 22
INSPECTION......................................................................... 22
Brake Pads..................................................................... 22
Brake Disc Thickness........................................................... 22
Brake Disc Lateral Runout and Warpage.......................................... 22
BRAKE PAD REPLACEMENT.............................................................. 23
Rear Brake Caliper............................................................. 23
Front Brake Caliper: All But FLSTS/FXSTS....................................... 25
TIRES AND WHEELS 1.9................................................................... 26
TIRES.............................................................................. 26
TIRE REPLACEMENT................................................................... 27
WHEEL BEARINGS..................................................................... 27
WHEEL SPOKES....................................................................... 27
PRIMARY CHAIN 1.10..................................................................... 28
INSPECTION......................................................................... 28
PRIMARY CHAINCASE LUBRICANT 1.11....................................................... 29
CHANGING LUBRICANT................................................................. 29
CLUTCH 1.12............................................................................ 31
ADJUSTMENT......................................................................... 31
TRANSMISSION LUBRICANT 1.13............................................................ 33
CHANGING LUBRICANT................................................................. 33
REAR BELT DEFLECTION 1.14.............................................................. 34
INSPECTION......................................................................... 34
REAR BELT AND SPROCKETS 1.15........................................................... 35
GENERAL............................................................................ 35
CLEANING........................................................................... 35
INSPECTION......................................................................... 35
Sprockets...................................................................... 35
Rear Belt...................................................................... 35
SUSPENSION ADJUSTMENTS 1.16............................................................ 37
REAR SHOCK PRELOAD................................................................. 37
STEERING HEAD BEARINGS: ALL BUT FLSTS/FXSTS 1.17....................................... 38
ADJUSTMENT......................................................................... 38
Bearing Adjustment (Fall-away)................................................. 38
LUBRICATION........................................................................ 38
STEERING HEAD BEARINGS: FLSTS/FXSTS 1.18............................................... 39
GENERAL............................................................................ 39
Lubrication.................................................................... 39
Special Tool Fabrication....................................................... 39
FLSTS MODELS....................................................................... 40
FXSTS MODELS....................................................................... 40
ROCKER BEARINGS: FLSTS/FXSTS 1.19...................................................... 42
INSPECTION......................................................................... 42
FRONT FORK OIL 1.20.................................................................... 44
REPLACING FORK OIL................................................................. 44
SPARK PLUGS 1.21....................................................................... 46
INSPECTION......................................................................... 46
AIR CLEANER FILTER 1.22................................................................ 47
REMOVAL............................................................................ 47
INSTALLATION....................................................................... 48
CABLE AND CHASSIS LUBRICATION 1.23..................................................... 49
GENERAL............................................................................ 49
CABLES AND HAND LEVERS............................................................. 49
FOOT SHIFT LEVER................................................................... 49
JIFFY STAND........................................................................ 49
THROTTLE CABLES 1.24................................................................... 50
CABLE INSPECTION, LUBRICATION AND ADJUSTMENT....................................... 50
Inspection and Lubrication..................................................... 50
Adjustment..................................................................... 51
ENRICHENER: CARBURETED 1.25............................................................ 52
IDLE SPEED AND IGNITION TIMING: CARBURETED 1.26........................................ 53
IDLE SPEED INSPECTION.............................................................. 53
IGNITION TIMING.................................................................... 53
FUEL SUPPLY VALVE FILTER: CARBURETED 1.27.............................................. 54
INSPECTION......................................................................... 54
FUEL SYSTEM LINES AND FITTINGS..................................................... 55
ENGINE MOUNTS 1.28..................................................................... 56
INSPECTION......................................................................... 56
HEADLAMP ALIGNMENT 1.29................................................................ 57
INSPECTION......................................................................... 57
ADJUSTMENT......................................................................... 58
FLSTS/FXSTS Models............................................................. 58
FLSTC/FLSTF/FXSTB/FXST MODELS.................................................. 58
FXSTD MODELS................................................................... 58
CRITICAL FASTENERS 1.30................................................................ 59
INSPECTION......................................................................... 59
STORAGE 1.31........................................................................... 60
GENERAL............................................................................ 60
REMOVAL FROM STORAGE............................................................... 61
TROUBLESHOOTING 1.32................................................................... 62
GENERAL............................................................................ 62
ENGINE............................................................................. 62
Starter Motor Does Not Operate or Does Not Turn Engine Over.................... 62
Engine Turns Over But Does Not Start........................................... 62
Starts Hard.................................................................... 62
Starts But Runs Irregularly or Misses.......................................... 62
A Spark Plug Fouls Repeatedly.................................................. 63
Pre-Ignition or Detonation (Knocks or Pings)................................... 63
Overheating.................................................................... 63
Valve Train Noise.............................................................. 63
Excessive Vibration............................................................ 63
Check Engine Light Illuminates During Operation................................ 63
LUBRICATION SYSTEM................................................................. 63
Oil Does Not Return To Oil Tank................................................ 63
Engine Uses Too Much Oil Or Smokes Excessively................................. 63
Engine Leaks Oil From Cases, Push Rods, Hoses, Etc............................. 63
Low Oil Pressure............................................................... 64
High Oil Pressure.............................................................. 64
ELECTRICAL SYSTEM.................................................................. 64
Alternator Does Not Charge..................................................... 64
Alternator Charge Rate Is Below Normal......................................... 64
Speedometer Operates Erratically............................................... 64
CARBURETOR......................................................................... 64
Floods......................................................................... 64
TRANSMISSION....................................................................... 64
Shifts Hard.................................................................... 64
Jumps Out Of Gear.............................................................. 64
Clutch Slips................................................................... 64
Clutch Drags Or Does Not Release............................................... 64
Clutch Chatters................................................................ 64
HANDLING........................................................................... 65
Irregularities................................................................. 65
BRAKES............................................................................. 65
Brake Does Not Hold Normally................................................... 65
2 - CHASSIS................................................................................ 66
SPECIFICATIONS 2.1..................................................................... 68
TORQUE VALUES 2.2...................................................................... 69
TIRES.............................................................................. 72
VEHICLE IDENTIFICATION NUMBER 2.3...................................................... 73
GENERAL............................................................................ 73
FRONT WHEEL: FXST/FLSTC/FLSTF/FXSTB 2.4................................................ 74
REMOVAL............................................................................ 74
DISASSEMBLY........................................................................ 74
Disc Wheel..................................................................... 74
Laced Wheel.................................................................... 74
CLEANING AND INSPECTION............................................................ 76
ASSEMBLY........................................................................... 76
Disc Wheel..................................................................... 76
Laced Wheel.................................................................... 76
INSTALLATION....................................................................... 76
FXST, FLSTC, FLSTF, FXSTB Models............................................... 76
FRONT WHEEL: FXSTD 2.5................................................................. 77
REMOVAL............................................................................ 77
DISASSEMBLY........................................................................ 77
CLEANING AND INSPECTION............................................................ 77
ASSEMBLY........................................................................... 78
INSTALLATION....................................................................... 78
FRONT WHEEL: FLSTS 2.6................................................................. 79
REMOVAL............................................................................ 79
DISASSEMBLY........................................................................ 79
CLEANING AND INSPECTION............................................................ 79
ASSEMBLY........................................................................... 79
INSTALLATION....................................................................... 81
FRONT WHEEL: FXSTS 2.7................................................................. 82
REMOVAL............................................................................ 82
DISASSEMBLY........................................................................ 82
CLEANING AND INSPECTION............................................................ 82
ASSEMBLY........................................................................... 82
INSTALLATION....................................................................... 84
REAR WHEEL 2.8......................................................................... 85
REMOVAL............................................................................ 85
DISASSEMBLY........................................................................ 85
CLEANING AND INSPECTION............................................................ 87
ASSEMBLY........................................................................... 87
INSTALLATION....................................................................... 87
SEALED WHEEL BEARINGS 2.9.............................................................. 88
INSPECTION......................................................................... 88
REMOVAL............................................................................ 88
INSTALLATION....................................................................... 89
WHEEL LACING: 16 IN. RIM 2.10.......................................................... 90
GENERAL............................................................................ 90
PROCEDURE.......................................................................... 90
WHEEL LACING: 21 IN. RIM 2.11.......................................................... 92
PROCEDURE.......................................................................... 92
TRUING LACED WHEEL 2.12................................................................ 94
GENERAL............................................................................ 94
LATERAL TRUING..................................................................... 94
RADIAL TRUING...................................................................... 95
DISC RIM RUNOUT 2.13................................................................... 96
GENERAL............................................................................ 96
LATERAL RUNOUT..................................................................... 96
RADIAL RUNOUT...................................................................... 96
TIRES 2.14............................................................................. 97
GENERAL............................................................................ 97
REMOVAL............................................................................ 97
CLEANING AND INSPECTION............................................................ 97
INSTALLATION....................................................................... 98
CHECKING TIRE RUNOUT............................................................... 99
Radial Runout.................................................................. 99
Lateral Runout................................................................. 99
WHEEL BALANCING....................................................................100
VEHICLE ALIGNMENT 2.15.................................................................101
INSPECTION.........................................................................101
FRONT BRAKE MASTER CYLINDER 2.16.......................................................102
GENERAL............................................................................102
REMOVAL/DISASSEMBLY................................................................102
CLEANING AND INSPECTION............................................................104
ASSEMBLY/INSTALLATION..............................................................104
REAR BRAKE MASTER CYLINDER/RESERVOIR 2.17..............................................106
REMOVAL............................................................................106
INSTALLATION.......................................................................106
DISASSEMBLY........................................................................109
CLEANING AND INSPECTION............................................................110
ASSEMBLY...........................................................................110
FRONT BRAKE CALIPER: ALL BUT FLSTS/FXSTS 2.18..........................................112
REMOVAL............................................................................112
DISASSEMBLY........................................................................112
CLEANING, INSPECTION AND REPAIR....................................................114
ASSEMBLY...........................................................................114
INSTALLATION.......................................................................115
FRONT BRAKE CALIPER: FLSTS 2.19........................................................117
FRONT BRAKE CALIPER................................................................117
Removal........................................................................117
Installation...................................................................117
BRAKE REACTION LINK................................................................119
Removal........................................................................119
Installation...................................................................119
FRONT BRAKE CALIPER: FXSTS 2.20........................................................120
REMOVAL............................................................................120
INSTALLATION.......................................................................121
DISASSEMBLY........................................................................122
CLEANING AND INSPECTION............................................................122
ASSEMBLY...........................................................................123
REAR BRAKE CALIPER 2.21................................................................124
REMOVAL............................................................................124
DISASSEMBLY........................................................................124
CLEANING, INSPECTION AND REPAIR....................................................126
ASSEMBLY...........................................................................126
INSTALLATION.......................................................................127
FRONT FORKS: ALL BUT FLSTS/FXSTS 2.22..................................................128
GENERAL............................................................................128
REMOVAL............................................................................128
DISASSEMBLY........................................................................128
CLEANING AND INSPECTION............................................................128
ASSEMBLY...........................................................................132
INSTALLATION.......................................................................132
SPRINGER FORK: FLSTS/FXSTS 2.23........................................................133
GENERAL............................................................................133
HANDLEBAR AND RISERS...............................................................133
Removal........................................................................133
Installation...................................................................133
FRONT SHOCK ABSORBER...............................................................135
Removal........................................................................135
Installation...................................................................135
RIGID FORK.........................................................................136
Removal........................................................................136
Installation...................................................................136
SPRING FORK........................................................................137
Disassembly....................................................................137
Assembly.......................................................................139
FORK ROCKERS.......................................................................141
Removal........................................................................141
Installation...................................................................141
FORK STEM BEARINGS.................................................................142
Removal/Installation...........................................................142
STEERING HEAD 2.24.....................................................................143
REMOVAL............................................................................143
FLSTC, FLSTF Models............................................................143
FXSTD, FXST, FXSTB Models......................................................143
FLSTS, FXSTS Models............................................................144
CLEANING AND INSPECTION............................................................144
All Models.....................................................................144
DISASSEMBLY........................................................................144
Removing Lower Bearings From Fork Stem.........................................144
Steering Head Bearing Race Removal.............................................145
ASSEMBLY...........................................................................145
INSTALLATION.......................................................................146
FLSTC, FLSTF Models............................................................146
FXSTD, FXST, FXSTB Models......................................................146
FLSTS, FXSTS Models............................................................146
REAR FORK 2.25.........................................................................147
REMOVAL............................................................................147
CLEANING AND INSPECTION............................................................147
INSTALLATION.......................................................................148
REAR SHOCK ABSORBERS 2.26..............................................................149
GENERAL............................................................................149
REMOVAL............................................................................149
INSTALLATION.......................................................................149
THROTTLE CONTROL 2.27..................................................................150
REMOVAL/DISASSEMBLY................................................................150
CLEANING AND INSPECTION............................................................150
ASSEMBLY/INSTALLATION..............................................................150
CABLE ROUTING......................................................................151
All Models Except FLSTS/FXSTS/FXSTD............................................151
FXSTS Models...................................................................151
FLSTS Models...................................................................151
FXSTD Models...................................................................151
CLUTCH HAND CONTROL 2.28...............................................................152
REMOVAL............................................................................152
INSTALLATION.......................................................................152
FRONT FENDER: ALL BUT FLSTS/FXSTS 2.29.................................................153
FXST, FXSTB MODELS.................................................................153
Removal........................................................................153
Installation...................................................................153
FLSTC MODELS.......................................................................153
Removal........................................................................153
Installation...................................................................153
FLSTF MODELS.......................................................................153
Removal........................................................................153
Installation...................................................................153
FXSTD Models.......................................................................154
Removal........................................................................154
Installation...................................................................154
FRONT FENDER: FLSTS 2.30...............................................................155
REMOVAL............................................................................155
Front Fender...................................................................155
Front Fender Bearing Replacement...............................................155
INSTALLATION.......................................................................156
FRONT FENDER: FXSTS 2.31...............................................................157
REMOVAL............................................................................157
INSTALLATION.......................................................................158
REAR FENDER: ALL BUT FXSTD/FLSTS 2.32..................................................159
REMOVAL............................................................................159
FXST, FXSTS and FXSTB..........................................................159
FLSTC..........................................................................160
FLSTF..........................................................................160
WIRE CONDUIT REPLACEMENT...........................................................161
INSTALLATION.......................................................................162
REAR FENDER: FXSTD 2.33................................................................163
REMOVAL............................................................................163
DISASSEMBLY........................................................................163
ASSEMBLY...........................................................................164
INSTALLATION.......................................................................164
REAR FENDER: FLSTS 2.34................................................................165
REMOVAL............................................................................165
INSTALLATION.......................................................................165
BELT GUARD/DEBRIS DEFLECTOR 2.35.......................................................166
REMOVAL............................................................................166
Belt Guard.....................................................................166
Debris Deflector...............................................................166
INSTALLATION.......................................................................166
Belt Guard.....................................................................166
Debris Deflector...............................................................166
JIFFY STAND 2.36.......................................................................167
CLEANING...........................................................................167
REMOVAL............................................................................168
INSTALLATION.......................................................................168
FORK LOCK 2.37.........................................................................169
REMOVAL............................................................................169
INSTALLATION.......................................................................169
SEAT/STRAP RETENTION NUT 2.38..........................................................170
REPLACEMENT........................................................................170
SEAT: FXST/FXSTB/FXSTS 2.39............................................................171
REMOVAL/INSTALLATION...............................................................171
Seat Strap.....................................................................171
Seat...........................................................................171
SEAT: FLSTF/FLSTC 2.40.................................................................172
REMOVAL/INSTALLATION...............................................................172
Seat...........................................................................172
Sissy Bar: FLSTC Models........................................................172
SEAT: FLSTS 2.41.......................................................................173
REMOVAL/INSTALLATION...............................................................173
SEAT: FXSTD 2.42.......................................................................174
REMOVAL/INSTALLATION...............................................................174
SADDLEBAGS: FLSTC 2.43.................................................................175
REMOVAL............................................................................175
INSTALLATION.......................................................................175
SADDLEBAGS: FLSTS 2.44.................................................................176
REMOVAL............................................................................176
INSTALLATION.......................................................................176
WINDSHIELD: FLSTC 2.45.................................................................177
REMOVAL............................................................................177
INSTALLATION.......................................................................177
3 - ENGINE.................................................................................178
SPECIFICATIONS 3.1.....................................................................180
ENGINE TORQUE VALUES 3.2...............................................................182
SERVICE WEAR LIMITS 3.3................................................................183
GENERAL............................................................................183
ENGINE OIL FLOW 3.4....................................................................185
OIL FEED...........................................................................185
TOP END............................................................................186
BOTTOM END.........................................................................186
CHAIN GUIDE BRACKET................................................................190
OIL RETURN.........................................................................190
OIL PUMP OPERATION 3.5.................................................................191
GENERAL............................................................................191
OPERATION..........................................................................191
BREATHER OPERATION 3.6.................................................................192
GENERAL............................................................................192
OIL PRESSURE 3.7.......................................................................193
OIL PRESSURE INDICATOR LAMP........................................................193
CHECKING OIL PRESSURE..............................................................193
HOW TO USE THIS SECTION 3.8............................................................194
TOP END REPAIR.....................................................................194
BOTTOM END REPAIR..................................................................194
TYPICAL SYMPTOMS...................................................................194
TOP END SERVICE 3.9....................................................................195
ENGINE IN CHASSIS..................................................................195
ENGINE REMOVED FROM CHASSIS........................................................196
BOTTOM END SERVICE 3.10................................................................197
ENGINE IN CHASSIS: CAM COMPARTMENT SERVICE.........................................197
ENGINE REMOVED: FLYWHEEL COMPARTMENT SERVICE OR COMPLETE ENGINE OVERHAUL...........198
TROUBLESHOOTING 3.11...................................................................199
DIAGNOSING VALVE TRAIN NOISE.......................................................199
COMPRESSION TEST...................................................................199
CYLINDER LEAKAGE TEST..............................................................200
DIAGNOSING SMOKING ENGINE OR HIGH OIL CONSUMPTION..................................200
Check Prior To Cylinder Head Removal...........................................200
Check After Cylinder Head Removal..............................................200
STRIPPING MOTORCYCLE FOR SERVICE 3.12..................................................201
PROCEDURE..........................................................................201
ASSEMBLING MOTORCYCLE AFTER SERVICE 3.13...............................................202
PROCEDURE..........................................................................202
REMOVING ENGINE FROM CHASSIS 3.14......................................................203
PROCEDURE..........................................................................203
INSTALLING ENGINE IN CHASSIS 3.15......................................................204
PROCEDURE..........................................................................204
TOP END OVERHAUL: DISASSEMBLY 3.16.....................................................206
GENERAL............................................................................206
BREATHER ASSEMBLY..................................................................206
ROCKER ARM SUPPORT PLATE...........................................................207
PUSHRODS, LIFTERS AND COVERS.......................................................208
CYLINDER HEAD......................................................................208
CYLINDER...........................................................................209
PISTON.............................................................................210
TOP END OVERHAUL: ASSEMBLY 3.17........................................................211
GENERAL............................................................................211
PISTON.............................................................................211
CYLINDER...........................................................................212
CYLINDER HEAD......................................................................214
PUSHRODS, LIFTERS AND COVERS.......................................................217
ROCKER ARM SUPPORT PLATE...........................................................218
BREATHER ASSEMBLY..................................................................219
BOTTOM END OVERHAUL: DISASSEMBLY 3.18..................................................220
GENERAL............................................................................220
COVER AND CAM SUPPORT PLATE........................................................220
CRANKCASE..........................................................................223
COUNTERBALANCER ASSEMBLY...........................................................224
BOTTOM END OVERHAUL: ASSEMBLY 3.19.....................................................227
GENERAL............................................................................227
COUNTERBALANCER ASSEMBLY...........................................................227
CRANKCASE..........................................................................230
COVER AND CAM SUPPORT PLATE........................................................234
BREATHER ASSEMBLY 3.20.................................................................240
REMOVAL OVERVIEW...................................................................240
DISASSEMBLY........................................................................240
INSPECTION.........................................................................240
ASSEMBLY...........................................................................240
INSTALLATION OVERVIEW..............................................................240
ROCKER ARM SUPPORT PLATE 3.21..........................................................241
REMOVAL OVERVIEW...................................................................241
DISASSEMBLY........................................................................241
CLEANING AND INSPECTION............................................................241
ASSEMBLY...........................................................................243
INSTALLATION OVERVIEW..............................................................243
PUSHRODS, LIFTERS AND COVERS 3.22......................................................244
REMOVAL OVERVIEW...................................................................244
DISASSEMBLY........................................................................244
CLEANING AND INSPECTION............................................................244
LIFTER INSPECTION..................................................................245
ASSEMBLY...........................................................................245
INSTALLATION OVERVIEW..............................................................245
CYLINDER HEAD 3.23.....................................................................246
REMOVAL OVERVIEW...................................................................246
DISASSEMBLY........................................................................246
CLEANING...........................................................................247
INSPECTION.........................................................................248
Cylinder Head..................................................................248
Valve Guides...................................................................248
Valves.........................................................................248
Valve Springs..................................................................248
Tapered Keepers................................................................249
Valve Seats....................................................................249
VALVE GUIDE REPLACEMENT............................................................249
Removal........................................................................249
Installation...................................................................250
VALVE AND SEAT REFACING............................................................253
ASSEMBLY...........................................................................256
INSTALLATION OVERVIEW..............................................................258
CYLINDER 3.24..........................................................................259
REMOVAL OVERVIEW...................................................................259
CLEANING...........................................................................259
INSPECTION.........................................................................260
DEGLAZING CYLINDER.................................................................261
BORING AND HONING CYLINDER.........................................................263
INSTALLATION OVERVIEW..............................................................263
PISTON 3.25............................................................................264
REMOVAL OVERVIEW...................................................................264
DISASSEMBLY........................................................................264
Piston Rings...................................................................264
CLEANING...........................................................................264
INSPECTION.........................................................................265
ASSEMBLY...........................................................................267
Piston Rings...................................................................267
INSTALLATION OVERVIEW..............................................................268
UPPER CONNECTING ROD 3.26..............................................................269
REMOVAL OVERVIEW...................................................................269
DISASSEMBLY/ASSEMBLY...............................................................269
Removing Upper Connecting Rod Bushing..........................................269
Installing Upper Connecting Rod Bushing........................................270
Reaming Upper Connecting Rod Bushing...........................................271
Honing Upper Connecting Rod Bushing............................................272
INSTALLATION OVERVIEW..............................................................272
COVER AND CAM SUPPORT PLATE 3.27.......................................................274
REMOVAL OVERVIEW...................................................................274
DISASSEMBLY/ASSEMBLY...............................................................275
CRANKSHAFT BUSHING.................................................................275
Removal........................................................................275
Installation...................................................................275
Reaming Crankshaft Bushing.....................................................276
CAMSHAFTS AND CAMSHAFT BEARINGS....................................................277
Removal........................................................................277
Installation...................................................................280
CAM CHAIN TENSIONERS...............................................................284
Removal........................................................................284
Installation...................................................................284
OIL PRESSURE RELIEF VALVE..........................................................285
Removal........................................................................285
Installation...................................................................285
CAM NEEDLE BEARINGS................................................................286
Removal........................................................................286
Installation...................................................................287
CLEANING AND INSPECTION............................................................288
INSTALLATION OVERVIEW..............................................................288
OIL PUMP 3.28..........................................................................289
REMOVAL OVERVIEW...................................................................289
CLEANING AND INSPECTION............................................................289
INSTALLATION OVERVIEW..............................................................290
CRANKCASE 3.29.........................................................................291
REMOVAL OVERVIEW...................................................................291
RIGHT CRANKCASE HALF...............................................................291
Chain Guide Screen.............................................................291
Crankshaft (Roller) Bearing....................................................291
Piston Jets....................................................................292
LEFT CRANKCASE HALF................................................................293
Crankshaft (Roller) Bearing....................................................293
CYLINDER STUDS.....................................................................295
Removal........................................................................295
Installation...................................................................295
PIPE PLUG AND OIL FITTINGS.........................................................295
Removal/Installation...........................................................295
CLEANING AND INSPECTION............................................................296
INSTALLATION OVERVIEW..............................................................296
COUNTERBALANCER ASSEMBLY 3.30..........................................................297
REMOVAL OVERVIEW...................................................................297
CLEANING, INSPECTION AND REPAIR....................................................297
General........................................................................297
Balance Shaft Support Bearings.................................................297
Front and Rear Balance Sprockets...............................................298
Hydraulic Tensioners...........................................................298
Chain Tensioner Guides.........................................................298
Chain Guide Bracket............................................................298
Balance Chain..................................................................298
INSTALLATION OVERVIEW..............................................................298
FLYWHEEL/CONNECTING ROD 3.31...........................................................299
REMOVAL OVERVIEW...................................................................299
INSPECTION.........................................................................299
INSTALLATION OVERVIEW..............................................................299
OIL TANK 3.32..........................................................................300
REMOVAL/DISASSEMBLY................................................................300
Oil Tank.......................................................................300
Oil Line Fittings/Retainers....................................................302
INSTALLATION.......................................................................303
4 - FUEL SYSTEM............................................................................304
SPECIFICATIONS 4.1.....................................................................306
TORQUE VALUES......................................................................306
FUEL SYSTEM TROUBLESHOOTING 4.2........................................................307
CARBURETOR.........................................................................307
VACUUM PISTON ASSEMBLY.............................................................309
ENRICHENER: CARBURETED 4.3.............................................................310
GENERAL............................................................................310
OPERATION..........................................................................310
Cool Engine....................................................................310
Warm Climate or Hot Engine.....................................................310
CARBURETOR 4.4.........................................................................311
REMOVAL............................................................................311
INSTALLATION.......................................................................313
DISASSEMBLY........................................................................313
Vacuum Piston Chamber..........................................................313
Carburetor Body................................................................313
Accelerator Pump...............................................................313
CLEANING AND INSPECTION............................................................314
Vacuum Piston Components.......................................................314
Carburetor Body Components.....................................................314
Float Replacement..............................................................314
Accelerator Pump...............................................................314
ASSEMBLY...........................................................................315
Vacuum Piston Chamber..........................................................315
Carburetor Body................................................................315
Accelerator Pump...............................................................315
CARBURETOR ADJUSTMENTS 4.5.............................................................316
OPERATION CHECK – VACUUM PISTON....................................................316
Opening Malfunction............................................................316
Closing Malfunction............................................................316
FLOAT BOWL.........................................................................316
Float Bowl Inlet (Needle) Valve Replacement....................................316
Float Level....................................................................317
FUEL SUPPLY VALVE: CARBURETED 4.6......................................................320
GENERAL............................................................................320
OPERATION..........................................................................320
REMOVAL, INSPECTION AND INSTALLATION...............................................320
TROUBLESHOOTING....................................................................320
Vacuum Test....................................................................321
FUEL TANK: CARBURETED 4.7..............................................................322
GENERAL............................................................................322
REMOVAL............................................................................322
All But FXSTD Models...........................................................322
FXSTD Models...................................................................323
CLEANING AND INSPECTION............................................................323
INSTALLATION.......................................................................326
All But FXSTD Models...........................................................326
FXSTD Models...................................................................326
VAPOR VALVE........................................................................327
AIR CLEANER: CARBURETED 4.8............................................................328
REMOVAL............................................................................328
INSTALLATION.......................................................................328
BACKPLATE ASSEMBLY- CALIFORNIA MODELS..............................................329
EXHAUST SYSTEM: ALL BUT FXSTD/FLSTF/FLSTS 4.9..........................................330
GENERAL............................................................................330
REMOVAL............................................................................330
INSTALLATION.......................................................................330
DISASSEMBLY........................................................................330
ASSEMBLY...........................................................................330
EXHAUST SYSTEM: FXSTD/FLSTF 4.10.......................................................332
REMOVAL............................................................................332
Mufflers Only..................................................................332
Exhaust System.................................................................332
INSTALLATION.......................................................................332
Mufflers Only..................................................................332
Exhaust System.................................................................332
EXHAUST SYSTEM: FLSTS 4.11.............................................................334
REMOVAL............................................................................334
INSTALLATION.......................................................................334
EVAPORATIVE EMISSIONS CONTROL: CA MODELS 4.12..........................................336
GENERAL............................................................................336
CHARCOAL CANISTER..................................................................338
Removal........................................................................338
Installation...................................................................338
HOSE ROUTING/REPLACEMENT...........................................................339
5 - ELECTRIC STARTER.......................................................................340
SPECIFICATIONS 5.1.....................................................................342
TORQUE VALUES......................................................................342
ELECTRIC STARTER SYSTEM 5.2............................................................343
GENERAL............................................................................343
Wiring Diagrams................................................................343
Starter Relay..................................................................343
OPERATION..........................................................................343
STARTER RELAY 5.3......................................................................347
REMOVAL............................................................................347
INSTALLATION.......................................................................347
STARTER 5.4............................................................................348
REMOVAL............................................................................348
INSTALLATION.......................................................................349
DISASSEMBLY, INSPECTION AND REPAIR.................................................350
ASSEMBLY...........................................................................353
STARTER SOLENOID 5.5...................................................................355
GENERAL............................................................................355
DISASSEMBLY........................................................................355
ASSEMBLY...........................................................................355
STARTER JACKSHAFT 5.6..................................................................356
REMOVAL/DISASSEMBLY................................................................356
ASSEMBLY/INSTALLATION..............................................................357
6 - DRIVE..................................................................................358
SPECIFICATIONS 6.1.....................................................................360
TORQUE VALUES......................................................................360
PRIMARY CHAINCASE 6.2..................................................................361
GENERAL............................................................................361
PRIMARY CHAINCASE COVER............................................................361
Removal........................................................................361
Installation...................................................................362
PRIMARY CHAINCASE HOUSING..........................................................362
Removal........................................................................362
Inspection And Repair..........................................................363
Mainshaft Bearing and Oil Seal.................................................363
Installation...................................................................364
DRIVE COMPONENTS 6.3...................................................................365
PRIMARY CHAIN AND COMPENSATING SPROCKET............................................365
Removal........................................................................365
Installation...................................................................366
Sprocket Alignment.............................................................368
CHAIN TENSIONER SHOE...............................................................368
CLUTCH 6.4.............................................................................369
REMOVAL/INSTALLATION...............................................................369
CLUTCH PACK ONLY...................................................................369
Partial Disassembly............................................................369
Assembly.......................................................................369
CLEANING AND INSPECTION............................................................371
CLUTCH PACK AND BEARING............................................................371
Complete Disassembly...........................................................371
Assembly.......................................................................372
TRANSMISSION SPROCKET 6.5..............................................................374
REMOVAL............................................................................374
CLEANING AND INSPECTION............................................................374
INSTALLATION.......................................................................374
DRIVE BELT 6.6.........................................................................376
REMOVAL............................................................................376
INSPECTION.........................................................................376
INSTALLATION.......................................................................377
7 - TRANSMISSION...........................................................................378
SPECIFICATIONS 7.1.....................................................................380
TORQUE VALUES......................................................................381
TRANSMISSION 7.2.......................................................................382
GENERAL............................................................................382
Neutral........................................................................382
1st Gear.......................................................................382
2nd Gear.......................................................................382
3rd Gear.......................................................................382
4th Gear.......................................................................382
5th Gear.......................................................................382
SHIFTER LINKAGE ADJUSTMENT.........................................................384
SHIFTER CAM ASSEMBLY 7.3...............................................................385
REMOVAL/DISASSEMBLY................................................................385
CLEANING AND INSPECTION............................................................387
ASSEMBLY/INSTALLATION..............................................................387
SHIFTER FORKS 7.4......................................................................389
REMOVAL............................................................................389
CLEANING AND INSPECTION............................................................389
INSTALLATION.......................................................................390
TRANSMISSION CLUTCH RELEASE COVER 7.5..................................................391
REMOVAL/DISASSEMBLY................................................................391
CLEANING AND INSPECTION............................................................392
ASSEMBLY/INSTALLATION..............................................................392
MAINSHAFT AND COUNTERSHAFT 7.6.........................................................394
REMOVAL............................................................................394
INSTALLATION.......................................................................395
DISASSEMBLY........................................................................396
CLEANING AND INSPECTION............................................................396
Replacing Side Door Bearings...................................................396
ASSEMBLY...........................................................................398
TRANSMISSION CASE 7.7..................................................................403
REMOVAL............................................................................403
General........................................................................403
Main Drive Gear and Bearing....................................................403
INSTALLATION.......................................................................403
Main Drive Gear and Bearing....................................................403
DISASSEMBLY........................................................................406
Shifter Arm Assembly...........................................................406
CLEANING AND INSPECTION............................................................406
ASSEMBLY...........................................................................407
Shifter Pawl/Lever Assembly....................................................407
8 - ELECTRICAL.............................................................................408
SPECIFICATIONS 8.1.....................................................................410
TORQUE VALUES......................................................................410
BULB REQUIREMENTS 8.2..................................................................412
GENERAL............................................................................412
IGNITION SYSTEM: CARBURETED MODELS 8.3.................................................413
GENERAL............................................................................413
TROUBLESHOOTING....................................................................413
ELECTRICAL PANEL 8.4...................................................................417
GENERAL............................................................................417
REMOVAL............................................................................417
INSTALLATION.......................................................................418
IGNITION MODULE 8.5....................................................................419
GENERAL............................................................................419
IGNITION TIMING....................................................................419
REMOVAL: ALL BUT FXSTD.............................................................419
REMOVAL: FXSTD.....................................................................420
INSTALLATION: ALL BUT FXSTD........................................................420
INSTALLATION: FXSTD................................................................420
BANK ANGLE SENSOR (BAS) 8.6............................................................421
GENERAL............................................................................421
OPERATION..........................................................................421
TESTING............................................................................421
REMOVAL/INSTALLATION...............................................................421
MANIFOLD ABSOLUTE PRESSURE SENSOR (MAP): CARBURETED MODELS 8.7.........................422
GENERAL............................................................................422
REMOVAL............................................................................422
INSTALLATION.......................................................................423
CRANK POSITION SENSOR (CKP) 8.8........................................................424
GENERAL............................................................................424
REMOVAL............................................................................424
INSTALLATION.......................................................................425
SPARK PLUG CABLES 8.9..................................................................426
GENERAL............................................................................426
REMOVAL............................................................................426
INSPECTION.........................................................................426
INSTALLATION.......................................................................426
IGNITION COIL 8.10.....................................................................427
REMOVAL............................................................................427
INSTALLATION.......................................................................427
FUSES 8.11.............................................................................428
GENERAL............................................................................428
REMOVAL............................................................................428
INSTALLATION.......................................................................428
RELAYS 8.12............................................................................429
GENERAL............................................................................429
REMOVAL............................................................................429
INSTALLATION.......................................................................429
MAIN CIRCUIT BREAKER 8.13..............................................................430
GENERAL............................................................................430
REMOVAL............................................................................430
INSTALLATION.......................................................................430
IGNITION/LIGHT SWITCH 8.14.............................................................431
GENERAL............................................................................431
REPLACEMENT........................................................................431
ALTERNATOR 8.15........................................................................432
REMOVAL/DISASSEMBLY................................................................432
CLEANING/INSPECTION................................................................432
ASSEMBLY/INSTALLATION..............................................................432
VOLTAGE REGULATOR 8.16.................................................................433
REMOVAL............................................................................433
INSTALLATION.......................................................................434
BATTERY 8.17...........................................................................436
BATTERY TESTING....................................................................436
General........................................................................436
Voltmeter Test.................................................................436
Load Test......................................................................436
CHARGING BATTERY...................................................................437
Safety Precautions.............................................................437
Using a Battery Charger........................................................437
BATTERY CABLES 8.18....................................................................439
ROUTING PROCEDURE..................................................................439
HEADLAMP 8.19..........................................................................440
GENERAL............................................................................440
REMOVAL/INSTALLATION...............................................................440
FXSTD, FXSTS and FLSTS Models..................................................440
FXST and FXSTB Models..........................................................440
FLSTC and FLSTF Models.........................................................440
TAIL LAMP: ALL BUT FXSTD/FLSTS 8.20....................................................442
GENERAL............................................................................442
BULB REPLACEMENT...................................................................442
BASE REPLACEMENT...................................................................442
TAIL LAMP: FXSTD 8.21..................................................................444
REMOVAL............................................................................444
INSTALLATION.......................................................................445
TAIL LAMP: FLSTS 8.22..................................................................446
BULB REPLACEMENT...................................................................446
TAIL LAMP REPLACEMENT..............................................................446
PASSING LAMPS: FLSTS 8.23..............................................................447
PASSING LAMP BRACKET...............................................................447
Removal........................................................................447
Installation...................................................................447
PASSING LAMPS......................................................................447
Removal........................................................................447
Installation...................................................................447
PASSING LAMPS: FLSTC 8.24..............................................................449
PASSING LAMP BRACKET...............................................................449
Removal........................................................................449
Installation...................................................................449
PASSING LAMPS......................................................................449
Removal........................................................................449
Installation...................................................................449
FRONT FENDER LAMP: FLSTS 8.25..........................................................451
REMOVAL............................................................................451
INSTALLATION.......................................................................451
TURN SIGNALS/RUNNING LIGHTS 8.26.......................................................452
BULB REPLACEMENT: ALL BUT FLSTC....................................................452
BULB REPLACEMENT: FLSTC............................................................452
LAMP REPLACEMENT...................................................................452
General........................................................................452
Front Turn Signals: All But FLSTC..............................................453
Rear Turn Signals: All But FXSTD...............................................453
Rear Turn Signals: FXSTD.......................................................453
TURN SIGNAL/TURN SIGNAL SECURITY MODULE 8.27...........................................456
GENERAL............................................................................456
REMOVAL/...........................................................................456
INSTALLATION.......................................................................456
TSM/TSSM Configuration.............................................................457
PASSWORD LEARNING..................................................................457
Using Scanalyzer/Digital Technician............................................457
Without Scanalyzer.............................................................457
TSM/TSSM KEY FOB AND CODE ASSIGNMENT 8.28..............................................459
GENERAL............................................................................459
USING SCANALYZER ON EFI MODELS.....................................................459
POWER DISRUPTION AND CONFIGURING...................................................459
KEY FOB ASSIGNMENT.................................................................460
PERSONAL CODE ENTRY................................................................460
First Time Code Entry: TSSM Only...............................................460
Modifying Existing Codes: TSSM Only............................................460
FUEL GAUGE: CARBURETED 8.29............................................................464
GENERAL............................................................................464
REMOVAL: ALL BUT FXSTD.............................................................464
INSTALLATION: ALL BUT FXSTD........................................................466
FUEL GAUGE REMOVAL: FXSTD..........................................................466
FUEL GAUGE INSTALLATION: FXSTD.....................................................466
FUEL GAUGE SENDER REMOVAL: FXSTD...................................................467
FUEL GAUGE SENDER INSTALLATION: FXSTD..............................................467
FUEL GAUGE: EFI 8.30...................................................................468
GENERAL............................................................................468
Removal............................................................................468
INSTALLATiON.......................................................................468
INSTRUMENT CONSOLE: FXSTD 8.31.........................................................469
REMOVAL............................................................................469
INSTALLATION.......................................................................469
SPEEDOMETER: ALL BUT FXSTD 8.32........................................................470
REMOVAL............................................................................470
INSTALLATION.......................................................................470
SPEEDOMETER: FXSTD 8.33................................................................471
REMOVAL............................................................................471
INSTALLATION.......................................................................471
VEHICLE SPEED SENSOR: VSS 8.34.........................................................473
GENERAL............................................................................473
REMOVAL............................................................................473
INSTALLATION.......................................................................473
INDICATOR LAMPS: All But FXSTD 8.35....................................................474
GENERAL............................................................................474
REMOVAL............................................................................474
INSTALLATION.......................................................................474
INDICATOR LAMPS: FXSTD 8.36............................................................475
GENERAL............................................................................475
REMOVAL............................................................................475
INSTALLATION.......................................................................475
NEUTRAL SWITCH 8.37....................................................................476
GENERAL............................................................................476
REMOVAL............................................................................476
INSTALLATION.......................................................................476
OIL PRESSURE SWITCH 8.38...............................................................477
GENERAL............................................................................477
REMOVAL............................................................................477
INSTALLATION.......................................................................477
REAR STOP LIGHT SWITCH 8.39............................................................478
GENERAL............................................................................478
REMOVAL............................................................................478
INSTALLATION.......................................................................478
HORN: ALL BUT FLSTS 8.40...............................................................479
INSPECTION.........................................................................479
REPLACEMENT........................................................................479
HORN: FLSTS 8.41.......................................................................480
INSPECTION.........................................................................480
REPLACEMENT........................................................................480
MAIN WIRING HARNESS 8.42...............................................................481
REMOVAL............................................................................481
INSTALLATION.......................................................................482
HANDLEBAR SWITCH ASSEMBLIES 8.43.......................................................484
GENERAL............................................................................484
REPAIR PROCEDURES..................................................................484
RIGHT HANDLEBAR SWITCH 8.44............................................................485
REMOVAL............................................................................485
INSTALLATION.......................................................................485
DISASSEMBLY........................................................................487
SWITCH REPAIR/REPLACEMENT..........................................................488
Upper Housing Repair...........................................................488
Lower Housing Repair...........................................................489
ASSEMBLY...........................................................................490
LEFT HANDLEBAR SWITCH 8.45.............................................................491
REMOVAL............................................................................491
INSTALLATION.......................................................................491
DISASSEMBLY........................................................................492
SWITCH REPAIR/REPLACEMENT..........................................................492
Upper Housing Repair...........................................................492
Lower Housing Repair...........................................................493
ASSEMBLY...........................................................................493
9 - FUEL INJECTION.........................................................................494
SPECIFICATIONS 9.1.....................................................................496
TORQUE VALUES......................................................................496
ELECTRONIC FUEL INJECTION (EFI) SYSTEM 9.2.............................................498
GENERAL............................................................................498
For Information on Related Topics See:.........................................498
TROUBLESHOOTING....................................................................498
IDLE SPEED: EFI 9.3....................................................................500
GENERAL............................................................................500
SCANALYZER.........................................................................500
Data Link Connector............................................................500
Scanalyzer Cartridge...........................................................500
INSTALLATION.......................................................................500
SETTING IDLE SPEED.................................................................500
AIR CLEANER: EFI 9.4...................................................................501
REMOVAL............................................................................501
INSTALLATION.......................................................................501
FUEL TANK: EFI 9.5.....................................................................502
GENERAL............................................................................502
REMOVAL............................................................................502
CLEANING AND INSPECTION............................................................506
INSTALLATION.......................................................................506
All But FXSTDI.................................................................506
FXSTDI.........................................................................507
ELECTRONIC CONTROL MODULE (ECM) 9.6....................................................508
GENERAL............................................................................508
REMOVAL............................................................................508
INSTALLATION.......................................................................508
THROTTLE POSITION SENSOR (TP) 9.7......................................................509
GENERAL............................................................................509
REMOVAL............................................................................509
INSTALLATION.......................................................................509
INTAKE AIR TEMPERATURE SENSOR (IAT) 9.8................................................510
GENERAL............................................................................510
REMOVAL............................................................................510
INSTALLATION.......................................................................510
ENGINE TEMPERATURE SENSOR (ET) 9.9.....................................................511
GENERAL............................................................................511
REMOVAL............................................................................511
INSTALLATION.......................................................................512
INDUCTION MODULE 9.10..................................................................513
GENERAL............................................................................513
REMOVAL............................................................................513
INSTALLATION.......................................................................514
IDLE AIR CONTROL (IAC) 9.11............................................................515
GENERAL............................................................................515
REMOVAL............................................................................515
INSTALLATION.......................................................................515
MANIFOLD ABSOLUTE PRESSURE SENSOR (MAP): EFI MODELS 9.12...............................516
GENERAL............................................................................516
REMOVAL............................................................................516
INSTALLATION.......................................................................516
FUEL INJECTORS 9.13....................................................................517
GENERAL............................................................................517
REMOVAL............................................................................517
INSTALLATION.......................................................................517
FUEL PUMP/FUEL GAUGE SENDING UNIT 9.14.................................................518
GENERAL............................................................................518
REMOVAL............................................................................518
DISASSEMBLY/ASSEMBLY...............................................................521
Fuel Filter....................................................................521
Regulator......................................................................521
Fuel Pump......................................................................522
Fuel Level Sending Unit........................................................523
Fuel Pump Module Connector/O-Ring..............................................523
Fuel Supply Check Valve/Tube...................................................524
INSTALLATION.......................................................................525
FUEL PRESSURE TEST 9.15................................................................526
GENERAL............................................................................526
TESTING............................................................................526
APPENDICES.................................................................................530
APPENDIX A - TOOLS.....................................................................531
APPENDIX B - WIRING....................................................................547
WIRING DIAGRAMS....................................................................566
APPENDIX C - METRIC CONVERSIONS........................................................609
ELECTRICAL DIAGNOSTICS MANUAL.................................................................. 2
1 - STARTING AND CHARGING..................................................................614
STARTER TROUBLESHOOTING 1.1............................................................616
STARTING SYSTEM DIAGNOSIS 1.2..........................................................618
DIAGNOSTICS........................................................................618
Diagnostic Notes...............................................................618
Starter Test 1.................................................................618
Starter Test 2: Solenoid Clicks................................................619
Starter Test 3: Relay Clicks...................................................619
Starter Test 4: Nothing Clicks.................................................620
Starter Test 5: Starter Spins, But Does Not Engage.............................621
Starter Test 6: Starter Stalls or Spins Too Slowly.............................621
STARTER ACTIVATION CIRCUITS 1.3........................................................622
DIAGNOSTICS/TROUBLESHOOTING 1.4........................................................623
GENERAL............................................................................623
VOLTAGE DROPS......................................................................623
STARTER SYSTEM TESTING 1.5.............................................................626
“ON-MOTORCYCLE” TESTS..............................................................626
Starter Relay Test.............................................................626
Starter Current Draw Test......................................................626
TESTING ASSEMBLED STARTER 1.6..........................................................627
FREE RUNNING CURRENT DRAW TEST.....................................................627
STARTER SOLENOID...................................................................627
SOLENOID PULL-IN TEST..............................................................628
SOLENOID HOLD-IN TEST..............................................................628
SOLENOID RETURN TEST...............................................................628
CHARGING SYSTEM 1.7....................................................................629
GENERAL............................................................................629
Alternator.....................................................................629
Voltage Regulator..............................................................629
TROUBLESHOOTING....................................................................629
Battery........................................................................629
Wiring.........................................................................629
Voltage Regulator Inspection...................................................629
Test 1.7 (Part 1 of 2).........................................................630
Test 1.7 (Part 2 of 2).........................................................631
TESTING............................................................................633
Milliampere Draw Test..........................................................633
Total Current Draw Test........................................................633
Current and Voltage Output Test................................................634
Voltage Output Test............................................................634
Stator Check...................................................................634
AC Output Check................................................................635
IGNITION COIL 1.8......................................................................636
TROUBLESHOOTING....................................................................636
Ignition Coil Primary Circuit Test.............................................636
Ignition Coil Secondary Circuit Test...........................................636
Test Results...................................................................636
Ignition Coil Substitution.....................................................636
BATTERY LOAD TEST 1.9..................................................................637
GENERAL............................................................................637
2 - INSTRUMENTS............................................................................638
FUEL GAUGE OPERATION 2.1...............................................................640
THEORY OF OPERATION................................................................640
FUEL GAUGE AND SENDER TEST.........................................................640
SPEEDOMETER 2.2........................................................................641
GENERAL............................................................................641
Reset Switch...................................................................641
Diagnostic Mode................................................................641
THEORY OF OPERATION................................................................642
DIAGNOSTICS........................................................................642
Diagnostic Notes...............................................................642
Speedometer Trouble Codes......................................................642
Speedometer Test 1.............................................................643
Speedometer Test 2A............................................................644
Speedometer Test 2B............................................................645
SPEEDOMETER PERFORMANCE CHECK 2.3......................................................647
GENERAL............................................................................647
TESTING............................................................................647
Speedometer Operation Test.....................................................647
Speedometer Needle Sweep Test..................................................648
Speedometer Sensor Test........................................................648
Tachometer Testing.............................................................648
INDICATOR LAMPS 2.4....................................................................649
GENERAL............................................................................649
DIAGNOSTICS........................................................................650
Oil Pressure or Neutral Indicator Will Not Function............................650
High Beam or R/L Turn Signal Indicator Will Not Function.......................650
3 - TSM & TSSM.............................................................................652
TSM/TSSM OVERVIEW 3.1..................................................................654
GENERAL............................................................................654
TROUBLESHOOTING....................................................................654
TSM/TSSM FEATURES 3.2..................................................................656
GENERAL............................................................................656
TURN SIGNAL FUNCTIONS..............................................................656
TSM/TSSM Features..............................................................656
BANK ANGLE FUNCTIONS...............................................................656
TSM/TSSM Features..............................................................656
SECURITY ALARM AND IMMOBILIZATION FUNCTIONS........................................656
TSSM Only Feature..............................................................656
TSM/TSSM VEHICLE DELIVERY 3.3..........................................................658
GENERAL............................................................................658
USING SCANALYZER ON EFI MODELS.....................................................658
SIDECAR CONFIGURATION..............................................................658
POWER DISRUPTION AND CONFIGURING...................................................658
KEY FOB ASSIGNMENT.................................................................659
PERSONAL CODE ENTRY................................................................659
First Time Code Entry: TSSM Only...............................................659
Modifying Existing Codes: TSSM Only............................................659
TSM/TSSM TURN SIGNAL FUNCTIONS 3.4.....................................................663
GENERAL............................................................................663
AUTOMATIC CANCELLATION.............................................................663
MANUAL CANCELLATION................................................................663
FOUR-WAY FLASHING..................................................................663
DIAGNOSTICS MODE...................................................................663
TSM/TSSM BANK ANGLE FUNCTION 3.5.......................................................664
GENERAL............................................................................664
OPERATION..........................................................................664
SECURITY SYSTEM (TSSM) FUNCTIONS 3.6...................................................665
GENERAL............................................................................665
Security System Operation......................................................665
Security System Options........................................................665
Differences By Market Specifications...........................................665
ALARM SENSITIVITY..................................................................665
Sensitivity....................................................................665
Transport Mode.................................................................665
AUTO-ARMING FUNCTION...............................................................666
STORAGE MODE.......................................................................666
ARMING/DISARMING SECURITY SYSTEM (TSSM) 3.7............................................669
GENERAL............................................................................669
SECURITY LAMP......................................................................669
USING KEY FOB......................................................................669
General........................................................................669
Arming the System..............................................................669
Disarming the System...........................................................669
Troubleshooting................................................................669
USING THE PERSONAL CODE............................................................670
General........................................................................670
Disarming the System...........................................................670
CHECKING FOR TROUBLE CODES: TSM/TSSM 3.8...............................................671
GENERAL............................................................................671
CODE TYPES.........................................................................671
Current........................................................................671
Historic.......................................................................671
TURN SIGNAL DIAGNOSTICS............................................................671
CHECKING FOR TROUBLE CODES: TSSM ONLY 3.9..............................................673
SECURITY LAMP......................................................................673
BREAKOUT BOX: TSM/TSSM 3.10............................................................675
GENERAL............................................................................675
INSTALLATION.......................................................................675
REMOVAL............................................................................675
SCANALYZER: EFI MODELS ONLY 3.11.......................................................676
SCANALYZER DIAGNOSTICS.............................................................676
General........................................................................676
Serial Data Connector..........................................................676
Scanalyzer Cartridge...........................................................676
INSTALLATION.......................................................................676
USAGE..............................................................................678
Checking Codes.................................................................678
Clearing Codes.................................................................678
REMOVAL............................................................................678
INITIAL DIAGNOSTIC CHECK: TSM/TSSM 3.12................................................679
GENERAL............................................................................679
Diagnostic Notes...............................................................679
Scanalyzer Icon................................................................679
Circuit Diagram/Wire Harness Connector Table...................................679
Job/Time Code Values...........................................................679
INITIAL DIAGNOSTICS................................................................679
Diagnostic Tips................................................................679
Diagnostic Notes...............................................................679
Multiple Trouble Codes.........................................................680
Diagnostic Check (Part 1 of 2).................................................682
Diagnostic Check (Part 2 of 2).................................................683
NO SECURITY LAMP AT KEY ON 3.13........................................................684
GENERAL............................................................................684
No TSSM Power..................................................................684
DIAGNOSTICS........................................................................684
Diagnostic Tips................................................................684
Diagnostic Notes...............................................................684
Test 3.13 (Part 1 of 3)........................................................686
Test 3.13 (Part 2 of 3)........................................................687
Test 3.13 (Part 3 of 3)........................................................688
SECURITY LAMP ON CONTINUOUSLY 3.14.....................................................689
GENERAL............................................................................689
DIAGNOSTICS........................................................................689
Diagnostic Notes...............................................................689
Test 3.14......................................................................691
KEY FOB SIGNAL TO TSSM WEAK OR FAILS 3.15..............................................692
GENERAL............................................................................692
DIAGNOSTICS........................................................................692
Diagnostic Tips................................................................692
Diagnostic Notes...............................................................692
Test 3.15......................................................................694
TURN SIGNAL ERRORS 3.16................................................................695
GENERAL............................................................................695
DIAGNOSTICS........................................................................695
Diagnostic Tips................................................................695
Diagnostic Notes: All Turn Signal Flow Charts..................................699
Turn Signal Error 1A...........................................................700
Turn Signal Error 1B...........................................................701
Turn Signal Error 1C...........................................................702
Turn Signal Error 2A...........................................................703
Turn Signal Error 2B...........................................................704
Turn Signal Error 2C...........................................................705
Turn Signal Error 3A...........................................................706
Turn Signal Error 3B...........................................................707
Turn Signal Error 3C...........................................................708
Turn Signal Error 3D...........................................................709
Turn Signal Error 4A...........................................................710
DTC B0563 3.17.........................................................................711
GENERAL............................................................................711
Battery Voltage High...........................................................711
DIAGNOSTICS........................................................................711
Diagnostic Tips................................................................711
Diagnostic Notes...............................................................711
DTC B1125 3.18.........................................................................712
GENERAL............................................................................712
Ignition Enable Output High....................................................712
DIAGNOSTICS........................................................................712
Diagnostic Tips................................................................712
Diagnostic Notes...............................................................712
Test 3.18......................................................................714
DTC B1131, B1132 3.19..................................................................715
GENERAL............................................................................715
Alarm Output Low (DTC B1131) or Alarm Output High (DTC B1132)..................715
DIAGNOSTICS........................................................................715
Diagnostic Tips................................................................715
Diagnostic Notes...............................................................715
Test 3.19......................................................................717
DTC B1134 3.20.........................................................................718
GENERAL............................................................................718
Starter Output High............................................................718
DIAGNOSTICS........................................................................718
Diagnostic Notes...............................................................718
Test 3.20......................................................................720
DTC B1135 3.21.........................................................................721
GENERAL............................................................................721
Accelerometer Fault............................................................721
DTC U1016, U1255 3.22..................................................................722
GENERAL............................................................................722
Loss of ECM Serial Data........................................................722
DIAGNOSTICS........................................................................722
Diagnostic Notes...............................................................722
Test 3.22......................................................................724
TSM/TSSM 3.23..........................................................................726
REMOVAL/INSTALLATION...............................................................726
PASSWORD LEARNING..................................................................726
Using Scanalyzer...............................................................726
Without Scanalyzer.............................................................726
TSSM MAINTENANCE 3.24..................................................................729
GENERAL............................................................................729
KEY FOB............................................................................729
Schedule.......................................................................729
Battery Replacement............................................................729
SIREN (IF INSTALLED)...............................................................730
Schedule.......................................................................730
Battery Replacement............................................................730
4 - ENGINE MANAGEMENT (CARBURETED).........................................................732
SPECIFICATIONS 4.1.....................................................................734
DIAGNOSTIC INTRODUCTION 4.2............................................................735
SYSTEM PROBLEMS....................................................................735
No Start.......................................................................735
Poor Performance...............................................................735
Check Engine Lamp..............................................................735
RESOLVING PROBLEMS.................................................................735
CHECKING FOR TROUBLE CODES 4.3.........................................................736
CHECK ENGINE LAMP..................................................................736
CODE TYPES.........................................................................737
Current........................................................................737
Historic.......................................................................737
Functional.....................................................................737
RETRIEVING TROUBLE CODES...........................................................737
MULTIPLE TROUBLE CODES.............................................................737
SCANALYZER 4.4.........................................................................738
SCANALYZER DIAGNOSTICS.............................................................738
Data Link Connector............................................................738
Scanalyzer Cartridge...........................................................738
INSTALLATION.......................................................................738
USAGE..............................................................................740
Checking Codes.................................................................740
Clearing Codes.................................................................740
REMOVAL............................................................................740
CHECK ENGINE LAMP DIAGNOSTICS 4.5......................................................741
ACTIVATION.........................................................................741
CLEARING CODES.....................................................................742
BREAKOUT BOX 4.6.......................................................................743
GENERAL............................................................................743
INSTALLATION.......................................................................743
REMOVAL............................................................................743
WIGGLE TEST 4.7........................................................................744
GENERAL............................................................................744
PROCEDURE..........................................................................744
Using Scanalyzer (Part No. HD-41325)...........................................744
Using DVOM (Part No. HD-39978).................................................744
INITIAL DIAGNOSTIC CHECK 4.8...........................................................745
GENERAL............................................................................745
Diagnostic Notes...............................................................745
Scanalyzer Icon................................................................745
Circuit Diagram/Wire Harness Connector Table...................................745
Job/Time Code Values...........................................................745
INITIAL DIAGNOSTICS................................................................745
General Information............................................................745
Diagnostic Tips................................................................745
Diagnostic Notes...............................................................745
All diagnostic codes are listed on page 4-13 in Table 4-5......................745
Other Codes....................................................................745
Diagnostic Check (Part 1 of 2).................................................748
Diagnostic Check (Part 2 of 2).................................................749
NO CHECK ENGINE LAMP AT KEY ON 4.9.....................................................750
GENERAL............................................................................750
DIAGNOSTICS........................................................................750
Diagnostic Tips................................................................750
Diagnostic Notes...............................................................750
Test 4.9.......................................................................752
CHECK ENGINE LAMP ON CONTINUOUSLY 4.10.................................................753
GENERAL............................................................................753
DIAGNOSTICS........................................................................753
Diagnostic Notes...............................................................753
Test 4.10......................................................................755
ENGINE CRANKS, BUT WILL NOT START 4.11.................................................756
GENERAL............................................................................756
DIAGNOSTICS........................................................................756
Diagnostic Notes...............................................................756
Test 4.11 (Part 1 of 3)........................................................758
Test 4.11 (Part 2 of 3)........................................................759
Test 4.11 (Part 3 of 3)........................................................760
NO SPARK/NO CHECK ENGINE LAMP AT KEY ON 4.12...........................................761
GENERAL............................................................................761
DIAGNOSTICS........................................................................761
Diagnostic Notes...............................................................761
Test 4.12......................................................................762
MISFIRE 4.13...........................................................................763
GENERAL............................................................................763
Misfire at Idle or Under Load..................................................763
DIAGNOSTICS........................................................................763
Diagnostic Notes...............................................................763
Test 4.13......................................................................765
DTC 12 4.14............................................................................766
GENERAL............................................................................766
MAP Sensor.....................................................................766
DIAGNOSTICS........................................................................766
Diagnostic Tips................................................................766
Diagnostic Notes...............................................................766
Scanalyzer Notes...............................................................766
Test 4.14 (Part 1 of 2)........................................................768
Test 4.14 (Part 2 of 2)........................................................769
DTC 16 4.15............................................................................770
GENERAL............................................................................770
Battery Voltage................................................................770
DIAGNOSTICS........................................................................770
Scanalyzer Notes...............................................................770
Diagnostic Notes...............................................................770
Test 4.15 (Part 1 of 2)........................................................771
Test 4.15 (Part 2 of 2)........................................................772
DTC 24, 25 4.16........................................................................773
GENERAL............................................................................773
Front Ignition Coil (DTC 24) and Rear Ignition Coil (DTC 25)...................773
DIAGNOSTICS........................................................................773
Diagnostic Notes...............................................................773
Scanalyzer Notes...............................................................773
Test 4.16......................................................................775
DTC 41 4.17............................................................................776
GENERAL............................................................................776
Crank Position Sensor..........................................................776
DIAGNOSTICS........................................................................776
Diagnostic Notes...............................................................776
Test 4.17......................................................................778
DTC 44 4.18............................................................................779
GENERAL............................................................................779
TSM/TSSM.......................................................................779
DIAGNOSTICS........................................................................779
Diagnostic Notes...............................................................779
Test 4.18 (Part 1 of 2)........................................................780
Test 4.18 (Part 2 of 2)........................................................781
DTC 52, 53, 54 AND 55 4.19.............................................................782
GENERAL............................................................................782
Ignition Module Failure........................................................782
5 - ENGINE MANAGEMENT (EFI)................................................................784
SPECIFICATIONS 5.1.....................................................................786
EFI SYSTEM 5.2.........................................................................788
GENERAL............................................................................788
TROUBLESHOOTING....................................................................788
EFI DIAGNOSTIC INTRODUCTION 5.3........................................................790
SYSTEM PROBLEMS....................................................................790
No Start.......................................................................790
Poor Performance...............................................................790
Check Engine Lamp..............................................................790
RESOLVING PROBLEMS.................................................................790
CHECKING FOR TROUBLE CODES: EFI 5.4....................................................791
CHECK ENGINE LAMP..................................................................791
CODE TYPES.........................................................................792
Current........................................................................792
Historic.......................................................................792
RETRIEVING TROUBLE CODES...........................................................792
MULTIPLE TROUBLE CODES.............................................................792
SCANALYZER: EFI 5.5....................................................................793
SCANALYZER DIAGNOSTICS.............................................................793
Serial Data Connector..........................................................793
Scanalyzer Cartridge...........................................................793
INSTALLATION.......................................................................793
USAGE..............................................................................795
Checking Codes.................................................................795
Clearing Codes.................................................................795
REMOVAL............................................................................795
CHECK ENGINE LAMP DIAGNOSTICS: EFI 5.6.................................................796
GENERAL............................................................................796
ACTIVATION.........................................................................796
CLEARING CODES.....................................................................797
BREAKOUT BOX: EFI 5.7..................................................................798
GENERAL............................................................................798
INSTALLATION.......................................................................798
REMOVAL............................................................................798
WIGGLE TEST 5.8........................................................................799
GENERAL............................................................................799
PROCEDURE..........................................................................799
Using Scanalyzer (Part No. HD-41325)...........................................799
Using DVOM (Part No. HD-39978).................................................799
INITIAL DIAGNOSTIC CHECK: EFI 5.9......................................................800
GENERAL............................................................................800
Diagnostic Notes...............................................................800
Scanalyzer Icon................................................................800
Circuit Diagram/Wire Harness Connector Table...................................800
Job/Time Code Values...........................................................800
INITIAL DIAGNOSTICS................................................................800
General Information............................................................800
Diagnostic Tips................................................................800
Diagnostic Notes...............................................................800
Other Codes....................................................................800
Diagnostic Check (Part 1 of 2).................................................807
Diagnostic Check (Part 2 of 2).................................................808
NO CHECK ENGINE LAMP AT KEY ON 5.10....................................................809
GENERAL............................................................................809
Diagnostic Trouble Codes P1651, P1652..........................................809
DIAGNOSTICS........................................................................809
Diagnostic Tips................................................................809
Diagnostic Notes...............................................................809
Test 5.10......................................................................811
CHECK ENGINE LAMP ON CONTINUOUSLY 5.11.................................................812
GENERAL............................................................................812
Diagnostic Trouble Code P1651..................................................812
DIAGNOSTICS........................................................................812
Diagnostic Notes...............................................................812
Test 5.11......................................................................814
ENGINE CRANKS, BUT WILL NOT START 5.12.................................................815
GENERAL............................................................................815
DIAGNOSTICS........................................................................815
Diagnostic Notes...............................................................815
Diagnostic Tips................................................................815
Test 5.12 (Part 1 of 4)........................................................817
Test 5.12 (Part 2 of 4)........................................................818
Test 5.12 (Part 3 of 4)........................................................819
Test 5.12 (Part 4 of 4)........................................................820
NO ECM POWER 5.13......................................................................821
GENERAL............................................................................821
No Spark/No Check Engine Lamp at Key ON........................................821
DIAGNOSTICS........................................................................821
Diagnostic Notes...............................................................821
Test 5.13 (Part 1 of 2)........................................................823
Test 5.13 (Part 2 of 2)........................................................824
STARTS, THEN STALLS 5.14...............................................................825
GENERAL............................................................................825
Diagnostic Trouble Codes U1300, U1301: Serial Data Failure.....................825
DIAGNOSTICS........................................................................825
Diagnostic Tips................................................................825
Diagnostic Notes...............................................................825
Test 5.14 (Part 1 of 2)........................................................827
Test 5.14 (Part 2 of 2)........................................................828
FUEL SYSTEM ELECTRICAL TEST 5.15.......................................................829
GENERAL............................................................................829
DIAGNOSTICS........................................................................829
Diagnostic Notes...............................................................829
Test 5.15 (Part 1 of 4)........................................................831
Test 5.15 (Part 2 of 4)........................................................832
Test 5.15 (Part 3 of 4)........................................................833
Test 5.15 (Part 4 of 4)........................................................833
SYSTEM RELAY CHECK 5.16................................................................834
GENERAL............................................................................834
System Relay...................................................................834
DIAGNOSTICS........................................................................834
Diagnostic Notes...............................................................834
Test 5.16 (Part 1 of 3)........................................................836
Test 5.16 (Part 2 of 3)........................................................837
Test 5.16 (Part 3 of 3)........................................................837
FUEL PRESSURE TEST 5.17................................................................838
GENERAL............................................................................838
TESTING............................................................................838
DIAGNOSTICS........................................................................840
Diagnostic Notes...............................................................840
Scanalyzer Notes...............................................................840
Test 5.17......................................................................841
IDLE AIR CONTROL 5.18..................................................................842
GENERAL............................................................................842
IAC Operation..................................................................842
Diagnostic Trouble Code P0505: Loss of Idle Speed Control......................842
DIAGNOSTICS........................................................................842
Diagnostic Tips................................................................842
Diagnostic Notes...............................................................843
Test 5.18 (Part 1 of 2)........................................................845
Test 5.18 (Part 2 of 2)........................................................846
MISFIRE AT IDLE OR UNDER LOAD 5.19.....................................................847
GENERAL............................................................................847
Misfire at Idle or Under Load..................................................847
DIAGNOSTICS........................................................................847
Diagnostic Notes...............................................................847
Test 5.19 (Part 1 of 3)........................................................849
Test 5.19 (Part 2 of 3)........................................................850
Test 5.19 (Part 3 of 3)........................................................851
COMBUSTION ABSENT/INTERMITTENT 5.20....................................................852
GENERAL............................................................................852
Diagnostic Trouble Codes P1353, P1356, P1357, P1358: No Combustion.............852
DIAGNOSTICS........................................................................852
Diagnostic Notes...............................................................852
Test 5.20 (Part 1 of 2)........................................................854
Test 5.20 (Part 2 of 2)........................................................855
DTC P0107, P0108 5.21..................................................................856
GENERAL............................................................................856
MAP Sensor.....................................................................856
DIAGNOSTICS........................................................................856
Diagnostic Tips................................................................856
Diagnostic Notes...............................................................856
Scanalyzer Notes...............................................................856
Test 5.21 (Part 1 of 2)........................................................858
Test 5.21 (Part 2 of 2)........................................................859
DTC P0112, P0113 5.22..................................................................860
GENERAL............................................................................860
IAT Sensor.....................................................................860
DIAGNOSTICS........................................................................860
Diagnostic Tips................................................................860
Diagnostic Notes...............................................................860
Scanalyzer Notes...............................................................860
Test 5.22 (Part 1 of 2)........................................................862
Test 5.22 (Part 2 of 2)........................................................863
DTC P0117, P0118 5.23..................................................................864
GENERAL............................................................................864
ET Sensor......................................................................864
DIAGNOSTICS........................................................................864
Diagnostic Tips................................................................864
Diagnostic Notes...............................................................864
Scanalyzer Notes...............................................................864
Test 5.23 (Part 1 of 2)........................................................866
Test 5.23 (Part 2 of 2)........................................................867
DTC P0122, P0123 5.24..................................................................868
GENERAL............................................................................868
TP Sensor......................................................................868
DIAGNOSTICS........................................................................868
Diagnostic Tips................................................................868
Diagnostic Notes...............................................................868
Scanalyzer Notes...............................................................868
Test 5.24 (Part 1 of 2)........................................................870
Test 5.24 (Part 2 of 2)........................................................871
DTC P0261, P0262, P0263, P0264 5.25....................................................872
GENERAL............................................................................872
Fuel Injectors.................................................................872
DIAGNOSTICS........................................................................872
Diagnostic Notes...............................................................872
Test 5.25 (Part 1 of 3)........................................................874
Test 5.25 (Part 2 of 3)........................................................875
Test 5.25 (Part 3 of 3)........................................................876
DTC P0373, P0374 5.26..................................................................877
GENERAL............................................................................877
CKP Sensor.....................................................................877
DIAGNOSTICS........................................................................877
Diagnostic Tips................................................................877
Diagnostic Notes...............................................................877
Test 5.26......................................................................879
DTC P0501, P0502 5.27..................................................................880
GENERAL............................................................................880
Vehicle Speed Sensor...........................................................880
DIAGNOSTICS........................................................................880
Diagnostic Notes...............................................................880
Test 5.27 (Part 1 of 2)........................................................882
Test 5.27 (Part 2 of 2)........................................................883
DTC P0562, P0563 5.28..................................................................884
GENERAL............................................................................884
Battery Voltage................................................................884
DIAGNOSTICS........................................................................884
Diagnostic Tips................................................................884
Scanalyzer Notes...............................................................884
Diagnostic Notes...............................................................884
Test 5.28 (Part 1 of 2)........................................................886
Test 5.28 (Part 2 of 2)........................................................887
DTC P0603, P0605 5.29..................................................................888
GENERAL............................................................................888
ECM Failure....................................................................888
DIAGNOSTICS........................................................................888
DTC P0603 Test.................................................................888
DTC P0605 Test.................................................................888
DTC P1009, P1010 5.30..................................................................889
GENERAL............................................................................889
Password Problem...............................................................889
DIAGNOSTICS........................................................................889
Diagnostic Notes...............................................................889
Test 5.30......................................................................891
DTC P1351, P1352, P1354, P1355 5.31....................................................892
GENERAL............................................................................892
Ignition Coil..................................................................892
DIAGNOSTICS........................................................................892
Diagnostic Notes...............................................................892
Test 5.31 (Part 1 of 2)........................................................894
Test 5.31 (Part 2 of 2)........................................................895
DTC P1653, P1654 5.32..................................................................896
GENERAL............................................................................896
Tachometer.....................................................................896
DIAGNOSTICS........................................................................896
Diagnostic Notes...............................................................896
Test 5.32......................................................................898
DTC U1064, U1255 5.33..................................................................899
GENERAL............................................................................899
Loss of TSM/TSSM Serial Data...................................................899
DIAGNOSTICS........................................................................899
Diagnostic Notes...............................................................899
Test 5.33......................................................................901
6 - WIRING.................................................................................902
CONNECTOR LOCATIONS 6.1................................................................904
AMP MULTILOCK ELECTRICAL CONNECTORS 6.2................................................906
REMOVING SOCKET/PIN TERMINALS......................................................906
INSTALLING SOCKET/PIN TERMINALS....................................................906
CRIMPING INSTRUCTIONS..............................................................909
DEUTSCH ELECTRICAL CONNECTORS 6.3......................................................910
GENERAL............................................................................910
REMOVING/DISASSEMBLING.............................................................910
REMOVING/INSTALLING SOCKETS........................................................910
REMOVING/INSTALLING PINS...........................................................911
ASSEMBLING/INSTALLING..............................................................912
CRIMPING INSTRUCTIONS..............................................................913
MINI-DEUTSCH CONNECTORS 6.4............................................................915
GENERAL............................................................................915
For Size 20, 16 and 12 Contacts Wire Range 26-12 AWG...........................915
CRIMPING INSTRUCTIONS..............................................................915
SEALED BUTT SPLICE CONNECTORS 6.5......................................................917
INSTALLATION.......................................................................917
PACKARD ELECTRICAL CONNECTORS 6.6......................................................918
GENERAL............................................................................918
PULL-TO-SEAT TERMINALS.............................................................919
Removing External Latch Type...................................................919
Installing External Latch Type.................................................919
PUSH-TO-SEAT TERMINALS.............................................................919
Removing Push-to-Seat Terminals................................................919
Installing Push-to-Seat Terminals..............................................920
CRIMPING INSTRUCTIONS..............................................................920
PACKARD ECM CONNECTOR 6.7..............................................................922
DISASSEMBLY........................................................................922
ASSEMBLY...........................................................................922
CRIMPING INSTRUCTIONS..............................................................923
INDEX TO WIRING DIAGRAMS 6.8...........................................................924
2003 ALL CARBURETED SOFTAIL DOM. and INT. MODELS, MAIN HARNESS.........................926
2003 ALL CARBURETED SOFTAIL DOM. and INT. MODELS, IGNITION CIRCUIT.....................928
2003 ALL EFI SOFTAIL DOM. and INT. MODELS, MAIN HARNESS: SHEET 1 OF 3..................935
2003 ALL CARBURETED SOFTAIL DOM. and INT. MODELS, LIGHTING CIRCUIT: SHEET 1 OF 2.......929
2003 ALL CARBURETED SOFTAIL DOM. and INT. MODELS, HORN & INSTRUMENTS...................931
2003 ALL CARBURETED SOFTAIL DOM. and INT. MODELS, SECURITY CIRCUIT: SHEET 1 OF 2.......933
2003 ALL CARBURETED SOFTAIL DOM. and INT. MODELS, SECURITY CIRCUIT: SHEET 2 OF 2.......934
2003 ALL CARBURETED SOFTAIL DOM. and INT. MODELS, CHARGING & STARTING CIRCUITS.........932
2003 ALL EFI SOFTAIL DOM. and INT. MODELS, MAIN HARNESS: SHEET 2 OF 3..................936
2003 ALL EFI SOFTAIL DOM. and INT. MODELS, MAIN HARNESS: SHEET 3 OF 3..................937
2003 ALL CARBURETED SOFTAIL DOM. and INT. MODELS, LIGHTS, SPEEDO. & INDICATORS.........927
2003 ALL EFI SOFTAIL DOM. and INT. MODELS, IGNITION CIRCUIT............................938
2003 ALL EFI SOFTAIL DOM. and INT. MODELS, IGNITION & CHARGING CIRCUITS................939
2003 ALL EFI SOFTAIL DOM. and INT. MODELS, LIGHTING CIRCUIT: SHEET 1 OF 2..............940
2003 ALL EFI SOFTAIL DOM. and INT. MODELS, LIGHTING CIRCUIT: SHEET 2 OF 2..............941
2003 ALL EFI SOFTAIL DOM. and INT. MODELS, HORN & INSTRUMENTS CIRCUIT: SHEET 1 OF 2....942
2003 ALL CARBURETED SOFTAIL DOM. and INT. MODELS, LIGHTING CIRCUIT: SHEET 2 OF 2.......930
2003 ALL EFI SOFTAIL DOM. and INT. MODELS, HORN & INSTRUMENTS CIRCUIT: SHEET 2 OF 2....943
2003 ALL EFI SOFTAIL DOM. and INT. MODELS, STARTING CIRCUIT............................944
2003 ALL EFI SOFTAIL DOM. and INT. MODELS, SECURITY CIRCUIT: SHEET 1 OF 2..............945
2003 ALL EFI SOFTAIL DOM. and INT. MODELS, SECURITY CIRCUIT: SHEET 2 OF 2..............946
2003 HARLEY DAVIDSON SOFTAIL MODELS ELECTRICAL DIAGNOSTICS + SERVICE MANUAL – PDF DOWNLOAD:
PLEASE NOTE:
This is the SAME MANUAL used by the dealerships to diagnose your vehicle
No waiting for couriers / posts as this is a PDF manual and you can download it within 2 minutes time once you make the payment.
Your payment is all safe and the delivery of the manual is INSTANT – You will be taken to the DOWNLOAD PAGE.
So have no hesitations whatsoever and write to us about any queries you may have : heydownloadss @gmail.com
S.V
✹
What Our Customers Say
★★★★★Live reviews from customers
Loading customer reviews...
🌟 Related Products
Discover more professional manuals for your equipment
