2005 Harley Davidson Sportster XLH Models Electrical Diagnostics + Service Manual – PDF DOWNLOAD
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2005 Harley Davidson Sportster XLH Models Electrical Diagnostics + Service Manual – PDF DOWNLOAD2005 Harley Davidson Sportster XLH Models Electrical Diagnostics + Service Manual – PDF DOWNLOAD
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2005 Harley Davidson Sportster XLH Models Electrical Diagnostics + Service Manual – PDF DOWNLOAD
SERVICE MANUAL Part Number 99484-05 ELECTRICAL DIAGNOSTICS Part Number 99495-05
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.
After a new motorcycle has been driven its first 1000 miles (1600 km), and at every 5000 mile (8000 km) interval thereafter, have a Harley-Davidson dealer perform the service operations listed under 1.3 MAINTENANCE SCHEDULE.
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:
2005 Harley Davidson Sportster XLH Models Electrical Diagnostics + Service Manual – PDF DOWNLOAD
2005 XLH MODELS..................................................................... 1
SERVICE MANUAL.................................................................. 1
Part Number 99484-05........................................................ 1
ELECTRICAL DIAGNOSTICS.......................................................... 1
Part Number 99495-05........................................................ 1
sm01a.pdf........................................................................... 0
GENERAL 1.1..................................................................... 5
SERVICING A NEW MOTORCYCLE.................................................. 5
SHOP PRACTICES.............................................................. 5
Repair Notes............................................................ 5
Safety.................................................................. 5
Removing Parts.......................................................... 5
Cleaning................................................................ 5
Disassembly and Assembly................................................ 5
REPAIR AND REPLACEMENT PROCEDURES........................................... 6
Hardware and Threaded Parts............................................. 6
Wiring, Hoses and Lines................................................. 6
Instruments and Gauges.................................................. 6
Bearings................................................................ 6
Bushings................................................................ 6
Gaskets................................................................. 6
Lip Type Seals.......................................................... 6
O-Rings (Preformed Packings)............................................ 6
Gears................................................................... 7
Shafts.................................................................. 7
Part Replacement........................................................ 7
CLEANING.................................................................... 7
Part Protection......................................................... 7
Cleaning Process........................................................ 7
Rust or Corrosion Removal............................................... 7
Bearings................................................................ 7
TOOL SAFETY................................................................. 7
Air Tools............................................................... 7
Wrenches................................................................ 7
Pliers/Cutters/Prybars.................................................. 7
Hammers................................................................. 8
Punches/Chisels......................................................... 8
Screwdrivers............................................................ 8
Ratchets and Handles.................................................... 8
Sockets................................................................. 8
Storage Units........................................................... 8
FUEL AND OIL 1.2................................................................ 9
FUEL........................................................................ 9
GASOLINE BLENDS............................................................. 9
ENGINE OIL.................................................................. 9
WINTER LUBRICATION.......................................................... 9
MAINTENANCE SCHEDULE 1.3........................................................ 10
CRITICAL FASTENERS 1.4.......................................................... 14
INSPECTION.................................................................. 14
ENGINE OIL AND FILTER 1.5....................................................... 15
CHECKING AND ADDING OIL..................................................... 15
Removing and Replacing Oil Filler Cap................................... 15
Checking Oil With Cold Engine........................................... 15
Checking Oil With Warm Engine........................................... 15
CHANGING OIL AND FILTER..................................................... 16
General................................................................. 16
Draining Oil Tank....................................................... 16
Removing Oil Filter..................................................... 17
Installing New Oil Filter............................................... 17
Refilling Oil Tank...................................................... 17
BATTERY MAINTENANCE 1.6......................................................... 18
GENERAL..................................................................... 18
LEFT SIDE COVER............................................................. 19
Removal................................................................. 19
Installation............................................................ 19
BATTERY DISCONNECTION AND REMOVAL........................................... 20
BATTERY INSPECTION.......................................................... 20
BATTERY STORAGE............................................................. 21
BATTERY INSTALLATION AND CONNECTION......................................... 21
BRAKES 1.7...................................................................... 22
GENERAL..................................................................... 22
INSPECTION.................................................................. 22
TROUBLESHOOTING............................................................. 22
BLEEDING HYDRAULIC BRAKE SYSTEM 1.8............................................. 23
GENERAL..................................................................... 23
BLEEDING FRONT BRAKE........................................................ 23
BLEEDING REAR BRAKE......................................................... 25
BRAKE PADS AND DISCS 1.9........................................................ 26
INSPECTION.................................................................. 26
Brake Pads.............................................................. 26
Brake Disc Thickness, Lateral Runout and Warpage........................ 26
BRAKE PAD REPLACEMENT....................................................... 26
Front Brake Caliper..................................................... 26
Rear Brake Caliper...................................................... 29
TIRES AND WHEELS 1.10........................................................... 31
TIRES....................................................................... 31
TIRE WEAR INDICATORS........................................................ 31
WHEEL BEARINGS.............................................................. 32
WHEEL SPOKES................................................................ 32
PRIMARY CHAIN 1.11.............................................................. 33
INSPECTION.................................................................. 33
ADJUSTMENT.................................................................. 33
CLUTCH 1.12..................................................................... 34
ADJUSTMENT.................................................................. 34
TRANSMISSION LUBRICANT 1.13..................................................... 36
GENERAL..................................................................... 36
DRAINING LUBRICANT.......................................................... 36
REFILLING LUBRICANT......................................................... 36
REAR BELT DEFLECTION 1.14....................................................... 38
INSPECTION.................................................................. 38
BELT DEFLECTION ADJUSTMENT.................................................. 40
WHEEL ALIGNMENT............................................................. 41
Checking Wheel Alignment................................................ 41
Wheel Alignment Adjustment.............................................. 41
REAR BELT AND SPROCKETS 1.15.................................................... 42
GENERAL..................................................................... 42
CLEANING.................................................................... 42
INSPECTION.................................................................. 42
Sprockets............................................................... 42
Rear Belt............................................................... 42
SHOCK ABSORBER ADJUSTMENT 1.16.................................................. 44
GENERAL..................................................................... 44
PROCEDURE................................................................... 44
STEERING HEAD BEARINGS 1.17..................................................... 45
GENERAL..................................................................... 45
ADJUSTMENT.................................................................. 45
LUBRICATION................................................................. 45
REAR FORK BEARINGS 1.18......................................................... 46
GENERAL..................................................................... 46
PROCEDURE................................................................... 46
sm01b.pdf........................................................................... 0
Front Fork Oil 1.19............................................................. 47
GENERAL..................................................................... 47
CHANGING FORK OIL........................................................... 47
Filling Fork Oil–Forks Assembled, in Frame.............................. 48
Filling Fork Oil - Forks Disassembled, out of Frame..................... 48
SPARK PLUGS 1.20................................................................ 49
GENERAL..................................................................... 49
ADJUSTMENT.................................................................. 49
CLEANING AND INSPECTION..................................................... 49
Inspection.............................................................. 49
Spark Plug Condition.................................................... 49
Cleaning................................................................ 49
INSTALLATION................................................................ 49
CABLE AND CHASSIS LUBRICATION 1.21.............................................. 50
GENERAL..................................................................... 50
CABLES AND HAND LEVERS...................................................... 50
FOOT SHIFT LEVER AND REAR BRAKE PEDAL....................................... 50
JIFFY STAND................................................................. 50
Steering Head Bearings...................................................... 50
AIR FILTER ELEMENT 1.22......................................................... 51
GENERAL..................................................................... 51
REMOVAL..................................................................... 51
CLEANING, INSPECTION AND REPAIR............................................. 52
INSTALLATION................................................................ 52
THROTTLE CABLES AND ENRICHENER 1.23............................................. 53
CABLE INSPECTION, LUBRICATION AND ADJUSTMENT................................ 53
Inspection and Lubrication.............................................. 53
Adjustment.............................................................. 53
ENRICHENER ADJUSTMENT....................................................... 54
IDLE SPEED AND IGNITION TIMING 1.24............................................. 55
IDLE SPEED ADJUSTMENT....................................................... 55
IGNITION TIMING............................................................. 55
FUEL SUPPLY VALVE FILTER 1.25................................................... 56
INSPECTION.................................................................. 56
FUEL SYSTEM LINES AND FITTINGS.............................................. 57
ENGINE MOUNTS AND STABILIZER LINKS 1.26......................................... 58
INSPECTION.................................................................. 58
HEADLAMP ALIGNMENT 1.27......................................................... 59
INSPECTION.................................................................. 59
ADJUSTMENT.................................................................. 59
XL 883C and XL 1200C Models............................................. 59
XL 883, XL 883L and XL 1200R Models..................................... 60
FLUID/LUBRICANT REQUIREMENTS 1.28............................................... 61
BRAKE FLUID................................................................. 61
Brake Component Grease...................................................... 61
FRONT FORK OIL.............................................................. 61
ENGINE OIL.................................................................. 61
PRIMARY DRIVE/TRANSMISSION LUBRICANT........................................ 61
STORAGE 1.29.................................................................... 62
GENERAL..................................................................... 62
REMOVAL FROM STORAGE........................................................ 63
TROUBLESHOOTING 1.30............................................................ 64
GENERAL..................................................................... 64
ENGINE...................................................................... 64
Starting Motor Does Not Operate or Does Not Turn Engine Over............ 64
Engine Turns Over But Does Not Start.................................... 64
Starts Hard............................................................. 64
Starts But Runs Irregularly or Misses................................... 64
Spark Plug Fouls Repeatedly............................................. 65
Pre-Ignition or Detonation (Knocks or Pings)............................ 65
Overheating............................................................. 65
Valve Train Noise....................................................... 65
Excessive Vibration..................................................... 65
ENGINE LUBRICATION SYSTEM................................................... 65
Oil Does Not Return To Oil Tank......................................... 65
Engine Uses Too Much Oil or Smokes Excessively.......................... 65
Engine Leaks Oil From Cases, Push Rods, Hoses, Etc...................... 65
ELECTRICAL SYSTEM........................................................... 65
Alternator Does Not Charge.............................................. 65
Alternator Charge Rate Is Below Normal.................................. 65
Speedometer Operates Erratically........................................ 65
FUEL........................................................................ 66
Carburetor Floods....................................................... 66
TRANSMISSION................................................................ 66
Shifts Hard............................................................. 66
Jumps Out of Gear....................................................... 66
CLUTCH...................................................................... 66
Slips................................................................... 66
Drags or Does Not Release............................................... 66
Chatters................................................................ 66
CHASSIS..................................................................... 66
Irregular/Inadequate Brake Action....................................... 66
Handling Irregularities................................................. 66
sm02a.pdf........................................................................... 0
SPECIFICATIONS 2.1.............................................................. 69
TIRES....................................................................... 70
TORQUE VALUES 2.2............................................................... 71
VEHICLE IDENTIFICATION NUMBER (VIN) 2.3......................................... 74
GENERAL..................................................................... 74
WHEELS 2.4...................................................................... 75
GENERAL..................................................................... 75
TROUBLESHOOTING............................................................. 75
FRONT WHEEL................................................................. 77
Removal................................................................. 77
Disassembly............................................................. 79
Cleaning and Inspection................................................. 79
Assembly................................................................ 79
Installation............................................................ 80
REAR WHEEL.................................................................. 81
Removal................................................................. 81
Disassembly............................................................. 83
Cleaning and Inspection................................................. 83
Assembly................................................................ 83
Installation............................................................ 84
SEALED WHEEL BEARINGS....................................................... 85
Inspection.............................................................. 85
Removal................................................................. 85
Installation............................................................ 85
WHEEL LACING: 16 INCH RIM 2.5................................................... 87
GENERAL..................................................................... 87
Procedure................................................................... 88
WHEEL LACING: 19 INCH RIM 2.6................................................... 90
General..................................................................... 90
PROCEDURE................................................................... 90
WHEEL LACING: 21 INCH RIM 2.7................................................... 94
General..................................................................... 94
PROCEDURE................................................................... 94
TRUING LACED WHEELS 2.8......................................................... 98
PROCEDURE................................................................... 98
CHECKING CAST RIM RUNOUT 2.9....................................................101
CHECKING LATERAL AND RADIAL RUNOUT..........................................101
TIRES 2.10......................................................................102
GENERAL.....................................................................102
REMOVAL.....................................................................102
CLEANING, INSPECTION AND REPAIR.............................................103
INSTALLATION................................................................103
Tube Type Tires.........................................................103
Tubeless Tires..........................................................104
CHECKING TIRE RUNOUT........................................................104
Lateral Runout..........................................................104
Radial Runout...........................................................105
Wheel Balancing.............................................................105
Weights For Laced Wheels................................................105
Weights for Cast Wheels.................................................105
sm02b.pdf........................................................................... 0
FRONT BRAKE MASTER CYLINDER 2.11................................................107
GENERAL.....................................................................107
REMOVAL.....................................................................107
DISASSEMBLY.................................................................108
CLEANING, INSPECTION AND REPAIR.............................................110
ASSEMBLY....................................................................110
INSTALLATION................................................................112
REAR BRAKE MASTER CYLINDER 2.12.................................................114
GENERAL.....................................................................114
REMOVAL.....................................................................114
DISASSEMBLY.................................................................117
CLEANING, INSPECTION AND REPAIR.............................................117
ASSEMBLY....................................................................118
INSTALLATION................................................................120
REAR BRAKE MASTER CYLINDER RESERVOIR 2.13.......................................121
GENERAL.....................................................................121
REMOVAL.....................................................................121
INSTALLATION................................................................122
FRONT BRAKE CALIPER 2.14........................................................123
REMOVAL.....................................................................123
DISASSEMBLY.................................................................124
CLEANING, INSPECTION AND REPAIR.............................................126
ASSEMBLY....................................................................126
LUBRICATING FRONT CALIPER BOLT PINS AND BOOTS...............................128
INSTALLATION................................................................129
REAR BRAKE CALIPER 2.15.........................................................131
REMOVAL.....................................................................131
DISASSEMBLY.................................................................133
CLEANING, INSPECTION AND REPAIR.............................................134
ASSEMBLY....................................................................135
LUBRICATING REAR CALIPER BOLT PINS AND BOOTS................................136
INSTALLATION................................................................137
BRAKE LINES 2.16................................................................140
FRONT BRAKE LINE............................................................140
Removal.................................................................140
Installation............................................................141
REAR BRAKE LINE.............................................................142
Removal.................................................................142
Installation............................................................142
FRONT FORK 2.17.................................................................144
GENERAL.....................................................................144
REMOVAL.....................................................................144
DISASSEMBLY.................................................................144
CLEANING, INSPECTION AND REPAIR.............................................144
ASSEMBLY....................................................................146
INSTALLATION................................................................146
FORK STEM AND BRACKET ASSEMBLY 2.18.............................................147
REMOVAL/DISASSEMBLY.........................................................147
CLEANING, INSPECTION AND REPAIR.............................................147
ASSEMBLY/INSTALLATION.......................................................147
REAR FORK 2.19..................................................................148
REMOVAL.....................................................................148
DISASSEMBLY.................................................................148
CLEANING AND INSPECTION.....................................................149
ASSEMBLY....................................................................149
INSTALLATION................................................................149
REAR SHOCK ABSORBER 2.20........................................................150
GENERAL.....................................................................150
REMOVAL.....................................................................150
CLEANING AND INSPECTION.....................................................150
INSTALLATION................................................................150
sm02c.pdf........................................................................... 0
STABILIZER LINKS 2.21...........................................................151
GENERAL.....................................................................151
UPPER FRONT STABILIZER LINK.................................................151
Removal.................................................................151
Installation............................................................151
LOWER FRONT STABILIZER LINK.................................................152
Removal.................................................................152
Installation............................................................152
REAR STABILIZER LINK........................................................152
Removal.................................................................152
Installation............................................................152
FRONT ENGINE MOUNT/ISOLATOR 2.22................................................153
REMOVAL.....................................................................153
INSTALLATION................................................................153
REAR ENGINE MOUNT/ISOLATOR 2.23.................................................154
REMOVAL.....................................................................154
INSTALLATION................................................................154
THROTTLE CONTROL 2.24...........................................................156
REMOVAL/DISASSEMBLY.........................................................156
CLEANING, INSPECTION AND REPAIR.............................................156
ASSEMBLY/INSTALLATION.......................................................156
HANDLEBARS 2.25.................................................................158
REMOVAL.....................................................................158
All Models..............................................................158
XL 883/XL 883L/XL 1200R.................................................158
XL 883C/XL 1200C........................................................159
INSTALLATION................................................................159
XL 883/XL 883L/XL 1200R.................................................159
XL 883C/XL 1200C........................................................159
All Models..............................................................160
CLUTCH CONTROL 2.26.............................................................161
GENERAL.....................................................................161
REMOVAL/DISASSEMBLY.........................................................161
Clutch Cable–Lower......................................................161
Clutch Lever and Clutch Cable–Upper.....................................162
Clutch Hand Control.....................................................162
ASSEMBLY/INSTALLATION.......................................................163
Clutch Hand Control.....................................................163
Clutch Lever and Clutch Cable–Upper.....................................163
Clutch Cable–Lower......................................................163
EXHAUST SYSTEM 2.27.............................................................164
REMOVAL.....................................................................164
Mufflers and Exhaust Pipes..............................................164
Muffler Interconnect Bracket............................................165
INSTALLATION................................................................166
Muffler Interconnect Bracket............................................166
Exhaust Pipes and Mufflers..............................................166
FRONT FENDER 2.28...............................................................167
REMOVAL.....................................................................167
INSTALLATION................................................................167
REAR FENDER 2.29................................................................168
REMOVAL.....................................................................168
INSTALLATION................................................................170
BELT GUARD/DEBRIS DEFLECTOR 2.30................................................171
REMOVAL.....................................................................171
Belt Guard..............................................................171
Debris Deflector........................................................171
INSTALLATION................................................................171
Belt Guard..............................................................171
Debris Deflector........................................................171
JIFFY STAND 2.31................................................................172
GENERAL.....................................................................172
REMOVAL.....................................................................173
CLEANING AND LUBRICATION....................................................173
INSTALLATION................................................................173
SEAT 2.32.......................................................................174
GENERAL.....................................................................174
REMOVAL.....................................................................174
INSTALLATION................................................................174
RIDER FOOT CONTROLS: XL 883/XL 883L/XL 1200R 2.33...............................176
RIGHT FOOTREST AND REAR BRAKE PEDAL ASSEMBLY................................176
Removal.................................................................176
Installation............................................................176
LEFT FOOTREST AND SHIFT LEVER ASSEMBLY......................................176
Removal.................................................................176
Installation............................................................176
RIDER FOOT CONTROLS: XL 883C/XL 1200C 2.34......................................178
RIGHT FOOTREST AND REAR BRAKE PEDAL ASSEMBLY................................178
Removal.................................................................178
Installation............................................................178
LEFT FOOTREST AND SHIFT LEVER ASSEMBLY......................................180
Removal.................................................................180
Installation............................................................180
ADJUSTING SHIFT PEDAL.......................................................181
PASSENGER FOOTRESTS 2.35........................................................182
GENERAL.....................................................................182
REMOVAL.....................................................................182
INSTALLATION................................................................182
FORK LOCK 2.36..................................................................183
REMOVAL.....................................................................183
INSTALLATION................................................................184
sm03a.pdf........................................................................... 0
SPECIFICATIONS 3.1..............................................................187
SERVICE WEAR LIMITS 3.2.........................................................190
GENERAL.....................................................................190
TORQUE VALUES 3.3...............................................................192
ENGINE 3.4......................................................................194
GENERAL.....................................................................194
TROUBLESHOOTING 3.5.............................................................195
DIAGNOSING VALVE TRAIN NOISE................................................195
COMPRESSION TEST............................................................195
Compression Test Procedure..............................................195
CYLINDER LEAKAGE TEST.......................................................196
Cylinder Leakage Test Procedure.........................................196
DIAGNOSING SMOKING ENGINE OR HIGH OIL CONSUMPTION...........................197
Check Prior To Cylinder Head Removal....................................197
Check After Cylinder Head Removal.......................................197
ADJUSTMENT/TESTING..........................................................197
General.................................................................197
ENGINE LUBRICATION SYSTEM 3.6...................................................198
GENERAL.....................................................................198
OIL PUMP....................................................................198
OIL PRESSURE 3.7................................................................201
GENERAL.....................................................................201
Oil Pressure Indicator Lamp.............................................201
CHECKING OIL PRESSURE.......................................................202
CRANKCASE BREATHING SYSTEM 3.8..................................................203
GENERAL.....................................................................203
HOW TO USE THIS SECTION 3.9.....................................................204
TYPICAL SYMPTOMS............................................................204
TOP END REPAIR..............................................................204
BOTTOM END REPAIR...........................................................204
TOP END SERVICE 3.10............................................................205
ENGINE IN CHASSIS...........................................................205
ENGINE REMOVED FROM CHASSIS.................................................206
BOTTOM END SERVICE 3.11.........................................................207
ENGINE IN CHASSIS: CAM COMPARTMENT SERVICE..................................207
ENGINE REMOVED: FLYWHEEL COMPARTMENT SERVICE OR COMPLETE ENGINE OVERHAUL....208
REMOVING ENGINE FROM CHASSIS 3.12...............................................209
GENERAL.....................................................................209
PROCEDURE...................................................................209
INSTALLING ENGINE IN CHASSIS 3.13...............................................213
GENERAL.....................................................................213
PROCEDURE...................................................................213
sm03b.pdf........................................................................... 0
TOP END OVERHAUL: DISASSEMBLY 3.14..............................................216
GENERAL.....................................................................216
STRIPPING MOTORCYCLE FOR TOP END REPAIR.....................................216
CYLINDER HEAD...............................................................217
Disassembling Rocker Covers.............................................217
Removing Cylinder Head..................................................218
Disassembling Push Rods and Covers......................................220
CYLINDER AND PISTON.........................................................220
CYLINDER HEAD 3.15..............................................................223
REMOVAL.....................................................................223
DISASSEMBLY.................................................................223
CLEANING AND INSPECTION.....................................................224
Cylinder Heads..........................................................224
Rocker Arm Assemblies...................................................225
Valves..................................................................226
Valve Seats.............................................................226
Valve Guides............................................................226
Valve Springs...........................................................226
Spark Plug Threads......................................................227
Push Rods...............................................................227
REPLACING ROCKER ARM BUSHINGS...............................................227
REPLACING VALVE GUIDES......................................................228
Removal.................................................................228
Installation............................................................229
REFACING VALVE SEATS........................................................232
Replacing Valve Seats...................................................234
ASSEMBLY....................................................................235
INSTALLATION................................................................236
CYLINDER AND PISTON 3.16........................................................237
REMOVAL/DISASSEMBLY.........................................................237
CLEANING, INSPECTION, AND REPAIR............................................237
Checking Gasket Surface.................................................237
Measuring Cylinder Bore.................................................238
Measuring Piston to Cylinder Fit........................................239
Boring and Honing Cylinder..............................................239
Fitting Piston Rings....................................................240
CONNECTING ROD BUSHINGS.....................................................241
Removing Upper Connecting Rod Bushing...................................241
Installing Upper Connecting Rod Bushing.................................243
Reaming Upper Connecting Rod Bushing....................................244
Honing Upper Connecting Rod Bushing.....................................244
Repair..................................................................244
ASSEMBLY/INSTALLATION.......................................................244
TOP END OVERHAUL: ASSEMBLY 3.17.................................................245
GENERAL.....................................................................245
PISTON AND CYLINDER.........................................................245
PUSH RODS, COVERS AND RETAINERS.............................................246
CYLINDER HEAD...............................................................247
Rocker Covers...............................................................249
ASSEMBLING MOTORCYCLE AFTER TOP END REPAIR..................................251
BOTTOM END OVERHAUL: DISASSEMBLY 3.18...........................................252
GENERAL.....................................................................252
TAPPETS.....................................................................252
OIL PUMP....................................................................252
GEARCASE COVER AND CAM GEARS................................................252
CRANKCASE...................................................................254
Removing Piston Oil Jets................................................255
Removing Cylinder Base Studs............................................255
VALVE TAPPETS 3.19..............................................................256
GENERAL.....................................................................256
REMOVAL.....................................................................256
CLEANING AND INSPECTION.....................................................256
INSTALLATION................................................................256
sm03c.pdf........................................................................... 0
GEARCASE COVER AND CAM GEARS 3.20...............................................258
GENERAL.....................................................................258
REMOVAL/DISASSEMBLY.........................................................258
CLEANING, INSPECTION AND REPAIR.............................................258
Cam and Pinion Gear Identification, Inspection and Selection............258
Bushing Inspection and Removal..........................................260
BUSHING INSTALLATION........................................................260
Cam Gear Bushings in Right Crankcase Half...............................260
Cam Gear Bushings (Except Rear Intake Bushing) in Gearcase Cover........261
Rear Intake Cam Gear Bushing in Gearcase Cover..........................261
Pinion Shaft Bushing in Gearcase Cover..................................261
BUSHING REAMING.............................................................262
Cam Gear Bushings in Right Crankcase Half...............................262
Cam Gear Bushings (Except Rear Intake Bushing) in Gearcase Cover........263
Rear Intake Cam Gear Bushing in Gearcase Cover..........................263
Pinion Shaft Bushing in Gearcase Cover..................................264
ASSEMBLY/INSTALLATION.......................................................264
OIL PUMP 3.21...................................................................265
GENERAL.....................................................................265
REMOVAL.....................................................................265
DISASSEMBLY.................................................................266
CLEANING, INSPECTION AND REPAIR.............................................266
ASSEMBLY....................................................................266
INSTALLATION................................................................266
OIL FILTER MOUNT 3.22...........................................................267
GENERAL.....................................................................267
DISASSEMBLY.................................................................267
CLEANING AND INSPECTION.....................................................267
ASSEMBLY....................................................................267
CRANKCASE 3.23..................................................................268
GENERAL.....................................................................268
REMOVAL.....................................................................268
DISASSEMBLY.................................................................269
FITTING PINION BEARINGS.....................................................271
Bearing Selection.......................................................272
LAPPING ENGINE MAIN BEARING RACES...........................................276
Assembling Crankcase Halves.................................................276
BOTTOM END OVERHAUL: ASSEMBLY 3.24..............................................277
GENERAL.....................................................................277
CRANKCASE...................................................................277
Installing Piston Oil Jets..............................................277
Installing Pinion Shaft Bearing.........................................278
Installing Left Main Bearing............................................279
Assembling Crankcase Halves.............................................279
Installing Cylinder Base Studs..........................................281
CAM GEARS AND GEARCASE COVER................................................282
TAPPETS.....................................................................285
ASSEMBLING TOP END OF ENGINE................................................285
OIL TANK 3.25...................................................................286
OIL HOSE ROUTING............................................................286
REMOVAL.....................................................................287
INSTALLATION................................................................289
sm04a.pdf........................................................................... 0
SPECIFICATIONS 4.1..............................................................292
TORQUE VALUES 4.2...............................................................293
TROUBLESHOOTING 4.3.............................................................294
ENRICHENER 4.4..................................................................296
GENERAL.....................................................................296
OPERATION...................................................................296
Cool Engine.............................................................296
Warm or Hot Engine......................................................296
CARBURETOR 4.5..................................................................297
GENERAL.....................................................................297
ADJUSTMENT..................................................................297
Float Level.............................................................297
OPERATION CHECK: VACUUM PISTON..............................................299
Opening Malfunction.....................................................299
Closing Malfunction.....................................................299
REMOVAL.....................................................................299
DISASSEMBLY.................................................................301
Vacuum Piston Chamber...................................................301
Carburetor Body.........................................................301
Accelerator Pump........................................................301
CLEANING, INSPECTION AND REPAIR.............................................302
Vacuum Piston Components................................................302
Carburetor Body Components..............................................302
Accelerator Pump........................................................302
ASSEMBLY....................................................................302
Vacuum Piston Chamber...................................................302
Carburetor Body.........................................................302
Accelerator Pump........................................................302
INSTALLATION................................................................303
Carburetor..............................................................303
Carburetor Fuel Overflow/Drain Hose Routing.............................303
AIR CLEANER 4.6.................................................................304
REMOVAL.....................................................................304
CLEANING, INSPECTION AND REPAIR.............................................305
INSTALLATION................................................................305
FUEL SUPPLY VALVE 4.7...........................................................306
GENERAL.....................................................................306
OPERATION...................................................................306
REMOVAL, INSPECTION AND INSTALLATION........................................306
TROUBLESHOOTING.............................................................307
Vacuum Test.............................................................307
FUEL TANK 4.8...................................................................308
GENERAL.....................................................................308
REMOVAL.....................................................................309
CLEANING, INSPECTION AND REPAIR.............................................310
INSTALLATION................................................................310
Console Replacement.........................................................311
Special Tools Needed....................................................311
Removal.................................................................311
Installation............................................................312
EVAPORATIVE EMISSIONS CONTROL–CA MODELS 4.9.....................................314
GENERAL.....................................................................314
REMOVAL.....................................................................315
Charcoal Canister.......................................................315
Vapor Valve.............................................................315
INSTALLATION................................................................316
Charcoal Canister.......................................................316
Vapor Valve.............................................................316
HOSE ROUTING................................................................317
Carburetor..............................................................317
Canister Hose Routings..................................................317
INTAKE LEAK TEST 4.10...........................................................318
GENERAL.....................................................................318
LEAK TESTER.................................................................318
Parts List..............................................................318
Tester Assembly.........................................................318
PROCEDURE...................................................................319
sm05a.pdf........................................................................... 0
SPECIFICATIONS 5.1..............................................................322
TORQUE VALUES 5.2...............................................................323
ELECTRIC STARTER SYSTEM 5.3.....................................................324
GENERAL.....................................................................324
Wiring Diagram..........................................................324
Starter Relay...........................................................324
Operation...................................................................324
STARTER MOTOR 5.4...............................................................327
REMOVAL.....................................................................327
DISASSEMBLY, INSPECTION AND REPAIR..........................................329
ASSEMBLY....................................................................332
INSTALLATION................................................................332
STARTER SOLENOID 5.5............................................................333
GENERAL.....................................................................333
DISASSEMBLY.................................................................333
ASSEMBLY....................................................................333
sm06a.pdf........................................................................... 0
SPECIFICATIONS 6.1..............................................................336
TORQUE VALUES 6.2...............................................................338
PRIMARY CHAIN ADJUSTER 6.3......................................................339
GENERAL.....................................................................339
REMOVAL.....................................................................339
Primary Cover...........................................................339
Primary Chain Adjuster..................................................341
INSTALLATION................................................................341
Primary Chain Adjuster..................................................341
Primary Cover...........................................................341
CLUTCH RELEASE MECHANISM 6.4....................................................343
REMOVAL/DISASSEMBLY.........................................................343
CLEANING, INSPECTION AND REPAIR.............................................344
ASSEMBLY/INSTALLATION.......................................................344
PRIMARY DRIVE/CLUTCH 6.5........................................................345
GENERAL.....................................................................345
REMOVAL.....................................................................347
DISASSEMBLY.................................................................347
INSPECTION AND REPAIR.......................................................348
ASSEMBLY....................................................................349
INSTALLATION................................................................351
SECONDARY DRIVE BELT 6.6........................................................352
REMOVAL.....................................................................352
INSTALLATION................................................................353
TRANSMISSION 6.7................................................................354
OPERATION...................................................................354
CASE DISASSEMBLY FOR TRANSMISSION REMOVAL 6.8...................................355
GENERAL.....................................................................355
RIGHT CRANKCASE REMOVAL.....................................................355
TRANSMISSION REMOVAL AND DISASSEMBLY 6.9........................................358
TRANSMISSION REMOVAL FROM LEFT CRANKCASE....................................358
MAINSHAFT/COUNTERSHAFT......................................................360
MAINSHAFT DISASSEMBLY.......................................................362
Cleaning And Inspection.................................................362
COUNTERSHAFT DISASSEMBLY....................................................363
Cleaning And Inspection.................................................363
TRANSMISSION ASSEMBLY 6.10......................................................364
MAINSHAFT ASSEMBLY..........................................................364
COUNTERSHAFT ASSEMBLY.......................................................365
MAIN DRIVE GEAR 6.11............................................................366
REMOVAL.....................................................................366
DISASSEMBLY.................................................................366
ASSEMBLY....................................................................367
INSTALLATION................................................................367
TRANSMISSION RIGHT CASE BEARINGS 6.12...........................................369
REMOVAL.....................................................................369
INSTALLATION................................................................369
Main Drive Gear Ball Bearing............................................369
Countershaft Needle Bearing.............................................369
Shifter Drum Bushing....................................................369
TRANSMISSION LEFT CASE BEARINGS 6.13............................................370
REMOVAL.....................................................................370
Mainshaft and Countershaft Bearings.....................................370
Shifter Drum Bushing....................................................370
INSTALLATION................................................................370
Mainshaft and Countershaft Bearings.....................................370
Shifter Drum Bushing....................................................370
TRANSMISSION INSTALLATION 6.14..................................................371
INSTALLATION................................................................371
SHIFTER FORKS AND DRUM ASSEMBLY.............................................372
ASSEMBLING CRANKCASES.......................................................373
SHIFTER SHAFT INSTALLATION..................................................375
TRANSMISSION SPROCKET 6.15......................................................376
REMOVAL.....................................................................376
INSTALLATION................................................................377
sm07a.pdf........................................................................... 0
SPECIFICATIONS 7.1..............................................................380
IGNITION....................................................................380
CHARGING SYSTEM.............................................................380
BATTERY.....................................................................380
FUSES.......................................................................380
TORQUE VALUEs 7.2...............................................................381
BULB REQUIREMENTS 7.3...........................................................382
BULB CHART..................................................................382
ELECTRICAL BRACKET 7.4..........................................................383
GENERAL.....................................................................383
REMOVAL.....................................................................383
INSTALLATION................................................................384
IGNITION SYSTEM 7.5.............................................................385
GENERAL.....................................................................385
TROUBLESHOOTING.............................................................385
MANIFOLD ABSOLUTE PRESSURE SENSOR: MAP 7.6......................................387
REMOVAL.....................................................................387
INSTALLATION................................................................387
IGNITION/LIGHT SWITCH 7.7.......................................................388
GENERAL.....................................................................388
REMOVAL.....................................................................389
INSTALLATION................................................................389
IGNITION CONTROL MODULE: ICM 7.8................................................390
GENERAL.....................................................................390
REMOVAL.....................................................................390
INSTALLATION................................................................390
SPARK PLUG CABLES 7.9...........................................................391
GENERAL.....................................................................391
REMOVAL.....................................................................391
INSPECTION..................................................................391
INSTALLATION................................................................391
IGNITION COIL 7.10..............................................................393
GENERAL.....................................................................393
TROUBLESHOOTING.............................................................393
REMOVAL.....................................................................393
INSTALLATION................................................................393
CHARGING SYSTEM 7.11............................................................394
GENERAL.....................................................................394
ALTERNATOR..................................................................394
VOLTAGE REGULATOR...........................................................394
ALTERNATOR 7.12.................................................................395
REMOVAL AND DISASSEMBLY.....................................................395
Rotor...................................................................395
Stator..................................................................395
CLEANING, INSPECTION AND REPAIR.............................................395
ASSEMBLY AND INSTALLATION...................................................396
Stator..................................................................396
Rotor...................................................................397
VOLTAGE REGULATOR 7.13..........................................................398
GENERAL.....................................................................398
REMOVAL.....................................................................398
INSTALLATION................................................................399
BATTERY 7.14....................................................................400
TESTING.....................................................................400
Voltmeter Test..........................................................400
Load Test...............................................................400
BATTERY CHARGING............................................................401
General.................................................................401
Safety Precautions......................................................401
Charging Battery........................................................402
BATTERY CABLES 7.15.............................................................403
REMOVAL.....................................................................403
INSTALLATION................................................................404
sm07b.pdf........................................................................... 0
HEADLAMP 7.16...................................................................406
REPLACEMENT: XL 883C/XL 1200C...............................................406
REPLACEMENT: XL 883/XL 883L/ XL 1200R.......................................409
INDICATOR LAMPS 7.17............................................................411
REPLACEMENT: XL 883C/XL 1200C...............................................411
REPLACEMENT: XL 883/XL 883L.................................................411
REPLACEMENT: XL 1200R.......................................................412
TAIL LAMP 7.18..................................................................413
BULB REPLACEMENT............................................................413
BASE REPLACEMENT............................................................413
TURN SIGNALS 7.19...............................................................415
BULB REPLACEMENT............................................................415
FRONT HOUSING REPLACEMENT...................................................415
REAR HOUSING REPLACEMENT....................................................417
REAR STOP LIGHT SWITCH 7.20.....................................................419
GENERAL.....................................................................419
REPLACEMENT.................................................................419
HANDLEBAR SWITCHES 7.21.........................................................420
GENERAL.....................................................................420
REPAIR PROCEDURES...........................................................420
CONNECTORS..................................................................421
RIGHT HANDLEBAR SWITCH 7.22.....................................................422
REMOVAL.....................................................................422
INSTALLATION................................................................423
DISASSEMBLY.................................................................425
SWITCH REPAIR/REPLACEMENT...................................................426
Upper Switch Housing Repair.............................................426
Lower Switch Housing Repair.............................................427
ASSEMBLY....................................................................428
LEFT HANDLEBAR SWITCH 7.23......................................................429
REMOVAL.....................................................................429
INSTALLATION................................................................429
DISASSEMBLY.................................................................430
SWITCH REPAIR/REPLACEMENT...................................................430
Upper Switch Housing Repair.............................................430
Lower Switch Housing Repair.............................................431
ASSEMBLY....................................................................432
HORN 7.24.......................................................................433
TROUBLESHOOTING.............................................................433
VOLTAGE TEST................................................................433
REPLACEMENT: ALL MODELS EXCEPT XL 1200C.....................................433
REPLACEMENT: XL 1200C.......................................................434
FUSES AND STARTER RELAY 7.25....................................................435
GENERAL.....................................................................435
REPLACING MAXI-FUSE.........................................................435
REPLACING 15-AMP FUSES......................................................436
REPLACING STARTER RELAY.....................................................436
MAXI-FUSE HOLDER 7.26...........................................................437
REPLACEMENT.................................................................437
RELAY/FUSE BLOCK 7.27...........................................................438
REMOVAL.....................................................................438
INSTALLATION................................................................439
SPEEDOMETER: XL 883/XL 883L 7.28................................................440
REMOVAL.....................................................................440
INSTALLATION................................................................440
SPEEDOMETER: XL 883C/XL 1200C 7.29..............................................441
REMOVAL.....................................................................441
INSTALLATION................................................................441
SPEEDOMETER AND TACHOMETER: XL 1200R 7.30.......................................442
TRIP ODOMETER RESET SWITCH REPLACEMENT......................................442
SPEEDOMETER REMOVAL.........................................................443
TACHOMETER REMOVAL..........................................................443
SPEEDOMETER INSTALLATION....................................................444
TACHOMETER INSTALLATION.....................................................444
TURN SIGNAL/SECURITY MODULE: TSM/TSSM 7.31......................................445
GENERAL.....................................................................445
REMOVAL.....................................................................445
TESTING.....................................................................445
INSTALLATION................................................................445
OIL PRESSURE SWITCH 7.32........................................................446
GENERAL.....................................................................446
REMOVAL.....................................................................446
INSTALLATION................................................................446
CRANK POSITION SENSOR: CKP 7.33.................................................447
GENERAL.....................................................................447
REMOVAL.....................................................................447
INSTALLATION................................................................447
VEHICLE SPEED SENSOR: VSS 7.34..................................................448
GENERAL.....................................................................448
REMOVAL.....................................................................448
INSTALLATION................................................................448
NEUTRAL INDICATOR SWITCH 7.35...................................................449
GENERAL.....................................................................449
TEST........................................................................449
REPLACEMENT.................................................................449
BANK ANGLE SENSOR: BAS 7.36.....................................................450
GENERAL.....................................................................450
OPERATION...................................................................450
TESTING.....................................................................450
REPLACEMENT.................................................................450
sm_appa.pdf......................................................................... 0
APPENDIX A–TOOLS A.1............................................................ 0
sm_appb1.pdf........................................................................ 0
APPENDIX B–WIRING AMP MULTILOCK ELECTRICAL CONNECTORS B.1....................... 0
REMOVING SOCKET/PIN TERMINALS............................................... 0
INSTALLING SOCKET/PIN TERMINALS............................................. 0
CRIMPING INSTRUCTIONS....................................................... 0
DEUTSCH ELECTRICAL CONNECTORS B.2............................................... 0
GENERAL..................................................................... 0
REMOVING/DISASSEMBLING...................................................... 0
REMOVING/INSTALLING SOCKETS................................................. 0
REMOVING/INSTALLING PINS.................................................... 0
ASSEMBLING/INSTALLING....................................................... 0
CRIMPING INSTRUCTIONS....................................................... 0
MINI-DEUTSCH CONNECTORS B.3..................................................... 0
GENERAL..................................................................... 0
For Size 20, 16 and 12 Contacts Wire Range 26-12 AWG.................... 0
CRIMPING INSTRUCTIONS....................................................... 0
PACKARD ELECTRICAL CONNECTORS B.4............................................... 0
GENERAL..................................................................... 0
REMOVING PULL-TO-SEAT TERMINALS/EXTERNAL LATCH TYPE......................... 0
INSTALLING PULL-TO-SEAT TERMINALS/EXTERNAL LATCH TYPE....................... 0
SEALED BUTT SPLICE CONNECTORS B.5............................................... 0
INSTALLING SEALED BUTT SPLICE CONNECTORS.................................... 0
CONNECTOR LOCATIONS B.6......................................................... 0
INDEX TO WIRING DIAGRAMS B.7.................................................... 0
sm_appc.pdf......................................................................... 0
APPENDIX C–METRIC CONVERSIONS C.1............................................... 0
FLUID CONVERSIONS C.2........................................................... 0
UNITED STATES SYSTEM........................................................ 0
METRIC SYSTEM............................................................... 0
BRITISH IMPERIAL SYSTEM..................................................... 0
sm_appd.pdf......................................................................... 0
APPENDIX D: COMPENSATING SPROCKET D.1........................................... 0
GENERAL..................................................................... 0
REMOVAL/DISASSEMBLY......................................................... 0
CLEANING, INSPECTION AND REPAIR............................................. 0
ASSEMBLY/INSTALLATION....................................................... 0
xe01a.pdf........................................................................... 0
STARTER TROUBLESHOOTING 1.1.....................................................454
STARTING SYSTEM DIAGNOSIS 1.2...................................................456
DIAGNOSTICS.................................................................456
Diagnostic Notes........................................................456
Starter Testing 1.......................................................457
Starter Testing 2: Solenoid Clicks......................................458
Starter Testing 3: Relay Clicks.........................................458
Starter Testing 4: Nothing Clicks.......................................459
Starter Testing 5: Starter Spins But Does Not Engage....................460
Starter Testing 6: Starter Stalls or Spins Too Slowly...................460
STARTER ACTIVATION CIRCUITS 1.3.................................................461
DIAGNOSTICS/TROUBLESHOOTING 1.4.................................................462
GENERAL.....................................................................462
VOLTAGE DROPS...............................................................462
TESTING STARTER ON MOTORCYCLE 1.5...............................................464
STARTER RELAY TEST..........................................................464
STARTER CURRENT DRAW TEST...................................................464
TESTING STARTER ON BENCH 1.6....................................................465
FREE RUNNING CURRENT DRAW TEST..............................................465
STARTER SOLENOID............................................................465
SOLENOID PULL-IN TEST.......................................................466
SOLENOID HOLD-IN TEST.......................................................466
SOLENOID RETURN TEST........................................................466
CHARGING SYSTEM 1.7.............................................................467
GENERAL.....................................................................467
Alternator..............................................................467
Voltage Regulator.......................................................467
TROUBLESHOOTING.............................................................467
Battery.................................................................467
Wiring..................................................................467
Voltage Regulator Inspection............................................467
Charging System Test 1.7 (Part 1 of 2)..................................469
Charging System Test 1.7 (Part 2 of 2)..................................470
TESTING.....................................................................471
Milliampere Draw Test...................................................471
Total Current Draw Test.................................................471
Current and Voltage Output Test.........................................472
Voltage Output Test.....................................................472
Stator Check............................................................472
AC Output Check.........................................................473
IGNITION COIL 1.8...............................................................474
TROUBLESHOOTING.............................................................474
Primary Circuit Test....................................................474
Secondary Circuit Test..................................................474
Test Results............................................................474
Ignition Coil Substitution..............................................474
BATTERY LOAD TEST 1.9...........................................................475
GENERAL.....................................................................475
xe02a.pdf........................................................................... 0
CHECKING FOR DIAGNOSTIC TROUBLE CODES 2.1.......................................478
CHECK ENGINE LAMP...........................................................478
SECURITY LAMP...............................................................479
Turn Signal Module (TSM)................................................479
Turn Signal Security Module (TSSM)......................................479
CODE TYPES..................................................................480
Current.................................................................480
Historic................................................................480
RETRIEVING DIAGNOSTIC TROUBLE CODES.........................................480
MULTIPLE DIAGNOSTIC TROUBLE CODES...........................................480
INITIAL DIAGNOSTIC CHECK: SPEEDOMETER 2.2.......................................481
GENERAL.....................................................................481
Diagnostic Notes........................................................481
Circuit Diagram/Wire Harness Connector Table............................481
Job/Time Code Values....................................................481
Reprogramming ICM.......................................................481
INITIAL DIAGNOSTICS.........................................................482
Diagnostic Tips.........................................................482
Diagnostic Notes........................................................482
Other Diagnostic Trouble Codes..........................................482
Initial Diagnostic Check (Part 1 of 3)..................................484
Initial Diagnostic Check (Part 2 of 3)..................................485
Initial Diagnostic Check (Part 3 of 3)..................................486
SPEEDOMETER SELF DIAGNOSTICS 2.3................................................487
GENERAL.....................................................................487
DIAGNOSTICS.................................................................487
Diagnostic Tips.........................................................487
Diagnostic Notes........................................................487
Speedometer Self Diagnostics (flow chart)...............................488
SPEEDOMETER/TACHOMETER 2.4......................................................489
GENERAL.....................................................................489
Reset Switch............................................................489
SPEEDOMETER THEORY OF OPERATION.............................................490
TACHOMETER THEORY OF OPERATION..............................................490
DIAGNOSTICS.................................................................490
Diagnostic Notes........................................................490
Test 2.4 (Part 1 of 2)..................................................492
TACHOMETER INOPERATIVE..................................................492
Test 2.4 (Part 2 of 2)..................................................493
BREAKOUT BOX: SPEEDOMETER/TACHOMETER 2.5........................................494
GENERAL.....................................................................494
SPEEDOMETER.................................................................494
Installation............................................................494
Removal.................................................................494
TACHOMETER..................................................................494
Installation............................................................494
Removal.................................................................494
INDICATOR LAMPS 2.6.............................................................495
GENERAL.....................................................................495
Job/Time Code Values....................................................495
Diagnostic Notes........................................................495
DIAGNOSTICS.................................................................497
Oil Pressure or Neutral Indicator Will Not Function.....................497
High Beam or R/L Turn Signal Indicator Will Not Function................497
DTC B1006, B1007 2.7............................................................498
GENERAL.....................................................................498
Accessory Or Ignition Line Overvoltage..................................498
Test 2.7................................................................499
DTC B1008 2.8...................................................................500
GENERAL.....................................................................500
Reset Switch Closed.....................................................500
Diagnostic Notes........................................................500
Test 2.8................................................................501
DTC U1016, U1255 2.9............................................................502
GENERAL.....................................................................502
Loss of ICM Serial Data.................................................502
DIAGNOSTICS.................................................................502
Diagnostic Notes........................................................502
Test 2.9................................................................504
DTC U1064, U1255 2.10...........................................................505
GENERAL.....................................................................505
Loss of TSM/TSSM Serial Data............................................505
DIAGNOSTICS.................................................................505
Diagnostic Notes........................................................505
Test 2.10...............................................................507
DTC U1300, U1301 OR BUS ER 2.11.................................................508
GENERAL.....................................................................508
Serial Data Low or Serial Data Open/High................................508
DIAGNOSTICS.................................................................508
Diagnostic Tips.........................................................508
Diagnostic Notes........................................................508
Test 2.11 (Part 1 of 2).................................................510
Test 2.11 (Part 2 of 2).................................................511
xe03a.pdf........................................................................... 0
TSM/TSSM OVERVIEW 3.1...........................................................514
GENERAL.....................................................................514
TROUBLESHOOTING.............................................................514
TSM/TSSM FEATURES 3.2...........................................................516
GENERAL.....................................................................516
TURN SIGNAL FUNCTIONS.......................................................516
BANK ANGLE FUNCTIONS........................................................516
SECURITY ALARM AND IMMOBILIZATION FUNCTIONS.................................516
TSSM Only Feature.......................................................516
TSM/TSSM VEHICLE DELIVERY 3.3...................................................518
GENERAL.....................................................................518
SIDECAR CONFIGURATION.......................................................518
POWER DISRUPTION AND CONFIGURING............................................518
KEY FOB ASSIGNMENT..........................................................519
PERSONAL CODE ENTRY.........................................................519
First Time Code Entry: TSSM Only........................................519
Modifying Existing Codes: TSSM Only.....................................519
TSM/TSSM TURN SIGNAL FUNCTIONS 3.4..............................................523
GENERAL.....................................................................523
AUTOMATIC CANCELLATION......................................................523
MANUAL CANCELLATION.........................................................523
FOUR-WAY FLASHING...........................................................523
DIAGNOSTICS MODE............................................................523
TSM/TSSM BANK ANGLE FUNCTION 3.5................................................524
GENERAL.....................................................................524
OPERATION...................................................................524
SECURITY SYSTEM (TSSM) FUNCTIONS 3.6............................................525
GENERAL.....................................................................525
Security System Operation...............................................525
Security System Options.................................................525
Differences By Market Specifications....................................525
ALARM SENSITIVITY...........................................................525
Sensitivity.............................................................525
Transport Mode..........................................................525
AUTO-ARMING FUNCTION........................................................526
STORAGE MODE................................................................526
ARMING/DISARMING SECURITY SYSTEM (TSSM) 3.7.....................................529
GENERAL.....................................................................529
SECURITY LAMP...............................................................529
USING KEY FOB...............................................................529
General.................................................................529
Arming the System.......................................................529
Disarming the System....................................................529
Troubleshooting.........................................................529
USING THE PERSONAL CODE.....................................................530
General.................................................................530
Disarming the System....................................................530
CHECKING FOR DIAGNOSTIC TROUBLE CODES 3.8.......................................531
TSM.........................................................................531
TSSM........................................................................531
CODE TYPES..................................................................533
Current.................................................................533
Historic................................................................533
RETRIEVING DIAGNOSTIC TROUBLE CODES.........................................533
MULTIPLE DIAGNOSTIC TROUBLE CODES...........................................533
INITIAL DIAGNOSTIC CHECK: TSM/TSSM 3.9..........................................534
GENERAL.....................................................................534
Diagnostic Notes........................................................534
Circuit Diagram/Wire Harness Connector Table............................534
Job/Time Code Values....................................................534
Reprogramming ICM.......................................................534
INITIAL DIAGNOSTICS.........................................................534
Diagnostic Tips.........................................................534
Diagnostic Notes........................................................534
Other Diagnostic Trouble Codes (DTCs)...................................534
Initial Diagnostic Check (Part 1 of 3)..................................537
Initial Diagnostic Check (Part 2 of 3)..................................538
Initial Diagnostic Check (Part 3 of 3)..................................539
SPEEDOMETER SELF DIAGNOSTICS 3.10...............................................540
GENERAL.....................................................................540
DIAGNOSTICS.................................................................540
Diagnostic Tips.........................................................540
Diagnostic Notes........................................................540
Speedometer Self Diagnostics (chart)....................................541
BREAKOUT BOX: TSM/TSSM 3.11.....................................................542
GENERAL.....................................................................542
INSTALLATION................................................................542
REMOVAL.....................................................................542
NO SECURITY LAMP AT KEY ON 3.12.................................................543
GENERAL.....................................................................543
No TSSM Power (Security Equipped Vehicles Only).........................543
Job/Time Code Values....................................................543
DIAGNOSTICS.................................................................543
Diagnostic Tips.........................................................543
Diagnostic Notes........................................................543
Test 3.12 (Part 1 of 3).................................................545
Test 3.12 (Part 2 of 3).................................................546
Test 3.12 (Part 3 of 3).................................................547
SECURITY LAMP ON CONTINUOUSLY 3.13..............................................548
GENERAL.....................................................................548
Job/Time Code Values....................................................548
DIAGNOSTICS.................................................................548
Diagnostic Notes........................................................548
Test 3.13...............................................................550
xe03b.pdf........................................................................... 0
KEY FOB SIGNAL TO TSSM WEAK OR FAILS 3.14.......................................552
GENERAL.....................................................................552
Security Equipped Vehicles Only.........................................552
Job/Time Code Values....................................................552
DIAGNOSTICS.................................................................552
Diagnostic Tips.........................................................552
Diagnostic Notes........................................................552
Test 3.14...............................................................554
TURN SIGNAL ERRORS 3.15.........................................................555
GENERAL.....................................................................555
Job/Time Code Values....................................................555
DIAGNOSTICS.................................................................555
Diagnostic Tips.........................................................555
Diagnostic Notes: All Turn Signal Flow Charts...........................558
Turn Signal Error 1A (Part 1 of 2)......................................560
Turn Signal Error 1A (Part 2 of 2)......................................561
Turn Signal Error 2A....................................................562
Turn Signal Error 2B....................................................563
Turn Signal Error 2C....................................................564
Turn Signal Error 2D....................................................565
Turn Signal Error 3A....................................................566
DTC B0563 3.16..................................................................567
GENERAL.....................................................................567
Battery Voltage High....................................................567
DIAGNOSTICS.................................................................567
Diagnostic Tips.........................................................567
Diagnostic Notes........................................................567
DTC B1131, B1132 3.17...........................................................568
GENERAL.....................................................................568
Alarm Output Low (DTC B1131) or Alarm Output High (DTC B1132)...........568
DIAGNOSTICS.................................................................568
Diagnostic Tips.........................................................568
Diagnostic Notes........................................................568
Test 3.17...............................................................570
DTC B1134 3.18..................................................................571
GENERAL.....................................................................571
Starter Output High.....................................................571
DIAGNOSTICS.................................................................571
Diagnostic Notes........................................................571
Test 3.18...............................................................573
DTC B1135 3.19..................................................................574
GENERAL.....................................................................574
Accelerometer Fault.....................................................574
DTC U1016, U1255 3.20...........................................................575
GENERAL.....................................................................575
Loss of ICM Serial Data.................................................575
DIAGNOSTICS.................................................................575
Diagnostic Notes........................................................575
Test 3.20...............................................................577
DTC U1097, U1255 3.21...........................................................578
GENERAL.....................................................................578
Loss of Speedometer Serial Data.........................................578
DIAGNOSTICS.................................................................578
Diagnostic Notes........................................................578
Test 3.21...............................................................580
DTC U1300, U1301 OR BUS ER 3.22.................................................581
GENERAL.....................................................................581
DIAGNOSTICS.................................................................581
Diagnostic Tips.........................................................581
Diagnostic Notes........................................................581
PASSWORD LEARN 3.23.............................................................582
GENERAL.....................................................................582
PASSWORD LEARNING...........................................................582
TSSM MAINTENANCE 3.24...........................................................584
GENERAL.....................................................................584
KEY FOB.....................................................................584
Schedule................................................................584
Battery Replacement.....................................................584
SIREN (IF INSTALLED)........................................................585
Schedule................................................................585
Battery Replacement.....................................................585
xe04a.pdf........................................................................... 0
SPECIFICATIONS 4.1..............................................................588
DIAGNOSTIC INTRODUCTION 4.2.....................................................589
SYSTEM PROBLEMS.............................................................589
No Start................................................................589
Poor Performance........................................................589
Check Engine Lamp.......................................................589
RESOLVING PROBLEMS..........................................................589
CHECKING FOR DIAGNOSTIC TROUBLE CODES 4.3.......................................590
CHECK ENGINE LAMP...........................................................590
SECURITY LAMP...............................................................591
CODE TYPES..................................................................591
Current.................................................................591
Historic................................................................591
RETRIEVING DIAGNOSTIC TROUBLE CODES.........................................592
MULTIPLE DIAGNOSTIC TROUBLE CODES...........................................592
INITIAL DIAGNOSTIC CHECK: ICM 4.4...............................................593
GENERAL.....................................................................593
Diagnostic Notes........................................................593
Circuit Diagram/Wire Harness Connector Table............................593
Reprogramming ICM.......................................................593
INITIAL DIAGNOSTICS.........................................................593
General Information.....................................................593
Diagnostic Tips.........................................................593
Diagnostic Notes........................................................593
Other DTCs..............................................................593
Initial Diagnostic Check (Part 1 of 3)..................................597
Initial Diagnostic Check (Part 2 of 3)..................................598
Initial Diagnostic Check (Part 3 of 3)..................................599
SPEEDOMETER SELF DIAGNOSTICS 4.5................................................600
GENERAL.....................................................................600
DIAGNOSTICS.................................................................600
Diagnostic Tips.........................................................600
Diagnostic Notes........................................................600
Speedometer Self Diagnostics (flow chart)...............................601
BREAKOUT BOX: ICM 4.6...........................................................602
GENERAL.....................................................................602
INSTALLATION................................................................602
REMOVAL.....................................................................602
WIGGLE TEST 4.7.................................................................603
GENERAL.....................................................................603
PROCEDURE...................................................................603
Using DVOM (Part No. HD-39978)..........................................603
INTAKE LEAK TEST 4.8............................................................604
GENERAL.....................................................................604
LEAK TESTER.................................................................604
Parts List..............................................................604
Tester Assembly.........................................................604
PROCEDURE...................................................................605
ENGINE CRANKS BUT WILL NOT START 4.9............................................606
GENERAL.....................................................................606
DIAGNOSTICS.................................................................606
Diagnostic Notes........................................................606
Test 4.9 (Part 1 of 3)..................................................608
Test 4.9 (Part 2 of 3)..................................................609
Test 4.9 (Part 3 of 3)..................................................610
STARTS THEN STALLS 4.10.........................................................611
GENERAL.....................................................................611
Serial Data Low or Serial Data Open/High................................611
DIAGNOSTICS.................................................................611
Diagnostic Tips.........................................................611
Diagnostic Notes........................................................611
Test 4.10 (Part 1 of 2).................................................613
Test 4.10 (Part 2 of 2).................................................614
NO SPARK/NO ICM POWER 4.11......................................................615
GENERAL.....................................................................615
DIAGNOSTICS.................................................................615
Diagnostic Notes........................................................615
Test 4.11...............................................................617
MISFIRE 4.12....................................................................618
GENERAL.....................................................................618
Misfire at Idle or Under Load...........................................618
DIAGNOSTICS.................................................................618
Diagnostic Notes........................................................618
Test 4.12...............................................................620
xe04b.pdf........................................................................... 0
DTC P0106, P0107, P0108 4.13....................................................622
GENERAL.....................................................................622
MAP Sensor..............................................................622
DIAGNOSTICS.................................................................622
Diagnostic Tips.........................................................622
Diagnostic Notes........................................................622
Test 4.13 (Part 1 of 2).................................................624
Test 4.13 (Part 2 of 2).................................................625
DTC P0371, P0372, P0374 4.14....................................................626
GENERAL.....................................................................626
Crank Position Sensor...................................................626
DIAGNOSTICS.................................................................626
Diagnostic Notes........................................................626
Test 4.14...............................................................628
DTC P0501, P0502 4.15...........................................................629
GENERAL.....................................................................629
Vehicle Speed Sensor....................................................629
DIAGNOSTICS.................................................................629
Diagnostic Notes........................................................629
Test 4.15 (Part 1 of 2).................................................631
Test 4.15 (Part 2 of 2).................................................632
DTC P0562, P0563 4.16...........................................................633
GENERAL.....................................................................633
Battery Voltage.........................................................633
DIAGNOSTICS.................................................................633
Diagnostic Notes........................................................633
Test 4.16 (Part 1 of 2).................................................635
Test 4.16 (Part 2 of 2).................................................636
DTC P0602, P0603, P0604, P0605, P0607 4.17......................................637
GENERAL.....................................................................637
ICM Failure.............................................................637
DIAGNOSTICS.................................................................637
DTC P0607 Test..........................................................637
DTC P0602, P0603, P0604, P0605 Test.....................................637
DTC P1009, P1010 4.18...........................................................638
GENERAL.....................................................................638
Password Problem........................................................638
DIAGNOSTICS.................................................................638
Diagnostic Notes........................................................638
Test 4.18...............................................................640
DTC P1351, P1352, P1354, P1355 4.19.............................................641
GENERAL.....................................................................641
Ignition Coil...........................................................641
DIAGNOSTICS.................................................................641
Diagnostic Notes........................................................641
Test 4.19 (Part 1 of 2).................................................643
Test 4.19 (Part 2 of 2).................................................644
DTC U1064 4.20..................................................................645
GENERAL.....................................................................645
Loss of TSM/TSSM Serial Data............................................645
DIAGNOSTICS.................................................................645
Diagnostic Notes........................................................645
Test 4.20...............................................................647
DTC U1097 4.21..................................................................648
GENERAL.....................................................................648
Loss of Speedometer Serial Data.........................................648
DIAGNOSTICS.................................................................648
Diagnostic Notes........................................................648
Test 4.21...............................................................650
xe05a.pdf........................................................................... 0
CONNECTOR LOCATIONS 5.1.........................................................654
AMP MULTILOCK ELECTRICAL CONNECTORS 5.2.........................................655
REMOVING SOCKET/PIN TERMINALS...............................................655
INSTALLING SOCKET/PIN TERMINALS.............................................655
CRIMPING INSTRUCTIONS.......................................................658
DEUTSCH ELECTRICAL CONNECTORS 5.3...............................................659
GENERAL.....................................................................659
REMOVING/DISASSEMBLING......................................................659
REMOVING/INSTALLING SOCKETS.................................................659
REMOVING/INSTALLING PINS....................................................660
ASSEMBLING/INSTALLING.......................................................661
CRIMPING INSTRUCTIONS.......................................................662
MINI-DEUTSCH ELECTRICAL CONNECTORS 5.4..........................................664
GENERAL.....................................................................664
For Size 20, 16 and 12 Contacts Wire Range 26-12 AWG....................664
CRIMPING INSTRUCTIONS.......................................................664
SEALED BUTT SPLICE CONNECTORS 5.5...............................................666
INSTALLATION................................................................666
PACKARD ELECTRICAL CONNECTORS 5.6...............................................667
GENERAL.....................................................................667
PULL-TO-SEAT TERMINALS......................................................668
Removing External Latch Type............................................668
Installing External Latch Type..........................................668
PUSH-TO-SEAT TERMINALS......................................................668
Removing Push-to-Seat Terminals.........................................668
Installing Push-to-Seat Terminals.......................................669
CRIMPING INSTRUCTIONS.......................................................669
MICRO 64 TERMINALS..........................................................671
General.................................................................671
Removal.................................................................671
Installation............................................................671
Crimping Instructions...................................................672
INDEX TO WIRING DIAGRAMS 5.7....................................................673
sm_appa.pdf......................................................................... 0
APPENDIX A–TOOLS A.1............................................................694
sm_appb1.pdf........................................................................ 0
APPENDIX B–WIRING AMP MULTILOCK ELECTRICAL CONNECTORS B.1.......................712
REMOVING SOCKET/PIN TERMINALS...............................................712
INSTALLING SOCKET/PIN TERMINALS.............................................714
CRIMPING INSTRUCTIONS.......................................................716
DEUTSCH ELECTRICAL CONNECTORS B.2...............................................717
GENERAL.....................................................................717
REMOVING/DISASSEMBLING......................................................717
REMOVING/INSTALLING SOCKETS.................................................717
REMOVING/INSTALLING PINS....................................................719
ASSEMBLING/INSTALLING.......................................................719
CRIMPING INSTRUCTIONS.......................................................719
MINI-DEUTSCH CONNECTORS B.3.....................................................722
GENERAL.....................................................................722
For Size 20, 16 and 12 Contacts Wire Range 26-12 AWG....................722
CRIMPING INSTRUCTIONS.......................................................722
PACKARD ELECTRICAL CONNECTORS B.4...............................................724
GENERAL.....................................................................724
REMOVING PULL-TO-SEAT TERMINALS/EXTERNAL LATCH TYPE.........................724
INSTALLING PULL-TO-SEAT TERMINALS/EXTERNAL LATCH TYPE.......................725
SEALED BUTT SPLICE CONNECTORS B.5...............................................726
INSTALLING SEALED BUTT SPLICE CONNECTORS....................................726
CONNECTOR LOCATIONS B.6.........................................................727
INDEX TO WIRING DIAGRAMS B.7....................................................728
sm_appc.pdf......................................................................... 0
APPENDIX C–METRIC CONVERSIONS C.1...............................................748
FLUID CONVERSIONS C.2...........................................................749
UNITED STATES SYSTEM........................................................749
METRIC SYSTEM...............................................................749
BRITISH IMPERIAL SYSTEM.....................................................749
sm_appd.pdf......................................................................... 0
APPENDIX D: COMPENSATING SPROCKET D.1...........................................750
GENERAL.....................................................................750
REMOVAL/DISASSEMBLY.........................................................750
CLEANING, INSPECTION AND REPAIR.............................................751
ASSEMBLY/INSTALLATION.......................................................751
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