2006 Harley Davidson Sportster XLH Models Electrical Diagnostics + Service Manual – PDF DOWNLOAD
IMAGES PREVIEW OF THE MANUAL:
2006 Harley Davidson Sportster XLH Models Electrical Diagnostics + Service Manual – PDF DOWNLOAD2006 Harley Davidson Sportster XLH Models Electrical Diagnostics + Service Manual – PDF DOWNLOAD
DESCRIPTION:
2006 Harley Davidson Sportster XLH Models Electrical Diagnostics + Service Manual – PDF DOWNLOAD
SERVICE MANUAL
Part Number 99484-06
ELECTRICAL DIAGNOSTICS Part Number 99495-06
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:
2006 Harley Davidson Sportster XLH Models Electrical Diagnostics + Service Manual – PDF DOWNLOAD
2006 XLH MODELS................................................................. 1
SERVICE MANUAL.............................................................. 1
Part Number 99484-06.................................................... 1
ELECTRICAL DIAGNOSTICS...................................................... 1
Part Number 99495-06.................................................... 1
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................................................ 6
Magnetic Parts Trays.................................................... 6
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)............................................ 7
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.................................................. 8
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
GENERAL..................................................................... 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
LEFT SIDE COVER 1.6............................................................. 18
GENERAL..................................................................... 18
OPENING LEFT SIDE COVER..................................................... 19
CLOSING LEFT SIDE COVER..................................................... 19
REMOVING LEFT SIDE COVER.................................................... 19
INSTALLING LEFT SIDE COVER.................................................. 19
BATTERY MAINTENANCE 1.7......................................................... 20
GENERAL..................................................................... 20
BATTERY DISCONNECTION AND REMOVAL........................................... 21
BATTERY INSPECTION.......................................................... 22
BATTERY STORAGE............................................................. 22
BATTERY INSTALLATION AND CONNECTION......................................... 23
BRAKES 1.8...................................................................... 24
GENERAL..................................................................... 24
INSPECTION.................................................................. 24
TROUBLESHOOTING............................................................. 24
BLEEDING HYDRAULIC BRAKE SYSTEM 1.9............................................. 25
GENERAL..................................................................... 25
BLEEDING FRONT BRAKE........................................................ 25
BLEEDING REAR BRAKE......................................................... 27
BRAKE PADS AND DISCS 1.10....................................................... 28
INSPECTION.................................................................. 28
Brake Pads.............................................................. 28
Brake Disc Thickness, Lateral Runout and Warpage........................ 28
BRAKE PAD REPLACEMENT– FRONT................................................ 29
BRAKE PAD REPLACEMENT–REAR.................................................. 32
TIRES AND WHEELS 1.11........................................................... 35
TIRES....................................................................... 35
TIRE WEAR INDICATORS........................................................ 35
WHEEL BEARINGS.............................................................. 36
WHEEL SPOKES................................................................ 36
PRIMARY CHAIN 1.12.............................................................. 37
INSPECTION.................................................................. 37
ADJUSTMENT.................................................................. 38
CLUTCH 1.13..................................................................... 39
ADJUSTMENT.................................................................. 39
TRANSMISSION LUBRICANT 1.14..................................................... 41
GENERAL..................................................................... 41
DRAINING LUBRICANT.......................................................... 41
REFILLING LUBRICANT......................................................... 41
REAR BELT DEFLECTION 1.15....................................................... 43
INSPECTION.................................................................. 43
BELT DEFLECTION ADJUSTMENT.................................................. 45
WHEEL ALIGNMENT............................................................. 46
Checking Wheel Alignment................................................ 46
Adjusting Wheel Alignment............................................... 46
REAR BELT AND SPROCKETS 1.16.................................................... 47
GENERAL..................................................................... 47
CLEANING.................................................................... 47
INSPECTION.................................................................. 47
Sprockets............................................................... 47
Rear Belt............................................................... 47
SHOCK ABSORBER ADJUSTMENT 1.17.................................................. 49
GENERAL..................................................................... 49
PROCEDURE................................................................... 49
STEERING HEAD BEARINGS 1.18..................................................... 50
GENERAL..................................................................... 50
ADJUSTMENT.................................................................. 50
LUBRICATION................................................................. 50
REAR FORK BEARINGS 1.19......................................................... 51
GENERAL..................................................................... 51
PROCEDURE................................................................... 51
FRONT FORK OIL 1.20............................................................. 53
GENERAL..................................................................... 53
CHANGING FORK OIL........................................................... 53
Filling Fork Oil: Forks Assembled, in Frame............................. 54
Filling Fork Oil: Forks Disassembled, out of Frame...................... 54
SPARK PLUGS 1.21................................................................ 55
GENERAL..................................................................... 55
ADJUSTMENT.................................................................. 55
CLEANING AND INSPECTION..................................................... 55
Inspection.............................................................. 55
Spark Plug Condition.................................................... 55
Cleaning................................................................ 55
INSTALLATION................................................................ 55
CABLE AND CHASSIS LUBRICATION 1.22.............................................. 56
GENERAL..................................................................... 56
CABLES AND HAND LEVERS...................................................... 56
FOOT SHIFT LEVER AND REAR BRAKE PEDAL....................................... 56
JIFFY STAND................................................................. 56
STEERING HEAD BEARINGS...................................................... 56
AIR FILTER ELEMENT 1.23......................................................... 57
GENERAL..................................................................... 57
REMOVAL..................................................................... 57
CLEANING, INSPECTION AND REPAIR............................................. 58
INSTALLATION................................................................ 58
THROTTLE CABLES AND ENRICHENER 1.24............................................. 59
CABLE INSPECTION, LUBRICATION AND ADJUSTMENT................................ 59
Inspection and Lubrication.............................................. 59
Adjustment.............................................................. 59
ENRICHENER ADJUSTMENT....................................................... 60
IDLE SPEED AND IGNITION TIMING 1.25............................................. 61
IDLE SPEED ADJUSTMENT....................................................... 61
IGNITION TIMING............................................................. 61
FUEL SUPPLY VALVE FILTER 1.26................................................... 62
INSPECTION.................................................................. 62
FUEL SYSTEM LINES AND FITTINGS.............................................. 63
ENGINE MOUNTS AND STABILIZER LINKS 1.27......................................... 64
INSPECTION.................................................................. 64
HEADLAMP ALIGNMENT 1.28......................................................... 65
INSPECTION.................................................................. 65
ADJUSTMENT.................................................................. 66
XL 883, XL 883L, XL 883R, XL 1200R...................................... 66
XL 883C, XL 1200C....................................................... 66
FLUID/LUBRICANT REQUIREMENTS 1.29............................................... 67
BRAKE FLUID................................................................. 67
BRAKE COMPONENT GREASE...................................................... 67
FRONT FORK OIL.............................................................. 67
ENGINE OIL.................................................................. 67
PRIMARY DRIVE/TRANSMISSION LUBRICANT........................................ 67
STORAGE 1.30.................................................................... 68
GENERAL..................................................................... 68
REMOVAL FROM STORAGE........................................................ 69
TROUBLESHOOTING 1.31............................................................ 70
GENERAL..................................................................... 70
ENGINE...................................................................... 70
Starting Motor Does Not Operate or Does Not Turn Engine Over............ 70
Engine Turns Over But Does Not Start.................................... 70
Starts Hard............................................................. 70
Starts But Runs Irregularly or Misses................................... 71
Spark Plug Fouls Repeatedly............................................. 71
Pre-Ignition or Detonation (Knocks or Pings)............................ 71
Overheating............................................................. 71
Valve Train Noise....................................................... 71
Excessive Vibration..................................................... 71
ENGINE LUBRICATION SYSTEM................................................... 72
Oil Does Not Return To Oil Tank......................................... 72
Engine Uses Too Much Oil or Smokes Excessively.......................... 72
Engine Leaks Oil From Cases, Push Rods, Hoses, Etc...................... 72
FUEL........................................................................ 72
Carburetor Floods....................................................... 72
ELECTRICAL SYSTEM........................................................... 72
Alternator Does Not Charge.............................................. 72
Alternator Charge Rate Is Below Normal.................................. 72
Speedometer Operates Erratically........................................ 72
TRANSMISSION................................................................ 72
Shifts Hard............................................................. 72
Jumps Out of Gear....................................................... 72
CLUTCH...................................................................... 73
Slips................................................................... 73
Drags or Does Not Release............................................... 73
Chatters................................................................ 73
CHASSIS..................................................................... 73
Irregular/Inadequate Brake Action....................................... 73
Handling Irregularities................................................. 73
SPECIFICATIONS 2.1.............................................................. 77
TIRES....................................................................... 78
TORQUE VALUES 2.2............................................................... 79
VEHICLE IDENTIFICATION NUMBER (VIN) 2.3......................................... 82
GENERAL..................................................................... 82
WHEELS 2.4...................................................................... 84
GENERAL..................................................................... 84
TROUBLESHOOTING............................................................. 85
FRONT WHEEL................................................................. 86
Removal................................................................. 86
Disassembly............................................................. 87
Cleaning and Inspection................................................. 87
Assembly................................................................ 87
Installation............................................................ 90
REAR WHEEL.................................................................. 91
Removal................................................................. 91
Disassembly............................................................. 92
Cleaning and Inspection................................................. 92
Assembly................................................................ 92
Installation............................................................ 94
SEALED WHEEL BEARINGS....................................................... 95
Inspection.............................................................. 95
Removal................................................................. 96
Installation............................................................ 97
WHEEL LACING: 16 INCH RIM 2.5................................................... 98
GENERAL..................................................................... 98
PROCEDURE................................................................... 99
WHEEL LACING: 19 INCH RIM 2.6...................................................101
GENERAL.....................................................................101
PROCEDURE...................................................................101
WHEEL LACING: 21 INCH RIM 2.7...................................................105
GENERAL.....................................................................105
PROCEDURE...................................................................105
TRUING LACED WHEELS 2.8.........................................................109
PROCEDURE...................................................................109
CHECKING CAST WHEEL RUNOUT 2.9..................................................112
CHECKING LATERAL AND RADIAL RUNOUT..........................................112
TIRES 2.10......................................................................113
GENERAL.....................................................................113
REMOVAL.....................................................................113
CLEANING, INSPECTION AND REPAIR.............................................114
INSTALLATION................................................................114
Tube Type Tires.........................................................114
Tubeless Tires..........................................................115
CHECKING TIRE RUNOUT........................................................115
Lateral Runout..........................................................115
Radial Runout...........................................................116
WHEEL BALANCING.............................................................116
Weights For Laced Wheels................................................116
Weights for Cast Wheels.................................................116
FRONT BRAKE MASTER CYLINDER 2.11................................................117
GENERAL.....................................................................117
REMOVAL.....................................................................117
DISASSEMBLY.................................................................120
CLEANING, INSPECTION AND REPAIR.............................................121
ASSEMBLY....................................................................121
INSTALLATION................................................................123
REAR BRAKE MASTER CYLINDER 2.12.................................................125
GENERAL.....................................................................125
INSPECTION..................................................................125
REMOVAL.....................................................................126
DISASSEMBLY.................................................................128
CLEANING, INSPECTION AND REPAIR.............................................130
ASSEMBLY....................................................................130
INSTALLATION................................................................133
REAR BRAKE MASTER CYLINDER RESERVOIR 2.13.......................................134
GENERAL.....................................................................134
REMOVAL.....................................................................134
INSTALLATION................................................................135
FRONT BRAKE CALIPER 2.14........................................................136
REMOVAL.....................................................................136
DISASSEMBLY.................................................................137
CLEANING, INSPECTION AND REPAIR.............................................139
ASSEMBLY....................................................................139
LUBRICATING FRONT CALIPER BOLT PINS AND BOOTS...............................140
INSTALLING BRAKE PADS IN CALIPER............................................141
INSTALLATION................................................................141
REAR BRAKE CALIPER 2.15.........................................................144
REMOVAL.....................................................................144
DISASSEMBLY.................................................................146
CLEANING, INSPECTION AND REPAIR.............................................147
ASSEMBLY....................................................................148
LUBRICATING REAR CALIPER BOLT PINS AND BOOTS................................149
INSTALLATION................................................................150
BRAKE LINES 2.16................................................................153
FRONT BRAKE LINE............................................................153
Removal.................................................................153
Installation............................................................154
REAR BRAKE LINE.............................................................155
Removal.................................................................155
Installation............................................................156
FRONT FORK 2.17.................................................................157
GENERAL.....................................................................157
REMOVAL.....................................................................157
DISASSEMBLY.................................................................157
CLEANING, INSPECTION AND REPAIR.............................................157
ASSEMBLY....................................................................159
INSTALLATION................................................................159
FORK STEM AND BRACKET ASSEMBLY 2.18.............................................160
GENERAL.....................................................................160
REMOVAL/DISASSEMBLY.........................................................160
CLEANING, INSPECTION AND REPAIR.............................................160
ASSEMBLY/INSTALLATION.......................................................160
REAR FORK 2.19..................................................................161
GENERAL.....................................................................161
REMOVAL.....................................................................161
DISASSEMBLY.................................................................162
CLEANING AND INSPECTION.....................................................162
ASSEMBLY....................................................................162
INSTALLATION................................................................163
REAR SHOCK ABSORBERS 2.20.......................................................164
GENERAL.....................................................................164
REMOVAL.....................................................................164
CLEANING AND INSPECTION.....................................................164
INSTALLATION................................................................164
STABILIZER LINKS 2.21...........................................................165
GENERAL.....................................................................165
UPPER FRONT STABILIZER LINK.................................................165
Removal.................................................................165
Installation............................................................165
LOWER FRONT STABILIZER LINK.................................................166
Removal.................................................................166
Installation............................................................166
REAR STABILIZER LINK........................................................166
Removal.................................................................166
Installation............................................................166
FRONT ENGINE MOUNT/ISOLATOR 2.22................................................167
GENERAL.....................................................................167
REMOVAL.....................................................................167
INSTALLATION................................................................168
REAR ENGINE MOUNT/ISOLATOR 2.23.................................................169
GENERAL.....................................................................169
REMOVAL.....................................................................169
INSTALLATION................................................................171
THROTTLE CONTROL 2.24...........................................................172
REMOVAL/DISASSEMBLY.........................................................172
CLEANING, INSPECTION AND REPAIR.............................................172
ASSEMBLY/INSTALLATION.......................................................172
HANDLEBARS 2.25.................................................................174
REMOVAL.....................................................................174
All Models..............................................................174
XL 883, XL 883L, XL 883R, XL 1200R......................................174
XL 883C, XL 1200C.......................................................175
INSTALLATION................................................................175
XL 883, XL 883L, XL 883R, XL 1200R......................................175
XL 883C, XL 1200C.......................................................175
All Models..............................................................176
CLUTCH CONTROL 2.26.............................................................177
GENERAL.....................................................................177
REMOVAL/DISASSEMBLY.........................................................177
Clutch Cable–Lower......................................................177
Clutch Lever and Clutch Cable–Upper.....................................178
Clutch Hand Control.....................................................178
ASSEMBLY/INSTALLATION.......................................................178
Clutch Hand Control.....................................................178
Clutch Lever and Clutch Cable–Upper.....................................179
Clutch Cable–Lower......................................................179
Finish..................................................................179
EXHAUST SYSTEM 2.27.............................................................180
REMOVAL.....................................................................180
Mufflers and Exhaust Pipes..............................................180
Muffler Interconnect Bracket............................................181
INSTALLATION................................................................182
Muffler Interconnect Bracket............................................182
Exhaust Pipes and Mufflers..............................................182
FRONT FENDER 2.28...............................................................183
REMOVAL.....................................................................183
INSTALLATION................................................................183
REAR FENDER 2.29................................................................184
REMOVAL.....................................................................184
INSTALLATION................................................................186
BELT GUARD AND DEBRIS DEFLECTOR 2.30............................................188
REMOVAL.....................................................................188
Belt Guard..............................................................188
Debris Deflector........................................................188
INSTALLATION................................................................188
Belt Guard..............................................................188
Debris Deflector........................................................188
JIFFY STAND 2.31................................................................189
GENERAL.....................................................................189
REMOVAL.....................................................................190
CLEANING AND LUBRICATION....................................................190
INSTALLATION................................................................190
SEAT 2.32.......................................................................191
GENERAL.....................................................................191
REMOVAL.....................................................................191
INSTALLATION................................................................191
RIDER FOOT CONTROLS: XL 883, XL 883L, XL 883R, XL 1200R 2.33....................193
RIGHT FOOTREST AND REAR BRAKE PEDAL ASSEMBLY................................193
Removal.................................................................193
Installation............................................................193
LEFT FOOTREST AND SHIFT LEVER ASSEMBLY......................................193
Removal.................................................................193
Installation............................................................193
RIDER FOOT CONTROLS: XL 883C, XL 1200C 2.34.....................................195
RIGHT FOOTREST AND REAR BRAKE PEDAL ASSEMBLY................................195
Removal.................................................................195
Installation............................................................195
LEFT FOOTREST AND SHIFT LEVER ASSEMBLY......................................197
Removal.................................................................197
Installation............................................................197
ADJUSTING SHIFT PEDAL.......................................................198
PASSENGER FOOTRESTS 2.35........................................................199
GENERAL.....................................................................199
REMOVAL.....................................................................199
INSTALLATION................................................................199
FORK LOCK 2.36..................................................................200
REMOVAL.....................................................................200
INSTALLATION................................................................201
SPECIFICATIONS 3.1..............................................................205
SERVICE WEAR LIMITS 3.2.........................................................208
GENERAL.....................................................................208
TORQUE VALUES 3.3...............................................................210
ENGINE 3.4......................................................................212
GENERAL.....................................................................212
TROUBLESHOOTING 3.5.............................................................213
DIAGNOSING VALVE TRAIN NOISE................................................213
COMPRESSION TEST............................................................213
Compression Test Procedure..............................................213
CYLINDER LEAKAGE TEST.......................................................214
Cylinder Leakage Test Procedure.........................................214
DIAGNOSING SMOKING ENGINE OR HIGH OIL CONSUMPTION...........................215
Check Prior To Cylinder Head Removal....................................215
Check After Cylinder Head Removal.......................................215
ADJUSTMENT/TESTING..........................................................215
General.................................................................215
ENGINE LUBRICATION SYSTEM 3.6...................................................216
GENERAL.....................................................................216
OIL PUMP....................................................................216
OIL PRESSURE 3.7................................................................219
GENERAL.....................................................................219
Oil Pressure Indicator Lamp.............................................219
CHECKING OIL PRESSURE.......................................................219
CRANKCASE BREATHING SYSTEM 3.8..................................................221
GENERAL.....................................................................221
HOW TO USE THIS SECTION 3.9.....................................................222
TYPICAL SYMPTOMS............................................................222
TOP END REPAIR..............................................................222
BOTTOM END REPAIR...........................................................222
TOP END SERVICE 3.10............................................................223
ENGINE IN CHASSIS...........................................................223
ENGINE REMOVED FROM CHASSIS.................................................224
BOTTOM END SERVICE 3.11.........................................................225
ENGINE IN CHASSIS: CAM COMPARTMENT SERVICE..................................225
ENGINE REMOVED: FLYWHEEL COMPARTMENT SERVICE OR COMPLETE ENGINE OVERHAUL....226
REMOVING ENGINE FROM CHASSIS 3.12...............................................227
GENERAL.....................................................................227
PROCEDURE...................................................................227
INSTALLING ENGINE IN CHASSIS 3.13...............................................231
GENERAL.....................................................................231
PROCEDURE...................................................................231
TOP END OVERHAUL: DISASSEMBLY 3.14..............................................234
GENERAL.....................................................................234
STRIPPING MOTORCYCLE FOR TOP END REPAIR.....................................234
CYLINDER HEAD...............................................................235
Disassembling Rocker Covers.............................................235
Removing Cylinder Head..................................................236
Disassembling Push Rods and Covers......................................238
CYLINDER AND PISTON.........................................................238
CYLINDER HEAD 3.15..............................................................241
GENERAL.....................................................................241
REMOVAL.....................................................................241
DISASSEMBLY.................................................................241
CLEANING AND INSPECTION.....................................................242
Cylinder Heads..........................................................242
Rocker Arm Assemblies...................................................243
Valves..................................................................244
Valve Seats.............................................................244
Valve Guides............................................................244
Valve Springs...........................................................244
Spark Plug Threads......................................................245
Push Rods...............................................................245
REPLACING ROCKER ARM BUSHINGS...............................................245
REPLACING VALVE GUIDES......................................................246
Removal.................................................................246
Installation............................................................247
REFACING VALVE SEATS........................................................250
Replacing Valve Seats...................................................252
ASSEMBLY....................................................................253
INSTALLATION................................................................254
CYLINDER AND PISTON 3.16........................................................255
REMOVAL/DISASSEMBLY.........................................................255
CLEANING, INSPECTION, AND REPAIR............................................255
Checking Gasket Surface.................................................255
Measuring Cylinder Bore.................................................256
Measuring Piston to Cylinder Fit........................................257
Boring and Honing Cylinder..............................................257
Fitting Piston Rings....................................................258
CONNECTING ROD BUSHINGS.....................................................260
Removing Upper Connecting Rod Bushing...................................260
Installing Upper Connecting Rod Bushing.................................261
Reaming Upper Connecting Rod Bushing....................................262
Honing Upper Connecting Rod Bushing.....................................263
Repair..................................................................263
ASSEMBLY/INSTALLATION.......................................................263
TOP END OVERHAUL: ASSEMBLY 3.17.................................................264
GENERAL.....................................................................264
PISTON AND CYLINDER.........................................................264
PUSH RODS, COVERS AND RETAINERS.............................................266
CYLINDER HEAD...............................................................267
Rocker Covers...............................................................269
ASSEMBLING MOTORCYCLE AFTER TOP END REPAIR..................................271
BOTTOM END OVERHAUL: DISASSEMBLY 3.18...........................................272
GENERAL.....................................................................272
TAPPETS.....................................................................272
OIL PUMP....................................................................272
GEARCASE COVER AND CAM GEARS................................................273
CRANKCASE...................................................................274
Removing Piston Oil Jets................................................275
Removing Cylinder Base Studs............................................275
VALVE TAPPETS 3.19..............................................................276
GENERAL.....................................................................276
REMOVAL.....................................................................276
CLEANING AND INSPECTION.....................................................276
INSTALLATION................................................................276
GEARCASE COVER AND CAM GEARS 3.20...............................................278
GENERAL.....................................................................278
REMOVAL/DISASSEMBLY.........................................................278
CLEANING, INSPECTION AND REPAIR.............................................278
Cam and Pinion Gear Identification, Inspection and Selection............278
Bushing Inspection and Removal..........................................280
BUSHING INSTALLATION........................................................280
Cam Gear Bushings in Right Crankcase....................................280
Cam Gear Bushings (Except Rear Intake Bushing) in Gearcase Cover........281
Rear Intake Cam Gear Bushing in Gearcase Cover..........................281
Pinion Shaft Bushing in Gearcase Cover..................................281
BUSHING REAMING.............................................................282
Cam Gear Bushings in Right Crankcase....................................282
Cam Gear Bushings (Except Rear Intake Bushing) in Gearcase Cover........283
Rear Intake Cam Gear Bushing in Gearcase Cover..........................283
Pinion Shaft Bushing in Gearcase Cover..................................284
ASSEMBLY/INSTALLATION.......................................................284
OIL PUMP 3.21...................................................................285
GENERAL.....................................................................285
REMOVAL.....................................................................285
DISASSEMBLY.................................................................286
CLEANING, INSPECTION AND REPAIR.............................................286
ASSEMBLY....................................................................286
INSTALLATION................................................................286
OIL FILTER MOUNT 3.22...........................................................287
GENERAL.....................................................................287
DISASSEMBLY.................................................................287
CLEANING AND INSPECTION.....................................................287
ASSEMBLY....................................................................287
CRANKCASE 3.23..................................................................288
GENERAL.....................................................................288
REMOVAL.....................................................................288
DISASSEMBLY.................................................................288
FITTING PINION BEARINGS.....................................................291
Bearing Selection.......................................................292
LAPPING ENGINE MAIN BEARING RACES...........................................296
Assembling Crankcase Halves.................................................296
BOTTOM END OVERHAUL: ASSEMBLY 3.24..............................................297
GENERAL.....................................................................297
CRANKCASE...................................................................297
Installing Piston Oil Jets..............................................297
Installing Pinion Shaft Bearing.........................................298
Installing Left Main Bearing............................................299
Assembling Crankcase Halves.............................................299
Installing Cylinder Base Studs..........................................302
CAM GEARS AND GEARCASE COVER................................................303
TAPPETS.....................................................................306
ASSEMBLING TOP END OF ENGINE................................................306
OIL TANK 3.25...................................................................307
OIL HOSE ROUTING............................................................307
REMOVAL.....................................................................308
INSTALLATION................................................................310
SPECIFICATIONS 4.1..............................................................314
TORQUE VALUES 4.2...............................................................315
TROUBLESHOOTING 4.3.............................................................316
ENRICHENER 4.4..................................................................318
GENERAL.....................................................................318
OPERATION...................................................................318
Cool Engine.............................................................318
Warm or Hot Engine......................................................318
CARBURETOR 4.5..................................................................319
GENERAL.....................................................................319
ADJUSTMENT..................................................................319
Float Level.............................................................319
OPERATION CHECK: VACUUM PISTON..............................................321
Opening Malfunction.....................................................321
Closing Malfunction.....................................................321
REMOVAL.....................................................................321
DISASSEMBLY.................................................................323
Vacuum Piston Chamber...................................................323
Carburetor Body.........................................................323
Accelerator Pump........................................................323
CLEANING, INSPECTION AND REPAIR.............................................324
Vacuum Piston Components................................................324
Carburetor Body Components..............................................324
Accelerator Pump........................................................324
ASSEMBLY....................................................................324
Vacuum Piston Chamber...................................................324
Carburetor Body.........................................................324
Accelerator Pump........................................................324
INSTALLATION................................................................325
Carburetor..............................................................325
Carburetor Fuel Overflow/Drain Hose Routing.............................325
AIR CLEANER 4.6.................................................................326
REMOVAL.....................................................................326
CLEANING, INSPECTION AND REPAIR.............................................327
INSTALLATION................................................................327
FUEL SUPPLY VALVE 4.7...........................................................328
GENERAL.....................................................................328
OPERATION...................................................................328
REMOVAL, INSPECTION AND INSTALLATION........................................328
TROUBLESHOOTING.............................................................329
Vacuum Test.............................................................329
FUEL TANK 4.8...................................................................330
GENERAL.....................................................................330
REMOVAL.....................................................................332
CLEANING, INSPECTION AND REPAIR.............................................332
INSTALLATION................................................................333
CONSOLE REPLACEMENT.........................................................333
Removal.................................................................333
Installation............................................................335
EVAPORATIVE EMISSIONS CONTROL–CA MODELS 4.9.....................................336
GENERAL.....................................................................336
REMOVAL.....................................................................337
Charcoal Canister.......................................................337
Vapor Valve.............................................................338
INSTALLATION................................................................338
Vapor Valve.............................................................338
Charcoal Canister.......................................................339
HOSE ROUTING................................................................340
Carburetor..............................................................340
Canister Hose Routings..................................................340
INTAKE LEAK TEST 4.10...........................................................341
GENERAL.....................................................................341
LEAK TESTER.................................................................341
Parts List..............................................................341
Tester Assembly.........................................................341
Tester Adjustment.......................................................341
PROCEDURE...................................................................342
SPECIFICATIONS 5.1..............................................................346
TORQUE VALUES 5.2...............................................................347
ELECTRIC STARTER SYSTEM 5.3.....................................................348
GENERAL.....................................................................348
Wiring Diagram..........................................................348
Starter Relay...........................................................348
OPERATION...................................................................348
STARTER MOTOR 5.4...............................................................351
REMOVAL.....................................................................351
DISASSEMBLY, INSPECTION AND REPAIR..........................................353
ASSEMBLY....................................................................356
INSTALLATION................................................................357
STARTER SOLENOID 5.5............................................................358
GENERAL.....................................................................358
DISASSEMBLY.................................................................359
ASSEMBLY....................................................................359
FINAL.......................................................................359
SPECIFICATIONS 6.1..............................................................362
TORQUE VALUES 6.2...............................................................364
PRIMARY CHAIN ADJUSTER 6.3......................................................365
GENERAL.....................................................................365
REMOVAL.....................................................................365
Primary Cover...........................................................365
Primary Chain Adjuster..................................................367
INSTALLATION................................................................367
Primary Chain Adjuster..................................................367
Primary Cover...........................................................367
CLUTCH RELEASE MECHANISM 6.4....................................................369
REMOVAL/DISASSEMBLY.........................................................369
CLEANING, INSPECTION AND REPAIR.............................................370
ASSEMBLY/INSTALLATION.......................................................370
PRIMARY DRIVE/CLUTCH 6.5........................................................371
GENERAL.....................................................................371
REMOVAL.....................................................................373
DISASSEMBLY.................................................................374
INSPECTION AND REPAIR.......................................................375
ASSEMBLY....................................................................376
INSTALLATION................................................................377
SECONDARY DRIVE BELT 6.6........................................................379
REMOVAL.....................................................................379
INSTALLATION................................................................381
TRANSMISSION 6.7................................................................382
OPERATION...................................................................382
CASE DISASSEMBLY FOR TRANSMISSION REMOVAL 6.8...................................383
GENERAL.....................................................................383
ENGINE REMOVAL AND DISASSEMBLY..............................................383
TRANSMISSION REMOVAL AND DISASSEMBLY 6.9........................................386
TRANSMISSION REMOVAL FROM LEFT CRANKCASE....................................386
MAINSHAFT/COUNTERSHAFT......................................................388
MAINSHAFT DISASSEMBLY.......................................................390
Cleaning And Inspection.................................................390
COUNTERSHAFT DISASSEMBLY....................................................391
Cleaning And Inspection.................................................391
TRANSMISSION ASSEMBLY 6.10......................................................392
GENERAL.....................................................................392
MAINSHAFT ASSEMBLY..........................................................392
COUNTERSHAFT ASSEMBLY.......................................................393
MAIN DRIVE GEAR AND BEARING 6.11................................................394
GENERAL.....................................................................394
REMOVAL.....................................................................395
Main Drive Gear.........................................................395
Main Drive Gear Ball Bearing............................................396
DISASSEMBLY.................................................................396
ASSEMBLY....................................................................397
INSTALLATION................................................................398
Main Drive Gear Ball Bearing............................................398
Main Drive Gear.........................................................399
Main Drive Gear Seal....................................................400
TRANSMISSION RIGHT CASE BEARINGS 6.12...........................................402
REMOVAL.....................................................................402
Countershaft Needle Bearing.............................................402
Shifter Drum Bushing....................................................402
INSTALLATION................................................................402
Countershaft Needle Bearing.............................................402
Shifter Drum Bushing....................................................402
TRANSMISSION LEFT CASE BEARINGS 6.13............................................403
REMOVAL.....................................................................403
Mainshaft and Countershaft Bearings.....................................403
Shifter Drum Bushing....................................................403
INSTALLATION................................................................403
Mainshaft and Countershaft Bearings.....................................403
Shifter Drum Bushing....................................................403
TRANSMISSION INSTALLATION 6.14..................................................404
GENERAL.....................................................................404
INSTALLATION................................................................404
SHIFTER FORKS AND DRUM ASSEMBLY.............................................405
ASSEMBLING CRANKCASES.......................................................406
SHIFTER SHAFT INSTALLATION..................................................408
TRANSMISSION SPROCKET 6.15......................................................409
REMOVAL.....................................................................409
INSTALLATION................................................................410
SPECIFICATIONS 7.1..............................................................414
IGNITION....................................................................414
CHARGING SYSTEM.............................................................414
BATTERY.....................................................................414
FUSES.......................................................................414
TORQUE VALUES 7.2...............................................................415
BULB REQUIREMENTS 7.3...........................................................416
BULB CHART..................................................................416
BATTERY TRAY 7.4................................................................417
GENERAL.....................................................................417
REMOVAL.....................................................................417
INSTALLATION................................................................418
IGNITION SYSTEM 7.5.............................................................419
GENERAL.....................................................................419
TROUBLESHOOTING.............................................................419
MANIFOLD ABSOLUTE PRESSURE SENSOR (MAP) 7.6.....................................421
REMOVAL.....................................................................421
INSTALLATION................................................................421
IGNITION/LIGHT SWITCH 7.7.......................................................422
GENERAL.....................................................................422
REMOVAL.....................................................................423
INSTALLATION................................................................423
IGNITION CONTROL MODULE (ICM) 7.8...............................................424
GENERAL.....................................................................424
REMOVAL.....................................................................424
INSTALLATION................................................................424
SPARK PLUG CABLES 7.9...........................................................425
GENERAL.....................................................................425
REMOVAL.....................................................................425
INSPECTION..................................................................426
INSTALLATION................................................................426
IGNITION COIL 7.10..............................................................427
GENERAL.....................................................................427
TROUBLESHOOTING.............................................................427
REMOVAL.....................................................................427
INSTALLATION................................................................427
CHARGING SYSTEM 7.11............................................................428
GENERAL.....................................................................428
ALTERNATOR..................................................................428
VOLTAGE REGULATOR...........................................................428
ALTERNATOR 7.12.................................................................429
REMOVAL AND DISASSEMBLY.....................................................429
Rotor...................................................................429
Stator..................................................................429
CLEANING, INSPECTION AND REPAIR.............................................429
ASSEMBLY AND INSTALLATION...................................................430
Stator..................................................................430
Rotor...................................................................431
Final Assembly..........................................................431
VOLTAGE REGULATOR 7.13..........................................................432
GENERAL.....................................................................432
REMOVAL.....................................................................432
INSTALLATION................................................................433
BATTERY 7.14....................................................................434
GENERAL.....................................................................434
VOLTMETER TEST..............................................................434
CONDUCTANCE TEST............................................................434
LOAD TEST...................................................................435
CHARGING....................................................................436
General.................................................................436
Safety Precautions......................................................436
Charging Battery........................................................436
BATTERY CABLES 7.15.............................................................438
REMOVAL.....................................................................438
INSTALLATION................................................................439
HEADLAMP 7.16...................................................................442
REPLACEMENT–XL 883, XL 883L, XL 883R, XL 1200R..............................442
REPLACEMENT–XL 883C, XL 1200C...............................................443
INDICATOR LAMPS 7.17............................................................446
REPLACEMENT–XL 883, XL 883L, XL 883R........................................446
REPLACEMENT–XL 1200R........................................................446
REPLACEMENT–XL 883C, XL 1200C...............................................447
TAIL LAMP 7.18..................................................................448
BULB REPLACEMENT............................................................448
BASE REPLACEMENT............................................................448
TURN SIGNALS 7.19...............................................................450
BULB REPLACEMENT............................................................450
FRONT HOUSING REPLACEMENT...................................................450
REAR HOUSING REPLACEMENT....................................................451
REAR STOP LAMP SWITCH 7.20......................................................454
GENERAL.....................................................................454
REPLACEMENT.................................................................454
HANDLEBAR SWITCHES 7.21.........................................................455
GENERAL.....................................................................455
REPAIR PROCEDURES...........................................................455
CONNECTORS..................................................................456
RIGHT HANDLEBAR SWITCH 7.22.....................................................457
REMOVAL.....................................................................457
INSTALLATION................................................................458
DISASSEMBLY.................................................................460
SWITCH REPAIR/REPLACEMENT...................................................461
Upper Switch Housing Repair.............................................461
Lower Switch Housing Repair.............................................462
ASSEMBLY....................................................................463
LEFT HANDLEBAR SWITCH 7.23......................................................464
REMOVAL.....................................................................464
INSTALLATION................................................................464
DISASSEMBLY.................................................................465
SWITCH REPAIR/REPLACEMENT...................................................466
Upper Switch Housing Repair.............................................466
Lower Switch Housing Repair.............................................467
ASSEMBLY....................................................................467
HORN 7.24.......................................................................468
TROUBLESHOOTING.............................................................468
VOLTAGE TEST................................................................468
REPLACEMENT: ALL MODELS EXCEPT XL 1200C.....................................468
REPLACEMENT: XL 1200C.......................................................469
MAXI-FUSE 7.25..................................................................470
GENERAL.....................................................................470
REMOVING....................................................................470
INSTALLING..................................................................470
SYSTEM FUSES AND STARTER RELAY 7.26.............................................471
GENERAL.....................................................................471
REPLACING 15-AMP FUSES......................................................471
REPLACING STARTER RELAY.....................................................471
MAXI-FUSE HOLDER 7.27...........................................................472
REPLACEMENT.................................................................472
RELAY/FUSE BLOCK 7.28...........................................................473
GENERAL.....................................................................473
REMOVAL.....................................................................473
INSTALLATION................................................................474
SPEEDOMETER: XL 883, XL 883L, XL 883R 7.29......................................475
REMOVAL.....................................................................475
INSTALLATION................................................................475
SPEEDOMETER AND TACHOMETER: XL 1200R 7.30.......................................476
TRIP ODOMETER RESET SWITCH REPLACEMENT......................................476
SPEEDOMETER REMOVAL.........................................................477
TACHOMETER REMOVAL..........................................................477
SPEEDOMETER INSTALLATION....................................................478
TACHOMETER INSTALLATION.....................................................478
SPEEDOMETER: XL 883C, XL 1200C 7.31.............................................479
REMOVAL.....................................................................479
INSTALLATION................................................................480
TURN SIGNAL/SECURITY MODULE (TSM/TSSM) 7.32.....................................481
GENERAL.....................................................................481
TESTING.....................................................................481
REMOVAL.....................................................................481
INSTALLATION................................................................482
OIL PRESSURE SWITCH 7.33........................................................483
GENERAL.....................................................................483
REMOVAL.....................................................................483
INSTALLATION................................................................483
CRANK POSITION SENSOR (CKP) 7.34................................................484
GENERAL.....................................................................484
REMOVAL.....................................................................484
INSTALLATION................................................................484
VEHICLE SPEED SENSOR (VSS) 7.35.................................................485
GENERAL.....................................................................485
REMOVAL.....................................................................485
INSTALLATION................................................................485
NEUTRAL INDICATOR SWITCH 7.36...................................................486
GENERAL.....................................................................486
TEST........................................................................486
REPLACEMENT.................................................................487
Optional Security Siren 7.37....................................................489
GENERAL.....................................................................489
REMOVAL.....................................................................489
DISASSEMBLY.................................................................489
Battery Replacement.........................................................490
ASSEMBLY....................................................................491
INSTALLATION................................................................491
BANK ANGLE SENSOR (BAS) 7.38....................................................492
GENERAL.....................................................................492
OPERATION...................................................................492
TESTING.....................................................................492
REPLACEMENT.................................................................492
APPENDIX A–TOOLS A.1............................................................494
APPENDIX B–WIRING AMP MULTILOCK ELECTRICAL CONNECTORS B.1.......................512
REMOVING SOCKET/PIN TERMINALS...............................................512
INSTALLING SOCKET/PIN TERMINALS.............................................514
CRIMPING INSTRUCTIONS.......................................................516
DEUTSCH ELECTRICAL CONNECTORS B.2...............................................517
GENERAL.....................................................................517
REMOVING/DISASSEMBLING......................................................517
REMOVING/INSTALLING SOCKETS.................................................517
REMOVING/INSTALLING PINS....................................................519
ASSEMBLING/INSTALLING.......................................................519
CRIMPING INSTRUCTIONS.......................................................519
MINI-DEUTSCH CONNECTORS B.3.....................................................522
GENERAL.....................................................................522
For Size 20, 16 and 12 Contacts Wire Range 26-12 AWG....................522
CRIMPING INSTRUCTIONS.......................................................522
PACKARD ELECTRICAL CONNECTORS B.4...............................................524
GENERAL.....................................................................524
REMOVING PULL-TO-SEAT TERMINALS/EXTERNAL LATCH TYPE.........................524
INSTALLING PULL-TO-SEAT TERMINALS/EXTERNAL LATCH TYPE.......................525
SEALED BUTT SPLICE CONNECTORS B.5...............................................526
INSTALlation................................................................526
CONNECTOR LOCATIONS B.6.........................................................527
INDEX TO WIRING DIAGRAMS B.7....................................................528
2006 ALL SPORTSTER DOM. and INT. MODELS, LIGHTS, PAGE 2 OF 2....................560
2006 ALL SPORTSTER DOM. and INT. MODELS, MAIN HARNESS, PAGE 2 OF 2..............550
STARTING........................................................................554
2006 ALL SPORTSTER DOM. and INT. MODELS, STARTING AND CHARGING, PAGE 1 OF 1.....554
2006 ALL SPORTSTER DOM. and INT. MODELS, HORN AND INSTRUMENTS, PAGE 1 OF 1......556
2006 ALL SPORTSTER DOM. and INT. MODELS, MAIN HARNESS, PAGE 1 OF 2..............548
2006 ALL SPORTSTER DOM. and INT. MODELS, SECURITY, PAGE 1 OF 2..................562
2006 ALL SPORTSTER DOM. and INT. MODELS, SECURITY, PAGE 2 OF 2..................564
2006 ALL SPORTSTER DOM. and INT. MODELS, IGNITION CIRCUIT, PAGE 1 OF 1..........552
2006 ALL SPORTSTER DOM. and INT. MODELS, LIGHTS, PAGE 1 OF 2....................558
APPENDIX C–METRIC CONVERSIONS C.1...............................................566
FLUID CONVERSIONS C.2...........................................................567
UNITED STATES SYSTEM........................................................567
METRIC SYSTEM...............................................................567
BRITISH IMPERIAL SYSTEM.....................................................567
APPENDIX D: COMPENSATING SPROCKET D.1...........................................568
GENERAL.....................................................................568
REMOVAL/DISASSEMBLY.........................................................568
CLEANING, INSPECTION AND REPAIR.............................................569
ASSEMBLY/INSTALLATION.......................................................569
APPENDIX E–GLOSSARY E.1.........................................................570
STARTER TROUBLESHOOTING 1.1.....................................................576
STARTING SYSTEM DIAGNOSIS 1.2...................................................578
DIAGNOSTICS.................................................................578
Diagnostic Notes........................................................578
Starter Testing 1.......................................................579
Starter Testing 2: Solenoid Clicks......................................580
Starter Testing 3: Relay Clicks.........................................580
Starter Testing 4: Nothing Clicks.......................................581
Starter Testing 5: Starter Spins But Does Not Engage....................582
Starter Testing 6: Starter Stalls or Spins Too Slowly...................582
STARTER ACTIVATION CIRCUITS 1.3.................................................583
DIAGNOSTICS/TROUBLESHOOTING 1.4.................................................584
GENERAL.....................................................................584
VOLTAGE DROPS...............................................................584
TESTING STARTER ON MOTORCYCLE 1.5...............................................586
STARTER RELAY TEST..........................................................586
STARTER CURRENT DRAW TEST...................................................586
TESTING STARTER ON BENCH 1.6....................................................587
FREE RUNNING CURRENT DRAW TEST..............................................587
STARTER SOLENOID............................................................587
SOLENOID PULL-IN TEST.......................................................588
SOLENOID HOLD-IN TEST.......................................................588
SOLENOID RETURN TEST........................................................588
CHARGING SYSTEM 1.7.............................................................589
GENERAL.....................................................................589
Alternator..............................................................589
Voltage Regulator.......................................................589
TROUBLESHOOTING.............................................................589
Battery.................................................................589
Wiring..................................................................589
Voltage Regulator Inspection............................................589
Charging System Test 1.7 (Part 1 of 2)..................................591
Charging System Test 1.7 (Part 2 of 2)..................................592
TESTING.....................................................................593
Milliampere Draw Test...................................................593
Total Current Draw Test.................................................593
Current and Voltage Output Test.........................................594
Stator Check............................................................595
AC Output Check.........................................................596
IGNITION COIL 1.8...............................................................597
TROUBLESHOOTING.............................................................597
Primary Circuit Test....................................................597
Secondary Circuit Test..................................................597
Test Results............................................................597
Ignition Coil Substitution..............................................597
BATTERY TESTING 1.9.............................................................598
GENERAL.....................................................................598
VOLTMETER TEST..............................................................598
CONDUCTANCE TEST............................................................598
LOAD TEST...................................................................599
CHECKING FOR DIAGNOSTIC TROUBLE CODES 2.1.......................................602
CHECK ENGINE LAMP...........................................................602
SECURITY LAMP...............................................................603
Turn Signal Module (TSM)................................................603
Turn Signal Security Module (TSSM)......................................603
CODE TYPES..................................................................604
Current.................................................................604
Historic................................................................604
RETRIEVING DIAGNOSTIC TROUBLE CODES.........................................604
MULTIPLE DIAGNOSTIC TROUBLE CODES...........................................604
INITIAL DIAGNOSTIC CHECK: SPEEDOMETER 2.2.......................................605
GENERAL.....................................................................605
Diagnostic Notes........................................................605
Circuit Diagram/Wire Harness Connector Table............................605
Job/Time Code Values....................................................605
Reprogramming ICM.......................................................605
INITIAL DIAGNOSTICS.........................................................606
Diagnostic Tips.........................................................606
Diagnostic Notes........................................................606
Other Diagnostic Trouble Codes..........................................606
Initial Diagnostic Check (Part 1 of 3)..................................608
Initial Diagnostic Check (Part 2 of 3)..................................609
Initial Diagnostic Check (Part 3 of 3)..................................610
SPEEDOMETER SELF DIAGNOSTICS 2.3................................................611
GENERAL.....................................................................611
DIAGNOSTICS.................................................................611
Diagnostic Tips.........................................................611
Diagnostic Notes........................................................611
Speedometer Self Diagnostics (flow chart)...............................612
SPEEDOMETER/TACHOMETER 2.4......................................................613
GENERAL.....................................................................613
Reset Switch............................................................613
SPEEDOMETER THEORY OF OPERATION.............................................614
TACHOMETER THEORY OF OPERATION..............................................614
DIAGNOSTICS.................................................................614
Diagnostic Notes........................................................614
Test 2.4 (Part 1 of 2)..................................................616
TACHOMETER INOPERATIVE..................................................616
Test 2.4 (Part 2 of 2)..................................................617
BREAKOUT BOX: SPEEDOMETER/TACHOMETER 2.5........................................618
GENERAL.....................................................................618
SPEEDOMETER.................................................................618
Installation............................................................618
Removal.................................................................618
TACHOMETER..................................................................618
Installation............................................................618
Removal.................................................................618
INDICATOR LAMPS 2.6.............................................................619
GENERAL.....................................................................619
Job/Time Code Values....................................................619
Diagnostic Notes........................................................619
DIAGNOSTICS.................................................................621
Oil Pressure or Neutral Indicator Will Not Function.....................621
High Beam or R/L Turn Signal Indicator Will Not Function................621
DTC B1006, B1007 2.7............................................................622
GENERAL.....................................................................622
Accessory Or Ignition Line Overvoltage..................................622
Test 2.7................................................................623
DTC B1008 2.8...................................................................624
GENERAL.....................................................................624
Reset Switch Closed.....................................................624
Diagnostic Notes........................................................624
Test 2.8................................................................625
DTC U1016, U1255 2.9............................................................626
GENERAL.....................................................................626
Loss of ICM Serial Data.................................................626
DIAGNOSTICS.................................................................626
Diagnostic Notes........................................................626
Test 2.9................................................................628
DTC U1064, U1255 2.10...........................................................629
GENERAL.....................................................................629
Loss of TSM/TSSM Serial Data............................................629
DIAGNOSTICS.................................................................629
Diagnostic Notes........................................................629
Test 2.10...............................................................631
DTC U1300, U1301 OR BUS ER 2.11.................................................632
GENERAL.....................................................................632
Serial Data Low or Serial Data Open/High................................632
DIAGNOSTICS.................................................................632
Diagnostic Tips.........................................................632
Diagnostic Notes........................................................632
Test 2.11 (Part 1 of 2).................................................634
Test 2.11 (Part 2 of 2).................................................635
TSM/TSSM OVERVIEW 3.1...........................................................638
GENERAL.....................................................................638
TROUBLESHOOTING.............................................................638
TSM/TSSM FEATURES 3.2...........................................................640
GENERAL.....................................................................640
TURN SIGNAL FUNCTIONS.......................................................640
BANK ANGLE FUNCTIONS........................................................640
SECURITY ALARM AND IMMOBILIZATION FUNCTIONS.................................640
TSSM Only Feature.......................................................640
TSM/TSSM VEHICLE DELIVERY 3.3...................................................642
GENERAL.....................................................................642
SIDECAR CONFIGURATION.......................................................642
POWER DISRUPTION AND CONFIGURING............................................642
KEY FOB ASSIGNMENT..........................................................643
PERSONAL CODE ENTRY.........................................................643
First Time Code Entry: TSSM Only........................................643
Modifying Existing Codes: TSSM Only.....................................643
TSM/TSSM TURN SIGNAL FUNCTIONS 3.4..............................................647
GENERAL.....................................................................647
AUTOMATIC CANCELLATION......................................................647
MANUAL CANCELLATION.........................................................647
FOUR-WAY FLASHING...........................................................647
DIAGNOSTIC MODE.............................................................647
TSM/TSSM BANK ANGLE FUNCTION 3.5................................................648
GENERAL.....................................................................648
OPERATION...................................................................648
SECURITY SYSTEM (TSSM) FUNCTIONS 3.6............................................649
GENERAL.....................................................................649
Security System Operation...............................................649
Security System Options.................................................649
Differences By Market Specifications....................................649
ALARM SENSITIVITY...........................................................649
Sensitivity.............................................................649
Transport Mode..........................................................649
AUTO-ARMING FUNCTION........................................................650
STORAGE MODE................................................................650
ARMING/DISARMING SECURITY SYSTEM (TSSM) 3.7.....................................653
GENERAL.....................................................................653
SECURITY LAMP...............................................................653
USING KEY FOB...............................................................653
General.................................................................653
Arming the System.......................................................653
Disarming the System....................................................653
Troubleshooting.........................................................653
USING THE PERSONAL CODE.....................................................654
General.................................................................654
Disarming the System....................................................654
CHECKING FOR DIAGNOSTIC TROUBLE CODES 3.8.......................................655
TSM.........................................................................655
TSSM........................................................................655
CODE TYPES..................................................................657
Current.................................................................657
Historic................................................................657
RETRIEVING DIAGNOSTIC TROUBLE CODES.........................................657
MULTIPLE DIAGNOSTIC TROUBLE CODES...........................................657
INITIAL DIAGNOSTIC CHECK: TSM/TSSM 3.9..........................................658
GENERAL.....................................................................658
Diagnostic Notes........................................................658
Circuit Diagram/Wire Harness Connector Table............................658
Job/Time Code Values....................................................658
Reprogramming ICM.......................................................658
INITIAL DIAGNOSTICS.........................................................658
Diagnostic Tips.........................................................658
Diagnostic Notes........................................................658
Other Diagnostic Trouble Codes (DTCs)...................................658
Initial Diagnostic Check (Part 1 of 3)..................................661
Initial Diagnostic Check (Part 2 of 3)..................................662
Initial Diagnostic Check (Part 3 of 3)..................................663
SPEEDOMETER SELF DIAGNOSTICS 3.10...............................................664
GENERAL.....................................................................664
DIAGNOSTICS.................................................................664
Diagnostic Tips.........................................................664
Diagnostic Notes........................................................664
Speedometer Self Diagnostics (chart)....................................665
BREAKOUT BOX: TSM/TSSM 3.11.....................................................666
GENERAL.....................................................................666
INSTALLATION................................................................666
REMOVAL.....................................................................666
NO SECURITY LAMP AT KEY ON 3.12.................................................667
GENERAL.....................................................................667
No TSSM Power (Security Equipped Vehicles Only).........................667
Job/Time Code Values....................................................667
DIAGNOSTICS.................................................................667
Diagnostic Tips.........................................................667
Diagnostic Notes........................................................667
Test 3.12 (Part 1 of 3).................................................669
Test 3.12 (Part 2 of 3).................................................670
Test 3.12 (Part 3 of 3).................................................671
SECURITY LAMP ON CONTINUOUSLY 3.13..............................................672
GENERAL.....................................................................672
Job/Time Code Values....................................................672
DIAGNOSTICS.................................................................672
Diagnostic Notes........................................................672
Test 3.13...............................................................674
KEY FOB SIGNAL TO TSSM WEAK OR FAILS 3.14.......................................676
GENERAL.....................................................................676
Security Equipped Vehicles Only.........................................676
Job/Time Code Values....................................................676
DIAGNOSTICS.................................................................676
Diagnostic Tips.........................................................676
Diagnostic Notes........................................................676
Test 3.14...............................................................678
TURN SIGNAL ERRORS: DTC B1121, B1122, B1141 3.15................................679
GENERAL.....................................................................679
Job/Time Code Values....................................................679
DIAGNOSTICS.................................................................679
Diagnostic Tips.........................................................679
Diagnostic Notes: All Turn Signal Flow Charts...........................682
Turn Signal Error 1A (Part 1 of 2)......................................684
Turn Signal Error 1A (Part 2 of 2)......................................685
Turn Signal Error 2A....................................................686
Turn Signal Error 2B....................................................687
Turn Signal Error 2C....................................................688
Turn Signal Error 2D....................................................689
Turn Signal Error 3A....................................................690
DTC B0563 3.16..................................................................691
GENERAL.....................................................................691
Battery Voltage High....................................................691
DIAGNOSTICS.................................................................691
Diagnostic Tips.........................................................691
Diagnostic Notes........................................................691
DTC B1131, B1132 3.17...........................................................692
GENERAL.....................................................................692
Alarm Output Low (DTC B1131) or Alarm Output High (DTC B1132)...........692
DIAGNOSTICS.................................................................692
Diagnostic Tips.........................................................692
Diagnostic Notes........................................................692
Test 3.17...............................................................694
DTC B1134 3.18..................................................................695
GENERAL.....................................................................695
Starter Output High.....................................................695
DIAGNOSTICS.................................................................695
Diagnostic Notes........................................................695
Test 3.18...............................................................697
DTC B1135 3.19..................................................................698
GENERAL.....................................................................698
Accelerometer Fault.....................................................698
DTC U1016, U1255 3.20...........................................................699
GENERAL.....................................................................699
Loss of ICM Serial Data.................................................699
DIAGNOSTICS.................................................................699
Diagnostic Notes........................................................699
Test 3.20...............................................................701
DTC U1097, U1255 3.21...........................................................702
GENERAL.....................................................................702
Loss of Speedometer Serial Data.........................................702
DIAGNOSTICS.................................................................702
Diagnostic Notes........................................................702
Test 3.21...............................................................704
DTC U1300, U1301 OR BUS ER 3.22.................................................705
GENERAL.....................................................................705
DIAGNOSTICS.................................................................705
Diagnostic Tips.........................................................705
Diagnostic Notes........................................................705
PASSWORD LEARN 3.23.............................................................706
GENERAL.....................................................................706
PASSWORD LEARNING...........................................................706
TSSM MAINTENANCE 3.24...........................................................708
GENERAL.....................................................................708
KEY FOB.....................................................................708
Schedule................................................................708
Battery Replacement.....................................................708
SECURITY SIREN (IF INSTALLED)...............................................709
Schedule................................................................709
Battery Replacement.....................................................709
SPECIFICATIONS 4.1..............................................................712
DIAGNOSTIC INTRODUCTION 4.2.....................................................713
SYSTEM PROBLEMS.............................................................713
No Start................................................................713
Poor Performance........................................................713
Check Engine Lamp.......................................................713
RESOLVING PROBLEMS..........................................................713
CHECKING FOR DIAGNOSTIC TROUBLE CODES 4.3.......................................714
CHECK ENGINE LAMP...........................................................714
SECURITY LAMP...............................................................715
CODE TYPES..................................................................715
Current.................................................................715
Historic................................................................715
RETRIEVING DIAGNOSTIC TROUBLE CODES.........................................716
MULTIPLE DIAGNOSTIC TROUBLE CODES...........................................716
INITIAL DIAGNOSTIC CHECK: ICM 4.4...............................................717
GENERAL.....................................................................717
Diagnostic Notes........................................................717
Circuit Diagram/Wire Harness Connector Table............................717
Reprogramming ICM.......................................................717
INITIAL DIAGNOSTICS.........................................................717
General Information.....................................................717
Diagnostic Tips.........................................................717
Diagnostic Notes........................................................717
Other DTCs..............................................................717
Initial Diagnostic Check (Part 1 of 3)..................................721
Initial Diagnostic Check (Part 2 of 3)..................................722
Initial Diagnostic Check (Part 3 of 3)..................................723
SPEEDOMETER SELF DIAGNOSTICS 4.5................................................724
GENERAL.....................................................................724
DIAGNOSTICS.................................................................724
Diagnostic Tips.........................................................724
Diagnostic Notes........................................................724
Speedometer Self Diagnostics (flow chart)...............................725
BREAKOUT BOX: ICM 4.6...........................................................726
GENERAL.....................................................................726
INSTALLATION................................................................726
REMOVAL.....................................................................726
WIGGLE TEST 4.7.................................................................727
GENERAL.....................................................................727
PROCEDURE...................................................................727
Using DVOM (Part No. HD-39978)..........................................727
INTAKE LEAK TEST 4.8............................................................728
GENERAL.....................................................................728
LEAK TESTER.................................................................728
Parts List..............................................................728
Tester Assembly.........................................................728
Tester Adjustment.......................................................728
PROCEDURE...................................................................729
ENGINE CRANKS BUT WILL NOT START 4.9............................................730
GENERAL.....................................................................730
DIAGNOSTICS.................................................................730
Diagnostic Notes........................................................730
Test 4.9 (Part 1 of 3)..................................................732
Test 4.9 (Part 2 of 3)..................................................733
Test 4.9 (Part 3 of 3)..................................................734
STARTS THEN STALLS 4.10.........................................................735
GENERAL.....................................................................735
Serial Data Low or Serial Data Open/High................................735
DIAGNOSTICS.................................................................735
Diagnostic Tips.........................................................735
Diagnostic Notes........................................................735
Test 4.10 (Part 1 of 2).................................................737
Test 4.10 (Part 2 of 2).................................................738
NO SPARK/NO ICM POWER 4.11......................................................739
GENERAL.....................................................................739
DIAGNOSTICS.................................................................739
Diagnostic Notes........................................................739
Test 4.11...............................................................741
MISFIRE 4.12....................................................................742
GENERAL.....................................................................742
Misfire at Idle or Under Load...........................................742
DIAGNOSTICS.................................................................742
Diagnostic Notes........................................................742
Test 4.12...............................................................744
DTC P0106, P0107, P0108 4.13....................................................746
GENERAL.....................................................................746
MAP Sensor..............................................................746
DIAGNOSTICS.................................................................746
Diagnostic Tips.........................................................746
Diagnostic Notes........................................................746
Test 4.13 (Part 1 of 2).................................................748
Test 4.13 (Part 2 of 2).................................................749
DTC P0371, P0372, P0374 4.14....................................................750
GENERAL.....................................................................750
Crank Position Sensor...................................................750
DIAGNOSTICS.................................................................750
Diagnostic Notes........................................................750
Test 4.14 (Part 1 of 2).................................................752
Test 4.14 (Part 2 of 2).................................................753
DTC P0501, P0502 4.15...........................................................754
GENERAL.....................................................................754
Vehicle Speed Sensor....................................................754
DIAGNOSTICS.................................................................754
Diagnostic Notes........................................................754
Test 4.15 (Part 1 of 2).................................................756
Test 4.15 (Part 2 of 2).................................................757
DTC P0562, P0563 4.16...........................................................758
GENERAL.....................................................................758
Battery Voltage.........................................................758
DIAGNOSTICS.................................................................758
Diagnostic Notes........................................................758
Test 4.16 (Part 1 of 2).................................................760
Test 4.16 (Part 2 of 2).................................................761
DTC P0602, P0603, P0604, P0605, P0607 4.17......................................762
GENERAL.....................................................................762
ICM Failure.............................................................762
DIAGNOSTICS.................................................................762
DTC P0607 Test..........................................................762
DTC P0602, P0603, P0604, P0605 Test.....................................762
DTC P1009, P1010 4.18...........................................................763
GENERAL.....................................................................763
Password Problem........................................................763
DIAGNOSTICS.................................................................763
Diagnostic Notes........................................................763
Test 4.18...............................................................765
DTC P1351, P1352, P1354, P1355 4.19.............................................766
GENERAL.....................................................................766
Ignition Coil...........................................................766
DIAGNOSTICS.................................................................766
Diagnostic Notes........................................................766
Test 4.19 (Part 1 of 2).................................................768
Test 4.19 (Part 2 of 2).................................................769
DTC U1064 4.20..................................................................770
GENERAL.....................................................................770
Loss of TSM/TSSM Serial Data............................................770
DIAGNOSTICS.................................................................770
Diagnostic Notes........................................................770
Test 4.20...............................................................772
DTC U1097 4.21..................................................................773
GENERAL.....................................................................773
Loss of Speedometer Serial Data.........................................773
DIAGNOSTICS.................................................................773
Diagnostic Notes........................................................773
Test 4.21...............................................................775
CONNECTOR LOCATIONS 5.1.........................................................778
AMP MULTILOCK ELECTRICAL CONNECTORS 5.2.........................................779
REMOVING SOCKET/PIN TERMINALS...............................................779
INSTALLING SOCKET/PIN TERMINALS.............................................779
CRIMPING INSTRUCTIONS.......................................................782
DEUTSCH ELECTRICAL CONNECTORS 5.3...............................................783
GENERAL.....................................................................783
REMOVING/DISASSEMBLING......................................................783
REMOVING/INSTALLING SOCKETS.................................................783
REMOVING/INSTALLING PINS....................................................784
ASSEMBLING/INSTALLING.......................................................785
CRIMPING INSTRUCTIONS.......................................................786
MINI-DEUTSCH ELECTRICAL CONNECTORS 5.4..........................................788
GENERAL.....................................................................788
For Size 20, 16 and 12 Contacts Wire Range 26-12 AWG....................788
CRIMPING INSTRUCTIONS.......................................................788
SEALED BUTT SPLICE CONNECTORS 5.5...............................................790
INSTALLATION................................................................790
PACKARD ELECTRICAL CONNECTORS 5.6...............................................791
GENERAL.....................................................................791
PULL-TO-SEAT TERMINALS......................................................792
Removing External Latch Type............................................792
Installing External Latch Type..........................................792
PUSH-TO-SEAT TERMINALS......................................................792
Removing Push-to-Seat Terminals.........................................792
Installing Push-to-Seat Terminals.......................................793
CRIMPING INSTRUCTIONS.......................................................793
MICRO 64 TERMINALS..........................................................795
General.................................................................795
Removal.................................................................795
Installation............................................................795
Crimping Instructions...................................................796
INDEX TO WIRING DIAGRAMS 5.7....................................................797
APPENDIX A–GLOSSARY A.1.........................................................816
This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
S.V
✹
What Our Customers Say
★★★★★Live reviews from customers
Loading customer reviews...
🌟 Related Products
Discover more professional manuals for your equipment
