2006 Harley Davidson Touring Models Electrical Diagnostics + FLHTCUSE Service Supplement + Service Manual – PDF DOWNLOAD
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2006 Harley Davidson Touring Models Electrical Diagnostics + Service Manual – PDF DOWNLOAD2006 Harley Davidson Touring Models Electrical Diagnostics + Service Manual – PDF DOWNLOAD
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2006 Harley Davidson Touring Models Electrical Diagnostics + FLHTCUSE Service Supplement + Service Manual – PDF DOWNLOAD
SERVICE MANUAL
Part Number 99483-06
ELECTRICAL DIAGNOSTICS Part Number 99497-06
FLHTCUSE SERVICE SUPPLEMENT Part Number 99500-06
GENERAL
REPAIR NOTES
General maintenance practices are given in this section. All special tools and torque values are noted at the point of use and all required parts or materials can be found in the appropriate PARTS CATALOG.
Safety
Safety is always the most important consideration when performing any job. Be sure you have a complete understanding of the task to be performed. Use common sense. Use the proper tools. 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.
Always use blocking or proper stands to support the part that has been hoisted. If a part cannot be removed, verify that all bolts and attaching hardware have been removed. Check to see if any parts are in the way of the part being removed. When removing hoses, wiring or tubes, always tag each part to ensure proper installation.
TABLE OF CONTENTS:
2006 Harley Davidson Touring Models Electrical Diagnostics + FLHTCUSE Service Supplement + Service Manual – PDF DOWNLOAD
maintoc.pdf..................................................................................................... 0
2006 TOURING MODELS......................................................................................... 1
SERVICE MANUAL.......................................................................................... 1
Part Number 99483-06................................................................................ 1
FLHTCUSE SERVICE SUPPLEMENT............................................................................. 1
Part Number 99500-06................................................................................ 1
ELECTRICAL DIAGNOSTICS.................................................................................. 1
Part Number 99497-06................................................................................ 1
sm01a.pdf....................................................................................................... 0
GENERAL 1.1................................................................................................. 4
REPAIR NOTES............................................................................................ 4
Safety.............................................................................................. 4
Removing Parts...................................................................................... 4
Cleaning............................................................................................ 4
Disassembly and Assembly............................................................................ 4
Checking Torques on Fasteners with Lock Patches..................................................... 4
REPAIR AND REPLACEMENT PROCEDURES....................................................................... 4
Hardware and Threaded Parts......................................................................... 4
Wiring, Hoses and Lines............................................................................. 4
Instruments and Gauges.............................................................................. 4
Bearings............................................................................................ 5
Bushings............................................................................................ 5
Gaskets............................................................................................. 5
Lip Type Seals...................................................................................... 5
O-Rings (Preformed Packings)........................................................................ 5
Gears............................................................................................... 5
Shafts.............................................................................................. 5
Part Replacement.................................................................................... 5
CLEANING................................................................................................ 5
Part Protection..................................................................................... 5
Cleaning Process.................................................................................... 5
Rust or Corrosion Removal........................................................................... 6
Bearings............................................................................................ 6
TOOL SAFETY............................................................................................. 7
AIR TOOLS........................................................................................... 7
WRENCHES............................................................................................ 7
PLIERS/CUTTERS/PRYBARS.............................................................................. 7
HAMMERS............................................................................................. 7
PUNCHES/CHISELS..................................................................................... 7
SCREWDRIVERS........................................................................................ 7
RATCHETS AND HANDLES................................................................................ 7
SOCKETS............................................................................................. 7
STORAGE UNITS........................................................................................... 8
MAINTENANCE SCHEDULE 1.2.................................................................................... 9
GENERAL................................................................................................. 9
sm01b.pdf....................................................................................................... 0
ENGINE OIL/FILTER 1.3....................................................................................... 12
GENERAL................................................................................................. 12
PROCEDURE............................................................................................... 12
AIR CLEANER 1.4............................................................................................. 14
GENERAL................................................................................................. 14
PROCEDURE............................................................................................... 14
TIRES 1.5................................................................................................... 16
GENERAL................................................................................................. 16
PROCEDURE............................................................................................... 16
WHEEL SPOKES 1.6............................................................................................ 17
GENERAL................................................................................................. 17
PROCEDURE............................................................................................... 17
PRIMARY CHAIN/LUBRICANT 1.7................................................................................. 18
GENERAL................................................................................................. 18
PROCEDURE............................................................................................... 18
PRIMARY CHAIN ADJUSTMENT............................................................................ 18
PRIMARY CHAIN LUBRICANT............................................................................. 19
CLUTCH ADJUSTMENT 1.8....................................................................................... 20
GENERAL................................................................................................. 20
PROCEDURE............................................................................................... 20
TRANSMISSION LUBRICANT 1.9.................................................................................. 22
GENERAL................................................................................................. 22
PROCEDURE............................................................................................... 22
DRIVE BELT 1.10............................................................................................. 23
GENERAL................................................................................................. 23
PROCEDURE............................................................................................... 23
THROTTLE CABLES 1.11........................................................................................ 26
GENERAL................................................................................................. 26
PROCEDURE............................................................................................... 26
LUBRICATION......................................................................................... 26
ADJUSTMENT.......................................................................................... 27
ENRICHENER CONTROL 1.12..................................................................................... 29
GENERAL................................................................................................. 29
PROCEDURE............................................................................................... 29
FUEL SYSTEM 1.13............................................................................................ 30
GENERAL................................................................................................. 30
PROCEDURE............................................................................................... 30
LINES AND FITTINGS.................................................................................. 30
FUEL FILTER (CARBURETED)............................................................................ 30
FUEL FILTER CANISTER (FUEL INJECTED)................................................................ 31
BRAKES 1.14................................................................................................. 32
GENERAL................................................................................................. 32
PROCEDURE............................................................................................... 32
BRAKE FLUID......................................................................................... 32
BRAKE PADS AND DISCS................................................................................ 32
SPARK PLUGS 1.15............................................................................................ 33
GENERAL................................................................................................. 33
PROCEDURE............................................................................................... 33
ENGINE IDLE SPEED 1.16...................................................................................... 34
GENERAL................................................................................................. 34
PROCEDURE............................................................................................... 34
FRONT FORK OIL 1.17......................................................................................... 35
GENERAL................................................................................................. 35
PROCEDURE............................................................................................... 35
STEERING HEAD BEARINGS 1.18................................................................................. 36
GENERAL................................................................................................. 36
PROCEDURE............................................................................................... 36
GREASING............................................................................................ 36
CHECKING............................................................................................ 36
INSPECTING/REPLACING................................................................................ 36
CRITICAL FASTENERS 1.19..................................................................................... 37
GENERAL................................................................................................. 37
PROCEDURE............................................................................................... 37
ENGINE MOUNTS....................................................................................... 37
OTHER FASTENERS..................................................................................... 37
BATTERY 1.20................................................................................................ 39
GENERAL................................................................................................. 39
PROCEDURE............................................................................................... 39
TROUBLESHOOTING 1.21........................................................................................ 40
GENERAL................................................................................................. 40
ENGINE.................................................................................................. 40
Starter Motor Does Not Operate or Does Not Turn Engine Over......................................... 40
Engine Turns Over But Does Not Start................................................................ 40
Starts Hard......................................................................................... 40
Starts But Runs Irregularly or Misses............................................................... 40
A Spark Plug Fouls Repeatedly....................................................................... 41
Pre-Ignition or Detonation (Knocks or Pings)........................................................ 41
Overheating......................................................................................... 41
Valve Train Noise................................................................................... 41
Excessive Vibration................................................................................. 41
Check Engine Lamp Illuminates During Operation...................................................... 41
LUBRICATION SYSTEM...................................................................................... 41
Oil Does Not Return To Oil Pan...................................................................... 41
Engine Uses Too Much Oil Or Smokes Excessively...................................................... 41
Engine Leaks Oil From Case, Push Rods, Hoses, Etc................................................... 41
Low Oil Pressure.................................................................................... 42
High Oil Pressure................................................................................... 42
ELECTRICAL SYSTEM....................................................................................... 42
Alternator Does Not Charge.......................................................................... 42
Alternator Charge Rate Is Below Normal.............................................................. 42
Speedometer Operates Erratically.................................................................... 42
CARBURETOR.............................................................................................. 42
Carburetor Floods................................................................................... 42
TRANSMISSION............................................................................................ 42
Transmission Shifts Hard............................................................................ 42
Jumps Out Of Gear................................................................................... 42
Clutch Slips........................................................................................ 42
Clutch Drags Or Does Not Release.................................................................... 42
Clutch Chatters..................................................................................... 42
BRAKES.................................................................................................. 43
Brake Does Not Hold Normally........................................................................ 43
HANDLING................................................................................................ 43
Irregularities...................................................................................... 43
sm02a.pdf....................................................................................................... 0
SPECIFICATIONS 2.1.......................................................................................... 46
DIMENSIONS (in.)........................................................................................ 46
WEIGHT (lbs.)........................................................................................... 46
CAPACITIES (U.S.)....................................................................................... 46
DIMENSIONS (mm)......................................................................................... 46
WEIGHT (kg)............................................................................................. 46
CAPACITIES (Metric)..................................................................................... 46
TIRE DATA............................................................................................... 47
REAR WHEEL SPROCKET..................................................................................... 47
TORQUE VALUES........................................................................................... 47
TORQUE VALUES (CONT.’D)............................................................................. 48
VEHICLE IDENTIFICATION NUMBER (V.I.N.) 2.2.................................................................. 50
FRONT WHEEL 2.3............................................................................................. 51
GENERAL................................................................................................. 51
PRELIMINARY INSPECTION.................................................................................. 51
REMOVAL................................................................................................. 51
DISASSEMBLY............................................................................................. 51
CLEANING AND INSPECTION................................................................................. 52
ASSEMBLY................................................................................................ 53
INSTALLATION............................................................................................ 54
REAR WHEEL 2.4.............................................................................................. 56
GENERAL................................................................................................. 56
PRELIMINARY INSPECTION.................................................................................. 56
REMOVAL................................................................................................. 56
DISASSEMBLY............................................................................................. 56
CLEANING AND INSPECTION................................................................................. 57
ASSEMBLY................................................................................................ 58
INSTALLATION............................................................................................ 60
CHECKING RIM RUNOUT 2.5..................................................................................... 63
INSPECTION.............................................................................................. 63
WHEEL LACING–16 INCH RIM 2.6................................................................................ 64
GENERAL................................................................................................. 64
WHEEL LACING............................................................................................ 64
SPOKE TIGHTNESS......................................................................................... 66
TRUING LACED WHEEL 2.7...................................................................................... 67
PROCEDURE............................................................................................... 67
TIRES AND TUBES 2.8......................................................................................... 69
GENERAL................................................................................................. 69
REMOVAL................................................................................................. 69
CLEANING AND INSPECTION................................................................................. 69
INSTALLATION............................................................................................ 70
Checking Tire Radial Runout......................................................................... 71
Checking Tire Lateral Runout........................................................................ 71
Wheel Balancing..................................................................................... 71
VEHICLE ALIGNMENT 2.9....................................................................................... 73
METHOD A................................................................................................ 73
METHOD B................................................................................................ 76
INSPECTION.............................................................................................. 78
Front Rubber Mount.................................................................................. 78
Rear Swingarm Mounts................................................................................ 78
Engine Stabilizer Links............................................................................. 78
FRONT BRAKE MASTER CYLINDER 2.10............................................................................ 79
GENERAL................................................................................................. 79
REMOVAL/DISASSEMBLY..................................................................................... 79
CLEANING AND INSPECTION................................................................................. 80
ASSEMBLY/INSTALLATION................................................................................... 80
REAR BRAKE MASTER CYLINDER 2.11............................................................................. 84
REMOVAL................................................................................................. 84
PRELIMINARY INSTRUCTIONS............................................................................ 84
BRAKE PEDAL/MASTER CYLINDER ASSEMBLY, REMOVAL....................................................... 84
BRAKE PEDAL/MASTER CYLINDER ASSEMBLY, INSTALLATION.................................................. 85
REAR BRAKE LINE, REMOVAL............................................................................ 85
REAR BRAKE LINE, INSTALLATION....................................................................... 86
INSTALLATION............................................................................................ 86
FINAL INSTRUCTIONS.................................................................................. 86
MASTER CYLINDER......................................................................................... 88
DISASSEMBLY......................................................................................... 88
CLEANING AND INSPECTION............................................................................. 89
ASSEMBLY............................................................................................ 90
FRONT BRAKE CALIPER 2.12.................................................................................... 93
INSPECTION.............................................................................................. 93
BRAKE PADS.......................................................................................... 93
BRAKE LINE/HOSE INSPECTION.......................................................................... 93
FRONT BRAKE PAD REPLACEMENT............................................................................. 93
PAD INSTALLATION.................................................................................... 94
CALIPER REMOVAL......................................................................................... 96
CALIPER DISASSEMBLY..................................................................................... 96
CLEANING AND INSPECTION................................................................................. 97
CALIPER ASSEMBLY........................................................................................ 97
CALIPER INSTALLATION.................................................................................... 98
REAR BRAKE CALIPER 2.13..................................................................................... 100
INSPECTION.............................................................................................. 100
BRAKE DISC THICKNESS/WARPAGE........................................................................ 100
BRAKE PADS.......................................................................................... 100
BRAKE LINE/HOSE INSPECTION.......................................................................... 100
REAR BRAKE PAD REPLACEMENT.............................................................................. 100
CALIPER REMOVAL......................................................................................... 103
CALIPER DISASSEMBLY..................................................................................... 103
CLEANING AND INSPECTION................................................................................. 104
CALIPER ASSEMBLY........................................................................................ 104
CALIPER INSTALLATION.................................................................................... 105
BLEEDING HYDRAULIC BRAKES 2.14.............................................................................. 107
GENERAL................................................................................................. 107
FRONT FORKS 2.15............................................................................................ 109
CHANGING FORK OIL....................................................................................... 109
REMOVAL................................................................................................. 109
DISASSEMBLY............................................................................................. 110
CLEANING AND INSPECTION................................................................................. 111
ASSEMBLY................................................................................................ 111
INSTALLATION............................................................................................ 114
LOWER FORK BRACKET COVER/AIR DAM 2.16....................................................................... 115
LOWER FORK BRACKET COVER (FLHRS)........................................................................ 115
REMOVAL............................................................................................. 115
INSTALLATION........................................................................................ 115
AIR DAM (FLTR).......................................................................................... 115
REMOVAL............................................................................................. 115
INSTALLATION........................................................................................ 115
STEERING HEAD BEARINGS 2.17................................................................................. 116
LUBRICATION............................................................................................. 116
CHECKING................................................................................................ 116
ADJUSTMENT.............................................................................................. 116
REMOVAL................................................................................................. 117
INSPECTION.............................................................................................. 118
ASSEMBLY................................................................................................ 119
INSTALLATION............................................................................................ 119
REAR AIR SUSPENSION 2.18.................................................................................... 120
GENERAL................................................................................................. 120
REAR AIR SUSPENSION..................................................................................... 122
REMOVAL/INSTALLATION.................................................................................... 122
Compression Fitting................................................................................. 122
Air Tubes........................................................................................... 123
sm02b.pdf....................................................................................................... 0
REAR SHOCK ABSORBERS 2.19................................................................................... 124
ADJUSTMENT.............................................................................................. 124
REMOVAL................................................................................................. 124
DISASSEMBLY............................................................................................. 125
CLEANING AND INSPECTION................................................................................. 125
ASSEMBLY................................................................................................ 125
INSTALLATION............................................................................................ 125
REAR SWINGARM 2.20.......................................................................................... 126
REMOVAL................................................................................................. 126
DISASSEMBLY/ASSEMBLY.................................................................................... 127
Bearing Removal..................................................................................... 127
Bearing Installation................................................................................ 128
Pivot Shaft Disassembly............................................................................. 128
Pivot Shaft Assembly................................................................................ 128
INSTALLATION............................................................................................ 129
THROTTLE CABLES (NON-CRUISE) 2.21........................................................................... 133
ADJUSTMENT.............................................................................................. 133
REMOVAL................................................................................................. 134
THROTTLE SIDE....................................................................................... 134
CARBURETOR/INDUCTION MODULE SIDE.................................................................... 135
CLEANING AND INSPECTION................................................................................. 135
INSTALLATION............................................................................................ 135
THROTTLE SIDE....................................................................................... 135
CARBURETOR/INDUCTION MODULE SIDE.................................................................... 136
LUBRICATION............................................................................................. 137
CLUTCH CABLE 2.22........................................................................................... 138
ADJUSTMENT.............................................................................................. 138
REMOVAL................................................................................................. 138
INSTALLATION............................................................................................ 139
HANDLEBARS 2.23............................................................................................. 142
HANDLEBAR ADJUSTMENT.................................................................................... 142
HANDLEBAR REMOVAL....................................................................................... 142
HANDLEBAR INSTALLATION.................................................................................. 142
LEFT HAND GRIP.......................................................................................... 143
REMOVAL............................................................................................. 143
INSTALLATION........................................................................................ 143
RUBBER MOUNTS........................................................................................... 144
REMOVAL............................................................................................. 144
INSTALLATION........................................................................................ 144
MIRRORS 2.24................................................................................................ 146
all models (except flhx)................................................................................ 146
Removal............................................................................................. 146
Installation........................................................................................ 146
flhx.................................................................................................... 146
Removal............................................................................................. 146
Installation........................................................................................ 146
SEAT 2.25................................................................................................... 147
FLHR.................................................................................................... 147
REMOVAL............................................................................................. 147
INSTALLATION........................................................................................ 147
FLHRC................................................................................................... 148
REMOVAL............................................................................................. 148
INSTALLATION........................................................................................ 148
FLHRS, FLHX, FLTR....................................................................................... 148
REMOVAL............................................................................................. 148
INSTALLATION........................................................................................ 149
FLHT.................................................................................................... 149
REMOVAL............................................................................................. 149
INSTALLATION........................................................................................ 149
FLHTC/U................................................................................................. 150
REMOVAL............................................................................................. 150
INSTALLATION........................................................................................ 150
SEAT RETENTION NUT REPLACEMENT...................................................................... 150
SADDLEBAG 2.26.............................................................................................. 151
OPENING................................................................................................. 151
FLHRC............................................................................................... 151
FLHRS............................................................................................... 151
FLHR, FLHX, FLHT/C/U, FLTR.......................................................................... 151
CLOSING................................................................................................. 152
FLHRC............................................................................................... 152
FLHRS............................................................................................... 152
FLHR, FLHX, FLHT/C/U, FLTR.......................................................................... 152
REMOVAL................................................................................................. 152
INSTALLATION............................................................................................ 153
LATCH SPRING REPLACEMENT (FLHR, FLHX, FLHT/C/U, FLTR)................................................... 153
REMOVAL............................................................................................. 153
INSTALLATION........................................................................................ 154
CABLE ASSEMBLY/LATCH/SCRIPT (FLHRS)..................................................................... 154
CABLE ASSEMBLY...................................................................................... 154
LATCH............................................................................................... 156
SCRIPT.............................................................................................. 156
SADDLEBAG GUARD/SUPPORT RAIL............................................................................ 156
REMOVAL............................................................................................. 156
INSTALLATION........................................................................................ 156
TOUR-PAK 2.27............................................................................................... 158
FLHTC................................................................................................... 158
REMOVAL............................................................................................. 158
INSTALLATION........................................................................................ 158
FLHTCU.................................................................................................. 159
REMOVAL............................................................................................. 159
INSTALLATION........................................................................................ 160
Adjustment.............................................................................................. 161
LOCKSET, HINGES, LATCHES, catches, TETHER, TETHER BRACKETS.............................................. 162
LOCKSET............................................................................................. 162
HINGES.............................................................................................. 163
LATCHES/LOCKSET CATCH............................................................................... 163
CATCHES............................................................................................. 164
TETHER.............................................................................................. 164
TETHER BRACKETS..................................................................................... 164
TOUR-PAK LIGHTS/BACKREST/SPEAKER BOX 2.28................................................................... 166
GENERAL................................................................................................. 166
SIDE MARKER LIGHTS (FLHTCU)............................................................................. 166
REMOVAL............................................................................................. 166
INSTALLATION........................................................................................ 166
TOUR-PAK LIGHTS HARNESS................................................................................. 166
REMOVAL............................................................................................. 166
INSTALLATION........................................................................................ 166
WRAP-AROUND LIGHTS (FLHTCU)............................................................................. 167
BULB REPLACEMENT.................................................................................... 167
REMOVAL............................................................................................. 167
INSTALLATION........................................................................................ 168
PASSENGER BACKREST/RUBBER ISOLATORS (FLHTCU)............................................................ 168
PASSENGER BACKREST.................................................................................. 168
RUBBER ISOLATORS.................................................................................... 169
PASSENGER BACKREST FLAP (FLHTCU)........................................................................ 169
BACKREST FLAP....................................................................................... 169
SPEAKER BOX (FLHTCU).................................................................................... 170
REMOVAL............................................................................................. 170
INSTALLATION........................................................................................ 170
LOWER FAIRING/ENGINE GUARD 2.29............................................................................. 171
LOWER FAIRING (FLHTCU).................................................................................. 171
REMOVAL............................................................................................. 171
INSTALLATION........................................................................................ 171
DISASSEMBLY......................................................................................... 171
ASSEMBLY............................................................................................ 172
ENGINE GUARD............................................................................................ 172
REMOVAL............................................................................................. 172
INSTALLATION........................................................................................ 172
UPPER FAIRING/WINDSHIELD (FLHX, FLHT/C/U) 2.30.............................................................. 174
OUTER FAIRING/WINDSHIELD................................................................................ 174
REMOVAL............................................................................................. 174
INSTALLATION........................................................................................ 174
FAIRING CAP............................................................................................. 175
REMOVAL............................................................................................. 175
INSTALLATION........................................................................................ 175
INNER FAIRING........................................................................................... 175
REMOVAL............................................................................................. 175
INSTALLATION........................................................................................ 178
AIR DEFLECTORS (FLHTCU)................................................................................. 180
REMOVAL............................................................................................. 180
INSTALLATION........................................................................................ 180
UPPER FAIRING/WINDSHIELD (FLTR) 2.31........................................................................ 181
WINDSHIELD ONLY......................................................................................... 181
REMOVAL............................................................................................. 181
INSTALLATION........................................................................................ 181
OUTER FAIRING........................................................................................... 181
REMOVAL............................................................................................. 181
INSTALLATION........................................................................................ 182
BEZEL................................................................................................... 183
REMOVAL............................................................................................. 183
INSTALLATION........................................................................................ 184
INSTRUMENT NACELLE...................................................................................... 184
REMOVAL............................................................................................. 184
INSTALLATION........................................................................................ 185
INNER FAIRING........................................................................................... 187
REMOVAL............................................................................................. 187
INSTALLATION........................................................................................ 188
GLOVE BOX DOOR/HINGE.................................................................................... 190
REMOVAL............................................................................................. 190
INSTALLATION........................................................................................ 190
WINDSHIELD/HEADLAMP NACELLE (FLHR/C/S) 2.32................................................................. 191
WINDSHIELD REMOVAL...................................................................................... 191
WINDSHIELD INSTALLATION................................................................................. 191
NACELLE REMOVAL (FLHR/C)................................................................................ 191
NACELLE INSTALLATION (FLHR/C)........................................................................... 192
NACELLE REMOVAL (FLHRS)................................................................................. 193
NACELLE INSTALLATION (FLHRS)............................................................................ 194
FRONT FENDER 2.33........................................................................................... 195
REMOVAL................................................................................................. 195
INSTALLATION............................................................................................ 196
REAR FENDER 2.34............................................................................................ 197
REMOVAL................................................................................................. 197
INSTALLATION............................................................................................ 198
REAR FENDER LIGHTS CONDUIT.............................................................................. 199
REMOVAL............................................................................................. 199
INSTALLATION........................................................................................ 199
REAR FENDER CLOISONNE................................................................................... 200
REMOVAL............................................................................................. 200
INSTALLATION........................................................................................ 200
REAR FACIA (FLHX) 2.35...................................................................................... 201
REMOVAL................................................................................................. 201
INSTALLATION............................................................................................ 201
STUD PLATE.............................................................................................. 201
REMOVAL............................................................................................. 201
INSTALLATION........................................................................................ 201
REAR FACIA LAMP......................................................................................... 202
REMOVAL............................................................................................. 202
INSTALLATION........................................................................................ 202
JIFFY STAND 2.36............................................................................................ 203
GENERAL................................................................................................. 203
REMOVAL................................................................................................. 203
INSTALLATION............................................................................................ 204
FOOTBOARDS/FOOTRESTS 2.37................................................................................... 205
RIDER FOOTBOARD......................................................................................... 205
REMOVAL............................................................................................. 205
INSTALLATION........................................................................................ 205
DISASSEMBLY......................................................................................... 205
ASSEMBLY............................................................................................ 205
PASSENGER FOOTBOARD..................................................................................... 205
REMOVAL............................................................................................. 205
INSTALLATION........................................................................................ 206
DISASSEMBLY......................................................................................... 207
ASSEMBLY............................................................................................ 207
PASSENGER FOOTREST (FLHRS, FLHX)........................................................................ 207
REMOVAL............................................................................................. 207
INSTALLATION........................................................................................ 207
DISASSEMBLY......................................................................................... 207
ASSEMBLY............................................................................................ 208
EXHAUST SYSTEM 2.38......................................................................................... 209
REMOVAL................................................................................................. 209
INSTALLATION............................................................................................ 209
DISASSEMBLY............................................................................................. 211
ASSEMBLY................................................................................................ 213
sm03a.pdf....................................................................................................... 0
SPECIFICATIONS 3.1.......................................................................................... 215
MANUFACTURING TOLERANCES................................................................................ 215
MANUFACTURING TOLERANCES (CONT.).................................................................... 216
TORQUE VALUES........................................................................................... 216
SERVICE WEAR LIMITS 3.2..................................................................................... 217
GENERAL................................................................................................. 217
SERVICE WEAR LIMITS (CONT.)......................................................................... 218
GENERAL INFORMATION 3.3..................................................................................... 219
FUEL.................................................................................................... 219
GASOLINE/ALCOHOL BLENDS............................................................................. 219
LUBRICATION............................................................................................. 219
CHECKING ENGINE OIL LEVEL........................................................................... 219
CHANGING ENGINE OIL AND FILTER...................................................................... 220
WINTER LUBRICATION.................................................................................. 221
OIL PRESSURE INDICATOR LAMP......................................................................... 221
ENGINE OIL FLOW..................................................................................... 222
Oil Feed (Figures 3-6, 3-7)......................................................................... 222
Top End (Figures 3-6, 3-7).......................................................................... 222
Bottom End (Figures 3-6, 3-7, 3-8).................................................................. 224
Oil Return (Figures 3-6, 3-8)....................................................................... 224
Oil Pump Operation.................................................................................. 224
Breather Operation.................................................................................. 227
HOW TO USE THIS SECTION 3.4................................................................................. 228
GENERAL................................................................................................. 228
Top End Overhaul.................................................................................... 228
Bottom End Overhaul................................................................................. 228
Subassembly Service and Repair...................................................................... 229
STRIPPING MOTORCYCLE FOR SERVICE 3.5........................................................................ 230
PROCEDURE............................................................................................... 230
ASSEMBLING MOTORCYCLE AFTER STRIPPING 3.6................................................................... 231
PROCEDURE............................................................................................... 231
REMOVING ENGINE FROM CHASSIS 3.7............................................................................ 233
PROCEDURE............................................................................................... 233
INSTALLING ENGINE IN CHASSIS 3.8............................................................................ 237
PROCEDURE............................................................................................... 237
sm03b.pdf....................................................................................................... 0
TOP END OVERHAUL 3.9........................................................................................ 243
DISASSEMBLY............................................................................................. 243
ASSEMBLY................................................................................................ 247
BOTTOM END OVERHAUL 3.10.................................................................................... 255
DISASSEMBLY............................................................................................. 255
ASSEMBLY................................................................................................ 257
SUBASSEMBLY SERVICE AND REPAIR 3.11......................................................................... 265
TOP END................................................................................................. 265
BREATHER ASSEMBLY....................................................................................... 265
Removal............................................................................................. 265
Disassembly......................................................................................... 265
Cleaning and Inspection............................................................................. 265
Assembly............................................................................................ 265
Installation........................................................................................ 265
ROCKER ARM ASSEMBLY..................................................................................... 266
Removal............................................................................................. 266
Disassembly......................................................................................... 266
Cleaning and Inspection............................................................................. 266
Assembly............................................................................................ 267
Installation........................................................................................ 268
PUSH RODS/LIFTERS/COVERS................................................................................ 269
Removal............................................................................................. 269
Disassembly......................................................................................... 269
Cleaning and Inspection............................................................................. 269
Assembly............................................................................................ 269
Installation........................................................................................ 270
CYLINDER HEAD........................................................................................... 273
Removal............................................................................................. 273
Disassembly......................................................................................... 273
Cleaning and Inspection............................................................................. 274
VALVE GUIDE REPLACEMENT............................................................................. 275
VALVE AND SEAT REFACING............................................................................. 279
Assembly............................................................................................ 280
Installation........................................................................................ 281
CYLINDER................................................................................................ 282
Removal............................................................................................. 282
Cleaning and Inspection............................................................................. 282
Installation........................................................................................ 284
sm03c.pdf....................................................................................................... 0
PISTON...................................................................................................... 285
Removal................................................................................................. 285
Disassembly............................................................................................. 285
Piston Rings, Removal................................................................................... 285
Cleaning and Inspection................................................................................. 285
Assembly................................................................................................ 287
Piston Rings, Installation.............................................................................. 287
Installation............................................................................................ 288
UPPER CONNECTING ROD........................................................................................ 290
Removal................................................................................................. 290
Disassembly/Assembly.................................................................................... 290
Upper Connecting Rod Bushing............................................................................ 290
Reaming Upper Rod Bushing............................................................................... 291
Honing Upper Rod Bushing................................................................................ 292
Installation............................................................................................ 293
BOTTOM END.................................................................................................. 295
CAM SUPPORT PLATE........................................................................................... 295
Removal................................................................................................. 295
Disassembly/Assembly.................................................................................... 295
Crankshaft Bushing...................................................................................... 295
Reaming Crankshaft Bushing.............................................................................. 296
Camshafts/Camshaft Bearings............................................................................. 297
Cam Chain Tensioners.................................................................................... 303
Oil Pressure Relief Valve............................................................................... 304
Cam Needle Bearings..................................................................................... 304
Installation............................................................................................ 306
OIL PUMP.................................................................................................... 307
Removal................................................................................................. 307
Cleaning and Inspection................................................................................. 307
Installation............................................................................................ 307
CRANKCASE................................................................................................... 309
Removal................................................................................................. 309
Disassembly/Assembly.................................................................................... 309
RIGHT CRANKCASE HALF.................................................................................... 309
Crankshaft Bearing...................................................................................... 309
Piston Jets............................................................................................. 310
LEFT CRANKCASE HALF..................................................................................... 310
Sprocket Shaft Bearing.................................................................................. 310
Sprocket Shaft Bearing Inner Race....................................................................... 312
Cylinder Studs.......................................................................................... 315
Pipe Plug and Oil Fittings.............................................................................. 315
Cleaning and Inspection................................................................................. 315
Installation............................................................................................ 315
FLYWHEEL/CONNECTING ROD ASSEMBLY............................................................................ 316
Removal................................................................................................. 316
Inspection.............................................................................................. 316
Installation............................................................................................ 316
sm04a.pdf....................................................................................................... 0
SPECIFICATIONS 4.1.......................................................................................... 319
CVH CARBURETOR JET SIZES................................................................................ 319
FUEL TANK CAPACITY...................................................................................... 319
TORQUE VALUES........................................................................................... 319
FUEL SYSTEM TROUBLESHOOTING (CARBURETED) 4.2................................................................ 320
ENRICHENER (CARBURETED) 4.3................................................................................. 323
GENERAL................................................................................................. 323
OPERATION............................................................................................... 323
Enrichener.......................................................................................... 323
Cool Engine......................................................................................... 324
Warm Climate Or Hot Engine.......................................................................... 324
ADJUSTMENTS............................................................................................. 324
Slow Idle........................................................................................... 324
Enrichener Control.................................................................................. 325
CARBURETOR 4.4.............................................................................................. 327
REMOVAL................................................................................................. 327
INSTALLATION............................................................................................ 327
DISASSEMBLY............................................................................................. 328
CLEANING AND INSPECTION................................................................................. 330
Carburetor Housing.................................................................................. 330
ASSEMBLY................................................................................................ 332
AIR CLEANER 4.5............................................................................................. 334
REMOVAL................................................................................................. 334
CLEANING AND INSPECTION................................................................................. 334
INSTALLATION............................................................................................ 335
VACUUM OPERATED FUEL VALVE (CARBURETED) 4.6................................................................. 336
GENERAL................................................................................................. 336
TROUBLESHOOTING......................................................................................... 336
REMOVAL................................................................................................. 336
CLEANING AND INSPECTION................................................................................. 337
INSTALLATION............................................................................................ 337
FUEL TANK ADAPTER....................................................................................... 338
FUEL TANK (CARBURETED) 4.7.................................................................................. 339
COMPLETE REMOVAL........................................................................................ 339
FLHX, FLHT.......................................................................................... 339
FLHR/S.............................................................................................. 339
CLEANING AND INSPECTION................................................................................. 340
INSTALLATION (AFTER COMPLETE REMOVAL)................................................................... 341
FLHX, FLHT.......................................................................................... 341
FLHR/S.............................................................................................. 341
PARTIAL REMOVAL......................................................................................... 343
FLHX, FLHT.......................................................................................... 343
FLHR/S.............................................................................................. 343
INSTALLATION (AFTER PARTIAL REMOVAL).................................................................... 344
FLHX, FLHT.......................................................................................... 344
FLHR/S.............................................................................................. 344
EVAPORATIVE EMISSIONS CONTROL SYSTEM 4.8.................................................................... 345
CALIFORNIA MODELS ONLY.................................................................................. 345
TROUBLESHOOTING......................................................................................... 346
VAPOR VALVE............................................................................................. 346
REMOVAL............................................................................................. 346
INSTALLATION........................................................................................ 346
CHARCOAL CANISTER....................................................................................... 347
REMOVAL............................................................................................. 347
INSTALLATION........................................................................................ 347
Charcoal Canister Hose Routing...................................................................... 348
Purge Tube:......................................................................................... 348
Fuel Vapor Vent Tube:............................................................................... 348
Clean Air Inlet Tube:............................................................................... 349
sm05a.pdf....................................................................................................... 0
SPECIFICATIONS 5.1.......................................................................................... 353
STARTER................................................................................................. 353
SERVICE WEAR LIMITS..................................................................................... 353
TORQUE VALUES........................................................................................... 353
STARTER SYSTEM 5.2.......................................................................................... 354
GENERAL................................................................................................. 354
Operation (Figure 5-1).............................................................................. 354
STARTER RELAY 5.3........................................................................................... 356
REMOVAL................................................................................................. 356
FLHR/C/S............................................................................................ 356
FLHX, FLHT/C/U, FLTR................................................................................ 356
INSTALLATION............................................................................................ 356
FLHR/C/S............................................................................................ 356
FLHX, FLHT/C/U, FLTR................................................................................ 357
STARTER 5.4................................................................................................. 358
REMOVAL................................................................................................. 358
INSTALLATION............................................................................................ 358
DISASSEMBLY, TESTING AND REPAIR......................................................................... 360
ASSEMBLY................................................................................................ 364
STARTER SOLENOID 5.5........................................................................................ 365
GENERAL................................................................................................. 365
DISASSEMBLY............................................................................................. 365
ASSEMBLY................................................................................................ 365
STARTER JACKSHAFT 5.6....................................................................................... 366
REMOVAL/DISASSEMBLY..................................................................................... 366
ASSEMBLY/INSTALLATION................................................................................... 367
sm06a.pdf....................................................................................................... 0
SPECIFICATIONS 6.1.......................................................................................... 371
OVERALL GEAR RATIOS..................................................................................... 371
CHAINS AND BELTS........................................................................................ 371
SPROCKETS............................................................................................... 371
CLUTCH.................................................................................................. 371
TORQUE VALUES........................................................................................... 371
PRIMARY CHAIN AND SPROCKETS 6.2............................................................................. 373
PRIMARY CHAIN ADJUSTMENT................................................................................ 373
ADJUSTER SHOE REPLACEMENT............................................................................... 373
DISASSEMBLY............................................................................................. 374
CLEANING AND INSPECTION................................................................................. 374
ASSEMBLY................................................................................................ 374
CLUTCH 6.3.................................................................................................. 375
ADJUSTMENT.............................................................................................. 375
REMOVAL/INSTALLATION.................................................................................... 375
PARTIAL DISASSEMBLY................................................................................. 375
ASSEMBLY............................................................................................ 375
CLEANING AND INSPECTION................................................................................. 375
COMPLETE DISASSEMBLY................................................................................ 377
ASSEMBLY............................................................................................ 378
SECONDARY DRIVE BELT AND SPROCKETS 6.4...................................................................... 380
ADJUSTMENT.............................................................................................. 380
CLEANING AND INSPECTION................................................................................. 380
REPLACEMENT............................................................................................. 381
REMOVAL............................................................................................. 381
INSTALLATION........................................................................................ 381
TRANSMISSION SPROCKET................................................................................... 382
REMOVAL............................................................................................. 382
CLEANING AND INSPECTION............................................................................. 382
INSTALLATION........................................................................................ 382
REAR WHEEL SPROCKET..................................................................................... 383
REMOVAL............................................................................................. 383
CLEANING AND INSPECTION............................................................................. 384
INSTALLATION........................................................................................ 384
PRIMARY CHAINCASE 6.5....................................................................................... 385
GENERAL................................................................................................. 385
LUBRICATION............................................................................................. 385
REMOVAL................................................................................................. 385
INSPECTION AND REPAIR................................................................................... 387
DISASSEMBLY............................................................................................. 388
MAINSHAFT BEARING AND LIP SEAL...................................................................... 388
MAINSHAFT BEARING INNER RACE........................................................................ 389
STARTER JACKSHAFT LIP SEAL AND BUSHING - PRIMARY CHAINCASE.......................................... 390
STARTER JACKSHAFT BUSHING - PRIMARY CHAINCASE COVER................................................. 390
SHIFTER BUSHINGS.................................................................................... 390
INSTALLATION............................................................................................ 391
sm07a.pdf....................................................................................................... 0
SPECIFICATIONS 7.1.......................................................................................... 399
TRANSMISSION DATA....................................................................................... 399
SERVICE WEAR LIMITS..................................................................................... 399
SERVICE WEAR LIMITS (CONT.’D)....................................................................... 400
TORQUE VALUES........................................................................................... 400
TRANSMISSION POWER FLOW 7.2................................................................................. 401
GENERAL................................................................................................. 401
Neutral............................................................................................. 401
1st Gear............................................................................................ 401
2nd Gear............................................................................................ 401
3rd Gear............................................................................................ 401
4th Gear............................................................................................ 401
5th Gear............................................................................................ 401
SHIFT LINKAGE 7.3........................................................................................... 403
ADJUSTMENT.............................................................................................. 403
SHIFT ROD........................................................................................... 403
SHIFTER CAM ASSEMBLY/SHIFTER FORKS 7.4...................................................................... 404
DISASSEMBLY............................................................................................. 404
CLEANING AND INSPECTION................................................................................. 405
ASSEMBLY................................................................................................ 406
CLUTCH RELEASE COVER 7.5.................................................................................... 410
REMOVAL/DISASSEMBLY..................................................................................... 410
CLEANING AND INSPECTION................................................................................. 410
ASSEMBLY/INSTALLATION................................................................................... 410
MAINSHAFT/COUNTERSHAFT 7.6.................................................................................. 413
REMOVAL................................................................................................. 413
DISASSEMBLY............................................................................................. 413
CLEANING AND INSPECTION................................................................................. 414
ASSEMBLY................................................................................................ 416
INSTALLATION............................................................................................ 419
MAIN DRIVE GEAR/BEARING 7.7................................................................................. 421
PRELIMINARY INSTRUCTIONS................................................................................ 421
REMOVAL................................................................................................. 421
CLEANING AND INSPECTION................................................................................. 422
Needle Bearing Replacement.......................................................................... 422
INSTALLATION............................................................................................ 424
FINAL INSTRUCTIONS...................................................................................... 425
Countershaft Needle Bearing Replacement............................................................. 428
TRANSMISSION CASE/OIL PAN 7.8............................................................................... 429
GENERAL................................................................................................. 429
REMOVAL................................................................................................. 429
Transmission Case and Oil Pan....................................................................... 429
Oil Pan Only........................................................................................ 430
CLEANING AND INSPECTION................................................................................. 431
INSTALLATION............................................................................................ 431
Oil Pan Only........................................................................................ 431
Transmission Case and Oil Pan....................................................................... 431
sm08a.pdf....................................................................................................... 0
SPECIFICATIONS 8.1.......................................................................................... 435
IGNITION TIMING......................................................................................... 435
ALTERNATOR SYSTEM....................................................................................... 435
BATTERY................................................................................................. 435
FUSES................................................................................................... 435
SPARK PLUG.............................................................................................. 436
TORQUE VALUES........................................................................................... 436
BULB CHART 8.2.............................................................................................. 437
SYSTEM FUSES 8.3............................................................................................ 439
MAXI-FUSE............................................................................................... 439
REMOVAL............................................................................................. 439
INSTALLATION........................................................................................ 439
MAXI-FUSE HOLDER........................................................................................ 439
REMOVAL............................................................................................. 439
INSTALLATION........................................................................................ 439
SYSTEM FUSES/RELAYS..................................................................................... 439
REMOVAL............................................................................................. 439
INSTALLATION........................................................................................ 440
FUSE BLOCK.............................................................................................. 440
REMOVAL............................................................................................. 440
INSTALLATION........................................................................................ 440
EFI FUSES............................................................................................... 440
ICM (CARBURETED) 8.4........................................................................................ 441
REMOVAL................................................................................................. 441
INSTALLATION............................................................................................ 441
SENSORS (CARBURETED) 8.5.................................................................................... 442
MAP SENSOR.............................................................................................. 442
Removal............................................................................................. 442
Installation........................................................................................ 442
CKP SENSOR.............................................................................................. 442
IGNITION COIL 8.6........................................................................................... 443
REMOVAL................................................................................................. 443
INSTALLATION............................................................................................ 443
SPARK PLUGS/SPARK PLUG CABLES 8.7........................................................................... 444
SPARK PLUGS............................................................................................. 444
REMOVAL............................................................................................. 444
INSPECTION.......................................................................................... 444
CLEANING............................................................................................ 444
ADJUSTMENT.......................................................................................... 444
INSTALLATION........................................................................................ 444
SPARK PLUG CABLES....................................................................................... 445
REMOVAL............................................................................................. 445
INSPECTION.......................................................................................... 445
INSTALLATION........................................................................................ 445
ALTERNATOR/STATOR 8.8....................................................................................... 446
REMOVAL................................................................................................. 446
CLEANING AND INSPECTION................................................................................. 447
INSTALLATION............................................................................................ 447
VOLTAGE REGULATOR 8.9....................................................................................... 449
REMOVAL................................................................................................. 449
INSTALLATION............................................................................................ 449
BATTERY 8.10................................................................................................ 451
GENERAL................................................................................................. 451
BATTERY TESTS........................................................................................... 451
VOLTMETER TEST...................................................................................... 451
CONDUCTANCE TEST.................................................................................... 452
LOAD TEST........................................................................................... 452
DISCONNECTION AND REMOVAL............................................................................... 453
CLEANING AND INSPECTION................................................................................. 453
BATTERY CHARGING........................................................................................ 453
SAFETY PRECAUTIONS.................................................................................. 453
CHARGING BATTERY.................................................................................... 454
BATTERY CABLE ROUTING................................................................................... 455
INSTALLATION AND CONNECTION............................................................................. 455
STORAGE................................................................................................. 456
HEADLAMP (FLHR/C/S, FLHX, FLHT/C/U) 8.11.................................................................... 457
HEADLAMP ASSEMBLY....................................................................................... 457
REMOVAL............................................................................................. 457
INSTALLATION........................................................................................ 457
HEADLAMP BULB REPLACEMENT............................................................................... 457
HEADLAMP ADJUSTMENT..................................................................................... 458
HEADLAMP (FLTR) 8.12........................................................................................ 460
HEADLAMP ASSEMBLY....................................................................................... 460
REMOVAL............................................................................................. 460
INSTALLATION........................................................................................ 460
HEADLAMP BULB REPLACEMENT............................................................................... 461
REMOVAL............................................................................................. 461
INSTALLATION........................................................................................ 461
HEADLAMP ADJUSTMENT..................................................................................... 461
AUXILIARY LAMPS 8.13........................................................................................ 463
AUXILIARY LAMP BULB..................................................................................... 463
REMOVAL............................................................................................. 463
INSTALLATION........................................................................................ 463
AUXILIARY LAMP HOUSING.................................................................................. 464
REMOVAL............................................................................................. 464
INSTALLATION........................................................................................ 465
AUXILIARY LAMP BRACKET.................................................................................. 466
REMOVAL............................................................................................. 466
INSTALLATION........................................................................................ 466
ADJUSTMENT.............................................................................................. 466
TAIL LAMP ASSEMBLY 8.14..................................................................................... 468
TAIL LAMP/TAIL LAMP BULB................................................................................ 468
REMOVAL............................................................................................. 468
INSTALLATION........................................................................................ 468
CIRCUIT BOARD/CHROME BASE............................................................................... 468
REMOVAL............................................................................................. 468
INSTALLATION........................................................................................ 469
REAR FENDER LIGHTS HARNESS.............................................................................. 470
REMOVAL............................................................................................. 470
INSTALLATION........................................................................................ 470
FENDER TIP LAMPS 8.15....................................................................................... 472
FRONT FENDER TIP LAMP................................................................................... 472
REMOVAL............................................................................................. 472
INSTALLATION........................................................................................ 472
FRONT FENDER TIP LAMP JUMPER HARNESS.................................................................... 472
REMOVAL............................................................................................. 472
INSTALLATION........................................................................................ 473
REAR FENDER TIP LAMP.................................................................................... 475
REMOVAL............................................................................................. 475
INSTALLATION........................................................................................ 476
TURN SIGNAL LAMPS 8.16...................................................................................... 477
BULB REPLACEMENT........................................................................................ 477
REMOVAL............................................................................................. 477
INSTALLATION........................................................................................ 477
FRONT TURN SIGNAL LAMP.................................................................................. 477
FLHR/C, FLHT/C/U.................................................................................... 477
FLHRS............................................................................................... 479
FLHX................................................................................................ 481
FLTR................................................................................................ 482
REAR TURN SIGNAL LAMP................................................................................... 483
FLHR/C, FLHT/C/U.................................................................................... 483
FLHRS, FLHX, FLTR................................................................................... 484
REAR TURN SIGNAL LAMPS BRACKET.......................................................................... 485
FLHR/C, FLHT/C/U.................................................................................... 485
FLHRS, FLHX, FLTR................................................................................... 485
INSTALLATION........................................................................................ 485
LICENSE PLATE LAMPS/BRACKET (FLHX) 8.17..................................................................... 486
BULB REPLACEMENT........................................................................................ 486
REMOVAL............................................................................................. 486
INSTALLATION........................................................................................ 486
LICENSE PLATE LAMPS..................................................................................... 486
REMOVAL............................................................................................. 486
INSTALLATION........................................................................................ 486
LICENSE PLATE BRACKET................................................................................... 487
REMOVAL............................................................................................. 487
INSTALLATION........................................................................................ 487
TSM/TSSM 8.18............................................................................................... 488
REMOVAL................................................................................................. 488
INSTALLATION............................................................................................ 488
sm08b.pdf....................................................................................................... 0
IGNITION/LIGHT KEY SWITCH AND FORK LOCK 8.19................................................................ 489
FLHX, FLHT/C/U, FLTR.................................................................................... 489
REMOVAL............................................................................................. 489
INSTALLATION........................................................................................ 490
FLHR/C/S................................................................................................ 492
IGNITION/LIGHT KEY SWITCH........................................................................... 492
FORK LOCK........................................................................................... 493
FAIRING CAP SWITCHES (FLHTC/U) 8.20......................................................................... 494
REMOVAL................................................................................................. 494
INSTALLATION............................................................................................ 495
INSTRUMENT NACELLE SWITCHES (FLTR) 8.21..................................................................... 496
REMOVAL................................................................................................. 496
LEFT SIDE SWITCH.................................................................................... 496
RIGHT SIDE SWITCHES................................................................................. 497
INSTALLATION............................................................................................ 497
LEFT SIDE SWITCH.................................................................................... 497
RIGHT SIDE SWITCHES................................................................................. 498
HANDLEBAR SWITCHES 8.22..................................................................................... 500
GENERAL................................................................................................. 500
REMOVAL................................................................................................. 500
RIGHT HANDLEBAR CONTROLS............................................................................ 500
LEFT HANDLEBAR CONTROLS............................................................................. 501
INSTALLATION............................................................................................ 501
RIGHT HANDLEBAR CONTROLS............................................................................ 501
LEFT HANDLEBAR CONTROLS............................................................................. 503
SWITCH REPAIR/REPLACEMENT............................................................................... 506
RIGHT SIDE HANDLEBAR SWITCHES....................................................................... 506
LEFT SIDE HANDLEBAR SWITCHES........................................................................ 506
SPECIFIC REPAIR PROCEDURES.............................................................................. 506
UPPER SWITCH HOUSINGS............................................................................... 506
LOWER SWITCH HOUSINGS............................................................................... 508
GENERAL REPAIR PROCEDURES............................................................................... 514
RIGHT SIDE HANDLEBAR SWITCHES....................................................................... 516
LEFT SIDE HANDLEBAR SWITCHES........................................................................ 516
STOPLIGHT SWITCHES 8.23..................................................................................... 517
FRONT STOPLIGHT SWITCH.................................................................................. 517
REMOVAL/INSTALLATION................................................................................ 517
REAR STOPLIGHT SWITCH................................................................................... 517
REMOVAL............................................................................................. 517
INSTALLATION........................................................................................ 517
NEUTRAL SWITCH 8.24......................................................................................... 518
REMOVAL................................................................................................. 518
INSTALLATION............................................................................................ 518
OIL PRESSURE SWITCH/SENDER 8.25............................................................................. 519
REMOVAL................................................................................................. 519
INSTALLATION............................................................................................ 519
HORN 8.26................................................................................................... 520
TROUBLESHOOTING......................................................................................... 520
REMOVAL................................................................................................. 520
INSTALLATION............................................................................................ 520
CIGARETTE LIGHTER (FLHX, FLHT/C/U, FLTR) 8.27............................................................... 521
GENERAL................................................................................................. 521
TROUBLESHOOTING......................................................................................... 521
REMOVAL................................................................................................. 521
INSTALLATION............................................................................................ 521
GAUGES/INSTRUMENTS (FLHX, FLHT/C/U, FLTR) 8.28.............................................................. 522
GAUGE/LAMP- 2 INCH DIAMETER............................................................................. 522
REMOVAL............................................................................................. 522
INSTALLATION........................................................................................ 522
GAUGES- 4 INCH DIAMETER................................................................................. 522
TACHOMETER.......................................................................................... 522
REMOVAL............................................................................................. 522
INSTALLATION........................................................................................ 523
VSS..................................................................................................... 523
REMOVAL............................................................................................. 523
INSTALLATION........................................................................................ 524
SPEEDOMETER............................................................................................. 524
REMOVAL............................................................................................. 524
INSTALLATION........................................................................................ 524
INDICATOR LAMPS......................................................................................... 525
REMOVAL............................................................................................. 525
INSTALLATION........................................................................................ 525
GAUGES/INSTRUMENTS (FLHR/C/S) 8.29.......................................................................... 526
FUEL GAUGE.............................................................................................. 526
REMOVAL............................................................................................. 526
INSTALLATION........................................................................................ 526
VSS..................................................................................................... 527
SPEEDOMETER............................................................................................. 527
REMOVAL............................................................................................. 527
INSTALLATION........................................................................................ 528
INDICATOR LIGHTS........................................................................................ 528
REMOVAL............................................................................................. 528
INSTALLATION........................................................................................ 528
IGNITION SWITCH......................................................................................... 529
FUEL LEVEL SENDER (CARBURETED) 8.30......................................................................... 530
FLHX, FLHT CANOPY....................................................................................... 530
REMOVAL............................................................................................. 530
INSTALLATION........................................................................................ 530
FLHR/S CANOPY........................................................................................... 531
REMOVAL............................................................................................. 531
INSTALLATION........................................................................................ 532
FUEL LEVEL SENDER....................................................................................... 533
REMOVAL............................................................................................. 533
INSTALLATION........................................................................................ 533
sm08c.pdf....................................................................................................... 0
CRUISE CONTROL (FLHRC, FLHTCU, FLTR) 8.31................................................................... 535
GENERAL................................................................................................. 535
SYSTEM OPERATION........................................................................................ 535
CABLE ADJUSTMENT........................................................................................ 536
THROTTLE CABLE...................................................................................... 537
IDLE CABLE.......................................................................................... 537
CABLE LASH INITIALIZATION........................................................................... 537
THROTTLE/IDLE CABLES.................................................................................... 538
REMOVAL............................................................................................. 538
INSTALLATION........................................................................................ 538
CRUISE CABLE............................................................................................ 540
REMOVAL............................................................................................. 540
INSTALLATION........................................................................................ 540
CRUISE CONTROL MODULE................................................................................... 541
REMOVAL............................................................................................. 541
INSTALLATION........................................................................................ 542
CRUISE CONTROL SWITCHES................................................................................. 542
FAIRING CAP......................................................................................... 542
HANDLEBAR........................................................................................... 542
ADVANCED AUDIO SYSTEM (FLHX, FLHTC/U, FLTR) 8.32............................................................ 543
RADIO (STORAGE BOX)..................................................................................... 543
REMOVAL............................................................................................. 543
INSTALLATION........................................................................................ 543
FRONT FAIRING SPEAKERS.................................................................................. 544
REMOVAL............................................................................................. 544
INSTALLATION........................................................................................ 544
CONSOLE POD ASSEMBLY.................................................................................... 544
REMOVAL............................................................................................. 544
INSTALLATION........................................................................................ 545
FRONT HEADSET RECEPTACLE................................................................................ 546
REMOVAL............................................................................................. 546
INSTALLATION........................................................................................ 546
REAR HEADSET RECEPTACLE................................................................................. 546
REAR PASSENGER SWITCHES................................................................................. 546
REMOVAL............................................................................................. 546
INSTALLATION........................................................................................ 547
REAR SPEAKERS........................................................................................... 547
REMOVAL............................................................................................. 547
INSTALLATION........................................................................................ 548
CB MODULE............................................................................................... 549
REMOVAL............................................................................................. 549
INSTALLATION........................................................................................ 549
CB LOADING COIL......................................................................................... 549
REMOVAL............................................................................................. 549
INSTALLATION........................................................................................ 549
AUDIO HARNESS........................................................................................... 549
RADIO ANTENNA CABLE..................................................................................... 549
CB ANTENNA CABLE........................................................................................ 549
WIRE TROUGH 8.33............................................................................................ 550
REMOVAL................................................................................................. 550
INSTALLATION............................................................................................ 551
MAIN HARNESS 8.34........................................................................................... 553
REMOVAL................................................................................................. 553
REMOVAL- ALL MODELS (PART I)........................................................................ 553
REMOVAL- FLHR/C/S (PART II)......................................................................... 553
REMOVAL- FLHX, FLHT/C/U (PART II)................................................................... 554
REMOVAL- FLTR (PART II)............................................................................. 556
REMOVAL- ALL MODELS (PART III)...................................................................... 556
INSTALLATION............................................................................................ 561
INSTALLATION- ALL MODELS (PART I)................................................................... 561
INSTALLATION- FLHR/C/S (PART II).................................................................... 564
INSTALLATION- FLHX, FLHT/C/U (PART II).............................................................. 565
INSTALLATION- FLTR (PART II)........................................................................ 565
INSTALLATION- ALL MODELS (PART III)................................................................. 565
FRAME GROUND STUD REPLACEMENT........................................................................... 566
INTERCONNECT HARNESS 8.35................................................................................... 567
FLHX, FLHT/C/U.......................................................................................... 567
REMOVAL............................................................................................. 567
INSTALLATION........................................................................................ 570
FLTR.................................................................................................... 571
REMOVAL............................................................................................. 571
INSTALLATION........................................................................................ 573
RADIO ANTENNA CABLE 8.36.................................................................................... 575
FLHTC/U................................................................................................. 575
REMOVAL............................................................................................. 575
INSTALLATION........................................................................................ 575
FLHX, FLTR.............................................................................................. 577
REMOVAL............................................................................................. 577
INSTALLATION........................................................................................ 577
AUDIO HARNESS (FLHTCU) 8.37................................................................................. 579
REMOVAL................................................................................................. 579
INSTALLATION............................................................................................ 581
CB ANTENNA CABLE (FLHTCU) 8.38.............................................................................. 583
REMOVAL................................................................................................. 583
INSTALLATION............................................................................................ 583
sm09a Fuel injection.pdf........................................................................................ 0
SPECIFICATIONS 9.1.......................................................................................... 587
EFI FUSES............................................................................................... 587
TORQUE VALUES........................................................................................... 587
ELECTRICAL BRACKET ASSEMBLY 9.2............................................................................. 589
DATA LINK CONNECTOR..................................................................................... 589
SETTING ENGINE IDLE SPEED........................................................................... 589
EFI SYSTEM RELAY/EFI FUSES.............................................................................. 590
REMOVAL............................................................................................. 590
INSTALLATION........................................................................................ 590
ECM..................................................................................................... 590
REMOVAL............................................................................................. 590
INSTALLATION........................................................................................ 590
SECURITY SIREN CONNECTOR................................................................................ 590
REMOVAL............................................................................................. 590
INSTALLATION........................................................................................ 591
ELECTRICAL BRACKET...................................................................................... 591
REMOVAL............................................................................................. 591
INSTALLATION........................................................................................ 591
SENSORS 9.3................................................................................................. 592
GENERAL................................................................................................. 592
IAT SENSOR.......................................................................................... 592
TP SENSOR........................................................................................... 592
MAP SENSOR.......................................................................................... 592
BAS................................................................................................. 592
CKP SENSOR.............................................................................................. 592
REMOVAL............................................................................................. 592
INSTALLATION........................................................................................ 593
ET SENSOR............................................................................................... 593
REMOVAL............................................................................................. 593
INSTALLATION........................................................................................ 593
FUEL TANK (FUEL INJECTED) 9.4............................................................................... 594
COMPLETE REMOVAL........................................................................................ 594
FLHXI, FLHT/C/U/I, FLTRI............................................................................ 594
FLHR/C/S/I.......................................................................................... 596
INSTALLATION (AFTER COMPLETE REMOVAL)................................................................... 596
FLHXI, FLHT/C/U/I, FLTRI............................................................................ 596
FLHR/C/S/I.......................................................................................... 598
PARTIAL REMOVAL......................................................................................... 598
FLHXI, FLHT/C/U/I, FLTRI............................................................................ 598
FLHR/C/S/I.......................................................................................... 599
INSTALLATION (AFTER PARTIAL REMOVAL).................................................................... 600
FLHXI, FLHT/C/U/I, FLTRI............................................................................ 600
FLHR/C/S/I.......................................................................................... 600
CONSOLE POD/CANOPY...................................................................................... 601
FLHXI, FLHT/C/U/I, FLTRI............................................................................ 601
REMOVAL............................................................................................. 601
INSTALLATION........................................................................................ 602
INSTRUMENT CONSOLE/CANOPY............................................................................... 604
FLHR/C/S/I.......................................................................................... 604
REMOVAL............................................................................................. 604
INSTALLATION........................................................................................ 604
FUEL FILTER CANISTER.................................................................................... 605
REMOVAL............................................................................................. 605
INSTALLATION........................................................................................ 605
FUEL PRESSURE REGULATOR................................................................................. 606
REMOVAL............................................................................................. 606
INSTALLATION........................................................................................ 606
FUEL PUMP............................................................................................... 607
REMOVAL............................................................................................. 607
INSTALLATION........................................................................................ 607
FUEL PUMP/FUEL LEVEL SENDER WIRING...................................................................... 608
FUEL LEVEL SENDER....................................................................................... 608
REMOVAL............................................................................................. 608
INSTALLATION........................................................................................ 608
FUEL SUPPLY CHECK VALVE/TUBE............................................................................ 608
REMOVAL............................................................................................. 608
INSTALLATION........................................................................................ 609
sm09b.pdf....................................................................................................... 0
INDUCTION MODULE ASSEMBLY 9.5............................................................................... 611
INDUCTION MODULE........................................................................................ 611
REMOVAL............................................................................................. 611
INSTALLATION........................................................................................ 612
FUEL SUPPLY TUBE/FUEL RAIL/ FUEL INJECTORS.............................................................. 613
REMOVAL............................................................................................. 613
INSTALLATION........................................................................................ 614
IAT SENSOR.............................................................................................. 614
REMOVAL............................................................................................. 614
INSTALLATION........................................................................................ 614
TP SENSOR............................................................................................... 615
REMOVAL............................................................................................. 615
INSTALLATION........................................................................................ 615
MAP SENSOR.............................................................................................. 615
REMOVAL............................................................................................. 615
INSTALLATION........................................................................................ 616
IAC..................................................................................................... 617
REMOVAL............................................................................................. 617
INSTALLATION........................................................................................ 617
sm_appa.pdf..................................................................................................... 0
TOOLS A.1................................................................................................... 621
sm_appb1.pdf.................................................................................................... 0
DEUTSCH ELECTRICAL CONNECTORS B.1........................................................................... 641
GENERAL................................................................................................. 641
REMOVING/DISASSEMBLING.................................................................................. 641
REMOVING/INSTALLING SOCKETS............................................................................. 641
REMOVING/INSTALLING PINS................................................................................ 642
ASSEMBLING/INSTALLING................................................................................... 644
CRIMPING INSTRUCTIONS................................................................................... 644
STANDARD TERMINALS.................................................................................. 644
MINI TERMINALS...................................................................................... 646
SOLID BARREL CONTACTS............................................................................... 646
MULTILOCK ELECTRICAL CONNECTORS B.2......................................................................... 648
REMOVING SOCKET/PIN TERMINALS........................................................................... 648
INSTALLING SOCKET/PIN TERMINALS......................................................................... 648
CRIMPING INSTRUCTIONS................................................................................... 652
DELPHI ELECTRICAL CONNECTORS B.3............................................................................ 653
GENERAL................................................................................................. 653
REMOVING SOCKET TERMINALS............................................................................... 653
INSTALLING SOCKET TERMINALS............................................................................. 653
PACKARD ELECTRICAL CONNECTORS B.4........................................................................... 655
150 METRI-PACK SERIES................................................................................... 655
General............................................................................................. 655
Disassembly......................................................................................... 655
Assembly............................................................................................ 655
280 METRI-PACK SERIES................................................................................... 655
General............................................................................................. 655
System Fuse Block................................................................................... 655
480 METRI-PACK SERIES................................................................................... 657
General............................................................................................. 657
Disassembly......................................................................................... 657
Assembly............................................................................................ 658
630 METRI-PACK SERIES................................................................................... 659
General............................................................................................. 659
Disassembly......................................................................................... 659
Assembly............................................................................................ 659
800 METRI-PACK SERIES................................................................................... 659
General............................................................................................. 659
Disassembly......................................................................................... 659
Assembly............................................................................................ 659
PACKARD MICRO 64........................................................................................ 660
General............................................................................................. 660
Disassembly......................................................................................... 660
Assembly............................................................................................ 661
Crimping Instructions............................................................................... 661
PACKARD 100W............................................................................................ 662
General............................................................................................. 662
Disassembly......................................................................................... 662
Assembly............................................................................................ 663
Crimping Instructions............................................................................... 663
AUTOFUSE ELECTRICAL CONNECTOR B.5........................................................................... 665
GENERAL................................................................................................. 665
DISASSEMBLY............................................................................................. 665
ASSEMBLY................................................................................................ 665
SEALED BUTT SPLICE CONNECTORS B.6........................................................................... 666
PROCEDURE............................................................................................... 666
ELECTRICAL CONNECTOR LOCATIONS B.7.......................................................................... 668
FLHX, FLHT/C/U.......................................................................................... 668
FLHX, FLHT/C/U (Continued).......................................................................... 670
FLTR.................................................................................................... 674
FLTR (Continued).................................................................................... 675
FLTR (Continued).................................................................................... 676
FLHR/C/S................................................................................................ 677
FLHR/C/S (Continued)................................................................................ 678
WIRING DIAGRAMS B.8......................................................................................... 679
sm_appc.pdf..................................................................................................... 0
METRIC CONVERSIONS C.1...................................................................................... 705
FLUID CONVERSIONS C.2....................................................................................... 706
UNITED STATES SYSTEM.................................................................................... 706
METRIC SYSTEM........................................................................................... 706
BRITISH IMPERIAL SYSTEM................................................................................. 706
sm_appd.pdf..................................................................................................... 0
JAPANESE MAINSHAFT/COUNTERSHAFT D.1......................................................................... 707
DISASSEMBLY............................................................................................. 707
CLEANING AND INSPECTION................................................................................. 709
ASSEMBLY................................................................................................ 710
sm_appe.pdf..................................................................................................... 0
ACRONYMS AND ABBREVIATIONS E.1.............................................................................. 713
spb01a.pdf...................................................................................................... 0
HYDRAULIC CLUTCH 1.1........................................................................................ 717
GENERAL................................................................................................. 717
CHECKING AND CORRECTING CLUTCH FLUID LEVEL.............................................................. 717
ENGINE LUBRICATION 1.2...................................................................................... 719
GENERAL................................................................................................. 719
CRITICAL FASTENERS 1.3...................................................................................... 720
INSPECTION.............................................................................................. 720
spb02a.pdf...................................................................................................... 0
SPECIFICATIONS 2.1.......................................................................................... 723
TORQUE VALUES 2.2........................................................................................... 724
VEHICLE IDENTIFICATION NUMBER (V.I.N.) 2.3.................................................................. 725
GENERAL................................................................................................. 725
FOOTBOARDS AND CONTROLS 2.4................................................................................. 726
RIDER FOOTBOARDS........................................................................................ 726
Removal............................................................................................. 726
Installation........................................................................................ 726
PASSENGER FOOTBOARDS.................................................................................... 728
Removal............................................................................................. 728
Disassembly......................................................................................... 728
Assembly............................................................................................ 728
Installation........................................................................................ 728
SHIFT LEVER............................................................................................. 728
Replacement......................................................................................... 728
REAR BRAKE PEDAL........................................................................................ 728
Replacement......................................................................................... 728
REAR WHEEL 2.5.............................................................................................. 729
REMOVAL................................................................................................. 729
INSTALLATION............................................................................................ 729
FRONT AXLE COVERS 2.6....................................................................................... 730
REPLACEMENT............................................................................................. 730
LOWER TRIPLE CLAMP COVER 2.7................................................................................ 731
REPLACEMENT............................................................................................. 731
HANDLEBARS 2.8.............................................................................................. 732
REMOVAL................................................................................................. 732
DISASSEMBLY............................................................................................. 734
ASSEMBLY................................................................................................ 735
INSTALLATION............................................................................................ 738
HEATED HANDGRIPS........................................................................................ 740
Initial Disassembly................................................................................. 740
Replacing Left Handgrip............................................................................. 741
Replacing Right Handgrip............................................................................ 742
Final Assembly...................................................................................... 744
CLUTCH MASTER CYLINDER/RESERVOIR 2.9........................................................................ 745
GENERAL................................................................................................. 745
REMOVAL................................................................................................. 745
DISASSEMBLY............................................................................................. 746
ASSEMBLY................................................................................................ 747
INSTALLATION............................................................................................ 748
CLUTCH HAND LEVER 2.10...................................................................................... 749
INSTALLATION............................................................................................ 749
CLUTCH FLUID LINE 2.11...................................................................................... 750
REPLACEMENT............................................................................................. 750
CLUTCH FLUID LINE ROUTING............................................................................... 752
BLEEDING CLUTCH FLUID LINE.............................................................................. 752
SEAT 2.12................................................................................................... 754
GENERAL................................................................................................. 754
REMOVAL................................................................................................. 754
CLEANING AND INSPECTION................................................................................. 755
INSTALLATION............................................................................................ 755
RIDER BACKREST 2.13......................................................................................... 756
GENERAL................................................................................................. 756
REMOVAL................................................................................................. 757
INSTALLATION............................................................................................ 757
ADJUSTMENT.............................................................................................. 757
Vertical Adjustment................................................................................. 757
Tilt Angle.......................................................................................... 757
Forward/Aft Adjustment.............................................................................. 758
TOUR-PAK 2.14............................................................................................... 759
General................................................................................................. 759
REMOVAL................................................................................................. 759
INSTALLATION............................................................................................ 761
AM/FM/WB RADIO ANTENNA.................................................................................. 762
Removal............................................................................................. 762
Installation........................................................................................ 762
CB RADIO ANTENNA........................................................................................ 762
Removal............................................................................................. 762
Installation........................................................................................ 762
SADDLEBAG SUPPORTS 2.15..................................................................................... 763
REMOVAL................................................................................................. 763
INSTALLATION............................................................................................ 763
MUFFLER END CAP 2.16........................................................................................ 765
REPLACEMENT............................................................................................. 765
spb03a.pdf...................................................................................................... 0
SPECIFICATIONS 3.1.......................................................................................... 769
GENERAL................................................................................................. 769
MANUFACTURING TOLERANCES................................................................................ 769
SERVICE WEAR LIMITS 3.2..................................................................................... 771
GENERAL................................................................................................. 771
TORQUE VALUES 3.3........................................................................................... 773
BREATHER ASSEMBLY 3.4....................................................................................... 774
REMOVAL................................................................................................. 774
DISASSEMBLY............................................................................................. 774
CLEANING AND INSPECTION................................................................................. 774
ASSEMBLY................................................................................................ 774
INSTALLATION............................................................................................ 774
ROCKER HOUSING 3.5.......................................................................................... 775
VALVE SPRING TO ROCKER HOUSING CLEARANCE................................................................ 775
CYLINDER HEADS 3.6.......................................................................................... 778
GENERAL................................................................................................. 778
Removal................................................................................................. 778
Disassembly............................................................................................. 778
Cleaning................................................................................................ 780
Inspection.............................................................................................. 781
Cylinder Head....................................................................................... 781
Valve Guides........................................................................................ 781
Valves.............................................................................................. 781
Valve Springs....................................................................................... 781
Tapered Keepers..................................................................................... 781
Valve Seats......................................................................................... 781
VALVE GUIDE REPLACEMENT................................................................................. 782
Removal............................................................................................. 782
Installation........................................................................................ 783
VALVE AND SEAT REFACING................................................................................. 786
Assembly................................................................................................ 789
Installation............................................................................................ 791
PISTONS 3.7................................................................................................. 792
GENERAL................................................................................................. 792
BORING AND HONING CYLINDERS 3.8............................................................................. 793
CYLINDER BORE FINISHED SIZE............................................................................. 793
CAMS AND TIMING MARKS 3.9................................................................................... 794
GENERAL................................................................................................. 794
FLYWHEEL/CONNECTING ROD ASSEMBLY 3.10....................................................................... 795
GENERAL................................................................................................. 795
SPROCKET SHAFT BEARING INNER RACE REPLACEMENT........................................................... 795
OIL VENT LINE 3.11.......................................................................................... 798
REPLACEMENT............................................................................................. 798
OIL COOLER OPERATION 3.12................................................................................... 799
GENERAL................................................................................................. 799
Closed Thermostat................................................................................... 801
Partially Open Thermostat........................................................................... 801
Fully Open Thermostat............................................................................... 801
OIL COOLER 3.13............................................................................................. 802
REMOVAL................................................................................................. 802
INSTALLATION............................................................................................ 802
OIL FILTER MOUNT 3.14....................................................................................... 803
REMOVAL................................................................................................. 803
DISASSEMBLY............................................................................................. 803
ASSEMBLY................................................................................................ 804
INSTALLATION............................................................................................ 804
THERMOSTAT 3.15............................................................................................. 805
TEST PROCEDURE.......................................................................................... 805
REMOVAL................................................................................................. 805
INSTALLATION............................................................................................ 805
spb04a.pdf...................................................................................................... 0
AIR CLEANER COVER 4.1....................................................................................... 809
GENERAL................................................................................................. 809
REMOVAL................................................................................................. 809
INSTALLATION............................................................................................ 809
spb05a.pdf...................................................................................................... 0
SPECIFICATIONS 5.1.......................................................................................... 813
spb06a.pdf...................................................................................................... 0
SPECIFICATIONS 6.1.......................................................................................... 817
TORQUE VALUES 6.2........................................................................................... 818
CLUTCH RELEASE BEARING AND PUSH ROD 6.3..................................................................... 819
GENERAL................................................................................................. 819
REMOVAL................................................................................................. 819
INSTALLATION............................................................................................ 819
Measuring Release Plate Movement.................................................................... 820
Installing Clutch Inspection Cover.................................................................. 820
spb07a.pdf...................................................................................................... 0
SPECIFICATIONS 7.1.......................................................................................... 823
SERVICE WEAR LIMITS 7.2..................................................................................... 824
TORQUE VALUES 7.3........................................................................................... 825
CLUTCH RELEASE COVER 7.4.................................................................................... 826
REMOVAL................................................................................................. 826
INSTALLATION............................................................................................ 827
SECONDARY CLUTCH ACTUATOR 7.5............................................................................... 828
REBUILD................................................................................................. 828
spb08a.pdf...................................................................................................... 0
BULB REQUIREMENTS 8.1....................................................................................... 831
BULB CHART.............................................................................................. 831
HEADLAMP 8.2................................................................................................ 832
GENERAL................................................................................................. 832
REMOVAL................................................................................................. 832
INSTALLATION............................................................................................ 833
AUXILIARY LAMPS AND BRACKETS 8.3............................................................................ 835
LAMP REMOVAL............................................................................................ 835
LAMP BRACKET REMOVAL.................................................................................... 836
LAMP BRACKET INSTALLATION............................................................................... 836
LAMP INSTALLATION....................................................................................... 836
Mounting Lamp....................................................................................... 836
Lamp Alignment...................................................................................... 837
Final Assembly...................................................................................... 837
BULB REPLACEMENT........................................................................................ 838
FRONT TURN SIGNALS 8.4...................................................................................... 839
REMOVAL................................................................................................. 839
INSTALLATION............................................................................................ 840
XM RADIO 8.5................................................................................................ 841
GENERAL................................................................................................. 841
RECEIVER MODULE......................................................................................... 841
Removal............................................................................................. 841
Installation........................................................................................ 841
ANTENNA................................................................................................. 842
Removal............................................................................................. 842
Installation........................................................................................ 842
SOUND SYSTEM AMPLIFIER 8.6.................................................................................. 843
GENERAL................................................................................................. 843
REMOVAL................................................................................................. 843
INSTALLATION............................................................................................ 843
GARAGE DOOR OPENER 8.7...................................................................................... 845
TRANSMITTER............................................................................................. 845
Removal............................................................................................. 845
Installation........................................................................................ 845
RECEIVER................................................................................................ 845
Installation........................................................................................ 845
REMOTE CONTROL GARAGE DOOR OPENER....................................................................... 846
FCC Notices......................................................................................... 846
Program the Receiver and Transmitter................................................................ 846
spb_appa1.pdf................................................................................................... 0
INDEX TO WIRING DIAGRAMS A.1................................................................................ 851
fe08a.pdf....................................................................................................... 0
DEUTSCH ELECTRICAL CONNECTORS 8.1...........................................................................1355
GENERAL.................................................................................................1355
REMOVING/DISASSEMBLING..................................................................................1355
REMOVING/INSTALLING SOCKETS.............................................................................1355
REMOVING/INSTALLING PINS................................................................................1356
ASSEMBLING/INSTALLING...................................................................................1358
CRIMPING INSTRUCTIONS...................................................................................1358
STANDARD TERMINALS..................................................................................1358
MINI TERMINALS......................................................................................1360
SOLID BARREL CONTACTS...............................................................................1360
MULTILOCK ELECTRICAL CONNECTORS 8.2.........................................................................1362
REMOVING SOCKET/PIN TERMINALS...........................................................................1362
INSTALLING SOCKET/PIN TERMINALS.........................................................................1362
CRIMPING INSTRUCTIONS...................................................................................1366
DELPHI ELECTRICAL CONNECTORS 8.3............................................................................1367
GENERAL.................................................................................................1367
REMOVING SOCKET TERMINALS...............................................................................1367
INSTALLING SOCKET TERMINALS.............................................................................1367
PACKARD ELECTRICAL CONNECTORS 8.4...........................................................................1369
150 METRI-PACK SERIES...................................................................................1369
General.............................................................................................1369
Disassembly.........................................................................................1369
Assembly............................................................................................1369
280 METRI-PACK SERIES...................................................................................1369
General.............................................................................................1369
System Fuse Block...................................................................................1369
480 METRI-PACK SERIES...................................................................................1371
General.............................................................................................1371
Disassembly.........................................................................................1371
Assembly............................................................................................1372
630 METRI-PACK SERIES...................................................................................1373
General.............................................................................................1373
Disassembly.........................................................................................1373
Assembly............................................................................................1373
800 METRI-PACK SERIES...................................................................................1373
General.............................................................................................1373
Disassembly.........................................................................................1373
Assembly............................................................................................1373
PACKARD MICRO 64........................................................................................1374
General.............................................................................................1374
Disassembly.........................................................................................1374
Assembly............................................................................................1375
Crimping Instructions...............................................................................1375
PACKARD 100W............................................................................................1376
General.............................................................................................1376
Disassembly.........................................................................................1376
Assembly............................................................................................1377
Crimping Instructions...............................................................................1377
AUTOFUSE ELECTRICAL CONNECTOR 8.5...........................................................................1379
GENERAL.................................................................................................1379
DISASSEMBLY.............................................................................................1379
ASSEMBLY................................................................................................1379
SEALED BUTT SPLICE CONNECTORS 8.6...........................................................................1380
PROCEDURE...............................................................................................1380
ELECTRICAL CONNECTOR LOCATIONS 8.7..........................................................................1382
FLHX, FLHT/C/U..........................................................................................1382
FLHX, FLHT/C/U (Continued)..........................................................................1384
FLTR....................................................................................................1388
FLTR (Continued)....................................................................................1389
FLTR (Continued)....................................................................................1390
FLHR/C/S................................................................................................1391
FLHR/C/S (Continued)................................................................................1392
WIRING DIAGRAMS 8.8.........................................................................................1393
fe08_tc.pdf..................................................................................................... 0
WIRING 8....................................................................................................1353
fe07a.pdf....................................................................................................... 0
CRUISE CONTROL 7.1..........................................................................................1331
GENERAL.................................................................................................1331
SYSTEM OPERATION........................................................................................1331
TROUBLESHOOTING.........................................................................................1332
CRUISE INOPERATIVE DIAGNOSTICS 7.2..........................................................................1333
GENERAL.................................................................................................1333
INOPERATIVE DIAGNOSTICS.................................................................................1333
Diagnostic Notes....................................................................................1333
CRUISE DROPOUT DIAGNOSTICS 7.3..............................................................................1336
GENERAL.................................................................................................1336
DROPOUT DIAGNOSTICS.....................................................................................1336
CRUISE CHART A: INITIAL DIAGNOSTICS 7.4.....................................................................1339
DIAGNOSTICS.............................................................................................1339
Test 7.4 (Part 1 of 2)..............................................................................1339
Test 7.4 (Part 2 of 2)..............................................................................1340
CRUISE CHART B: RESUME SWITCH 7.5...........................................................................1341
DIAGNOSTICS.............................................................................................1341
Test 7.5............................................................................................1341
CRUISE CHART C: CRUISE ENGAGED LAMP 7.6.....................................................................1342
DIAGNOSTICS.............................................................................................1342
Test 7.6............................................................................................1342
CRUISE CHART D: CRUISE POWER 7.7............................................................................1343
DIAGNOSTICS.............................................................................................1343
Test 7.7............................................................................................1343
CRUISE CHART E: CRUISE ENABLE 7.8...........................................................................1345
DIAGNOSTICS.............................................................................................1345
Test 7.8............................................................................................1345
Diagnostic Notes....................................................................................1345
CRUISE CHART F-1: BRAKE LIGHTS ON 7.9.......................................................................1346
DIAGNOSTICS.............................................................................................1346
Test 7.9............................................................................................1346
CRUISE CHART F-2: BRAKE LIGHTS OFF 7.10.....................................................................1347
DIAGNOSTICS.............................................................................................1347
Test 7.10 (Part 1 of 2).............................................................................1347
Test 7.10 (Part 2 of 2).............................................................................1348
Diagnostic Notes....................................................................................1348
CRUISE CHART G: THROTTLE SWITCH 7.11........................................................................1349
DIAGNOSTICS.............................................................................................1349
Test 7.11...........................................................................................1349
CRUISE CHART H: SPEEDOMETER INPUT 7.12......................................................................1350
DIAGNOSTICS.............................................................................................1350
Diagnostic Notes....................................................................................1350
Test 7.12...........................................................................................1350
CRUISE CHART I: TACHOMETER INPUT 7.13.......................................................................1351
DIAGNOSTICS.............................................................................................1351
Test 7.13...........................................................................................1351
fe07_tc.pdf..................................................................................................... 0
CRUISE CONTROL 7............................................................................................1329
fe06a.pdf....................................................................................................... 0
RADIO DIAGNOSTICS 6.1.......................................................................................1221
SYSTEM DESCRIPTION......................................................................................1221
ONBOARD DIAGNOSTICS.....................................................................................1221
General.............................................................................................1221
Radio Diagnostic Display............................................................................1221
RADIO SWITCH DIAGNOSTICS: DTC B2006-B2015 6.2...............................................................1226
GENERAL.................................................................................................1226
DIAGNOSTICS.............................................................................................1226
Diagnostic Notes....................................................................................1226
Test 6.2a...........................................................................................1227
Test 6.2b (Part 1 of 3).............................................................................1228
Test 6.2b (Part 2 of 3).............................................................................1229
Test 6.2b (Part 3 of 3).............................................................................1230
Test 6.2c (Part 1 of 3).............................................................................1231
Test 6.2c (Part 2 of 3).............................................................................1232
Test 6.2c (Part 3 of 3).............................................................................1233
Test 6.2d (Part 1 of 3).............................................................................1234
Test 6.2d (Part 2 of 3).............................................................................1235
Test 6.2d (Part 3 of 3).............................................................................1236
Test 6.2e (Part 1 of 2).............................................................................1237
Test 6.2e (Part 2 of 2).............................................................................1238
Test 6.2f (Part 1 of 2).............................................................................1239
Test 6.2f (Part 2 of 2).............................................................................1240
Test 6.2g (Part 1 of 2).............................................................................1241
Test 6.2g (Part 2 of 2).............................................................................1242
Test 6.2h...........................................................................................1243
Test 6.2i...........................................................................................1244
Test 6.2j...........................................................................................1245
RADIO SPEAKER DIAGNOSTICS: DTC B2016-B2027 6.3..............................................................1246
GENERAL.................................................................................................1246
DIAGNOSTICS.............................................................................................1246
Diagnostic Notes....................................................................................1246
Test 6.3a...........................................................................................1247
Test 6.3b...........................................................................................1249
Test 6.3c...........................................................................................1250
Test 6.3d...........................................................................................1251
Test 6.3e...........................................................................................1252
Test 6.3f...........................................................................................1254
Test 6.3g...........................................................................................1255
Test 6.3h...........................................................................................1256
Test 6.3i...........................................................................................1257
Test 6.3j...........................................................................................1259
Test 6.3k...........................................................................................1260
Test 6.3l...........................................................................................1261
SERIAL DATA BUS DIAGNOSTICS 6.4.............................................................................1262
GENERAL.................................................................................................1262
LOSS OF SERIAL DATA: DTC U1016......................................................................1262
STARTS, THEN STALLS: DTC U1300, U1301...............................................................1262
DIAGNOSTICS.............................................................................................1262
Diagnostic Notes....................................................................................1262
Test 6.4a...........................................................................................1263
Test 6.4b...........................................................................................1266
Test 6.4c (Part 1 of 3).............................................................................1267
Test 6.4c (Part 2 of 3).............................................................................1269
Test 6.4c (Part 3 of 3).............................................................................1270
Test 6.4d...........................................................................................1271
Test 6.4e...........................................................................................1273
Test 6.4f...........................................................................................1275
Test 6.4g...........................................................................................1277
Test 6.4h...........................................................................................1278
ADVANCED AUDIO SYSTEM SYMPTOMS 6.5..........................................................................1280
GENERAL.................................................................................................1280
DIAGNOSTICS.............................................................................................1280
Diagnostic Notes....................................................................................1280
Test 6.5a...........................................................................................1281
Test 6.5b...........................................................................................1283
Test 6.5c...........................................................................................1284
Test 6.5d...........................................................................................1284
Test 6.5e...........................................................................................1285
Test 6.5f...........................................................................................1286
Test 6.5g (Part 1 of 4).............................................................................1287
Test 6.5g (Part 2 of 4).............................................................................1288
Test 6.5g (3 of 4)..................................................................................1289
Test 6.5g (4 of 4)..................................................................................1290
Test 6.5h (1 of 3)..................................................................................1291
Test 6.5h (2 of 3)..................................................................................1293
Test 6.5h (3 of 3)..................................................................................1294
Test 6.5i...........................................................................................1295
Test 6.5j (Part 1 of 2).............................................................................1296
Test 6.5j (Part 2 of 2).............................................................................1297
Test 6.5k...........................................................................................1299
Test 6.5l (1 of 5)..................................................................................1301
Test 6.5l (2 of 5)..................................................................................1302
Test 6.5l (3 of 5)..................................................................................1303
Test 6.5l (4 of 5)..................................................................................1304
Test 6.5l (5 of 5)..................................................................................1305
Test 6.5m (1 of 4)..................................................................................1307
Test 6.5m (2 of 4)..................................................................................1308
Test 6.5m (3 of 4)..................................................................................1309
Test 6.5m (4 of 4)..................................................................................1310
Test 6.5n (Part 1 of 2).............................................................................1312
Test 6.5n (Part 2 of 2).............................................................................1314
Test 6.5o (Part 1 of 2).............................................................................1315
Test 6.5o (Part 2 of 2).............................................................................1316
Test 6.5p...........................................................................................1318
Test 6.5q (Part 1 of 2).............................................................................1320
Test 6.5q (Part 2 of 2).............................................................................1322
Test 6.5r...........................................................................................1323
Test 6.5s...........................................................................................1324
Test 6.5t (Part 1 of 2).............................................................................1325
Test 6.5t (Part 2 of 2).............................................................................1326
Test 6.5u...........................................................................................1327
Test 6.5v...........................................................................................1328
fe06_tc.pdf..................................................................................................... 0
ADVANCED AUDIO SYSTEM 6.....................................................................................1219
fe05b.pdf....................................................................................................... 0
DTC P0107, P0108 5.19.......................................................................................1167
GENERAL.................................................................................................1167
MAP Sensor..........................................................................................1167
DIAGNOSTICS.............................................................................................1167
Diagnostic Tips.....................................................................................1167
Diagnostic Notes....................................................................................1167
Test 5.19 (Part 1 of 2).............................................................................1169
Test 5.19 (Part 2 of 2).............................................................................1170
DTC P0112, P0113 5.20.......................................................................................1171
GENERAL.................................................................................................1171
IAT Sensor..........................................................................................1171
DIAGNOSTICS.............................................................................................1171
Diagnostic Tips.....................................................................................1171
Diagnostic Notes....................................................................................1171
Test 5.20 (Part 1 of 2).............................................................................1173
Test 5.20 (Part 2 of 2).............................................................................1174
DTC P0117, P0118 5.21.......................................................................................1175
GENERAL.................................................................................................1175
ET Sensor...........................................................................................1175
DIAGNOSTICS.............................................................................................1175
Diagnostic Tips.....................................................................................1175
Diagnostic Notes....................................................................................1175
Test 5.21 (Part 1 of 2).............................................................................1177
Test 5.21 (Part 2 of 2).............................................................................1178
DTC P0122, P0123 5.22.......................................................................................1179
GENERAL.................................................................................................1179
TP Sensor...........................................................................................1179
DIAGNOSTICS.............................................................................................1179
Diagnostic Tips.....................................................................................1179
Diagnostic Notes....................................................................................1179
Test 5.22 (Part 1 of 2).............................................................................1181
Test 5.22 (Part 2 of 2).............................................................................1182
DTC P0261, P0262, P0263, P0264 5.23.........................................................................1183
GENERAL.................................................................................................1183
Fuel Injectors......................................................................................1183
DIAGNOSTICS.............................................................................................1183
Diagnostic Notes....................................................................................1183
Test 5.23 (Part 1 of 3).............................................................................1186
Test 5.23 (Part 2 of 3).............................................................................1187
Test 5.23 (Part 3 of 3).............................................................................1188
DTC P0373, P0374 5.24.......................................................................................1189
GENERAL.................................................................................................1189
CKP Sensor..........................................................................................1189
DIAGNOSTICS.............................................................................................1189
Diagnostic Tips.....................................................................................1189
Diagnostic Notes....................................................................................1189
Test 5.24...........................................................................................1191
DTC P0501, P0502 5.25.......................................................................................1192
GENERAL.................................................................................................1192
Vehicle Speed Sensor................................................................................1192
DIAGNOSTICS.............................................................................................1192
Diagnostic Notes....................................................................................1192
Test 5.25 (Part 1 of 2).............................................................................1194
Test 5.25 (Part 2 of 2).............................................................................1195
DTC P0562, P0563 5.26.......................................................................................1196
GENERAL.................................................................................................1196
Battery Voltage.....................................................................................1196
DIAGNOSTICS.............................................................................................1196
Diagnostic Tips.....................................................................................1196
Diagnostic Notes....................................................................................1196
Test 5.26 (Part 1 of 2).............................................................................1199
Test 5.26 (Part 2 of 2).............................................................................1200
DTC P0603, P0605 5.27.......................................................................................1201
GENERAL.................................................................................................1201
ECM Failure.........................................................................................1201
DIAGNOSTICS.............................................................................................1201
DTC P0603...........................................................................................1201
DTC P0605...........................................................................................1201
DTC P1009, P1010 5.28.......................................................................................1202
GENERAL.................................................................................................1202
Password Problem....................................................................................1202
DIAGNOSTICS.............................................................................................1202
Diagnostic Notes....................................................................................1202
Test 5.28...........................................................................................1205
DTC P1351, P1352, P1354, P1355 5.29.........................................................................1206
GENERAL.................................................................................................1206
Ignition Coil.......................................................................................1206
DIAGNOSTICS.............................................................................................1206
Diagnostic Notes....................................................................................1206
Test 5.29 (Part 1 of 2).............................................................................1209
Test 5.29 (Part 2 of 2).............................................................................1210
DTC U1064, U1255 5.30.......................................................................................1211
GENERAL.................................................................................................1211
Loss of TSM/TSSM Serial Data........................................................................1211
DIAGNOSTICS.............................................................................................1211
Diagnostic Notes....................................................................................1211
Test 5.30...........................................................................................1214
DTC U1097, U1255 5.31.......................................................................................1215
GENERAL.................................................................................................1215
Loss of Speedometer Serial Data.....................................................................1215
DIAGNOSTICS.............................................................................................1215
Diagnostic Notes....................................................................................1215
Test 5.31...........................................................................................1218
fe05a.pdf....................................................................................................... 0
SPECIFICATIONS 5.1..........................................................................................1099
EFI SYSTEM 5.2..............................................................................................1101
GENERAL.................................................................................................1101
EFI ENGINE HEAT MANAGEMENT..............................................................................1101
Injected Twin Cam High Temperature Idle.............................................................1101
Phase 1.............................................................................................1101
Phase 2.............................................................................................1101
Phase 3.............................................................................................1101
TROUBLESHOOTING.........................................................................................1101
EFI DIAGNOSTIC INTRODUCTION 5.3.............................................................................1103
SYSTEM PROBLEMS.........................................................................................1103
No Start............................................................................................1103
Poor Performance....................................................................................1103
Check Engine Lamp...................................................................................1103
RESOLVING PROBLEMS......................................................................................1103
CHECKING FOR DIAGNOSTIC TROUBLE CODES: EFI 5.4..............................................................1104
CHECK ENGINE LAMP.......................................................................................1104
CODE TYPES..............................................................................................1105
Current.............................................................................................1105
Historic............................................................................................1105
RETRIEVING DIAGNOSTIC TROUBLE CODES.....................................................................1105
MULTIPLE DIAGNOSTIC TROUBLE CODES.......................................................................1105
INITIAL DIAGNOSTIC CHECK: EFI 5.5...........................................................................1106
GENERAL.................................................................................................1106
Diagnostic Notes....................................................................................1106
Circuit Diagram/Wire Harness Connector Table........................................................1106
Reprogramming ECM...................................................................................1106
INITIAL DIAGNOSTICS.....................................................................................1106
General Information.................................................................................1106
Diagnostic Tips.....................................................................................1106
Diagnostic Notes....................................................................................1106
Other Codes.........................................................................................1106
Diagnostic Check (Part 1 of 2)......................................................................1113
Diagnostic Check (Part 2 of 2)......................................................................1114
SPEEDOMETER SELF DIAGNOSTICS 5.6............................................................................1115
GENERAL.................................................................................................1115
DIAGNOSTICS.............................................................................................1115
Diagnostic Tips.....................................................................................1115
Diagnostic Notes....................................................................................1115
Speedometer Self Diagnostics (chart)................................................................1116
BREAKOUT BOX: EFI 5.7.......................................................................................1117
GENERAL.................................................................................................1117
INSTALLATION............................................................................................1117
REMOVAL.................................................................................................1117
WIGGLE TEST 5.8.............................................................................................1118
GENERAL.................................................................................................1118
PROCEDURE...............................................................................................1118
INTAKE LEAK TEST 5.9........................................................................................1119
GENERAL.................................................................................................1119
LEAK TESTER.............................................................................................1119
Parts List..........................................................................................1119
Tester Assembly.....................................................................................1119
INTAKE LEAK TESTING.....................................................................................1120
ENGINE CRANKS, BUT WILL NOT START 5.10......................................................................1121
GENERAL.................................................................................................1121
DIAGNOSTICS.............................................................................................1121
Diagnostic Notes....................................................................................1121
Diagnostic Tips.....................................................................................1121
Test 5.10 (Part 1 of 4).............................................................................1124
Test 5.10 (Part 2 of 4).............................................................................1125
Test 5.10 (Part 3 of 4).............................................................................1126
Test 5.10 (Part 4 of 4).............................................................................1127
NO ECM POWER 5.11...........................................................................................1128
GENERAL.................................................................................................1128
No Spark/No Check Engine Lamp at Key ON.............................................................1128
DIAGNOSTICS.............................................................................................1128
Diagnostic Notes....................................................................................1128
Test 5.11 (Part 1 of 2).............................................................................1131
Test 5.11 (Part 2 of 2).............................................................................1132
STARTS, THEN STALLS 5.12....................................................................................1133
GENERAL.................................................................................................1133
Diagnostic Trouble Codes U1300, U1301 or “BUS Er”...................................................1133
DIAGNOSTICS.............................................................................................1133
Diagnostic Tips.....................................................................................1133
Diagnostic Notes....................................................................................1133
Test 5.12 (Part 1 of 2).............................................................................1136
Test 5.12 (Part 2 of 2).............................................................................1137
FUEL SYSTEM ELECTRICAL TEST 5.13............................................................................1138
GENERAL.................................................................................................1138
DIAGNOSTICS.............................................................................................1138
Diagnostic Notes....................................................................................1138
Test 5.13 (Part 1 of 4).............................................................................1140
Test 5.13 (Part 2 of 4).............................................................................1141
Test 5.13 (Part 3 of 4).............................................................................1142
Test 5.13 (Part 4 of 4).............................................................................1142
SYSTEM RELAY CHECK 5.14.....................................................................................1143
GENERAL.................................................................................................1143
System Relay........................................................................................1143
DIAGNOSTICS.............................................................................................1143
Diagnostic Notes....................................................................................1143
Test 5.14 (Part 1 of 3).............................................................................1146
Test 5.14 (Part 2 of 3).............................................................................1147
Test 5.14 (Part 3 of 3).............................................................................1147
FUEL PRESSURE TEST 5.15.....................................................................................1148
GENERAL.................................................................................................1148
TESTING.................................................................................................1148
DIAGNOSTICS.............................................................................................1150
Diagnostic Notes....................................................................................1150
Test 5.15...........................................................................................1151
IDLE AIR CONTROL, DTC P0505 5.16............................................................................1152
GENERAL.................................................................................................1152
IAC Operation.......................................................................................1152
Diagnostic Trouble Code P0505: Loss of Idle Speed Control...........................................1152
DIAGNOSTICS.............................................................................................1152
Diagnostic Tips.....................................................................................1152
Diagnostic Notes....................................................................................1153
Test 5.16 (Part 1 of 2).............................................................................1155
Test 5.16 (Part 2 of 2).............................................................................1156
MISFIRE AT IDLE OR UNDER LOAD 5.17..........................................................................1157
GENERAL.................................................................................................1157
Misfire at Idle or Under Load.......................................................................1157
DIAGNOSTICS.............................................................................................1157
Diagnostic Notes....................................................................................1157
Test 5.17 (Part 1 of 3).............................................................................1159
Test 5.17 (Part 2 of 3).............................................................................1160
Test 5.17 (Part 3 of 3).............................................................................1161
COMBUSTION ABSENT/INTERMITTENT 5.18.........................................................................1162
GENERAL.................................................................................................1162
Diagnostic Trouble Codes P1353, P1356, P1357, P1358: No Combustion..................................1162
DIAGNOSTICS.............................................................................................1162
Diagnostic Notes....................................................................................1162
Test 5.18 (Part 1 of 2).............................................................................1165
Test 5.18 (Part 2 of 2).............................................................................1166
fe05_tc.pdf..................................................................................................... 0
ENGINE MANAGEMENT (EFI) 5...................................................................................1097
fe04b.pdf....................................................................................................... 0
DTC P0106, P0107, P0108 4.13................................................................................1065
GENERAL.................................................................................................1065
MAP Sensor..........................................................................................1065
DIAGNOSTICS.............................................................................................1065
Diagnostic Tips.....................................................................................1065
Diagnostic Notes....................................................................................1065
Test 4.13 (Part 1 of 2).............................................................................1067
Test 4.13 (Part 2 of 2).............................................................................1068
DTC P0562, P0563 4.14.......................................................................................1069
GENERAL.................................................................................................1069
Battery Voltage.....................................................................................1069
DIAGNOSTICS.............................................................................................1069
Diagnostic Notes....................................................................................1069
Test 4.14 (Part 1 of 2).............................................................................1071
Test 4.14 (Part 2 of 2).............................................................................1072
DTC P1009, P1010 4.15.......................................................................................1073
GENERAL.................................................................................................1073
Password Problem....................................................................................1073
DIAGNOSTICS.............................................................................................1073
Diagnostic Notes....................................................................................1073
Test 4.15...........................................................................................1076
DTC P1351, P1352, P1354, P1355 4.16.........................................................................1077
GENERAL.................................................................................................1077
Ignition Coil.......................................................................................1077
DIAGNOSTICS.............................................................................................1077
Diagnostic Notes....................................................................................1077
Test 4.16 (Part 1 of 2).............................................................................1079
Test 4.16 (Part 2 of 2).............................................................................1080
DTC P0371, P0372, P0374 4.17................................................................................1081
GENERAL.................................................................................................1081
Crank Position Sensor...............................................................................1081
DIAGNOSTICS.............................................................................................1081
Diagnostic Notes....................................................................................1081
Test 4.17...........................................................................................1083
DTC P0501, P0502 4.18.......................................................................................1084
GENERAL.................................................................................................1084
Vehicle Speed Sensor................................................................................1084
DIAGNOSTICS.............................................................................................1084
Diagnostic Notes....................................................................................1084
Test 4.18 (Part 1 of 2).............................................................................1086
Test 4.18 (Part 2 of 2).............................................................................1087
DTC P0602, P0603, P0604, P0605, P0607 4.19..................................................................1088
GENERAL.................................................................................................1088
ICM Failure.........................................................................................1088
DIAGNOSTICS.............................................................................................1088
DTC P0607 Test......................................................................................1088
DTC P0602, P0603, P0604, P0605 Test.................................................................1088
DTC U1064 4.20..............................................................................................1089
GENERAL.................................................................................................1089
Loss of TSM/TSSM Serial Data........................................................................1089
DIAGNOSTICS.............................................................................................1089
Diagnostic Notes....................................................................................1089
Test 4.20...........................................................................................1092
DTC U1097 4.21..............................................................................................1093
GENERAL.................................................................................................1093
Loss of Speedometer Serial Data.....................................................................1093
DIAGNOSTICS.............................................................................................1093
Diagnostic Notes....................................................................................1093
Test 4.21...........................................................................................1096
fe04a.pdf....................................................................................................... 0
SPECIFICATIONS 4.1..........................................................................................1033
DIAGNOSTIC INTRODUCTION 4.2.................................................................................1034
SYSTEM PROBLEMS.........................................................................................1034
No Start............................................................................................1034
Poor Performance....................................................................................1034
Check Engine Lamp...................................................................................1034
RESOLVING PROBLEMS......................................................................................1034
CHECKING FOR TROUBLE CODES 4.3..............................................................................1035
CHECK ENGINE LAMP.......................................................................................1035
CODE TYPES..............................................................................................1036
Current.............................................................................................1036
Historic............................................................................................1036
RETRIEVING DIAGNOSTIC TROUBLE CODES.....................................................................1036
MULTIPLE DIAGNOSTIC TROUBLE CODES.......................................................................1036
INITIAL DIAGNOSTIC CHECK: ICM 4.4...........................................................................1037
GENERAL.................................................................................................1037
Diagnostic Notes....................................................................................1037
Circuit Diagram/Wire Harness Connector Table........................................................1037
Reprogramming ICM...................................................................................1037
INITIAL DIAGNOSTICS.....................................................................................1037
General Information.................................................................................1037
Diagnostic Tips.....................................................................................1037
Diagnostic Notes....................................................................................1037
Initial Diagnostic Check (Part 1 of 2)..............................................................1042
Initial Diagnostic Check (Part 2 of 2)..............................................................1043
SPEEDOMETER SELF DIAGNOSTICS 4.5............................................................................1044
GENERAL.................................................................................................1044
DIAGNOSTICS.............................................................................................1044
Diagnostic Tips.....................................................................................1044
Diagnostic Notes....................................................................................1044
Speedometer Self Diagnostics (chart)................................................................1045
BREAKOUT BOX: ICM 4.6.......................................................................................1046
GENERAL.................................................................................................1046
INSTALLATION............................................................................................1046
REMOVAL.................................................................................................1046
WIGGLE TEST 4.7.............................................................................................1047
GENERAL.................................................................................................1047
PROCEDURE...............................................................................................1047
INTAKE LEAK TEST 4.8........................................................................................1048
GENERAL.................................................................................................1048
LEAK TESTER.............................................................................................1048
Parts List..........................................................................................1048
Tester Assembly.....................................................................................1048
INTAKE LEAK TESTING.....................................................................................1049
ENGINE CRANKS, BUT WILL NOT START 4.9.......................................................................1050
GENERAL.................................................................................................1050
DIAGNOSTICS.............................................................................................1050
Diagnostic Notes....................................................................................1050
Test 4.9 (Part 1 of 3)..............................................................................1052
Test 4.9 (Part 2 of 3)..............................................................................1053
Test 4.9 (Part 3 of 3)..............................................................................1054
STARTS, THEN STALLS 4.10....................................................................................1055
GENERAL.................................................................................................1055
Diagnostic Trouble Codes U1300, U1301, P1009, P1010 or “BUS Er”.....................................1055
DIAGNOSTICS.............................................................................................1055
Diagnostic Tips.....................................................................................1055
Diagnostic Notes....................................................................................1055
Test 4.10 (Part 1 of 2).............................................................................1058
Test 4.10 (Part 2 of 2).............................................................................1059
NO SPARK/NO ICM POWER 4.11..................................................................................1060
GENERAL.................................................................................................1060
DIAGNOSTICS.............................................................................................1060
Diagnostic Notes....................................................................................1060
Test 4.11...........................................................................................1061
MISFIRE 4.12................................................................................................1062
GENERAL.................................................................................................1062
Misfire at Idle or Under Load.......................................................................1062
DIAGNOSTICS.............................................................................................1062
Diagnostic Notes....................................................................................1062
Test 4.12...........................................................................................1064
fe04_tc.pdf..................................................................................................... 0
ENGINE MANAGEMENT (CARB) 4..................................................................................1031
fe03b.pdf....................................................................................................... 0
KEY FOB SIGNAL TO TSSM WEAK OR FAILS 3.14................................................................... 989
GENERAL................................................................................................. 989
Security Equipped Vehicles Only..................................................................... 989
Job/Time Code Values................................................................................ 989
DIAGNOSTICS............................................................................................. 989
Diagnostic Tips..................................................................................... 989
Diagnostic Notes.................................................................................... 989
Test 3.14........................................................................................... 991
TURN SIGNAL ERRORS 3.15..................................................................................... 992
GENERAL................................................................................................. 992
Job/Time Code Values................................................................................ 992
DIAGNOSTICS............................................................................................. 992
Diagnostic Tips..................................................................................... 992
Diagnostic Notes: All Turn Signal Flow Charts....................................................... 995
Turn Signal Error 1A (Part 1 of 2).................................................................. 996
Turn Signal Error 1A (Part 2 of 2).................................................................. 997
Turn Signal Error 2A................................................................................ 998
Turn Signal Error 2B................................................................................ 999
Turn Signal Error 2C................................................................................1000
Turn Signal Error 2D................................................................................1001
Turn Signal Error 3A................................................................................1002
DTC B0563 3.16..............................................................................................1003
GENERAL.................................................................................................1003
Battery Voltage High................................................................................1003
DIAGNOSTICS.............................................................................................1003
Diagnostic Tips.....................................................................................1003
Diagnostic Notes....................................................................................1003
DTC B1131, B1132 3.17.......................................................................................1004
GENERAL.................................................................................................1004
Alarm Output Low (DTC B1131) or Alarm Output High (DTC B1132).......................................1004
DIAGNOSTICS.............................................................................................1004
Diagnostic Tips.....................................................................................1004
Diagnostic Notes....................................................................................1004
Test 3.17...........................................................................................1006
DTC B1134 3.18..............................................................................................1007
GENERAL.................................................................................................1007
Starter Output High.................................................................................1007
DIAGNOSTICS.............................................................................................1007
Diagnostic Notes....................................................................................1007
Test 3.18...........................................................................................1009
DTC B1135 3.19..............................................................................................1010
GENERAL.................................................................................................1010
Accelerometer Fault.................................................................................1010
DTC B1151, B1152, B1153 3.20................................................................................1011
GENERAL.................................................................................................1011
Sidecar BAS Low (DTC B1151), High (DTC B1152) or Out of Range (DTC B1153)...........................1011
DIAGNOSTICS.............................................................................................1011
Diagnostic Tips.....................................................................................1011
Diagnostic Notes....................................................................................1011
Test 3.20...........................................................................................1013
DTC U1016, U1255 3.21.......................................................................................1014
GENERAL.................................................................................................1014
Loss of ICM/ECM Serial Data.........................................................................1014
DIAGNOSTICS.............................................................................................1014
Diagnostic Notes....................................................................................1014
Test 3.21...........................................................................................1019
DTC U1097, U1255 3.22.......................................................................................1020
GENERAL.................................................................................................1020
Loss of Speedometer Serial Data.....................................................................1020
DIAGNOSTICS.............................................................................................1020
Diagnostic Notes....................................................................................1020
Test 3.22...........................................................................................1025
DTC U1300, U1301 or “BUS ER” 3.23...........................................................................1026
GENERAL.................................................................................................1026
Serial Data Low or Serial data Open/High............................................................1026
DIAGNOSTICS.............................................................................................1026
Diagnostic Tips.....................................................................................1026
PASSWORD LEARN 3.24.........................................................................................1027
GENERAL.................................................................................................1027
PASSWORD LEARNING.......................................................................................1027
TSSM MAINTENANCE 3.25.......................................................................................1029
GENERAL.................................................................................................1029
KEY FOB.................................................................................................1029
Schedule............................................................................................1029
Battery Replacement.................................................................................1029
SIREN (IF INSTALLED)....................................................................................1030
Schedule............................................................................................1030
Battery Replacement.................................................................................1030
fe03a.pdf....................................................................................................... 0
TSM/TSSM OVERVIEW 3.1....................................................................................... 947
GENERAL................................................................................................. 947
TROUBLESHOOTING......................................................................................... 947
TSM/TSSM FEATURES 3.2....................................................................................... 949
GENERAL................................................................................................. 949
TURN SIGNAL FUNCTIONS................................................................................... 949
TSM/TSSM Features................................................................................... 949
BANK ANGLE FUNCTIONS.................................................................................... 949
TSM/TSSM Features................................................................................... 949
SECURITY ALARM AND IMMOBILIZATION FUNCTIONS............................................................. 949
TSSM Only Feature................................................................................... 949
TSM/TSSM VEHICLE DELIVERY 3.3............................................................................... 951
GENERAL................................................................................................. 951
SIDECAR CONFIGURATION................................................................................... 951
POWER DISRUPTION AND CONFIGURING........................................................................ 951
KEY FOB ASSIGNMENT...................................................................................... 952
PERSONAL CODE ENTRY..................................................................................... 952
First Time Code Entry: TSSM Only.................................................................... 952
Modifying Existing Codes: TSSM Only................................................................. 952
TSM/TSSM TURN SIGNAL FUNCTIONS 3.4.......................................................................... 956
GENERAL................................................................................................. 956
AUTOMATIC CANCELLATION.................................................................................. 956
MANUAL CANCELLATION..................................................................................... 956
FOUR-WAY FLASHING....................................................................................... 957
DIAGNOSTICS MODE........................................................................................ 957
TSM/TSSM BANK ANGLE FUNCTION 3.5............................................................................ 958
GENERAL................................................................................................. 958
OPERATION............................................................................................... 958
SECURITY SYSTEM (TSSM) FUNCTIONS 3.6........................................................................ 959
GENERAL................................................................................................. 959
Security System Operation........................................................................... 959
Security System Options............................................................................. 959
Differences By Market Specifications................................................................ 959
ALARM SENSITIVITY....................................................................................... 959
Sensitivity......................................................................................... 959
Transport Mode...................................................................................... 959
AUTO-ARMING FUNCTION.................................................................................... 960
STORAGE MODE............................................................................................ 960
ARMING/DISARMING SECURITY SYSTEM (TSSM) 3.7................................................................. 963
GENERAL................................................................................................. 963
SECURITY LAMP........................................................................................... 963
USING KEY FOB........................................................................................... 963
General............................................................................................. 963
Arming the System................................................................................... 963
Disarming the System................................................................................ 963
Troubleshooting..................................................................................... 963
USING THE PERSONAL CODE................................................................................. 964
General............................................................................................. 964
Disarming the System................................................................................ 964
CHECKING FOR DIAGNOSTIC TROUBLE CODES 3.8................................................................... 965
TSM..................................................................................................... 965
TSSM.................................................................................................... 965
CODE TYPES.............................................................................................. 967
Current............................................................................................. 967
Historic............................................................................................ 967
RETRIEVING DIAGNOSTIC TROUBLE CODES..................................................................... 967
MULTIPLE DIAGNOSTIC TROUBLE CODES....................................................................... 967
INITIAL DIAGNOSTIC CHECK: TSM/TSSM 3.9...................................................................... 968
GENERAL................................................................................................. 968
Diagnostic Notes.................................................................................... 968
Circuit Diagram/Wire Harness Connector Table........................................................ 968
Job/Time Code Values................................................................................ 968
Reprogramming ICM/ECM............................................................................... 968
INITIAL DIAGNOSTICS..................................................................................... 968
Diagnostic Tips..................................................................................... 968
Diagnostic Notes.................................................................................... 968
Other Diagnostic Trouble Codes (DTC’s).............................................................. 968
Initial Diagnostic Check (Part 1 of 3).............................................................. 974
Initial Diagnostic Check (Part 2 of 3).............................................................. 975
Diagnostic Check (Part 3 of 3)...................................................................... 976
SPEEDOMETER SELF DIAGNOSTICS 3.10........................................................................... 977
GENERAL................................................................................................. 977
DIAGNOSTICS............................................................................................. 977
Diagnostic Tips..................................................................................... 977
Diagnostic Notes.................................................................................... 977
Speedometer Self Diagnostics (chart)................................................................ 978
BREAKOUT BOX: TSM/TSSM 3.11................................................................................. 979
GENERAL................................................................................................. 979
INSTALLATION............................................................................................ 979
REMOVAL................................................................................................. 979
NO SECURITY LAMP AT KEY ON 3.12............................................................................. 980
GENERAL................................................................................................. 980
No TSSM Power (Security Equipped Vehicles Only)..................................................... 980
Job/Time Code Values................................................................................ 980
DIAGNOSTICS............................................................................................. 980
Diagnostic Tips..................................................................................... 980
Diagnostic Notes.................................................................................... 980
Test 3.12 (Part 1 of 3)............................................................................. 982
Test 3.12 (Part 2 of 3)............................................................................. 983
Test 3.12 (Part 3 of 3)............................................................................. 984
SECURITY LAMP ON CONTINUOUSLY 3.13.......................................................................... 985
GENERAL................................................................................................. 985
Job/Time Code Values................................................................................ 985
DIAGNOSTICS............................................................................................. 985
Diagnostic Notes.................................................................................... 985
Test 3.13........................................................................................... 987
fe03_tc.pdf..................................................................................................... 0
TSM/TSSM 3.................................................................................................. 945
fe02a.pdf....................................................................................................... 0
CHECKING FOR DIAGNOSTIC TROUBLE CODES 2.1................................................................... 897
CHECK ENGINE LAMP....................................................................................... 897
SECURITY LAMP........................................................................................... 898
CODE TYPES.............................................................................................. 899
Current............................................................................................. 899
Historic............................................................................................ 899
RETRIEVING DIAGNOSTIC TROUBLE CODES..................................................................... 899
MULTIPLE DIAGNOSTIC TROUBLE CODES....................................................................... 899
INITIAL DIAGNOSTIC CHECK: SPEEDOMETER 2.2................................................................... 900
GENERAL................................................................................................. 900
Diagnostic Notes.................................................................................... 900
Circuit Diagram/Wire Harness Connector Table........................................................ 900
INITIAL DIAGNOSTICS..................................................................................... 901
Diagnostic Tips..................................................................................... 901
Diagnostic Notes.................................................................................... 901
Other Codes......................................................................................... 901
Diagnostic Check (Part 1 of 2)...................................................................... 907
Diagnostic Check (Part 2 of 2)...................................................................... 908
SPEEDOMETER SELF DIAGNOSTICS 2.3............................................................................ 909
GENERAL................................................................................................. 909
DIAGNOSTICS............................................................................................. 909
Diagnostic Tips..................................................................................... 909
Diagnostic Notes.................................................................................... 909
Speedometer Self Diagnostics (chart)................................................................ 910
SPEEDOMETER/TACHOMETER 2.4.................................................................................. 911
GENERAL................................................................................................. 911
Reset Switch........................................................................................ 911
SPEEDOMETER THEORY OF OPERATION......................................................................... 912
Job/Time Code Values................................................................................ 912
TACHOMETER THEORY OF OPERATION.......................................................................... 912
DIAGNOSTICS............................................................................................. 912
Diagnostic Notes.................................................................................... 912
Test 2.4 (Part 1 of 2).............................................................................. 913
Test 2.4 (Part 2 of 2).............................................................................. 914
BREAKOUT BOX: SPEEDOMETER 2.5............................................................................... 915
GENERAL................................................................................................. 915
INSTALLATION............................................................................................ 915
REMOVAL................................................................................................. 915
FUEL GAUGE 2.6.............................................................................................. 916
THEORY OF OPERATION..................................................................................... 916
FUEL GAUGE AND SENDER TEST.............................................................................. 916
OIL, AIR AND VOLTMETER GAUGES 2.7........................................................................... 917
Oil Pressure Gauge and Indicator Light.................................................................. 917
Problem............................................................................................. 917
Ambient Air Temperature Gauge........................................................................... 918
Problem............................................................................................. 918
Voltmeter Gauge......................................................................................... 918
Problem............................................................................................. 918
INDICATOR LAMPS: FLHX, FLHT/C/U, FLTR 2.8................................................................... 919
GENERAL................................................................................................. 919
Job/Time Code Values................................................................................ 919
DIAGNOSTICS............................................................................................. 920
Oil Pressure or Neutral Indicator Will Not Function................................................. 920
High Beam or R/L Turn Signal Indicator Will Not Function............................................ 920
INDICATOR LAMPS: FLHR/C/S 2.9............................................................................... 921
GENERAL................................................................................................. 921
Job/Time Code Values................................................................................ 921
DIAGNOSTICS............................................................................................. 922
Oil Pressure or Neutral Indicator Will Not Function................................................. 922
High Beam or R/L Turn Signal Indicator Will Not Function............................................ 922
DTC B1004, B1005 2.10....................................................................................... 923
GENERAL................................................................................................. 923
DIAGNOSTICS............................................................................................. 923
Diagnostic Tips..................................................................................... 923
Diagnostic Notes.................................................................................... 923
Test 2.10: DTC B1004................................................................................ 925
Test 2.10: DTC B1005................................................................................ 926
DTC B1006, B1007 2.11....................................................................................... 927
GENERAL................................................................................................. 927
Accessory Or Ignition Line Overvoltage.............................................................. 927
Test 2.11........................................................................................... 928
DTC B1008 2.12.............................................................................................. 929
GENERAL................................................................................................. 929
Reset Switch Closed................................................................................. 929
DIAGNOSTICS............................................................................................. 929
Diagnostic Notes.................................................................................... 929
Test 2.12........................................................................................... 931
DTC U1016 2.13.............................................................................................. 932
GENERAL................................................................................................. 932
Loss of ICM/ECM Serial Data......................................................................... 932
DIAGNOSTICS............................................................................................. 932
Diagnostic Notes.................................................................................... 932
Test 2.13........................................................................................... 937
DTC U1064, U1255 2.14....................................................................................... 938
GENERAL................................................................................................. 938
Loss of TSM/TSSM Serial Data........................................................................ 938
DIAGNOSTICS............................................................................................. 938
Diagnostic Notes.................................................................................... 938
Test 2.14........................................................................................... 943
DTC U1300, U1301 or “BUS ER” 2.15........................................................................... 944
GENERAL................................................................................................. 944
Serial Data Low or Serial Data Open/High............................................................ 944
DIAGNOSTICS............................................................................................. 944
Diagnostic Tips..................................................................................... 944
fe02_tc.pdf..................................................................................................... 0
INSTRUMENTS 2............................................................................................... 895
fe01a.pdf....................................................................................................... 0
STARTER TROUBLESHOOTING 1.1................................................................................. 873
Table 1-1. Starter Does Not Run or Runs At Very Low Speeds.............................................. 873
Table 1-2. Pinion Does Not Engage With Ring Gear While Starter is Cranked or Engine Cannot Be Cra....... 874
Table 1-3. Starter Does Not Stop Running................................................................ 874
STARTING SYSTEM DIAGNOSIS 1.2............................................................................... 875
Diagnostic Notes........................................................................................ 875
Job/Time Code Values.................................................................................... 875
Starter Testing 1....................................................................................... 875
Starter Testing 2: Solenoid Clicks...................................................................... 876
Starter Testing 3: Relay Clicks......................................................................... 876
Starter Testing 4: Nothing Clicks....................................................................... 877
Starter Testing 5: Starter Spins, But Does Not Engage................................................... 878
Starter Testing 6: Starter Stalls or Spins Too Slowly................................................... 878
STARTER ACTIVATION CIRCUITS 1.3............................................................................. 879
DIAGNOSTICS/TROUBLESHOOTING 1.4............................................................................. 880
STARTER SYSTEM TESTING 1.5.................................................................................. 881
TESTING ASSEMBLED STARTER 1.6............................................................................... 883
CHARGING SYSTEM 1.7......................................................................................... 885
Alternator.............................................................................................. 885
Voltage Regulator....................................................................................... 885
Battery................................................................................................. 885
Wiring.................................................................................................. 886
Voltage Regulator Inspection............................................................................ 886
Job/Time Code Values.................................................................................... 886
Test 1.7 (Part 1 of 2).................................................................................. 887
Test 1.7 (Part 2 of 2).................................................................................. 888
MILLIAMP DRAW TEST...................................................................................... 889
Table 1-4. Milliampere Draw Test (Ignition Switch OFF).................................................. 889
TOTAL CURRENT DRAW TEST................................................................................. 889
CURRENT OUTPUT TEST..................................................................................... 890
VOLTAGE OUTPUT TEST..................................................................................... 890
STATOR CHECK............................................................................................ 890
AC OUTPUT CHECK......................................................................................... 891
BATTERY TESTING 1.8......................................................................................... 892
Table 1-5. Voltmeter Test............................................................................... 892
Table 1-6. Battery Load Test............................................................................ 893
fe01_tc.pdf..................................................................................................... 0
STARTING/CHARGING 1......................................................................................... 871
2006 HARLEY DAVIDSON TOURING MODELS ELECTRICAL DIAGNOSTICS + FLHTCUSE SERVICE SUPPLEMENT + SERVICE MANUAL:
PLEASE NOTE:
This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
Require some other service manual or have any queries: please WRITE to us at [email protected]
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