2006 Harley Davidson XLH Models Electrical Diagnostics + Service Manual – PDF DOWNLOAD

Description

2006 Harley Davidson XLH Models Electrical Diagnostics + Service Manual – PDF DOWNLOAD

FILE DETAILS:

2006 Harley Davidson XLH Models Electrical Diagnostics + Service Manual – PDF DOWNLOAD

Language : English
Pages : 1794
Downloadable : Yes
File Type : PDF
Size: 69.6 MB

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DESCRIPTION:

2006 Harley Davidson XLH Models Electrical Diagnostics + Service Manual – PDF DOWNLOAD

SERVICE MANUAL
Part Number 99484-06

ELECTRICAL DIAGNOSTICS
Part Number 99495-06

GENERAL:
SERVICING A NEW:
MOTORCYCLE:
Service operations to be performed before customer delivery
are specified in the applicable model year PREDELIVERY
AND SETUP MANUAL.
The performance of new motorcycle initial service is required
to keep warranty in force and to ensure proper emissions systems
operation.
After a new motorcycle has been driven its first 1000 miles
(1600 km), and at every 5000 mile (8000 km) interval thereafter,
have a Harley-Davidson dealer perform the service operations
listed under 1.3 MAINTENANCE SCHEDULE.
Safety:
Safety is always the most important consideration when performing
any job. Be sure you have a complete understanding
of the task to be performed. Use common sense. Use the
proper tools. Protect yourself and bystanders with approved
eye protection. Don’t just do the job – do the job safely.

TABLE OF CONTENTS:

2006 Harley Davidson XLH Models Electrical Diagnostics + Service Manual – PDF DOWNLOAD

0-Table of Contents 1
2006 XLH MODELS 1
SERVICE MANUAL 1
Part Number 99484-06 1
ELECTRICAL DIAGNOSTICS 1
Part Number 99495-06 1
1-Maintenance 3
sm01_tc pdf 3
sm01a pdf 5
GENERAL 1 1 5
SERVICING A NEW MOTORCYCLE 5
SHOP PRACTICES 5
Repair Notes 5
Safety 5
Removing Parts 5
Cleaning 5
Disassembly and Assembly 6
Magnetic Parts Trays 6
REPAIR AND REPLACEMENT PROCEDURES 6
Hardware and Threaded Parts 6
Wiring, Hoses and Lines 6
Instruments and Gauges 6
Bearings 6
Bushings 6
Gaskets 6
Lip Type Seals 6
O-Rings (Preformed Packings) 7
Gears 7
Shafts 7
Part Replacement 7
CLEANING 7
Part Protection 7
Cleaning Process 7
Rust or Corrosion Removal 7
Bearings 7
TOOL SAFETY 7
Air Tools 7
Wrenches 7
Pliers/Cutters/Prybars 8
Hammers 8
Punches/Chisels 8
Screwdrivers 8
Ratchets and Handles 8
Sockets 8
Storage Units 8
FUEL AND OIL 1 2 9
FUEL 9
GASOLINE BLENDS 9
ENGINE OIL 9
WINTER LUBRICATION 9
MAINTENANCE SCHEDULE 1 3 10
GENERAL 10
CRITICAL FASTENERS 1 4 14
INSPECTION 14
ENGINE OIL AND FILTER 1 5 15
CHECKING AND ADDING OIL 15
Removing and Replacing Oil Filler Cap 15
Checking Oil With Cold Engine 15
Checking Oil With Warm Engine 15
CHANGING OIL AND FILTER 16
General 16
Draining Oil Tank 16
Removing Oil Filter 17
Installing New Oil Filter 17
Refilling Oil Tank 17
LEFT SIDE COVER 1 6 18
GENERAL 18
OPENING LEFT SIDE COVER 19
CLOSING LEFT SIDE COVER 19
REMOVING LEFT SIDE COVER 19
INSTALLING LEFT SIDE COVER 19
BATTERY MAINTENANCE 1 7 20
GENERAL 20
BATTERY DISCONNECTION AND REMOVAL 21
BATTERY INSPECTION 22
BATTERY STORAGE 22
BATTERY INSTALLATION AND CONNECTION 23
BRAKES 1 8 24
GENERAL 24
INSPECTION 24
TROUBLESHOOTING 24
BLEEDING HYDRAULIC BRAKE SYSTEM 1 9 25
GENERAL 25
BLEEDING FRONT BRAKE 25
BLEEDING REAR BRAKE 27
BRAKE PADS AND DISCS 1 10 28
INSPECTION 28
Brake Pads 28
Brake Disc Thickness, Lateral Runout and Warpage 28
29
32
TIRES AND WHEELS 1 11 35
TIRES 35
TIRE WEAR INDICATORS 35
WHEEL BEARINGS 36
WHEEL SPOKES 36
PRIMARY CHAIN 1 12 37
INSPECTION 37
ADJUSTMENT 38
CLUTCH 1 13 39
ADJUSTMENT 39
TRANSMISSION LUBRICANT 1 14 41
GENERAL 41
DRAINING LUBRICANT 41
REFILLING LUBRICANT 41
REAR BELT DEFLECTION 1 15 43
INSPECTION 43
BELT DEFLECTION ADJUSTMENT 45
WHEEL ALIGNMENT 46
Checking Wheel Alignment 46
Adjusting Wheel Alignment 46
REAR BELT AND SPROCKETS 1 16 47
GENERAL 47
CLEANING 47
INSPECTION 47
Sprockets 47
Rear Belt 47
SHOCK ABSORBER ADJUSTMENT 1 17 49
GENERAL 49
PROCEDURE 49
STEERING HEAD BEARINGS 1 18 50
GENERAL 50
ADJUSTMENT 50
LUBRICATION 50
REAR FORK BEARINGS 1 19 51
GENERAL 51
PROCEDURE 51
sm01b pdf 53
FRONT FORK OIL 1 20 53
GENERAL 53
CHANGING FORK OIL 53
Filling Fork Oil: Forks Assembled, in Frame 54
Filling Fork Oil: Forks Disassembled, out of Frame 54
SPARK PLUGS 1 21 55
GENERAL 55
ADJUSTMENT 55
CLEANING AND INSPECTION 55
Inspection 55
Spark Plug Condition 55
Cleaning 55
INSTALLATION 55
CABLE AND CHASSIS LUBRICATION 1 22 56
GENERAL 56
CABLES AND HAND LEVERS 56
FOOT SHIFT LEVER AND REAR BRAKE PEDAL 56
JIFFY STAND 56
STEERING HEAD BEARINGS 56
AIR FILTER ELEMENT 1 23 57
GENERAL 57
REMOVAL 57
CLEANING, INSPECTION AND REPAIR 58
INSTALLATION 58
THROTTLE CABLES AND ENRICHENER 1 24 59
CABLE INSPECTION, LUBRICATION AND ADJUSTMENT 59
Inspection and Lubrication 59
Adjustment 59
ENRICHENER ADJUSTMENT 60
IDLE SPEED AND IGNITION TIMING 1 25 61
IDLE SPEED ADJUSTMENT 61
IGNITION TIMING 61
FUEL SUPPLY VALVE FILTER 1 26 62
INSPECTION 62
FUEL SYSTEM LINES AND FITTINGS 63
ENGINE MOUNTS AND STABILIZER LINKS 1 27 64
INSPECTION 64
HEADLAMP ALIGNMENT 1 28 65
INSPECTION 65
ADJUSTMENT 66
XL 883, XL 883L, XL 883R, XL 1200R 66
XL 883C, XL 1200C 66
FLUID/LUBRICANT REQUIREMENTS 1 29 67
BRAKE FLUID 67
BRAKE COMPONENT GREASE 67
FRONT FORK OIL 67
ENGINE OIL 67
PRIMARY DRIVE/TRANSMISSION LUBRICANT 67
STORAGE 1 30 68
GENERAL 68
REMOVAL FROM STORAGE 69
TROUBLESHOOTING 1 31 70
GENERAL 70
ENGINE 70
Starting Motor Does Not Operate or Does Not Turn Engine Over 70
Engine Turns Over But Does Not Start 70
Starts Hard 70
Starts But Runs Irregularly or Misses 71
Spark Plug Fouls Repeatedly 71
Pre-Ignition or Detonation (Knocks or Pings) 71
Overheating 71
Valve Train Noise 71
Excessive Vibration 71
ENGINE LUBRICATION SYSTEM 72
Oil Does Not Return To Oil Tank 72
Engine Uses Too Much Oil or Smokes Excessively 72
Engine Leaks Oil From Cases, Push Rods, Hoses, Etc 72
FUEL 72
Carburetor Floods 72
ELECTRICAL SYSTEM 72
Alternator Does Not Charge 72
Alternator Charge Rate Is Below Normal 72
Speedometer Operates Erratically 72
TRANSMISSION 72
Shifts Hard 72
Jumps Out of Gear 72
CLUTCH 73
Slips 73
Drags or Does Not Release 73
Chatters 73
CHASSIS 73
Irregular/Inadequate Brake Action 73
Handling Irregularities 73
2-Chassis 75
sm02_tc pdf 75
sm02a pdf 77
SPECIFICATIONS 2 1 77
TIRES 78
TORQUE VALUES 2 2 79
VEHICLE IDENTIFICATION NUMBER (VIN) 2 3 82
GENERAL 82
WHEELS 2 4 84
GENERAL 84
TROUBLESHOOTING 85
FRONT WHEEL 86
Removal 86
Disassembly 87
Cleaning and Inspection 87
Assembly 87
Installation 90
REAR WHEEL 91
Removal 91
Disassembly 92
Cleaning and Inspection 92
Assembly 92
Installation 94
SEALED WHEEL BEARINGS 95
Inspection 95
Removal 96
Installation 97
WHEEL LACING: 16 INCH RIM 2 5 98
GENERAL 98
PROCEDURE 99
WHEEL LACING: 19 INCH RIM 2 6 101
GENERAL 101
PROCEDURE 101
WHEEL LACING: 21 INCH RIM 2 7 105
GENERAL 105
PROCEDURE 105
TRUING LACED WHEELS 2 8 109
PROCEDURE 109
CHECKING CAST WHEEL RUNOUT 2 9 112
CHECKING LATERAL AND RADIAL RUNOUT 112
TIRES 2 10 113
GENERAL 113
REMOVAL 113
CLEANING, INSPECTION AND REPAIR 114
INSTALLATION 114
Tube Type Tires 114
Tubeless Tires 115
CHECKING TIRE RUNOUT 115
Lateral Runout 115
Radial Runout 116
WHEEL BALANCING 116
Weights For Laced Wheels 116
Weights for Cast Wheels 116
sm02b pdf 117
FRONT BRAKE MASTER CYLINDER 2 11 117
GENERAL 117
REMOVAL 117
DISASSEMBLY 120
CLEANING, INSPECTION AND REPAIR 121
ASSEMBLY 121
INSTALLATION 123
REAR BRAKE MASTER CYLINDER 2 12 125
GENERAL 125
INSPECTION 125
REMOVAL 126
DISASSEMBLY 128
CLEANING, INSPECTION AND REPAIR 130
ASSEMBLY 130
INSTALLATION 133
REAR BRAKE MASTER CYLINDER RESERVOIR 2 13 134
GENERAL 134
REMOVAL 134
INSTALLATION 135
FRONT BRAKE CALIPER 2 14 136
REMOVAL 136
DISASSEMBLY 137
CLEANING, INSPECTION AND REPAIR 139
ASSEMBLY 139
LUBRICATING FRONT CALIPER BOLT PINS AND BOOTS 140
INSTALLING BRAKE PADS IN CALIPER 141
INSTALLATION 141
REAR BRAKE CALIPER 2 15 144
REMOVAL 144
DISASSEMBLY 146
CLEANING, INSPECTION AND REPAIR 147
ASSEMBLY 148
LUBRICATING REAR CALIPER BOLT PINS AND BOOTS 149
INSTALLATION 150
BRAKE LINES 2 16 153
FRONT BRAKE LINE 153
Removal 153
Installation 154
REAR BRAKE LINE 155
Removal 155
Installation 156
FRONT FORK 2 17 157
GENERAL 157
REMOVAL 157
DISASSEMBLY 157
CLEANING, INSPECTION AND REPAIR 157
ASSEMBLY 159
INSTALLATION 159
FORK STEM AND BRACKET ASSEMBLY 2 18 160
GENERAL 160
REMOVAL/DISASSEMBLY 160
CLEANING, INSPECTION AND REPAIR 160
ASSEMBLY/INSTALLATION 160
REAR FORK 2 19 161
GENERAL 161
REMOVAL 161
DISASSEMBLY 162
CLEANING AND INSPECTION 162
ASSEMBLY 162
INSTALLATION 163
REAR SHOCK ABSORBERS 2 20 164
GENERAL 164
REMOVAL 164
CLEANING AND INSPECTION 164
INSTALLATION 164
sm02c pdf 165
STABILIZER LINKS 2 21 165
GENERAL 165
UPPER FRONT STABILIZER LINK 165
Removal 165
Installation 165
LOWER FRONT STABILIZER LINK 166
Removal 166
Installation 166
REAR STABILIZER LINK 166
Removal 166
Installation 166
FRONT ENGINE MOUNT/ISOLATOR 2 22 167
GENERAL 167
REMOVAL 167
INSTALLATION 168
REAR ENGINE MOUNT/ISOLATOR 2 23 169
GENERAL 169
REMOVAL 169
INSTALLATION 171
THROTTLE CONTROL 2 24 172
REMOVAL/DISASSEMBLY 172
CLEANING, INSPECTION AND REPAIR 172
ASSEMBLY/INSTALLATION 172
HANDLEBARS 2 25 174
REMOVAL 174
All Models 174
XL 883, XL 883L, XL 883R, XL 1200R 174
XL 883C, XL 1200C 175
INSTALLATION 175
XL 883, XL 883L, XL 883R, XL 1200R 175
XL 883C, XL 1200C 175
All Models 176
CLUTCH CONTROL 2 26 177
GENERAL 177
REMOVAL/DISASSEMBLY 177
177
178
Clutch Hand Control 178
ASSEMBLY/INSTALLATION 178
Clutch Hand Control 178
179
179
Finish 179
EXHAUST SYSTEM 2 27 180
REMOVAL 180
Mufflers and Exhaust Pipes 180
Muffler Interconnect Bracket 181
INSTALLATION 182
Muffler Interconnect Bracket 182
Exhaust Pipes and Mufflers 182
FRONT FENDER 2 28 183
REMOVAL 183
INSTALLATION 183
REAR FENDER 2 29 184
REMOVAL 184
INSTALLATION 186
BELT GUARD AND DEBRIS DEFLECTOR 2 30 188
REMOVAL 188
Belt Guard 188
Debris Deflector 188
INSTALLATION 188
Belt Guard 188
Debris Deflector 188
JIFFY STAND 2 31 189
GENERAL 189
REMOVAL 190
CLEANING AND LUBRICATION 190
INSTALLATION 190
SEAT 2 32 191
GENERAL 191
REMOVAL 191
INSTALLATION 191
RIDER FOOT CONTROLS: XL 883, XL 883L, XL 883R, XL 1200R 2 33 193
RIGHT FOOTREST AND REAR BRAKE PEDAL ASSEMBLY 193
Removal 193
Installation 193
LEFT FOOTREST AND SHIFT LEVER ASSEMBLY 193
Removal 193
Installation 193
RIDER FOOT CONTROLS: XL 883C, XL 1200C 2 34 195
RIGHT FOOTREST AND REAR BRAKE PEDAL ASSEMBLY 195
Removal 195
Installation 195
LEFT FOOTREST AND SHIFT LEVER ASSEMBLY 197
Removal 197
Installation 197
ADJUSTING SHIFT PEDAL 198
PASSENGER FOOTRESTS 2 35 199
GENERAL 199
REMOVAL 199
INSTALLATION 199
FORK LOCK 2 36 200
REMOVAL 200
INSTALLATION 201
3-Engine 203
sm03_tc pdf 203
sm03a pdf 205
SPECIFICATIONS 3 1 205
SERVICE WEAR LIMITS 3 2 208
GENERAL 208
TORQUE VALUES 3 3 210
ENGINE 3 4 212
GENERAL 212
TROUBLESHOOTING 3 5 213
DIAGNOSING VALVE TRAIN NOISE 213
COMPRESSION TEST 213
Compression Test Procedure 213
CYLINDER LEAKAGE TEST 214
Cylinder Leakage Test Procedure 214
DIAGNOSING SMOKING ENGINE OR HIGH OIL CONSUMPTION 215
Check Prior To Cylinder Head Removal 215
Check After Cylinder Head Removal 215
ADJUSTMENT/TESTING 215
General 215
ENGINE LUBRICATION SYSTEM 3 6 216
GENERAL 216
OIL PUMP 216
OIL PRESSURE 3 7 219
GENERAL 219
Oil Pressure Indicator Lamp 219
CHECKING OIL PRESSURE 219
CRANKCASE BREATHING SYSTEM 3 8 221
GENERAL 221
HOW TO USE THIS SECTION 3 9 222
TYPICAL SYMPTOMS 222
TOP END REPAIR 222
BOTTOM END REPAIR 222
TOP END SERVICE 3 10 223
ENGINE IN CHASSIS 223
ENGINE REMOVED FROM CHASSIS 224
BOTTOM END SERVICE 3 11 225
ENGINE IN CHASSIS: CAM COMPARTMENT SERVICE 225
ENGINE REMOVED: FLYWHEEL COMPARTMENT SERVICE OR COMPLETE ENGINE OVERHAUL 226
REMOVING ENGINE FROM CHASSIS 3 12 227
GENERAL 227
PROCEDURE 227
INSTALLING ENGINE IN CHASSIS 3 13 231
GENERAL 231
PROCEDURE 231
sm03b pdf 234
TOP END OVERHAUL: DISASSEMBLY 3 14 234
GENERAL 234
STRIPPING MOTORCYCLE FOR TOP END REPAIR 234
CYLINDER HEAD 235
Disassembling Rocker Covers 235
Removing Cylinder Head 236
Disassembling Push Rods and Covers 238
CYLINDER AND PISTON 238
CYLINDER HEAD 3 15 241
GENERAL 241
REMOVAL 241
DISASSEMBLY 241
CLEANING AND INSPECTION 242
Cylinder Heads 242
Rocker Arm Assemblies 243
Valves 244
Valve Seats 244
Valve Guides 244
Valve Springs 244
Spark Plug Threads 245
Push Rods 245
REPLACING ROCKER ARM BUSHINGS 245
REPLACING VALVE GUIDES 246
Removal 246
Installation 247
REFACING VALVE SEATS 250
Replacing Valve Seats 252
ASSEMBLY 253
INSTALLATION 254
CYLINDER AND PISTON 3 16 255
REMOVAL/DISASSEMBLY 255
CLEANING, INSPECTION, AND REPAIR 255
Checking Gasket Surface 255
Measuring Cylinder Bore 256
Measuring Piston to Cylinder Fit 257
Boring and Honing Cylinder 257
Fitting Piston Rings 258
CONNECTING ROD BUSHINGS 260
Removing Upper Connecting Rod Bushing 260
Installing Upper Connecting Rod Bushing 261
Reaming Upper Connecting Rod Bushing 262
Honing Upper Connecting Rod Bushing 263
Repair 263
ASSEMBLY/INSTALLATION 263
TOP END OVERHAUL: ASSEMBLY 3 17 264
GENERAL 264
PISTON AND CYLINDER 264
PUSH RODS, COVERS AND RETAINERS 266
CYLINDER HEAD 267
Rocker Covers 269
ASSEMBLING MOTORCYCLE AFTER TOP END REPAIR 271
BOTTOM END OVERHAUL: DISASSEMBLY 3 18 272
GENERAL 272
TAPPETS 272
OIL PUMP 272
GEARCASE COVER AND CAM GEARS 273
CRANKCASE 274
Removing Piston Oil Jets 275
Removing Cylinder Base Studs 275
VALVE TAPPETS 3 19 276
GENERAL 276
REMOVAL 276
CLEANING AND INSPECTION 276
INSTALLATION 276
sm03c pdf 278
GEARCASE COVER AND CAM GEARS 3 20 278
GENERAL 278
REMOVAL/DISASSEMBLY 278
CLEANING, INSPECTION AND REPAIR 278
Cam and Pinion Gear Identification, Inspection and Selection 278
Bushing Inspection and Removal 280
BUSHING INSTALLATION 280
Cam Gear Bushings in Right Crankcase 280
Cam Gear Bushings (Except Rear Intake Bushing) in Gearcase Cover 281
Rear Intake Cam Gear Bushing in Gearcase Cover 281
Pinion Shaft Bushing in Gearcase Cover 281
BUSHING REAMING 282
Cam Gear Bushings in Right Crankcase 282
Cam Gear Bushings (Except Rear Intake Bushing) in Gearcase Cover 283
Rear Intake Cam Gear Bushing in Gearcase Cover 283
Pinion Shaft Bushing in Gearcase Cover 284
ASSEMBLY/INSTALLATION 284
OIL PUMP 3 21 285
GENERAL 285
REMOVAL 285
DISASSEMBLY 286
CLEANING, INSPECTION AND REPAIR 286
ASSEMBLY 286
INSTALLATION 286
OIL FILTER MOUNT 3 22 287
GENERAL 287
DISASSEMBLY 287
CLEANING AND INSPECTION 287
ASSEMBLY 287
CRANKCASE 3 23 288
GENERAL 288
REMOVAL 288
DISASSEMBLY 288
FITTING PINION BEARINGS 291
Bearing Selection 292
LAPPING ENGINE MAIN BEARING RACES 296
Assembling Crankcase Halves 296
BOTTOM END OVERHAUL: ASSEMBLY 3 24 297
GENERAL 297
CRANKCASE 297
Installing Piston Oil Jets 297
Installing Pinion Shaft Bearing 298
Installing Left Main Bearing 299
Assembling Crankcase Halves 299
Installing Cylinder Base Studs 302
CAM GEARS AND GEARCASE COVER 303
TAPPETS 306
ASSEMBLING TOP END OF ENGINE 306
OIL TANK 3 25 307
OIL HOSE ROUTING 307
REMOVAL 308
INSTALLATION 310
4-Fuel System 312
sm04_tc pdf 312
sm04a pdf 314
SPECIFICATIONS 4 1 314
TORQUE VALUES 4 2 315
TROUBLESHOOTING 4 3 316
ENRICHENER 4 4 318
GENERAL 318
OPERATION 318
Cool Engine 318
Warm or Hot Engine 318
CARBURETOR 4 5 319
GENERAL 319
ADJUSTMENT 319
Float Level 319
OPERATION CHECK: VACUUM PISTON 321
Opening Malfunction 321
Closing Malfunction 321
REMOVAL 321
DISASSEMBLY 323
Vacuum Piston Chamber 323
Carburetor Body 323
Accelerator Pump 323
CLEANING, INSPECTION AND REPAIR 324
Vacuum Piston Components 324
Carburetor Body Components 324
Accelerator Pump 324
ASSEMBLY 324
Vacuum Piston Chamber 324
Carburetor Body 324
Accelerator Pump 324
INSTALLATION 325
Carburetor 325
Carburetor Fuel Overflow/Drain Hose Routing 325
AIR CLEANER 4 6 326
REMOVAL 326
CLEANING, INSPECTION AND REPAIR 327
INSTALLATION 327
FUEL SUPPLY VALVE 4 7 328
GENERAL 328
OPERATION 328
REMOVAL, INSPECTION AND INSTALLATION 328
TROUBLESHOOTING 329
Vacuum Test 329
FUEL TANK 4 8 330
GENERAL 330
REMOVAL 332
CLEANING, INSPECTION AND REPAIR 332
INSTALLATION 333
CONSOLE REPLACEMENT 333
Removal 333
Installation 335
336
GENERAL 336
REMOVAL 337
Charcoal Canister 337
Vapor Valve 338
INSTALLATION 338
Vapor Valve 338
Charcoal Canister 339
HOSE ROUTING 340
Carburetor 340
Canister Hose Routings 340
INTAKE LEAK TEST 4 10 341
GENERAL 341
LEAK TESTER 341
Parts List 341
Tester Assembly 341
Tester Adjustment 341
PROCEDURE 342
5-Electric Starter 344
sm05_tc pdf 344
sm05a pdf 346
SPECIFICATIONS 5 1 346
TORQUE VALUES 5 2 347
ELECTRIC STARTER SYSTEM 5 3 348
GENERAL 348
Wiring Diagram 348
Starter Relay 348
OPERATION 348
STARTER MOTOR 5 4 351
REMOVAL 351
DISASSEMBLY, INSPECTION AND REPAIR 353
ASSEMBLY 356
INSTALLATION 357
STARTER SOLENOID 5 5 358
GENERAL 358
DISASSEMBLY 359
ASSEMBLY 359
FINAL 359
6-Drive & Transmission 360
sm06_tc pdf 360
sm06a pdf 362
SPECIFICATIONS 6 1 362
TORQUE VALUES 6 2 364
PRIMARY CHAIN ADJUSTER 6 3 365
GENERAL 365
REMOVAL 365
Primary Cover 365
Primary Chain Adjuster 367
INSTALLATION 367
Primary Chain Adjuster 367
Primary Cover 367
CLUTCH RELEASE MECHANISM 6 4 369
REMOVAL/DISASSEMBLY 369
CLEANING, INSPECTION AND REPAIR 370
ASSEMBLY/INSTALLATION 370
PRIMARY DRIVE/CLUTCH 6 5 371
GENERAL 371
REMOVAL 373
DISASSEMBLY 374
INSPECTION AND REPAIR 375
ASSEMBLY 376
INSTALLATION 377
SECONDARY DRIVE BELT 6 6 379
REMOVAL 379
INSTALLATION 381
TRANSMISSION 6 7 382
OPERATION 382
CASE DISASSEMBLY FOR TRANSMISSION REMOVAL 6 8 383
GENERAL 383
ENGINE REMOVAL AND DISASSEMBLY 383
TRANSMISSION REMOVAL AND DISASSEMBLY 6 9 386
TRANSMISSION REMOVAL FROM LEFT CRANKCASE 386
MAINSHAFT/COUNTERSHAFT 388
MAINSHAFT DISASSEMBLY 390
Cleaning And Inspection 390
COUNTERSHAFT DISASSEMBLY 391
Cleaning And Inspection 391
sm06b pdf 392
TRANSMISSION ASSEMBLY 6 10 392
GENERAL 392
MAINSHAFT ASSEMBLY 392
COUNTERSHAFT ASSEMBLY 393
MAIN DRIVE GEAR AND BEARING 6 11 394
GENERAL 394
REMOVAL 395
Main Drive Gear 395
Main Drive Gear Ball Bearing 396
DISASSEMBLY 396
ASSEMBLY 397
INSTALLATION 398
Main Drive Gear Ball Bearing 398
Main Drive Gear 399
Main Drive Gear Seal 400
TRANSMISSION RIGHT CASE BEARINGS 6 12 402
REMOVAL 402
Countershaft Needle Bearing 402
Shifter Drum Bushing 402
INSTALLATION 402
Countershaft Needle Bearing 402
Shifter Drum Bushing 402
TRANSMISSION LEFT CASE BEARINGS 6 13 403
REMOVAL 403
Mainshaft and Countershaft Bearings 403
Shifter Drum Bushing 403
INSTALLATION 403
Mainshaft and Countershaft Bearings 403
Shifter Drum Bushing 403
TRANSMISSION INSTALLATION 6 14 404
GENERAL 404
INSTALLATION 404
SHIFTER FORKS AND DRUM ASSEMBLY 405
ASSEMBLING CRANKCASES 406
SHIFTER SHAFT INSTALLATION 408
TRANSMISSION SPROCKET 6 15 409
REMOVAL 409
INSTALLATION 410
7-Electrical 412
sm07_tc pdf 412
sm07a pdf 414
SPECIFICATIONS 7 1 414
IGNITION 414
CHARGING SYSTEM 414
BATTERY 414
FUSES 414
TORQUE VALUES 7 2 415
BULB REQUIREMENTS 7 3 416
BULB CHART 416
BATTERY TRAY 7 4 417
GENERAL 417
REMOVAL 417
INSTALLATION 418
IGNITION SYSTEM 7 5 419
GENERAL 419
TROUBLESHOOTING 419
MANIFOLD ABSOLUTE PRESSURE SENSOR (MAP) 7 6 421
REMOVAL 421
INSTALLATION 421
IGNITION/LIGHT SWITCH 7 7 422
GENERAL 422
REMOVAL 423
INSTALLATION 423
IGNITION CONTROL MODULE (ICM) 7 8 424
GENERAL 424
REMOVAL 424
INSTALLATION 424
SPARK PLUG CABLES 7 9 425
GENERAL 425
REMOVAL 425
INSPECTION 426
INSTALLATION 426
IGNITION COIL 7 10 427
GENERAL 427
TROUBLESHOOTING 427
REMOVAL 427
INSTALLATION 427
CHARGING SYSTEM 7 11 428
GENERAL 428
ALTERNATOR 428
VOLTAGE REGULATOR 428
ALTERNATOR 7 12 429
REMOVAL AND DISASSEMBLY 429
Rotor 429
Stator 429
CLEANING, INSPECTION AND REPAIR 429
ASSEMBLY AND INSTALLATION 430
Stator 430
Rotor 431
Final Assembly 431
VOLTAGE REGULATOR 7 13 432
GENERAL 432
REMOVAL 432
INSTALLATION 433
BATTERY 7 14 434
GENERAL 434
VOLTMETER TEST 434
CONDUCTANCE TEST 434
LOAD TEST 435
CHARGING 436
General 436
Safety Precautions 436
Charging Battery 436
BATTERY CABLES 7 15 438
REMOVAL 438
INSTALLATION 439
sm07b pdf 442
HEADLAMP 7 16 442
442
443
INDICATOR LAMPS 7 17 446
446
446
447
TAIL LAMP 7 18 448
BULB REPLACEMENT 448
BASE REPLACEMENT 448
TURN SIGNALS 7 19 450
BULB REPLACEMENT 450
FRONT HOUSING REPLACEMENT 450
REAR HOUSING REPLACEMENT 451
REAR STOP LAMP SWITCH 7 20 454
GENERAL 454
REPLACEMENT 454
HANDLEBAR SWITCHES 7 21 455
GENERAL 455
REPAIR PROCEDURES 455
CONNECTORS 456
RIGHT HANDLEBAR SWITCH 7 22 457
REMOVAL 457
INSTALLATION 458
DISASSEMBLY 460
SWITCH REPAIR/REPLACEMENT 461
Upper Switch Housing Repair 461
Lower Switch Housing Repair 462
ASSEMBLY 463
LEFT HANDLEBAR SWITCH 7 23 464
REMOVAL 464
INSTALLATION 464
DISASSEMBLY 465
SWITCH REPAIR/REPLACEMENT 466
Upper Switch Housing Repair 466
Lower Switch Housing Repair 467
ASSEMBLY 467
HORN 7 24 468
TROUBLESHOOTING 468
VOLTAGE TEST 468
REPLACEMENT: ALL MODELS EXCEPT XL 1200C 468
REPLACEMENT: XL 1200C 469
MAXI-FUSE 7 25 470
GENERAL 470
REMOVING 470
INSTALLING 470
SYSTEM FUSES AND STARTER RELAY 7 26 471
GENERAL 471
REPLACING 15-AMP FUSES 471
REPLACING STARTER RELAY 471
sm07c pdf 472
MAXI-FUSE HOLDER 7 27 472
REPLACEMENT 472
RELAY/FUSE BLOCK 7 28 473
GENERAL 473
REMOVAL 473
INSTALLATION 474
SPEEDOMETER: XL 883, XL 883L, XL 883R 7 29 475
REMOVAL 475
INSTALLATION 475
SPEEDOMETER AND TACHOMETER: XL 1200R 7 30 476
TRIP ODOMETER RESET SWITCH REPLACEMENT 476
SPEEDOMETER REMOVAL 477
TACHOMETER REMOVAL 477
SPEEDOMETER INSTALLATION 478
TACHOMETER INSTALLATION 478
SPEEDOMETER: XL 883C, XL 1200C 7 31 479
REMOVAL 479
INSTALLATION 480
TURN SIGNAL/SECURITY MODULE (TSM/TSSM) 7 32 481
GENERAL 481
TESTING 481
REMOVAL 481
INSTALLATION 482
OIL PRESSURE SWITCH 7 33 483
GENERAL 483
REMOVAL 483
INSTALLATION 483
CRANK POSITION SENSOR (CKP) 7 34 484
GENERAL 484
REMOVAL 484
INSTALLATION 484
VEHICLE SPEED SENSOR (VSS) 7 35 485
GENERAL 485
REMOVAL 485
INSTALLATION 485
NEUTRAL INDICATOR SWITCH 7 36 486
GENERAL 486
TEST 486
REPLACEMENT 487
Optional Security Siren 7 37 489
GENERAL 489
REMOVAL 489
DISASSEMBLY 489
Battery Replacement 490
ASSEMBLY 491
INSTALLATION 491
BANK ANGLE SENSOR (BAS) 7 38 492
GENERAL 492
OPERATION 492
TESTING 492
REPLACEMENT 492
Appendix 494
smbk_tc pdf 494
sm_apptc pdf 496
496
sm_appa pdf 514
sm_appa pdf 514
514
sm_appb1 pdf 532
532
REMOVING SOCKET/PIN TERMINALS 532
INSTALLING SOCKET/PIN TERMINALS 534
CRIMPING INSTRUCTIONS 536
DEUTSCH ELECTRICAL CONNECTORS B 2 537
GENERAL 537
REMOVING/DISASSEMBLING 537
REMOVING/INSTALLING SOCKETS 537
REMOVING/INSTALLING PINS 539
ASSEMBLING/INSTALLING 539
CRIMPING INSTRUCTIONS 539
MINI-DEUTSCH CONNECTORS B 3 542
GENERAL 542
For Size 20, 16 and 12 Contacts Wire Range 26-12 AWG 542
CRIMPING INSTRUCTIONS 542
PACKARD ELECTRICAL CONNECTORS B 4 544
GENERAL 544
REMOVING PULL-TO-SEAT TERMINALS/EXTERNAL LATCH TYPE 544
INSTALLING PULL-TO-SEAT TERMINALS/EXTERNAL LATCH TYPE 545
SEALED BUTT SPLICE CONNECTORS B 5 546
INSTALlation 546
CONNECTOR LOCATIONS B 6 547
INDEX TO WIRING DIAGRAMS B 7 548
sm_appb2 pdf 568
2006 ALL SPORTSTER DOM and INT MODELS, LIGHTS, PAGE 2 OF 2 580
2006 ALL SPORTSTER DOM and INT MODELS, MAIN HARNESS, PAGE 2 OF 2 570
STARTING 574
2006 ALL SPORTSTER DOM and INT MODELS, STARTING AND CHARGING, PAGE 1 OF 1 574
2006 ALL SPORTSTER DOM and INT MODELS, HORN AND INSTRUMENTS, PAGE 1 OF 1 576
2006 ALL SPORTSTER DOM and INT MODELS, MAIN HARNESS, PAGE 1 OF 2 568
2006 ALL SPORTSTER DOM and INT MODELS, SECURITY, PAGE 1 OF 2 582
2006 ALL SPORTSTER DOM and INT MODELS, SECURITY, PAGE 2 OF 2 584
2006 ALL SPORTSTER DOM and INT MODELS, IGNITION CIRCUIT, PAGE 1 OF 1 572
2006 ALL SPORTSTER DOM and INT MODELS, LIGHTS, PAGE 1 OF 2 578
sm_appc pdf 586
586
FLUID CONVERSIONS C 2 587
UNITED STATES SYSTEM 587
METRIC SYSTEM 587
BRITISH IMPERIAL SYSTEM 587
sm_appd pdf 588
APPENDIX D: COMPENSATING SPROCKET D 1 588
GENERAL 588
REMOVAL/DISASSEMBLY 588
CLEANING, INSPECTION AND REPAIR 589
ASSEMBLY/INSTALLATION 589
sm_appe pdf 590
590
sm_appb1 pdf 592
592
REMOVING SOCKET/PIN TERMINALS 592
INSTALLING SOCKET/PIN TERMINALS 594
CRIMPING INSTRUCTIONS 596
DEUTSCH ELECTRICAL CONNECTORS B 2 597
GENERAL 597
REMOVING/DISASSEMBLING 597
REMOVING/INSTALLING SOCKETS 597
REMOVING/INSTALLING PINS 599
ASSEMBLING/INSTALLING 599
CRIMPING INSTRUCTIONS 599
MINI-DEUTSCH CONNECTORS B 3 602
GENERAL 602
For Size 20, 16 and 12 Contacts Wire Range 26-12 AWG 602
CRIMPING INSTRUCTIONS 602
PACKARD ELECTRICAL CONNECTORS B 4 604
GENERAL 604
REMOVING PULL-TO-SEAT TERMINALS/EXTERNAL LATCH TYPE 604
INSTALLING PULL-TO-SEAT TERMINALS/EXTERNAL LATCH TYPE 605
SEALED BUTT SPLICE CONNECTORS B 5 606
INSTALlation 606
CONNECTOR LOCATIONS B 6 607
INDEX TO WIRING DIAGRAMS B 7 608
sm_appb2 pdf 628
2006 ALL SPORTSTER DOM and INT MODELS, LIGHTS, PAGE 2 OF 2 640
2006 ALL SPORTSTER DOM and INT MODELS, MAIN HARNESS, PAGE 2 OF 2 630
STARTING 634
2006 ALL SPORTSTER DOM and INT MODELS, STARTING AND CHARGING, PAGE 1 OF 1 634
2006 ALL SPORTSTER DOM and INT MODELS, HORN AND INSTRUMENTS, PAGE 1 OF 1 636
2006 ALL SPORTSTER DOM and INT MODELS, MAIN HARNESS, PAGE 1 OF 2 628
2006 ALL SPORTSTER DOM and INT MODELS, SECURITY, PAGE 1 OF 2 642
2006 ALL SPORTSTER DOM and INT MODELS, SECURITY, PAGE 2 OF 2 644
2006 ALL SPORTSTER DOM and INT MODELS, IGNITION CIRCUIT, PAGE 1 OF 1 632
2006 ALL SPORTSTER DOM and INT MODELS, LIGHTS, PAGE 1 OF 2 638
sm_appc pdf 646
646
FLUID CONVERSIONS C 2 647
UNITED STATES SYSTEM 647
METRIC SYSTEM 647
BRITISH IMPERIAL SYSTEM 647
sm_appd pdf 648
APPENDIX D: COMPENSATING SPROCKET D 1 648
GENERAL 648
REMOVAL/DISASSEMBLY 648
CLEANING, INSPECTION AND REPAIR 649
ASSEMBLY/INSTALLATION 649
sm_appe pdf 650
650
EDM 1-Starting & Charging 652
xe01_tc pdf 652
xe01a pdf 654
STARTER TROUBLESHOOTING 1 1 654
STARTING SYSTEM DIAGNOSIS 1 2 656
DIAGNOSTICS 656
Diagnostic Notes 656
Starter Testing 1 657
Starter Testing 2: Solenoid Clicks 658
Starter Testing 3: Relay Clicks 658
Starter Testing 4: Nothing Clicks 659
Starter Testing 5: Starter Spins But Does Not Engage 660
Starter Testing 6: Starter Stalls or Spins Too Slowly 660
STARTER ACTIVATION CIRCUITS 1 3 661
DIAGNOSTICS/TROUBLESHOOTING 1 4 662
GENERAL 662
VOLTAGE DROPS 662
TESTING STARTER ON MOTORCYCLE 1 5 664
STARTER RELAY TEST 664
STARTER CURRENT DRAW TEST 664
TESTING STARTER ON BENCH 1 6 665
FREE RUNNING CURRENT DRAW TEST 665
STARTER SOLENOID 665
SOLENOID PULL-IN TEST 666
SOLENOID HOLD-IN TEST 666
SOLENOID RETURN TEST 666
CHARGING SYSTEM 1 7 667
GENERAL 667
Alternator 667
Voltage Regulator 667
TROUBLESHOOTING 667
Battery 667
Wiring 667
Voltage Regulator Inspection 667
Charging System Test 1 7 (Part 1 of 2) 669
Charging System Test 1 7 (Part 2 of 2) 670
TESTING 671
Milliampere Draw Test 671
Total Current Draw Test 671
Current and Voltage Output Test 672
Stator Check 673
AC Output Check 674
IGNITION COIL 1 8 675
TROUBLESHOOTING 675
Primary Circuit Test 675
Secondary Circuit Test 675
Test Results 675
Ignition Coil Substitution 675
BATTERY TESTING 1 9 676
GENERAL 676
VOLTMETER TEST 676
CONDUCTANCE TEST 676
LOAD TEST 677
EDM 2-Instruments 678
xe02_tc pdf 678
xe02a pdf 680
CHECKING FOR DIAGNOSTIC TROUBLE CODES 2 1 680
CHECK ENGINE LAMP 680
SECURITY LAMP 681
Turn Signal Module (TSM) 681
Turn Signal Security Module (TSSM) 681
CODE TYPES 682
Current 682
Historic 682
RETRIEVING DIAGNOSTIC TROUBLE CODES 682
MULTIPLE DIAGNOSTIC TROUBLE CODES 682
INITIAL DIAGNOSTIC CHECK: SPEEDOMETER 2 2 683
GENERAL 683
Diagnostic Notes 683
Circuit Diagram/Wire Harness Connector Table 683
Job/Time Code Values 683
Reprogramming ICM 683
INITIAL DIAGNOSTICS 684
Diagnostic Tips 684
Diagnostic Notes 684
Other Diagnostic Trouble Codes 684
Initial Diagnostic Check (Part 1 of 3) 686
Initial Diagnostic Check (Part 2 of 3) 687
Initial Diagnostic Check (Part 3 of 3) 688
SPEEDOMETER SELF DIAGNOSTICS 2 3 689
GENERAL 689
DIAGNOSTICS 689
Diagnostic Tips 689
Diagnostic Notes 689
Speedometer Self Diagnostics (flow chart) 690
SPEEDOMETER/TACHOMETER 2 4 691
GENERAL 691
Reset Switch 691
SPEEDOMETER THEORY OF OPERATION 692
TACHOMETER THEORY OF OPERATION 692
DIAGNOSTICS 692
Diagnostic Notes 692
Test 2 4 (Part 1 of 2) 694
TACHOMETER INOPERATIVE 694
Test 2 4 (Part 2 of 2) 695
BREAKOUT BOX: SPEEDOMETER/TACHOMETER 2 5 696
GENERAL 696
SPEEDOMETER 696
Installation 696
Removal 696
TACHOMETER 696
Installation 696
Removal 696
INDICATOR LAMPS 2 6 697
GENERAL 697
Job/Time Code Values 697
Diagnostic Notes 697
DIAGNOSTICS 699
Oil Pressure or Neutral Indicator Will Not Function 699
High Beam or R/L Turn Signal Indicator Will Not Function 699
DTC B1006, B1007 2 7 700
GENERAL 700
Accessory Or Ignition Line Overvoltage 700
Test 2 7 701
DTC B1008 2 8 702
GENERAL 702
Reset Switch Closed 702
Diagnostic Notes 702
Test 2 8 703
DTC U1016, U1255 2 9 704
GENERAL 704
Loss of ICM Serial Data 704
DIAGNOSTICS 704
Diagnostic Notes 704
Test 2 9 706
DTC U1064, U1255 2 10 707
GENERAL 707
Loss of TSM/TSSM Serial Data 707
DIAGNOSTICS 707
Diagnostic Notes 707
Test 2 10 709
DTC U1300, U1301 OR BUS ER 2 11 710
GENERAL 710
Serial Data Low or Serial Data Open/High 710
DIAGNOSTICS 710
Diagnostic Tips 710
Diagnostic Notes 710
Test 2 11 (Part 1 of 2) 712
Test 2 11 (Part 2 of 2) 713
EDM 3-TSM & TSSM 714
xe03_tc pdf 714
xe03a pdf 716
TSM/TSSM OVERVIEW 3 1 716
GENERAL 716
TROUBLESHOOTING 716
TSM/TSSM FEATURES 3 2 718
GENERAL 718
TURN SIGNAL FUNCTIONS 718
BANK ANGLE FUNCTIONS 718
SECURITY ALARM AND IMMOBILIZATION FUNCTIONS 718
TSSM Only Feature 718
TSM/TSSM VEHICLE DELIVERY 3 3 720
GENERAL 720
SIDECAR CONFIGURATION 720
POWER DISRUPTION AND CONFIGURING 720
KEY FOB ASSIGNMENT 721
PERSONAL CODE ENTRY 721
First Time Code Entry: TSSM Only 721
Modifying Existing Codes: TSSM Only 721
TSM/TSSM TURN SIGNAL FUNCTIONS 3 4 725
GENERAL 725
AUTOMATIC CANCELLATION 725
MANUAL CANCELLATION 725
FOUR-WAY FLASHING 725
DIAGNOSTIC MODE 725
TSM/TSSM BANK ANGLE FUNCTION 3 5 726
GENERAL 726
OPERATION 726
SECURITY SYSTEM (TSSM) FUNCTIONS 3 6 727
GENERAL 727
Security System Operation 727
Security System Options 727
Differences By Market Specifications 727
ALARM SENSITIVITY 727
Sensitivity 727
Transport Mode 727
AUTO-ARMING FUNCTION 728
STORAGE MODE 728
ARMING/DISARMING SECURITY SYSTEM (TSSM) 3 7 731
GENERAL 731
SECURITY LAMP 731
USING KEY FOB 731
General 731
Arming the System 731
Disarming the System 731
Troubleshooting 731
USING THE PERSONAL CODE 732
General 732
Disarming the System 732
CHECKING FOR DIAGNOSTIC TROUBLE CODES 3 8 733
TSM 733
TSSM 733
CODE TYPES 735
Current 735
Historic 735
RETRIEVING DIAGNOSTIC TROUBLE CODES 735
MULTIPLE DIAGNOSTIC TROUBLE CODES 735
INITIAL DIAGNOSTIC CHECK: TSM/TSSM 3 9 736
GENERAL 736
Diagnostic Notes 736
Circuit Diagram/Wire Harness Connector Table 736
Job/Time Code Values 736
Reprogramming ICM 736
INITIAL DIAGNOSTICS 736
Diagnostic Tips 736
Diagnostic Notes 736
Other Diagnostic Trouble Codes (DTCs) 736
Initial Diagnostic Check (Part 1 of 3) 739
Initial Diagnostic Check (Part 2 of 3) 740
Initial Diagnostic Check (Part 3 of 3) 741
SPEEDOMETER SELF DIAGNOSTICS 3 10 742
GENERAL 742
DIAGNOSTICS 742
Diagnostic Tips 742
Diagnostic Notes 742
Speedometer Self Diagnostics (chart) 743
BREAKOUT BOX: TSM/TSSM 3 11 744
GENERAL 744
INSTALLATION 744
REMOVAL 744
NO SECURITY LAMP AT KEY ON 3 12 745
GENERAL 745
No TSSM Power (Security Equipped Vehicles Only) 745
Job/Time Code Values 745
DIAGNOSTICS 745
Diagnostic Tips 745
Diagnostic Notes 745
Test 3 12 (Part 1 of 3) 747
Test 3 12 (Part 2 of 3) 748
Test 3 12 (Part 3 of 3) 749
SECURITY LAMP ON CONTINUOUSLY 3 13 750
GENERAL 750
Job/Time Code Values 750
DIAGNOSTICS 750
Diagnostic Notes 750
Test 3 13 752
xe03b pdf 754
KEY FOB SIGNAL TO TSSM WEAK OR FAILS 3 14 754
GENERAL 754
Security Equipped Vehicles Only 754
Job/Time Code Values 754
DIAGNOSTICS 754
Diagnostic Tips 754
Diagnostic Notes 754
Test 3 14 756
TURN SIGNAL ERRORS: DTC B1121, B1122, B1141 3 15 757
GENERAL 757
Job/Time Code Values 757
DIAGNOSTICS 757
Diagnostic Tips 757
Diagnostic Notes: All Turn Signal Flow Charts 760
Turn Signal Error 1A (Part 1 of 2) 762
Turn Signal Error 1A (Part 2 of 2) 763
Turn Signal Error 2A 764
Turn Signal Error 2B 765
Turn Signal Error 2C 766
Turn Signal Error 2D 767
Turn Signal Error 3A 768
DTC B0563 3 16 769
GENERAL 769
Battery Voltage High 769
DIAGNOSTICS 769
Diagnostic Tips 769
Diagnostic Notes 769
DTC B1131, B1132 3 17 770
GENERAL 770
Alarm Output Low (DTC B1131) or Alarm Output High (DTC B1132) 770
DIAGNOSTICS 770
Diagnostic Tips 770
Diagnostic Notes 770
Test 3 17 772
DTC B1134 3 18 773
GENERAL 773
Starter Output High 773
DIAGNOSTICS 773
Diagnostic Notes 773
Test 3 18 775
DTC B1135 3 19 776
GENERAL 776
Accelerometer Fault 776
DTC U1016, U1255 3 20 777
GENERAL 777
Loss of ICM Serial Data 777
DIAGNOSTICS 777
Diagnostic Notes 777
Test 3 20 779
DTC U1097, U1255 3 21 780
GENERAL 780
Loss of Speedometer Serial Data 780
DIAGNOSTICS 780
Diagnostic Notes 780
Test 3 21 782
DTC U1300, U1301 OR BUS ER 3 22 783
GENERAL 783
DIAGNOSTICS 783
Diagnostic Tips 783
Diagnostic Notes 783
PASSWORD LEARN 3 23 784
GENERAL 784
PASSWORD LEARNING 784
TSSM MAINTENANCE 3 24 786
GENERAL 786
KEY FOB 786
Schedule 786
Battery Replacement 786
SECURITY SIREN (IF INSTALLED) 787
Schedule 787
Battery Replacement 787
EDM 4-Engine Management 788
xe04_tc pdf 788
xe04a pdf 790
SPECIFICATIONS 4 1 790
DIAGNOSTIC INTRODUCTION 4 2 791
SYSTEM PROBLEMS 791
No Start 791
Poor Performance 791
Check Engine Lamp 791
RESOLVING PROBLEMS 791
CHECKING FOR DIAGNOSTIC TROUBLE CODES 4 3 792
CHECK ENGINE LAMP 792
SECURITY LAMP 793
CODE TYPES 793
Current 793
Historic 793
RETRIEVING DIAGNOSTIC TROUBLE CODES 794
MULTIPLE DIAGNOSTIC TROUBLE CODES 794
INITIAL DIAGNOSTIC CHECK: ICM 4 4 795
GENERAL 795
Diagnostic Notes 795
Circuit Diagram/Wire Harness Connector Table 795
Reprogramming ICM 795
INITIAL DIAGNOSTICS 795
General Information 795
Diagnostic Tips 795
Diagnostic Notes 795
Other DTCs 795
Initial Diagnostic Check (Part 1 of 3) 799
Initial Diagnostic Check (Part 2 of 3) 800
Initial Diagnostic Check (Part 3 of 3) 801
SPEEDOMETER SELF DIAGNOSTICS 4 5 802
GENERAL 802
DIAGNOSTICS 802
Diagnostic Tips 802
Diagnostic Notes 802
Speedometer Self Diagnostics (flow chart) 803
BREAKOUT BOX: ICM 4 6 804
GENERAL 804
INSTALLATION 804
REMOVAL 804
WIGGLE TEST 4 7 805
GENERAL 805
PROCEDURE 805
Using DVOM (Part No HD-39978) 805
INTAKE LEAK TEST 4 8 806
GENERAL 806
LEAK TESTER 806
Parts List 806
Tester Assembly 806
Tester Adjustment 806
PROCEDURE 807
ENGINE CRANKS BUT WILL NOT START 4 9 808
GENERAL 808
DIAGNOSTICS 808
Diagnostic Notes 808
Test 4 9 (Part 1 of 3) 810
Test 4 9 (Part 2 of 3) 811
Test 4 9 (Part 3 of 3) 812
STARTS THEN STALLS 4 10 813
GENERAL 813
Serial Data Low or Serial Data Open/High 813
DIAGNOSTICS 813
Diagnostic Tips 813
Diagnostic Notes 813
Test 4 10 (Part 1 of 2) 815
Test 4 10 (Part 2 of 2) 816
NO SPARK/NO ICM POWER 4 11 817
GENERAL 817
DIAGNOSTICS 817
Diagnostic Notes 817
Test 4 11 819
MISFIRE 4 12 820
GENERAL 820
Misfire at Idle or Under Load 820
DIAGNOSTICS 820
Diagnostic Notes 820
Test 4 12 822
xe04b pdf 824
DTC P0106, P0107, P0108 4 13 824
GENERAL 824
MAP Sensor 824
DIAGNOSTICS 824
Diagnostic Tips 824
Diagnostic Notes 824
Test 4 13 (Part 1 of 2) 826
Test 4 13 (Part 2 of 2) 827
DTC P0371, P0372, P0374 4 14 828
GENERAL 828
Crank Position Sensor 828
DIAGNOSTICS 828
Diagnostic Notes 828
Test 4 14 (Part 1 of 2) 830
Test 4 14 (Part 2 of 2) 831
DTC P0501, P0502 4 15 832
GENERAL 832
Vehicle Speed Sensor 832
DIAGNOSTICS 832
Diagnostic Notes 832
Test 4 15 (Part 1 of 2) 834
Test 4 15 (Part 2 of 2) 835
DTC P0562, P0563 4 16 836
GENERAL 836
Battery Voltage 836
DIAGNOSTICS 836
Diagnostic Notes 836
Test 4 16 (Part 1 of 2) 838
Test 4 16 (Part 2 of 2) 839
DTC P0602, P0603, P0604, P0605, P0607 4 17 840
GENERAL 840
ICM Failure 840
DIAGNOSTICS 840
DTC P0607 Test 840
DTC P0602, P0603, P0604, P0605 Test 840
DTC P1009, P1010 4 18 841
GENERAL 841
Password Problem 841
DIAGNOSTICS 841
Diagnostic Notes 841
Test 4 18 843
DTC P1351, P1352, P1354, P1355 4 19 844
GENERAL 844
Ignition Coil 844
DIAGNOSTICS 844
Diagnostic Notes 844
Test 4 19 (Part 1 of 2) 846
Test 4 19 (Part 2 of 2) 847
DTC U1064 4 20 848
GENERAL 848
Loss of TSM/TSSM Serial Data 848
DIAGNOSTICS 848
Diagnostic Notes 848
Test 4 20 850
DTC U1097 4 21 851
GENERAL 851
Loss of Speedometer Serial Data 851
DIAGNOSTICS 851
Diagnostic Notes 851
Test 4 21 853
EDM 5-Wiring 854
xe05_tc pdf 854
xe05a pdf 856
CONNECTOR LOCATIONS 5 1 856
AMP MULTILOCK ELECTRICAL CONNECTORS 5 2 857
REMOVING SOCKET/PIN TERMINALS 857
INSTALLING SOCKET/PIN TERMINALS 857
CRIMPING INSTRUCTIONS 860
DEUTSCH ELECTRICAL CONNECTORS 5 3 861
GENERAL 861
REMOVING/DISASSEMBLING 861
REMOVING/INSTALLING SOCKETS 861
REMOVING/INSTALLING PINS 862
ASSEMBLING/INSTALLING 863
CRIMPING INSTRUCTIONS 864
MINI-DEUTSCH ELECTRICAL CONNECTORS 5 4 866
GENERAL 866
For Size 20, 16 and 12 Contacts Wire Range 26-12 AWG 866
CRIMPING INSTRUCTIONS 866
SEALED BUTT SPLICE CONNECTORS 5 5 868
INSTALLATION 868
PACKARD ELECTRICAL CONNECTORS 5 6 869
GENERAL 869
PULL-TO-SEAT TERMINALS 870
Removing External Latch Type 870
Installing External Latch Type 870
PUSH-TO-SEAT TERMINALS 870
Removing Push-to-Seat Terminals 870
Installing Push-to-Seat Terminals 871
CRIMPING INSTRUCTIONS 871
MICRO 64 TERMINALS 873
General 873
Removal 873
Installation 873
Crimping Instructions 874
INDEX TO WIRING DIAGRAMS 5 7 875
EDM Appendix 894
xebk_tc pdf 894
xe_appa pdf 896
896
maintoc 898
2006 XLH MODELS 898
SERVICE MANUAL 898
Part Number 99484-06 898
ELECTRICAL DIAGNOSTICS 898
Part Number 99495-06 898
sm_appa 900
sm_appa pdf 900
900
sm_appb1 pdf 918
918
REMOVING SOCKET/PIN TERMINALS 918
INSTALLING SOCKET/PIN TERMINALS 920
CRIMPING INSTRUCTIONS 922
DEUTSCH ELECTRICAL CONNECTORS B 2 923
GENERAL 923
REMOVING/DISASSEMBLING 923
REMOVING/INSTALLING SOCKETS 923
REMOVING/INSTALLING PINS 925
ASSEMBLING/INSTALLING 925
CRIMPING INSTRUCTIONS 925
MINI-DEUTSCH CONNECTORS B 3 928
GENERAL 928
For Size 20, 16 and 12 Contacts Wire Range 26-12 AWG 928
CRIMPING INSTRUCTIONS 928
PACKARD ELECTRICAL CONNECTORS B 4 930
GENERAL 930
REMOVING PULL-TO-SEAT TERMINALS/EXTERNAL LATCH TYPE 930
INSTALLING PULL-TO-SEAT TERMINALS/EXTERNAL LATCH TYPE 931
SEALED BUTT SPLICE CONNECTORS B 5 932
INSTALlation 932
CONNECTOR LOCATIONS B 6 933
INDEX TO WIRING DIAGRAMS B 7 934
sm_appb2 pdf 954
2006 ALL SPORTSTER DOM and INT MODELS, LIGHTS, PAGE 2 OF 2 966
2006 ALL SPORTSTER DOM and INT MODELS, MAIN HARNESS, PAGE 2 OF 2 956
STARTING 960
2006 ALL SPORTSTER DOM and INT MODELS, STARTING AND CHARGING, PAGE 1 OF 1 960
2006 ALL SPORTSTER DOM and INT MODELS, HORN AND INSTRUMENTS, PAGE 1 OF 1 962
2006 ALL SPORTSTER DOM and INT MODELS, MAIN HARNESS, PAGE 1 OF 2 954
2006 ALL SPORTSTER DOM and INT MODELS, SECURITY, PAGE 1 OF 2 968
2006 ALL SPORTSTER DOM and INT MODELS, SECURITY, PAGE 2 OF 2 970
2006 ALL SPORTSTER DOM and INT MODELS, IGNITION CIRCUIT, PAGE 1 OF 1 958
2006 ALL SPORTSTER DOM and INT MODELS, LIGHTS, PAGE 1 OF 2 964
sm_appc pdf 972
972
FLUID CONVERSIONS C 2 973
UNITED STATES SYSTEM 973
METRIC SYSTEM 973
BRITISH IMPERIAL SYSTEM 973
sm_appd pdf 974
APPENDIX D: COMPENSATING SPROCKET D 1 974
GENERAL 974
REMOVAL/DISASSEMBLY 974
CLEANING, INSPECTION AND REPAIR 975
ASSEMBLY/INSTALLATION 975
sm_appe pdf 976
976
sm_appb1 978
APPENDIX B–WIRING AMP MULTILOCK ELECTRICAL CONNECTORS B 1 978
REMOVING SOCKET/PIN TERMINALS 978
INSTALLING SOCKET/PIN TERMINALS 980
CRIMPING INSTRUCTIONS 982
DEUTSCH ELECTRICAL CONNECTORS B 2 983
GENERAL 983
REMOVING/DISASSEMBLING 983
REMOVING/INSTALLING SOCKETS 983
REMOVING/INSTALLING PINS 985
ASSEMBLING/INSTALLING 985
CRIMPING INSTRUCTIONS 985
MINI-DEUTSCH CONNECTORS B 3 988
GENERAL 988
For Size 20, 16 and 12 Contacts Wire Range 26-12 AWG 988
CRIMPING INSTRUCTIONS 988
PACKARD ELECTRICAL CONNECTORS B 4 990
GENERAL 990
REMOVING PULL-TO-SEAT TERMINALS/EXTERNAL LATCH TYPE 990
INSTALLING PULL-TO-SEAT TERMINALS/EXTERNAL LATCH TYPE 991
SEALED BUTT SPLICE CONNECTORS B 5 992
INSTALlation 992
CONNECTOR LOCATIONS B 6 993
INDEX TO WIRING DIAGRAMS B 7 994
sm_appb2 1014
2006 ALL SPORTSTER DOM and INT MODELS, LIGHTS, PAGE 2 OF 2 1026
2006 ALL SPORTSTER DOM and INT MODELS, MAIN HARNESS, PAGE 2 OF 2 1016
STARTING 1020
2006 ALL SPORTSTER DOM and INT MODELS, STARTING AND CHARGING, PAGE 1 OF 1 1020
2006 ALL SPORTSTER DOM and INT MODELS, HORN AND INSTRUMENTS, PAGE 1 OF 1 1022
2006 ALL SPORTSTER DOM and INT MODELS, MAIN HARNESS, PAGE 1 OF 2 1014
2006 ALL SPORTSTER DOM and INT MODELS, SECURITY, PAGE 1 OF 2 1028
2006 ALL SPORTSTER DOM and INT MODELS, SECURITY, PAGE 2 OF 2 1030
2006 ALL SPORTSTER DOM and INT MODELS, IGNITION CIRCUIT, PAGE 1 OF 1 1018
2006 ALL SPORTSTER DOM and INT MODELS, LIGHTS, PAGE 1 OF 2 1024
sm_appc 1032
APPENDIX C–METRIC CONVERSIONS C 1 1032
FLUID CONVERSIONS C 2 1033
UNITED STATES SYSTEM 1033
METRIC SYSTEM 1033
BRITISH IMPERIAL SYSTEM 1033
sm_appd 1034
APPENDIX D: COMPENSATING SPROCKET D 1 1034
GENERAL 1034
REMOVAL/DISASSEMBLY 1034
CLEANING, INSPECTION AND REPAIR 1035
ASSEMBLY/INSTALLATION 1035
sm_appe 1036
APPENDIX E–GLOSSARY E 1 1036
sm_apptc 1038
APPENDIX A–TOOLS A 1 1038
sm01_tc 1056
sm01a 1058
GENERAL 1 1 1058
SERVICING A NEW MOTORCYCLE 1058
SHOP PRACTICES 1058
Repair Notes 1058
Safety 1058
Removing Parts 1058
Cleaning 1058
Disassembly and Assembly 1059
Magnetic Parts Trays 1059
REPAIR AND REPLACEMENT PROCEDURES 1059
Hardware and Threaded Parts 1059
Wiring, Hoses and Lines 1059
Instruments and Gauges 1059
Bearings 1059
Bushings 1059
Gaskets 1059
Lip Type Seals 1059
O-Rings (Preformed Packings) 1060
Gears 1060
Shafts 1060
Part Replacement 1060
CLEANING 1060
Part Protection 1060
Cleaning Process 1060
Rust or Corrosion Removal 1060
Bearings 1060
TOOL SAFETY 1060
Air Tools 1060
Wrenches 1060
Pliers/Cutters/Prybars 1061
Hammers 1061
Punches/Chisels 1061
Screwdrivers 1061
Ratchets and Handles 1061
Sockets 1061
Storage Units 1061
FUEL AND OIL 1 2 1062
FUEL 1062
GASOLINE BLENDS 1062
ENGINE OIL 1062
WINTER LUBRICATION 1062
MAINTENANCE SCHEDULE 1 3 1063
GENERAL 1063
CRITICAL FASTENERS 1 4 1067
INSPECTION 1067
ENGINE OIL AND FILTER 1 5 1068
CHECKING AND ADDING OIL 1068
Removing and Replacing Oil Filler Cap 1068
Checking Oil With Cold Engine 1068
Checking Oil With Warm Engine 1068
CHANGING OIL AND FILTER 1069
General 1069
Draining Oil Tank 1069
Removing Oil Filter 1070
Installing New Oil Filter 1070
Refilling Oil Tank 1070
LEFT SIDE COVER 1 6 1071
GENERAL 1071
OPENING LEFT SIDE COVER 1072
CLOSING LEFT SIDE COVER 1072
REMOVING LEFT SIDE COVER 1072
INSTALLING LEFT SIDE COVER 1072
BATTERY MAINTENANCE 1 7 1073
GENERAL 1073
BATTERY DISCONNECTION AND REMOVAL 1074
BATTERY INSPECTION 1075
BATTERY STORAGE 1075
BATTERY INSTALLATION AND CONNECTION 1076
BRAKES 1 8 1077
GENERAL 1077
INSPECTION 1077
TROUBLESHOOTING 1077
BLEEDING HYDRAULIC BRAKE SYSTEM 1 9 1078
GENERAL 1078
BLEEDING FRONT BRAKE 1078
BLEEDING REAR BRAKE 1080
BRAKE PADS AND DISCS 1 10 1081
INSPECTION 1081
Brake Pads 1081
Brake Disc Thickness, Lateral Runout and Warpage 1081
BRAKE PAD REPLACEMENT– FRONT 1082
BRAKE PAD REPLACEMENT–REAR 1085
TIRES AND WHEELS 1 11 1088
TIRES 1088
TIRE WEAR INDICATORS 1088
WHEEL BEARINGS 1089
WHEEL SPOKES 1089
PRIMARY CHAIN 1 12 1090
INSPECTION 1090
ADJUSTMENT 1091
CLUTCH 1 13 1092
ADJUSTMENT 1092
TRANSMISSION LUBRICANT 1 14 1094
GENERAL 1094
DRAINING LUBRICANT 1094
REFILLING LUBRICANT 1094
REAR BELT DEFLECTION 1 15 1096
INSPECTION 1096
BELT DEFLECTION ADJUSTMENT 1098
WHEEL ALIGNMENT 1099
Checking Wheel Alignment 1099
Adjusting Wheel Alignment 1099
REAR BELT AND SPROCKETS 1 16 1100
GENERAL 1100
CLEANING 1100
INSPECTION 1100
Sprockets 1100
Rear Belt 1100
SHOCK ABSORBER ADJUSTMENT 1 17 1102
GENERAL 1102
PROCEDURE 1102
STEERING HEAD BEARINGS 1 18 1103
GENERAL 1103
ADJUSTMENT 1103
LUBRICATION 1103
REAR FORK BEARINGS 1 19 1104
GENERAL 1104
PROCEDURE 1104
sm01b 1106
FRONT FORK OIL 1 20 1106
GENERAL 1106
CHANGING FORK OIL 1106
Filling Fork Oil: Forks Assembled, in Frame 1107
Filling Fork Oil: Forks Disassembled, out of Frame 1107
SPARK PLUGS 1 21 1108
GENERAL 1108
ADJUSTMENT 1108
CLEANING AND INSPECTION 1108
Inspection 1108
Spark Plug Condition 1108
Cleaning 1108
INSTALLATION 1108
CABLE AND CHASSIS LUBRICATION 1 22 1109
GENERAL 1109
CABLES AND HAND LEVERS 1109
FOOT SHIFT LEVER AND REAR BRAKE PEDAL 1109
JIFFY STAND 1109
STEERING HEAD BEARINGS 1109
AIR FILTER ELEMENT 1 23 1110
GENERAL 1110
REMOVAL 1110
CLEANING, INSPECTION AND REPAIR 1111
INSTALLATION 1111
THROTTLE CABLES AND ENRICHENER 1 24 1112
CABLE INSPECTION, LUBRICATION AND ADJUSTMENT 1112
Inspection and Lubrication 1112
Adjustment 1112
ENRICHENER ADJUSTMENT 1113
IDLE SPEED AND IGNITION TIMING 1 25 1114
IDLE SPEED ADJUSTMENT 1114
IGNITION TIMING 1114
FUEL SUPPLY VALVE FILTER 1 26 1115
INSPECTION 1115
FUEL SYSTEM LINES AND FITTINGS 1116
ENGINE MOUNTS AND STABILIZER LINKS 1 27 1117
INSPECTION 1117
HEADLAMP ALIGNMENT 1 28 1118
INSPECTION 1118
ADJUSTMENT 1119
XL 883, XL 883L, XL 883R, XL 1200R 1119
XL 883C, XL 1200C 1119
FLUID/LUBRICANT REQUIREMENTS 1 29 1120
BRAKE FLUID 1120
BRAKE COMPONENT GREASE 1120
FRONT FORK OIL 1120
ENGINE OIL 1120
PRIMARY DRIVE/TRANSMISSION LUBRICANT 1120
STORAGE 1 30 1121
GENERAL 1121
REMOVAL FROM STORAGE 1122
TROUBLESHOOTING 1 31 1123
GENERAL 1123
ENGINE 1123
Starting Motor Does Not Operate or Does Not Turn Engine Over 1123
Engine Turns Over But Does Not Start 1123
Starts Hard 1123
Starts But Runs Irregularly or Misses 1124
Spark Plug Fouls Repeatedly 1124
Pre-Ignition or Detonation (Knocks or Pings) 1124
Overheating 1124
Valve Train Noise 1124
Excessive Vibration 1124
ENGINE LUBRICATION SYSTEM 1125
Oil Does Not Return To Oil Tank 1125
Engine Uses Too Much Oil or Smokes Excessively 1125
Engine Leaks Oil From Cases, Push Rods, Hoses, Etc 1125
FUEL 1125
Carburetor Floods 1125
ELECTRICAL SYSTEM 1125
Alternator Does Not Charge 1125
Alternator Charge Rate Is Below Normal 1125
Speedometer Operates Erratically 1125
TRANSMISSION 1125
Shifts Hard 1125
Jumps Out of Gear 1125
CLUTCH 1126
Slips 1126
Drags or Does Not Release 1126
Chatters 1126
CHASSIS 1126
Irregular/Inadequate Brake Action 1126
Handling Irregularities 1126
sm02_tc 1128
sm02a 1130
SPECIFICATIONS 2 1 1130
TIRES 1131
TORQUE VALUES 2 2 1132
VEHICLE IDENTIFICATION NUMBER (VIN) 2 3 1135
GENERAL 1135
WHEELS 2 4 1137
GENERAL 1137
TROUBLESHOOTING 1138
FRONT WHEEL 1139
Removal 1139
Disassembly 1140
Cleaning and Inspection 1140
Assembly 1140
Installation 1143
REAR WHEEL 1144
Removal 1144
Disassembly 1145
Cleaning and Inspection 1145
Assembly 1145
Installation 1147
SEALED WHEEL BEARINGS 1148
Inspection 1148
Removal 1149
Installation 1150
WHEEL LACING: 16 INCH RIM 2 5 1151
GENERAL 1151
PROCEDURE 1152
WHEEL LACING: 19 INCH RIM 2 6 1154
GENERAL 1154
PROCEDURE 1154
WHEEL LACING: 21 INCH RIM 2 7 1158
GENERAL 1158
PROCEDURE 1158
TRUING LACED WHEELS 2 8 1162
PROCEDURE 1162
CHECKING CAST WHEEL RUNOUT 2 9 1165
CHECKING LATERAL AND RADIAL RUNOUT 1165
TIRES 2 10 1166
GENERAL 1166
REMOVAL 1166
CLEANING, INSPECTION AND REPAIR 1167
INSTALLATION 1167
Tube Type Tires 1167
Tubeless Tires 1168
CHECKING TIRE RUNOUT 1168
Lateral Runout 1168
Radial Runout 1169
WHEEL BALANCING 1169
Weights For Laced Wheels 1169
Weights for Cast Wheels 1169
sm02b 1170
FRONT BRAKE MASTER CYLINDER 2 11 1170
GENERAL 1170
REMOVAL 1170
DISASSEMBLY 1173
CLEANING, INSPECTION AND REPAIR 1174
ASSEMBLY 1174
INSTALLATION 1176
REAR BRAKE MASTER CYLINDER 2 12 1178
GENERAL 1178
INSPECTION 1178
REMOVAL 1179
DISASSEMBLY 1181
CLEANING, INSPECTION AND REPAIR 1183
ASSEMBLY 1183
INSTALLATION 1186
REAR BRAKE MASTER CYLINDER RESERVOIR 2 13 1187
GENERAL 1187
REMOVAL 1187
INSTALLATION 1188
FRONT BRAKE CALIPER 2 14 1189
REMOVAL 1189
DISASSEMBLY 1190
CLEANING, INSPECTION AND REPAIR 1192
ASSEMBLY 1192
LUBRICATING FRONT CALIPER BOLT PINS AND BOOTS 1193
INSTALLING BRAKE PADS IN CALIPER 1194
INSTALLATION 1194
REAR BRAKE CALIPER 2 15 1197
REMOVAL 1197
DISASSEMBLY 1199
CLEANING, INSPECTION AND REPAIR 1200
ASSEMBLY 1201
LUBRICATING REAR CALIPER BOLT PINS AND BOOTS 1202
INSTALLATION 1203
BRAKE LINES 2 16 1206
FRONT BRAKE LINE 1206
Removal 1206
Installation 1207
REAR BRAKE LINE 1208
Removal 1208
Installation 1209
FRONT FORK 2 17 1210
GENERAL 1210
REMOVAL 1210
DISASSEMBLY 1210
CLEANING, INSPECTION AND REPAIR 1210
ASSEMBLY 1212
INSTALLATION 1212
FORK STEM AND BRACKET ASSEMBLY 2 18 1213
GENERAL 1213
REMOVAL/DISASSEMBLY 1213
CLEANING, INSPECTION AND REPAIR 1213
ASSEMBLY/INSTALLATION 1213
REAR FORK 2 19 1214
GENERAL 1214
REMOVAL 1214
DISASSEMBLY 1215
CLEANING AND INSPECTION 1215
ASSEMBLY 1215
INSTALLATION 1216
REAR SHOCK ABSORBERS 2 20 1217
GENERAL 1217
REMOVAL 1217
CLEANING AND INSPECTION 1217
INSTALLATION 1217
sm02c 1218
STABILIZER LINKS 2 21 1218
GENERAL 1218
UPPER FRONT STABILIZER LINK 1218
Removal 1218
Installation 1218
LOWER FRONT STABILIZER LINK 1219
Removal 1219
Installation 1219
REAR STABILIZER LINK 1219
Removal 1219
Installation 1219
FRONT ENGINE MOUNT/ISOLATOR 2 22 1220
GENERAL 1220
REMOVAL 1220
INSTALLATION 1221
REAR ENGINE MOUNT/ISOLATOR 2 23 1222
GENERAL 1222
REMOVAL 1222
INSTALLATION 1224
THROTTLE CONTROL 2 24 1225
REMOVAL/DISASSEMBLY 1225
CLEANING, INSPECTION AND REPAIR 1225
ASSEMBLY/INSTALLATION 1225
HANDLEBARS 2 25 1227
REMOVAL 1227
All Models 1227
XL 883, XL 883L, XL 883R, XL 1200R 1227
XL 883C, XL 1200C 1228
INSTALLATION 1228
XL 883, XL 883L, XL 883R, XL 1200R 1228
XL 883C, XL 1200C 1228
All Models 1229
CLUTCH CONTROL 2 26 1230
GENERAL 1230
REMOVAL/DISASSEMBLY 1230
Clutch Cable–Lower 1230
Clutch Lever and Clutch Cable–Upper 1231
Clutch Hand Control 1231
ASSEMBLY/INSTALLATION 1231
Clutch Hand Control 1231
Clutch Lever and Clutch Cable–Upper 1232
Clutch Cable–Lower 1232
Finish 1232
EXHAUST SYSTEM 2 27 1233
REMOVAL 1233
Mufflers and Exhaust Pipes 1233
Muffler Interconnect Bracket 1234
INSTALLATION 1235
Muffler Interconnect Bracket 1235
Exhaust Pipes and Mufflers 1235
FRONT FENDER 2 28 1236
REMOVAL 1236
INSTALLATION 1236
REAR FENDER 2 29 1237
REMOVAL 1237
INSTALLATION 1239
BELT GUARD AND DEBRIS DEFLECTOR 2 30 1241
REMOVAL 1241
Belt Guard 1241
Debris Deflector 1241
INSTALLATION 1241
Belt Guard 1241
Debris Deflector 1241
JIFFY STAND 2 31 1242
GENERAL 1242
REMOVAL 1243
CLEANING AND LUBRICATION 1243
INSTALLATION 1243
SEAT 2 32 1244
GENERAL 1244
REMOVAL 1244
INSTALLATION 1244
RIDER FOOT CONTROLS: XL 883, XL 883L, XL 883R, XL 1200R 2 33 1246
RIGHT FOOTREST AND REAR BRAKE PEDAL ASSEMBLY 1246
Removal 1246
Installation 1246
LEFT FOOTREST AND SHIFT LEVER ASSEMBLY 1246
Removal 1246
Installation 1246
RIDER FOOT CONTROLS: XL 883C, XL 1200C 2 34 1248
RIGHT FOOTREST AND REAR BRAKE PEDAL ASSEMBLY 1248
Removal 1248
Installation 1248
LEFT FOOTREST AND SHIFT LEVER ASSEMBLY 1250
Removal 1250
Installation 1250
ADJUSTING SHIFT PEDAL 1251
PASSENGER FOOTRESTS 2 35 1252
GENERAL 1252
REMOVAL 1252
INSTALLATION 1252
FORK LOCK 2 36 1253
REMOVAL 1253
INSTALLATION 1254
sm03_tc 1256
sm03a 1258
SPECIFICATIONS 3 1 1258
SERVICE WEAR LIMITS 3 2 1261
GENERAL 1261
TORQUE VALUES 3 3 1263
ENGINE 3 4 1265
GENERAL 1265
TROUBLESHOOTING 3 5 1266
DIAGNOSING VALVE TRAIN NOISE 1266
COMPRESSION TEST 1266
Compression Test Procedure 1266
CYLINDER LEAKAGE TEST 1267
Cylinder Leakage Test Procedure 1267
DIAGNOSING SMOKING ENGINE OR HIGH OIL CONSUMPTION 1268
Check Prior To Cylinder Head Removal 1268
Check After Cylinder Head Removal 1268
ADJUSTMENT/TESTING 1268
General 1268
ENGINE LUBRICATION SYSTEM 3 6 1269
GENERAL 1269
OIL PUMP 1269
OIL PRESSURE 3 7 1272
GENERAL 1272
Oil Pressure Indicator Lamp 1272
CHECKING OIL PRESSURE 1272
CRANKCASE BREATHING SYSTEM 3 8 1274
GENERAL 1274
HOW TO USE THIS SECTION 3 9 1275
TYPICAL SYMPTOMS 1275
TOP END REPAIR 1275
BOTTOM END REPAIR 1275
TOP END SERVICE 3 10 1276
ENGINE IN CHASSIS 1276
ENGINE REMOVED FROM CHASSIS 1277
BOTTOM END SERVICE 3 11 1278
ENGINE IN CHASSIS: CAM COMPARTMENT SERVICE 1278
ENGINE REMOVED: FLYWHEEL COMPARTMENT SERVICE OR COMPLETE ENGINE OVERHAUL 1279
REMOVING ENGINE FROM CHASSIS 3 12 1280
GENERAL 1280
PROCEDURE 1280
INSTALLING ENGINE IN CHASSIS 3 13 1284
GENERAL 1284
PROCEDURE 1284
sm03b 1287
TOP END OVERHAUL: DISASSEMBLY 3 14 1287
GENERAL 1287
STRIPPING MOTORCYCLE FOR TOP END REPAIR 1287
CYLINDER HEAD 1288
Disassembling Rocker Covers 1288
Removing Cylinder Head 1289
Disassembling Push Rods and Covers 1291
CYLINDER AND PISTON 1291
CYLINDER HEAD 3 15 1294
GENERAL 1294
REMOVAL 1294
DISASSEMBLY 1294
CLEANING AND INSPECTION 1295
Cylinder Heads 1295
Rocker Arm Assemblies 1296
Valves 1297
Valve Seats 1297
Valve Guides 1297
Valve Springs 1297
Spark Plug Threads 1298
Push Rods 1298
REPLACING ROCKER ARM BUSHINGS 1298
REPLACING VALVE GUIDES 1299
Removal 1299
Installation 1300
REFACING VALVE SEATS 1303
Replacing Valve Seats 1305
ASSEMBLY 1306
INSTALLATION 1307
CYLINDER AND PISTON 3 16 1308
REMOVAL/DISASSEMBLY 1308
CLEANING, INSPECTION, AND REPAIR 1308
Checking Gasket Surface 1308
Measuring Cylinder Bore 1309
Measuring Piston to Cylinder Fit 1310
Boring and Honing Cylinder 1310
Fitting Piston Rings 1311
CONNECTING ROD BUSHINGS 1313
Removing Upper Connecting Rod Bushing 1313
Installing Upper Connecting Rod Bushing 1314
Reaming Upper Connecting Rod Bushing 1315
Honing Upper Connecting Rod Bushing 1316
Repair 1316
ASSEMBLY/INSTALLATION 1316
TOP END OVERHAUL: ASSEMBLY 3 17 1317
GENERAL 1317
PISTON AND CYLINDER 1317
PUSH RODS, COVERS AND RETAINERS 1319
CYLINDER HEAD 1320
Rocker Covers 1322
ASSEMBLING MOTORCYCLE AFTER TOP END REPAIR 1324
BOTTOM END OVERHAUL: DISASSEMBLY 3 18 1325
GENERAL 1325
TAPPETS 1325
OIL PUMP 1325
GEARCASE COVER AND CAM GEARS 1326
CRANKCASE 1327
Removing Piston Oil Jets 1328
Removing Cylinder Base Studs 1328
VALVE TAPPETS 3 19 1329
GENERAL 1329
REMOVAL 1329
CLEANING AND INSPECTION 1329
INSTALLATION 1329
sm03c 1331
GEARCASE COVER AND CAM GEARS 3 20 1331
GENERAL 1331
REMOVAL/DISASSEMBLY 1331
CLEANING, INSPECTION AND REPAIR 1331
Cam and Pinion Gear Identification, Inspection and Selection 1331
Bushing Inspection and Removal 1333
BUSHING INSTALLATION 1333
Cam Gear Bushings in Right Crankcase 1333
Cam Gear Bushings (Except Rear Intake Bushing) in Gearcase Cover 1334
Rear Intake Cam Gear Bushing in Gearcase Cover 1334
Pinion Shaft Bushing in Gearcase Cover 1334
BUSHING REAMING 1335
Cam Gear Bushings in Right Crankcase 1335
Cam Gear Bushings (Except Rear Intake Bushing) in Gearcase Cover 1336
Rear Intake Cam Gear Bushing in Gearcase Cover 1336
Pinion Shaft Bushing in Gearcase Cover 1337
ASSEMBLY/INSTALLATION 1337
OIL PUMP 3 21 1338
GENERAL 1338
REMOVAL 1338
DISASSEMBLY 1339
CLEANING, INSPECTION AND REPAIR 1339
ASSEMBLY 1339
INSTALLATION 1339
OIL FILTER MOUNT 3 22 1340
GENERAL 1340
DISASSEMBLY 1340
CLEANING AND INSPECTION 1340
ASSEMBLY 1340
CRANKCASE 3 23 1341
GENERAL 1341
REMOVAL 1341
DISASSEMBLY 1341
FITTING PINION BEARINGS 1344
Bearing Selection 1345
LAPPING ENGINE MAIN BEARING RACES 1349
Assembling Crankcase Halves 1349
BOTTOM END OVERHAUL: ASSEMBLY 3 24 1350
GENERAL 1350
CRANKCASE 1350
Installing Piston Oil Jets 1350
Installing Pinion Shaft Bearing 1351
Installing Left Main Bearing 1352
Assembling Crankcase Halves 1352
Installing Cylinder Base Studs 1355
CAM GEARS AND GEARCASE COVER 1356
TAPPETS 1359
ASSEMBLING TOP END OF ENGINE 1359
OIL TANK 3 25 1360
OIL HOSE ROUTING 1360
REMOVAL 1361
INSTALLATION 1363
sm04_tc 1365
sm04a 1367
SPECIFICATIONS 4 1 1367
TORQUE VALUES 4 2 1368
TROUBLESHOOTING 4 3 1369
ENRICHENER 4 4 1371
GENERAL 1371
OPERATION 1371
Cool Engine 1371
Warm or Hot Engine 1371
CARBURETOR 4 5 1372
GENERAL 1372
ADJUSTMENT 1372
Float Level 1372
OPERATION CHECK: VACUUM PISTON 1374
Opening Malfunction 1374
Closing Malfunction 1374
REMOVAL 1374
DISASSEMBLY 1376
Vacuum Piston Chamber 1376
Carburetor Body 1376
Accelerator Pump 1376
CLEANING, INSPECTION AND REPAIR 1377
Vacuum Piston Components 1377
Carburetor Body Components 1377
Accelerator Pump 1377
ASSEMBLY 1377
Vacuum Piston Chamber 1377
Carburetor Body 1377
Accelerator Pump 1377
INSTALLATION 1378
Carburetor 1378
Carburetor Fuel Overflow/Drain Hose Routing 1378
AIR CLEANER 4 6 1379
REMOVAL 1379
CLEANING, INSPECTION AND REPAIR 1380
INSTALLATION 1380
FUEL SUPPLY VALVE 4 7 1381
GENERAL 1381
OPERATION 1381
REMOVAL, INSPECTION AND INSTALLATION 1381
TROUBLESHOOTING 1382
Vacuum Test 1382
FUEL TANK 4 8 1383
GENERAL 1383
REMOVAL 1385
CLEANING, INSPECTION AND REPAIR 1385
INSTALLATION 1386
CONSOLE REPLACEMENT 1386
Removal 1386
Installation 1388
EVAPORATIVE EMISSIONS CONTROL–CA MODELS 4 9 1389
GENERAL 1389
REMOVAL 1390
Charcoal Canister 1390
Vapor Valve 1391
INSTALLATION 1391
Vapor Valve 1391
Charcoal Canister 1392
HOSE ROUTING 1393
Carburetor 1393
Canister Hose Routings 1393
INTAKE LEAK TEST 4 10 1394
GENERAL 1394
LEAK TESTER 1394
Parts List 1394
Tester Assembly 1394
Tester Adjustment 1394
PROCEDURE 1395
sm05_tc 1397
sm05a 1399
SPECIFICATIONS 5 1 1399
TORQUE VALUES 5 2 1400
ELECTRIC STARTER SYSTEM 5 3 1401
GENERAL 1401
Wiring Diagram 1401
Starter Relay 1401
OPERATION 1401
STARTER MOTOR 5 4 1404
REMOVAL 1404
DISASSEMBLY, INSPECTION AND REPAIR 1406
ASSEMBLY 1409
INSTALLATION 1410
STARTER SOLENOID 5 5 1411
GENERAL 1411
DISASSEMBLY 1412
ASSEMBLY 1412
FINAL 1412
sm06_tc 1413
sm06a 1415
SPECIFICATIONS 6 1 1415
TORQUE VALUES 6 2 1417
PRIMARY CHAIN ADJUSTER 6 3 1418
GENERAL 1418
REMOVAL 1418
Primary Cover 1418
Primary Chain Adjuster 1420
INSTALLATION 1420
Primary Chain Adjuster 1420
Primary Cover 1420
CLUTCH RELEASE MECHANISM 6 4 1422
REMOVAL/DISASSEMBLY 1422
CLEANING, INSPECTION AND REPAIR 1423
ASSEMBLY/INSTALLATION 1423
PRIMARY DRIVE/CLUTCH 6 5 1424
GENERAL 1424
REMOVAL 1426
DISASSEMBLY 1427
INSPECTION AND REPAIR 1428
ASSEMBLY 1429
INSTALLATION 1430
SECONDARY DRIVE BELT 6 6 1432
REMOVAL 1432
INSTALLATION 1434
TRANSMISSION 6 7 1435
OPERATION 1435
CASE DISASSEMBLY FOR TRANSMISSION REMOVAL 6 8 1436
GENERAL 1436
ENGINE REMOVAL AND DISASSEMBLY 1436
TRANSMISSION REMOVAL AND DISASSEMBLY 6 9 1439
TRANSMISSION REMOVAL FROM LEFT CRANKCASE 1439
MAINSHAFT/COUNTERSHAFT 1441
MAINSHAFT DISASSEMBLY 1443
Cleaning And Inspection 1443
COUNTERSHAFT DISASSEMBLY 1444
Cleaning And Inspection 1444
sm06b 1445
TRANSMISSION ASSEMBLY 6 10 1445
GENERAL 1445
MAINSHAFT ASSEMBLY 1445
COUNTERSHAFT ASSEMBLY 1446
MAIN DRIVE GEAR AND BEARING 6 11 1447
GENERAL 1447
REMOVAL 1448
Main Drive Gear 1448
Main Drive Gear Ball Bearing 1449
DISASSEMBLY 1449
ASSEMBLY 1450
INSTALLATION 1451
Main Drive Gear Ball Bearing 1451
Main Drive Gear 1452
Main Drive Gear Seal 1453
TRANSMISSION RIGHT CASE BEARINGS 6 12 1455
REMOVAL 1455
Countershaft Needle Bearing 1455
Shifter Drum Bushing 1455
INSTALLATION 1455
Countershaft Needle Bearing 1455
Shifter Drum Bushing 1455
TRANSMISSION LEFT CASE BEARINGS 6 13 1456
REMOVAL 1456
Mainshaft and Countershaft Bearings 1456
Shifter Drum Bushing 1456
INSTALLATION 1456
Mainshaft and Countershaft Bearings 1456
Shifter Drum Bushing 1456
TRANSMISSION INSTALLATION 6 14 1457
GENERAL 1457
INSTALLATION 1457
SHIFTER FORKS AND DRUM ASSEMBLY 1458
ASSEMBLING CRANKCASES 1459
SHIFTER SHAFT INSTALLATION 1461
TRANSMISSION SPROCKET 6 15 1462
REMOVAL 1462
INSTALLATION 1463
sm07_tc 1465
sm07a 1467
SPECIFICATIONS 7 1 1467
IGNITION 1467
CHARGING SYSTEM 1467
BATTERY 1467
FUSES 1467
TORQUE VALUES 7 2 1468
BULB REQUIREMENTS 7 3 1469
BULB CHART 1469
BATTERY TRAY 7 4 1470
GENERAL 1470
REMOVAL 1470
INSTALLATION 1471
IGNITION SYSTEM 7 5 1472
GENERAL 1472
TROUBLESHOOTING 1472
MANIFOLD ABSOLUTE PRESSURE SENSOR (MAP) 7 6 1474
REMOVAL 1474
INSTALLATION 1474
IGNITION/LIGHT SWITCH 7 7 1475
GENERAL 1475
REMOVAL 1476
INSTALLATION 1476
IGNITION CONTROL MODULE (ICM) 7 8 1477
GENERAL 1477
REMOVAL 1477
INSTALLATION 1477
SPARK PLUG CABLES 7 9 1478
GENERAL 1478
REMOVAL 1478
INSPECTION 1479
INSTALLATION 1479
IGNITION COIL 7 10 1480
GENERAL 1480
TROUBLESHOOTING 1480
REMOVAL 1480
INSTALLATION 1480
CHARGING SYSTEM 7 11 1481
GENERAL 1481
ALTERNATOR 1481
VOLTAGE REGULATOR 1481
ALTERNATOR 7 12 1482
REMOVAL AND DISASSEMBLY 1482
Rotor 1482
Stator 1482
CLEANING, INSPECTION AND REPAIR 1482
ASSEMBLY AND INSTALLATION 1483
Stator 1483
Rotor 1484
Final Assembly 1484
VOLTAGE REGULATOR 7 13 1485
GENERAL 1485
REMOVAL 1485
INSTALLATION 1486
BATTERY 7 14 1487
GENERAL 1487
VOLTMETER TEST 1487
CONDUCTANCE TEST 1487
LOAD TEST 1488
CHARGING 1489
General 1489
Safety Precautions 1489
Charging Battery 1489
BATTERY CABLES 7 15 1491
REMOVAL 1491
INSTALLATION 1492
sm07b 1495
HEADLAMP 7 16 1495
REPLACEMENT–XL 883, XL 883L, XL 883R, XL 1200R 1495
REPLACEMENT–XL 883C, XL 1200C 1496
INDICATOR LAMPS 7 17 1499
REPLACEMENT–XL 883, XL 883L, XL 883R 1499
REPLACEMENT–XL 1200R 1499
REPLACEMENT–XL 883C, XL 1200C 1500
TAIL LAMP 7 18 1501
BULB REPLACEMENT 1501
BASE REPLACEMENT 1501
TURN SIGNALS 7 19 1503
BULB REPLACEMENT 1503
FRONT HOUSING REPLACEMENT 1503
REAR HOUSING REPLACEMENT 1504
REAR STOP LAMP SWITCH 7 20 1507
GENERAL 1507
REPLACEMENT 1507
HANDLEBAR SWITCHES 7 21 1508
GENERAL 1508
REPAIR PROCEDURES 1508
CONNECTORS 1509
RIGHT HANDLEBAR SWITCH 7 22 1510
REMOVAL 1510
INSTALLATION 1511
DISASSEMBLY 1513
SWITCH REPAIR/REPLACEMENT 1514
Upper Switch Housing Repair 1514
Lower Switch Housing Repair 1515
ASSEMBLY 1516
LEFT HANDLEBAR SWITCH 7 23 1517
REMOVAL 1517
INSTALLATION 1517
DISASSEMBLY 1518
SWITCH REPAIR/REPLACEMENT 1519
Upper Switch Housing Repair 1519
Lower Switch Housing Repair 1520
ASSEMBLY 1520
HORN 7 24 1521
TROUBLESHOOTING 1521
VOLTAGE TEST 1521
REPLACEMENT: ALL MODELS EXCEPT XL 1200C 1521
REPLACEMENT: XL 1200C 1522
MAXI-FUSE 7 25 1523
GENERAL 1523
REMOVING 1523
INSTALLING 1523
SYSTEM FUSES AND STARTER RELAY 7 26 1524
GENERAL 1524
REPLACING 15-AMP FUSES 1524
REPLACING STARTER RELAY 1524
sm07c 1525
MAXI-FUSE HOLDER 7 27 1525
REPLACEMENT 1525
RELAY/FUSE BLOCK 7 28 1526
GENERAL 1526
REMOVAL 1526
INSTALLATION 1527
SPEEDOMETER: XL 883, XL 883L, XL 883R 7 29 1528
REMOVAL 1528
INSTALLATION 1528
SPEEDOMETER AND TACHOMETER: XL 1200R 7 30 1529
TRIP ODOMETER RESET SWITCH REPLACEMENT 1529
SPEEDOMETER REMOVAL 1530
TACHOMETER REMOVAL 1530
SPEEDOMETER INSTALLATION 1531
TACHOMETER INSTALLATION 1531
SPEEDOMETER: XL 883C, XL 1200C 7 31 1532
REMOVAL 1532
INSTALLATION 1533
TURN SIGNAL/SECURITY MODULE (TSM/TSSM) 7 32 1534
GENERAL 1534
TESTING 1534
REMOVAL 1534
INSTALLATION 1535
OIL PRESSURE SWITCH 7 33 1536
GENERAL 1536
REMOVAL 1536
INSTALLATION 1536
CRANK POSITION SENSOR (CKP) 7 34 1537
GENERAL 1537
REMOVAL 1537
INSTALLATION 1537
VEHICLE SPEED SENSOR (VSS) 7 35 1538
GENERAL 1538
REMOVAL 1538
INSTALLATION 1538
NEUTRAL INDICATOR SWITCH 7 36 1539
GENERAL 1539
TEST 1539
REPLACEMENT 1540
Optional Security Siren 7 37 1542
GENERAL 1542
REMOVAL 1542
DISASSEMBLY 1542
Battery Replacement 1543
ASSEMBLY 1544
INSTALLATION 1544
BANK ANGLE SENSOR (BAS) 7 38 1545
GENERAL 1545
OPERATION 1545
TESTING 1545
REPLACEMENT 1545
smbk_tc 1547
xe_appa 1549
APPENDIX A–GLOSSARY A 1 1549
xe01_tc 1551
xe01a 1553
STARTER TROUBLESHOOTING 1 1 1553
STARTING SYSTEM DIAGNOSIS 1 2 1555
DIAGNOSTICS 1555
Diagnostic Notes 1555
Starter Testing 1 1556
Starter Testing 2: Solenoid Clicks 1557
Starter Testing 3: Relay Clicks 1557
Starter Testing 4: Nothing Clicks 1558
Starter Testing 5: Starter Spins But Does Not Engage 1559
Starter Testing 6: Starter Stalls or Spins Too Slowly 1559
STARTER ACTIVATION CIRCUITS 1 3 1560
DIAGNOSTICS/TROUBLESHOOTING 1 4 1561
GENERAL 1561
VOLTAGE DROPS 1561
TESTING STARTER ON MOTORCYCLE 1 5 1563
STARTER RELAY TEST 1563
STARTER CURRENT DRAW TEST 1563
TESTING STARTER ON BENCH 1 6 1564
FREE RUNNING CURRENT DRAW TEST 1564
STARTER SOLENOID 1564
SOLENOID PULL-IN TEST 1565
SOLENOID HOLD-IN TEST 1565
SOLENOID RETURN TEST 1565
CHARGING SYSTEM 1 7 1566
GENERAL 1566
Alternator 1566
Voltage Regulator 1566
TROUBLESHOOTING 1566
Battery 1566
Wiring 1566
Voltage Regulator Inspection 1566
Charging System Test 1 7 (Part 1 of 2) 1568
Charging System Test 1 7 (Part 2 of 2) 1569
TESTING 1570
Milliampere Draw Test 1570
Total Current Draw Test 1570
Current and Voltage Output Test 1571
Stator Check 1572
AC Output Check 1573
IGNITION COIL 1 8 1574
TROUBLESHOOTING 1574
Primary Circuit Test 1574
Secondary Circuit Test 1574
Test Results 1574
Ignition Coil Substitution 1574
BATTERY TESTING 1 9 1575
GENERAL 1575
VOLTMETER TEST 1575
CONDUCTANCE TEST 1575
LOAD TEST 1576
xe02_tc 1577
xe02a 1579
CHECKING FOR DIAGNOSTIC TROUBLE CODES 2 1 1579
CHECK ENGINE LAMP 1579
SECURITY LAMP 1580
Turn Signal Module (TSM) 1580
Turn Signal Security Module (TSSM) 1580
CODE TYPES 1581
Current 1581
Historic 1581
RETRIEVING DIAGNOSTIC TROUBLE CODES 1581
MULTIPLE DIAGNOSTIC TROUBLE CODES 1581
INITIAL DIAGNOSTIC CHECK: SPEEDOMETER 2 2 1582
GENERAL 1582
Diagnostic Notes 1582
Circuit Diagram/Wire Harness Connector Table 1582
Job/Time Code Values 1582
Reprogramming ICM 1582
INITIAL DIAGNOSTICS 1583
Diagnostic Tips 1583
Diagnostic Notes 1583
Other Diagnostic Trouble Codes 1583
Initial Diagnostic Check (Part 1 of 3) 1585
Initial Diagnostic Check (Part 2 of 3) 1586
Initial Diagnostic Check (Part 3 of 3) 1587
SPEEDOMETER SELF DIAGNOSTICS 2 3 1588
GENERAL 1588
DIAGNOSTICS 1588
Diagnostic Tips 1588
Diagnostic Notes 1588
Speedometer Self Diagnostics (flow chart) 1589
SPEEDOMETER/TACHOMETER 2 4 1590
GENERAL 1590
Reset Switch 1590
SPEEDOMETER THEORY OF OPERATION 1591
TACHOMETER THEORY OF OPERATION 1591
DIAGNOSTICS 1591
Diagnostic Notes 1591
Test 2 4 (Part 1 of 2) 1593
TACHOMETER INOPERATIVE 1593
Test 2 4 (Part 2 of 2) 1594
BREAKOUT BOX: SPEEDOMETER/TACHOMETER 2 5 1595
GENERAL 1595
SPEEDOMETER 1595
Installation 1595
Removal 1595
TACHOMETER 1595
Installation 1595
Removal 1595
INDICATOR LAMPS 2 6 1596
GENERAL 1596
Job/Time Code Values 1596
Diagnostic Notes 1596
DIAGNOSTICS 1598
Oil Pressure or Neutral Indicator Will Not Function 1598
High Beam or R/L Turn Signal Indicator Will Not Function 1598
DTC B1006, B1007 2 7 1599
GENERAL 1599
Accessory Or Ignition Line Overvoltage 1599
Test 2 7 1600
DTC B1008 2 8 1601
GENERAL 1601
Reset Switch Closed 1601
Diagnostic Notes 1601
Test 2 8 1602
DTC U1016, U1255 2 9 1603
GENERAL 1603
Loss of ICM Serial Data 1603
DIAGNOSTICS 1603
Diagnostic Notes 1603
Test 2 9 1605
DTC U1064, U1255 2 10 1606
GENERAL 1606
Loss of TSM/TSSM Serial Data 1606
DIAGNOSTICS 1606
Diagnostic Notes 1606
Test 2 10 1608
DTC U1300, U1301 OR BUS ER 2 11 1609
GENERAL 1609
Serial Data Low or Serial Data Open/High 1609
DIAGNOSTICS 1609
Diagnostic Tips 1609
Diagnostic Notes 1609
Test 2 11 (Part 1 of 2) 1611
Test 2 11 (Part 2 of 2) 1612
xe03_tc 1613
xe03a 1615
TSM/TSSM OVERVIEW 3 1 1615
GENERAL 1615
TROUBLESHOOTING 1615
TSM/TSSM FEATURES 3 2 1617
GENERAL 1617
TURN SIGNAL FUNCTIONS 1617
BANK ANGLE FUNCTIONS 1617
SECURITY ALARM AND IMMOBILIZATION FUNCTIONS 1617
TSSM Only Feature 1617
TSM/TSSM VEHICLE DELIVERY 3 3 1619
GENERAL 1619
SIDECAR CONFIGURATION 1619
POWER DISRUPTION AND CONFIGURING 1619
KEY FOB ASSIGNMENT 1620
PERSONAL CODE ENTRY 1620
First Time Code Entry: TSSM Only 1620
Modifying Existing Codes: TSSM Only 1620
TSM/TSSM TURN SIGNAL FUNCTIONS 3 4 1624
GENERAL 1624
AUTOMATIC CANCELLATION 1624
MANUAL CANCELLATION 1624
FOUR-WAY FLASHING 1624
DIAGNOSTIC MODE 1624
TSM/TSSM BANK ANGLE FUNCTION 3 5 1625
GENERAL 1625
OPERATION 1625
SECURITY SYSTEM (TSSM) FUNCTIONS 3 6 1626
GENERAL 1626
Security System Operation 1626
Security System Options 1626
Differences By Market Specifications 1626
ALARM SENSITIVITY 1626
Sensitivity 1626
Transport Mode 1626
AUTO-ARMING FUNCTION 1627
STORAGE MODE 1627
ARMING/DISARMING SECURITY SYSTEM (TSSM) 3 7 1630
GENERAL 1630
SECURITY LAMP 1630
USING KEY FOB 1630
General 1630
Arming the System 1630
Disarming the System 1630
Troubleshooting 1630
USING THE PERSONAL CODE 1631
General 1631
Disarming the System 1631
CHECKING FOR DIAGNOSTIC TROUBLE CODES 3 8 1632
TSM 1632
TSSM 1632
CODE TYPES 1634
Current 1634
Historic 1634
RETRIEVING DIAGNOSTIC TROUBLE CODES 1634
MULTIPLE DIAGNOSTIC TROUBLE CODES 1634
INITIAL DIAGNOSTIC CHECK: TSM/TSSM 3 9 1635
GENERAL 1635
Diagnostic Notes 1635
Circuit Diagram/Wire Harness Connector Table 1635
Job/Time Code Values 1635
Reprogramming ICM 1635
INITIAL DIAGNOSTICS 1635
Diagnostic Tips 1635
Diagnostic Notes 1635
Other Diagnostic Trouble Codes (DTCs) 1635
Initial Diagnostic Check (Part 1 of 3) 1638
Initial Diagnostic Check (Part 2 of 3) 1639
Initial Diagnostic Check (Part 3 of 3) 1640
SPEEDOMETER SELF DIAGNOSTICS 3 10 1641
GENERAL 1641
DIAGNOSTICS 1641
Diagnostic Tips 1641
Diagnostic Notes 1641
Speedometer Self Diagnostics (chart) 1642
BREAKOUT BOX: TSM/TSSM 3 11 1643
GENERAL 1643
INSTALLATION 1643
REMOVAL 1643
NO SECURITY LAMP AT KEY ON 3 12 1644
GENERAL 1644
No TSSM Power (Security Equipped Vehicles Only) 1644
Job/Time Code Values 1644
DIAGNOSTICS 1644
Diagnostic Tips 1644
Diagnostic Notes 1644
Test 3 12 (Part 1 of 3) 1646
Test 3 12 (Part 2 of 3) 1647
Test 3 12 (Part 3 of 3) 1648
SECURITY LAMP ON CONTINUOUSLY 3 13 1649
GENERAL 1649
Job/Time Code Values 1649
DIAGNOSTICS 1649
Diagnostic Notes 1649
Test 3 13 1651
xe03b 1653
KEY FOB SIGNAL TO TSSM WEAK OR FAILS 3 14 1653
GENERAL 1653
Security Equipped Vehicles Only 1653
Job/Time Code Values 1653
DIAGNOSTICS 1653
Diagnostic Tips 1653
Diagnostic Notes 1653
Test 3 14 1655
TURN SIGNAL ERRORS: DTC B1121, B1122, B1141 3 15 1656
GENERAL 1656
Job/Time Code Values 1656
DIAGNOSTICS 1656
Diagnostic Tips 1656
Diagnostic Notes: All Turn Signal Flow Charts 1659
Turn Signal Error 1A (Part 1 of 2) 1661
Turn Signal Error 1A (Part 2 of 2) 1662
Turn Signal Error 2A 1663
Turn Signal Error 2B 1664
Turn Signal Error 2C 1665
Turn Signal Error 2D 1666
Turn Signal Error 3A 1667
DTC B0563 3 16 1668
GENERAL 1668
Battery Voltage High 1668
DIAGNOSTICS 1668
Diagnostic Tips 1668
Diagnostic Notes 1668
DTC B1131, B1132 3 17 1669
GENERAL 1669
Alarm Output Low (DTC B1131) or Alarm Output High (DTC B1132) 1669
DIAGNOSTICS 1669
Diagnostic Tips 1669
Diagnostic Notes 1669
Test 3 17 1671
DTC B1134 3 18 1672
GENERAL 1672
Starter Output High 1672
DIAGNOSTICS 1672
Diagnostic Notes 1672
Test 3 18 1674
DTC B1135 3 19 1675
GENERAL 1675
Accelerometer Fault 1675
DTC U1016, U1255 3 20 1676
GENERAL 1676
Loss of ICM Serial Data 1676
DIAGNOSTICS 1676
Diagnostic Notes 1676
Test 3 20 1678
DTC U1097, U1255 3 21 1679
GENERAL 1679
Loss of Speedometer Serial Data 1679
DIAGNOSTICS 1679
Diagnostic Notes 1679
Test 3 21 1681
DTC U1300, U1301 OR BUS ER 3 22 1682
GENERAL 1682
DIAGNOSTICS 1682
Diagnostic Tips 1682
Diagnostic Notes 1682
PASSWORD LEARN 3 23 1683
GENERAL 1683
PASSWORD LEARNING 1683
TSSM MAINTENANCE 3 24 1685
GENERAL 1685
KEY FOB 1685
Schedule 1685
Battery Replacement 1685
SECURITY SIREN (IF INSTALLED) 1686
Schedule 1686
Battery Replacement 1686
xe04_tc 1687
xe04a 1689
SPECIFICATIONS 4 1 1689
DIAGNOSTIC INTRODUCTION 4 2 1690
SYSTEM PROBLEMS 1690
No Start 1690
Poor Performance 1690
Check Engine Lamp 1690
RESOLVING PROBLEMS 1690
CHECKING FOR DIAGNOSTIC TROUBLE CODES 4 3 1691
CHECK ENGINE LAMP 1691
SECURITY LAMP 1692
CODE TYPES 1692
Current 1692
Historic 1692
RETRIEVING DIAGNOSTIC TROUBLE CODES 1693
MULTIPLE DIAGNOSTIC TROUBLE CODES 1693
INITIAL DIAGNOSTIC CHECK: ICM 4 4 1694
GENERAL 1694
Diagnostic Notes 1694
Circuit Diagram/Wire Harness Connector Table 1694
Reprogramming ICM 1694
INITIAL DIAGNOSTICS 1694
General Information 1694
Diagnostic Tips 1694
Diagnostic Notes 1694
Other DTCs 1694
Initial Diagnostic Check (Part 1 of 3) 1698
Initial Diagnostic Check (Part 2 of 3) 1699
Initial Diagnostic Check (Part 3 of 3) 1700
SPEEDOMETER SELF DIAGNOSTICS 4 5 1701
GENERAL 1701
DIAGNOSTICS 1701
Diagnostic Tips 1701
Diagnostic Notes 1701
Speedometer Self Diagnostics (flow chart) 1702
BREAKOUT BOX: ICM 4 6 1703
GENERAL 1703
INSTALLATION 1703
REMOVAL 1703
WIGGLE TEST 4 7 1704
GENERAL 1704
PROCEDURE 1704
Using DVOM (Part No HD-39978) 1704
INTAKE LEAK TEST 4 8 1705
GENERAL 1705
LEAK TESTER 1705
Parts List 1705
Tester Assembly 1705
Tester Adjustment 1705
PROCEDURE 1706
ENGINE CRANKS BUT WILL NOT START 4 9 1707
GENERAL 1707
DIAGNOSTICS 1707
Diagnostic Notes 1707
Test 4 9 (Part 1 of 3) 1709
Test 4 9 (Part 2 of 3) 1710
Test 4 9 (Part 3 of 3) 1711
STARTS THEN STALLS 4 10 1712
GENERAL 1712
Serial Data Low or Serial Data Open/High 1712
DIAGNOSTICS 1712
Diagnostic Tips 1712
Diagnostic Notes 1712
Test 4 10 (Part 1 of 2) 1714
Test 4 10 (Part 2 of 2) 1715
NO SPARK/NO ICM POWER 4 11 1716
GENERAL 1716
DIAGNOSTICS 1716
Diagnostic Notes 1716
Test 4 11 1718
MISFIRE 4 12 1719
GENERAL 1719
Misfire at Idle or Under Load 1719
DIAGNOSTICS 1719
Diagnostic Notes 1719
Test 4 12 1721
xe04b 1723
DTC P0106, P0107, P0108 4 13 1723
GENERAL 1723
MAP Sensor 1723
DIAGNOSTICS 1723
Diagnostic Tips 1723
Diagnostic Notes 1723
Test 4 13 (Part 1 of 2) 1725
Test 4 13 (Part 2 of 2) 1726
DTC P0371, P0372, P0374 4 14 1727
GENERAL 1727
Crank Position Sensor 1727
DIAGNOSTICS 1727
Diagnostic Notes 1727
Test 4 14 (Part 1 of 2) 1729
Test 4 14 (Part 2 of 2) 1730
DTC P0501, P0502 4 15 1731
GENERAL 1731
Vehicle Speed Sensor 1731
DIAGNOSTICS 1731
Diagnostic Notes 1731
Test 4 15 (Part 1 of 2) 1733
Test 4 15 (Part 2 of 2) 1734
DTC P0562, P0563 4 16 1735
GENERAL 1735
Battery Voltage 1735
DIAGNOSTICS 1735
Diagnostic Notes 1735
Test 4 16 (Part 1 of 2) 1737
Test 4 16 (Part 2 of 2) 1738
DTC P0602, P0603, P0604, P0605, P0607 4 17 1739
GENERAL 1739
ICM Failure 1739
DIAGNOSTICS 1739
DTC P0607 Test 1739
DTC P0602, P0603, P0604, P0605 Test 1739
DTC P1009, P1010 4 18 1740
GENERAL 1740
Password Problem 1740
DIAGNOSTICS 1740
Diagnostic Notes 1740
Test 4 18 1742
DTC P1351, P1352, P1354, P1355 4 19 1743
GENERAL 1743
Ignition Coil 1743
DIAGNOSTICS 1743
Diagnostic Notes 1743
Test 4 19 (Part 1 of 2) 1745
Test 4 19 (Part 2 of 2) 1746
DTC U1064 4 20 1747
GENERAL 1747
Loss of TSM/TSSM Serial Data 1747
DIAGNOSTICS 1747
Diagnostic Notes 1747
Test 4 20 1749
DTC U1097 4 21 1750
GENERAL 1750
Loss of Speedometer Serial Data 1750
DIAGNOSTICS 1750
Diagnostic Notes 1750
Test 4 21 1752
xe05_tc 1753
xe05a 1755
CONNECTOR LOCATIONS 5 1 1755
AMP MULTILOCK ELECTRICAL CONNECTORS 5 2 1756
REMOVING SOCKET/PIN TERMINALS 1756
INSTALLING SOCKET/PIN TERMINALS 1756
CRIMPING INSTRUCTIONS 1759
DEUTSCH ELECTRICAL CONNECTORS 5 3 1760
GENERAL 1760
REMOVING/DISASSEMBLING 1760
REMOVING/INSTALLING SOCKETS 1760
REMOVING/INSTALLING PINS 1761
ASSEMBLING/INSTALLING 1762
CRIMPING INSTRUCTIONS 1763
MINI-DEUTSCH ELECTRICAL CONNECTORS 5 4 1765
GENERAL 1765
For Size 20, 16 and 12 Contacts Wire Range 26-12 AWG 1765
CRIMPING INSTRUCTIONS 1765
SEALED BUTT SPLICE CONNECTORS 5 5 1767
INSTALLATION 1767
PACKARD ELECTRICAL CONNECTORS 5 6 1768
GENERAL 1768
PULL-TO-SEAT TERMINALS 1769
Removing External Latch Type 1769
Installing External Latch Type 1769
PUSH-TO-SEAT TERMINALS 1769
Removing Push-to-Seat Terminals 1769
Installing Push-to-Seat Terminals 1770
CRIMPING INSTRUCTIONS 1770
MICRO 64 TERMINALS 1772
General 1772
Removal 1772
Installation 1772
Crimping Instructions 1773
INDEX TO WIRING DIAGRAMS 5 7 1774
xebk_tc 1793

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