2008 Harley Davidson VRSC Models Service Manual – PDF DOWNLOAD

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2008 Harley Davidson VRSC Models Service Manual – PDF DOWNLOAD

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2008 Harley Davidson VRSC Models Service Manual – PDF DOWNLOAD

ABOUT THIS MANUAL
GENERAL:

• This Service Manual has been prepared with two purposes in mind. First, it will acquaint the user with the construction of the Harley-Davidson product and assist in the performance of basic maintenance and repair.
• Secondly, it will introduce to the professional Harley-Davidson Technician the latest field-tested and factory-approved major repair methods. We sincerely believe that this Service Manual will make your association with Harley-Davidson products more pleasant and profitable.

HOW TO USE YOUR SERVICE MANUAL:

Refer to the table below for the content layout of this manual.
NO. CHAPTER
1 Maintenance
2 Chassis
3 Engine
4 Fuel System
5 Starter
6 Cooling System
7 Transmission
8 Electrical
A Appendix A Connector Repair
B Appendix B Wiring
C Appendix C ABS
D Appendix D Valve Lash
E Appendix E Conversions
F Appendix F Glossary

• Use the TABLE OF CONTENTS (which follows this FOREWORD) and the INDEX (at the back of this manual) to quickly locate subjects. Sections and topics in this manual are sequentially numbered for easy navigation.
• For example, a cross-reference shown as 2.1 SPECIFICATIONS refers to chapter 2 CHASSIS, heading 2.1 SPECIFICATIONS.
• For quick and easy reference, all pages contain a section number followed by a page number. For example, page 3-5 refers to page 5 in section 3.
• A number of acronyms and abbreviations are used in this document. See the D.1 GLOSSARY for a list of acronyms, abbreviations and definitions.

TABLE OF CONTENTS:

2008 Harley Davidson VRSC Models Service Manual – PDF DOWNLOAD

COVER..................................................................  1
FOREWORD...............................................................  2
TABLE OF CONTENTS......................................................  4
1. MAINTENANCE......................................................... 14
	1.1 GENERAL........................................................ 16
		Servicing a New Motorcycle..................................... 16
		Safe Operating Maintenance..................................... 16
		Shop Practices................................................. 16
		Repair and Replacement Procedures.............................. 17
		Cleaning....................................................... 18
		Tool Safety.................................................... 18
	1.2 MAINTENANCE SCHEDULE........................................... 20
		General........................................................ 20
	1.3 FUEL AND OIL................................................... 23
		Fuel........................................................... 23
		Gasoline Blends................................................ 23
		Engine Lubrication............................................. 23
		Winter Lubrication............................................. 23
	1.4 BULB REQUIREMENTS.............................................. 25
		General........................................................ 25
	1.5 AIR CLEANER AND EXHAUST SYSTEM................................. 26
		Removal........................................................ 26
		Installation................................................... 27
		Exhaust System Leak Check...................................... 28
	1.6 RADIATOR SIDE COVERS........................................... 29
		Removal........................................................ 29
		Installation................................................... 30
	1.7 COOLING SYSTEM................................................. 31
		Checking Coolant Level in Overflow Bottle...................... 31
		Check for Coolant in System.................................... 31
	1.8 ENGINE OIL AND FILTER.......................................... 32
		Checking and Adding Oil........................................ 32
		Changing Oil and Filter........................................ 33
	1.9 BATTERY MAINTENANCE............................................ 35
		General........................................................ 35
		Disconnection/Removal.......................................... 36
		Cleaning and Inspection........................................ 36
		Charging Battery............................................... 36
		Installation/Connection........................................ 38
		Storage........................................................ 39
	1.10 BRAKES........................................................ 40
		Fluid Inspection............................................... 40
		Rear Brake Pedal............................................... 41
	1.11 BRAKE PADS AND DISCS.......................................... 42
		Inspection..................................................... 42
		Brake Pad Replacement.......................................... 42
	1.12 BLEEDING BRAKES............................................... 46
		General........................................................ 46
		Procedure...................................................... 46
	1.13 TIRES AND WHEELS.............................................. 48
		Tires.......................................................... 48
		Wheel Bearings................................................. 48
	1.14 CLUTCH........................................................ 49
		General........................................................ 49
		Checking Clutch Fluid Level.................................... 49
	1.15 BLEEDING CLUTCH FLUID LINE.................................... 50
		Procedure...................................................... 50
	1.16 REAR BELT DEFLECTION.......................................... 52
		Inspection..................................................... 52
	1.17 REAR BELT AND SPROCKETS....................................... 54
		General........................................................ 54
		Cleaning....................................................... 54
		Inspection..................................................... 54
	1.18 DRIVE BELT REPLACEMENT........................................ 56
		Replacement.................................................... 56
	1.19 DRIVE SPROCKET FLANGE......................................... 58
		Replacement.................................................... 58
	1.20 SUSPENSION ADJUSTMENTS........................................ 60
		Rear Shock Absorbers: VRSC Models.............................. 60
	1.21 STEERING HEAD BEARINGS........................................ 61
		Adjustment (Fall-Away)......................................... 61
	1.22 SPARK PLUGS AND COIL.......................................... 62
		General........................................................ 62
		Removal/Inspection............................................. 62
		Installation................................................... 63
	1.23 CABLE, LINE AND FRAME INSPECTION.............................. 64
		General........................................................ 64
		Cables and Hand Levers......................................... 64
		Jiffy Stand.................................................... 64
		Fuel System Lines and Fittings................................. 64
		Hydraulic Lines................................................ 64
	1.24 THROTTLE CABLES............................................... 65
		Inspection..................................................... 65
		Lubrication.................................................... 65
		Adjustment..................................................... 65
	1.25 VALVE LASH.................................................... 66
		Lash Measurement............................................... 66
		Camshaft Inspection............................................ 69
		Verify Cam Timing.............................................. 70
		Lash Adjustment................................................ 71
	1.26 SECONDARY CAM CHAIN........................................... 77
		General........................................................ 77
		Adjustment..................................................... 77
	1.27 HEADLAMP ALIGNMENT............................................ 80
		Inspection..................................................... 80
		Adjustment..................................................... 80
	1.28 CRITICAL FASTENERS............................................ 82
		Inspection..................................................... 82
	1.29 STORAGE....................................................... 83
		General........................................................ 83
		Placing in Storage............................................. 83
		Removal from Storage........................................... 83
	1.30 TROUBLESHOOTING............................................... 85
		General........................................................ 85
		Engine......................................................... 85
		Lubrication System............................................. 86
		Electrical System.............................................. 86
		Transmission................................................... 86
		Handling....................................................... 87
		Brakes......................................................... 87
2. CHASSIS............................................................. 88
	2.1 SPECIFICATIONS: CHASSIS........................................ 90
		General........................................................ 90
	2.2 VEHICLE IDENTIFICATION NUMBER (V.I.N.)......................... 92
		Vehicle Identification Number: VRSC Models..................... 92
	2.3 FRAME AND LOWER FRAME RAILS.................................... 94
		General........................................................ 94
		Removal........................................................ 94
		Installation................................................... 94
	2.4 FRONT ENGINE MOUNT............................................. 96
		Replacement.................................................... 96
	2.5 FRONT ENGINE MOUNT ASSEMBLY.................................... 97
		Removal........................................................ 97
		Disassembly And Assembly....................................... 97
		Installation................................................... 97
	2.6 REAR ENGINE MOUNTS............................................. 99
		Removal........................................................ 99
		Installation................................................... 99
	2.7 ENGINE REPLACEMENT.............................................100
		General........................................................100
		Removal........................................................100
		Installation...................................................105
	2.8 FOOTRESTS AND FOOT CONTROLS: FORWARD MOUNT.....................108
		Rider Footrests................................................108
	2.9 FOOTRESTS AND FOOT CONTROLS: MID-MOUNT.........................110
		Rider Footrests................................................110
	2.10 PASSENGER FOOTRESTS...........................................112
		Passenger Footrests............................................112
	2.11 THROTTLE CABLES...............................................113
		Removal/Disassembly............................................113
		Cleaning And Inspection........................................113
		Assembly and Installation......................................113
	2.12 CLUTCH MASTER CYLINDER AND RESERVOIR..........................115
		General........................................................115
		Removal........................................................115
		Disassembly....................................................115
		Assembly.......................................................116
		Installation...................................................117
	2.13 CLUTCH HAND LEVER.............................................118
		Removal........................................................118
		Installation...................................................118
	2.14 CLUTCH FLUID LINE.............................................119
		Removal........................................................119
		Installation...................................................119
	2.15 SECONDARY CLUTCH ACTUATOR.....................................120
		Removal........................................................120
		Assembly.......................................................120
		Installation...................................................120
	2.16 FRONT BRAKE MASTER CYLINDER/RESERVOIR.........................122
		General........................................................122
		Removal and Disassembly........................................122
		Cleaning and Inspection........................................124
		Assembly.......................................................124
		Installation...................................................124
	2.17 FRONT BRAKE CALIPER...........................................126
		Removal........................................................126
		Installation...................................................126
	2.18 REAR BRAKE MASTER CYLINDER AND RESERVOIR: FORWARD CONTROLS....128
		Removal........................................................128
		Disassembly....................................................130
		Cleaning and Inspection........................................130
		Assembly.......................................................130
		Installation...................................................131
	2.19 REAR BRAKE RESERVOIR: MID-MOUNT CONTROLS......................132
		Removal........................................................132
		Installation...................................................132
	2.20 REAR BRAKE MASTER CYLINDER: MID-MOUNT CONTROLS................133
		Removal........................................................133
		Disassembly....................................................133
		Cleaning and Inspection........................................135
		Assembly.......................................................135
		Installation...................................................135
	2.21 REAR BRAKE CALIPER............................................137
		Removal........................................................137
		Installation...................................................137
	2.22 HANDLEBARS: VRSCAW............................................138
		Removal........................................................138
		Installation...................................................139
	2.23 HANDLEBARS: ALL EXCEPT VRSCAW.................................140
		Removal........................................................140
		Installation...................................................140
	2.24 FRONT WHEEL...................................................142
		General........................................................142
		Removal........................................................143
		Disassembly....................................................144
		Cleaning and Inspection........................................145
		Assembly.......................................................145
		Installation...................................................146
	2.25 WHEEL LACING..................................................147
		Procedure......................................................147
	2.26 TRUING LACED WHEELS...........................................151
		General........................................................151
		Lateral Truing.................................................151
		Radial Truing..................................................151
	2.27 REAR WHEEL....................................................153
		General........................................................153
		Removal........................................................154
		Disassembly....................................................155
		Cleaning and Inspection........................................156
		Assembly.......................................................156
		Installation...................................................156
	2.28 SEALED WHEEL BEARINGS.........................................158
		General........................................................158
		Inspection: Lateral End Play...................................158
		Removal........................................................158
		Installation...................................................159
	2.29 DISC RIM RUNOUT...............................................161
		General........................................................161
		Lateral Runout.................................................161
		Radial Runout..................................................161
	2.30 TIRES.........................................................162
		General........................................................162
		Removal........................................................162
		Cleaning, Inspection, and Repair...............................162
		Tire Replacement...............................................162
		Installation...................................................163
	2.31 WHEEL ALIGNMENT...............................................164
		General........................................................164
		Inspection.....................................................164
		Verification...................................................164
		Centering Engine...............................................165
	2.32 FRONT FENDER..................................................167
		Removal........................................................167
		Installation...................................................167
	2.33 FRONT FORK....................................................168
		Removal........................................................168
		Disassembly....................................................168
		Cleaning and Inspection........................................169
		Assembly.......................................................171
		Installation...................................................172
	2.34 STEERING HEAD.................................................173
		Removal........................................................173
		Cleaning and Inspection........................................174
		Assembly.......................................................175
		Installation...................................................175
	2.35 FORK LOCK.....................................................176
		General........................................................176
		Removal........................................................176
		Installation...................................................176
	2.36 BELT GUARD AND DEBRIS DEFLECTOR...............................177
		Removal........................................................177
		Installation...................................................177
	2.37 REAR SHOCK ABSORBERS..........................................178
		Removal........................................................178
		Installation...................................................178
	2.38 SWINGARM......................................................180
		Removal........................................................180
		Disassembly and Assembly.......................................181
		Installation...................................................183
	2.39 SEAT..........................................................185
		Removal........................................................185
		Cleaning and Inspection........................................185
		Installation...................................................185
	2.40 REAR FENDER...................................................187
		Removal........................................................187
		Installation...................................................187
	2.41 JIFFY STAND...................................................188
		Cleaning.......................................................188
		Jiffy Stand Interlock: International Models....................188
		Removal........................................................188
		Installation...................................................189
3. ENGINE..............................................................190
	3.1 SPECIFICATIONS: ENGINE.........................................192
		General........................................................192
	3.2 SERVICE WEAR LIMITS............................................196
		General........................................................196
	3.3 HOW TO USE THIS SECTION........................................198
		Top End Repair.................................................198
		Bottom End Repair..............................................198
		Typical Symptoms...............................................198
	3.4 OIL FLOW.......................................................199
		General........................................................199
	3.5 OIL PRESSURE...................................................203
		Oil Pressure Indicator Lamp....................................203
		Checking Oil Pressure..........................................203
	3.6 TROUBLESHOOTING................................................204
		Compression Test...............................................204
		Diagnosing Valve Train Noise...................................204
		Cylinder Leakage Test..........................................204
		Diagnosing Smoking Engine or High Oil Consumption..............205
	3.7 STRIPPING MOTORCYCLE FOR SERVICE...............................206
		General........................................................206
		Engine Cradle and Stand........................................206
	3.8 CAMSHAFTS, DRIVE CHAINS AND CAMSHAFT TIMING....................208
		General........................................................208
		Removal........................................................208
		Camshaft Inspection............................................211
		Primary Cam Drive Removal......................................213
		Primary Cam Drive Installation.................................214
		Installation of Cams, Timing Chains and Camshaft Timing........216
	3.9 CYLINDER HEAD..................................................225
		Removal........................................................225
		Disassembly....................................................226
		Valve Seat Refacing............................................232
		Head Assembly..................................................233
		Installation...................................................235
	3.10 UPPER AND LOWER CRANKCASE SEPARATION..........................237
		Disassembly....................................................237
	3.11 ENGINE BOTTOM END SERVICE.....................................241
		Crankshaft, Piston and Cylinder Liner Removal/Installation.....241
	3.12 OIL PUMP......................................................255
		Oil Pump.......................................................255
	3.13 OIL FILTER MOUNT..............................................257
		Removal/Installation...........................................257
4. FUEL SYSTEM.........................................................258
	4.1 SPECIFICATIONS: FUEL SYSTEM....................................260
		General........................................................260
	4.2 ELECTRONIC FUEL INJECTION (EFI)................................261
		Troubleshooting................................................261
	4.3 FUEL TANK......................................................262
		Removal........................................................262
		Cleaning and Inspecting........................................263
		Installation...................................................263
	4.4 THROTTLE POSITION SENSOR (TP)..................................264
		General........................................................264
		Removal........................................................264
		Installation...................................................264
	4.5 INTAKE AIR TEMPERATURE SENSOR (IAT)............................265
		General........................................................265
		Removal........................................................265
		Installation...................................................265
	4.6 ENGINE COOLANT TEMPERATURE SENSOR (ECT)........................267
		General........................................................267
		Removal........................................................267
		Installation...................................................267
	4.7 THROTTLE BODY AND FUEL RAIL....................................269
		Removal........................................................269
		Installation...................................................269
	4.8 IDLE AIR CONTROL (IAC).........................................272
		General........................................................272
		Removal........................................................272
		Installation...................................................272
	4.9 MANIFOLD ABSOLUTE PRESSURE SENSOR (MAP)........................273
		Removal........................................................273
		Installation...................................................273
	4.10 OXYGEN SENSOR.................................................274
		Oxygen Sensor..................................................274
		Oxygen Sensor..................................................275
	4.11 FUEL INJECTORS................................................277
		General........................................................277
		Removal........................................................277
		Disassembly....................................................277
		Assembly.......................................................277
		Installation...................................................278
	4.12 FUEL PUMP/FILTER/SENDER ASSEMBLY..............................279
		Removal........................................................279
		Installation...................................................280
		Suction Side Fuel Filter.......................................281
		Pressure Side Fuel Filter......................................281
		Fuel Pump......................................................281
		Fuel Level Sensor..............................................283
	4.13 FUEL PRESSURE TEST............................................284
		General........................................................284
		Testing........................................................284
	4.14 EXHAUST SYSTEM: VRSCAW........................................286
		Removal........................................................286
		Installation...................................................288
	4.15 EXHAUST SYSTEM: VRSCD.........................................289
		Removal........................................................289
		Installation...................................................290
		Exhaust Pipes..................................................291
		Mufflers.......................................................292
	4.16 EXHAUST SYSTEM: VRSCDX........................................294
		Removal........................................................294
		Installation...................................................295
	4.17 VAPOR VALVE...................................................297
		General........................................................297
		Replacement....................................................297
	4.18 INTAKE LEAK TEST..............................................298
		General........................................................298
		Leak Tester....................................................298
		Procedure......................................................298
	4.19 EVAPORATIVE EMISSIONS CONTROL (CA MODELS).....................300
		General........................................................300
		Purge Solenoid.................................................300
		Carbon Canister................................................301
		Tube Routing/Replacement.......................................301
5. STARTER.............................................................302
	5.1 SPECIFICATIONS: STARTER........................................304
		General........................................................304
	5.2 STARTER SYSTEM.................................................305
		General........................................................305
		Operation......................................................305
	5.3 STARTER RELAY..................................................307
		Removal........................................................307
		Installation...................................................307
	5.4 STARTER........................................................308
		Removal........................................................308
		Installation...................................................308
	5.5 STARTER SOLENOID...............................................309
		General........................................................309
		Removal........................................................309
		Installation...................................................309
6. COOLING SYSTEM......................................................312
	6.1 SPECIFICATIONS: COOLING SYSTEM.................................314
		General........................................................314
	6.2 COOLANT FLOW...................................................315
		General........................................................315
		Flow Description...............................................315
		Troubleshooting................................................315
		Pressure Cap...................................................315
		Pressure Cap Test..............................................316
		System Pressure Test...........................................317
		Leak Detection Dye Test........................................317
		Tests for Blown Gasket.........................................318
	6.3 ENGINE COOLANT.................................................319
		General........................................................319
		Replacing Coolant..............................................319
	6.4 THERMOSTAT.....................................................321
		General........................................................321
		Removal........................................................321
		Installation...................................................321
	6.5 WATER PUMP.....................................................323
		Removal........................................................323
		Installation...................................................324
	6.6 COOLANT PIPES AND HOSES........................................326
		Removal........................................................326
		Disassembly....................................................326
		Assembly.......................................................328
		Installation...................................................328
	6.7 OIL LINE FITTINGS..............................................329
		General........................................................329
		Removal........................................................329
		Installation...................................................330
	6.8 RADIATOR AND OIL COOLER........................................331
		General........................................................331
		Removal........................................................331
		Installation...................................................333
	6.9 OIL COOLER.....................................................336
		Removal........................................................336
		Installation...................................................336
7. TRANSMISSION........................................................338
	7.1 SPECIFICATIONS: TRANSMISSION...................................340
		General........................................................340
	7.2 CLUTCH.........................................................341
		Removal........................................................341
		Disassembly....................................................345
		Cleaning and Inspection........................................345
		Assembly.......................................................346
		Installation...................................................349
	7.3 TRANSMISSION...................................................352
		Disassembly....................................................352
		Assembly.......................................................355
	7.4 COUNTERBALANCER BEARING REPLACEMENT............................364
		Removal........................................................364
		Installation...................................................367
	7.5 SHIFT SHAFT AND SEAL...........................................371
		General........................................................371
		Removal........................................................371
		Installation...................................................372
	7.6 OUTPUT SHAFT...................................................373
		General........................................................373
		Disassembly - 2nd Gear End.....................................373
		Assembly - 2nd Gear End........................................378
		Assembly - 1st Gear End........................................380
	7.7 INPUT SHAFT....................................................383
		Disassembly - 2nd Gear End.....................................383
		Assembly - 2nd Gear End........................................386
		Disassembly - 1st Gear End.....................................387
		Assembly - 1st Gear End........................................388
8. ELECTRICAL..........................................................390
	8.1 SPECIFICATIONS: ELECTRICAL.....................................392
		General........................................................392
	8.2 ELECTRONIC CONTROL MODULE (ECM)................................393
		General........................................................393
		Removal........................................................393
		Installation...................................................393
	8.3 RELAY AND FUSE BLOCK...........................................394
		General........................................................394
		Relay/Fuse Block Removal.......................................394
		Fuse Replacement...............................................394
		Relay Replacement..............................................394
		Relay/Fuse Block Installation..................................394
	8.4 MAXI-FUSE......................................................396
		General........................................................396
		Replacement....................................................396
	8.5 VOLTAGE REGULATOR..............................................397
		General........................................................397
		Removal........................................................397
		Installation...................................................397
	8.6 IGNITION/HEADLAMP KEY SWITCH...................................399
		General........................................................399
		Replacement....................................................399
	8.7 HEADLAMP: VRSCAW...............................................400
		General........................................................400
		Headlamp Bulb..................................................400
	8.8 HEADLAMP: VRSCD/VRSCDX.........................................402
		General........................................................402
		Headlamp Bulb..................................................402
	8.9 TAIL LAMP......................................................404
		Removal........................................................404
		Installation...................................................404
	8.10 TURN SIGNALS AND RUNNING LIGHTS...............................406
		Bulb Replacement...............................................406
		Lamp Replacement...............................................406
	8.11 TURN SIGNAL SECURITY MODULE (TSSM)............................408
		General........................................................408
		Removal........................................................408
		Installation...................................................408
	8.12 CRANK POSITION SENSOR (CKP)...................................409
		General........................................................409
		Removal........................................................409
		Installation...................................................409
	8.13 ALTERNATOR....................................................410
		General........................................................410
		Removal........................................................410
		Disassembly....................................................411
		Assembly.......................................................412
		Installation...................................................412
	8.14 INSTRUMENT CLUSTER: VRSCAW....................................414
		General........................................................414
		Removal........................................................414
		Installation...................................................415
	8.15 INSTRUMENT CLUSTER: VRSCD/VRSCDX..............................416
		General........................................................416
		Removal........................................................416
		Installation...................................................416
	8.16 VEHICLE SPEED SENSOR (VSS)....................................417
		General........................................................417
		Removal........................................................417
		Installation...................................................417
	8.17 NEUTRAL SWITCH................................................418
		General........................................................418
		Removal........................................................418
		Installation...................................................418
	8.18 OIL PRESSURE SWITCH...........................................419
		General........................................................419
		Removal........................................................419
		Installation...................................................419
	8.19 STOPLIGHT SWITCH: FORWARD MOUNT CONTROLS......................420
		General........................................................420
		Removal........................................................420
		Installation...................................................420
	8.20 STOPLIGHT SWITCH: MID-MOUNT CONTROLS..........................421
		General........................................................421
		Removal........................................................421
		Installation...................................................421
	8.21 HORN..........................................................422
		Inspection.....................................................422
		Replacement....................................................422
	8.22 COOLING FANS..................................................424
		General........................................................424
		Removal........................................................424
		Disassembly....................................................424
		Assembly.......................................................425
		Installation...................................................425
	8.23 HANDLEBAR SWITCH ASSEMBLIES...................................426
		General........................................................426
		Repair Procedures..............................................426
	8.24 RIGHT HANDLEBAR SWITCH........................................427
		Removal........................................................427
		Installation...................................................427
		Disassembly....................................................429
		Switch Repair/Replacement......................................430
		Assembly.......................................................432
	8.25 LEFT HANDLEBAR SWITCH.........................................433
		Removal........................................................433
		Installation...................................................433
		Disassembly....................................................434
		Switch Repair/Replacement......................................434
		Assembly.......................................................435
A. APPENDIX A CONNECTOR REPAIR.........................................438
	A.1 AMP 1-PLACE CONNECTORS.........................................440
		AMP 1-Place Connector Repair...................................440
	A.2 AMP MULTILOCK CONNECTORS.......................................442
		AMP Multilock Connector Repair.................................442
	A.3 AUTOFUSE ELECTRICAL CONNECTOR..................................446
		General........................................................446
		Autofuse Connector Repair......................................446
		Assembly.......................................................446
	A.4 DELPHI CONNECTORS..............................................447
		Delphi Connector Repair........................................447
	A.5 DELPHI MAXI-FUSE HOUSING.......................................449
		Delphi Maxi-Fuse Housing Repair................................449
	A.6 DEUTSCH 1-PLACE ELECTRICAL CONNECTORS..........................451
		Deutsch 1-Place Connector Repair...............................451
	A.7 DEUSCH ELECTRICAL CONNECTORS...................................452
		Deutsch Connector Repair.......................................452
	A.8 DEUTSCH MINI-TERMINAL CRIMPS...................................456
		Deutsch Mini Terminal Crimps...................................456
	A.9 DEUTSCH STANDARD TERMINALS.....................................457
		Deutsch Standard Terminal Crimps...............................457
	A.10 DEUTSCH SOLID BARREL TERMINALS................................458
		Deutsch Solid Barrel Terminal Crimps...........................458
	A.11 MOLEX CONNECTORS..............................................460
		Molex Connector Repair.........................................460
		Crimp Terminal to Lead.........................................461
	A.12 PACKARD 150 METRI-PACK CONNECTORS.............................464
		150 Metri-Pack Connector Repair................................464
	A.13 PACKARD 280 METRI-PACK RELAY AND FUSE BLOCK CONNECTORS........466
		Fuse Block Repair..............................................466
	A.14 PACKARD 480 METRI-PACK CONNECTORS.............................467
		480 Metri-Pack Connector Repair................................467
	A.15 PACKARD 630 METRI-PACK CONNECTORS.............................468
		630 Metri-Pack Connector Repair................................468
	A.16 PACKARD METRI-PACK TERMINALS..................................469
		Metri-Pack Terminal Crimps.....................................469
	A.17 PACKARD ECM CONNECTOR.........................................471
		Packard 100W Connector Repair..................................471
	A.18 PACKARD MICRO-64 CONNECTORS...................................473
		Packard Micro-64 Connector Repair..............................473
	A.19 SEALED SPLICE CONNECTORS......................................476
		Sealed Splice Connector Repair.................................476
B. APPENDIX B WIRING...................................................478
	B.1 CONNECTORS.....................................................480
		Connector Locations............................................480
	B.2 WIRING DIAGRAMS................................................482
		Wiring Diagram Information.....................................482
		2008 VRSC Wiring Diagrams......................................483
C. APPENDIX C ABS......................................................508
	C.1 ABS MODULE.....................................................510
		Removal........................................................510
		Installation...................................................511
	C.2 WHEEL SPEED SENSOR.............................................512
		Front Wheel Speed Sensor.......................................512
		Rear Wheel Speed Sensor........................................513
	C.3 ABS BRAKE LINES................................................514
		Front Master Cylinder to ABS Module............................514
		ABS Module to Front Brake Calipers.............................514
		Rear Master Cylinder to ABS Module.............................516
		ABS Module to Rear Brake Caliper...............................517
D. APPENDIX D VALVE LASH...............................................520
	D.1 VALVE TAPPET SHIMS.............................................522
		Tables.........................................................522
	D.2 VALVE LASH CALCULATION WORKSHEET 1.............................523
		Worksheet 1....................................................523
	D.3 VALVE LASH CALCULATION WORKSHEET 2.............................524
		Worksheet 2....................................................524
E. APPENDIX E CONVERSIONS..............................................526
	E.1 LENGTH CONVERSION..............................................528
		Conversion Table...............................................528
	E.2 FLUID CONVERSION...............................................529
		United States System...........................................529
		Metric System..................................................529
		British Imperial System........................................529
	E.3 TORQUE CONVERSION..............................................530
		United States System...........................................530
		Metric System..................................................530
F. APPENDIX F GLOSSARY.................................................532
	F.1 GLOSSARY.......................................................534
		Acronyms and Abbreviations.....................................534
TOOLS..................................................................538
TORQUE VALUES..........................................................546
INDEX..................................................................558

2008 HARLEY DAVIDSON VRSC MODELS SERVICE MANUAL – PDF DOWNLOAD:

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