HARLEY DAVIDSON VRSCA V-ROD 1131cc 2002-2009 SERVICE REPAIR SHOP MANUAL – PDF DOWNLOAD

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HARLEY DAVIDSON VRSCA V-ROD 1131cc 2002-2009 SERVICE REPAIR SHOP MANUAL

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LANGUAGE:ENGLISH
PAGES:446
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FILE TYPE:PDF

HARLEY DAVIDSON VRSCA V-ROD 1131CC 2002-2009 SERVICE REPAIR SHOP MANUAL – PDF DOWNLOAD:

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DESCRIPTION:

HARLEY DAVIDSON VRSCA V-ROD 1131cc 2002-2009 SERVICE REPAIR SHOP 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 sin- cerely believe that this Service Manual will make your association with Harley-Davidson products more pleasant and profitable.

Safety

Safety is always the most important consideration when per- forming any Job. Be sure you have a complete understanding of the task to be performed- Use common sense. Use the proper tools. Protect yourself and bystanders with approved eye protection. Don’t just do the job — do the job safely.

Removing Parts

Always consider the weight of a part when lifting. Use a hoist whenever necessary. Do not lift heavy parts by hand. A hoist and adjustable lifting beam or sling are needed to remove some parts. The lengths of chains or cables from the hoist to the part should be equal and parallel and should be posi- tioned directly over the center of the part. Be sure that no obstructions will interfere with the lifting operation. Never leave a part suspended in mid-air.

TABLE OF CONTENTS:

HARLEY DAVIDSON VRSCA V-ROD 1131cc 2002-2009 SERVICE REPAIR SHOP MANUAL

Index...............................................  2
Table of Contents...................................  5
1. Maintenance...................................... 13
	Fuel and Oil.................................... 18
	Airbox and Air Filter........................... 22
	Cooling System.................................. 25
	Engine Oil and Filter........................... 26
	Battery Maintenance............................. 28
	Brakes.......................................... 31
	Bleeding Brakes................................. 33
	Brake Pads and Discs............................ 34
	Tires and Wheels................................ 37
	Clutch.......................................... 38
	Bleeding Clutch................................. 39
	Rear Belt Deflection............................ 41
	Rear Belt and Sprockets......................... 43
	Suspension Adjustments.......................... 45
	Steering Head Bearings.......................... 46
	Front Fork Oil.................................. 47
	Spark Plug/Coil................................. 49
	Cable and Chassis Lubrication................... 51
	Throttle Cables................................. 52
	Valve Lash...................................... 53
	Verify Cam Tiiming.............................. 57
	Lash Adjustment................................. 58
	Secondary Cam Chain............................. 63
	Headlamp Alignment.............................. 66
	Critical Fasteners.............................. 67
	Storage......................................... 68
	Troubleshooting................................. 70
2. Chassis.......................................... 74
	Specifications.................................. 75
	Torque Values................................... 76
	V.I.N........................................... 79
	Frame/Lower Frame Rails......................... 80
	Front Engine Mount.............................. 82
	Exhaust System.................................. 85
	Rear Engine Mounts.............................. 87
	Engine Replacement.............................. 88
	Jiffy Stand..................................... 97
	Footrests/Foot Controls......................... 99
	Throttle Cables.................................101
	Clutch Master Cylinder/Reservoir................103
	Clutch Hand Lever...............................106
	Clutch Fluid Line...............................107
	Secondary Clutch Actuator.......................108
	Front Brake Master Cylinder/Reservoir...........110
	Front Brake Calipers............................114
	Rear Brake Master Cylinder/Reservoir............119
	Rear Brake Caliper..............................125
	Handlebars......................................130
	Front Wheel.....................................132
	Rear Wheel......................................136
	Sealed Wheel Bearings...........................141
	Disc Rim Runout.................................144
	Tires...........................................145
	Front Fender....................................150
	Front Fork......................................151
	Steering Head...................................156
	Fork Lock.......................................159
	Belt Guard/Debris Deflector.....................160
	Rear Shock Absorbers............................161
	Rear Fork.......................................163
	Seat Latch......................................166
	Seat............................................167
	Rear Fender/Supports............................169
3. Engine...........................................171
	Specifications..................................172
	Service Wear Limits.............................177
	Engine Torque Values............................178
	Oil Flow........................................179
	Oil Pressure....................................183
	Troubleshooting.................................185
	Stripping Motorcycle For Service................187
	Throttle Body...................................189
	Top End Disassembly.............................191
	Cylinder Head Service...........................197
	Oil Pump........................................207
	Clutch..........................................209
	Upper and Lower Crankcase Service...............221
	Counterbalancer Bearing Replacement.............236
	Crankshaft Bearing Replacement..................242
	Shift Shaft and Seal............................244
	Crankshaft, Piston and Cylinder Liner...........246
	Oil Filter Mount................................260
	Cam Drive.......................................261
	Cylinder Heads..................................264
	Installing and Timing the Cams..................266
4. Fuel System......................................272
	Specifications..................................273
	Fuel Pump/Filters/Fuel Level Sender Assembly....274
	Suction Side Fuel Filter........................277
	Fuel Pump.......................................278
	Fuel Tank.......................................279
	Vapor Valve.....................................281
	Evaporative Emissions Control - CA Models.......282
	Purge Solenoid/Vapor Valve......................283
	Charcoal Canister...............................284
	Hose Routing/Replacement........................285
5. Electric Starter.................................286
	Specifications..................................287
	Electric Starter System.........................288
	Starter Relay...................................290
	Starter.........................................292
	Starter Solenoid................................293
6. Cooling System...................................295
	Specifications..................................296
	Coolant Flow....................................297
	Troubleshooting.................................299
	Pressure Cap Test...............................300
	System Pressure Test............................301
	Leak Detection Dye Test?Blown Gasket............302
	Engine Coolant..................................303
	Thermostat......................................305
	Water Pump......................................307
	Coolant Pipes and Hoses.........................309
	Oil Line Fittings...............................312
	Radiator/Oil Cooler.............................313
	Oil Cooler......................................316
7. Transmission.....................................318
	Specifications..................................319
	Output Shaft....................................320
	Input Shaft.....................................329
8. Electrical.......................................335
	Specifications..................................336
	Torque Values...................................337
	Bulb Requirements...............................338
	Relay/Fuse Block................................339
	Crank Position Sensor: CKP......................341
	Maxi-Fuse.......................................342
	Ignition/Light Switch...........................343
	Alternator......................................344
	Voltage Regulator...............................346
	Battery.........................................348
	Battery Cables..................................353
	Headlamp........................................354
	Tail Lamp.......................................356
	Turn Signal/Running Lights......................358
	Turn Signal Security Module:TSSM................360
	Instrument Cluster..............................361
	Vehicle Speed Sensor:VSS........................363
	Neutral Switch..................................364
	Oil Pressure Switch.............................365
	Stop Light Switch...............................367
	Horn............................................368
	Cooling Fans....................................369
9. Fuel Injection...................................371
	Specifications..................................372
	Torque Values...................................373
	Electronic Fuel Injection:EFI...................374
	Electronic Control Module:ECM...................376
	Throttle Position Sensor:TP.....................377
	Intake Air Temperature Sensor:IAT...............378
	Engine Coolant Temperature Sensor:ECT...........379
	Idle Air Control:IAC............................380
	Manifold Absolute Pressure Sensor:MAP...........382
	Fuel Rail/Fuel Injectors........................383
	Fuel Pressure Test..............................385
	Intake Leak Test................................387
Appendix............................................389
	Appendix A - Tools..............................390
	Appendix B - Wiring.............................402
	Appendix C - Conversions........................423
Index...............................................438

PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.