2002 Harley Davidson Touring FLT Models Electrical Diagnostics + Service Manual – PDF DOWNLOAD
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2002 Harley Davidson Touring FLT Models Electrical Diagnostics + Service Manual – PDF DOWNLOAD
2002 Harley Davidson Touring FLT Models Electrical Diagnostics + Service Manual – PDF DOWNLOAD
DESCRIPTION:
2002 Harley Davidson Touring FLT Models Electrical Diagnostics + Service Manual – PDF DOWNLOAD
REPAIR NOTES
General maintenance practices are given in this section. All special tools and torque values are noted at the point of use and all required parts or materials can be found in the appropriate
PARTS CATALOG:
Safety Safety is always the most important consideration when performing any job. Be sure you have a complete understanding of the task to be performed. Use common sense. Use the proper tools. Don’t just do the job – do the job safely.
Removing Parts:
Always consider the weight of a part when lifting. Use a hoist whenever necessary. Do not lift heavy parts by hand. A hoist and adjustable lifting beam or sling are needed to remove some parts. The lengths of chains or cables from the hoist to the part should be equal and parallel, and should be positioned directly over the center of the part.
- Be sure that no obstructions will interfere with the lifting operation. Never leave a part suspended in mid-air. Always use blocking or proper stands to support the part that has been hoisted.
- If a part cannot be removed, verify that all bolts and attaching hardware have been removed. Check to see if any parts are in the way of the part being removed. When removing hoses, wiring or tubes, always tag each part to ensure proper installation.
Cleaning :
- If you intend to reuse parts, follow good shop practice and thoroughly clean the parts before assembly. Keep all dirt out of parts; the unit will perform better and last longer. Seals, filters and covers are used in this vehicle to keep out environmental dirt and dust.
- These items must be kept in good condition to ensure satisfactory operation. Clean and inspect all parts as they are removed. Be sure all holes and passages are clean and open. After cleaning, cover all parts with clean lint-free cloth, paper or other material. Be sure the part is clean when it is installed.
TABLE OF CONTENTS:
2002 Harley Davidson Touring FLT Models Electrical Diagnostics + Service Manual – PDF DOWNLOAD
KEYWORD SEARCH................................................................................. 0 CONTENTS....................................................................................... 1 MAIN SERVICE MANUAL............................................................................ 2 1 - MAINTENANCE............................................................................ 2 TROUBLESHOOTING 1.1.................................................................... 4 GENERAL............................................................................ 4 ENGINE............................................................................. 4 Starter Motor Does Not Operate or Does Not Turn Engine Over.................... 4 Engine Turns Over But Does Not Start........................................... 4 Starts Hard.................................................................... 4 Starts But Runs Irregularly or Misses.......................................... 4 A Spark Plug Fouls Repeatedly.................................................. 5 Pre-Ignition or Detonation (Knocks or Pings)................................... 5 Overheating.................................................................... 5 Valve Train Noise.............................................................. 5 Excessive Vibration............................................................ 5 Check Engine Lamp Illuminates During Operation................................. 5 LUBRICATION SYSTEM................................................................. 5 Oil Does Not Return To Oil Pan................................................. 5 Engine Uses Too Much Oil Or Smokes Excessively................................. 5 Engine Leaks Oil From Case, Push Rods, Hoses, Etc.............................. 5 Low Oil Pressure............................................................... 5 High Oil Pressure.............................................................. 6 ELECTRICAL SYSTEM.................................................................. 6 Alternator Does Not Charge..................................................... 6 Alternator Charge Rate Is Below Normal......................................... 6 Speedometer Operates Erratically............................................... 6 CARBURETOR......................................................................... 6 Carburetor Floods.............................................................. 6 TRANSMISSION....................................................................... 6 Transmission Shifts Hard....................................................... 6 Jumps Out Of Gear.............................................................. 6 Clutch Slips................................................................... 6 Clutch Drags Or Does Not Release............................................... 6 Clutch Chatters................................................................ 6 BRAKES............................................................................. 6 Brake Does Not Hold Normally................................................... 6 HANDLING........................................................................... 6 Irregularities................................................................. 6 SHOP PRACTICES 1.2..................................................................... 8 REPAIR NOTES....................................................................... 8 Safety......................................................................... 8 Removing Parts................................................................. 8 Cleaning....................................................................... 8 Disassembly and Assembly....................................................... 8 Checking Torques on Fasteners with Lock Patches................................ 8 REPAIR AND REPLACEMENT PROCEDURES.................................................. 8 Hardware and Threaded Parts.................................................... 8 Wiring, Hoses and Lines........................................................ 8 Instruments and Gauges......................................................... 8 Bearings....................................................................... 8 Bushings....................................................................... 9 Gaskets........................................................................ 9 Lip Type Seals................................................................. 9 O-Rings (Preformed Packings)................................................... 9 Gears.......................................................................... 9 Shafts......................................................................... 9 Part Replacement............................................................... 9 CLEANING........................................................................... 9 Part Protection................................................................ 9 Cleaning Process............................................................... 9 Rust or Corrosion Removal...................................................... 9 Bearings....................................................................... 9 TOOL SAFETY 1.3........................................................................ 10 AIR TOOLS.......................................................................... 10 WRENCHES........................................................................... 10 PLIERS/CUTTERS/PRYBARS............................................................. 10 HAMMERS............................................................................ 10 PUNCHES/CHISELS.................................................................... 10 SCREWDRIVERS....................................................................... 10 RATCHETS AND HANDLES............................................................... 10 SOCKETS............................................................................ 10 STORAGE UNITS...................................................................... 11 SCHEDULED MAINTENANCE TABLE 1.4........................................................ 12 SCHEDULED MAINTENANCE PROCEDURES 1.5................................................... 17 BATTERY............................................................................ 17 ENGINE OIL/ENGINE OIL FILTER....................................................... 17 PRIMARY CHAIN...................................................................... 18 PRIMARY CHAIN LUBRICANT............................................................ 19 CLUTCH ADJUSTMENT.................................................................. 20 TRANSMISSION LUBRICANT............................................................. 21 TIRES.............................................................................. 21 WHEEL SPOKES....................................................................... 22 STEERING HEAD BEARINGS............................................................. 22 BRAKE FLUID........................................................................ 22 BRAKE PAD LININGS AND DISCS........................................................ 23 DRIVE BELT......................................................................... 23 REAR SHOCK ABSORBERS............................................................... 25 AIR CLEANER........................................................................ 25 FUEL SYSTEM LINES AND FITTINGS..................................................... 26 FUEL TANK FILTER (Carbureted)...................................................... 26 ENRICHENER CONTROL................................................................. 27 THROTTLE CABLES.................................................................... 28 Lubrication.................................................................... 28 Adjustment..................................................................... 30 SPARK PLUGS........................................................................ 30 ELECTRICAL COMPONENTS.............................................................. 31 ENGINE IDLE SPEED.................................................................. 31 REAR SWING ARM PIVOT SHAFT NUT..................................................... 32 FASTENERS.......................................................................... 32 ENGINE MOUNTS...................................................................... 32 Top............................................................................ 32 Bottom......................................................................... 32 FRONT FORK OIL..................................................................... 33 ROAD TEST.......................................................................... 33 2 - CHASSIS................................................................................ 34 SPECIFICATIONS 2.1..................................................................... 36 DIMENSIONS (in.)................................................................... 36 WEIGHT (lbs.)...................................................................... 36 CAPACITIES (U.S.).................................................................. 36 DIMENSIONS (mm).................................................................... 36 WEIGHT (kg)........................................................................ 36 CAPACITIES (Metric)................................................................ 36 TIRE DATA.......................................................................... 37 REAR WHEEL SPROCKET................................................................ 37 TORQUE VALUES...................................................................... 37 TORQUE VALUES (CONT.’D)........................................................ 38 VEHICLE IDENTIFICATION NUMBER (VIN)................................................ 40 FRONT WHEEL 2.2........................................................................ 41 GENERAL............................................................................ 41 PRELIMINARY INSPECTION............................................................. 41 REMOVAL............................................................................ 41 DISASSEMBLY........................................................................ 41 CLEANING AND INSPECTION............................................................ 42 ASSEMBLY........................................................................... 43 INSTALLATION....................................................................... 44 REAR WHEEL 2.3......................................................................... 46 GENERAL............................................................................ 46 PRELIMINARY INSPECTION............................................................. 46 REMOVAL............................................................................ 46 DISASSEMBLY........................................................................ 46 CLEANING AND INSPECTION............................................................ 47 ASSEMBLY........................................................................... 48 INSTALLATION....................................................................... 49 CHECKING CAST RIM RUNOUT 2.4........................................................... 52 INSPECTION......................................................................... 52 WHEEL LACING - 16 INCH RIM 2.5......................................................... 53 GENERAL............................................................................ 53 WHEEL LACING....................................................................... 53 SPOKE TIGHTNESS.................................................................... 55 TRUING LACED WHEEL 2.6................................................................. 56 PROCEDURE.......................................................................... 56 TIRES AND TUBES 2.7.................................................................... 58 GENERAL............................................................................ 58 REMOVAL............................................................................ 58 CLEANING AND INSPECTION............................................................ 58 INSTALLATION....................................................................... 59 Checking Tire Radial Runout.................................................... 60 Checking Tire Lateral Runout................................................... 60 Wheel Balancing................................................................ 61 VEHICLE ALIGNMENT 2.8.................................................................. 62 PROCEDURE.......................................................................... 62 FRONT BRAKE MASTER CYLINDER 2.9........................................................ 65 GENERAL............................................................................ 65 REMOVAL/DISASSEMBLY................................................................ 65 CLEANING AND INSPECTION............................................................ 66 ASSEMBLY/INSTALLATION.............................................................. 66 REAR BRAKE MASTER CYLINDER 2.10........................................................ 70 REMOVAL............................................................................ 70 PRELIMINARY INSTRUCTIONS....................................................... 70 BRAKE PEDAL/MASTER CYLINDER ASSEMBLY, REMOVAL.................................. 70 BRAKE PEDAL/MASTER CYLINDER ASSEMBLY, INSTALLATION............................. 71 REAR BRAKE LINE, REMOVAL....................................................... 71 REAR BRAKE LINE, INSTALLATION.................................................. 72 INSTALLATION....................................................................... 72 FINAL INSTRUCTIONS............................................................. 72 MASTER CYLINDER.................................................................... 74 DISASSEMBLY.................................................................... 74 CLEANING AND INSPECTION........................................................ 75 ASSEMBLY....................................................................... 76 FRONT BRAKE CALIPER 2.11............................................................... 78 INSPECTION......................................................................... 78 BRAKE PADS..................................................................... 78 BRAKE LINE/HOSE INSPECTION..................................................... 78 FRONT BRAKE PAD REPLACEMENT........................................................ 78 PAD INSTALLATION............................................................... 79 CALIPER REMOVAL.................................................................... 80 CALIPER DISASSEMBLY................................................................ 81 CLEANING AND INSPECTION............................................................ 82 CALIPER ASSEMBLY................................................................... 82 CALIPER INSTALLATION............................................................... 83 REAR BRAKE CALIPER 2.12................................................................ 84 INSPECTION......................................................................... 84 BRAKE DISC THICKNESS/WARPAGE................................................... 84 BRAKE PADS..................................................................... 84 BRAKE LINE/HOSE INSPECTION..................................................... 84 REAR BRAKE PAD REPLACEMENT......................................................... 84 PAD INSTALLATION............................................................... 85 CALIPER REMOVAL.................................................................... 86 CALIPER DISASSEMBLY................................................................ 86 CLEANING AND INSPECTION............................................................ 88 CALIPER ASSEMBLY................................................................... 88 CALIPER INSTALLATION............................................................... 89 BLEEDING HYDRAULIC BRAKES 2.13......................................................... 90 GENERAL............................................................................ 90 FRONT FORKS 2.14....................................................................... 91 CHANGING FORK OIL.................................................................. 91 REMOVAL............................................................................ 91 DISASSEMBLY........................................................................ 92 LEFT FORK...................................................................... 92 RIGHT FORK..................................................................... 94 CLEANING AND INSPECTION............................................................ 94 ASSEMBLY........................................................................... 95 LEFT FORK...................................................................... 95 RIGHT FORK..................................................................... 97 INSTALLATION....................................................................... 99 STEERING HEAD BEARINGS 2.15............................................................ 100 LUBRICATION........................................................................ 100 CHECKING........................................................................... 100 ADJUSTMENT......................................................................... 100 REMOVAL............................................................................ 101 INSPECTION......................................................................... 102 ASSEMBLY........................................................................... 103 INSTALLATION....................................................................... 103 REAR AIR SUSPENSION 2.16............................................................... 104 GENERAL............................................................................ 104 REAR AIR SUSPENSION................................................................ 104 REMOVAL/INSTALLATION............................................................... 104 REAR SHOCK ABSORBERS 2.17.............................................................. 108 ADJUSTMENT......................................................................... 108 REMOVAL............................................................................ 108 DISASSEMBLY........................................................................ 108 CLEANING AND INSPECTION............................................................ 108 ASSEMBLY........................................................................... 108 INSTALLATION....................................................................... 109 REAR SWINGARM 2.18..................................................................... 110 REMOVAL............................................................................ 110 DISASSEMBLY/ASSEMBLY............................................................... 111 Bearing Removal................................................................ 111 Bearing Installation........................................................... 112 Pivot Shaft Disassembly........................................................ 112 Pivot Shaft Assembly........................................................... 112 INSTALLATION....................................................................... 113 THROTTLE CABLES (NON-CRUISE) 2.19...................................................... 118 ADJUSTMENT......................................................................... 118 REMOVAL............................................................................ 119 THROTTLE SIDE.................................................................. 119 CARBURETOR/INDUCTION MODULE SIDE............................................... 120 CLEANING AND INSPECTION............................................................ 120 INSTALLATION....................................................................... 120 THROTTLE SIDE.................................................................. 120 CARBURETOR/INDUCTION MODULE SIDE............................................... 121 LUBRICATION........................................................................ 122 CLUTCH CABLE 2.20...................................................................... 123 ADJUSTMENT......................................................................... 123 REMOVAL............................................................................ 123 INSTALLATION....................................................................... 124 SEAT 2.21.............................................................................. 126 FLHT............................................................................... 126 REMOVAL........................................................................ 126 INSTALLATION................................................................... 126 FLHTC/U............................................................................ 126 REMOVAL........................................................................ 126 INSTALLATION................................................................... 126 FLHR............................................................................... 127 REMOVAL........................................................................ 127 INSTALLATION................................................................... 127 FLHRC.............................................................................. 128 REMOVAL........................................................................ 128 INSTALLATION................................................................... 128 FLTR............................................................................... 128 REMOVAL........................................................................ 128 INSTALLATION................................................................... 128 SEAT RETENTION NUT REPLACEMENT................................................. 129 SADDLEBAG 2.22......................................................................... 130 OPENING............................................................................ 130 CLOSING............................................................................ 130 REMOVAL............................................................................ 130 INSTALLATION....................................................................... 131 INSPECTION AND REPAIR.............................................................. 131 TOUR-PAK 2.23.......................................................................... 133 FLHTC.............................................................................. 133 REMOVAL........................................................................ 133 INSTALLATION................................................................... 133 FLHTCU............................................................................. 134 REMOVAL........................................................................ 134 INSTALLATION................................................................... 135 TOUR-PAK LIGHTS/BACKREST/SPEAKER BOX 2.24.............................................. 136 GENERAL............................................................................ 136 SIDE MARKER LIGHTS FLHTC/U......................................................... 136 BULB/LENSE REPLACEMENT......................................................... 136 REMOVAL........................................................................ 136 INSTALLATION................................................................... 136 WRAP-AROUND LIGHT ASSEMBLY FLHTCU.................................................. 137 BULB REPLACEMENT............................................................... 137 REMOVAL........................................................................ 137 INSTALLATION................................................................... 138 PASSENGER BACKREST FLHTCU.......................................................... 138 REMOVAL........................................................................ 138 INSTALLATION................................................................... 139 SPEAKER BOX FLHTCU................................................................. 139 REMOVAL........................................................................ 139 INSTALLATION................................................................... 139 LOWER FAIRING/GLOVE BOXES (FLHTCU) 2.25................................................ 140 REMOVAL............................................................................ 140 INSTALLATION....................................................................... 140 UPPER FAIRING/WINDSHIELD (FLHT/C/U) 2.26............................................... 141 OUTER FAIRING/WINDSHIELD........................................................... 141 REMOVAL........................................................................ 141 INSTALLATION................................................................... 141 FAIRING CAP........................................................................ 142 REMOVAL........................................................................ 142 INSTALLATION................................................................... 142 INNER FAIRING...................................................................... 143 REMOVAL........................................................................ 143 INSTALLATION................................................................... 146 UPPER FAIRING/WINDSHIELD (FLTR) 2.27................................................... 149 WINDSHIELD ONLY.................................................................... 149 REMOVAL........................................................................ 149 INSTALLATION................................................................... 149 OUTER FAIRING...................................................................... 149 REMOVAL........................................................................ 149 INSTALLATION................................................................... 150 BEZEL.............................................................................. 151 REMOVAL........................................................................ 151 INSTALLATION................................................................... 151 INSTRUMENT NACELLE................................................................. 152 REMOVAL........................................................................ 152 INSTALLATION................................................................... 153 INNER FAIRING...................................................................... 155 REMOVAL........................................................................ 155 INSTALLATION................................................................... 156 GLOVE BOX DOOR/HINGE............................................................... 158 REMOVAL........................................................................ 158 INSTALLATION................................................................... 158 WINDSHIELD/HEADLAMP NACELLE (FLHR/C) 2.28.............................................. 159 WINDSHIELD REMOVAL................................................................. 159 WINDSHIELD INSTALLATION............................................................ 159 NACELLE REMOVAL.................................................................... 159 NACELLE INSTALLATION............................................................... 160 FRONT FENDER 2.29...................................................................... 162 REMOVAL............................................................................ 162 INSTALLATION....................................................................... 162 REAR FENDER 2.30....................................................................... 164 REMOVAL............................................................................ 164 INSTALLATION....................................................................... 165 JIFFY STAND 2.31....................................................................... 167 GENERAL............................................................................ 167 REMOVAL............................................................................ 167 INSTALLATION....................................................................... 168 EXHAUST SYSTEM 2.32.................................................................... 169 REMOVAL............................................................................ 169 INSTALLATION....................................................................... 169 3 - ENGINE................................................................................. 172 SPECIFICATIONS 3.1..................................................................... 174 MANUFACTURING TOLERANCES........................................................... 174 MANUFACTURING TOLERANCES (CONT.)............................................... 175 TORQUE VALUES...................................................................... 175 SERVICE WEAR LIMITS 3.2................................................................ 176 GENERAL............................................................................ 176 GENERAL INFORMATION 3.3................................................................ 178 FUEL............................................................................... 178 GASOLINE/ALCOHOL BLENDS........................................................ 178 LUBRICATION........................................................................ 178 CHECKING ENGINE OIL LEVEL...................................................... 178 CHANGING ENGINE OIL AND FILTER................................................. 179 WINTER LUBRICATION............................................................. 180 OIL PRESSURE INDICATOR LAMP.................................................... 180 ENGINE OIL FLOW................................................................ 181 Oil Feed (Figures 3-6, 3-7).................................................... 181 Top End (Figures 3-6, 3-7)..................................................... 181 Bottom End (Figures 3-6, 3-7, 3-8)............................................. 183 Oil Return (Figures 3-6, 3-8).................................................. 183 Oil Pump Operation............................................................. 183 Breather Operation............................................................. 186 HOW TO USE THIS SECTION 3.4............................................................ 187 GENERAL............................................................................ 187 Top End Overhaul............................................................... 187 Bottom End Overhaul............................................................ 187 Subassembly Service and Repair................................................. 188 STRIPPING MOTORCYCLE FOR SERVICE 3.5................................................... 189 PROCEDURE.......................................................................... 189 ASSEMBLING MOTORCYCLE AFTER STRIPPING 3.6.............................................. 191 PROCEDURE.......................................................................... 191 REMOVING ENGINE FROM CHASSIS 3.7....................................................... 194 PROCEDURE.......................................................................... 194 INSTALLING ENGINE IN CHASSIS 3.8....................................................... 199 PROCEDURE.......................................................................... 199 SPECIAL TOOLS (for Servicing of the Twin Cam 88 Engine) 3.9............................ 206 SPECIAL TOOLS...................................................................... 208 TOP END OVERHAUL 3.10.................................................................. 210 DISASSEMBLY........................................................................ 210 ASSEMBLY........................................................................... 214 BOTTOM END OVERHAUL 3.11............................................................... 222 DISASSEMBLY........................................................................ 222 ASSEMBLY........................................................................... 224 SUBASSEMBLY SERVICE AND REPAIR 3.12.................................................... 232 TOP END............................................................................ 232 BREATHER ASSEMBLY.................................................................. 232 Removal........................................................................ 232 Disassembly.................................................................... 232 Cleaning and Inspection........................................................ 232 Assembly....................................................................... 232 Installation................................................................... 232 ROCKER ARM ASSEMBLY................................................................ 233 Removal........................................................................ 233 Disassembly.................................................................... 233 Cleaning and Inspection........................................................ 233 Assembly....................................................................... 234 Installation................................................................... 235 PUSH RODS/LIFTERS/COVERS........................................................... 236 Removal........................................................................ 236 Disassembly.................................................................... 236 Cleaning and Inspection........................................................ 236 Assembly....................................................................... 236 Installation................................................................... 237 CYLINDER HEAD...................................................................... 240 Removal........................................................................ 240 Disassembly.................................................................... 240 Cleaning and Inspection........................................................ 241 VALVE GUIDE REPLACEMENT........................................................ 242 VALVE AND SEAT REFACING........................................................ 245 Assembly....................................................................... 248 Installation................................................................... 250 CYLINDER........................................................................... 251 Removal........................................................................ 251 Cleaning and Inspection........................................................ 251 Installation................................................................... 253 PISTON................................................................................. 254 Removal............................................................................ 254 Disassembly........................................................................ 254 Piston Rings....................................................................... 254 Cleaning and Inspection............................................................ 254 Assembly........................................................................... 255 Piston Rings....................................................................... 255 Installation....................................................................... 256 UPPER CONNECTING ROD................................................................... 257 Removal............................................................................ 257 Disassembly/Assembly............................................................... 257 Upper Connecting Rod Bushing....................................................... 257 Reaming Upper Rod Bushing.......................................................... 258 Honing Upper Rod Bushing........................................................... 259 Installation....................................................................... 260 BOTTOM END............................................................................. 262 CAM SUPPORT PLATE...................................................................... 262 Removal............................................................................ 262 Disassembly/Assembly............................................................... 262 Crankshaft Bushing................................................................. 262 Reaming Crankshaft Bushing......................................................... 263 Camshafts/Camshaft Bearings........................................................ 264 Cam Chain Tensioners............................................................... 270 Oil Pressure Relief Valve.......................................................... 271 Cam Needle Bearings................................................................ 271 Cleaning and Inspection............................................................ 273 Installation....................................................................... 273 OIL PUMP............................................................................... 274 Removal............................................................................ 274 Cleaning and Inspection............................................................ 274 Installation....................................................................... 274 CRANKCASE.............................................................................. 276 Removal............................................................................ 276 Disassembly/Assembly............................................................... 276 RIGHT CRANKCASE HALF............................................................... 276 Crankshaft (Roller) Bearing........................................................ 276 Piston Jets........................................................................ 277 LEFT CRANKCASE HALF................................................................ 277 Sprocket Shaft (Timken) Bearing.................................................... 277 Cylinder Studs..................................................................... 284 Pipe Plug and Oil Fittings......................................................... 284 Cleaning and Inspection............................................................ 284 Installation....................................................................... 284 FLYWHEEL/CONNECTING ROD ASSEMBLY....................................................... 285 Removal............................................................................ 285 Inspection......................................................................... 285 Installation....................................................................... 285 4 - FUEL SYSTEM............................................................................ 286 SPECIFICATIONS 4.1..................................................................... 288 CVH CARBURETOR JET SIZES........................................................... 288 FUEL TANK CAPACITY................................................................. 288 TORQUE VALUES...................................................................... 288 FUEL SYSTEM TROUBLESHOOTING (CARBURETED) 4.2........................................... 289 ENRICHENER (CARBURETED) 4.3............................................................ 292 GENERAL............................................................................ 292 OPERATION.......................................................................... 292 Enrichener..................................................................... 292 Cool Engine.................................................................... 293 Warm Climate Or Hot Engine..................................................... 293 ADJUSTMENTS........................................................................ 293 Slow Idle...................................................................... 293 Enrichener Control............................................................. 294 CARBURETOR 4.4......................................................................... 296 REMOVAL............................................................................ 296 INSTALLATION....................................................................... 296 DISASSEMBLY - TOP END.............................................................. 297 DISASSEMBLY - BOTTOM END........................................................... 297 CLEANING AND INSPECTION............................................................ 299 Carburetor Housing............................................................. 299 Top End Components............................................................. 299 Bottom End Components.......................................................... 300 ASSEMBLY - TOP END................................................................. 300 ASSEMBLY - BOTTOM END.............................................................. 301 AIR CLEANER 4.5........................................................................ 303 GENERAL............................................................................ 303 REMOVAL............................................................................ 303 CLEANING AND INSPECTION............................................................ 303 INSTALLATION....................................................................... 304 VACUUM OPERATED FUEL VALVE (CARBURETED) 4.6............................................ 305 GENERAL............................................................................ 305 TROUBLESHOOTING.................................................................... 305 REMOVAL........................................................................ 305 CLEANING AND INSPECTION........................................................ 306 INSTALLATION................................................................... 306 FUEL TANK (CARBURETED) 4.7............................................................. 308 COMPLETE REMOVAL................................................................... 308 FLHT/C, FLTR................................................................... 308 FLHR........................................................................... 309 CLEANING AND INSPECTION............................................................ 309 INSTALLATION (AFTER COMPLETE REMOVAL).............................................. 310 FLHT/C, FLTR................................................................... 310 FLHR........................................................................... 311 PARTIAL REMOVAL.................................................................... 311 FLHT/C, FLTR................................................................... 311 FLHR........................................................................... 312 INSTALLATION (AFTER PARTIAL REMOVAL)............................................... 312 FLHT/C, FLTR................................................................... 312 FLHR........................................................................... 313 EVAPORATIVE EMISSIONS CONTROL SYSTEM 4.8............................................... 314 CALIFORNIA MODELS ONLY............................................................. 314 TROUBLESHOOTING.................................................................... 315 VAPOR VALVE........................................................................ 315 REMOVAL........................................................................ 315 INSTALLATION................................................................... 315 CHARCOAL CANISTER.................................................................. 316 REMOVAL........................................................................ 316 INSTALLATION................................................................... 316 Charcoal Canister Hose Routing................................................. 317 Purge Tube:.................................................................... 317 Fuel Vapor Vent Tube:.......................................................... 317 Clean Air Inlet Tube:.......................................................... 317 5 - ELECTRIC STARTER....................................................................... 318 SPECIFICATIONS 5.1..................................................................... 320 STARTER............................................................................ 320 SERVICE WEAR LIMITS................................................................ 320 TORQUE VALUES...................................................................... 320 STARTER SYSTEM 5.2..................................................................... 321 GENERAL............................................................................ 321 Operation (Figure 5-1)......................................................... 321 STARTER RELAY 5.3...................................................................... 323 REMOVAL............................................................................ 323 FLHR/C......................................................................... 323 FLTR, FLHT/C/U................................................................. 323 INSTALLATION....................................................................... 323 FLHR/C......................................................................... 323 FLTR, FLHT/C/U................................................................. 323 STARTER 5.4............................................................................ 324 REMOVAL............................................................................ 324 INSTALLATION....................................................................... 324 DISASSEMBLY, TESTING AND REPAIR.................................................... 326 ASSEMBLY........................................................................... 330 STARTER SOLENOID 5.5................................................................... 331 GENERAL............................................................................ 331 DISASSEMBLY........................................................................ 331 ASSEMBLY........................................................................... 331 STARTER JACKSHAFT 5.6.................................................................. 332 REMOVAL/DISASSEMBLY................................................................ 332 ASSEMBLY/INSTALLATION.............................................................. 333 6 - DRIVE.................................................................................. 334 SPECIFICATIONS 6.1..................................................................... 336 OVERALL GEAR RATIOS................................................................ 336 CHAINS AND BELTS................................................................... 336 SPROCKETS.......................................................................... 336 CLUTCH............................................................................. 336 TORQUE VALUES...................................................................... 336 PRIMARY CHAIN AND SPROCKETS 6.2........................................................ 338 PRIMARY CHAIN ADJUSTMENT........................................................... 338 ADJUSTER SHOE REPLACEMENT.......................................................... 338 DISASSEMBLY........................................................................ 340 CLEANING AND INSPECTION............................................................ 340 Sprocket Alignment (Figure 6-3, 6-4)........................................... 340 ASSEMBLY........................................................................... 341 CLUTCH 6.3............................................................................. 342 ADJUSTMENT......................................................................... 342 REMOVAL/INSTALLATION............................................................... 343 PARTIAL DISASSEMBLY............................................................ 343 ASSEMBLY....................................................................... 343 CLEANING AND INSPECTION............................................................ 345 COMPLETE DISASSEMBLY........................................................... 345 ASSEMBLY....................................................................... 346 SECONDARY DRIVE BELT AND SPROCKETS 6.4................................................. 348 ADJUSTMENT......................................................................... 348 INSPECTION......................................................................... 349 REPLACEMENT........................................................................ 350 Removal........................................................................ 350 Installation................................................................... 350 TRANSMISSION SPROCKET.............................................................. 350 Removal........................................................................ 350 Cleaning and Inspection........................................................ 351 Installation................................................................... 351 REAR WHEEL SPROCKET................................................................ 353 Removal........................................................................ 353 Cleaning and Inspection........................................................ 353 Installation................................................................... 353 PRIMARY CHAINCASE 6.5.................................................................. 354 GENERAL............................................................................ 354 LUBRICATION........................................................................ 354 REMOVAL............................................................................ 354 INSPECTION AND REPAIR.............................................................. 357 DISASSEMBLY........................................................................ 357 MAINSHAFT BEARING AND LIP SEAL................................................. 357 MAINSHAFT BEARING INNER RACE................................................... 358 STARTER JACKSHAFT BUSHING AND LIP SEAL - PRIMARY CHAINCASE..................... 359 STARTER JACKSHAFT BUSHING - PRIMARY CHAINCASE COVER............................ 359 SHIFTER BRACKET BUSHINGS....................................................... 360 INSTALLATION....................................................................... 361 7 - TRANSMISSION........................................................................... 366 SPECIFICATIONS 7.1..................................................................... 368 TRANSMISSION DATA.................................................................. 368 SERVICE WEAR LIMITS................................................................ 368 SERVICE WEAR LIMITS (CONT.’D).................................................. 369 TORQUE VALUES...................................................................... 369 TRANSMISSION POWER FLOW 7.2............................................................ 370 GENERAL............................................................................ 370 Neutral........................................................................ 370 1st Gear....................................................................... 370 2nd Gear....................................................................... 370 3rd Gear....................................................................... 370 4th Gear....................................................................... 370 5th Gear....................................................................... 370 SHIFTER LINKAGE 7.3.................................................................... 372 ADJUSTMENT......................................................................... 372 Shifter Linkage................................................................ 372 SHIFTER CAM ASSEMBLY/SHIFTER FORKS 7.4................................................. 373 DISASSEMBLY........................................................................ 373 CLEANING AND INSPECTION............................................................ 374 ASSEMBLY........................................................................... 375 CLUTCH RELEASE COVER 7.5............................................................... 379 REMOVAL/DISASSEMBLY................................................................ 379 CLEANING AND INSPECTION............................................................ 379 ASSEMBLY/INSTALLATION.............................................................. 380 MAINSHAFT/COUNTERSHAFT 7.6............................................................. 382 REMOVAL............................................................................ 382 DISASSEMBLY........................................................................ 382 CLEANING AND INSPECTION............................................................ 383 ASSEMBLY........................................................................... 385 INSTALLATION....................................................................... 388 MAIN DRIVE GEAR 7.7.................................................................... 389 REMOVAL............................................................................ 389 CLEANING AND INSPECTION............................................................ 389 Needle Bearing Replacement..................................................... 390 INSTALLATION....................................................................... 391 Countershaft Needle Bearing Replacement........................................ 394 TRANSMISSION CASE/OIL PAN 7.8.......................................................... 395 GENERAL............................................................................ 395 REMOVAL............................................................................ 395 Transmission Case and Oil Pan.................................................. 395 Oil Pan Only................................................................... 396 CLEANING AND INSPECTION............................................................ 397 INSTALLATION....................................................................... 397 Oil Pan Only................................................................... 397 Transmission Case and Oil Pan.................................................. 397 NOTES.................................................................................. 399 8 - ELECTRICAL............................................................................. 400 SPECIFICATIONS 8.1..................................................................... 402 IGNITION TIMING.................................................................... 402 ALTERNATOR SYSTEM.................................................................. 402 BATTERY............................................................................ 402 FUSES.............................................................................. 402 SPARK PLUG......................................................................... 403 TORQUE VALUES...................................................................... 403 BULB CHART 8.2......................................................................... 404 IGNITION MODULE 8.3.................................................................... 406 REMOVAL............................................................................ 406 INSTALLATION....................................................................... 406 ENGINE SENSORS 8.4..................................................................... 407 MANIFOLD ABSOLUTE PRESSURE SENSOR.................................................. 407 Removal........................................................................ 407 Installation................................................................... 407 CRANKSHAFT POSITION SENSOR......................................................... 407 IGNITION COIL 8.5...................................................................... 408 REMOVAL............................................................................ 408 INSTALLATION....................................................................... 408 SPARK PLUGS/SPARK PLUG CABLES 8.6...................................................... 409 SPARK PLUGS........................................................................ 409 REMOVAL........................................................................ 409 INSPECTION..................................................................... 409 CLEANING....................................................................... 409 ADJUSTMENT..................................................................... 409 INSTALLATION................................................................... 409 SPARK PLUG CABLES.................................................................. 410 REMOVAL........................................................................ 410 INSPECTION..................................................................... 410 INSTALLATION................................................................... 410 ALTERNATOR/STATOR 8.7.................................................................. 411 REMOVAL............................................................................ 411 CLEANING AND INSPECTION............................................................ 412 INSTALLATION....................................................................... 413 VOLTAGE REGULATOR 8.8.................................................................. 416 REMOVAL............................................................................ 416 INSTALLATION....................................................................... 416 BATTERY 8.9............................................................................ 420 GENERAL............................................................................ 420 VOLTMETER TEST..................................................................... 420 DISCONNECTION AND REMOVAL.......................................................... 421 CLEANING AND INSPECTION............................................................ 421 BATTERY CHARGING................................................................... 421 SAFETY PRECAUTIONS............................................................. 421 CHARGING BATTERY............................................................... 421 LOAD TEST.......................................................................... 422 BATTERY CABLE ROUTING.............................................................. 423 INSTALLATION AND CONNECTION........................................................ 423 STORAGE............................................................................ 424 HEADLAMP (FLHR/C, FLHT/C/U) 8.10....................................................... 425 HEADLAMP ASSEMBLY.................................................................. 425 REMOVAL........................................................................ 425 INSTALLATION................................................................... 425 HEADLAMP BULB REPLACEMENT.......................................................... 425 HEADLAMP ADJUSTMENT................................................................ 426 HEADLAMP (FLTR) 8.11................................................................... 428 HEADLAMP ASSEMBLY.................................................................. 428 REMOVAL........................................................................ 428 INSTALLATION................................................................... 428 HEADLAMP BULB REPLACEMENT.......................................................... 428 REMOVAL........................................................................ 428 INSTALLATION................................................................... 429 HEADLAMP ADJUSTMENT................................................................ 429 PASSING LAMPS 8.12..................................................................... 431 ADJUSTMENT......................................................................... 431 PASSING LAMP BULB.................................................................. 431 REMOVAL........................................................................ 431 INSTALLATION................................................................... 431 PASSING LAMP BRACKET............................................................... 431 REMOVAL........................................................................ 431 INSTALLATION................................................................... 432 PASSING LAMP....................................................................... 433 REMOVAL........................................................................ 433 INSTALLATION................................................................... 433 TAIL LAMP ASSEMBLY 8.13................................................................ 434 TAIL LAMP.......................................................................... 434 REMOVAL........................................................................ 434 INSTALLATION................................................................... 434 CIRCUIT BOARD/TAIL LAMP BRACKET ASSEMBLY........................................... 434 REMOVAL........................................................................ 434 INSTALLATION................................................................... 435 FENDER TIP LAMPS 8.14.................................................................. 437 FRONT FENDER TIP LAMP.............................................................. 437 REMOVAL........................................................................ 437 INSTALLATION................................................................... 437 FRONT FENDER TIP LAMP JUMPER HARNESS............................................... 437 REMOVAL........................................................................ 437 INSTALLATION................................................................... 439 REAR FENDER TIP LAMP............................................................... 439 REMOVAL........................................................................ 439 INSTALLATION................................................................... 440 TURN SIGNAL LAMPS 8.15................................................................. 442 GENERAL............................................................................ 442 FLHT/C/U, FLHR/C............................................................... 442 BULB REPLACEMENT................................................................... 442 FRONT TURN SIGNAL LAMP............................................................. 442 REMOVAL........................................................................ 442 INSTALLATION................................................................... 443 REAR TURN SIGNAL LAMP.............................................................. 444 REMOVAL........................................................................ 444 INSTALLATION................................................................... 444 TURN SIGNAL/SECURITY MODULE 8.16....................................................... 446 REMOVAL............................................................................ 446 INSTALLATION....................................................................... 446 IGNITION/LIGHT KEY SWITCH AND FORK LOCK 8.17........................................... 448 FLHT/C/U (Domestic)................................................................ 448 REMOVAL........................................................................ 448 INSTALLATION................................................................... 449 FLHT/C/U (International)........................................................... 449 REMOVAL........................................................................ 449 INSTALLATION................................................................... 450 FAIRING CAP SWITCHES (FLHTC/U) 8.18.................................................... 452 REMOVAL............................................................................ 452 INSTALLATION....................................................................... 452 INSTRUMENT NACELLE SWITCHES (FLTR) 8.19................................................ 455 REMOVAL............................................................................ 455 LEFT SIDE SWITCH............................................................... 455 RIGHT SIDE SWITCH.............................................................. 456 INSTALLATION....................................................................... 457 LEFT SIDE SWITCH............................................................... 457 RIGHT SIDE SWITCH.............................................................. 458 HANDLEBAR SWITCHES 8.20................................................................ 460 GENERAL............................................................................ 460 REMOVAL............................................................................ 460 RIGHT HANDLEBAR CONTROLS....................................................... 460 LEFT HANDLEBAR CONTROLS........................................................ 461 INSTALLATION....................................................................... 461 RIGHT HANDLEBAR CONTROLS....................................................... 461 LEFT HANDLEBAR CONTROLS........................................................ 463 SWITCH REPAIR/REPLACEMENT.......................................................... 466 RIGHT SIDE HANDLEBAR SWITCHES.................................................. 466 LEFT SIDE HANDLEBAR SWITCHES................................................... 466 SPECIFIC REPAIR PROCEDURES......................................................... 466 UPPER SWITCH HOUSINGS.......................................................... 466 LOWER SWITCH HOUSINGS.......................................................... 468 GENERAL REPAIR PROCEDURES.......................................................... 475 RIGHT SIDE HANDLEBAR SWITCHES.................................................. 476 LEFT SIDE HANDLEBAR SWITCHES................................................... 477 STOPLIGHT SWITCHES 8.21................................................................ 478 FRONT STOPLIGHT SWITCH............................................................. 478 REAR STOPLIGHT SWITCH.............................................................. 478 NEUTRAL SWITCH 8.22.................................................................... 479 GENERAL............................................................................ 479 REMOVAL............................................................................ 479 INSTALLATION....................................................................... 479 HORN 8.23.............................................................................. 480 TROUBLESHOOTING.................................................................... 480 REMOVAL............................................................................ 480 INSTALLATION....................................................................... 480 CIGARETTE LIGHTER (FLHTCU, FLTR) 8.24.................................................. 481 GENERAL............................................................................ 481 TROUBLESHOOTING.................................................................... 481 REMOVAL............................................................................ 481 INSTALLATION....................................................................... 481 GAUGES/INSTRUMENTS (FLHT/C/U, FLTR) 8.25............................................... 482 GAUGES- 2 INCH DIAMETER............................................................ 482 REMOVAL........................................................................ 482 INSTALLATION................................................................... 482 GAUGES- 4 INCH DIAMETER............................................................ 482 TACHOMETER..................................................................... 482 REMOVAL........................................................................ 482 INSTALLATION................................................................... 482 SPEEDOMETER SPEED SENSOR........................................................... 483 REMOVAL........................................................................ 483 INSTALLATION................................................................... 483 SPEEDOMETER........................................................................ 483 REMOVAL........................................................................ 483 INSTALLATION................................................................... 483 INDICATOR LAMPS.................................................................... 484 REMOVAL........................................................................ 484 INSTALLATION................................................................... 484 GAUGES/INSTRUMENTS (FLHR/C) 8.26....................................................... 485 FUEL GAUGE......................................................................... 485 REMOVAL........................................................................ 485 INSTALLATION................................................................... 485 SPEEDOMETER SPEED SENSOR........................................................... 486 REMOVAL........................................................................ 486 INSTALLATION................................................................... 486 SPEEDOMETER........................................................................ 486 REMOVAL........................................................................ 486 INSTALLATION................................................................... 487 INDICATOR LIGHTS................................................................... 487 REMOVAL........................................................................ 487 INSTALLATION................................................................... 488 FUEL LEVEL SENDER (Carbureted) 8.27.................................................... 489 ALL MODELS (EXCEPT FLHR)........................................................... 489 REMOVAL........................................................................ 489 INSTALLATION................................................................... 489 FLHR ONLY.......................................................................... 490 REMOVAL........................................................................ 490 INSTALLATION................................................................... 491 CRUISE CONTROL (FLHRC, FLTR, FLHTCU) 8.28.............................................. 492 GENERAL............................................................................ 492 SYSTEM OPERATION................................................................... 492 CABLE ADJUSTMENT................................................................... 493 THROTTLE CABLE................................................................. 493 IDLE CABLE..................................................................... 494 CABLE LASH INITIALIZATION...................................................... 494 THROTTLE/IDLE CABLES............................................................... 494 REMOVAL........................................................................ 494 INSTALLATION................................................................... 495 CRUISE CABLE....................................................................... 497 REMOVAL........................................................................ 497 INSTALLATION................................................................... 497 CRUISE CONTROL MODULE.............................................................. 498 REMOVAL........................................................................ 498 INSTALLATION................................................................... 498 AUDIO HARNESS...................................................................... 499 CRUISE CONTROL SWITCHES............................................................ 499 FAIRING CAP.................................................................... 499 HANDLEBAR...................................................................... 499 PREMIUM SOUND SYSTEM (FLHTC/U, FLTR) 8.29.............................................. 500 RADIO (FLHTC/U).................................................................... 500 REMOVAL........................................................................ 500 INSTALLATION................................................................... 501 FRONT FAIRING SPEAKERS............................................................. 501 REMOVAL........................................................................ 501 INSTALLATION................................................................... 501 CONSOLE POD ASSEMBLY............................................................... 502 REMOVAL........................................................................ 502 INSTALLATION................................................................... 502 INTERCOM/CB SWITCHES............................................................... 503 REMOVAL........................................................................ 503 INSTALLATION................................................................... 503 FRONT HEADSET RECEPTACLE........................................................... 504 REMOVAL........................................................................ 504 INSTALLATION................................................................... 504 REAR HEADSET RECEPTACLE............................................................ 504 REAR PASSENGER SWITCHES............................................................ 505 REMOVAL........................................................................ 505 INSTALLATION................................................................... 505 REAR SPEAKERS...................................................................... 507 REMOVAL........................................................................ 507 INSTALLATION................................................................... 507 FUSE BLOCKS........................................................................ 507 REMOVAL........................................................................ 507 INSTALLATION................................................................... 508 CB LOADING COIL.................................................................... 508 REMOVAL........................................................................ 508 INSTALLATION................................................................... 508 AUDIO HARNESS.................................................................. 509 RADIO ANTENNA CABLE............................................................ 509 CB ANTENNA CABLE............................................................... 509 WIRING HARNESSES AND CABLES (FLHT/C/U) 8.30............................................ 510 MAIN HARNESS....................................................................... 510 REMOVAL........................................................................ 510 INSTALLATION................................................................... 513 INTERCONNECT HARNESS............................................................... 517 REMOVAL........................................................................ 517 INSTALLATION................................................................... 517 AUDIO HARNESS...................................................................... 521 REMOVAL........................................................................ 521 INSTALLATION................................................................... 522 RADIO ANTENNA CABLE................................................................ 524 REMOVAL........................................................................ 524 INSTALLATION................................................................... 525 CB ANTENNA CABLE................................................................... 526 REMOVAL........................................................................ 526 INSTALLATION................................................................... 526 9 - FUEL INJECTION......................................................................... 528 SPECIFICATIONS 9.1..................................................................... 530 EFI FUSES.......................................................................... 530 TORQUE VALUES...................................................................... 530 ELECTRICAL BRACKET ASSEMBLY 9.2........................................................ 532 GENERAL............................................................................ 532 DATA LINK CONNECTOR................................................................ 532 SETTING ENGINE IDLE SPEED...................................................... 532 EFI SYSTEM RELAY................................................................... 533 REMOVAL........................................................................ 533 INSTALLATION................................................................... 533 EFI FUSES.......................................................................... 533 REMOVAL........................................................................ 533 INSTALLATION................................................................... 533 ELECTRONIC CONTROL MODULE.......................................................... 534 REMOVAL........................................................................ 534 INSTALLATION................................................................... 534 SIREN CONNECTOR.................................................................... 534 REMOVAL........................................................................ 534 INSTALLATION................................................................... 534 EFI WIRE HARNESS................................................................... 534 REMOVAL........................................................................ 534 INSTALLATION................................................................... 536 SENSORS 9.3............................................................................ 539 GENERAL............................................................................ 539 INTAKE AIR TEMPERATURE SENSOR.................................................. 539 THROTTLE POSITION SENSOR....................................................... 539 MANIFOLD ABSOLUTE PRESSURE SENSOR.............................................. 539 BANK ANGLE SENSOR.............................................................. 539 CRANKSHAFT POSITION SENSOR......................................................... 539 REMOVAL........................................................................ 539 INSTALLATION................................................................... 540 ENGINE TEMPERATURE SENSOR.......................................................... 541 REMOVAL........................................................................ 541 INSTALLATION................................................................... 541 FUEL TANK (FUEL INJECTED) 9.4.......................................................... 543 GENERAL............................................................................ 543 COMPLETE REMOVAL................................................................... 543 FLHTC/U-I, FLTR-I.............................................................. 543 FLHR/C-I....................................................................... 545 INSTALLATION (AFTER COMPLETE REMOVAL).............................................. 545 FLHTC/U-I, FLTR-I.............................................................. 545 FLHR/C-I....................................................................... 547 PARTIAL REMOVAL.................................................................... 547 FLHTC/U-I, FLTR-I.............................................................. 547 FLHR/C-I....................................................................... 548 INSTALLATION (AFTER PARTIAL REMOVAL)............................................... 549 FLHTC/U-I, FLTR-I.............................................................. 549 FLHR/C-I....................................................................... 549 CONSOLE POD/CANOPY................................................................. 550 FLHTC/U-I, FLTR-I.............................................................. 550 REMOVAL........................................................................ 550 INSTALLATION................................................................... 551 INSTRUMENT CONSOLE/CANOPY.......................................................... 552 FLHR/C-I....................................................................... 552 REMOVAL........................................................................ 552 INSTALLATION................................................................... 553 FUEL FILTER CANISTER............................................................... 554 REMOVAL........................................................................ 554 INSTALLATION................................................................... 555 FUEL PRESSURE REGULATOR............................................................ 555 REMOVAL........................................................................ 555 INSTALLATION................................................................... 556 FUEL PUMP.......................................................................... 556 REMOVAL........................................................................ 556 INSTALLATION................................................................... 556 FUEL PUMP/FUEL LEVEL SENDER WIRING................................................. 556 FUEL LEVEL SENDER.................................................................. 557 REMOVAL........................................................................ 557 INSTALLATION................................................................... 557 CANOPY CONNECTOR/O-RING............................................................ 558 REMOVAL........................................................................ 558 INSTALLATION................................................................... 558 FUEL SUPPLY CHECK VALVE/TUBE....................................................... 558 REMOVAL........................................................................ 558 INSTALLATION................................................................... 558 INDUCTION MODULE ASSEMBLY 9.5.......................................................... 560 GENERAL............................................................................ 560 INDUCTION MODULE................................................................... 560 REMOVAL........................................................................ 560 INSTALLATION................................................................... 561 FUEL SUPPLY LINE................................................................... 562 REMOVAL........................................................................ 562 INSTALLATION................................................................... 563 FUEL RAIL/FUEL SUPPLY TUBE......................................................... 563 REMOVAL........................................................................ 563 INSTALLATION................................................................... 563 FUEL INJECTORS..................................................................... 564 REMOVAL........................................................................ 564 INSTALLATION................................................................... 564 INTAKE AIR TEMPERATURE SENSOR...................................................... 565 REMOVAL........................................................................ 565 INSTALLATION................................................................... 565 THROTTLE POSITION SENSOR........................................................... 565 REMOVAL........................................................................ 565 INSTALLATION................................................................... 566 MANIFOLD ABSOLUTE PRESSURE SENSOR.................................................. 566 REMOVAL........................................................................ 566 INSTALLATION................................................................... 566 IDLE AIR CONTROL................................................................... 567 REMOVAL........................................................................ 567 INSTALLATION................................................................... 567 NOTES.................................................................................. 569 APPENDIX A - TOOLS......................................................................... 572 TOOLS A.1.............................................................................. 572 APPENDIX B - DEUTSCH ELECTRICAL CONNECTORS................................................. 590 DEUTSCH ELECTRICAL CONNECTORS B.1...................................................... 590 GENERAL............................................................................ 590 REMOVING/DISASSEMBLING............................................................. 590 REMOVING/INSTALLING SOCKETS........................................................ 590 REMOVING/INSTALLING PINS........................................................... 593 ASSEMBLING/INSTALLING.............................................................. 593 CRIMPING INSTRUCTIONS.............................................................. 593 SOLID BARREL CONTACT CRIMPING INSTRUCTIONS......................................... 595 For Size 20, 16 and 12 Contacts Wire Range 26-12 AWG........................... 595 AMP MULTILOCK ELECTRICAL CONNECTORS B.2................................................ 598 REMOVING SOCKET/PIN TERMINALS...................................................... 598 INSTALLING SOCKET/PIN TERMINALS.................................................... 598 CRIMPING INSTRUCTIONS.............................................................. 602 PACKARD ELECTRICAL CONNECTORS B.3...................................................... 603 GENERAL............................................................................ 603 PULL-TO-SEAT TERMINALS............................................................. 603 Removing Pull-to-seat Terminals External Latch Type............................ 603 Installing Pull-to-seat Terminals External Latch Type.......................... 604 Removing Pull-to-seat Terminals Wireform Type.................................. 605 Installing Pull-to-seat Terminals Wireform Type................................ 605 PUSH-TO-SEAT TERMINALS............................................................. 606 Removing Push-to-seat Terminals................................................ 606 Installing Push-to-seat Terminals.............................................. 606 CRIMPING INSTRUCTIONS.............................................................. 606 SEALED BUTT SPLICE CONNECTORS B.4...................................................... 608 PROCEDURE.......................................................................... 608 AMP ELECTRICAL CONNECTORS B.5.......................................................... 610 1-PLACE CONNECTOR.................................................................. 610 SOCKET TERMINAL................................................................ 610 PIN TERMINAL................................................................... 611 ELECTRICAL CONNECTOR LOCATIONS B.6..................................................... 612 WIRING DIAGRAMS B.7.................................................................... 624 APPENDIX C - METRIC CONVERSIONS............................................................ 638 METRIC CONVERSIONS C.1................................................................. 638 FASTENER TORQUE VALUES C.2............................................................. 639 GENERAL............................................................................ 639 FLUID CONVERSIONS C.3.................................................................. 640 UNITED STATES SYSTEM............................................................... 640 METRIC SYSTEM...................................................................... 640 BRITISH IMPERIAL SYSTEM............................................................ 640 ELECTRICAL DIAGNOSTICS MANUAL.................................................................. 642 1 - STARTING / CHARGING.................................................................... 642 STARTER TROUBLESHOOTING 1.1............................................................ 644 STARTING SYSTEM DIAGNOSIS 1.2.......................................................... 646 DIAGNOSTICS........................................................................ 646 Diagnostic Notes............................................................... 646 Starter Testing 1.............................................................. 646 Starter Testing 2: Solenoid Clicks............................................. 647 Starter Testing 3: Relay Clicks................................................ 647 Starter Testing 4: Nothing Clicks.............................................. 648 Starter Testing 5: Starter Spins, But Does Not Engage.......................... 649 Starter Testing 6: Starter Stalls or Spins Too Slowly.......................... 649 STARTER ACTIVATION CIRCUITS 1.3........................................................ 650 DIAGNOSTICS/TROUBLESHOOTING 1.4........................................................ 651 GENERAL............................................................................ 651 VOLTAGE DROPS...................................................................... 651 STARTER SYSTEM TESTING 1.5............................................................. 652 GENERAL............................................................................ 652 STARTER RELAY TEST 1............................................................... 652 STARTER RELAY TEST 2............................................................... 652 STARTER CURRENT DRAW TEST.......................................................... 653 TESTING ASSEMBLED STARTER 1.6.......................................................... 654 STARTER SOLENOID................................................................... 654 SOLENOID PULL-IN TEST.............................................................. 654 SOLENOID HOLD-IN TEST.............................................................. 654 SOLENOID RETURN TEST............................................................... 655 FREE RUNNING CURRENT DRAW TEST..................................................... 655 CHARGING SYSTEM 1.7.................................................................... 656 GENERAL............................................................................ 656 Alternator..................................................................... 656 Voltage Regulator.............................................................. 656 TROUBLESHOOTING.................................................................... 656 Battery........................................................................ 656 Wiring......................................................................... 656 Voltage Regulator Inspection................................................... 656 Test 1.7 (Part 1 of 2)......................................................... 657 Test 1.7 (Part 2 of 2)......................................................... 658 TESTING............................................................................ 659 REGULATOR BLEED TEST........................................................... 659 MILLIAMP DRAW TEST............................................................. 659 TOTAL CURRENT DRAW TEST........................................................ 659 CURRENT OUTPUT TEST............................................................ 660 VOLTAGE OUTPUT TEST............................................................ 660 STATOR CHECK................................................................... 660 AC OUTPUT CHECK................................................................ 661 BATTERY LOAD TEST 1.8.................................................................. 662 VOLTMETER TEST..................................................................... 662 LOAD TEST.......................................................................... 662 2 - INSTRUMENTS............................................................................ 664 GAUGES AND INSTRUMENTS 2.1............................................................. 666 GENERAL............................................................................ 666 DIAGNOSTICS........................................................................ 666 Fuel Level Gauge............................................................... 666 Fuel Level Sender Test......................................................... 666 Fuel Gauge: FLHR/C............................................................. 667 Low Fuel Level Lamp: FLHTCU, FLTR.............................................. 667 Low Fuel Level Lamp: FLHR/C.................................................... 667 Oil Pressure Gauge and Indicator Light......................................... 668 Ambient Air Temperature Gauge.................................................. 668 Voltmeter...................................................................... 669 Indicator Lights: FLHR/C....................................................... 669 SPEEDOMETER 2.2........................................................................ 670 GENERAL............................................................................ 670 Reset Switch................................................................... 670 Diagnostic Mode................................................................ 670 DIAGNOSTICS........................................................................ 671 Diagnostic Notes............................................................... 671 Speedometer Test 1............................................................. 672 Speedometer Test 2A............................................................ 673 Speedometer Test 2B............................................................ 674 SPEEDOMETER PERFORMANCE CHECK 2.3...................................................... 676 GENERAL............................................................................ 676 TESTING............................................................................ 676 Frequency Input Test........................................................... 676 Needle Sweep Test.............................................................. 677 Speedometer Sensor Test........................................................ 677 Tachometer Testing............................................................. 677 3 - TSM / TSSM............................................................................. 678 TSM/TSSM OVERVIEW 3.1.................................................................. 680 GENERAL............................................................................ 680 TROUBLESHOOTING.................................................................... 680 TSM/TSSM FEATURES 3.2.................................................................. 682 GENERAL............................................................................ 682 TURN SIGNAL FUNCTIONS.............................................................. 682 TSM/TSSM Features.............................................................. 682 BANK ANGLE FUNCTIONS............................................................... 682 TSM/TSSM Features.............................................................. 682 SECURITY ALARM AND IMMOBILIZATION FUNCTIONS........................................ 682 TSSM Only Feature.............................................................. 682 TSM/TSSM VEHICLE DELIVERY 3.3.......................................................... 684 GENERAL............................................................................ 684 USING SCANALYZER ON EFI MODELS..................................................... 684 SIDECAR CONFIGURATION.............................................................. 684 POWER DISRUPTION AND CONFIGURING................................................... 684 KEY FOB ASSIGNMENT................................................................. 685 PERSONAL CODE ENTRY................................................................ 685 First Time Code Entry: TSSM Only............................................... 685 Modifying Existing Codes: TSSM Only............................................ 685 TSM/TSSM TURN SIGNAL FUNCTIONS 3.4..................................................... 689 GENERAL............................................................................ 689 AUTOMATIC CANCELLATION............................................................. 689 MANUAL CANCELLATION................................................................ 689 FOUR-WAY FLASHING.................................................................. 689 DIAGNOSTICS MODE................................................................... 689 TSM/TSSM BANK ANGLE FUNCTION 3.5....................................................... 691 GENERAL............................................................................ 691 OPERATION.......................................................................... 691 SECURITY SYSTEM (TSSM) FUNCTIONS 3.6................................................... 692 GENERAL............................................................................ 692 Security System Operation...................................................... 692 Security System Options........................................................ 692 Differences By Market Specifications........................................... 692 ALARM SENSITIVITY.................................................................. 692 Sensitivity.................................................................... 692 Transport Mode................................................................. 692 AUTO-ARMING FUNCTION............................................................... 693 STORAGE MODE....................................................................... 693 ARMING/DISARMING SECURITY SYSTEM (TSSM) 3.7............................................ 696 GENERAL............................................................................ 696 SECURITY LAMP...................................................................... 696 USING KEY FOB...................................................................... 696 General........................................................................ 696 Arming the System.............................................................. 696 Disarming the System........................................................... 696 Troubleshooting................................................................ 696 USING THE PERSONAL CODE............................................................ 697 General........................................................................ 697 Disarming the System........................................................... 697 CHECKING FOR TROUBLE CODES: TSM/TSSM 3.8............................................... 698 GENERAL............................................................................ 698 CODE TYPES......................................................................... 698 Current........................................................................ 698 Historic....................................................................... 698 TURN SIGNAL DIAGNOSTICS............................................................ 698 CHECKING FOR TROUBLE CODES: TSSM ONLY 3.9.............................................. 700 SECURITY LAMP...................................................................... 700 BREAKOUT BOX: TSM/TSSM 3.10............................................................ 702 GENERAL............................................................................ 702 INSTALLATION....................................................................... 702 REMOVAL............................................................................ 702 SCANALYZER: EFI ONLY 3.11.............................................................. 703 SCANALYZER DIAGNOSTICS............................................................. 703 General........................................................................ 703 Data Link Connector............................................................ 703 Scanalyzer Cartridge........................................................... 703 INSTALLATION....................................................................... 703 USAGE.............................................................................. 705 Checking Codes................................................................. 705 Clearing Codes................................................................. 705 REMOVAL............................................................................ 705 INITIAL DIAGNOSTIC CHECK: TSM/TSSM 3.12................................................ 706 GENERAL............................................................................ 706 Diagnostic Notes............................................................... 706 Scanalyzer Icon................................................................ 706 Circuit Diagram/Wire Harness Connector Table................................... 706 Job/Time Code Values........................................................... 706 INITIAL DIAGNOSTICS................................................................ 706 Diagnostic Tips................................................................ 706 Diagnostic Notes............................................................... 707 Multiple Trouble Codes......................................................... 707 Diagnostic Check (Part 1 of 2)................................................. 709 Diagnostic Check (Part 2 of 2)................................................. 710 NO SECURITY LAMP AT KEY ON 3.13........................................................ 712 GENERAL............................................................................ 712 No TSSM Power.................................................................. 712 DIAGNOSTICS........................................................................ 712 Diagnostic Tips................................................................ 712 Diagnostic Notes............................................................... 712 Test 3.13 (Part 1 of 3)........................................................ 714 Test 3.13 (Part 2 of 3)........................................................ 715 Test 3.13 (Part 3 of 3)........................................................ 716 SECURITY LAMP ON CONTINUOUSLY 3.14..................................................... 717 GENERAL............................................................................ 717 DIAGNOSTICS........................................................................ 717 Diagnostic Notes............................................................... 717 Test 3.14...................................................................... 719 KEY FOB SIGNAL TO TSSM WEAK OR FAILS 3.15.............................................. 720 GENERAL............................................................................ 720 DIAGNOSTICS........................................................................ 720 Diagnostic Tips................................................................ 720 Diagnostic Notes............................................................... 720 Test 3.15...................................................................... 722 TURN SIGNAL ERRORS 3.16................................................................ 723 GENERAL............................................................................ 723 DIAGNOSTICS........................................................................ 723 Diagnostic Tips................................................................ 723 Diagnostic Notes: All Turn Signal Flow Charts.................................. 726 Turn Signal Error 1A........................................................... 727 Turn Signal Error 1B........................................................... 728 Turn Signal Error 1C........................................................... 729 Turn Signal Error 2A........................................................... 730 Turn Signal Error 2B........................................................... 731 Turn Signal Error 2C........................................................... 732 Turn Signal Error 3A........................................................... 733 Turn Signal Error 3B........................................................... 734 Turn Signal Error 3C........................................................... 735 Turn Signal Error 3D........................................................... 736 Turn Signal Error 4A........................................................... 737 DTC B0563 (EFI), DTC 11 (CARB) 3.17.................................................... 738 GENERAL............................................................................ 738 Battery Voltage High........................................................... 738 DIAGNOSTICS........................................................................ 738 Diagnostic Tips................................................................ 738 Diagnostic Notes............................................................... 738 DTC 25 (CARB ONLY) 3.18................................................................ 739 GENERAL............................................................................ 739 Ignition Enable Output High.................................................... 739 DIAGNOSTICS........................................................................ 739 Diagnostic Tips................................................................ 739 Diagnostic Notes............................................................... 739 Test 3.18...................................................................... 741 DTC B1131/ B1132 (EFI), DTC 31/32 (CARB) 3.19.......................................... 742 GENERAL............................................................................ 742 Alarm Output Low (DTC B1131/DTC 31) or Alarm Output High (DTC B1132/DTC 32).... 742 DIAGNOSTICS........................................................................ 742 Diagnostic Tips................................................................ 742 Diagnostic Notes............................................................... 742 Test 3.19...................................................................... 744 DTC B1134 (EFI), DTC 34 (CARB) 3.20.................................................... 745 GENERAL............................................................................ 745 Starter Output High............................................................ 745 DIAGNOSTICS........................................................................ 745 Diagnostic Notes............................................................... 745 Test 3.20...................................................................... 747 DTC B1135 (EFI), DTC 35 (CARB) 3.21.................................................... 748 GENERAL............................................................................ 748 Accelerometer Fault............................................................ 748 DTC U1016 (EFI), DTC 14, 24, 33, 43 (CARB) 3.22........................................ 749 GENERAL............................................................................ 749 Loss of ECM Serial Data........................................................ 749 DIAGNOSTICS........................................................................ 749 Diagnostic Notes............................................................... 749 Test 3.22...................................................................... 751 TSM/TSSM 3.23.......................................................................... 752 REMOVAL/INSTALLATION............................................................... 752 PASSWORD LEARNING.................................................................. 752 Using Scanalyzer............................................................... 752 Without Scanalyzer............................................................. 752 TSSM MAINTENANCE 3.24.................................................................. 755 GENERAL............................................................................ 755 KEY FOB............................................................................ 755 Schedule....................................................................... 755 Battery Replacement............................................................ 755 SIREN (IF INSTALLED)............................................................... 756 Schedule....................................................................... 756 Battery Replacement............................................................ 756 4 - ENGINE MANAGEMENT (CARB)............................................................... 758 SPECIFICATIONS 4.1..................................................................... 760 DIAGNOSTIC INTRODUCTION 4.2............................................................ 761 SYSTEM PROBLEMS.................................................................... 761 No Start....................................................................... 761 Poor Performance............................................................... 761 Check Engine Lamp.............................................................. 761 RESOLVING PROBLEMS................................................................. 761 CHECKING FOR TROUBLE CODES 4.3......................................................... 762 CHECK ENGINE LAMP.................................................................. 762 CODE TYPES......................................................................... 763 Current........................................................................ 763 Historic....................................................................... 763 Functional..................................................................... 763 RETRIEVING TROUBLE CODES........................................................... 763 MULTIPLE TROUBLE CODES............................................................. 763 SCANALYZER: CARB 4.4................................................................... 764 SCANALYZER DIAGNOSTICS............................................................. 764 Scanalyzer Cartridge........................................................... 764 INSTALLATION....................................................................... 764 USAGE.............................................................................. 766 Checking/Clearing Trouble Codes................................................ 766 REMOVAL............................................................................ 766 CHECK ENGINE LAMP DIAGNOSTICS: CARB 4.5................................................ 767 ACTIVATION......................................................................... 767 BREAKOUT BOX: CARB 4.6................................................................. 769 GENERAL............................................................................ 769 INSTALLATION....................................................................... 769 REMOVAL............................................................................ 769 WIGGLE TEST 4.7........................................................................ 770 GENERAL............................................................................ 770 PROCEDURE.......................................................................... 770 Using Scanalyzer (Part No. HD-41325)........................................... 770 Using DVOM (Part No. HD-39978)................................................. 770 INITIAL DIAGNOSTIC CHECK 4.8........................................................... 771 GENERAL............................................................................ 771 Diagnostic Notes............................................................... 771 Scanalyzer Icon................................................................ 771 Circuit Diagram/Connector Location Table....................................... 771 Job/Time Code Values........................................................... 771 INITIAL DIAGNOSTICS................................................................ 771 General........................................................................ 771 Diagnostic Tips................................................................ 771 Diagnostic Notes............................................................... 771 Diagnostic Check (Part 1 of 2)................................................. 774 Diagnostic Check (Part 2 of 2)................................................. 775 NO CHECK ENGINE LAMP AT KEY ON 4.9..................................................... 776 GENERAL............................................................................ 776 DIAGNOSTICS........................................................................ 776 Diagnostic Tips................................................................ 776 Diagnostic Notes............................................................... 776 Test 4.9....................................................................... 778 CHECK ENGINE LAMP ON CONTINUOUSLY 4.10................................................. 779 GENERAL............................................................................ 779 DIAGNOSTICS........................................................................ 779 Diagnostic Notes............................................................... 779 Test 4.10...................................................................... 781 ENGINE CRANKS, BUT WILL NOT START 4.11................................................. 782 GENERAL............................................................................ 782 DIAGNOSTICS........................................................................ 782 Diagnostic Notes............................................................... 782 Test 4.11 (Part 1 of 3)........................................................ 784 Test 4.11 (Part 2 of 3)........................................................ 785 Test 4.11 (Part 3 of 3)........................................................ 786 NO IGNITION MODULE POWER 4.12.......................................................... 787 GENERAL............................................................................ 787 No Spark/No Check Engine Lamp At Key ON........................................ 787 DIAGNOSTICS........................................................................ 787 Diagnostic Notes............................................................... 787 Test 4.12...................................................................... 788 MISFIRE 4.13........................................................................... 789 GENERAL............................................................................ 789 Misfire at Idle or Under Load.................................................. 789 DIAGNOSTICS........................................................................ 789 Diagnostic Notes............................................................... 789 Test 4.13...................................................................... 791 DTC 12 4.14............................................................................ 792 GENERAL............................................................................ 792 MAP Sensor..................................................................... 792 DIAGNOSTICS........................................................................ 792 Diagnostic Tips................................................................ 792 Diagnostic Notes............................................................... 792 Scanalyzer Notes............................................................... 792 Test 4.14...................................................................... 794 DTC 16 4.15............................................................................ 795 GENERAL............................................................................ 795 Battery Voltage................................................................ 795 DIAGNOSTICS........................................................................ 795 Scanalyzer Notes............................................................... 795 Diagnostic Notes............................................................... 795 Test 4.15 (Part 1 of 2)........................................................ 797 Test 4.15 (Part 2 of 2)........................................................ 798 DTC 24, 25 4.16........................................................................ 799 GENERAL............................................................................ 799 Front Ignition Coil (DTC 24) and Rear Ignition Coil (DTC 25)................... 799 DIAGNOSTICS........................................................................ 799 Diagnostic Notes............................................................... 799 Scanalyzer Notes............................................................... 799 Test 4.16...................................................................... 801 DTC 35 4.17............................................................................ 802 GENERAL............................................................................ 802 Tachometer: All Except FLHR.................................................... 802 DIAGNOSTICS........................................................................ 802 Diagnostic Notes............................................................... 802 Test 4.17...................................................................... 803 DTC 41 4.18............................................................................ 804 GENERAL............................................................................ 804 Crank Position Sensor.......................................................... 804 DIAGNOSTICS........................................................................ 804 Diagnostic Notes............................................................... 804 Test 4.18...................................................................... 806 DTC 44 4.19............................................................................ 807 GENERAL............................................................................ 807 TSM/TSSM....................................................................... 807 DIAGNOSTICS........................................................................ 807 Diagnostic Notes............................................................... 807 Test 4.19 (Part 1 of 2)........................................................ 808 Test 4.19 (Part 2 of 2)........................................................ 809 DTC 52, 53, 54, 55 4.20................................................................ 810 GENERAL............................................................................ 810 Ignition Module Failure........................................................ 810 IGNITION COIL 4.21..................................................................... 811 TROUBLESHOOTING.................................................................... 811 Ignition Coil Primary Circuit Test............................................. 811 Ignition Coil Secondary Circuit Test........................................... 811 Test Results................................................................... 811 Ignition Coil Substitution..................................................... 811 5 - ENGINE MANAGEMENT (EFI)................................................................ 812 SPECIFICATIONS 5.1..................................................................... 814 EFI SYSTEM 5.2......................................................................... 816 GENERAL............................................................................ 816 TROUBLESHOOTING.................................................................... 816 EFI DIAGNOSTIC INTRODUCTION 5.3........................................................ 818 SYSTEM PROBLEMS.................................................................... 818 No Start....................................................................... 818 Poor Performance............................................................... 818 Check Engine Lamp.............................................................. 818 RESOLVING PROBLEMS................................................................. 818 CHECKING FOR TROUBLE CODES: EFI 5.4.................................................... 819 CHECK ENGINE LAMP.................................................................. 819 CODE TYPES......................................................................... 820 Current........................................................................ 820 Historic....................................................................... 820 RETRIEVING TROUBLE CODES........................................................... 820 MULTIPLE TROUBLE CODES............................................................. 820 SCANALYZER: EFI 5.5.................................................................... 821 SCANALYZER DIAGNOSTICS............................................................. 821 Scanalyzer Cartridge........................................................... 821 INSTALLATION....................................................................... 821 USAGE.............................................................................. 823 Checking/Clearing Trouble Codes................................................ 823 REMOVAL............................................................................ 823 CHECK ENGINE LAMP DIAGNOSTICS: EFI 5.6................................................. 824 GENERAL............................................................................ 824 ACTIVATION......................................................................... 824 BREAKOUT BOX: EFI 5.7.................................................................. 826 GENERAL............................................................................ 826 INSTALLATION....................................................................... 826 REMOVAL............................................................................ 826 WIGGLE TEST 5.8........................................................................ 827 GENERAL............................................................................ 827 PROCEDURE.......................................................................... 827 Using Scanalyzer (HD-41325).................................................... 827 Using DVOM (HD-39978).......................................................... 827 INITIAL DIAGNOSTIC CHECK: EFI 5.9...................................................... 828 GENERAL............................................................................ 828 Diagnostic Notes............................................................... 828 Scanalyzer Icon................................................................ 828 Circuit Diagram/Connector Location Table....................................... 828 Job/Time Code Values........................................................... 828 INITIAL DIAGNOSTICS................................................................ 828 General........................................................................ 828 Diagnostic Tips................................................................ 828 Diagnostic Notes............................................................... 828 Other Codes.................................................................... 828 Diagnostic Check (Part 1 of 2)................................................. 834 Diagnostic Check (Part 2 of 2)................................................. 835 NO CHECK ENGINE LAMP AT KEY ON 5.10.................................................... 836 GENERAL............................................................................ 836 Diagnostic Trouble Codes P1652, P1651.......................................... 836 DIAGNOSTICS........................................................................ 836 Diagnostic Tips................................................................ 836 Diagnostic Notes............................................................... 836 Test 5.10...................................................................... 838 CHECK ENGINE LAMP ON CONTINUOUSLY 5.11................................................. 839 GENERAL............................................................................ 839 Diagnostic Trouble Code P1651.................................................. 839 DIAGNOSTICS........................................................................ 839 Diagnostic Notes............................................................... 839 Test 5.11...................................................................... 841 ENGINE CRANKS, BUT WILL NOT START 5.12................................................. 842 GENERAL............................................................................ 842 DIAGNOSTICS........................................................................ 842 Diagnostic Notes............................................................... 842 Diagnostic Tip................................................................. 842 Test 5.12 (Part 1 of 4)........................................................ 844 Test 5.12 (Part 2 of 4)........................................................ 845 Test 5.12 (Part 3 of 4)........................................................ 846 Test 5.12 (Part 4 of 4)........................................................ 847 NO ECM POWER 5.13...................................................................... 848 GENERAL............................................................................ 848 No Spark/No Check Engine Lamp at Key ON........................................ 848 DIAGNOSTICS........................................................................ 848 Diagnostic Notes............................................................... 848 Diagnostic Tip................................................................. 848 Test 5.13 (Part 1 of 2)........................................................ 851 Test 5.13 (Part 2 of 2)........................................................ 852 STARTS, THEN STALLS 5.14............................................................... 853 GENERAL............................................................................ 853 Diagnostic Trouble Codes U1300, U1301: Serial Data Failure..................... 853 DIAGNOSTICS........................................................................ 853 Diagnostic Tips................................................................ 853 Diagnostic Notes............................................................... 853 Test 5.14 (Part 1 of 2)........................................................ 855 Test 5.14 (Part 2 of 2)........................................................ 856 FUEL SYSTEM ELECTRICAL TEST 5.15....................................................... 857 GENERAL............................................................................ 857 DIAGNOSTICS........................................................................ 857 Diagnostic Notes............................................................... 857 Test 5.15 (Part 1 of 4)........................................................ 859 Test 5.15 (Part 2 of 4)........................................................ 860 Test 5.15 (Part 3 of 4)........................................................ 861 Test 5.15 (Part 4 of 4)........................................................ 861 SYSTEM RELAY CHECK 5.16................................................................ 862 GENERAL............................................................................ 862 System Relay................................................................... 862 DIAGNOSTICS........................................................................ 862 Diagnostic Notes............................................................... 862 Test 5.16 (Part 1 of 3)........................................................ 865 Test 5.16 (Part 2 of 3)........................................................ 866 Test 5.16 (Part 3 of 3)........................................................ 866 FUEL PRESSURE TEST 5.17................................................................ 867 GENERAL............................................................................ 867 TESTING............................................................................ 867 DIAGNOSTICS........................................................................ 869 Diagnostic Notes............................................................... 869 Scanalyzer Notes............................................................... 869 Test 5.17...................................................................... 870 IDLE AIR CONTROL 5.18.................................................................. 871 GENERAL............................................................................ 871 IAC Operation.................................................................. 871 Diagnostic Trouble Code P0505: Loss of Idle Speed Control...................... 871 DIAGNOSTICS........................................................................ 871 Diagnostic Tips................................................................ 871 Diagnostic Notes............................................................... 872 Test 5.18 (Part 1 of 2)........................................................ 874 Test 5.18 (Part 2 of 2)........................................................ 875 MISFIRE AT IDLE OR UNDER LOAD 5.19..................................................... 876 GENERAL............................................................................ 876 Misfire at Idle or Under Load.................................................. 876 DIAGNOSTICS........................................................................ 876 Diagnostic Notes............................................................... 876 Test 5.19 (Part 1 of 3)........................................................ 878 Test 5.19 (Part 2 of 3)........................................................ 879 Test 5.19 (Part 3 of 3)........................................................ 880 COMBUSTION ABSENT/INTERMITTENT 5.20.................................................... 881 GENERAL............................................................................ 881 Diagnostic Trouble Codes P1353, P1356, P1357, P1358: No Combustion............. 881 DIAGNOSTICS........................................................................ 881 Diagnostic Notes............................................................... 881 Test 5.20 (Part 1 of 2)........................................................ 884 Test 5.20 (Part 2 of 2)........................................................ 885 DTC P0107, P0108 5.21.................................................................. 886 GENERAL............................................................................ 886 MAP Sensor..................................................................... 886 DIAGNOSTICS........................................................................ 886 Diagnostic Tips................................................................ 886 Diagnostic Notes............................................................... 886 Scanalyzer Notes............................................................... 886 Test 5.21 (Part 1 of 2)........................................................ 888 Test 5.21 (Part 2 of 2)........................................................ 889 DTC P0112, P0113 5.22.................................................................. 890 GENERAL............................................................................ 890 IAT Sensor..................................................................... 890 DIAGNOSTICS........................................................................ 890 Diagnostic Tips................................................................ 890 Diagnostic Notes............................................................... 890 Scanalyzer Notes............................................................... 890 Test 5.22 (Part 1 of 2)........................................................ 892 Test 5.22 (Part 2 of 2)........................................................ 893 DTC P0117, P0118 5.23.................................................................. 894 GENERAL............................................................................ 894 ET Sensor...................................................................... 894 DIAGNOSTICS........................................................................ 894 Diagnostic Tips................................................................ 894 Diagnostic Notes............................................................... 894 Scanalyzer Notes............................................................... 894 Test 5.23 (Part 1 of 2)........................................................ 896 Test 5.23 (Part 2 of 2)........................................................ 897 DTC P0122, P0123 5.24.................................................................. 898 GENERAL............................................................................ 898 TP Sensor...................................................................... 898 DIAGNOSTICS........................................................................ 898 Diagnostic Tips................................................................ 898 Diagnostic Notes............................................................... 898 Scanalyzer Notes............................................................... 898 Test 5.24 (Part 1 of 2)........................................................ 900 Test 5.24 (Part 2 of 2)........................................................ 901 DTC P0261, P0262, P0263, P0264 5.25.................................................... 902 GENERAL............................................................................ 902 Fuel Injectors................................................................. 902 DIAGNOSTICS........................................................................ 902 Diagnostic Notes............................................................... 902 Test 5.25 (Part 1 of 3)........................................................ 905 Test 5.25 (Part 2 of 3)........................................................ 906 Test 5.25 (Part 3 of 3)........................................................ 907 DTC P0373, P0374 5.26.................................................................. 908 GENERAL............................................................................ 908 CKP Sensor..................................................................... 908 DIAGNOSTICS........................................................................ 908 Diagnostic Tips................................................................ 908 Diagnostic Notes............................................................... 908 Test 5.26...................................................................... 910 DTC P0501, P0502 5.27.................................................................. 911 GENERAL............................................................................ 911 Vehicle Speed Sensor........................................................... 911 DIAGNOSTICS........................................................................ 911 Diagnostic Notes............................................................... 911 Test 5.27 (Part 1 of 2)........................................................ 914 Test 5.27 (Part 2 of 2)........................................................ 915 DTC P0562, P0563 5.28.................................................................. 916 GENERAL............................................................................ 916 Battery Voltage................................................................ 916 DIAGNOSTICS........................................................................ 916 Diagnostic Tips................................................................ 916 Scanalyzer Notes............................................................... 916 Diagnostic Notes............................................................... 916 Test 5.28 (Part 1 of 2)........................................................ 919 Test 5.28 (Part 2 of 2)........................................................ 920 DTC P0603, P0605 5.29.................................................................. 921 GENERAL............................................................................ 921 ECM Failure.................................................................... 921 DIAGNOSTICS........................................................................ 921 DTC P0603 Test................................................................. 921 DTC P0605 Test................................................................. 921 DTC P1009, P1010 5.30.................................................................. 922 GENERAL............................................................................ 922 Password Problem............................................................... 922 DIAGNOSTICS........................................................................ 922 Diagnostic Notes............................................................... 922 Test 5.30...................................................................... 924 DTC P1351, P1352, P1354, P1355 5.31.................................................... 925 GENERAL............................................................................ 925 Ignition Coil.................................................................. 925 DIAGNOSTICS........................................................................ 925 Diagnostic Notes............................................................... 925 Test 5.31 (Part 1 of 2)........................................................ 928 Test 5.31 (Part 2 of 2)........................................................ 929 DTC P1653, P1654 5.32.................................................................. 930 GENERAL............................................................................ 930 Tachometer..................................................................... 930 DIAGNOSTICS........................................................................ 930 Diagnostic Notes............................................................... 930 Test 5.32...................................................................... 932 DTC U1016, U1064, U1255 5.33........................................................... 933 GENERAL............................................................................ 933 Loss of TSM/TSSM or ECM Serial Data............................................ 933 DIAGNOSTICS........................................................................ 933 Diagnostic Notes............................................................... 933 Test 5.33 (Part 1 of 2)........................................................ 935 Test 5.33 (Part 2 of 2)........................................................ 936 6 - PREMIUM SOUND.......................................................................... 938 DIAGNOSTIC INTRODUCTION 6.1............................................................ 940 GENERAL............................................................................ 940 DIAGNOSTIC MODE OVERVIEW 6.2........................................................... 941 GENERAL............................................................................ 941 DIAGNOSTIC MODE GROUP 1............................................................ 942 GENERAL........................................................................ 942 SAMPLE DIAGNOSTIC.............................................................. 942 DIAGNOSTIC MODE GROUP 2............................................................ 943 GENERAL........................................................................ 943 SAMPLE DIAGNOSTIC.............................................................. 943 BREAKOUT BOX 6.3....................................................................... 944 GENERAL............................................................................ 944 INSTALLATION....................................................................... 944 REMOVAL............................................................................ 944 RADIO SYMPTOM 1 6.4.................................................................... 945 GENERAL............................................................................ 945 Problem........................................................................ 945 Setup.......................................................................... 945 Functionality.................................................................. 945 DIAGNOSTICS........................................................................ 945 Diagnostic Notes............................................................... 945 Test 6.4 (Part 1 of 2)......................................................... 946 Test 6.4 (Part 2 of 2)......................................................... 947 RADIO SYMPTOM 2 6.5.................................................................... 948 GENERAL............................................................................ 948 Problem........................................................................ 948 Setup.......................................................................... 948 Functionality.................................................................. 948 DIAGNOSTICS........................................................................ 948 Diagnostic Notes............................................................... 948 Test 6.5 (Part 1 of 4)......................................................... 949 Test 6.5 (Part 2 of 4)......................................................... 950 Test 6.5 (Part 3 of 4)......................................................... 951 Test 6.5 (Part 4 of 4)......................................................... 952 RADIO SYMPTOM 3 6.6.................................................................... 953 GENERAL............................................................................ 953 Problem........................................................................ 953 Setup.......................................................................... 953 Functionality.................................................................. 953 DIAGNOSTICS........................................................................ 953 Diagnostic Notes............................................................... 953 Test 6.6 (Part 1 of 3)......................................................... 954 Test 6.6 (Part 2 of 3)......................................................... 955 Test 6.6 (Part 3 of 3)......................................................... 956 RADIO SYMPTOM 4 6.7.................................................................... 957 GENERAL............................................................................ 957 Problem........................................................................ 957 Setup.......................................................................... 957 Functionality.................................................................. 957 DIAGNOSTICS........................................................................ 957 Automatic Volume Control (AVC) Adjustment...................................... 957 Diagnostic Notes............................................................... 958 Test 6.7 (Part 1 of 2)......................................................... 958 Test 6.7 (Part 2 of 2)......................................................... 959 RADIO SYMPTOM 5 6.8.................................................................... 960 GENERAL............................................................................ 960 Problem........................................................................ 960 Setup.......................................................................... 960 Functionality.................................................................. 960 DIAGNOSTICS........................................................................ 960 Radio Antenna Test............................................................. 960 Test 6.8....................................................................... 960 RADIO SYMPTOM 6 6.9.................................................................... 961 GENERAL............................................................................ 961 Problem........................................................................ 961 Setup.......................................................................... 961 Functionality.................................................................. 961 DIAGNOSTICS........................................................................ 961 Diagnostic Notes............................................................... 961 Test 6.9 (Part 1 of 2)......................................................... 962 Test 6.9 (Part 2 of 2)......................................................... 963 RADIO SYMPTOM 7 6.10................................................................... 964 GENERAL............................................................................ 964 Problem........................................................................ 964 Setup.......................................................................... 964 Functionality.................................................................. 964 DIAGNOSTICS........................................................................ 964 Diagnostic Notes............................................................... 964 Test 6.10 (Part 1 of 2)........................................................ 965 Test 6.10 (Part 2 of 2)........................................................ 966 RADIO SYMPTOM 8 6.11................................................................... 967 GENERAL............................................................................ 967 Problem........................................................................ 967 Setup.......................................................................... 967 Functionality.................................................................. 967 DIAGNOSTICS........................................................................ 967 Diagnostic Notes............................................................... 967 Test 6.11 (Part 1 of 2)........................................................ 968 Test 6.11 (Part 2 of 2)........................................................ 969 RADIO SYMPTOM 9 6.12................................................................... 970 GENERAL............................................................................ 970 Problem........................................................................ 970 Setup.......................................................................... 970 Functionality.................................................................. 970 DIAGNOSTICS........................................................................ 970 Diagnostic Notes............................................................... 970 Test 6.12 (Part 1 of 3)........................................................ 971 Test 6.12 (Part 2 of 3)........................................................ 972 Test 6.12 (Part 3 of 3)........................................................ 973 RADIO SYMPTOM 10 6.13.................................................................. 974 GENERAL............................................................................ 974 Problem........................................................................ 974 Setup.......................................................................... 974 Functionality.................................................................. 974 DIAGNOSTICS........................................................................ 974 Diagnostic Notes............................................................... 974 Test 6.13 (Part 1 of 2)........................................................ 975 Test 6.13 (Part 2 of 2)........................................................ 976 RADIO SYMPTOM 11 6.14.................................................................. 977 GENERAL............................................................................ 977 Problem........................................................................ 977 Setup.......................................................................... 977 Functionality.................................................................. 977 DIAGNOSTICS........................................................................ 977 Diagnostic Notes............................................................... 977 Test 6.14 (Part 1 of 2)........................................................ 978 Test 6.14 (Part 2 of 2)........................................................ 979 RADIO SYMPTOM 12 6.15.................................................................. 980 GENERAL............................................................................ 980 Problem........................................................................ 980 Setup.......................................................................... 980 Functionality.................................................................. 980 DIAGNOSTICS........................................................................ 980 Diagnostic Notes............................................................... 980 Test 6.15 (Part 1 of 2)........................................................ 981 Test 6.15 (Part 2 of 2)........................................................ 982 CB Antenna Test................................................................ 982 SWR Adjustment................................................................. 982 RADIO SYMPTOM 13 6.16.................................................................. 984 GENERAL............................................................................ 984 Problem........................................................................ 984 Setup.......................................................................... 984 Functionality.................................................................. 984 DIAGNOSTICS........................................................................ 984 Diagnostic Notes............................................................... 984 Test 6.16 (Part 1 of 2)........................................................ 985 Test 6.16 (Part 2 of 2)........................................................ 986 RADIO SYMPTOM 14 6.17.................................................................. 987 GENERAL............................................................................ 987 Problem........................................................................ 987 Setup.......................................................................... 987 Functionality.................................................................. 987 DIAGNOSTICS........................................................................ 987 Diagnostic Notes............................................................... 987 Test 6.17 (Part 1 of 2)........................................................ 988 Test 6.17 (Part 2 of 2)........................................................ 989 RADIO SYMPTOM 15 6.18.................................................................. 990 GENERAL............................................................................ 990 Problem........................................................................ 990 Setup.......................................................................... 990 Functionality.................................................................. 990 DIAGNOSTICS........................................................................ 990 Diagnostic Notes............................................................... 990 Test 6.18...................................................................... 990 7 - CRUISE CONTROL......................................................................... 992 CRUISE CONTROL 7.1..................................................................... 994 GENERAL............................................................................ 994 OPERATION.......................................................................... 994 TROUBLESHOOTING.................................................................... 995 CRUISE INOPERATIVE DIAGNOSTICS 7.2..................................................... 996 GENERAL............................................................................ 996 INOPERATIVE DIAGNOSTICS............................................................ 996 Diagnostic Notes............................................................... 996 CRUISE DROPOUT DIAGNOSTICS 7.3......................................................... 999 GENERAL............................................................................ 999 DROPOUT DIAGNOSTICS................................................................ 999 CRUISE CHART A: INITIAL DIAGNOSTICS 7.4................................................1002 DIAGNOSTICS........................................................................1002 Test 7.4 (Part 1 of 2).........................................................1002 Test 7.4 (Part 2 of 2).........................................................1003 CRUISE CHART B: RESUME SWITCH 7.5......................................................1004 DIAGNOSTICS........................................................................1004 Test 7.5.......................................................................1004 CRUISE CHART C: CRUISE ENGAGED LAMP 7.6................................................1005 DIAGNOSTICS........................................................................1005 Test 7.6.......................................................................1005 CRUISE CHART D: CRUISE POWER 7.7.......................................................1006 DIAGNOSTICS........................................................................1006 Test 7.7.......................................................................1006 CRUISE CHART E: CRUISE ENABLE 7.8......................................................1008 DIAGNOSTICS........................................................................1008 Test 7.8.......................................................................1008 Diagnostic Notes...............................................................1008 CRUISE CHART F-1: BRAKE LIGHTS ON 7.9..................................................1009 DIAGNOSTICS........................................................................1009 Test 7.9.......................................................................1009 CRUISE CHART F-2: BRAKE LIGHTS OFF 7.10................................................1010 DIAGNOSTICS........................................................................1010 Test 7.10 (Part 1 of 2)........................................................1010 Test 7.10 (Part 2 of 2)........................................................1011 Diagnostic Notes...............................................................1011 CRUISE CHART G: THROTTLE SWITCH 7.11...................................................1012 DIAGNOSTICS........................................................................1012 Test 7.11......................................................................1012 CRUISE CHART H: SPEEDOMETER INPUT 7.12.................................................1013 DIAGNOSTICS........................................................................1013 Diagnostic Notes...............................................................1013 Test 7.12 (Part 1 of 2)........................................................1013 Test 7.12 (Part 2 of 2)........................................................1014 CRUISE CHART I: TACHOMETER INPUT 7.13..................................................1015 DIAGNOSTICS........................................................................1015 Test 7.13......................................................................1015 8 - WIRING.................................................................................1016 ELECTRICAL CONNECTOR LOCATIONS 8.1.....................................................1018 WIRING DIAGRAMS 8.2....................................................................1030 FLHRSEI SUPPLEMENT MANUAL...................................................................... 0 1 - MAINTENANCE............................................................................1044 2 - CHASSIS................................................................................1046 3 - ENGINE.................................................................................1080 4 - FUEL SYSTEM............................................................................1088 5 - ELECTRIC STARTER.......................................................................1090 6 - DRIVE..................................................................................1092 7 - TRANSMISSION...........................................................................1093 8 - ELECTRICAL.............................................................................1094 9 - FUEL INJECTION.........................................................................1106
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