2003 Harley Davidson Softail Models Electrical Diagnostics + Service Manual – PDF DOWNLOAD
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2003 Harley Davidson Softail Models Electrical Diagnostics + Service Manual
2003 Harley Davidson Softail Models Electrical Diagnostics + Service Manual
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2003 Harley Davidson Softail Models Electrical Diagnostics + Service Manual – PDF DOWNLOAD
SERVICE MANUAL
Part Number 99482-03
ELECTRICAL DIAGNOSTICS
Part Number 99498-03
GENERAL
SERVICING A NEW MOTORCYCLE
- Service operations to be performed before customer delivery are specified in the applicable model year PREDELIVERY AND SETUP MANUAL.
- The performance of new motorcycle initial service is required to keep warranty in force and to ensure proper emissions systems operation. See FIRST SCHEDULED MAINTENANCE under 1.3 MAINTENANCE SCHEDULE for details.
Safety
Safety is always the most important consideration when performing any job. Be sure you have a complete understanding of the task to be performed. Use common sense. Use the proper tools. Protect yourself and bystanders with approved eye protection. Don’t just do the job – do the job safely.
Removing Parts :
- Always consider the weight of a part when lifting. Use a hoist whenever necessary. Do not lift heavy parts by hand. A hoist and adjustable lifting beam or sling are needed to remove some parts.
- The lengths of chains or cables from the hoist to the part should be equal and parallel and should be positioned directly over the center of the part. Be sure that no obstructions will interfere with the lifting operation. Never leave a part suspended in mid-air.
TABLE OF CONTENTS:
2003 Harley Davidson Softail Models Electrical Diagnostics + Service Manual – PDF DOWNLOAD
KEYWORD SEARCH................................................................................. 0 CONTENTS....................................................................................... 1 MAIN SERVICE MANUAL............................................................................ 2 1 - MAINTENANCE............................................................................ 2 GENERAL 1.1............................................................................ 4 SERVICING A NEW MOTORCYCLE......................................................... 4 SAFE OPERATING MAINTENANCE......................................................... 4 SHOP PRACTICES..................................................................... 4 Repair Notes................................................................... 4 Safety......................................................................... 4 Removing Parts................................................................. 4 Cleaning....................................................................... 4 Disassembly and Assembly....................................................... 5 REPAIR AND REPLACEMENT PROCEDURES.................................................. 5 Hardware and Threaded Parts.................................................... 5 Wiring, Hoses and Lines........................................................ 5 Instruments and Gauges......................................................... 5 Bearings....................................................................... 5 Bushings....................................................................... 5 Gaskets........................................................................ 5 Lip Type Seals................................................................. 5 O-Rings (Preformed Packings)................................................... 5 Gears.......................................................................... 5 Shafts......................................................................... 5 Part Replacement............................................................... 5 CLEANING........................................................................... 6 Part Protection................................................................ 6 Cleaning Process............................................................... 6 Rust or Corrosion Removal...................................................... 6 TOOL SAFETY........................................................................ 6 Air Tools...................................................................... 6 Wrenches....................................................................... 6 Pliers/cutters/prybars......................................................... 6 Hammers........................................................................ 6 Punches/chisels................................................................ 6 Screwdrivers................................................................... 6 Ratchets and Handles........................................................... 7 Sockets........................................................................ 7 Storage Units.................................................................. 7 FUEL AND OIL 1.2....................................................................... 8 FUEL............................................................................... 8 GASOLINE BLENDS.................................................................... 8 ENGINE OIL......................................................................... 8 WINTER LUBRICATION................................................................. 8 MAINTENANCE SCHEDULE 1.3............................................................... 9 FIRST SCHEDULED MAINTENANCE........................................................ 9 ENGINE OIL AND FILTER 1.4.............................................................. 14 CHECKING AND ADDING OIL............................................................ 14 Type of Oil.................................................................... 14 Checking Oil Level............................................................. 14 CHANGING OIL AND FILTER............................................................ 15 BATTERY MAINTENANCE 1.5................................................................ 16 GENERAL............................................................................ 16 DISCONNECTION AND REMOVAL.......................................................... 17 INSTALLATION AND CONNECTION........................................................ 17 INSPECTION......................................................................... 18 STORAGE............................................................................ 18 BRAKES 1.6............................................................................. 19 FLUID INSPECTION................................................................... 19 REAR BRAKE PEDAL................................................................... 20 Pedal Height................................................................... 20 Pedal Lubrication.............................................................. 20 BLEEDING BRAKES 1.7.................................................................... 21 GENERAL............................................................................ 21 PROCEDURE.......................................................................... 21 BRAKE PADS AND DISCS 1.8............................................................... 22 INSPECTION......................................................................... 22 Brake Pads..................................................................... 22 Brake Disc Thickness........................................................... 22 Brake Disc Lateral Runout and Warpage.......................................... 22 BRAKE PAD REPLACEMENT.............................................................. 23 Rear Brake Caliper............................................................. 23 Front Brake Caliper: All But FLSTS/FXSTS....................................... 25 TIRES AND WHEELS 1.9................................................................... 26 TIRES.............................................................................. 26 TIRE REPLACEMENT................................................................... 27 WHEEL BEARINGS..................................................................... 27 WHEEL SPOKES....................................................................... 27 PRIMARY CHAIN 1.10..................................................................... 28 INSPECTION......................................................................... 28 PRIMARY CHAINCASE LUBRICANT 1.11....................................................... 29 CHANGING LUBRICANT................................................................. 29 CLUTCH 1.12............................................................................ 31 ADJUSTMENT......................................................................... 31 TRANSMISSION LUBRICANT 1.13............................................................ 33 CHANGING LUBRICANT................................................................. 33 REAR BELT DEFLECTION 1.14.............................................................. 34 INSPECTION......................................................................... 34 REAR BELT AND SPROCKETS 1.15........................................................... 35 GENERAL............................................................................ 35 CLEANING........................................................................... 35 INSPECTION......................................................................... 35 Sprockets...................................................................... 35 Rear Belt...................................................................... 35 SUSPENSION ADJUSTMENTS 1.16............................................................ 37 REAR SHOCK PRELOAD................................................................. 37 STEERING HEAD BEARINGS: ALL BUT FLSTS/FXSTS 1.17....................................... 38 ADJUSTMENT......................................................................... 38 Bearing Adjustment (Fall-away)................................................. 38 LUBRICATION........................................................................ 38 STEERING HEAD BEARINGS: FLSTS/FXSTS 1.18............................................... 39 GENERAL............................................................................ 39 Lubrication.................................................................... 39 Special Tool Fabrication....................................................... 39 FLSTS MODELS....................................................................... 40 FXSTS MODELS....................................................................... 40 ROCKER BEARINGS: FLSTS/FXSTS 1.19...................................................... 42 INSPECTION......................................................................... 42 FRONT FORK OIL 1.20.................................................................... 44 REPLACING FORK OIL................................................................. 44 SPARK PLUGS 1.21....................................................................... 46 INSPECTION......................................................................... 46 AIR CLEANER FILTER 1.22................................................................ 47 REMOVAL............................................................................ 47 INSTALLATION....................................................................... 48 CABLE AND CHASSIS LUBRICATION 1.23..................................................... 49 GENERAL............................................................................ 49 CABLES AND HAND LEVERS............................................................. 49 FOOT SHIFT LEVER................................................................... 49 JIFFY STAND........................................................................ 49 THROTTLE CABLES 1.24................................................................... 50 CABLE INSPECTION, LUBRICATION AND ADJUSTMENT....................................... 50 Inspection and Lubrication..................................................... 50 Adjustment..................................................................... 51 ENRICHENER: CARBURETED 1.25............................................................ 52 IDLE SPEED AND IGNITION TIMING: CARBURETED 1.26........................................ 53 IDLE SPEED INSPECTION.............................................................. 53 IGNITION TIMING.................................................................... 53 FUEL SUPPLY VALVE FILTER: CARBURETED 1.27.............................................. 54 INSPECTION......................................................................... 54 FUEL SYSTEM LINES AND FITTINGS..................................................... 55 ENGINE MOUNTS 1.28..................................................................... 56 INSPECTION......................................................................... 56 HEADLAMP ALIGNMENT 1.29................................................................ 57 INSPECTION......................................................................... 57 ADJUSTMENT......................................................................... 58 FLSTS/FXSTS Models............................................................. 58 FLSTC/FLSTF/FXSTB/FXST MODELS.................................................. 58 FXSTD MODELS................................................................... 58 CRITICAL FASTENERS 1.30................................................................ 59 INSPECTION......................................................................... 59 STORAGE 1.31........................................................................... 60 GENERAL............................................................................ 60 REMOVAL FROM STORAGE............................................................... 61 TROUBLESHOOTING 1.32................................................................... 62 GENERAL............................................................................ 62 ENGINE............................................................................. 62 Starter Motor Does Not Operate or Does Not Turn Engine Over.................... 62 Engine Turns Over But Does Not Start........................................... 62 Starts Hard.................................................................... 62 Starts But Runs Irregularly or Misses.......................................... 62 A Spark Plug Fouls Repeatedly.................................................. 63 Pre-Ignition or Detonation (Knocks or Pings)................................... 63 Overheating.................................................................... 63 Valve Train Noise.............................................................. 63 Excessive Vibration............................................................ 63 Check Engine Light Illuminates During Operation................................ 63 LUBRICATION SYSTEM................................................................. 63 Oil Does Not Return To Oil Tank................................................ 63 Engine Uses Too Much Oil Or Smokes Excessively................................. 63 Engine Leaks Oil From Cases, Push Rods, Hoses, Etc............................. 63 Low Oil Pressure............................................................... 64 High Oil Pressure.............................................................. 64 ELECTRICAL SYSTEM.................................................................. 64 Alternator Does Not Charge..................................................... 64 Alternator Charge Rate Is Below Normal......................................... 64 Speedometer Operates Erratically............................................... 64 CARBURETOR......................................................................... 64 Floods......................................................................... 64 TRANSMISSION....................................................................... 64 Shifts Hard.................................................................... 64 Jumps Out Of Gear.............................................................. 64 Clutch Slips................................................................... 64 Clutch Drags Or Does Not Release............................................... 64 Clutch Chatters................................................................ 64 HANDLING........................................................................... 65 Irregularities................................................................. 65 BRAKES............................................................................. 65 Brake Does Not Hold Normally................................................... 65 2 - CHASSIS................................................................................ 66 SPECIFICATIONS 2.1..................................................................... 68 TORQUE VALUES 2.2...................................................................... 69 TIRES.............................................................................. 72 VEHICLE IDENTIFICATION NUMBER 2.3...................................................... 73 GENERAL............................................................................ 73 FRONT WHEEL: FXST/FLSTC/FLSTF/FXSTB 2.4................................................ 74 REMOVAL............................................................................ 74 DISASSEMBLY........................................................................ 74 Disc Wheel..................................................................... 74 Laced Wheel.................................................................... 74 CLEANING AND INSPECTION............................................................ 76 ASSEMBLY........................................................................... 76 Disc Wheel..................................................................... 76 Laced Wheel.................................................................... 76 INSTALLATION....................................................................... 76 FXST, FLSTC, FLSTF, FXSTB Models............................................... 76 FRONT WHEEL: FXSTD 2.5................................................................. 77 REMOVAL............................................................................ 77 DISASSEMBLY........................................................................ 77 CLEANING AND INSPECTION............................................................ 77 ASSEMBLY........................................................................... 78 INSTALLATION....................................................................... 78 FRONT WHEEL: FLSTS 2.6................................................................. 79 REMOVAL............................................................................ 79 DISASSEMBLY........................................................................ 79 CLEANING AND INSPECTION............................................................ 79 ASSEMBLY........................................................................... 79 INSTALLATION....................................................................... 81 FRONT WHEEL: FXSTS 2.7................................................................. 82 REMOVAL............................................................................ 82 DISASSEMBLY........................................................................ 82 CLEANING AND INSPECTION............................................................ 82 ASSEMBLY........................................................................... 82 INSTALLATION....................................................................... 84 REAR WHEEL 2.8......................................................................... 85 REMOVAL............................................................................ 85 DISASSEMBLY........................................................................ 85 CLEANING AND INSPECTION............................................................ 87 ASSEMBLY........................................................................... 87 INSTALLATION....................................................................... 87 SEALED WHEEL BEARINGS 2.9.............................................................. 88 INSPECTION......................................................................... 88 REMOVAL............................................................................ 88 INSTALLATION....................................................................... 89 WHEEL LACING: 16 IN. RIM 2.10.......................................................... 90 GENERAL............................................................................ 90 PROCEDURE.......................................................................... 90 WHEEL LACING: 21 IN. RIM 2.11.......................................................... 92 PROCEDURE.......................................................................... 92 TRUING LACED WHEEL 2.12................................................................ 94 GENERAL............................................................................ 94 LATERAL TRUING..................................................................... 94 RADIAL TRUING...................................................................... 95 DISC RIM RUNOUT 2.13................................................................... 96 GENERAL............................................................................ 96 LATERAL RUNOUT..................................................................... 96 RADIAL RUNOUT...................................................................... 96 TIRES 2.14............................................................................. 97 GENERAL............................................................................ 97 REMOVAL............................................................................ 97 CLEANING AND INSPECTION............................................................ 97 INSTALLATION....................................................................... 98 CHECKING TIRE RUNOUT............................................................... 99 Radial Runout.................................................................. 99 Lateral Runout................................................................. 99 WHEEL BALANCING....................................................................100 VEHICLE ALIGNMENT 2.15.................................................................101 INSPECTION.........................................................................101 FRONT BRAKE MASTER CYLINDER 2.16.......................................................102 GENERAL............................................................................102 REMOVAL/DISASSEMBLY................................................................102 CLEANING AND INSPECTION............................................................104 ASSEMBLY/INSTALLATION..............................................................104 REAR BRAKE MASTER CYLINDER/RESERVOIR 2.17..............................................106 REMOVAL............................................................................106 INSTALLATION.......................................................................106 DISASSEMBLY........................................................................109 CLEANING AND INSPECTION............................................................110 ASSEMBLY...........................................................................110 FRONT BRAKE CALIPER: ALL BUT FLSTS/FXSTS 2.18..........................................112 REMOVAL............................................................................112 DISASSEMBLY........................................................................112 CLEANING, INSPECTION AND REPAIR....................................................114 ASSEMBLY...........................................................................114 INSTALLATION.......................................................................115 FRONT BRAKE CALIPER: FLSTS 2.19........................................................117 FRONT BRAKE CALIPER................................................................117 Removal........................................................................117 Installation...................................................................117 BRAKE REACTION LINK................................................................119 Removal........................................................................119 Installation...................................................................119 FRONT BRAKE CALIPER: FXSTS 2.20........................................................120 REMOVAL............................................................................120 INSTALLATION.......................................................................121 DISASSEMBLY........................................................................122 CLEANING AND INSPECTION............................................................122 ASSEMBLY...........................................................................123 REAR BRAKE CALIPER 2.21................................................................124 REMOVAL............................................................................124 DISASSEMBLY........................................................................124 CLEANING, INSPECTION AND REPAIR....................................................126 ASSEMBLY...........................................................................126 INSTALLATION.......................................................................127 FRONT FORKS: ALL BUT FLSTS/FXSTS 2.22..................................................128 GENERAL............................................................................128 REMOVAL............................................................................128 DISASSEMBLY........................................................................128 CLEANING AND INSPECTION............................................................128 ASSEMBLY...........................................................................132 INSTALLATION.......................................................................132 SPRINGER FORK: FLSTS/FXSTS 2.23........................................................133 GENERAL............................................................................133 HANDLEBAR AND RISERS...............................................................133 Removal........................................................................133 Installation...................................................................133 FRONT SHOCK ABSORBER...............................................................135 Removal........................................................................135 Installation...................................................................135 RIGID FORK.........................................................................136 Removal........................................................................136 Installation...................................................................136 SPRING FORK........................................................................137 Disassembly....................................................................137 Assembly.......................................................................139 FORK ROCKERS.......................................................................141 Removal........................................................................141 Installation...................................................................141 FORK STEM BEARINGS.................................................................142 Removal/Installation...........................................................142 STEERING HEAD 2.24.....................................................................143 REMOVAL............................................................................143 FLSTC, FLSTF Models............................................................143 FXSTD, FXST, FXSTB Models......................................................143 FLSTS, FXSTS Models............................................................144 CLEANING AND INSPECTION............................................................144 All Models.....................................................................144 DISASSEMBLY........................................................................144 Removing Lower Bearings From Fork Stem.........................................144 Steering Head Bearing Race Removal.............................................145 ASSEMBLY...........................................................................145 INSTALLATION.......................................................................146 FLSTC, FLSTF Models............................................................146 FXSTD, FXST, FXSTB Models......................................................146 FLSTS, FXSTS Models............................................................146 REAR FORK 2.25.........................................................................147 REMOVAL............................................................................147 CLEANING AND INSPECTION............................................................147 INSTALLATION.......................................................................148 REAR SHOCK ABSORBERS 2.26..............................................................149 GENERAL............................................................................149 REMOVAL............................................................................149 INSTALLATION.......................................................................149 THROTTLE CONTROL 2.27..................................................................150 REMOVAL/DISASSEMBLY................................................................150 CLEANING AND INSPECTION............................................................150 ASSEMBLY/INSTALLATION..............................................................150 CABLE ROUTING......................................................................151 All Models Except FLSTS/FXSTS/FXSTD............................................151 FXSTS Models...................................................................151 FLSTS Models...................................................................151 FXSTD Models...................................................................151 CLUTCH HAND CONTROL 2.28...............................................................152 REMOVAL............................................................................152 INSTALLATION.......................................................................152 FRONT FENDER: ALL BUT FLSTS/FXSTS 2.29.................................................153 FXST, FXSTB MODELS.................................................................153 Removal........................................................................153 Installation...................................................................153 FLSTC MODELS.......................................................................153 Removal........................................................................153 Installation...................................................................153 FLSTF MODELS.......................................................................153 Removal........................................................................153 Installation...................................................................153 FXSTD Models.......................................................................154 Removal........................................................................154 Installation...................................................................154 FRONT FENDER: FLSTS 2.30...............................................................155 REMOVAL............................................................................155 Front Fender...................................................................155 Front Fender Bearing Replacement...............................................155 INSTALLATION.......................................................................156 FRONT FENDER: FXSTS 2.31...............................................................157 REMOVAL............................................................................157 INSTALLATION.......................................................................158 REAR FENDER: ALL BUT FXSTD/FLSTS 2.32..................................................159 REMOVAL............................................................................159 FXST, FXSTS and FXSTB..........................................................159 FLSTC..........................................................................160 FLSTF..........................................................................160 WIRE CONDUIT REPLACEMENT...........................................................161 INSTALLATION.......................................................................162 REAR FENDER: FXSTD 2.33................................................................163 REMOVAL............................................................................163 DISASSEMBLY........................................................................163 ASSEMBLY...........................................................................164 INSTALLATION.......................................................................164 REAR FENDER: FLSTS 2.34................................................................165 REMOVAL............................................................................165 INSTALLATION.......................................................................165 BELT GUARD/DEBRIS DEFLECTOR 2.35.......................................................166 REMOVAL............................................................................166 Belt Guard.....................................................................166 Debris Deflector...............................................................166 INSTALLATION.......................................................................166 Belt Guard.....................................................................166 Debris Deflector...............................................................166 JIFFY STAND 2.36.......................................................................167 CLEANING...........................................................................167 REMOVAL............................................................................168 INSTALLATION.......................................................................168 FORK LOCK 2.37.........................................................................169 REMOVAL............................................................................169 INSTALLATION.......................................................................169 SEAT/STRAP RETENTION NUT 2.38..........................................................170 REPLACEMENT........................................................................170 SEAT: FXST/FXSTB/FXSTS 2.39............................................................171 REMOVAL/INSTALLATION...............................................................171 Seat Strap.....................................................................171 Seat...........................................................................171 SEAT: FLSTF/FLSTC 2.40.................................................................172 REMOVAL/INSTALLATION...............................................................172 Seat...........................................................................172 Sissy Bar: FLSTC Models........................................................172 SEAT: FLSTS 2.41.......................................................................173 REMOVAL/INSTALLATION...............................................................173 SEAT: FXSTD 2.42.......................................................................174 REMOVAL/INSTALLATION...............................................................174 SADDLEBAGS: FLSTC 2.43.................................................................175 REMOVAL............................................................................175 INSTALLATION.......................................................................175 SADDLEBAGS: FLSTS 2.44.................................................................176 REMOVAL............................................................................176 INSTALLATION.......................................................................176 WINDSHIELD: FLSTC 2.45.................................................................177 REMOVAL............................................................................177 INSTALLATION.......................................................................177 3 - ENGINE.................................................................................178 SPECIFICATIONS 3.1.....................................................................180 ENGINE TORQUE VALUES 3.2...............................................................182 SERVICE WEAR LIMITS 3.3................................................................183 GENERAL............................................................................183 ENGINE OIL FLOW 3.4....................................................................185 OIL FEED...........................................................................185 TOP END............................................................................186 BOTTOM END.........................................................................186 CHAIN GUIDE BRACKET................................................................190 OIL RETURN.........................................................................190 OIL PUMP OPERATION 3.5.................................................................191 GENERAL............................................................................191 OPERATION..........................................................................191 BREATHER OPERATION 3.6.................................................................192 GENERAL............................................................................192 OIL PRESSURE 3.7.......................................................................193 OIL PRESSURE INDICATOR LAMP........................................................193 CHECKING OIL PRESSURE..............................................................193 HOW TO USE THIS SECTION 3.8............................................................194 TOP END REPAIR.....................................................................194 BOTTOM END REPAIR..................................................................194 TYPICAL SYMPTOMS...................................................................194 TOP END SERVICE 3.9....................................................................195 ENGINE IN CHASSIS..................................................................195 ENGINE REMOVED FROM CHASSIS........................................................196 BOTTOM END SERVICE 3.10................................................................197 ENGINE IN CHASSIS: CAM COMPARTMENT SERVICE.........................................197 ENGINE REMOVED: FLYWHEEL COMPARTMENT SERVICE OR COMPLETE ENGINE OVERHAUL...........198 TROUBLESHOOTING 3.11...................................................................199 DIAGNOSING VALVE TRAIN NOISE.......................................................199 COMPRESSION TEST...................................................................199 CYLINDER LEAKAGE TEST..............................................................200 DIAGNOSING SMOKING ENGINE OR HIGH OIL CONSUMPTION..................................200 Check Prior To Cylinder Head Removal...........................................200 Check After Cylinder Head Removal..............................................200 STRIPPING MOTORCYCLE FOR SERVICE 3.12..................................................201 PROCEDURE..........................................................................201 ASSEMBLING MOTORCYCLE AFTER SERVICE 3.13...............................................202 PROCEDURE..........................................................................202 REMOVING ENGINE FROM CHASSIS 3.14......................................................203 PROCEDURE..........................................................................203 INSTALLING ENGINE IN CHASSIS 3.15......................................................204 PROCEDURE..........................................................................204 TOP END OVERHAUL: DISASSEMBLY 3.16.....................................................206 GENERAL............................................................................206 BREATHER ASSEMBLY..................................................................206 ROCKER ARM SUPPORT PLATE...........................................................207 PUSHRODS, LIFTERS AND COVERS.......................................................208 CYLINDER HEAD......................................................................208 CYLINDER...........................................................................209 PISTON.............................................................................210 TOP END OVERHAUL: ASSEMBLY 3.17........................................................211 GENERAL............................................................................211 PISTON.............................................................................211 CYLINDER...........................................................................212 CYLINDER HEAD......................................................................214 PUSHRODS, LIFTERS AND COVERS.......................................................217 ROCKER ARM SUPPORT PLATE...........................................................218 BREATHER ASSEMBLY..................................................................219 BOTTOM END OVERHAUL: DISASSEMBLY 3.18..................................................220 GENERAL............................................................................220 COVER AND CAM SUPPORT PLATE........................................................220 CRANKCASE..........................................................................223 COUNTERBALANCER ASSEMBLY...........................................................224 BOTTOM END OVERHAUL: ASSEMBLY 3.19.....................................................227 GENERAL............................................................................227 COUNTERBALANCER ASSEMBLY...........................................................227 CRANKCASE..........................................................................230 COVER AND CAM SUPPORT PLATE........................................................234 BREATHER ASSEMBLY 3.20.................................................................240 REMOVAL OVERVIEW...................................................................240 DISASSEMBLY........................................................................240 INSPECTION.........................................................................240 ASSEMBLY...........................................................................240 INSTALLATION OVERVIEW..............................................................240 ROCKER ARM SUPPORT PLATE 3.21..........................................................241 REMOVAL OVERVIEW...................................................................241 DISASSEMBLY........................................................................241 CLEANING AND INSPECTION............................................................241 ASSEMBLY...........................................................................243 INSTALLATION OVERVIEW..............................................................243 PUSHRODS, LIFTERS AND COVERS 3.22......................................................244 REMOVAL OVERVIEW...................................................................244 DISASSEMBLY........................................................................244 CLEANING AND INSPECTION............................................................244 LIFTER INSPECTION..................................................................245 ASSEMBLY...........................................................................245 INSTALLATION OVERVIEW..............................................................245 CYLINDER HEAD 3.23.....................................................................246 REMOVAL OVERVIEW...................................................................246 DISASSEMBLY........................................................................246 CLEANING...........................................................................247 INSPECTION.........................................................................248 Cylinder Head..................................................................248 Valve Guides...................................................................248 Valves.........................................................................248 Valve Springs..................................................................248 Tapered Keepers................................................................249 Valve Seats....................................................................249 VALVE GUIDE REPLACEMENT............................................................249 Removal........................................................................249 Installation...................................................................250 VALVE AND SEAT REFACING............................................................253 ASSEMBLY...........................................................................256 INSTALLATION OVERVIEW..............................................................258 CYLINDER 3.24..........................................................................259 REMOVAL OVERVIEW...................................................................259 CLEANING...........................................................................259 INSPECTION.........................................................................260 DEGLAZING CYLINDER.................................................................261 BORING AND HONING CYLINDER.........................................................263 INSTALLATION OVERVIEW..............................................................263 PISTON 3.25............................................................................264 REMOVAL OVERVIEW...................................................................264 DISASSEMBLY........................................................................264 Piston Rings...................................................................264 CLEANING...........................................................................264 INSPECTION.........................................................................265 ASSEMBLY...........................................................................267 Piston Rings...................................................................267 INSTALLATION OVERVIEW..............................................................268 UPPER CONNECTING ROD 3.26..............................................................269 REMOVAL OVERVIEW...................................................................269 DISASSEMBLY/ASSEMBLY...............................................................269 Removing Upper Connecting Rod Bushing..........................................269 Installing Upper Connecting Rod Bushing........................................270 Reaming Upper Connecting Rod Bushing...........................................271 Honing Upper Connecting Rod Bushing............................................272 INSTALLATION OVERVIEW..............................................................272 COVER AND CAM SUPPORT PLATE 3.27.......................................................274 REMOVAL OVERVIEW...................................................................274 DISASSEMBLY/ASSEMBLY...............................................................275 CRANKSHAFT BUSHING.................................................................275 Removal........................................................................275 Installation...................................................................275 Reaming Crankshaft Bushing.....................................................276 CAMSHAFTS AND CAMSHAFT BEARINGS....................................................277 Removal........................................................................277 Installation...................................................................280 CAM CHAIN TENSIONERS...............................................................284 Removal........................................................................284 Installation...................................................................284 OIL PRESSURE RELIEF VALVE..........................................................285 Removal........................................................................285 Installation...................................................................285 CAM NEEDLE BEARINGS................................................................286 Removal........................................................................286 Installation...................................................................287 CLEANING AND INSPECTION............................................................288 INSTALLATION OVERVIEW..............................................................288 OIL PUMP 3.28..........................................................................289 REMOVAL OVERVIEW...................................................................289 CLEANING AND INSPECTION............................................................289 INSTALLATION OVERVIEW..............................................................290 CRANKCASE 3.29.........................................................................291 REMOVAL OVERVIEW...................................................................291 RIGHT CRANKCASE HALF...............................................................291 Chain Guide Screen.............................................................291 Crankshaft (Roller) Bearing....................................................291 Piston Jets....................................................................292 LEFT CRANKCASE HALF................................................................293 Crankshaft (Roller) Bearing....................................................293 CYLINDER STUDS.....................................................................295 Removal........................................................................295 Installation...................................................................295 PIPE PLUG AND OIL FITTINGS.........................................................295 Removal/Installation...........................................................295 CLEANING AND INSPECTION............................................................296 INSTALLATION OVERVIEW..............................................................296 COUNTERBALANCER ASSEMBLY 3.30..........................................................297 REMOVAL OVERVIEW...................................................................297 CLEANING, INSPECTION AND REPAIR....................................................297 General........................................................................297 Balance Shaft Support Bearings.................................................297 Front and Rear Balance Sprockets...............................................298 Hydraulic Tensioners...........................................................298 Chain Tensioner Guides.........................................................298 Chain Guide Bracket............................................................298 Balance Chain..................................................................298 INSTALLATION OVERVIEW..............................................................298 FLYWHEEL/CONNECTING ROD 3.31...........................................................299 REMOVAL OVERVIEW...................................................................299 INSPECTION.........................................................................299 INSTALLATION OVERVIEW..............................................................299 OIL TANK 3.32..........................................................................300 REMOVAL/DISASSEMBLY................................................................300 Oil Tank.......................................................................300 Oil Line Fittings/Retainers....................................................302 INSTALLATION.......................................................................303 4 - FUEL SYSTEM............................................................................304 SPECIFICATIONS 4.1.....................................................................306 TORQUE VALUES......................................................................306 FUEL SYSTEM TROUBLESHOOTING 4.2........................................................307 CARBURETOR.........................................................................307 VACUUM PISTON ASSEMBLY.............................................................309 ENRICHENER: CARBURETED 4.3.............................................................310 GENERAL............................................................................310 OPERATION..........................................................................310 Cool Engine....................................................................310 Warm Climate or Hot Engine.....................................................310 CARBURETOR 4.4.........................................................................311 REMOVAL............................................................................311 INSTALLATION.......................................................................313 DISASSEMBLY........................................................................313 Vacuum Piston Chamber..........................................................313 Carburetor Body................................................................313 Accelerator Pump...............................................................313 CLEANING AND INSPECTION............................................................314 Vacuum Piston Components.......................................................314 Carburetor Body Components.....................................................314 Float Replacement..............................................................314 Accelerator Pump...............................................................314 ASSEMBLY...........................................................................315 Vacuum Piston Chamber..........................................................315 Carburetor Body................................................................315 Accelerator Pump...............................................................315 CARBURETOR ADJUSTMENTS 4.5.............................................................316 OPERATION CHECK – VACUUM PISTON....................................................316 Opening Malfunction............................................................316 Closing Malfunction............................................................316 FLOAT BOWL.........................................................................316 Float Bowl Inlet (Needle) Valve Replacement....................................316 Float Level....................................................................317 FUEL SUPPLY VALVE: CARBURETED 4.6......................................................320 GENERAL............................................................................320 OPERATION..........................................................................320 REMOVAL, INSPECTION AND INSTALLATION...............................................320 TROUBLESHOOTING....................................................................320 Vacuum Test....................................................................321 FUEL TANK: CARBURETED 4.7..............................................................322 GENERAL............................................................................322 REMOVAL............................................................................322 All But FXSTD Models...........................................................322 FXSTD Models...................................................................323 CLEANING AND INSPECTION............................................................323 INSTALLATION.......................................................................326 All But FXSTD Models...........................................................326 FXSTD Models...................................................................326 VAPOR VALVE........................................................................327 AIR CLEANER: CARBURETED 4.8............................................................328 REMOVAL............................................................................328 INSTALLATION.......................................................................328 BACKPLATE ASSEMBLY- CALIFORNIA MODELS..............................................329 EXHAUST SYSTEM: ALL BUT FXSTD/FLSTF/FLSTS 4.9..........................................330 GENERAL............................................................................330 REMOVAL............................................................................330 INSTALLATION.......................................................................330 DISASSEMBLY........................................................................330 ASSEMBLY...........................................................................330 EXHAUST SYSTEM: FXSTD/FLSTF 4.10.......................................................332 REMOVAL............................................................................332 Mufflers Only..................................................................332 Exhaust System.................................................................332 INSTALLATION.......................................................................332 Mufflers Only..................................................................332 Exhaust System.................................................................332 EXHAUST SYSTEM: FLSTS 4.11.............................................................334 REMOVAL............................................................................334 INSTALLATION.......................................................................334 EVAPORATIVE EMISSIONS CONTROL: CA MODELS 4.12..........................................336 GENERAL............................................................................336 CHARCOAL CANISTER..................................................................338 Removal........................................................................338 Installation...................................................................338 HOSE ROUTING/REPLACEMENT...........................................................339 5 - ELECTRIC STARTER.......................................................................340 SPECIFICATIONS 5.1.....................................................................342 TORQUE VALUES......................................................................342 ELECTRIC STARTER SYSTEM 5.2............................................................343 GENERAL............................................................................343 Wiring Diagrams................................................................343 Starter Relay..................................................................343 OPERATION..........................................................................343 STARTER RELAY 5.3......................................................................347 REMOVAL............................................................................347 INSTALLATION.......................................................................347 STARTER 5.4............................................................................348 REMOVAL............................................................................348 INSTALLATION.......................................................................349 DISASSEMBLY, INSPECTION AND REPAIR.................................................350 ASSEMBLY...........................................................................353 STARTER SOLENOID 5.5...................................................................355 GENERAL............................................................................355 DISASSEMBLY........................................................................355 ASSEMBLY...........................................................................355 STARTER JACKSHAFT 5.6..................................................................356 REMOVAL/DISASSEMBLY................................................................356 ASSEMBLY/INSTALLATION..............................................................357 6 - DRIVE..................................................................................358 SPECIFICATIONS 6.1.....................................................................360 TORQUE VALUES......................................................................360 PRIMARY CHAINCASE 6.2..................................................................361 GENERAL............................................................................361 PRIMARY CHAINCASE COVER............................................................361 Removal........................................................................361 Installation...................................................................362 PRIMARY CHAINCASE HOUSING..........................................................362 Removal........................................................................362 Inspection And Repair..........................................................363 Mainshaft Bearing and Oil Seal.................................................363 Installation...................................................................364 DRIVE COMPONENTS 6.3...................................................................365 PRIMARY CHAIN AND COMPENSATING SPROCKET............................................365 Removal........................................................................365 Installation...................................................................366 Sprocket Alignment.............................................................368 CHAIN TENSIONER SHOE...............................................................368 CLUTCH 6.4.............................................................................369 REMOVAL/INSTALLATION...............................................................369 CLUTCH PACK ONLY...................................................................369 Partial Disassembly............................................................369 Assembly.......................................................................369 CLEANING AND INSPECTION............................................................371 CLUTCH PACK AND BEARING............................................................371 Complete Disassembly...........................................................371 Assembly.......................................................................372 TRANSMISSION SPROCKET 6.5..............................................................374 REMOVAL............................................................................374 CLEANING AND INSPECTION............................................................374 INSTALLATION.......................................................................374 DRIVE BELT 6.6.........................................................................376 REMOVAL............................................................................376 INSPECTION.........................................................................376 INSTALLATION.......................................................................377 7 - TRANSMISSION...........................................................................378 SPECIFICATIONS 7.1.....................................................................380 TORQUE VALUES......................................................................381 TRANSMISSION 7.2.......................................................................382 GENERAL............................................................................382 Neutral........................................................................382 1st Gear.......................................................................382 2nd Gear.......................................................................382 3rd Gear.......................................................................382 4th Gear.......................................................................382 5th Gear.......................................................................382 SHIFTER LINKAGE ADJUSTMENT.........................................................384 SHIFTER CAM ASSEMBLY 7.3...............................................................385 REMOVAL/DISASSEMBLY................................................................385 CLEANING AND INSPECTION............................................................387 ASSEMBLY/INSTALLATION..............................................................387 SHIFTER FORKS 7.4......................................................................389 REMOVAL............................................................................389 CLEANING AND INSPECTION............................................................389 INSTALLATION.......................................................................390 TRANSMISSION CLUTCH RELEASE COVER 7.5..................................................391 REMOVAL/DISASSEMBLY................................................................391 CLEANING AND INSPECTION............................................................392 ASSEMBLY/INSTALLATION..............................................................392 MAINSHAFT AND COUNTERSHAFT 7.6.........................................................394 REMOVAL............................................................................394 INSTALLATION.......................................................................395 DISASSEMBLY........................................................................396 CLEANING AND INSPECTION............................................................396 Replacing Side Door Bearings...................................................396 ASSEMBLY...........................................................................398 TRANSMISSION CASE 7.7..................................................................403 REMOVAL............................................................................403 General........................................................................403 Main Drive Gear and Bearing....................................................403 INSTALLATION.......................................................................403 Main Drive Gear and Bearing....................................................403 DISASSEMBLY........................................................................406 Shifter Arm Assembly...........................................................406 CLEANING AND INSPECTION............................................................406 ASSEMBLY...........................................................................407 Shifter Pawl/Lever Assembly....................................................407 8 - ELECTRICAL.............................................................................408 SPECIFICATIONS 8.1.....................................................................410 TORQUE VALUES......................................................................410 BULB REQUIREMENTS 8.2..................................................................412 GENERAL............................................................................412 IGNITION SYSTEM: CARBURETED MODELS 8.3.................................................413 GENERAL............................................................................413 TROUBLESHOOTING....................................................................413 ELECTRICAL PANEL 8.4...................................................................417 GENERAL............................................................................417 REMOVAL............................................................................417 INSTALLATION.......................................................................418 IGNITION MODULE 8.5....................................................................419 GENERAL............................................................................419 IGNITION TIMING....................................................................419 REMOVAL: ALL BUT FXSTD.............................................................419 REMOVAL: FXSTD.....................................................................420 INSTALLATION: ALL BUT FXSTD........................................................420 INSTALLATION: FXSTD................................................................420 BANK ANGLE SENSOR (BAS) 8.6............................................................421 GENERAL............................................................................421 OPERATION..........................................................................421 TESTING............................................................................421 REMOVAL/INSTALLATION...............................................................421 MANIFOLD ABSOLUTE PRESSURE SENSOR (MAP): CARBURETED MODELS 8.7.........................422 GENERAL............................................................................422 REMOVAL............................................................................422 INSTALLATION.......................................................................423 CRANK POSITION SENSOR (CKP) 8.8........................................................424 GENERAL............................................................................424 REMOVAL............................................................................424 INSTALLATION.......................................................................425 SPARK PLUG CABLES 8.9..................................................................426 GENERAL............................................................................426 REMOVAL............................................................................426 INSPECTION.........................................................................426 INSTALLATION.......................................................................426 IGNITION COIL 8.10.....................................................................427 REMOVAL............................................................................427 INSTALLATION.......................................................................427 FUSES 8.11.............................................................................428 GENERAL............................................................................428 REMOVAL............................................................................428 INSTALLATION.......................................................................428 RELAYS 8.12............................................................................429 GENERAL............................................................................429 REMOVAL............................................................................429 INSTALLATION.......................................................................429 MAIN CIRCUIT BREAKER 8.13..............................................................430 GENERAL............................................................................430 REMOVAL............................................................................430 INSTALLATION.......................................................................430 IGNITION/LIGHT SWITCH 8.14.............................................................431 GENERAL............................................................................431 REPLACEMENT........................................................................431 ALTERNATOR 8.15........................................................................432 REMOVAL/DISASSEMBLY................................................................432 CLEANING/INSPECTION................................................................432 ASSEMBLY/INSTALLATION..............................................................432 VOLTAGE REGULATOR 8.16.................................................................433 REMOVAL............................................................................433 INSTALLATION.......................................................................434 BATTERY 8.17...........................................................................436 BATTERY TESTING....................................................................436 General........................................................................436 Voltmeter Test.................................................................436 Load Test......................................................................436 CHARGING BATTERY...................................................................437 Safety Precautions.............................................................437 Using a Battery Charger........................................................437 BATTERY CABLES 8.18....................................................................439 ROUTING PROCEDURE..................................................................439 HEADLAMP 8.19..........................................................................440 GENERAL............................................................................440 REMOVAL/INSTALLATION...............................................................440 FXSTD, FXSTS and FLSTS Models..................................................440 FXST and FXSTB Models..........................................................440 FLSTC and FLSTF Models.........................................................440 TAIL LAMP: ALL BUT FXSTD/FLSTS 8.20....................................................442 GENERAL............................................................................442 BULB REPLACEMENT...................................................................442 BASE REPLACEMENT...................................................................442 TAIL LAMP: FXSTD 8.21..................................................................444 REMOVAL............................................................................444 INSTALLATION.......................................................................445 TAIL LAMP: FLSTS 8.22..................................................................446 BULB REPLACEMENT...................................................................446 TAIL LAMP REPLACEMENT..............................................................446 PASSING LAMPS: FLSTS 8.23..............................................................447 PASSING LAMP BRACKET...............................................................447 Removal........................................................................447 Installation...................................................................447 PASSING LAMPS......................................................................447 Removal........................................................................447 Installation...................................................................447 PASSING LAMPS: FLSTC 8.24..............................................................449 PASSING LAMP BRACKET...............................................................449 Removal........................................................................449 Installation...................................................................449 PASSING LAMPS......................................................................449 Removal........................................................................449 Installation...................................................................449 FRONT FENDER LAMP: FLSTS 8.25..........................................................451 REMOVAL............................................................................451 INSTALLATION.......................................................................451 TURN SIGNALS/RUNNING LIGHTS 8.26.......................................................452 BULB REPLACEMENT: ALL BUT FLSTC....................................................452 BULB REPLACEMENT: FLSTC............................................................452 LAMP REPLACEMENT...................................................................452 General........................................................................452 Front Turn Signals: All But FLSTC..............................................453 Rear Turn Signals: All But FXSTD...............................................453 Rear Turn Signals: FXSTD.......................................................453 TURN SIGNAL/TURN SIGNAL SECURITY MODULE 8.27...........................................456 GENERAL............................................................................456 REMOVAL/...........................................................................456 INSTALLATION.......................................................................456 TSM/TSSM Configuration.............................................................457 PASSWORD LEARNING..................................................................457 Using Scanalyzer/Digital Technician............................................457 Without Scanalyzer.............................................................457 TSM/TSSM KEY FOB AND CODE ASSIGNMENT 8.28..............................................459 GENERAL............................................................................459 USING SCANALYZER ON EFI MODELS.....................................................459 POWER DISRUPTION AND CONFIGURING...................................................459 KEY FOB ASSIGNMENT.................................................................460 PERSONAL CODE ENTRY................................................................460 First Time Code Entry: TSSM Only...............................................460 Modifying Existing Codes: TSSM Only............................................460 FUEL GAUGE: CARBURETED 8.29............................................................464 GENERAL............................................................................464 REMOVAL: ALL BUT FXSTD.............................................................464 INSTALLATION: ALL BUT FXSTD........................................................466 FUEL GAUGE REMOVAL: FXSTD..........................................................466 FUEL GAUGE INSTALLATION: FXSTD.....................................................466 FUEL GAUGE SENDER REMOVAL: FXSTD...................................................467 FUEL GAUGE SENDER INSTALLATION: FXSTD..............................................467 FUEL GAUGE: EFI 8.30...................................................................468 GENERAL............................................................................468 Removal............................................................................468 INSTALLATiON.......................................................................468 INSTRUMENT CONSOLE: FXSTD 8.31.........................................................469 REMOVAL............................................................................469 INSTALLATION.......................................................................469 SPEEDOMETER: ALL BUT FXSTD 8.32........................................................470 REMOVAL............................................................................470 INSTALLATION.......................................................................470 SPEEDOMETER: FXSTD 8.33................................................................471 REMOVAL............................................................................471 INSTALLATION.......................................................................471 VEHICLE SPEED SENSOR: VSS 8.34.........................................................473 GENERAL............................................................................473 REMOVAL............................................................................473 INSTALLATION.......................................................................473 INDICATOR LAMPS: All But FXSTD 8.35....................................................474 GENERAL............................................................................474 REMOVAL............................................................................474 INSTALLATION.......................................................................474 INDICATOR LAMPS: FXSTD 8.36............................................................475 GENERAL............................................................................475 REMOVAL............................................................................475 INSTALLATION.......................................................................475 NEUTRAL SWITCH 8.37....................................................................476 GENERAL............................................................................476 REMOVAL............................................................................476 INSTALLATION.......................................................................476 OIL PRESSURE SWITCH 8.38...............................................................477 GENERAL............................................................................477 REMOVAL............................................................................477 INSTALLATION.......................................................................477 REAR STOP LIGHT SWITCH 8.39............................................................478 GENERAL............................................................................478 REMOVAL............................................................................478 INSTALLATION.......................................................................478 HORN: ALL BUT FLSTS 8.40...............................................................479 INSPECTION.........................................................................479 REPLACEMENT........................................................................479 HORN: FLSTS 8.41.......................................................................480 INSPECTION.........................................................................480 REPLACEMENT........................................................................480 MAIN WIRING HARNESS 8.42...............................................................481 REMOVAL............................................................................481 INSTALLATION.......................................................................482 HANDLEBAR SWITCH ASSEMBLIES 8.43.......................................................484 GENERAL............................................................................484 REPAIR PROCEDURES..................................................................484 RIGHT HANDLEBAR SWITCH 8.44............................................................485 REMOVAL............................................................................485 INSTALLATION.......................................................................485 DISASSEMBLY........................................................................487 SWITCH REPAIR/REPLACEMENT..........................................................488 Upper Housing Repair...........................................................488 Lower Housing Repair...........................................................489 ASSEMBLY...........................................................................490 LEFT HANDLEBAR SWITCH 8.45.............................................................491 REMOVAL............................................................................491 INSTALLATION.......................................................................491 DISASSEMBLY........................................................................492 SWITCH REPAIR/REPLACEMENT..........................................................492 Upper Housing Repair...........................................................492 Lower Housing Repair...........................................................493 ASSEMBLY...........................................................................493 9 - FUEL INJECTION.........................................................................494 SPECIFICATIONS 9.1.....................................................................496 TORQUE VALUES......................................................................496 ELECTRONIC FUEL INJECTION (EFI) SYSTEM 9.2.............................................498 GENERAL............................................................................498 For Information on Related Topics See:.........................................498 TROUBLESHOOTING....................................................................498 IDLE SPEED: EFI 9.3....................................................................500 GENERAL............................................................................500 SCANALYZER.........................................................................500 Data Link Connector............................................................500 Scanalyzer Cartridge...........................................................500 INSTALLATION.......................................................................500 SETTING IDLE SPEED.................................................................500 AIR CLEANER: EFI 9.4...................................................................501 REMOVAL............................................................................501 INSTALLATION.......................................................................501 FUEL TANK: EFI 9.5.....................................................................502 GENERAL............................................................................502 REMOVAL............................................................................502 CLEANING AND INSPECTION............................................................506 INSTALLATION.......................................................................506 All But FXSTDI.................................................................506 FXSTDI.........................................................................507 ELECTRONIC CONTROL MODULE (ECM) 9.6....................................................508 GENERAL............................................................................508 REMOVAL............................................................................508 INSTALLATION.......................................................................508 THROTTLE POSITION SENSOR (TP) 9.7......................................................509 GENERAL............................................................................509 REMOVAL............................................................................509 INSTALLATION.......................................................................509 INTAKE AIR TEMPERATURE SENSOR (IAT) 9.8................................................510 GENERAL............................................................................510 REMOVAL............................................................................510 INSTALLATION.......................................................................510 ENGINE TEMPERATURE SENSOR (ET) 9.9.....................................................511 GENERAL............................................................................511 REMOVAL............................................................................511 INSTALLATION.......................................................................512 INDUCTION MODULE 9.10..................................................................513 GENERAL............................................................................513 REMOVAL............................................................................513 INSTALLATION.......................................................................514 IDLE AIR CONTROL (IAC) 9.11............................................................515 GENERAL............................................................................515 REMOVAL............................................................................515 INSTALLATION.......................................................................515 MANIFOLD ABSOLUTE PRESSURE SENSOR (MAP): EFI MODELS 9.12...............................516 GENERAL............................................................................516 REMOVAL............................................................................516 INSTALLATION.......................................................................516 FUEL INJECTORS 9.13....................................................................517 GENERAL............................................................................517 REMOVAL............................................................................517 INSTALLATION.......................................................................517 FUEL PUMP/FUEL GAUGE SENDING UNIT 9.14.................................................518 GENERAL............................................................................518 REMOVAL............................................................................518 DISASSEMBLY/ASSEMBLY...............................................................521 Fuel Filter....................................................................521 Regulator......................................................................521 Fuel Pump......................................................................522 Fuel Level Sending Unit........................................................523 Fuel Pump Module Connector/O-Ring..............................................523 Fuel Supply Check Valve/Tube...................................................524 INSTALLATION.......................................................................525 FUEL PRESSURE TEST 9.15................................................................526 GENERAL............................................................................526 TESTING............................................................................526 APPENDICES.................................................................................530 APPENDIX A - TOOLS.....................................................................531 APPENDIX B - WIRING....................................................................547 WIRING DIAGRAMS....................................................................566 APPENDIX C - METRIC CONVERSIONS........................................................609 ELECTRICAL DIAGNOSTICS MANUAL.................................................................. 2 1 - STARTING AND CHARGING..................................................................614 STARTER TROUBLESHOOTING 1.1............................................................616 STARTING SYSTEM DIAGNOSIS 1.2..........................................................618 DIAGNOSTICS........................................................................618 Diagnostic Notes...............................................................618 Starter Test 1.................................................................618 Starter Test 2: Solenoid Clicks................................................619 Starter Test 3: Relay Clicks...................................................619 Starter Test 4: Nothing Clicks.................................................620 Starter Test 5: Starter Spins, But Does Not Engage.............................621 Starter Test 6: Starter Stalls or Spins Too Slowly.............................621 STARTER ACTIVATION CIRCUITS 1.3........................................................622 DIAGNOSTICS/TROUBLESHOOTING 1.4........................................................623 GENERAL............................................................................623 VOLTAGE DROPS......................................................................623 STARTER SYSTEM TESTING 1.5.............................................................626 “ON-MOTORCYCLE” TESTS..............................................................626 Starter Relay Test.............................................................626 Starter Current Draw Test......................................................626 TESTING ASSEMBLED STARTER 1.6..........................................................627 FREE RUNNING CURRENT DRAW TEST.....................................................627 STARTER SOLENOID...................................................................627 SOLENOID PULL-IN TEST..............................................................628 SOLENOID HOLD-IN TEST..............................................................628 SOLENOID RETURN TEST...............................................................628 CHARGING SYSTEM 1.7....................................................................629 GENERAL............................................................................629 Alternator.....................................................................629 Voltage Regulator..............................................................629 TROUBLESHOOTING....................................................................629 Battery........................................................................629 Wiring.........................................................................629 Voltage Regulator Inspection...................................................629 Test 1.7 (Part 1 of 2).........................................................630 Test 1.7 (Part 2 of 2).........................................................631 TESTING............................................................................633 Milliampere Draw Test..........................................................633 Total Current Draw Test........................................................633 Current and Voltage Output Test................................................634 Voltage Output Test............................................................634 Stator Check...................................................................634 AC Output Check................................................................635 IGNITION COIL 1.8......................................................................636 TROUBLESHOOTING....................................................................636 Ignition Coil Primary Circuit Test.............................................636 Ignition Coil Secondary Circuit Test...........................................636 Test Results...................................................................636 Ignition Coil Substitution.....................................................636 BATTERY LOAD TEST 1.9..................................................................637 GENERAL............................................................................637 2 - INSTRUMENTS............................................................................638 FUEL GAUGE OPERATION 2.1...............................................................640 THEORY OF OPERATION................................................................640 FUEL GAUGE AND SENDER TEST.........................................................640 SPEEDOMETER 2.2........................................................................641 GENERAL............................................................................641 Reset Switch...................................................................641 Diagnostic Mode................................................................641 THEORY OF OPERATION................................................................642 DIAGNOSTICS........................................................................642 Diagnostic Notes...............................................................642 Speedometer Trouble Codes......................................................642 Speedometer Test 1.............................................................643 Speedometer Test 2A............................................................644 Speedometer Test 2B............................................................645 SPEEDOMETER PERFORMANCE CHECK 2.3......................................................647 GENERAL............................................................................647 TESTING............................................................................647 Speedometer Operation Test.....................................................647 Speedometer Needle Sweep Test..................................................648 Speedometer Sensor Test........................................................648 Tachometer Testing.............................................................648 INDICATOR LAMPS 2.4....................................................................649 GENERAL............................................................................649 DIAGNOSTICS........................................................................650 Oil Pressure or Neutral Indicator Will Not Function............................650 High Beam or R/L Turn Signal Indicator Will Not Function.......................650 3 - TSM & TSSM.............................................................................652 TSM/TSSM OVERVIEW 3.1..................................................................654 GENERAL............................................................................654 TROUBLESHOOTING....................................................................654 TSM/TSSM FEATURES 3.2..................................................................656 GENERAL............................................................................656 TURN SIGNAL FUNCTIONS..............................................................656 TSM/TSSM Features..............................................................656 BANK ANGLE FUNCTIONS...............................................................656 TSM/TSSM Features..............................................................656 SECURITY ALARM AND IMMOBILIZATION FUNCTIONS........................................656 TSSM Only Feature..............................................................656 TSM/TSSM VEHICLE DELIVERY 3.3..........................................................658 GENERAL............................................................................658 USING SCANALYZER ON EFI MODELS.....................................................658 SIDECAR CONFIGURATION..............................................................658 POWER DISRUPTION AND CONFIGURING...................................................658 KEY FOB ASSIGNMENT.................................................................659 PERSONAL CODE ENTRY................................................................659 First Time Code Entry: TSSM Only...............................................659 Modifying Existing Codes: TSSM Only............................................659 TSM/TSSM TURN SIGNAL FUNCTIONS 3.4.....................................................663 GENERAL............................................................................663 AUTOMATIC CANCELLATION.............................................................663 MANUAL CANCELLATION................................................................663 FOUR-WAY FLASHING..................................................................663 DIAGNOSTICS MODE...................................................................663 TSM/TSSM BANK ANGLE FUNCTION 3.5.......................................................664 GENERAL............................................................................664 OPERATION..........................................................................664 SECURITY SYSTEM (TSSM) FUNCTIONS 3.6...................................................665 GENERAL............................................................................665 Security System Operation......................................................665 Security System Options........................................................665 Differences By Market Specifications...........................................665 ALARM SENSITIVITY..................................................................665 Sensitivity....................................................................665 Transport Mode.................................................................665 AUTO-ARMING FUNCTION...............................................................666 STORAGE MODE.......................................................................666 ARMING/DISARMING SECURITY SYSTEM (TSSM) 3.7............................................669 GENERAL............................................................................669 SECURITY LAMP......................................................................669 USING KEY FOB......................................................................669 General........................................................................669 Arming the System..............................................................669 Disarming the System...........................................................669 Troubleshooting................................................................669 USING THE PERSONAL CODE............................................................670 General........................................................................670 Disarming the System...........................................................670 CHECKING FOR TROUBLE CODES: TSM/TSSM 3.8...............................................671 GENERAL............................................................................671 CODE TYPES.........................................................................671 Current........................................................................671 Historic.......................................................................671 TURN SIGNAL DIAGNOSTICS............................................................671 CHECKING FOR TROUBLE CODES: TSSM ONLY 3.9..............................................673 SECURITY LAMP......................................................................673 BREAKOUT BOX: TSM/TSSM 3.10............................................................675 GENERAL............................................................................675 INSTALLATION.......................................................................675 REMOVAL............................................................................675 SCANALYZER: EFI MODELS ONLY 3.11.......................................................676 SCANALYZER DIAGNOSTICS.............................................................676 General........................................................................676 Serial Data Connector..........................................................676 Scanalyzer Cartridge...........................................................676 INSTALLATION.......................................................................676 USAGE..............................................................................678 Checking Codes.................................................................678 Clearing Codes.................................................................678 REMOVAL............................................................................678 INITIAL DIAGNOSTIC CHECK: TSM/TSSM 3.12................................................679 GENERAL............................................................................679 Diagnostic Notes...............................................................679 Scanalyzer Icon................................................................679 Circuit Diagram/Wire Harness Connector Table...................................679 Job/Time Code Values...........................................................679 INITIAL DIAGNOSTICS................................................................679 Diagnostic Tips................................................................679 Diagnostic Notes...............................................................679 Multiple Trouble Codes.........................................................680 Diagnostic Check (Part 1 of 2).................................................682 Diagnostic Check (Part 2 of 2).................................................683 NO SECURITY LAMP AT KEY ON 3.13........................................................684 GENERAL............................................................................684 No TSSM Power..................................................................684 DIAGNOSTICS........................................................................684 Diagnostic Tips................................................................684 Diagnostic Notes...............................................................684 Test 3.13 (Part 1 of 3)........................................................686 Test 3.13 (Part 2 of 3)........................................................687 Test 3.13 (Part 3 of 3)........................................................688 SECURITY LAMP ON CONTINUOUSLY 3.14.....................................................689 GENERAL............................................................................689 DIAGNOSTICS........................................................................689 Diagnostic Notes...............................................................689 Test 3.14......................................................................691 KEY FOB SIGNAL TO TSSM WEAK OR FAILS 3.15..............................................692 GENERAL............................................................................692 DIAGNOSTICS........................................................................692 Diagnostic Tips................................................................692 Diagnostic Notes...............................................................692 Test 3.15......................................................................694 TURN SIGNAL ERRORS 3.16................................................................695 GENERAL............................................................................695 DIAGNOSTICS........................................................................695 Diagnostic Tips................................................................695 Diagnostic Notes: All Turn Signal Flow Charts..................................699 Turn Signal Error 1A...........................................................700 Turn Signal Error 1B...........................................................701 Turn Signal Error 1C...........................................................702 Turn Signal Error 2A...........................................................703 Turn Signal Error 2B...........................................................704 Turn Signal Error 2C...........................................................705 Turn Signal Error 3A...........................................................706 Turn Signal Error 3B...........................................................707 Turn Signal Error 3C...........................................................708 Turn Signal Error 3D...........................................................709 Turn Signal Error 4A...........................................................710 DTC B0563 3.17.........................................................................711 GENERAL............................................................................711 Battery Voltage High...........................................................711 DIAGNOSTICS........................................................................711 Diagnostic Tips................................................................711 Diagnostic Notes...............................................................711 DTC B1125 3.18.........................................................................712 GENERAL............................................................................712 Ignition Enable Output High....................................................712 DIAGNOSTICS........................................................................712 Diagnostic Tips................................................................712 Diagnostic Notes...............................................................712 Test 3.18......................................................................714 DTC B1131, B1132 3.19..................................................................715 GENERAL............................................................................715 Alarm Output Low (DTC B1131) or Alarm Output High (DTC B1132)..................715 DIAGNOSTICS........................................................................715 Diagnostic Tips................................................................715 Diagnostic Notes...............................................................715 Test 3.19......................................................................717 DTC B1134 3.20.........................................................................718 GENERAL............................................................................718 Starter Output High............................................................718 DIAGNOSTICS........................................................................718 Diagnostic Notes...............................................................718 Test 3.20......................................................................720 DTC B1135 3.21.........................................................................721 GENERAL............................................................................721 Accelerometer Fault............................................................721 DTC U1016, U1255 3.22..................................................................722 GENERAL............................................................................722 Loss of ECM Serial Data........................................................722 DIAGNOSTICS........................................................................722 Diagnostic Notes...............................................................722 Test 3.22......................................................................724 TSM/TSSM 3.23..........................................................................726 REMOVAL/INSTALLATION...............................................................726 PASSWORD LEARNING..................................................................726 Using Scanalyzer...............................................................726 Without Scanalyzer.............................................................726 TSSM MAINTENANCE 3.24..................................................................729 GENERAL............................................................................729 KEY FOB............................................................................729 Schedule.......................................................................729 Battery Replacement............................................................729 SIREN (IF INSTALLED)...............................................................730 Schedule.......................................................................730 Battery Replacement............................................................730 4 - ENGINE MANAGEMENT (CARBURETED).........................................................732 SPECIFICATIONS 4.1.....................................................................734 DIAGNOSTIC INTRODUCTION 4.2............................................................735 SYSTEM PROBLEMS....................................................................735 No Start.......................................................................735 Poor Performance...............................................................735 Check Engine Lamp..............................................................735 RESOLVING PROBLEMS.................................................................735 CHECKING FOR TROUBLE CODES 4.3.........................................................736 CHECK ENGINE LAMP..................................................................736 CODE TYPES.........................................................................737 Current........................................................................737 Historic.......................................................................737 Functional.....................................................................737 RETRIEVING TROUBLE CODES...........................................................737 MULTIPLE TROUBLE CODES.............................................................737 SCANALYZER 4.4.........................................................................738 SCANALYZER DIAGNOSTICS.............................................................738 Data Link Connector............................................................738 Scanalyzer Cartridge...........................................................738 INSTALLATION.......................................................................738 USAGE..............................................................................740 Checking Codes.................................................................740 Clearing Codes.................................................................740 REMOVAL............................................................................740 CHECK ENGINE LAMP DIAGNOSTICS 4.5......................................................741 ACTIVATION.........................................................................741 CLEARING CODES.....................................................................742 BREAKOUT BOX 4.6.......................................................................743 GENERAL............................................................................743 INSTALLATION.......................................................................743 REMOVAL............................................................................743 WIGGLE TEST 4.7........................................................................744 GENERAL............................................................................744 PROCEDURE..........................................................................744 Using Scanalyzer (Part No. HD-41325)...........................................744 Using DVOM (Part No. HD-39978).................................................744 INITIAL DIAGNOSTIC CHECK 4.8...........................................................745 GENERAL............................................................................745 Diagnostic Notes...............................................................745 Scanalyzer Icon................................................................745 Circuit Diagram/Wire Harness Connector Table...................................745 Job/Time Code Values...........................................................745 INITIAL DIAGNOSTICS................................................................745 General Information............................................................745 Diagnostic Tips................................................................745 Diagnostic Notes...............................................................745 All diagnostic codes are listed on page 4-13 in Table 4-5......................745 Other Codes....................................................................745 Diagnostic Check (Part 1 of 2).................................................748 Diagnostic Check (Part 2 of 2).................................................749 NO CHECK ENGINE LAMP AT KEY ON 4.9.....................................................750 GENERAL............................................................................750 DIAGNOSTICS........................................................................750 Diagnostic Tips................................................................750 Diagnostic Notes...............................................................750 Test 4.9.......................................................................752 CHECK ENGINE LAMP ON CONTINUOUSLY 4.10.................................................753 GENERAL............................................................................753 DIAGNOSTICS........................................................................753 Diagnostic Notes...............................................................753 Test 4.10......................................................................755 ENGINE CRANKS, BUT WILL NOT START 4.11.................................................756 GENERAL............................................................................756 DIAGNOSTICS........................................................................756 Diagnostic Notes...............................................................756 Test 4.11 (Part 1 of 3)........................................................758 Test 4.11 (Part 2 of 3)........................................................759 Test 4.11 (Part 3 of 3)........................................................760 NO SPARK/NO CHECK ENGINE LAMP AT KEY ON 4.12...........................................761 GENERAL............................................................................761 DIAGNOSTICS........................................................................761 Diagnostic Notes...............................................................761 Test 4.12......................................................................762 MISFIRE 4.13...........................................................................763 GENERAL............................................................................763 Misfire at Idle or Under Load..................................................763 DIAGNOSTICS........................................................................763 Diagnostic Notes...............................................................763 Test 4.13......................................................................765 DTC 12 4.14............................................................................766 GENERAL............................................................................766 MAP Sensor.....................................................................766 DIAGNOSTICS........................................................................766 Diagnostic Tips................................................................766 Diagnostic Notes...............................................................766 Scanalyzer Notes...............................................................766 Test 4.14 (Part 1 of 2)........................................................768 Test 4.14 (Part 2 of 2)........................................................769 DTC 16 4.15............................................................................770 GENERAL............................................................................770 Battery Voltage................................................................770 DIAGNOSTICS........................................................................770 Scanalyzer Notes...............................................................770 Diagnostic Notes...............................................................770 Test 4.15 (Part 1 of 2)........................................................771 Test 4.15 (Part 2 of 2)........................................................772 DTC 24, 25 4.16........................................................................773 GENERAL............................................................................773 Front Ignition Coil (DTC 24) and Rear Ignition Coil (DTC 25)...................773 DIAGNOSTICS........................................................................773 Diagnostic Notes...............................................................773 Scanalyzer Notes...............................................................773 Test 4.16......................................................................775 DTC 41 4.17............................................................................776 GENERAL............................................................................776 Crank Position Sensor..........................................................776 DIAGNOSTICS........................................................................776 Diagnostic Notes...............................................................776 Test 4.17......................................................................778 DTC 44 4.18............................................................................779 GENERAL............................................................................779 TSM/TSSM.......................................................................779 DIAGNOSTICS........................................................................779 Diagnostic Notes...............................................................779 Test 4.18 (Part 1 of 2)........................................................780 Test 4.18 (Part 2 of 2)........................................................781 DTC 52, 53, 54 AND 55 4.19.............................................................782 GENERAL............................................................................782 Ignition Module Failure........................................................782 5 - ENGINE MANAGEMENT (EFI)................................................................784 SPECIFICATIONS 5.1.....................................................................786 EFI SYSTEM 5.2.........................................................................788 GENERAL............................................................................788 TROUBLESHOOTING....................................................................788 EFI DIAGNOSTIC INTRODUCTION 5.3........................................................790 SYSTEM PROBLEMS....................................................................790 No Start.......................................................................790 Poor Performance...............................................................790 Check Engine Lamp..............................................................790 RESOLVING PROBLEMS.................................................................790 CHECKING FOR TROUBLE CODES: EFI 5.4....................................................791 CHECK ENGINE LAMP..................................................................791 CODE TYPES.........................................................................792 Current........................................................................792 Historic.......................................................................792 RETRIEVING TROUBLE CODES...........................................................792 MULTIPLE TROUBLE CODES.............................................................792 SCANALYZER: EFI 5.5....................................................................793 SCANALYZER DIAGNOSTICS.............................................................793 Serial Data Connector..........................................................793 Scanalyzer Cartridge...........................................................793 INSTALLATION.......................................................................793 USAGE..............................................................................795 Checking Codes.................................................................795 Clearing Codes.................................................................795 REMOVAL............................................................................795 CHECK ENGINE LAMP DIAGNOSTICS: EFI 5.6.................................................796 GENERAL............................................................................796 ACTIVATION.........................................................................796 CLEARING CODES.....................................................................797 BREAKOUT BOX: EFI 5.7..................................................................798 GENERAL............................................................................798 INSTALLATION.......................................................................798 REMOVAL............................................................................798 WIGGLE TEST 5.8........................................................................799 GENERAL............................................................................799 PROCEDURE..........................................................................799 Using Scanalyzer (Part No. HD-41325)...........................................799 Using DVOM (Part No. HD-39978).................................................799 INITIAL DIAGNOSTIC CHECK: EFI 5.9......................................................800 GENERAL............................................................................800 Diagnostic Notes...............................................................800 Scanalyzer Icon................................................................800 Circuit Diagram/Wire Harness Connector Table...................................800 Job/Time Code Values...........................................................800 INITIAL DIAGNOSTICS................................................................800 General Information............................................................800 Diagnostic Tips................................................................800 Diagnostic Notes...............................................................800 Other Codes....................................................................800 Diagnostic Check (Part 1 of 2).................................................807 Diagnostic Check (Part 2 of 2).................................................808 NO CHECK ENGINE LAMP AT KEY ON 5.10....................................................809 GENERAL............................................................................809 Diagnostic Trouble Codes P1651, P1652..........................................809 DIAGNOSTICS........................................................................809 Diagnostic Tips................................................................809 Diagnostic Notes...............................................................809 Test 5.10......................................................................811 CHECK ENGINE LAMP ON CONTINUOUSLY 5.11.................................................812 GENERAL............................................................................812 Diagnostic Trouble Code P1651..................................................812 DIAGNOSTICS........................................................................812 Diagnostic Notes...............................................................812 Test 5.11......................................................................814 ENGINE CRANKS, BUT WILL NOT START 5.12.................................................815 GENERAL............................................................................815 DIAGNOSTICS........................................................................815 Diagnostic Notes...............................................................815 Diagnostic Tips................................................................815 Test 5.12 (Part 1 of 4)........................................................817 Test 5.12 (Part 2 of 4)........................................................818 Test 5.12 (Part 3 of 4)........................................................819 Test 5.12 (Part 4 of 4)........................................................820 NO ECM POWER 5.13......................................................................821 GENERAL............................................................................821 No Spark/No Check Engine Lamp at Key ON........................................821 DIAGNOSTICS........................................................................821 Diagnostic Notes...............................................................821 Test 5.13 (Part 1 of 2)........................................................823 Test 5.13 (Part 2 of 2)........................................................824 STARTS, THEN STALLS 5.14...............................................................825 GENERAL............................................................................825 Diagnostic Trouble Codes U1300, U1301: Serial Data Failure.....................825 DIAGNOSTICS........................................................................825 Diagnostic Tips................................................................825 Diagnostic Notes...............................................................825 Test 5.14 (Part 1 of 2)........................................................827 Test 5.14 (Part 2 of 2)........................................................828 FUEL SYSTEM ELECTRICAL TEST 5.15.......................................................829 GENERAL............................................................................829 DIAGNOSTICS........................................................................829 Diagnostic Notes...............................................................829 Test 5.15 (Part 1 of 4)........................................................831 Test 5.15 (Part 2 of 4)........................................................832 Test 5.15 (Part 3 of 4)........................................................833 Test 5.15 (Part 4 of 4)........................................................833 SYSTEM RELAY CHECK 5.16................................................................834 GENERAL............................................................................834 System Relay...................................................................834 DIAGNOSTICS........................................................................834 Diagnostic Notes...............................................................834 Test 5.16 (Part 1 of 3)........................................................836 Test 5.16 (Part 2 of 3)........................................................837 Test 5.16 (Part 3 of 3)........................................................837 FUEL PRESSURE TEST 5.17................................................................838 GENERAL............................................................................838 TESTING............................................................................838 DIAGNOSTICS........................................................................840 Diagnostic Notes...............................................................840 Scanalyzer Notes...............................................................840 Test 5.17......................................................................841 IDLE AIR CONTROL 5.18..................................................................842 GENERAL............................................................................842 IAC Operation..................................................................842 Diagnostic Trouble Code P0505: Loss of Idle Speed Control......................842 DIAGNOSTICS........................................................................842 Diagnostic Tips................................................................842 Diagnostic Notes...............................................................843 Test 5.18 (Part 1 of 2)........................................................845 Test 5.18 (Part 2 of 2)........................................................846 MISFIRE AT IDLE OR UNDER LOAD 5.19.....................................................847 GENERAL............................................................................847 Misfire at Idle or Under Load..................................................847 DIAGNOSTICS........................................................................847 Diagnostic Notes...............................................................847 Test 5.19 (Part 1 of 3)........................................................849 Test 5.19 (Part 2 of 3)........................................................850 Test 5.19 (Part 3 of 3)........................................................851 COMBUSTION ABSENT/INTERMITTENT 5.20....................................................852 GENERAL............................................................................852 Diagnostic Trouble Codes P1353, P1356, P1357, P1358: No Combustion.............852 DIAGNOSTICS........................................................................852 Diagnostic Notes...............................................................852 Test 5.20 (Part 1 of 2)........................................................854 Test 5.20 (Part 2 of 2)........................................................855 DTC P0107, P0108 5.21..................................................................856 GENERAL............................................................................856 MAP Sensor.....................................................................856 DIAGNOSTICS........................................................................856 Diagnostic Tips................................................................856 Diagnostic Notes...............................................................856 Scanalyzer Notes...............................................................856 Test 5.21 (Part 1 of 2)........................................................858 Test 5.21 (Part 2 of 2)........................................................859 DTC P0112, P0113 5.22..................................................................860 GENERAL............................................................................860 IAT Sensor.....................................................................860 DIAGNOSTICS........................................................................860 Diagnostic Tips................................................................860 Diagnostic Notes...............................................................860 Scanalyzer Notes...............................................................860 Test 5.22 (Part 1 of 2)........................................................862 Test 5.22 (Part 2 of 2)........................................................863 DTC P0117, P0118 5.23..................................................................864 GENERAL............................................................................864 ET Sensor......................................................................864 DIAGNOSTICS........................................................................864 Diagnostic Tips................................................................864 Diagnostic Notes...............................................................864 Scanalyzer Notes...............................................................864 Test 5.23 (Part 1 of 2)........................................................866 Test 5.23 (Part 2 of 2)........................................................867 DTC P0122, P0123 5.24..................................................................868 GENERAL............................................................................868 TP Sensor......................................................................868 DIAGNOSTICS........................................................................868 Diagnostic Tips................................................................868 Diagnostic Notes...............................................................868 Scanalyzer Notes...............................................................868 Test 5.24 (Part 1 of 2)........................................................870 Test 5.24 (Part 2 of 2)........................................................871 DTC P0261, P0262, P0263, P0264 5.25....................................................872 GENERAL............................................................................872 Fuel Injectors.................................................................872 DIAGNOSTICS........................................................................872 Diagnostic Notes...............................................................872 Test 5.25 (Part 1 of 3)........................................................874 Test 5.25 (Part 2 of 3)........................................................875 Test 5.25 (Part 3 of 3)........................................................876 DTC P0373, P0374 5.26..................................................................877 GENERAL............................................................................877 CKP Sensor.....................................................................877 DIAGNOSTICS........................................................................877 Diagnostic Tips................................................................877 Diagnostic Notes...............................................................877 Test 5.26......................................................................879 DTC P0501, P0502 5.27..................................................................880 GENERAL............................................................................880 Vehicle Speed Sensor...........................................................880 DIAGNOSTICS........................................................................880 Diagnostic Notes...............................................................880 Test 5.27 (Part 1 of 2)........................................................882 Test 5.27 (Part 2 of 2)........................................................883 DTC P0562, P0563 5.28..................................................................884 GENERAL............................................................................884 Battery Voltage................................................................884 DIAGNOSTICS........................................................................884 Diagnostic Tips................................................................884 Scanalyzer Notes...............................................................884 Diagnostic Notes...............................................................884 Test 5.28 (Part 1 of 2)........................................................886 Test 5.28 (Part 2 of 2)........................................................887 DTC P0603, P0605 5.29..................................................................888 GENERAL............................................................................888 ECM Failure....................................................................888 DIAGNOSTICS........................................................................888 DTC P0603 Test.................................................................888 DTC P0605 Test.................................................................888 DTC P1009, P1010 5.30..................................................................889 GENERAL............................................................................889 Password Problem...............................................................889 DIAGNOSTICS........................................................................889 Diagnostic Notes...............................................................889 Test 5.30......................................................................891 DTC P1351, P1352, P1354, P1355 5.31....................................................892 GENERAL............................................................................892 Ignition Coil..................................................................892 DIAGNOSTICS........................................................................892 Diagnostic Notes...............................................................892 Test 5.31 (Part 1 of 2)........................................................894 Test 5.31 (Part 2 of 2)........................................................895 DTC P1653, P1654 5.32..................................................................896 GENERAL............................................................................896 Tachometer.....................................................................896 DIAGNOSTICS........................................................................896 Diagnostic Notes...............................................................896 Test 5.32......................................................................898 DTC U1064, U1255 5.33..................................................................899 GENERAL............................................................................899 Loss of TSM/TSSM Serial Data...................................................899 DIAGNOSTICS........................................................................899 Diagnostic Notes...............................................................899 Test 5.33......................................................................901 6 - WIRING.................................................................................902 CONNECTOR LOCATIONS 6.1................................................................904 AMP MULTILOCK ELECTRICAL CONNECTORS 6.2................................................906 REMOVING SOCKET/PIN TERMINALS......................................................906 INSTALLING SOCKET/PIN TERMINALS....................................................906 CRIMPING INSTRUCTIONS..............................................................909 DEUTSCH ELECTRICAL CONNECTORS 6.3......................................................910 GENERAL............................................................................910 REMOVING/DISASSEMBLING.............................................................910 REMOVING/INSTALLING SOCKETS........................................................910 REMOVING/INSTALLING PINS...........................................................911 ASSEMBLING/INSTALLING..............................................................912 CRIMPING INSTRUCTIONS..............................................................913 MINI-DEUTSCH CONNECTORS 6.4............................................................915 GENERAL............................................................................915 For Size 20, 16 and 12 Contacts Wire Range 26-12 AWG...........................915 CRIMPING INSTRUCTIONS..............................................................915 SEALED BUTT SPLICE CONNECTORS 6.5......................................................917 INSTALLATION.......................................................................917 PACKARD ELECTRICAL CONNECTORS 6.6......................................................918 GENERAL............................................................................918 PULL-TO-SEAT TERMINALS.............................................................919 Removing External Latch Type...................................................919 Installing External Latch Type.................................................919 PUSH-TO-SEAT TERMINALS.............................................................919 Removing Push-to-Seat Terminals................................................919 Installing Push-to-Seat Terminals..............................................920 CRIMPING INSTRUCTIONS..............................................................920 PACKARD ECM CONNECTOR 6.7..............................................................922 DISASSEMBLY........................................................................922 ASSEMBLY...........................................................................922 CRIMPING INSTRUCTIONS..............................................................923 INDEX TO WIRING DIAGRAMS 6.8...........................................................924 2003 ALL CARBURETED SOFTAIL DOM. and INT. MODELS, MAIN HARNESS.........................926 2003 ALL CARBURETED SOFTAIL DOM. and INT. MODELS, IGNITION CIRCUIT.....................928 2003 ALL EFI SOFTAIL DOM. and INT. MODELS, MAIN HARNESS: SHEET 1 OF 3..................935 2003 ALL CARBURETED SOFTAIL DOM. and INT. MODELS, LIGHTING CIRCUIT: SHEET 1 OF 2.......929 2003 ALL CARBURETED SOFTAIL DOM. and INT. MODELS, HORN & INSTRUMENTS...................931 2003 ALL CARBURETED SOFTAIL DOM. and INT. MODELS, SECURITY CIRCUIT: SHEET 1 OF 2.......933 2003 ALL CARBURETED SOFTAIL DOM. and INT. MODELS, SECURITY CIRCUIT: SHEET 2 OF 2.......934 2003 ALL CARBURETED SOFTAIL DOM. and INT. MODELS, CHARGING & STARTING CIRCUITS.........932 2003 ALL EFI SOFTAIL DOM. and INT. MODELS, MAIN HARNESS: SHEET 2 OF 3..................936 2003 ALL EFI SOFTAIL DOM. and INT. MODELS, MAIN HARNESS: SHEET 3 OF 3..................937 2003 ALL CARBURETED SOFTAIL DOM. and INT. MODELS, LIGHTS, SPEEDO. & INDICATORS.........927 2003 ALL EFI SOFTAIL DOM. and INT. MODELS, IGNITION CIRCUIT............................938 2003 ALL EFI SOFTAIL DOM. and INT. MODELS, IGNITION & CHARGING CIRCUITS................939 2003 ALL EFI SOFTAIL DOM. and INT. MODELS, LIGHTING CIRCUIT: SHEET 1 OF 2..............940 2003 ALL EFI SOFTAIL DOM. and INT. MODELS, LIGHTING CIRCUIT: SHEET 2 OF 2..............941 2003 ALL EFI SOFTAIL DOM. and INT. MODELS, HORN & INSTRUMENTS CIRCUIT: SHEET 1 OF 2....942 2003 ALL CARBURETED SOFTAIL DOM. and INT. MODELS, LIGHTING CIRCUIT: SHEET 2 OF 2.......930 2003 ALL EFI SOFTAIL DOM. and INT. MODELS, HORN & INSTRUMENTS CIRCUIT: SHEET 2 OF 2....943 2003 ALL EFI SOFTAIL DOM. and INT. MODELS, STARTING CIRCUIT............................944 2003 ALL EFI SOFTAIL DOM. and INT. MODELS, SECURITY CIRCUIT: SHEET 1 OF 2..............945 2003 ALL EFI SOFTAIL DOM. and INT. MODELS, SECURITY CIRCUIT: SHEET 2 OF 2..............946
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