2003 Harley Davidson VRSCA Model Service Manual – PDF DOWNLOAD
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
2003 Harley Davidson VRSCA Model Service Manual – PDF DOWNLOAD
GENERAL:
- This Service Manual has been prepared with two purposes in mind. First, it will acquaint the user with the construction of the Harley-Davidson product and assist in the performance of basic maintenance and repair.
- Secondly, it will introduce to the professional Harley-Davidson Technician the latest fieldtested and factory- approved major repair methods. We sincerely believe that this Service Manual will make your association with Harley-Davidson products more pleasant and profitaЫe.
HOWTO USE YOUR SERVICE MANUAL
Information is arranged as follows:
• Section 1-Maintenance
• Section 2-Chassis
• Section 3-Engine
• Section 4-Fuel System
• Section 5-Electric Starter
• Section 6-Cooling System
• Section 7-Transmission
• Section 8-Electrical
• Section 9-Fuel lnjection
• Appendix А-Tools
• Appendix 8-Wiring
• Appendix C-Metric Conversions
• Appendix D-Service Templates
- Use the TABLE OF CONTENTS following this FOREWORD or the INDEX at the back of the book to find the desired subject.
- Note that each manual section contains sequentially numbered topics. T he numbering system allows quick cross references throughout the document.
TABLE OF CONTENTS:
2003 Harley Davidson VRSCA Model Service Manual – PDF DOWNLOAD
Front Cover......................................... 1 Index............................................... 3 Table of Contents................................... 6 1. Maintenance...................................... 14 Fuel and Oil.................................... 19 Airbox and Air Filter........................... 23 Cooling System.................................. 26 Engine Oil and Filter........................... 27 Battery Maintenance............................. 29 Brakes.......................................... 32 Bleeding Brakes................................. 34 Brake Pads and Discs............................ 35 Tires and Wheels................................ 38 Clutch.......................................... 39 Bleeding Clutch................................. 40 Rear Belt Deflection............................ 42 Rear Belt and Sprockets......................... 44 Suspension Adjustments.......................... 46 Steering Head Bearings.......................... 47 Front Fork Oil.................................. 48 Spark Plug/Coil................................. 50 Cable and Chassis Lubrication................... 52 Throttle Cables................................. 53 Valve Lash...................................... 54 Verify Cam Tiiming.............................. 58 Lash Adjustment................................. 59 Secondary Cam Chain............................. 64 Headlamp Alignment.............................. 67 Critical Fasteners.............................. 68 Storage......................................... 69 Troubleshooting................................. 71 2. Chassis.......................................... 75 Specifications.................................. 76 Torque Values................................... 77 V.I.N........................................... 80 Frame/Lower Frame Rails......................... 81 Front Engine Mount.............................. 83 Exhaust System.................................. 86 Rear Engine Mounts.............................. 88 Engine Replacement.............................. 89 Jiffy Stand..................................... 98 Footrests/Foot Controls.........................100 Throttle Cables.................................102 Clutch Master Cylinder/Reservoir................104 Clutch Hand Lever...............................107 Clutch Fluid Line...............................108 Secondary Clutch Actuator.......................109 Front Brake Master Cylinder/Reservoir...........111 Front Brake Calipers............................115 Rear Brake Master Cylinder/Reservoir............120 Rear Brake Caliper..............................126 Handlebars......................................131 Front Wheel.....................................133 Rear Wheel......................................137 Sealed Wheel Bearings...........................142 Disc Rim Runout.................................145 Tires...........................................146 Front Fender....................................151 Front Fork......................................152 Steering Head...................................157 Fork Lock.......................................160 Belt Guard/Debris Deflector.....................161 Rear Shock Absorbers............................162 Rear Fork.......................................164 Seat Latch......................................167 Seat............................................168 Rear Fender/Supports............................170 3. Engine...........................................172 Specifications..................................173 Service Wear Limits.............................178 Engine Torque Values............................179 Oil Flow........................................180 Oil Pressure....................................184 Troubleshooting.................................186 Stripping Motorcycle For Service................188 Throttle Body...................................190 Top End Disassembly.............................192 Cylinder Head Service...........................198 Oil Pump........................................208 Clutch..........................................210 Upper and Lower Crankcase Service...............222 Counterbalancer Bearing Replacement.............237 Crankshaft Bearing Replacement..................243 Shift Shaft and Seal............................245 Crankshaft, Piston and Cylinder Liner...........247 Oil Filter Mount................................261 Cam Drive.......................................262 Cylinder Heads..................................265 Installing and Timing the Cams..................267 4. Fuel System......................................273 Specifications..................................274 Fuel Pump/Filters/Fuel Level Sender Assembly....275 Suction Side Fuel Filter........................278 Fuel Pump.......................................279 Fuel Tank.......................................280 Vapor Valve.....................................282 Evaporative Emissions Control - CA Models.......283 Purge Solenoid/Vapor Valve......................284 Charcoal Canister...............................285 Hose Routing/Replacement........................286 5. Electric Starter.................................287 Specifications..................................288 Electric Starter System.........................289 Starter Relay...................................291 Starter.........................................293 Starter Solenoid................................294 6. Cooling System...................................296 Specifications..................................297 Coolant Flow....................................298 Troubleshooting.................................300 Pressure Cap Test...............................301 System Pressure Test............................302 Leak Detection Dye Test?Blown Gasket............303 Engine Coolant..................................304 Thermostat......................................306 Water Pump......................................308 Coolant Pipes and Hoses.........................310 Oil Line Fittings...............................313 Radiator/Oil Cooler.............................314 Oil Cooler......................................317 7. Transmission.....................................319 Specifications..................................320 Output Shaft....................................321 Input Shaft.....................................330 8. Electrical.......................................336 Specifications..................................337 Torque Values...................................338 Bulb Requirements...............................339 Relay/Fuse Block................................340 Crank Position Sensor: CKP......................342 Maxi-Fuse.......................................343 Ignition/Light Switch...........................344 Alternator......................................345 Voltage Regulator...............................347 Battery.........................................349 Battery Cables..................................354 Headlamp........................................355 Tail Lamp.......................................357 Turn Signal/Running Lights......................359 Turn Signal Security Module:TSSM................361 Instrument Cluster..............................362 Vehicle Speed Sensor:VSS........................364 Neutral Switch..................................365 Oil Pressure Switch.............................366 Stop Light Switch...............................368 Horn............................................369 Cooling Fans....................................370 9. Fuel Injection...................................372 Specifications..................................373 Torque Values...................................374 Electronic Fuel Injection:EFI...................375 Electronic Control Module:ECM...................377 Throttle Position Sensor:TP.....................378 Intake Air Temperature Sensor:IAT...............379 Engine Coolant Temperature Sensor:ECT...........380 Idle Air Control:IAC............................381 Manifold Absolute Pressure Sensor:MAP...........383 Fuel Rail/Fuel Injectors........................384 Fuel Pressure Test..............................386 Intake Leak Test................................388 Appendix............................................390 Appendix A - Tools..............................391 Appendix B - Wiring.............................403 Appendix C - Conversions........................424 Index...............................................439
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PLEASE NOTE:
- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]
S.V