2004 Harley-Davidson FLT Touring Service Manual 99483-04 – PDF DOWNLOAD
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2004 Harley-Davidson FLT Touring Service Manual 99483-04 – PDF DOWNLOAD
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2004 Harley-Davidson FLT Touring Service Manual 99483-04 – PDF DOWNLOAD
GENERAL:
The troubleshooting tables beginning on page 1-1 contain
detailed procedures to solve and correct problems. Follow the
1.2 STARTING SYSTEM DIAGNOSIS diagram to diagnose
starting system problems. The VOLTAGE DROPS procedure
below will help you to locate poor connections or components
with excessive voltage drops.
VOLTAGE DROPS
Check the integrity of all wiring, switches, circuit breakers and
connectors between the source and destination.
The voltage drop test measures the difference in potential or the
actual voltage dropped between the source and destination.
1. See ITEM A in Figure 1-1. Attach your red meter lead to
the most positive part of the circuit, which in this case
would be the positive post of the battery.
2. See ITEM B in Figure 1-1. Attach the black meter lead to
the final destination or component in the circuit (solenoid
terminal from relay).
3. Activate the starter and observe the meter reading. The
meter will read the voltage dropped or the difference in
potential between the source and destination.
4. An ideal circuit’s voltage drop would be 0 volts or no voltage
dropped, meaning no difference in potential.
5. See ITEM C in Figure 1-1. An open circuit should read
12 volts, displaying all the voltage dropped, and the
entire difference in potential displayed on the meter
TABLE OF CONTENTS:
2004 Harley-Davidson FLT Touring Service Manual 99483-04 – PDF DOWNLOAD
2004_touring 1
2004 FLT MODELS 2
SERVICE MANUAL 2
Part Number 99483-04 2
POLICE SERVICE SUPPLEMENT 2
Part Number 99483-04SP 2
ELECTRICAL DIAGNOSTICS 2
Part Number 99497-04 2
FLHTCSE SERVICE SUPPLEMENT 2
Part Number 99500-04 2
fe01_tc 3
STARTING/CHARGING 1 3
fe01a 5
STARTER TROUBLESHOOTING 1 1 5
Table 1-1 Starter Does Not Run or Runs At Very Low Speeds 5
Table 1-2 Pinion Does Not Engage With Ring Gear While Starter is Cranked or Engine Cannot Be Cra 6
Table 1-3 Starter Does Not Stop Running 6
STARTING SYSTEM DIAGNOSIS 1 2 7
Diagnostic Notes 7
Job/Time Code Values 7
Starter Testing 1 7
Starter Testing 2: Solenoid Clicks 8
Starter Testing 3: Relay Clicks 8
Starter Testing 4: Nothing Clicks 9
Starter Testing 5: Starter Spins, But Does Not Engage 10
Starter Testing 6: Starter Stalls or Spins Too Slowly 10
STARTER ACTIVATION CIRCUITS 1 3 11
DIAGNOSTICS/TROUBLESHOOTING 1 4 12
STARTER SYSTEM TESTING 1 5 13
TESTING ASSEMBLED STARTER 1 6 15
CHARGING SYSTEM 1 7 17
Alternator 17
Voltage Regulator 17
Battery 17
Wiring 17
Voltage Regulator Inspection 17
Job/Time Code Values 17
Test 1 7 (Part 1 of 2) 18
Test 1 7 (Part 2 of 2) 19
MILLIAMP DRAW TEST 20
Table 1-4 Milliampere Draw Test 20
TOTAL CURRENT DRAW TEST 20
CURRENT OUTPUT TEST 21
VOLTAGE OUTPUT TEST 21
STATOR CHECK 21
AC OUTPUT CHECK 22
BATTERY LOAD TEST 1 8 23
Table 1-5 Voltmeter Test 23
Table 1-6 Battery Load Test 23
fe02_tc 25
INSTRUMENTS 2 25
fe02a 27
2004 CHECKING FOR DIAGNOSTIC TROUBLE CODES 2 1 27
CHECK ENGINE LAMP 27
SECURITY LAMP 28
CODE TYPES 29
Current 29
Historic 29
RETRIEVING DIAGNOSTIC TROUBLE CODES 29
MULTIPLE DIAGNOSTIC TROUBLE CODES 29
INITIAL DIAGNOSTIC CHECK: SPEEDOMETER 2 2 30
GENERAL 30
Diagnostic Notes 30
Circuit Diagram/Wire Harness Connector Table 30
INITIAL DIAGNOSTICS 31
Diagnostic Tips 31
Diagnostic Notes 31
Other Codes 31
Diagnostic Check (Part 1 of 2) 37
Diagnostic Check (Part 2 of 2) 38
SPEEDOMETER SELF DIAGNOSTICS 2 3 39
GENERAL 39
DIAGNOSTICS 39
Diagnostic Tips 39
Diagnostic Notes 39
Speedometer Self Diagnostics (chart) 40
SPEEDOMETER/TACHOMETER 2 4 41
GENERAL 41
Reset Switch 41
SPEEDOMETER THEORY OF OPERATION 42
Job/Time Code Values 42
TACHOMETER THEORY OF OPERATION 42
DIAGNOSTICS 42
Diagnostic Notes 42
Test 2 4 (Part 1 of 2) 43
Test 2 4 (Part 2 of 2) 44
BREAKOUT BOX: SPEEDOMETER 2 5 45
GENERAL 45
INSTALLATION 45
REMOVAL 45
SPEEDOMETER PERFORMANCE CHECK 2 6 46
GENERAL 46
TESTING 46
Speedometer Operation Test 46
Speedometer Needle Sweep Test 47
Vehicle Speed Sensor Test 47
FUEL GAUGE OPERATION 2 7 48
THEORY OF OPERATION 48
FUEL GAUGE AND SENDER TEST 48
INDICATOR LAMPS: FLTR, FLHT/C/U 2 8 49
GENERAL 49
Job/Time Code Values 49
Diagnostic Notes 49
DIAGNOSTICS 50
Oil Pressure or Neutral Indicator Will Not Function 50
High Beam or R/L Turn Signal Indicator Will Not Function 50
INDICATOR LAMPS: FLHR/C/S 2 9 51
GENERAL 51
Job/Time Code Values 51
DIAGNOSTICS 52
Oil Pressure or Neutral Indicator Will Not Function 52
High Beam or R/L Turn Signal Indicator Will Not Function 52
DTC B1004, B1005 2 10 53
GENERAL 53
DIAGNOSTICS 53
Diagnostic Tips 53
Diagnostic Notes 53
Test 2 10: DTC 1004 55
Test 2 10: DTC B1005 56
DTC B1006, B1007 2 11 57
GENERAL 57
Accessory Or Ignition Line Overvoltage 57
Test 2 11 58
DTC B1008 2 12 59
GENERAL 59
Reset Switch Closed 59
DIAGNOSTICS 59
Diagnostic Notes 59
Test 2 12 61
DTC U1016 2 13 62
GENERAL 62
Loss of ICM/ECM Serial Data 62
DIAGNOSTICS 62
Diagnostic Notes 62
Test 2 13 67
DTC U1064, U1255 2 14 68
GENERAL 68
Loss of TSM/TSSM Serial Data 68
DIAGNOSTICS 68
Diagnostic Notes 68
Test 2 14 73
DTC U1300, U1301 or “BUS ER” 2 15 74
GENERAL 74
Serial Data Low or Serial data Open/High 74
DIAGNOSTICS 74
Diagnostic Tips 74
Diagnostic Notes 74
fe03_tc 75
TSM/TSSM 3 75
fe03a 77
TSM/TSSM OVERVIEW 3 1 77
GENERAL 77
TROUBLESHOOTING 77
TSM/TSSM FEATURES 3 2 79
GENERAL 79
TURN SIGNAL FUNCTIONS 79
TSM/TSSM Features 79
BANK ANGLE FUNCTIONS 79
TSM/TSSM Features 79
SECURITY ALARM AND IMMOBILIZATION FUNCTIONS 79
TSSM Only Feature 79
TSM/TSSM VEHICLE DELIVERY 3 3 81
GENERAL 81
SIDECAR CONFIGURATION 81
POWER DISRUPTION AND CONFIGURING 81
KEY FOB ASSIGNMENT 82
PERSONAL CODE ENTRY 82
First Time Code Entry: TSSM Only 82
Modifying Existing Codes: TSSM Only 82
TSM/TSSM TURN SIGNAL FUNCTIONS 3 4 86
GENERAL 86
AUTOMATIC CANCELLATION 86
MANUAL CANCELLATION 86
FOUR-WAY FLASHING 87
DIAGNOSTICS MODE 87
TSM/TSSM BANK ANGLE FUNCTION 3 5 88
GENERAL 88
OPERATION 88
SECURITY SYSTEM (TSSM) FUNCTIONS 3 6 89
GENERAL 89
Security System Operation 89
Security System Options 89
Differences By Market Specifications 89
ALARM SENSITIVITY 89
Sensitivity 89
Transport Mode 89
AUTO-ARMING FUNCTION 90
STORAGE MODE 90
ARMING/DISARMING SECURITY SYSTEM (TSSM) 3 7 93
GENERAL 93
SECURITY LAMP 93
USING KEY FOB 93
General 93
Arming the System 93
Disarming the System 93
Troubleshooting 93
USING THE PERSONAL CODE 94
General 94
Disarming the System 94
CHECKING FOR DIAGNOSTIC TROUBLE CODES 3 8 95
TSM 95
TSSM 95
CODE TYPES 97
Current 97
Historic 97
RETRIEVING DIAGNOSTIC TROUBLE CODES 97
MULTIPLE DIAGNOSTIC TROUBLE CODES 97
INITIAL DIAGNOSTIC CHECK: TSM/TSSM 3 9 98
GENERAL 98
Diagnostic Notes 98
Circuit Diagram/Wire Harness Connector Table 98
Reprogramming ICM/ECM 98
INITIAL DIAGNOSTICS 98
Diagnostic Tips 98
Diagnostic Notes 98
Other Codes 98
Initial Diagnostic Check (Part 1 of 2) 104
Initial Diagnostic Check (Part 2 of 2) 105
SPEEDOMETER SELF DIAGNOSTICS 3 10 106
GENERAL 106
DIAGNOSTICS 106
Diagnostic Tips 106
Diagnostic Notes 106
Speedometer Self Diagnostics (chart) 107
BREAKOUT BOX: TSM/TSSM 3 11 108
GENERAL 108
INSTALLATION 108
REMOVAL 108
NO SECURITY LAMP AT KEY ON 3 12 109
GENERAL 109
No TSSM Power (Security Equipped Vehicles Only) 109
Job/Time Code Values 109
DIAGNOSTICS 109
Diagnostic Tips 109
Diagnostic Notes 109
Test 3 12 (Part 1 of 3) 112
Test 3 12 (Part 2 of 3) 113
Test 3 12 (Part 3 of 3) 114
SECURITY LAMP ON CONTINUOUSLY 3 13 115
GENERAL 115
DIAGNOSTICS 115
Diagnostic Notes 115
Test 3 13 117
fe03b 119
KEY FOB SIGNAL TO TSSM WEAK OR FAILS 3 14 119
GENERAL 119
Security Equipped Vehicles Only 119
DIAGNOSTICS 119
Diagnostic Tips 119
Diagnostic Notes 119
Test 3 14 121
TURN SIGNAL ERRORS 3 15 122
GENERAL 122
DIAGNOSTICS 122
Diagnostic Tips 122
Diagnostic Notes: All Turn Signal Flow Charts 125
Turn Signal Error 1A (Part 1 of 2) 126
Turn Signal Error 1A (Part 2 of 2) 127
Turn Signal Error 2A 128
Turn Signal Error 2B 129
Turn Signal Error 2C 130
Turn Signal Error 2D 131
Turn Signal Error 3A 132
DTC B0563 3 16 133
GENERAL 133
Battery Voltage High 133
DIAGNOSTICS 133
Diagnostic Tips 133
Diagnostic Notes 133
DTC B1131, B1132 3 17 134
GENERAL 134
Alarm Output Low (DTC B1131) or Alarm Output High (DTC B1132) 134
DIAGNOSTICS 134
Diagnostic Tips 134
Diagnostic Notes 134
Test 3 17 136
DTC B1134 3 18 137
GENERAL 137
Starter Output High 137
DIAGNOSTICS 137
Diagnostic Notes 137
Test 3 18 139
DTC B1135 3 19 140
GENERAL 140
Accelerometer Fault 140
DTC B1151, B1152, B1153 3 20 141
GENERAL 141
Sidecar BAS Low (DTC B1151), High (DTC B1152) or Out of Range (DTC B1153) 141
DIAGNOSTICS 141
Diagnostic Tips 141
Diagnostic Notes 141
Test 3 20 143
DTC U1016, U1255 3 21 144
GENERAL 144
Loss of ICM/ECM Serial Data 144
DIAGNOSTICS 144
Diagnostic Notes 144
Test 3 21 149
DTC U1097, U1255 3 22 150
GENERAL 150
Loss of Speedometer Serial Data 150
DIAGNOSTICS 150
Diagnostic Notes 150
Test 3 22 155
DTC U1300, U1301 or “BUS ER” 3 23 156
GENERAL 156
Serial Data Low or Serial data Open/High 156
DIAGNOSTICS 156
Diagnostic Tips 156
Diagnostic Notes 156
PASSWORD LEARN 3 24 157
GENERAL 157
PASSWORD LEARNING 157
TSSM MAINTENANCE 3 25 159
GENERAL 159
KEY FOB 159
Schedule 159
Battery Replacement 159
SIREN (IF INSTALLED) 160
Schedule 160
Battery Replacement 160
fe04_tc 161
ENGINE MANAGEMENT (CARB) 4 161
fe04a 163
SPECIFICATIONS 4 1 163
DIAGNOSTIC INTRODUCTION 4 2 164
SYSTEM PROBLEMS 164
No Start 164
Poor Performance 164
Check Engine Lamp 164
RESOLVING PROBLEMS 164
CHECKING FOR TROUBLE CODES 4 3 165
CHECK ENGINE LAMP 165
CODE TYPES 166
Current 166
Historic 166
RETRIEVING DIAGNOSTIC TROUBLE CODES 166
MULTIPLE DIAGNOSTIC TROUBLE CODES 166
INITIAL DIAGNOSTIC CHECK: ICM 4 4 167
GENERAL 167
Diagnostic Notes 167
Circuit Diagram/Wire Harness Connector Table 167
Reprogramming ICM 167
INITIAL DIAGNOSTICS 167
General Information 167
Diagnostic Tips 167
Diagnostic Notes 167
Initial Diagnostic Check (Part 1 of 2) 172
Initial Diagnostic Check (Part 2 of 2) 173
SPEEDOMETER SELF DIAGNOSTICS 4 5 174
GENERAL 174
DIAGNOSTICS 174
Diagnostic Tips 174
Diagnostic Notes 174
Speedometer Self Diagnostics (chart) 175
BREAKOUT BOX: ICM 4 6 176
GENERAL 176
INSTALLATION 176
REMOVAL 176
WIGGLE TEST 4 7 177
GENERAL 177
PROCEDURE 177
INTAKE LEAK TEST 4 8 178
GENERAL 178
LEAK TESTER 178
Parts List 178
Tester Assembly 178
INTAKE LEAK TESTING 179
ENGINE CRANKS, BUT WILL NOT START 4 9 180
GENERAL 180
DIAGNOSTICS 180
Diagnostic Notes 180
Test 4 9 (Part 1 of 3) 182
Test 4 9 (Part 2 of 3) 183
Test 4 9 (Part 3 of 3) 184
STARTS, THEN STALLS 4 10 185
GENERAL 185
Diagnostic Trouble Codes U1300, U1301, P1009, P1010 or “BUS Er” 185
DIAGNOSTICS 185
Diagnostic Tips 185
Diagnostic Notes 185
Test 4 10 (Part 1 of 2) 188
Test 4 10 (Part 2 of 2) 189
NO SPARK/NO ICM POWER 4 11 190
GENERAL 190
DIAGNOSTICS 190
Diagnostic Notes 190
Test 4 11 191
MISFIRE 4 12 192
GENERAL 192
Misfire at Idle or Under Load 192
DIAGNOSTICS 192
Diagnostic Notes 192
Test 4 12 194
fe04b 195
DTC P0106, P0107, P0108 4 13 195
GENERAL 195
MAP Sensor 195
DIAGNOSTICS 195
Diagnostic Tips 195
Diagnostic Notes 195
Test 4 13 (Part 1 of 2) 197
Test 4 13 (Part 2 of 2) 198
DTC P0562, P0563 4 14 199
GENERAL 199
Battery Voltage 199
DIAGNOSTICS 199
Diagnostic Notes 199
Test 4 14 (Part 1 of 2) 201
Test 4 14 (Part 2 of 2) 202
DTC P1009, P1010 4 15 203
GENERAL 203
Password Problem 203
DIAGNOSTICS 203
Diagnostic Notes 203
Test 4 15 206
DTC P1351, P1352, P1354, P1355 4 16 207
GENERAL 207
Ignition Coil 207
DIAGNOSTICS 207
Diagnostic Notes 207
Test 4 16 (Part 1 of 2) 209
Test 4 16 (Part 2 of 2) 210
DTC P0373, P0374 4 17 211
GENERAL 211
Crank Position Sensor 211
DIAGNOSTICS 211
Diagnostic Notes 211
Test 4 17 213
DTC P0501, P0502 4 18 214
GENERAL 214
Vehicle Speed Sensor 214
DIAGNOSTICS 214
Diagnostic Notes 214
Test 4 18 (Part 1 of 2) 216
Test 4 18 (Part 2 of 2) 217
DTC P0602, P0603, P0604, P0605, P0607 4 19 218
GENERAL 218
ICM Failure 218
DIAGNOSTICS 218
DTC P0607 Test 218
DTC P0602, P0603, P0604, P0605 Test 218
DTC U1064 4 20 219
GENERAL 219
Loss of TSM/TSSM Serial Data 219
DIAGNOSTICS 219
Diagnostic Notes 219
Test 4 20 222
DTC U1097 4 21 223
GENERAL 223
Loss of Speedometer Serial Data 223
DIAGNOSTICS 223
Diagnostic Notes 223
Test 4 21 226
fe05_tc 227
ENGINE MANAGEMENT (EFI) 5 227
fe05a 229
SPECIFICATIONS 5 1 229
EFI SYSTEM 5 2 231
GENERAL 231
TROUBLESHOOTING 231
EFI DIAGNOSTIC INTRODUCTION 5 3 233
SYSTEM PROBLEMS 233
No Start 233
Poor Performance 233
Check Engine Lamp 233
RESOLVING PROBLEMS 233
CHECKING FOR DIAGNOSTIC TROUBLE CODES: EFI 5 4 234
CHECK ENGINE LAMP 234
CODE TYPES 235
Current 235
Historic 235
RETRIEVING DIAGNOSTIC TROUBLE CODES 235
MULTIPLE DIAGNOSTIC TROUBLE CODES 235
INITIAL DIAGNOSTIC CHECK: EFI 5 5 236
GENERAL 236
Diagnostic Notes 236
Circuit Diagram/Wire Harness Connector Table 236
Reprogramming ECM 236
INITIAL DIAGNOSTICS 236
General Information 236
Diagnostic Tips 236
Diagnostic Notes 236
Other Codes 236
Diagnostic Check (Part 1 of 2) 243
Diagnostic Check (Part 2 of 2) 244
SPEEDOMETER SELF DIAGNOSTICS 5 6 245
GENERAL 245
DIAGNOSTICS 245
Diagnostic Tips 245
Diagnostic Notes 245
Speedometer Self Diagnostics (chart) 246
BREAKOUT BOX: EFI 5 7 247
GENERAL 247
INSTALLATION 247
REMOVAL 247
WIGGLE TEST 5 8 248
GENERAL 248
PROCEDURE 248
INTAKE LEAK TEST 5 9 249
GENERAL 249
LEAK TESTER 249
Parts List 249
Tester Assembly 249
INTAKE LEAK TESTING 250
ENGINE CRANKS, BUT WILL NOT START 5 10 251
GENERAL 251
DIAGNOSTICS 251
Diagnostic Notes 251
Diagnostic Tips 251
Test 5 10 (Part 1 of 4) 254
Test 5 10 (Part 2 of 4) 255
Test 5 10 (Part 3 of 4) 256
Test 5 10 (Part 4 of 4) 257
NO ECM POWER 5 11 258
GENERAL 258
No Spark/No Check Engine Lamp at Key ON 258
DIAGNOSTICS 258
Diagnostic Notes 258
Test 5 11 (Part 1 of 2) 261
Test 5 11 (Part 2 of 2) 262
STARTS, THEN STALLS 5 12 263
GENERAL 263
Diagnostic Trouble Codes U1300, U1301 or “BUS Er” 263
DIAGNOSTICS 263
Diagnostic Tips 263
Diagnostic Notes 263
Test 5 12 (Part 1 of 2) 266
Test 5 12 (Part 2 of 2) 267
FUEL SYSTEM ELECTRICAL TEST 5 13 268
GENERAL 268
DIAGNOSTICS 268
Diagnostic Notes 268
Test 5 13 (Part 1 of 4) 270
Test 5 13 (Part 2 of 4) 271
Test 5 13 (Part 3 of 4) 272
Test 5 13 (Part 4 of 4) 272
SYSTEM RELAY CHECK 5 14 273
GENERAL 273
System Relay 273
DIAGNOSTICS 273
Diagnostic Notes 273
Test 5 14 (Part 1 of 3) 276
Test 5 14 (Part 2 of 3) 277
Test 5 14 (Part 3 of 3) 277
FUEL PRESSURE TEST 5 15 278
GENERAL 278
TESTING 278
DIAGNOSTICS 280
Diagnostic Notes 280
Test 5 15 281
IDLE AIR CONTROL 5 16 282
GENERAL 282
IAC Operation 282
Diagnostic Trouble Code P0505: Loss of Idle Speed Control 282
DIAGNOSTICS 282
Diagnostic Tips 282
Diagnostic Notes 283
Test 5 16 (Part 1 of 2) 285
Test 5 16 (Part 2 of 2) 286
MISFIRE AT IDLE OR UNDER LOAD 5 17 287
GENERAL 287
Misfire at Idle or Under Load 287
DIAGNOSTICS 287
Diagnostic Notes 287
Test 5 17 (Part 1 of 3) 289
Test 5 17 (Part 2 of 3) 290
Test 5 17 (Part 3 of 3) 291
COMBUSTION ABSENT/INTERMITTENT 5 18 292
GENERAL 292
Diagnostic Trouble Codes P1353, P1356, P1357, P1358: No Combustion 292
DIAGNOSTICS 292
Diagnostic Notes 292
Test 5 18 (Part 1 of 2) 295
Test 5 18 (Part 2 of 2) 296
fe05b 297
DTC P0107, P0108 5 19 297
GENERAL 297
MAP Sensor 297
DIAGNOSTICS 297
Diagnostic Tips 297
Diagnostic Notes 297
Test 5 19 (Part 1 of 2) 299
Test 5 19 (Part 2 of 2) 300
DTC P0112, P0113 5 20 301
GENERAL 301
IAT Sensor 301
DIAGNOSTICS 301
Diagnostic Tips 301
Diagnostic Notes 301
Test 5 20 (Part 1 of 2) 303
Test 5 20 (Part 2 of 2) 304
DTC P0117, P0118 5 21 305
GENERAL 305
ET Sensor 305
DIAGNOSTICS 305
Diagnostic Tips 305
Diagnostic Notes 305
Test 5 21 (Part 1 of 2) 307
Test 5 21 (Part 2 of 2) 308
DTC P0122, P0123 5 22 309
GENERAL 309
TP Sensor 309
DIAGNOSTICS 309
Diagnostic Tips 309
Diagnostic Notes 309
Test 5 22 (Part 1 of 2) 311
Test 5 22 (Part 2 of 2) 312
DTC P0261, P0262, P0263, P0264 5 23 313
GENERAL 313
Fuel Injectors 313
DIAGNOSTICS 313
Diagnostic Notes 313
Test 5 23 (Part 1 of 3) 316
Test 5 23 (Part 2 of 3) 317
Test 5 23 (Part 3 of 3) 318
DTC P0373, P0374 5 24 319
GENERAL 319
CKP Sensor 319
DIAGNOSTICS 319
Diagnostic Tips 319
Diagnostic Notes 319
Test 5 24 321
DTC P0501, P0502 5 25 322
GENERAL 322
Vehicle Speed Sensor 322
DIAGNOSTICS 322
Diagnostic Notes 322
Test 5 25 (Part 1 of 2) 324
Test 5 25 (Part 2 of 2) 325
DTC P0562, P0563 5 26 326
GENERAL 326
Battery Voltage 326
DIAGNOSTICS 326
Diagnostic Tips 326
Diagnostic Notes 326
Test 5 26 (Part 1 of 2) 329
Test 5 26 (Part 2 of 2) 330
DTC P0603, P0605 5 27 331
GENERAL 331
ECM Failure 331
DIAGNOSTICS 331
DTC P0603 331
DTC P0605 331
DTC P1009, P1010 5 28 332
GENERAL 332
Password Problem 332
DIAGNOSTICS 332
Diagnostic Notes 332
Test 5 28 335
DTC P1351, P1352, P1354, P1355 5 29 336
GENERAL 336
Ignition Coil 336
DIAGNOSTICS 336
Diagnostic Notes 336
Test 5 29 (Part 1 of 2) 339
Test 5 29 (Part 2 of 2) 340
DTC U1064, U1255 5 30 341
GENERAL 341
Loss of TSM/TSSM Serial Data 341
DIAGNOSTICS 341
Diagnostic Notes 341
Test 5 30 344
DTC U1097, U1255 5 31 345
GENERAL 345
Loss of Speedometer Serial Data 345
DIAGNOSTICS 345
Diagnostic Notes 345
Test 5 31 348
fe06_tc 349
PREMIUM SOUND 6 349
fe06a 351
DIAGNOSTIC INTRODUCTION 6 1 351
GENERAL 351
DIAGNOSTIC MODE OVERVIEW 6 2 352
GENERAL 352
DIAGNOSTIC MODE GROUP 1 353
GENERAL 353
SAMPLE DIAGNOSTIC 353
DIAGNOSTIC MODE GROUP 2 354
GENERAL 354
SAMPLE DIAGNOSTIC 354
BREAKOUT BOX 6 3 355
GENERAL 355
INSTALLATION 355
REMOVAL 355
RADIO SYMPTOM 1 6 4 356
GENERAL 356
Problem 356
Setup 356
Functionality 356
DIAGNOSTICS 356
Diagnostic Notes 356
Test 6 4 (Part 1 of 2) 357
Test 6 4 (Part 2 of 2) 358
RADIO SYMPTOM 2 6 5 359
GENERAL 359
Problem 359
Setup 359
Functionality 359
DIAGNOSTICS 359
Diagnostic Notes 359
Test 6 5 (Part 1 of 4) 360
Test 6 5 (Part 2 of 4) 361
Test 6 5 (Part 3 of 4) 362
Test 6 5 (Part 4 of 4) 363
RADIO SYMPTOM 3 6 6 364
GENERAL 364
Problem 364
Setup 364
Functionality 364
DIAGNOSTICS 364
Diagnostic Notes 364
Test 6 6 (Part 1 of 3) 365
Test 6 6 (Part 2 of 3) 366
Test 6 6 (Part 3 of 3) 367
RADIO SYMPTOM 4 6 7 368
GENERAL 368
Problem 368
Setup 368
Functionality 368
DIAGNOSTICS 368
Automatic Volume Control (AVC) Adjustment 368
Diagnostic Notes 369
Test 6 7 (Part 1 of 2) 369
Test 6 7 (Part 2 of 2) 370
RADIO SYMPTOM 5 6 8 371
GENERAL 371
Problem 371
Setup 371
Functionality 371
DIAGNOSTICS 371
Radio Antenna Test 371
Test 6 8 371
RADIO SYMPTOM 6 6 9 372
GENERAL 372
Problem 372
Setup 372
Functionality 372
DIAGNOSTICS 372
Diagnostic Notes 372
Test 6 9 (Part 1 of 2) 373
Test 6 9 (Part 2 of 2) 374
RADIO SYMPTOM 7 6 10 375
GENERAL 375
Problem 375
Setup 375
Functionality 375
DIAGNOSTICS 375
Diagnostic Notes 375
Test 6 10 (Part 1 of 2) 376
Test 6 10 (Part 2 of 2) 377
RADIO SYMPTOM 8 6 11 378
GENERAL 378
Problem 378
Setup 378
Functionality 378
DIAGNOSTICS 378
Diagnostic Notes 378
Test 6 11 (Part 1 of 2) 379
Test 6 11 (Part 2 of 2) 380
RADIO SYMPTOM 9 6 12 381
GENERAL 381
Problem 381
Setup 381
Functionality 381
DIAGNOSTICS 381
Diagnostic Notes 381
Test 6 12 (Part 1 of 3) 382
Test 6 12 (Part 2 of 3) 383
Test 6 12 (Part 3 of 3) 384
RADIO SYMPTOM 10 6 13 386
GENERAL 386
Problem 386
Setup 386
Functionality 386
DIAGNOSTICS 386
Test 6 13 387
RADIO SYMPTOM 11 6 14 388
GENERAL 388
Problem 388
Setup 388
Functionality 388
DIAGNOSTICS 388
Diagnostic Notes 388
Test 6 14 389
RADIO SYMPTOM 12 6 15 391
GENERAL 391
Problem 391
Setup 391
Functionality 391
DIAGNOSTICS 391
Diagnostic Notes 391
Test 6 15 (Part 1 of 2) 392
Test 6 15 (Part 2 of 2) 393
CB Antenna Test 393
SWR Adjustment 393
RADIO SYMPTOM 13 6 16 395
GENERAL 395
Problem 395
Setup 395
Functionality 395
DIAGNOSTICS 395
Diagnostic Notes 395
Test 6 16 (Part 1 of 2) 396
Test 6 16 (Part 2 of 2) 397
RADIO SYMPTOM 14 6 17 398
GENERAL 398
Problem 398
Setup 398
Functionality 398
DIAGNOSTICS 398
Diagnostic Notes 398
Test 6 17 (Part 1 of 2) 399
Test 6 17 (Part 2 of 2) 400
RADIO SYMPTOM 15 6 18 401
GENERAL 401
Problem 401
Setup 401
Functionality 401
DIAGNOSTICS 401
Diagnostic Notes 401
Test 6 18 401
fe07_tc 403
CRUISE CONTROL 7 403
fe07a 405
CRUISE CONTROL 7 1 405
GENERAL 405
SYSTEM OPERATION 405
TROUBLESHOOTING 406
CRUISE INOPERATIVE DIAGNOSTICS 7 2 407
GENERAL 407
INOPERATIVE DIAGNOSTICS 407
Diagnostic Notes 407
CRUISE DROPOUT DIAGNOSTICS 7 3 410
GENERAL 410
DROPOUT DIAGNOSTICS 410
CRUISE CHART A: INITIAL DIAGNOSTICS 7 4 413
DIAGNOSTICS 413
Test 7 4 (Part 1 of 2) 413
Test 7 4 (Part 2 of 2) 414
CRUISE CHART B: RESUME SWITCH 7 5 415
DIAGNOSTICS 415
Test 7 5 415
CRUISE CHART C: CRUISE ENGAGED LAMP 7 6 416
DIAGNOSTICS 416
Test 7 6 416
CRUISE CHART D: CRUISE POWER 7 7 417
DIAGNOSTICS 417
Test 7 7 417
CRUISE CHART E: CRUISE ENABLE 7 8 419
DIAGNOSTICS 419
Test 7 8 419
Diagnostic Notes 419
CRUISE CHART F-1: BRAKE LIGHTS ON 7 9 420
DIAGNOSTICS 420
Test 7 9 420
CRUISE CHART F-2: BRAKE LIGHTS OFF 7 10 421
DIAGNOSTICS 421
Test 7 10 (Part 1 of 2) 421
Test 7 10 (Part 2 of 2) 422
Diagnostic Notes 422
CRUISE CHART G: THROTTLE SWITCH 7 11 423
DIAGNOSTICS 423
Test 7 11 423
CRUISE CHART H: SPEEDOMETER INPUT 7 12 424
DIAGNOSTICS 424
Diagnostic Notes 424
Test 7 12 (Part 1 of 2) 424
CRUISE CHART I: TACHOMETER INPUT 7 13 425
DIAGNOSTICS 425
Test 7 13 425
fe08_tc 427
WIRING 8 427
fe08a 429
ELECTRICAL CONNECTOR LOCATIONS 8 1 429
DEUTSCH ELECTRICAL CONNECTORS 8 2 441
GENERAL 441
REMOVING/DISASSEMBLING 441
REMOVING/INSTALLING SOCKETS 441
REMOVING/INSTALLING PINS 442
ASSEMBLING/INSTALLING 444
CRIMPING INSTRUCTIONS 444
Standard Terminals 444
Mini Terminals 446
Solid Barrel Contacts 446
1-PLACE CABLE CONNECTOR 448
General 448
Removal 448
Installation 448
AMP MULTILOCK ELECTRICAL CONNECTORS 8 3 449
REMOVING SOCKET/PIN TERMINALS 449
INSTALLING SOCKET/PIN TERMINALS 449
CRIMPING INSTRUCTIONS 453
PACKARD ELECTRICAL CONNECTORS 8 4 454
150 METRI-PACK SERIES 454
General 454
Disassembly 454
Assembly 455
280 METRI-PACK SERIES 455
General 455
Fuel Injectors 455
System Fuse Block 457
480 METRI-PACK SERIES 457
General 457
Disassembly 457
Assembly 458
630 METRI-PACK SERIES 459
General 459
Disassembly 459
Assembly 459
800 METRI-PACK SERIES 459
General 459
Disassembly 459
Assembly 460
PACKARD MICRO 64 460
General 460
Disassembly 460
Assembly 461
Crimping Instructions 461
PACKARD 100W 462
General 462
Disassembly 462
Assembly 463
Crimping Instructions 463
AUTOFUSE ELECTRICAL CONNECTOR 8 5 465
GENERAL 465
DISASSEMBLY 465
ASSEMBLY 465
SEALED BUTT SPLICE CONNECTORS 8 6 466
PROCEDURE 466
AMP ELECTRICAL CONNECTORS 8 7 468
1-PLACE CONNECTOR 468
Socket Terminal 468
Pin Terminal 468
WIRING DIAGRAMS 8 8 471
maintoc 485
2004 FLT MODELS 485
SERVICE MANUAL 485
Part Number 99483-04 485
POLICE SERVICE SUPPLEMENT 485
Part Number 99483-04SP 485
ELECTRICAL DIAGNOSTICS 485
Part Number 99497-04 485
FLHTCSE SERVICE SUPPLEMENT 485
Part Number 99500-04 485
sm_appa 486
TOOLS A 1 486
sm_appb1 504
DEUTSCH ELECTRICAL CONNECTORS B 1 504
GENERAL 504
REMOVING/DISASSEMBLING 504
REMOVING/INSTALLING SOCKETS 504
REMOVING/INSTALLING PINS 505
ASSEMBLING/INSTALLING 507
CRIMPING INSTRUCTIONS 507
STANDARD TERMINALS 507
MINI TERMINALS 509
SOLID BARREL CONTACTS 509
1-PLACE CABLE CONNECTOR 511
General 511
Removal 511
Installation 511
AMP MULTILOCK ELECTRICAL CONNECTORS B 2 512
REMOVING SOCKET/PIN TERMINALS 512
INSTALLING SOCKET/PIN TERMINALS 512
CRIMPING INSTRUCTIONS 516
PACKARD ELECTRICAL CONNECTORS B 3 517
150 METRI-PACK SERIES 517
General 517
Disassembly 517
Assembly 518
280 METRI-PACK SERIES 518
General 518
Fuel Injectors 518
System Fuse Block 520
480 METRI-PACK SERIES 520
General 520
Disassembly 520
Assembly 521
630 METRI-PACK SERIES 522
General 522
Disassembly 522
Assembly 522
800 METRI-PACK SERIES 522
General 522
Disassembly 522
Assembly 523
PACKARD MICRO 64 523
General 523
Disassembly 523
Assembly 524
Crimping Instructions 524
PACKARD 100W 525
General 525
Disassembly 525
Assembly 526
Crimping Instructions 526
AUTOFUSE ELECTRICAL CONNECTOR B 4 528
General 528
Disassembly 528
Assembly 528
SEALED BUTT SPLICE CONNECTORS B 5 529
PROCEDURE 529
AMP ELECTRICAL CONNECTORS B 6 531
1-PLACE CONNECTOR 531
SOCKET TERMINAL 531
PIN TERMINAL 531
ELECTRICAL CONNECTOR LOCATIONS B 7 533
WIRING DIAGRAMS B 8 544
sm_appc 558
METRIC CONVERSIONS C 1 558
FLUID CONVERSIONS C 2 559
UNITED STATES SYSTEM 559
METRIC SYSTEM 559
BRITISH IMPERIAL SYSTEM 559
sm_appd 560
JAPANESE MAINSHAFT/COUNTERSHAFT D 1 560
DISASSEMBLY 560
CLEANING AND INSPECTION 562
ASSEMBLY 563
sm01_tc 566
sm01a 568
TROUBLESHOOTING 1 1 568
GENERAL 568
ENGINE 568
Starter Motor Does Not Operate or Does Not Turn Engine Over 568
Engine Turns Over But Does Not Start 568
Starts Hard 568
Starts But Runs Irregularly or Misses 568
A Spark Plug Fouls Repeatedly 569
Pre-Ignition or Detonation (Knocks or Pings) 569
Overheating 569
Valve Train Noise 569
Excessive Vibration 569
Check Engine Lamp Illuminates During Operation 569
LUBRICATION SYSTEM 569
Oil Does Not Return To Oil Pan 569
Engine Uses Too Much Oil Or Smokes Excessively 569
Engine Leaks Oil From Case, Push Rods, Hoses, Etc 569
Low Oil Pressure 570
High Oil Pressure 570
ELECTRICAL SYSTEM 570
Alternator Does Not Charge 570
Alternator Charge Rate Is Below Normal 570
Speedometer Operates Erratically 570
CARBURETOR 570
Carburetor Floods 570
TRANSMISSION 570
Transmission Shifts Hard 570
Jumps Out Of Gear 570
Clutch Slips 570
Clutch Drags Or Does Not Release 570
Clutch Chatters 570
BRAKES 571
Brake Does Not Hold Normally 571
HANDLING 571
Irregularities 571
SHOP PRACTICES 1 2 572
REPAIR NOTES 572
Safety 572
Removing Parts 572
Cleaning 572
Disassembly and Assembly 572
Checking Torques on Fasteners with Lock Patches 572
REPAIR AND REPLACEMENT PROCEDURES 572
Hardware and Threaded Parts 572
Wiring, Hoses and Lines 572
Instruments and Gauges 572
Bearings 573
Bushings 573
Gaskets 573
Lip Type Seals 573
O-Rings (Preformed Packings) 573
Gears 573
Shafts 573
Part Replacement 573
CLEANING 573
Part Protection 573
Cleaning Process 573
Rust or Corrosion Removal 574
Bearings 574
TOOL SAFETY 1 3 575
AIR TOOLS 575
WRENCHES 575
PLIERS/CUTTERS/PRYBARS 575
HAMMERS 575
PUNCHES/CHISELS 575
SCREWDRIVERS 575
RATCHETS AND HANDLES 575
SOCKETS 575
STORAGE UNITS 576
SCHEDULED MAINTENANCE TABLE 1 4 578
sm01b 582
SCHEDULED MAINTENANCE PROCEDURES 1 5 582
BATTERY 582
ENGINE OIL/ENGINE OIL FILTER 582
PRIMARY CHAIN 583
PRIMARY CHAIN LUBRICANT 584
CLUTCH ADJUSTMENT 585
TRANSMISSION LUBRICANT 586
TIRES 586
WHEEL SPOKES 587
STEERING HEAD BEARINGS 587
BRAKE FLUID 588
BRAKE PADS AND DISCS 588
DRIVE BELT 588
REAR SHOCK ABSORBERS 590
AIR CLEANER 590
FUEL SYSTEM LINES AND FITTINGS 591
FUEL TANK FILTER (Carbureted) 591
ENRICHENER CONTROL 593
THROTTLE CABLES 593
Lubrication 593
Adjustment 595
SPARK PLUGS 595
ELECTRICAL COMPONENTS 596
ENGINE IDLE SPEED 596
CRITICAL FASTENERS 597
ENGINE MOUNTS 597
Top 597
Bottom 597
FRONT FORK OIL 599
ROAD TEST 599
sm02_tc 600
sm02a 602
SPECIFICATIONS 2 1 602
DIMENSIONS (in ) 602
WEIGHT (lbs ) 602
CAPACITIES (U S ) 602
DIMENSIONS (mm) 602
WEIGHT (kg) 602
CAPACITIES (Metric) 602
TIRE DATA 603
REAR WHEEL SPROCKET 603
TORQUE VALUES 603
TORQUE VALUES (CONT ’D) 604
VEHICLE IDENTIFICATION NUMBER (VIN) 2 2 606
FRONT WHEEL 2 3 607
GENERAL 607
PRELIMINARY INSPECTION 607
REMOVAL 607
DISASSEMBLY 607
CLEANING AND INSPECTION 608
ASSEMBLY 608
INSTALLATION 610
REAR WHEEL 2 4 612
GENERAL 612
PRELIMINARY INSPECTION 612
REMOVAL 612
DISASSEMBLY 612
CLEANING AND INSPECTION 613
ASSEMBLY 614
INSTALLATION 615
CHECKING RIM RUNOUT 2 5 618
INSPECTION 618
WHEEL LACING – 16 INCH RIM 2 6 619
GENERAL 619
WHEEL LACING 619
SPOKE TIGHTNESS 621
TRUING LACED WHEEL 2 7 622
PROCEDURE 622
TIRES AND TUBES 2 8 624
GENERAL 624
REMOVAL 624
CLEANING AND INSPECTION 624
INSTALLATION 625
Checking Tire Radial Runout 626
Checking Tire Lateral Runout 626
Wheel Balancing 627
VEHICLE ALIGNMENT 2 9 628
METHOD A 628
METHOD B 631
INSPECTION 633
Front Rubber Mount 633
Rear Swingarm Mounts 633
Engine Stabilizer Links 633
FRONT BRAKE MASTER CYLINDER 2 10 634
GENERAL 634
REMOVAL/DISASSEMBLY 634
CLEANING AND INSPECTION 635
ASSEMBLY/INSTALLATION 635
REAR BRAKE MASTER CYLINDER 2 11 639
REMOVAL 639
PRELIMINARY INSTRUCTIONS 639
BRAKE PEDAL/MASTER CYLINDER ASSEMBLY, REMOVAL 639
BRAKE PEDAL/MASTER CYLINDER ASSEMBLY, INSTALLATION 640
REAR BRAKE LINE, REMOVAL 640
REAR BRAKE LINE, INSTALLATION 641
INSTALLATION 641
FINAL INSTRUCTIONS 641
MASTER CYLINDER 643
DISASSEMBLY 643
CLEANING AND INSPECTION 644
ASSEMBLY 645
FRONT BRAKE CALIPER 2 12 647
INSPECTION 647
BRAKE PADS 647
BRAKE LINE/HOSE INSPECTION 647
FRONT BRAKE PAD REPLACEMENT 647
PAD INSTALLATION 648
CALIPER REMOVAL 650
CALIPER DISASSEMBLY 650
CLEANING AND INSPECTION 651
CALIPER ASSEMBLY 651
CALIPER INSTALLATION 652
REAR BRAKE CALIPER 2 13 654
INSPECTION 654
BRAKE DISC THICKNESS/WARPAGE 654
BRAKE PADS 654
BRAKE LINE/HOSE INSPECTION 654
REAR BRAKE PAD REPLACEMENT 654
CALIPER REMOVAL 656
CALIPER DISASSEMBLY 656
CLEANING AND INSPECTION 658
CALIPER ASSEMBLY 658
CALIPER INSTALLATION 659
BLEEDING HYDRAULIC BRAKES 2 14 660
GENERAL 660
FRONT FORKS 2 15 661
CHANGING FORK OIL 661
FLHT/C/U, FLTR 661
FLHR/C/S 661
REMOVAL 662
DISASSEMBLY 662
LEFT FORK 662
RIGHT FORK 664
CLEANING AND INSPECTION 665
ASSEMBLY 665
LEFT FORK 665
RIGHT FORK 668
INSTALLATION 670
LOWER FORK BRACKET COVER/AIR DAM 2 16 671
LOWER FORK BRACKET COVER (FLHRS) 671
REMOVAL 671
INSTALLATION 671
AIR DAM (FLTR) 671
REMOVAL 671
INSTALLATION 671
STEERING HEAD BEARINGS 2 17 672
LUBRICATION 672
CHECKING 672
ADJUSTMENT 672
REMOVAL 673
INSPECTION 674
ASSEMBLY 675
INSTALLATION 675
REAR AIR SUSPENSION 2 18 676
GENERAL 676
REAR AIR SUSPENSION 678
REMOVAL/INSTALLATION 678
Compression Fitting 678
Air Tubes 679
sm02b 680
REAR SHOCK ABSORBERS 2 19 680
ADJUSTMENT 680
REMOVAL 680
DISASSEMBLY 680
CLEANING AND INSPECTION 681
ASSEMBLY 681
INSTALLATION 681
REAR SWINGARM 2 20 682
REMOVAL 682
DISASSEMBLY/ASSEMBLY 683
Bearing Removal 683
Bearing Installation 684
Pivot Shaft Disassembly 684
Pivot Shaft Assembly 684
INSTALLATION 685
THROTTLE CABLES (NON-CRUISE) 2 21 689
ADJUSTMENT 689
REMOVAL 690
THROTTLE SIDE 690
CARBURETOR/INDUCTION MODULE SIDE 691
CLEANING AND INSPECTION 691
INSTALLATION 691
THROTTLE SIDE 691
CARBURETOR/INDUCTION MODULE SIDE 692
LUBRICATION 693
CLUTCH CABLE 2 22 694
ADJUSTMENT 694
REMOVAL 694
INSTALLATION 695
HANDLEBARS 2 23 698
HANDLEBAR ADJUSTMENT 698
HANDLEBAR REMOVAL 698
HANDLEBAR INSTALLATION 698
LEFT HAND GRIP 699
REMOVAL 699
INSTALLATION 700
RUBBER MOUNTS 700
REMOVAL 700
INSTALLATION 701
SEAT 2 24 702
FLHR 702
REMOVAL 702
INSTALLATION 702
FLHRC 703
REMOVAL 703
INSTALLATION 703
FLHRS, FLTR 703
REMOVAL 703
INSTALLATION 704
FLHT 704
REMOVAL 704
INSTALLATION 704
FLHTC/U 704
REMOVAL 704
INSTALLATION 704
SEAT RETENTION NUT REPLACEMENT 705
SADDLEBAG 2 25 706
OPENING 706
FLHRC 706
FLHRS 706
FLHR, FLTR, FLHT/C/U 706
CLOSING 707
FLHRC 707
FLHRS 707
FLHR, FLTR, FLHT/C/U 707
REMOVAL 707
INSTALLATION 707
LATCH SPRING REPLACEMENT (FLHR, FLTR, FLHT/C/U) 708
REMOVAL 708
INSTALLATION 709
CABLE ASSEMBLY/LATCH/SCRIPT (FLHRS) 709
CABLE ASSEMBLY 709
LATCH 711
SCRIPT 711
SADDLEBAG GUARD/SUPPORT RAIL 711
REMOVAL 711
INSTALLATION 711
TOUR-PAK 2 26 713
FLHTC 713
REMOVAL 713
INSTALLATION 713
FLHTCU 714
REMOVAL 714
INSTALLATION 715
TOUR-PAK LIGHTS/BACKREST/SPEAKER BOX 2 27 716
GENERAL 716
SIDE MARKER LIGHTS FLHTC/U 716
BULB/LENSE REPLACEMENT 716
REMOVAL 716
INSTALLATION 716
WRAP-AROUND LIGHT ASSEMBLY FLHTCU 717
BULB REPLACEMENT 717
REMOVAL 717
INSTALLATION 718
PASSENGER BACKREST FLHTCU 718
REMOVAL 718
INSTALLATION 719
SPEAKER BOX FLHTCU 719
REMOVAL 719
INSTALLATION 719
LOWER FAIRING/ENGINE GUARD 2 28 720
LOWER FAIRING 720
REMOVAL 720
INSTALLATION 720
ENGINE GUARD 720
REMOVAL 720
INSTALLATION 720
UPPER FAIRING/WINDSHIELD (FLHT/C/U) 2 29 721
OUTER FAIRING/WINDSHIELD 721
REMOVAL 721
INSTALLATION 721
FAIRING CAP 721
REMOVAL 721
INSTALLATION 722
INNER FAIRING 723
REMOVAL 723
INSTALLATION 726
UPPER FAIRING/WINDSHIELD (FLTR) 2 30 728
WINDSHIELD ONLY 728
REMOVAL 728
INSTALLATION 728
OUTER FAIRING 728
REMOVAL 728
INSTALLATION 729
BEZEL 730
REMOVAL 730
INSTALLATION 731
INSTRUMENT NACELLE 731
REMOVAL 731
INSTALLATION 732
INNER FAIRING 733
REMOVAL 733
INSTALLATION 735
GLOVE BOX DOOR/HINGE 737
REMOVAL 737
INSTALLATION 737
WINDSHIELD/HEADLAMP NACELLE (FLHR/C/S) 2 31 738
WINDSHIELD REMOVAL 738
WINDSHIELD INSTALLATION 738
NACELLE REMOVAL (FLHR/C) 738
NACELLE INSTALLATION (FLHR/C) 739
NACELLE REMOVAL (FLHRS) 740
NACELLE INSTALLATION (FLHRS) 741
FRONT FENDER 2 32 742
REMOVAL 742
INSTALLATION 743
REAR FENDER 2 33 744
REMOVAL 744
INSTALLATION 745
REAR FENDER CLOISONNE 746
Removal 746
Installation 746
JIFFY STAND 2 34 747
GENERAL 747
REMOVAL 747
INSTALLATION 748
FOOTBOARDS/FOOTRESTS 2 35 749
RIDER FOOTBOARD 749
REMOVAL 749
INSTALLATION 749
DISASSEMBLY 750
ASSEMBLY 750
PASSENGER FOOTBOARD 750
REMOVAL 750
INSTALLATION 750
DISASSEMBLY 750
ASSEMBLY 750
PASSENGER FOOTREST (FLHRS) 751
REMOVAL 751
INSTALLATION 751
DISASSEMBLY 751
ASSEMBLY 751
EXHAUST SYSTEM 2 36 752
REMOVAL 752
INSTALLATION 752
sm03_tc 756
sm03a 758
SPECIFICATIONS 3 1 758
MANUFACTURING TOLERANCES 758
MANUFACTURING TOLERANCES (CONT ) 759
TORQUE VALUES 759
SERVICE WEAR LIMITS 3 2 760
GENERAL 760
SERVICE WEAR LIMITS (CONT ) 761
GENERAL INFORMATION 3 3 762
FUEL 762
GASOLINE/ALCOHOL BLENDS 762
LUBRICATION 762
CHECKING ENGINE OIL LEVEL 762
CHANGING ENGINE OIL AND FILTER 763
WINTER LUBRICATION 764
OIL PRESSURE INDICATOR LAMP 764
ENGINE OIL FLOW 765
Oil Feed (Figures 3-6, 3-7) 765
Top End (Figures 3-6, 3-7) 765
Bottom End (Figures 3-6, 3-7, 3-8) 767
Oil Return (Figures 3-6, 3-8) 767
Oil Pump Operation 767
Breather Operation 770
HOW TO USE THIS SECTION 3 4 771
GENERAL 771
Top End Overhaul 771
Bottom End Overhaul 771
Subassembly Service and Repair 772
STRIPPING MOTORCYCLE FOR SERVICE 3 5 773
PROCEDURE 773
ASSEMBLING MOTORCYCLE AFTER STRIPPING 3 6 775
PROCEDURE 775
REMOVING ENGINE FROM CHASSIS 3 7 778
PROCEDURE 778
INSTALLING ENGINE IN CHASSIS 3 8 783
PROCEDURE 783
sm03b 790
TOP END OVERHAUL 3 9 790
DISASSEMBLY 790
ASSEMBLY 794
BOTTOM END OVERHAUL 3 10 802
DISASSEMBLY 802
ASSEMBLY 804
SUBASSEMBLY SERVICE AND REPAIR 3 11 812
TOP END 812
BREATHER ASSEMBLY 812
Removal 812
Disassembly 812
Cleaning and Inspection 812
Assembly 812
Installation 812
ROCKER ARM ASSEMBLY 813
Removal 813
Disassembly 813
Cleaning and Inspection 813
Assembly 814
Installation 815
PUSH RODS/LIFTERS/COVERS 816
Removal 816
Disassembly 816
Cleaning and Inspection 816
Assembly 816
Installation 817
CYLINDER HEAD 820
Removal 820
Disassembly 820
Cleaning and Inspection 821
VALVE GUIDE REPLACEMENT 822
VALVE AND SEAT REFACING 825
Assembly 827
Installation 830
CYLINDER 831
Removal 831
Cleaning and Inspection 831
Installation 833
sm03c 834
PISTON 834
Removal 834
Disassembly 834
Piston Rings, Removal 834
Cleaning and Inspection 834
Assembly 836
Piston Rings, Installation 836
Installation 837
UPPER CONNECTING ROD 839
Removal 839
Disassembly/Assembly 839
Upper Connecting Rod Bushing 839
Reaming Upper Rod Bushing 840
Honing Upper Rod Bushing 841
Installation 842
BOTTOM END 844
CAM SUPPORT PLATE 844
Removal 844
Disassembly/Assembly 844
Crankshaft Bushing 844
Reaming Crankshaft Bushing 845
Camshafts/Camshaft Bearings 846
Cam Chain Tensioners 852
Oil Pressure Relief Valve 853
Cam Needle Bearings 853
Cleaning and Inspection 855
Installation 855
OIL PUMP 856
Removal 856
Cleaning and Inspection 856
Installation 856
CRANKCASE 858
Removal 858
Disassembly/Assembly 858
RIGHT CRANKCASE HALF 858
Crankshaft Bearing 858
Piston Jets 859
LEFT CRANKCASE HALF 859
Sprocket Shaft Bearing 859
Sprocket Shaft Bearing Inner Race 861
Cylinder Studs 864
Pipe Plug and Oil Fittings 864
Cleaning and Inspection 864
Installation 864
FLYWHEEL/CONNECTING ROD ASSEMBLY 865
Removal 865
Inspection 865
Installation 865
sm04_tc 866
sm04a 868
SPECIFICATIONS 4 1 868
CVH CARBURETOR JET SIZES 868
FUEL TANK CAPACITY 868
TORQUE VALUES 868
FUEL SYSTEM TROUBLESHOOTING (CARBURETED) 4 2 869
ENRICHENER (CARBURETED) 4 3 872
GENERAL 872
OPERATION 872
Enrichener 872
Cool Engine 873
Warm Climate Or Hot Engine 873
ADJUSTMENTS 873
Slow Idle 873
Enrichener Control 874
CARBURETOR 4 4 876
REMOVAL 876
INSTALLATION 876
DISASSEMBLY 877
CLEANING AND INSPECTION 879
Carburetor Housing 879
ASSEMBLY 880
AIR CLEANER 4 5 883
GENERAL 883
REMOVAL 883
CLEANING AND INSPECTION 883
INSTALLATION 884
VACUUM OPERATED FUEL VALVE (CARBURETED) 4 6 885
GENERAL 885
TROUBLESHOOTING 885
REMOVAL 885
CLEANING AND INSPECTION 886
INSTALLATION 886
FUEL TANK ADAPTER 887
FUEL TANK (CARBURETED) 4 7 888
COMPLETE REMOVAL 888
FLHT/C 888
FLHR/S 888
CLEANING AND INSPECTION 889
INSTALLATION (AFTER COMPLETE REMOVAL) 890
FLHT/C 890
FLHR/S 891
PARTIAL REMOVAL 891
FLHT/C 891
FLHR/S 892
INSTALLATION (AFTER PARTIAL REMOVAL) 892
FLHT/C 892
FLHR/S 893
EVAPORATIVE EMISSIONS CONTROL SYSTEM 4 8 894
CALIFORNIA MODELS ONLY 894
TROUBLESHOOTING 895
VAPOR VALVE 895
REMOVAL 895
INSTALLATION 895
CHARCOAL CANISTER 896
REMOVAL 896
INSTALLATION 896
Charcoal Canister Hose Routing 897
Purge Tube: 897
Fuel Vapor Vent Tube: 897
Clean Air Inlet Tube: 897
sm05_tc 898
sm05a 900
SPECIFICATIONS 5 1 900
STARTER 900
SERVICE WEAR LIMITS 900
TORQUE VALUES 900
STARTER SYSTEM 5 2 901
GENERAL 901
Operation (Figure 5-1) 901
STARTER RELAY 5 3 903
REMOVAL 903
FLHR/C/S 903
FLTR, FLHT/C/U 903
INSTALLATION 903
FLHR/C/S 903
FLTR, FLHT/C/U 904
STARTER 5 4 905
REMOVAL 905
INSTALLATION 905
DISASSEMBLY, TESTING AND REPAIR 907
ASSEMBLY 911
STARTER SOLENOID 5 5 912
GENERAL 912
DISASSEMBLY 912
ASSEMBLY 912
STARTER JACKSHAFT 5 6 913
REMOVAL/DISASSEMBLY 913
ASSEMBLY/INSTALLATION 914
sm06_tc 916
sm06a 918
SPECIFICATIONS 6 1 918
OVERALL GEAR RATIOS 918
CHAINS AND BELTS 918
SPROCKETS 918
CLUTCH 918
TORQUE VALUES 918
PRIMARY CHAIN AND SPROCKETS 6 2 920
PRIMARY CHAIN ADJUSTMENT 920
ADJUSTER SHOE REPLACEMENT 920
DISASSEMBLY 922
CLEANING AND INSPECTION 922
Sprocket Alignment (Figure 6-3, 6-4) 922
ASSEMBLY 923
CLUTCH 6 3 924
ADJUSTMENT 924
REMOVAL/INSTALLATION 925
PARTIAL DISASSEMBLY 925
ASSEMBLY 925
CLEANING AND INSPECTION 927
COMPLETE DISASSEMBLY 927
ASSEMBLY 928
SECONDARY DRIVE BELT AND SPROCKETS 6 4 930
ADJUSTMENT 930
CLEANING AND INSPECTION 931
REPLACEMENT 932
Removal 932
Installation 932
TRANSMISSION SPROCKET 932
Removal 932
Cleaning and Inspection 933
Installation 933
REAR WHEEL SPROCKET 935
Removal 935
Cleaning and Inspection 936
Installation 936
PRIMARY CHAINCASE 6 5 937
GENERAL 937
LUBRICATION 937
REMOVAL 937
INSPECTION AND REPAIR 940
DISASSEMBLY 940
MAINSHAFT BEARING AND LIP SEAL 940
MAINSHAFT BEARING INNER RACE 941
STARTER JACKSHAFT BUSHING AND LIP SEAL – PRIMARY CHAINCASE 942
STARTER JACKSHAFT BUSHING – PRIMARY CHAINCASE COVER 942
SHIFTER BRACKET BUSHINGS 943
INSTALLATION 944
sm07_tc 950
sm07a 952
SPECIFICATIONS 7 1 952
TRANSMISSION DATA 952
SERVICE WEAR LIMITS 952
SERVICE WEAR LIMITS (CONT ’D) 953
TORQUE VALUES 953
TRANSMISSION POWER FLOW 7 2 954
GENERAL 954
Neutral 954
1st Gear 954
2nd Gear 954
3rd Gear 954
4th Gear 954
5th Gear 954
SHIFTER LINKAGE 7 3 956
ADJUSTMENT 956
Shifter Linkage 956
SHIFTER CAM ASSEMBLY/SHIFTER FORKS 7 4 957
DISASSEMBLY 957
CLEANING AND INSPECTION 958
ASSEMBLY 959
CLUTCH RELEASE COVER 7 5 963
REMOVAL/DISASSEMBLY 963
CLEANING AND INSPECTION 963
ASSEMBLY/INSTALLATION 963
MAINSHAFT/COUNTERSHAFT 7 6 966
REMOVAL 966
DISASSEMBLY 966
CLEANING AND INSPECTION 967
ASSEMBLY 969
INSTALLATION 972
MAIN DRIVE GEAR 7 7 973
REMOVAL 973
CLEANING AND INSPECTION 973
Needle Bearing Replacement 974
INSTALLATION 975
Countershaft Needle Bearing Replacement 978
TRANSMISSION CASE/OIL PAN 7 8 979
GENERAL 979
REMOVAL 979
Transmission Case and Oil Pan 979
Oil Pan Only 980
CLEANING AND INSPECTION 981
INSTALLATION 981
Oil Pan Only 981
Transmission Case and Oil Pan 981
sm08_tc 984
sm08a 986
SPECIFICATIONS 8 1 986
IGNITION TIMING 986
ALTERNATOR SYSTEM 986
BATTERY 986
FUSES 986
SPARK PLUG 987
TORQUE VALUES 987
BULB CHART 8 2 988
SYSTEM FUSES 8 3 990
MAXI-FUSE 990
REMOVAL 990
INSTALLATION 990
MAXI-FUSE HOLDER 990
REMOVAL 990
INSTALLATION 990
SYSTEM FUSES/RELAYS 990
REMOVAL 990
INSTALLATION 991
FUSE BLOCK 991
REMOVAL 991
INSTALLATION 991
EFI FUSES 991
IGNITION CONTROL MODULE (CARBURETED) 8 4 992
REMOVAL 992
INSTALLATION 992
SENSORS (CARBURETED) 8 5 993
MANIFOLD ABSOLUTE PRESSURE SENSOR 993
Removal 993
Installation 993
CRANKSHAFT POSITION SENSOR 993
IGNITION COIL 8 6 994
REMOVAL 994
INSTALLATION 994
SPARK PLUGS/SPARK PLUG CABLES 8 7 995
SPARK PLUGS 995
REMOVAL 995
INSPECTION 995
CLEANING 995
ADJUSTMENT 995
INSTALLATION 995
SPARK PLUG CABLES 996
REMOVAL 996
INSPECTION 996
INSTALLATION 996
ALTERNATOR/STATOR 8 8 997
REMOVAL 997
CLEANING AND INSPECTION 998
INSTALLATION 999
VOLTAGE REGULATOR 8 9 1002
REMOVAL 1002
INSTALLATION 1003
BATTERY 8 10 1005
GENERAL 1005
VOLTMETER TEST 1005
DISCONNECTION AND REMOVAL 1006
CLEANING AND INSPECTION 1006
BATTERY CHARGING 1006
SAFETY PRECAUTIONS 1006
CHARGING BATTERY 1006
LOAD TEST 1007
BATTERY CABLE ROUTING 1008
INSTALLATION AND CONNECTION 1008
STORAGE 1009
HEADLAMP (FLHR/C/S, FLHT/C/U) 8 11 1010
HEADLAMP ASSEMBLY 1010
REMOVAL 1010
INSTALLATION 1010
HEADLAMP BULB REPLACEMENT 1010
HEADLAMP ADJUSTMENT 1011
HEADLAMP (FLTR) 8 12 1013
HEADLAMP ASSEMBLY 1013
REMOVAL 1013
INSTALLATION 1013
HEADLAMP BULB REPLACEMENT 1013
REMOVAL 1013
INSTALLATION 1014
HEADLAMP ADJUSTMENT 1014
PASSING LAMPS 8 13 1016
ADJUSTMENT 1016
PASSING LAMP BULB 1016
REMOVAL 1016
INSTALLATION 1016
PASSING LAMP 1017
REMOVAL 1017
INSTALLATION 1018
PASSING LAMP BRACKET 1018
REMOVAL 1018
INSTALLATION 1018
TAIL LAMP ASSEMBLY 8 14 1019
TAIL LAMP 1019
REMOVAL 1019
INSTALLATION 1019
CIRCUIT BOARD/TAIL LAMP BRACKET 1019
REMOVAL 1019
INSTALLATION 1020
FENDER TIP LAMPS 8 15 1022
FRONT FENDER TIP LAMP 1022
REMOVAL 1022
INSTALLATION 1022
FRONT FENDER TIP LAMP JUMPER HARNESS 1022
REMOVAL 1022
INSTALLATION 1024
REAR FENDER TIP LAMP 1025
REMOVAL 1025
INSTALLATION 1026
TURN SIGNAL LAMPS 8 16 1027
BULB REPLACEMENT 1027
REMOVAL 1027
INSTALLATION 1027
FRONT TURN SIGNAL LAMP 1027
FLHR/C, FLHT/C/U 1027
FLTR 1029
FLHRS 1029
REAR TURN SIGNAL LAMP 1031
REMOVAL 1031
INSTALLATION 1031
REAR TURN SIGNAL LAMP BRACKET 1032
REMOVAL 1032
INSTALLATION 1032
TURN SIGNAL/SECURITY MODULE 8 17 1033
REMOVAL 1033
INSTALLATION 1033
sm08b 1034
IGNITION/LIGHT KEY SWITCH AND FORK LOCK 8 18 1034
FLHT/C/U, FLTR (DOMESTIC) 1034
REMOVAL 1034
INSTALLATION 1035
FLHT/C/U, FLTR (INTERNATIONAL) 1036
REMOVAL 1036
INSTALLATION 1037
FLHR/C/S 1039
IGNITION/LIGHT KEY SWITCH 1039
FORK LOCK 1039
FAIRING CAP SWITCHES (FLHTC/U) 8 19 1041
REMOVAL 1041
INSTALLATION 1041
INSTRUMENT NACELLE SWITCHES (FLTR) 8 20 1044
REMOVAL 1044
LEFT SIDE SWITCH 1044
RIGHT SIDE SWITCHES 1045
INSTALLATION 1046
LEFT SIDE SWITCH 1046
RIGHT SIDE SWITCHES 1046
HANDLEBAR SWITCHES 8 21 1049
GENERAL 1049
REMOVAL 1049
RIGHT HANDLEBAR CONTROLS 1049
LEFT HANDLEBAR CONTROLS 1050
INSTALLATION 1050
RIGHT HANDLEBAR CONTROLS 1050
LEFT HANDLEBAR CONTROLS 1052
SWITCH REPAIR/REPLACEMENT 1055
RIGHT SIDE HANDLEBAR SWITCHES 1055
LEFT SIDE HANDLEBAR SWITCHES 1055
SPECIFIC REPAIR PROCEDURES 1055
UPPER SWITCH HOUSINGS 1055
LOWER SWITCH HOUSINGS 1057
GENERAL REPAIR PROCEDURES 1063
RIGHT SIDE HANDLEBAR SWITCHES 1065
LEFT SIDE HANDLEBAR SWITCHES 1065
STOPLIGHT SWITCHES 8 22 1066
FRONT STOPLIGHT SWITCH 1066
REAR STOPLIGHT SWITCH 1066
NEUTRAL SWITCH 8 23 1067
GENERAL 1067
REMOVAL 1067
INSTALLATION 1067
OIL PRESSURE SWITCH/SENDER 8 24 1068
REMOVAL 1068
INSTALLATION 1068
HORN 8 25 1069
TROUBLESHOOTING 1069
REMOVAL 1069
INSTALLATION 1069
CIGARETTE LIGHTER (FLHTCU, FLTR) 8 26 1070
GENERAL 1070
TROUBLESHOOTING 1070
REMOVAL 1070
INSTALLATION 1070
GAUGES/INSTRUMENTS (FLHT/C/U, FLTR) 8 27 1071
GAUGE/LAMP- 2 INCH DIAMETER 1071
REMOVAL 1071
INSTALLATION 1071
GAUGES- 4 INCH DIAMETER 1071
TACHOMETER 1071
REMOVAL 1071
INSTALLATION 1072
VEHICLE SPEED SENSOR 1072
REMOVAL 1072
INSTALLATION 1073
SPEEDOMETER 1073
REMOVAL 1073
INSTALLATION 1073
INDICATOR LAMPS 1074
REMOVAL 1074
INSTALLATION 1074
GAUGES/INSTRUMENTS (FLHR/C/S) 8 28 1075
FUEL GAUGE 1075
REMOVAL 1075
INSTALLATION 1075
VEHICLE SPEED SENSOR 1076
SPEEDOMETER 1076
REMOVAL 1076
INSTALLATION 1077
INDICATOR LIGHTS 1077
REMOVAL 1077
INSTALLATION 1078
IGNITION SWITCH 1078
FUEL LEVEL SENDER (CARBURETED) 8 29 1079
FLHT/C CANOPY 1079
REMOVAL 1079
INSTALLATION 1079
FLHR/S CANOPY 1080
REMOVAL 1080
INSTALLATION 1081
FUEL LEVEL SENDER 1081
REMOVAL 1081
INSTALLATION 1082
CANOPY CONNECTOR/O-RING 1083
REMOVAL 1083
INSTALLATION 1083
sm08c 1084
CRUISE CONTROL (FLHRC, FLTR, FLHTCU) 8 30 1084
GENERAL 1084
SYSTEM OPERATION 1084
CABLE ADJUSTMENT 1085
THROTTLE CABLE 1085
IDLE CABLE 1086
CABLE LASH INITIALIZATION 1086
THROTTLE/IDLE CABLES 1086
REMOVAL 1086
INSTALLATION 1087
CRUISE CABLE 1088
REMOVAL 1088
INSTALLATION 1089
CRUISE CONTROL MODULE 1090
REMOVAL 1090
INSTALLATION 1090
AUDIO HARNESS 1091
CRUISE CONTROL SWITCHES 1091
FAIRING CAP 1091
HANDLEBAR 1091
PREMIUM SOUND SYSTEM (FLHTC/U, FLTR) 8 31 1092
RADIO (FLHTC/U) 1092
REMOVAL 1092
INSTALLATION 1093
FRONT FAIRING SPEAKERS 1093
REMOVAL 1093
INSTALLATION 1093
CONSOLE POD ASSEMBLY 1094
REMOVAL 1094
INSTALLATION 1094
FRONT HEADSET RECEPTACLE 1095
REMOVAL 1095
INSTALLATION 1095
REAR HEADSET RECEPTACLE 1096
REAR PASSENGER SWITCHES 1096
REMOVAL 1096
INSTALLATION 1096
REAR SPEAKERS 1098
REMOVAL 1098
INSTALLATION 1098
CB LOADING COIL 1098
REMOVAL 1098
INSTALLATION 1099
AUDIO HARNESS 1099
RADIO ANTENNA CABLE 1099
CB ANTENNA CABLE 1099
WIRING HARNESSES AND CABLES 8 32 1100
MAIN HARNESS 1100
REMOVAL- ALL MODELS (PART I) 1100
REMOVAL- FLHR/C/S (PART II) 1100
REMOVAL- FLTR (PART II) 1101
REMOVAL- FLHT/C/U (PART II) 1102
REMOVAL- ALL MODELS (PART III) 1102
INSTALLATION- ALL MODELS (PART I) 1106
INSTALLATION- FLHR/C/S (PART II) 1109
INSTALLATION- FLTR (PART II) 1109
INSTALLATION- FLHT/C/U (PART II) 1110
INSTALLATION- ALL MODELS (PART III) 1110
FRAME GROUND STUD REPLACEMENT 1110
INTERCONNECT HARNESS (FLHTCU) 1112
REMOVAL 1112
INSTALLATION 1114
INTERCONNECT HARNESS (FLTR) 1117
REMOVAL 1117
INSTALLATION 1118
RADIO ANTENNA CABLE (FLHTC/U) 1121
REMOVAL 1121
INSTALLATION 1122
RADIO ANTENNA CABLE (FLTR) 1124
REMOVAL 1124
INSTALLATION 1124
AUDIO HARNESS (FLHTCU) 1126
REMOVAL 1126
INSTALLATION 1127
CB ANTENNA CABLE (FLHTCU) 1129
REMOVAL 1129
INSTALLATION 1129
IGNITION HARNESS (CARBURETED) 1131
REMOVAL 1131
INSTALLATION 1132
EFI HARNESS (FUEL INJECTED) 1134
REMOVAL 1134
INSTALLATION 1135
sm09_tc 1138
sm09a 1140
SPECIFICATIONS 9 1 1140
EFI FUSES 1140
TORQUE VALUES 1140
ELECTRICAL BRACKET ASSEMBLY 9 2 1142
GENERAL 1142
DATA LINK CONNECTOR 1142
SETTING ENGINE IDLE SPEED 1142
EFI SYSTEM RELAY 1143
REMOVAL 1143
INSTALLATION 1143
EFI FUSES 1143
REMOVAL 1143
INSTALLATION 1143
ELECTRONIC CONTROL MODULE 1143
REMOVAL 1143
INSTALLATION 1144
SECURITY SIREN CONNECTOR 1144
REMOVAL 1144
INSTALLATION 1144
EFI HARNESS 1144
SENSORS 9 3 1145
GENERAL 1145
INTAKE AIR TEMPERATURE SENSOR 1145
THROTTLE POSITION SENSOR 1145
MANIFOLD ABSOLUTE PRESSURE SENSOR 1145
BANK ANGLE SENSOR 1145
CRANKSHAFT POSITION SENSOR 1145
REMOVAL 1145
INSTALLATION 1146
ENGINE TEMPERATURE SENSOR 1146
REMOVAL 1146
INSTALLATION 1146
FUEL TANK (FUEL INJECTED) 9 4 1147
GENERAL 1147
COMPLETE REMOVAL 1147
FLHT/C/U/I, FLTRI 1147
FLHR/C/S/I 1149
INSTALLATION (AFTER COMPLETE REMOVAL) 1149
FLHT/C/U/I, FLTRI 1149
FLHR/C/S/I 1151
PARTIAL REMOVAL 1151
FLHT/C/U/I, FLTRI 1151
FLHR/C/S/I 1152
INSTALLATION (AFTER PARTIAL REMOVAL) 1153
FLHT/C/U/I, FLTRI 1153
FLHR/C/S/I 1154
CONSOLE POD/CANOPY 1154
FLHT/C/U/I, FLTRI 1154
REMOVAL 1154
INSTALLATION 1155
INSTRUMENT CONSOLE/CANOPY 1157
FLHR/C/S/I 1157
REMOVAL 1157
INSTALLATION 1158
FUEL FILTER CANISTER 1158
REMOVAL 1158
INSTALLATION 1159
FUEL PRESSURE REGULATOR 1159
REMOVAL 1159
INSTALLATION 1160
FUEL PUMP 1160
REMOVAL 1160
INSTALLATION 1161
FUEL PUMP/FUEL LEVEL SENDER WIRING 1161
FUEL LEVEL SENDER 1161
REMOVAL 1161
INSTALLATION 1162
CANOPY CONNECTOR/O-RING 1162
REMOVAL 1162
INSTALLATION 1162
FUEL SUPPLY CHECK VALVE/TUBE 1162
REMOVAL 1163
INSTALLATION 1163
sm09b 1166
INDUCTION MODULE ASSEMBLY 9 5 1166
GENERAL 1166
INDUCTION MODULE 1166
REMOVAL 1166
INSTALLATION 1167
FUEL SUPPLY LINE 1168
REMOVAL 1168
INSTALLATION 1169
FUEL RAIL/FUEL SUPPLY TUBE 1169
REMOVAL 1169
INSTALLATION 1170
FUEL INJECTORS 1170
REMOVAL 1170
INSTALLATION 1170
INTAKE AIR TEMPERATURE SENSOR 1171
REMOVAL 1171
INSTALLATION 1171
THROTTLE POSITION SENSOR 1171
REMOVAL 1171
INSTALLATION 1171
MANIFOLD ABSOLUTE PRESSURE SENSOR 1172
REMOVAL 1172
INSTALLATION 1172
IDLE AIR CONTROL 1173
REMOVAL 1173
INSTALLATION 1173
smbk_tc 1176
spa01_tc 1178
spa01a 1180
MAINTENANCE SCHEDULE 1 1 1180
spa02_tc 1184
spa02a 1186
SPECIFICATIONS 2 1 1186
VEHICLE IDENTIFICATION NUMBER 2 2 1187
GENERAL 1187
TIRES 2 3 1188
GENERAL 1188
SEAT 2 4 1189
OPERATION 1189
AIR SEAT RESERVOIR 1190
Removal 1190
Installation 1190
FOOTBOARDS 2 5 1191
GENERAL 1191
ADJUSTMENT 1191
Right Side 1191
Left Side 1191
LUGGAGE RACK 2 6 1192
REMOVAL 1192
INSTALLATION 1192
INSTRUMENT MOUNTING BRACKET: FLHP 2 7 1194
GENERAL 1194
INSTALLATION 1194
spa03_tc 1198
spa04_tc 1200
spa05_tc 1202
spa06_tc 1204
spa07_tc 1206
spa08_tc 1208
spa08a 1210
BULB CHART 8 1 1210
GENERAL 1210
SYSTEM FUSES/RELAYS 8 2 1212
GENERAL 1212
SYSTEM FUSES 1212
Removal 1212
Installation 1213
STROBE HEADLAMP 8 3 1214
GENERAL 1214
INSTALLATION 1214
STROBE KIT (PAR-36) 8 4 1219
GENERAL 1219
INSTALLATION 1219
POLE LAMP 8 5 1221
GENERAL 1221
INSTALLATION 1221
SIREN AND PUBLIC ADDRESS SYSTEM 8 6 1222
GENERAL 1222
TROUBLESHOOTING 1222
VOLTAGE CHECKS 8 7 1223
ALL MODELS 1223
RESISTANCE AND CONTINUITY CHECKS 1224
SPEAKER 8 8 1225
TROUBLESHOOTING 1225
REMOVAL 1225
INSTALLATION 1225
HANDLEBAR SWITCHES 8 9 1226
HORN/SIREN YELP SWITCH 1226
Removal 1226
Installation 1227
CLUTCH INTERLOCK SWITCH 1227
Removal 1227
Installation 1227
PURSUIT/AUXILIARY SWITCH 1228
Removal 1228
Installation 1228
SIREN AMPLIFIER 8 10 1230
AMPLIFIER 1230
Part No /Description 1230
REMOVAL 1230
INSTALLATION 1230
GAIN ADJUSTMENT 1230
MICROPHONE AND JACK 8 11 1231
MICROPHONE 1231
Troubleshooting 1231
REMOVAL 1231
INSTALLATION 1231
AIR HORN 8 12 1232
ENABLING AIR HORN 1232
TOUR-PAK 8 13 1233
GENERAL 1233
INSTALLATION 1233
ELECTRICAL CONNECTOR LOCATIONS 8 14 1238
WIRING DIAGRAMS 8 15 1240
spa09_tc 1254
spb01_tc 1256
spb01a 1258
HYDRAULIC CLUTCH 1 1 1258
GENERAL 1258
CHECKING AND CORRECTING CLUTCH FLUID LEVEL 1258
ENGINE LUBRICATION 1 2 1259
GENERAL 1259
CRITICAL FASTENERS 1 3 1260
INSPECTION 1260
spb02_tc 1262
spb02a 1264
SPECIFICATIONS 2 1 1264
TORQUE VALUES 2 2 1265
VEHICLE IDENTIFICATION NUMBER (V I N ) 2 3 1266
GENERAL 1266
REAR WHEEL 2 4 1267
REMOVAL 1267
INSTALLATION 1267
REAR BRAKE PADS 2 5 1268
GENERAL 1268
REPLACEMENT 1268
FOOTBOARDS AND CONTROLS 2 6 1270
RIDER FOOTBOARDS 1270
Removal 1270
Installation 1270
PASSENGER FOOTBOARDS 1270
Removal 1270
Installation 1270
Disassembly 1271
Assembly 1271
SHIFT LEVER 1272
Replacement 1272
REAR BRAKE PEDAL PAD 1272
Replacement 1272
FRONT AXLE COVERS 2 7 1273
REPLACEMENT 1273
LOWER TRIPLE CLAMP COVER 2 8 1274
REPLACEMENT 1274
HANDLEBARS 2 9 1275
REMOVAL/REPLACEMENT 1275
HANDGRIPS 1277
ASSEMBLY/INSTALLATION 1277
CLUTCH MASTER CYLINDER/RESERVOIR 2 10 1281
GENERAL 1281
REMOVAL 1281
DISASSEMBLY 1282
ASSEMBLY 1283
INSTALLATION 1284
CLUTCH HAND LEVER 2 11 1285
INSTALLATION 1285
CLUTCH FLUID LINE 2 12 1286
REPLACEMENT 1286
CLUTCH FLUID LINE ROUTING 1287
BLEEDING CLUTCH FLUID LINE 1288
SEAT 2 13 1289
REMOVAL 1289
CLEANING AND INSPECTION 1289
INSTALLATION 1289
RIDER BACKREST 2 14 1290
REMOVAL 1290
INSTALLATION 1290
PASSENGER BACKREST 2 15 1291
REMOVAL 1291
INSTALLATION 1291
SADDLEBAG SUPPORTS 2 16 1293
REMOVAL 1293
INSTALLATION 1293
MUFFLER END CAP 2 17 1295
REPLACEMENT 1295
spb03_tc 1296
spb03a 1298
SPECificATIONS 3 1 1298
MANUFACTURING TOLERANCES 3 2 1299
SERVICE WEAR LIMITS 3 3 1300
TORQUE VALUES 3 4 1302
BREATHER ASSEMBLY 3 5 1303
REMOVAL 1303
DISASSEMBLY 1303
CLEANING AND INSPECTION 1303
ASSEMBLY 1303
INSTALLATION 1303
ROCKER HOUSING 3 6 1304
VALVE SPRING TO ROCKER HOUSING CLEARANCE 1304
CYLINDER HEADS 3 7 1307
GENERAL 1307
PISTONS 3 8 1308
GENERAL 1308
BORING AND HONING CYLINDERS 3 9 1309
CYLINDER BORE FINISHED SIZE 1309
CAMS AND TIMING MARKS 3 10 1310
GENERAL 1310
FLYWHEEL/CONNECTING ROD ASSEMBLY 3 11 1311
GENERAL 1311
SPROCKET SHAFT BEARING INNER RACE REPLACEMENT 1311
OIL VENT LINE 3 12 1314
REPLACEMENT 1314
OIL COOLER OPERATION 3 13 1315
GENERAL 1315
Closed Thermostat 1317
Partially Open Thermostat 1317
Fully Open Thermostat 1317
OIL COOLER 3 14 1318
REMOVAL 1318
INSTALLATION 1318
OIL FILTER MOUNT 3 15 1319
REMOVAL 1319
DISASSEMBLY 1319
ASSEMBLY 1320
INSTALLATION 1320
THERMOSTAT 3 16 1321
TEST PROCEDURE 1321
REMOVAL 1321
INSTALLATION 1321
spb04_tc 1322
spb05_tc 1324
spb05a 1326
SPECIFICATIONS 5 1 1326
spb06_tc 1328
spb06a 1330
SPECIFICATIONS 6 1 1330
TORQUE VALUES 6 2 1331
CLUTCH RELEASE BEARING 6 3 1332
REMOVAL 1332
INSTALLATION 1332
spb07_tc 1334
spb07a 1336
SPECIFICATIONS 7 1 1336
SERVICE WEAR LIMITS 7 2 1337
TORQUE VALUES 7 3 1338
CLUTCH RELEASE COVER 7 4 1339
REMOVAL 1339
INSTALLATION 1340
SECONDARY CLUTCH ACTUATOR 7 5 1341
REBUILD 1341
spb08_tc 1342
spb08a 1344
TURN SIGNALS 8 1 1344
REMOVAL 1344
INSTALLATION 1345
PASSING LAMPS AND BRACKET 8 2 1346
REMOVAL 1346
INSTALLATION 1346
FRONT PASSING LAMP BRACKETS 8 3 1348
REMOVAL 1348
INSTALLATION 1348
GARAGE DOOR OPENER 8 4 1349
TRANSMITTER 1349
Removal 1349
Installation 1349
RECEIVER 1349
Installation 1349
REMOTE CONTROL GARAGE DOOR OPENER 1349
FCC Notices 1349
Program the Receiver and Transmitter 1350
WIRING HARNESS OVERLAY 8 5 1351
spb09_tc 1352
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