2006 Harley Davidson Touring Models Electrical Diagnostics + FLHTCUSE Service Supplement + Service Manual – PDF DOWNLOAD
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2006 Harley Davidson Touring Models Electrical Diagnostics + FLHTCUSE Service Supplement + Service Manual – PDF DOWNLOAD
- SERVICE MANUAL
Part Number 99483-06 - ELECTRICAL DIAGNOSTICS
Part Number 99497-06 - FLHTCUSE SERVICE SUPPLEMENT
Part Number 99500-06
GENERAL
REPAIR NOTES
General maintenance practices are given in this section. All special tools and torque values are noted at the point of use and all required parts or materials can be found in the appropriate PARTS CATALOG.
Safety
Safety is always the most important consideration when performing any job. Be sure you have a complete understanding of the task to be performed. Use common sense. Use the proper tools. 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.
- Always use blocking or proper stands to support the part that has been hoisted. If a part cannot be removed, verify that all bolts and attaching hardware have been removed. Check to see if any parts are in the way of the part being removed. When removing hoses, wiring or tubes, always tag each part to ensure proper installation.
TABLE OF CONTENTS:
2006 Harley Davidson Touring Models Electrical Diagnostics + FLHTCUSE Service Supplement + Service Manual – PDF DOWNLOAD
maintoc.pdf..................................................................................................... 0 2006 TOURING MODELS......................................................................................... 1 SERVICE MANUAL.......................................................................................... 1 Part Number 99483-06................................................................................ 1 FLHTCUSE SERVICE SUPPLEMENT............................................................................. 1 Part Number 99500-06................................................................................ 1 ELECTRICAL DIAGNOSTICS.................................................................................. 1 Part Number 99497-06................................................................................ 1 sm01a.pdf....................................................................................................... 0 GENERAL 1.1................................................................................................. 4 REPAIR NOTES............................................................................................ 4 Safety.............................................................................................. 4 Removing Parts...................................................................................... 4 Cleaning............................................................................................ 4 Disassembly and Assembly............................................................................ 4 Checking Torques on Fasteners with Lock Patches..................................................... 4 REPAIR AND REPLACEMENT PROCEDURES....................................................................... 4 Hardware and Threaded Parts......................................................................... 4 Wiring, Hoses and Lines............................................................................. 4 Instruments and Gauges.............................................................................. 4 Bearings............................................................................................ 5 Bushings............................................................................................ 5 Gaskets............................................................................................. 5 Lip Type Seals...................................................................................... 5 O-Rings (Preformed Packings)........................................................................ 5 Gears............................................................................................... 5 Shafts.............................................................................................. 5 Part Replacement.................................................................................... 5 CLEANING................................................................................................ 5 Part Protection..................................................................................... 5 Cleaning Process.................................................................................... 5 Rust or Corrosion Removal........................................................................... 6 Bearings............................................................................................ 6 TOOL SAFETY............................................................................................. 7 AIR TOOLS........................................................................................... 7 WRENCHES............................................................................................ 7 PLIERS/CUTTERS/PRYBARS.............................................................................. 7 HAMMERS............................................................................................. 7 PUNCHES/CHISELS..................................................................................... 7 SCREWDRIVERS........................................................................................ 7 RATCHETS AND HANDLES................................................................................ 7 SOCKETS............................................................................................. 7 STORAGE UNITS........................................................................................... 8 MAINTENANCE SCHEDULE 1.2.................................................................................... 9 GENERAL................................................................................................. 9 sm01b.pdf....................................................................................................... 0 ENGINE OIL/FILTER 1.3....................................................................................... 12 GENERAL................................................................................................. 12 PROCEDURE............................................................................................... 12 AIR CLEANER 1.4............................................................................................. 14 GENERAL................................................................................................. 14 PROCEDURE............................................................................................... 14 TIRES 1.5................................................................................................... 16 GENERAL................................................................................................. 16 PROCEDURE............................................................................................... 16 WHEEL SPOKES 1.6............................................................................................ 17 GENERAL................................................................................................. 17 PROCEDURE............................................................................................... 17 PRIMARY CHAIN/LUBRICANT 1.7................................................................................. 18 GENERAL................................................................................................. 18 PROCEDURE............................................................................................... 18 PRIMARY CHAIN ADJUSTMENT............................................................................ 18 PRIMARY CHAIN LUBRICANT............................................................................. 19 CLUTCH ADJUSTMENT 1.8....................................................................................... 20 GENERAL................................................................................................. 20 PROCEDURE............................................................................................... 20 TRANSMISSION LUBRICANT 1.9.................................................................................. 22 GENERAL................................................................................................. 22 PROCEDURE............................................................................................... 22 DRIVE BELT 1.10............................................................................................. 23 GENERAL................................................................................................. 23 PROCEDURE............................................................................................... 23 THROTTLE CABLES 1.11........................................................................................ 26 GENERAL................................................................................................. 26 PROCEDURE............................................................................................... 26 LUBRICATION......................................................................................... 26 ADJUSTMENT.......................................................................................... 27 ENRICHENER CONTROL 1.12..................................................................................... 29 GENERAL................................................................................................. 29 PROCEDURE............................................................................................... 29 FUEL SYSTEM 1.13............................................................................................ 30 GENERAL................................................................................................. 30 PROCEDURE............................................................................................... 30 LINES AND FITTINGS.................................................................................. 30 FUEL FILTER (CARBURETED)............................................................................ 30 FUEL FILTER CANISTER (FUEL INJECTED)................................................................ 31 BRAKES 1.14................................................................................................. 32 GENERAL................................................................................................. 32 PROCEDURE............................................................................................... 32 BRAKE FLUID......................................................................................... 32 BRAKE PADS AND DISCS................................................................................ 32 SPARK PLUGS 1.15............................................................................................ 33 GENERAL................................................................................................. 33 PROCEDURE............................................................................................... 33 ENGINE IDLE SPEED 1.16...................................................................................... 34 GENERAL................................................................................................. 34 PROCEDURE............................................................................................... 34 FRONT FORK OIL 1.17......................................................................................... 35 GENERAL................................................................................................. 35 PROCEDURE............................................................................................... 35 STEERING HEAD BEARINGS 1.18................................................................................. 36 GENERAL................................................................................................. 36 PROCEDURE............................................................................................... 36 GREASING............................................................................................ 36 CHECKING............................................................................................ 36 INSPECTING/REPLACING................................................................................ 36 CRITICAL FASTENERS 1.19..................................................................................... 37 GENERAL................................................................................................. 37 PROCEDURE............................................................................................... 37 ENGINE MOUNTS....................................................................................... 37 OTHER FASTENERS..................................................................................... 37 BATTERY 1.20................................................................................................ 39 GENERAL................................................................................................. 39 PROCEDURE............................................................................................... 39 TROUBLESHOOTING 1.21........................................................................................ 40 GENERAL................................................................................................. 40 ENGINE.................................................................................................. 40 Starter Motor Does Not Operate or Does Not Turn Engine Over......................................... 40 Engine Turns Over But Does Not Start................................................................ 40 Starts Hard......................................................................................... 40 Starts But Runs Irregularly or Misses............................................................... 40 A Spark Plug Fouls Repeatedly....................................................................... 41 Pre-Ignition or Detonation (Knocks or Pings)........................................................ 41 Overheating......................................................................................... 41 Valve Train Noise................................................................................... 41 Excessive Vibration................................................................................. 41 Check Engine Lamp Illuminates During Operation...................................................... 41 LUBRICATION SYSTEM...................................................................................... 41 Oil Does Not Return To Oil Pan...................................................................... 41 Engine Uses Too Much Oil Or Smokes Excessively...................................................... 41 Engine Leaks Oil From Case, Push Rods, Hoses, Etc................................................... 41 Low Oil Pressure.................................................................................... 42 High Oil Pressure................................................................................... 42 ELECTRICAL SYSTEM....................................................................................... 42 Alternator Does Not Charge.......................................................................... 42 Alternator Charge Rate Is Below Normal.............................................................. 42 Speedometer Operates Erratically.................................................................... 42 CARBURETOR.............................................................................................. 42 Carburetor Floods................................................................................... 42 TRANSMISSION............................................................................................ 42 Transmission Shifts Hard............................................................................ 42 Jumps Out Of Gear................................................................................... 42 Clutch Slips........................................................................................ 42 Clutch Drags Or Does Not Release.................................................................... 42 Clutch Chatters..................................................................................... 42 BRAKES.................................................................................................. 43 Brake Does Not Hold Normally........................................................................ 43 HANDLING................................................................................................ 43 Irregularities...................................................................................... 43 sm02a.pdf....................................................................................................... 0 SPECIFICATIONS 2.1.......................................................................................... 46 DIMENSIONS (in.)........................................................................................ 46 WEIGHT (lbs.)........................................................................................... 46 CAPACITIES (U.S.)....................................................................................... 46 DIMENSIONS (mm)......................................................................................... 46 WEIGHT (kg)............................................................................................. 46 CAPACITIES (Metric)..................................................................................... 46 TIRE DATA............................................................................................... 47 REAR WHEEL SPROCKET..................................................................................... 47 TORQUE VALUES........................................................................................... 47 TORQUE VALUES (CONT.’D)............................................................................. 48 VEHICLE IDENTIFICATION NUMBER (V.I.N.) 2.2.................................................................. 50 FRONT WHEEL 2.3............................................................................................. 51 GENERAL................................................................................................. 51 PRELIMINARY INSPECTION.................................................................................. 51 REMOVAL................................................................................................. 51 DISASSEMBLY............................................................................................. 51 CLEANING AND INSPECTION................................................................................. 52 ASSEMBLY................................................................................................ 53 INSTALLATION............................................................................................ 54 REAR WHEEL 2.4.............................................................................................. 56 GENERAL................................................................................................. 56 PRELIMINARY INSPECTION.................................................................................. 56 REMOVAL................................................................................................. 56 DISASSEMBLY............................................................................................. 56 CLEANING AND INSPECTION................................................................................. 57 ASSEMBLY................................................................................................ 58 INSTALLATION............................................................................................ 60 CHECKING RIM RUNOUT 2.5..................................................................................... 63 INSPECTION.............................................................................................. 63 WHEEL LACING–16 INCH RIM 2.6................................................................................ 64 GENERAL................................................................................................. 64 WHEEL LACING............................................................................................ 64 SPOKE TIGHTNESS......................................................................................... 66 TRUING LACED WHEEL 2.7...................................................................................... 67 PROCEDURE............................................................................................... 67 TIRES AND TUBES 2.8......................................................................................... 69 GENERAL................................................................................................. 69 REMOVAL................................................................................................. 69 CLEANING AND INSPECTION................................................................................. 69 INSTALLATION............................................................................................ 70 Checking Tire Radial Runout......................................................................... 71 Checking Tire Lateral Runout........................................................................ 71 Wheel Balancing..................................................................................... 71 VEHICLE ALIGNMENT 2.9....................................................................................... 73 METHOD A................................................................................................ 73 METHOD B................................................................................................ 76 INSPECTION.............................................................................................. 78 Front Rubber Mount.................................................................................. 78 Rear Swingarm Mounts................................................................................ 78 Engine Stabilizer Links............................................................................. 78 FRONT BRAKE MASTER CYLINDER 2.10............................................................................ 79 GENERAL................................................................................................. 79 REMOVAL/DISASSEMBLY..................................................................................... 79 CLEANING AND INSPECTION................................................................................. 80 ASSEMBLY/INSTALLATION................................................................................... 80 REAR BRAKE MASTER CYLINDER 2.11............................................................................. 84 REMOVAL................................................................................................. 84 PRELIMINARY INSTRUCTIONS............................................................................ 84 BRAKE PEDAL/MASTER CYLINDER ASSEMBLY, REMOVAL....................................................... 84 BRAKE PEDAL/MASTER CYLINDER ASSEMBLY, INSTALLATION.................................................. 85 REAR BRAKE LINE, REMOVAL............................................................................ 85 REAR BRAKE LINE, INSTALLATION....................................................................... 86 INSTALLATION............................................................................................ 86 FINAL INSTRUCTIONS.................................................................................. 86 MASTER CYLINDER......................................................................................... 88 DISASSEMBLY......................................................................................... 88 CLEANING AND INSPECTION............................................................................. 89 ASSEMBLY............................................................................................ 90 FRONT BRAKE CALIPER 2.12.................................................................................... 93 INSPECTION.............................................................................................. 93 BRAKE PADS.......................................................................................... 93 BRAKE LINE/HOSE INSPECTION.......................................................................... 93 FRONT BRAKE PAD REPLACEMENT............................................................................. 93 PAD INSTALLATION.................................................................................... 94 CALIPER REMOVAL......................................................................................... 96 CALIPER DISASSEMBLY..................................................................................... 96 CLEANING AND INSPECTION................................................................................. 97 CALIPER ASSEMBLY........................................................................................ 97 CALIPER INSTALLATION.................................................................................... 98 REAR BRAKE CALIPER 2.13..................................................................................... 100 INSPECTION.............................................................................................. 100 BRAKE DISC THICKNESS/WARPAGE........................................................................ 100 BRAKE PADS.......................................................................................... 100 BRAKE LINE/HOSE INSPECTION.......................................................................... 100 REAR BRAKE PAD REPLACEMENT.............................................................................. 100 CALIPER REMOVAL......................................................................................... 103 CALIPER DISASSEMBLY..................................................................................... 103 CLEANING AND INSPECTION................................................................................. 104 CALIPER ASSEMBLY........................................................................................ 104 CALIPER INSTALLATION.................................................................................... 105 BLEEDING HYDRAULIC BRAKES 2.14.............................................................................. 107 GENERAL................................................................................................. 107 FRONT FORKS 2.15............................................................................................ 109 CHANGING FORK OIL....................................................................................... 109 REMOVAL................................................................................................. 109 DISASSEMBLY............................................................................................. 110 CLEANING AND INSPECTION................................................................................. 111 ASSEMBLY................................................................................................ 111 INSTALLATION............................................................................................ 114 LOWER FORK BRACKET COVER/AIR DAM 2.16....................................................................... 115 LOWER FORK BRACKET COVER (FLHRS)........................................................................ 115 REMOVAL............................................................................................. 115 INSTALLATION........................................................................................ 115 AIR DAM (FLTR).......................................................................................... 115 REMOVAL............................................................................................. 115 INSTALLATION........................................................................................ 115 STEERING HEAD BEARINGS 2.17................................................................................. 116 LUBRICATION............................................................................................. 116 CHECKING................................................................................................ 116 ADJUSTMENT.............................................................................................. 116 REMOVAL................................................................................................. 117 INSPECTION.............................................................................................. 118 ASSEMBLY................................................................................................ 119 INSTALLATION............................................................................................ 119 REAR AIR SUSPENSION 2.18.................................................................................... 120 GENERAL................................................................................................. 120 REAR AIR SUSPENSION..................................................................................... 122 REMOVAL/INSTALLATION.................................................................................... 122 Compression Fitting................................................................................. 122 Air Tubes........................................................................................... 123 sm02b.pdf....................................................................................................... 0 REAR SHOCK ABSORBERS 2.19................................................................................... 124 ADJUSTMENT.............................................................................................. 124 REMOVAL................................................................................................. 124 DISASSEMBLY............................................................................................. 125 CLEANING AND INSPECTION................................................................................. 125 ASSEMBLY................................................................................................ 125 INSTALLATION............................................................................................ 125 REAR SWINGARM 2.20.......................................................................................... 126 REMOVAL................................................................................................. 126 DISASSEMBLY/ASSEMBLY.................................................................................... 127 Bearing Removal..................................................................................... 127 Bearing Installation................................................................................ 128 Pivot Shaft Disassembly............................................................................. 128 Pivot Shaft Assembly................................................................................ 128 INSTALLATION............................................................................................ 129 THROTTLE CABLES (NON-CRUISE) 2.21........................................................................... 133 ADJUSTMENT.............................................................................................. 133 REMOVAL................................................................................................. 134 THROTTLE SIDE....................................................................................... 134 CARBURETOR/INDUCTION MODULE SIDE.................................................................... 135 CLEANING AND INSPECTION................................................................................. 135 INSTALLATION............................................................................................ 135 THROTTLE SIDE....................................................................................... 135 CARBURETOR/INDUCTION MODULE SIDE.................................................................... 136 LUBRICATION............................................................................................. 137 CLUTCH CABLE 2.22........................................................................................... 138 ADJUSTMENT.............................................................................................. 138 REMOVAL................................................................................................. 138 INSTALLATION............................................................................................ 139 HANDLEBARS 2.23............................................................................................. 142 HANDLEBAR ADJUSTMENT.................................................................................... 142 HANDLEBAR REMOVAL....................................................................................... 142 HANDLEBAR INSTALLATION.................................................................................. 142 LEFT HAND GRIP.......................................................................................... 143 REMOVAL............................................................................................. 143 INSTALLATION........................................................................................ 143 RUBBER MOUNTS........................................................................................... 144 REMOVAL............................................................................................. 144 INSTALLATION........................................................................................ 144 MIRRORS 2.24................................................................................................ 146 all models (except flhx)................................................................................ 146 Removal............................................................................................. 146 Installation........................................................................................ 146 flhx.................................................................................................... 146 Removal............................................................................................. 146 Installation........................................................................................ 146 SEAT 2.25................................................................................................... 147 FLHR.................................................................................................... 147 REMOVAL............................................................................................. 147 INSTALLATION........................................................................................ 147 FLHRC................................................................................................... 148 REMOVAL............................................................................................. 148 INSTALLATION........................................................................................ 148 FLHRS, FLHX, FLTR....................................................................................... 148 REMOVAL............................................................................................. 148 INSTALLATION........................................................................................ 149 FLHT.................................................................................................... 149 REMOVAL............................................................................................. 149 INSTALLATION........................................................................................ 149 FLHTC/U................................................................................................. 150 REMOVAL............................................................................................. 150 INSTALLATION........................................................................................ 150 SEAT RETENTION NUT REPLACEMENT...................................................................... 150 SADDLEBAG 2.26.............................................................................................. 151 OPENING................................................................................................. 151 FLHRC............................................................................................... 151 FLHRS............................................................................................... 151 FLHR, FLHX, FLHT/C/U, FLTR.......................................................................... 151 CLOSING................................................................................................. 152 FLHRC............................................................................................... 152 FLHRS............................................................................................... 152 FLHR, FLHX, FLHT/C/U, FLTR.......................................................................... 152 REMOVAL................................................................................................. 152 INSTALLATION............................................................................................ 153 LATCH SPRING REPLACEMENT (FLHR, FLHX, FLHT/C/U, FLTR)................................................... 153 REMOVAL............................................................................................. 153 INSTALLATION........................................................................................ 154 CABLE ASSEMBLY/LATCH/SCRIPT (FLHRS)..................................................................... 154 CABLE ASSEMBLY...................................................................................... 154 LATCH............................................................................................... 156 SCRIPT.............................................................................................. 156 SADDLEBAG GUARD/SUPPORT RAIL............................................................................ 156 REMOVAL............................................................................................. 156 INSTALLATION........................................................................................ 156 TOUR-PAK 2.27............................................................................................... 158 FLHTC................................................................................................... 158 REMOVAL............................................................................................. 158 INSTALLATION........................................................................................ 158 FLHTCU.................................................................................................. 159 REMOVAL............................................................................................. 159 INSTALLATION........................................................................................ 160 Adjustment.............................................................................................. 161 LOCKSET, HINGES, LATCHES, catches, TETHER, TETHER BRACKETS.............................................. 162 LOCKSET............................................................................................. 162 HINGES.............................................................................................. 163 LATCHES/LOCKSET CATCH............................................................................... 163 CATCHES............................................................................................. 164 TETHER.............................................................................................. 164 TETHER BRACKETS..................................................................................... 164 TOUR-PAK LIGHTS/BACKREST/SPEAKER BOX 2.28................................................................... 166 GENERAL................................................................................................. 166 SIDE MARKER LIGHTS (FLHTCU)............................................................................. 166 REMOVAL............................................................................................. 166 INSTALLATION........................................................................................ 166 TOUR-PAK LIGHTS HARNESS................................................................................. 166 REMOVAL............................................................................................. 166 INSTALLATION........................................................................................ 166 WRAP-AROUND LIGHTS (FLHTCU)............................................................................. 167 BULB REPLACEMENT.................................................................................... 167 REMOVAL............................................................................................. 167 INSTALLATION........................................................................................ 168 PASSENGER BACKREST/RUBBER ISOLATORS (FLHTCU)............................................................ 168 PASSENGER BACKREST.................................................................................. 168 RUBBER ISOLATORS.................................................................................... 169 PASSENGER BACKREST FLAP (FLHTCU)........................................................................ 169 BACKREST FLAP....................................................................................... 169 SPEAKER BOX (FLHTCU).................................................................................... 170 REMOVAL............................................................................................. 170 INSTALLATION........................................................................................ 170 LOWER FAIRING/ENGINE GUARD 2.29............................................................................. 171 LOWER FAIRING (FLHTCU).................................................................................. 171 REMOVAL............................................................................................. 171 INSTALLATION........................................................................................ 171 DISASSEMBLY......................................................................................... 171 ASSEMBLY............................................................................................ 172 ENGINE GUARD............................................................................................ 172 REMOVAL............................................................................................. 172 INSTALLATION........................................................................................ 172 UPPER FAIRING/WINDSHIELD (FLHX, FLHT/C/U) 2.30.............................................................. 174 OUTER FAIRING/WINDSHIELD................................................................................ 174 REMOVAL............................................................................................. 174 INSTALLATION........................................................................................ 174 FAIRING CAP............................................................................................. 175 REMOVAL............................................................................................. 175 INSTALLATION........................................................................................ 175 INNER FAIRING........................................................................................... 175 REMOVAL............................................................................................. 175 INSTALLATION........................................................................................ 178 AIR DEFLECTORS (FLHTCU)................................................................................. 180 REMOVAL............................................................................................. 180 INSTALLATION........................................................................................ 180 UPPER FAIRING/WINDSHIELD (FLTR) 2.31........................................................................ 181 WINDSHIELD ONLY......................................................................................... 181 REMOVAL............................................................................................. 181 INSTALLATION........................................................................................ 181 OUTER FAIRING........................................................................................... 181 REMOVAL............................................................................................. 181 INSTALLATION........................................................................................ 182 BEZEL................................................................................................... 183 REMOVAL............................................................................................. 183 INSTALLATION........................................................................................ 184 INSTRUMENT NACELLE...................................................................................... 184 REMOVAL............................................................................................. 184 INSTALLATION........................................................................................ 185 INNER FAIRING........................................................................................... 187 REMOVAL............................................................................................. 187 INSTALLATION........................................................................................ 188 GLOVE BOX DOOR/HINGE.................................................................................... 190 REMOVAL............................................................................................. 190 INSTALLATION........................................................................................ 190 WINDSHIELD/HEADLAMP NACELLE (FLHR/C/S) 2.32................................................................. 191 WINDSHIELD REMOVAL...................................................................................... 191 WINDSHIELD INSTALLATION................................................................................. 191 NACELLE REMOVAL (FLHR/C)................................................................................ 191 NACELLE INSTALLATION (FLHR/C)........................................................................... 192 NACELLE REMOVAL (FLHRS)................................................................................. 193 NACELLE INSTALLATION (FLHRS)............................................................................ 194 FRONT FENDER 2.33........................................................................................... 195 REMOVAL................................................................................................. 195 INSTALLATION............................................................................................ 196 REAR FENDER 2.34............................................................................................ 197 REMOVAL................................................................................................. 197 INSTALLATION............................................................................................ 198 REAR FENDER LIGHTS CONDUIT.............................................................................. 199 REMOVAL............................................................................................. 199 INSTALLATION........................................................................................ 199 REAR FENDER CLOISONNE................................................................................... 200 REMOVAL............................................................................................. 200 INSTALLATION........................................................................................ 200 REAR FACIA (FLHX) 2.35...................................................................................... 201 REMOVAL................................................................................................. 201 INSTALLATION............................................................................................ 201 STUD PLATE.............................................................................................. 201 REMOVAL............................................................................................. 201 INSTALLATION........................................................................................ 201 REAR FACIA LAMP......................................................................................... 202 REMOVAL............................................................................................. 202 INSTALLATION........................................................................................ 202 JIFFY STAND 2.36............................................................................................ 203 GENERAL................................................................................................. 203 REMOVAL................................................................................................. 203 INSTALLATION............................................................................................ 204 FOOTBOARDS/FOOTRESTS 2.37................................................................................... 205 RIDER FOOTBOARD......................................................................................... 205 REMOVAL............................................................................................. 205 INSTALLATION........................................................................................ 205 DISASSEMBLY......................................................................................... 205 ASSEMBLY............................................................................................ 205 PASSENGER FOOTBOARD..................................................................................... 205 REMOVAL............................................................................................. 205 INSTALLATION........................................................................................ 206 DISASSEMBLY......................................................................................... 207 ASSEMBLY............................................................................................ 207 PASSENGER FOOTREST (FLHRS, FLHX)........................................................................ 207 REMOVAL............................................................................................. 207 INSTALLATION........................................................................................ 207 DISASSEMBLY......................................................................................... 207 ASSEMBLY............................................................................................ 208 EXHAUST SYSTEM 2.38......................................................................................... 209 REMOVAL................................................................................................. 209 INSTALLATION............................................................................................ 209 DISASSEMBLY............................................................................................. 211 ASSEMBLY................................................................................................ 213 sm03a.pdf....................................................................................................... 0 SPECIFICATIONS 3.1.......................................................................................... 215 MANUFACTURING TOLERANCES................................................................................ 215 MANUFACTURING TOLERANCES (CONT.).................................................................... 216 TORQUE VALUES........................................................................................... 216 SERVICE WEAR LIMITS 3.2..................................................................................... 217 GENERAL................................................................................................. 217 SERVICE WEAR LIMITS (CONT.)......................................................................... 218 GENERAL INFORMATION 3.3..................................................................................... 219 FUEL.................................................................................................... 219 GASOLINE/ALCOHOL BLENDS............................................................................. 219 LUBRICATION............................................................................................. 219 CHECKING ENGINE OIL LEVEL........................................................................... 219 CHANGING ENGINE OIL AND FILTER...................................................................... 220 WINTER LUBRICATION.................................................................................. 221 OIL PRESSURE INDICATOR LAMP......................................................................... 221 ENGINE OIL FLOW..................................................................................... 222 Oil Feed (Figures 3-6, 3-7)......................................................................... 222 Top End (Figures 3-6, 3-7).......................................................................... 222 Bottom End (Figures 3-6, 3-7, 3-8).................................................................. 224 Oil Return (Figures 3-6, 3-8)....................................................................... 224 Oil Pump Operation.................................................................................. 224 Breather Operation.................................................................................. 227 HOW TO USE THIS SECTION 3.4................................................................................. 228 GENERAL................................................................................................. 228 Top End Overhaul.................................................................................... 228 Bottom End Overhaul................................................................................. 228 Subassembly Service and Repair...................................................................... 229 STRIPPING MOTORCYCLE FOR SERVICE 3.5........................................................................ 230 PROCEDURE............................................................................................... 230 ASSEMBLING MOTORCYCLE AFTER STRIPPING 3.6................................................................... 231 PROCEDURE............................................................................................... 231 REMOVING ENGINE FROM CHASSIS 3.7............................................................................ 233 PROCEDURE............................................................................................... 233 INSTALLING ENGINE IN CHASSIS 3.8............................................................................ 237 PROCEDURE............................................................................................... 237 sm03b.pdf....................................................................................................... 0 TOP END OVERHAUL 3.9........................................................................................ 243 DISASSEMBLY............................................................................................. 243 ASSEMBLY................................................................................................ 247 BOTTOM END OVERHAUL 3.10.................................................................................... 255 DISASSEMBLY............................................................................................. 255 ASSEMBLY................................................................................................ 257 SUBASSEMBLY SERVICE AND REPAIR 3.11......................................................................... 265 TOP END................................................................................................. 265 BREATHER ASSEMBLY....................................................................................... 265 Removal............................................................................................. 265 Disassembly......................................................................................... 265 Cleaning and Inspection............................................................................. 265 Assembly............................................................................................ 265 Installation........................................................................................ 265 ROCKER ARM ASSEMBLY..................................................................................... 266 Removal............................................................................................. 266 Disassembly......................................................................................... 266 Cleaning and Inspection............................................................................. 266 Assembly............................................................................................ 267 Installation........................................................................................ 268 PUSH RODS/LIFTERS/COVERS................................................................................ 269 Removal............................................................................................. 269 Disassembly......................................................................................... 269 Cleaning and Inspection............................................................................. 269 Assembly............................................................................................ 269 Installation........................................................................................ 270 CYLINDER HEAD........................................................................................... 273 Removal............................................................................................. 273 Disassembly......................................................................................... 273 Cleaning and Inspection............................................................................. 274 VALVE GUIDE REPLACEMENT............................................................................. 275 VALVE AND SEAT REFACING............................................................................. 279 Assembly............................................................................................ 280 Installation........................................................................................ 281 CYLINDER................................................................................................ 282 Removal............................................................................................. 282 Cleaning and Inspection............................................................................. 282 Installation........................................................................................ 284 sm03c.pdf....................................................................................................... 0 PISTON...................................................................................................... 285 Removal................................................................................................. 285 Disassembly............................................................................................. 285 Piston Rings, Removal................................................................................... 285 Cleaning and Inspection................................................................................. 285 Assembly................................................................................................ 287 Piston Rings, Installation.............................................................................. 287 Installation............................................................................................ 288 UPPER CONNECTING ROD........................................................................................ 290 Removal................................................................................................. 290 Disassembly/Assembly.................................................................................... 290 Upper Connecting Rod Bushing............................................................................ 290 Reaming Upper Rod Bushing............................................................................... 291 Honing Upper Rod Bushing................................................................................ 292 Installation............................................................................................ 293 BOTTOM END.................................................................................................. 295 CAM SUPPORT PLATE........................................................................................... 295 Removal................................................................................................. 295 Disassembly/Assembly.................................................................................... 295 Crankshaft Bushing...................................................................................... 295 Reaming Crankshaft Bushing.............................................................................. 296 Camshafts/Camshaft Bearings............................................................................. 297 Cam Chain Tensioners.................................................................................... 303 Oil Pressure Relief Valve............................................................................... 304 Cam Needle Bearings..................................................................................... 304 Installation............................................................................................ 306 OIL PUMP.................................................................................................... 307 Removal................................................................................................. 307 Cleaning and Inspection................................................................................. 307 Installation............................................................................................ 307 CRANKCASE................................................................................................... 309 Removal................................................................................................. 309 Disassembly/Assembly.................................................................................... 309 RIGHT CRANKCASE HALF.................................................................................... 309 Crankshaft Bearing...................................................................................... 309 Piston Jets............................................................................................. 310 LEFT CRANKCASE HALF..................................................................................... 310 Sprocket Shaft Bearing.................................................................................. 310 Sprocket Shaft Bearing Inner Race....................................................................... 312 Cylinder Studs.......................................................................................... 315 Pipe Plug and Oil Fittings.............................................................................. 315 Cleaning and Inspection................................................................................. 315 Installation............................................................................................ 315 FLYWHEEL/CONNECTING ROD ASSEMBLY............................................................................ 316 Removal................................................................................................. 316 Inspection.............................................................................................. 316 Installation............................................................................................ 316 sm04a.pdf....................................................................................................... 0 SPECIFICATIONS 4.1.......................................................................................... 319 CVH CARBURETOR JET SIZES................................................................................ 319 FUEL TANK CAPACITY...................................................................................... 319 TORQUE VALUES........................................................................................... 319 FUEL SYSTEM TROUBLESHOOTING (CARBURETED) 4.2................................................................ 320 ENRICHENER (CARBURETED) 4.3................................................................................. 323 GENERAL................................................................................................. 323 OPERATION............................................................................................... 323 Enrichener.......................................................................................... 323 Cool Engine......................................................................................... 324 Warm Climate Or Hot Engine.......................................................................... 324 ADJUSTMENTS............................................................................................. 324 Slow Idle........................................................................................... 324 Enrichener Control.................................................................................. 325 CARBURETOR 4.4.............................................................................................. 327 REMOVAL................................................................................................. 327 INSTALLATION............................................................................................ 327 DISASSEMBLY............................................................................................. 328 CLEANING AND INSPECTION................................................................................. 330 Carburetor Housing.................................................................................. 330 ASSEMBLY................................................................................................ 332 AIR CLEANER 4.5............................................................................................. 334 REMOVAL................................................................................................. 334 CLEANING AND INSPECTION................................................................................. 334 INSTALLATION............................................................................................ 335 VACUUM OPERATED FUEL VALVE (CARBURETED) 4.6................................................................. 336 GENERAL................................................................................................. 336 TROUBLESHOOTING......................................................................................... 336 REMOVAL................................................................................................. 336 CLEANING AND INSPECTION................................................................................. 337 INSTALLATION............................................................................................ 337 FUEL TANK ADAPTER....................................................................................... 338 FUEL TANK (CARBURETED) 4.7.................................................................................. 339 COMPLETE REMOVAL........................................................................................ 339 FLHX, FLHT.......................................................................................... 339 FLHR/S.............................................................................................. 339 CLEANING AND INSPECTION................................................................................. 340 INSTALLATION (AFTER COMPLETE REMOVAL)................................................................... 341 FLHX, FLHT.......................................................................................... 341 FLHR/S.............................................................................................. 341 PARTIAL REMOVAL......................................................................................... 343 FLHX, FLHT.......................................................................................... 343 FLHR/S.............................................................................................. 343 INSTALLATION (AFTER PARTIAL REMOVAL).................................................................... 344 FLHX, FLHT.......................................................................................... 344 FLHR/S.............................................................................................. 344 EVAPORATIVE EMISSIONS CONTROL SYSTEM 4.8.................................................................... 345 CALIFORNIA MODELS ONLY.................................................................................. 345 TROUBLESHOOTING......................................................................................... 346 VAPOR VALVE............................................................................................. 346 REMOVAL............................................................................................. 346 INSTALLATION........................................................................................ 346 CHARCOAL CANISTER....................................................................................... 347 REMOVAL............................................................................................. 347 INSTALLATION........................................................................................ 347 Charcoal Canister Hose Routing...................................................................... 348 Purge Tube:......................................................................................... 348 Fuel Vapor Vent Tube:............................................................................... 348 Clean Air Inlet Tube:............................................................................... 349 sm05a.pdf....................................................................................................... 0 SPECIFICATIONS 5.1.......................................................................................... 353 STARTER................................................................................................. 353 SERVICE WEAR LIMITS..................................................................................... 353 TORQUE VALUES........................................................................................... 353 STARTER SYSTEM 5.2.......................................................................................... 354 GENERAL................................................................................................. 354 Operation (Figure 5-1).............................................................................. 354 STARTER RELAY 5.3........................................................................................... 356 REMOVAL................................................................................................. 356 FLHR/C/S............................................................................................ 356 FLHX, FLHT/C/U, FLTR................................................................................ 356 INSTALLATION............................................................................................ 356 FLHR/C/S............................................................................................ 356 FLHX, FLHT/C/U, FLTR................................................................................ 357 STARTER 5.4................................................................................................. 358 REMOVAL................................................................................................. 358 INSTALLATION............................................................................................ 358 DISASSEMBLY, TESTING AND REPAIR......................................................................... 360 ASSEMBLY................................................................................................ 364 STARTER SOLENOID 5.5........................................................................................ 365 GENERAL................................................................................................. 365 DISASSEMBLY............................................................................................. 365 ASSEMBLY................................................................................................ 365 STARTER JACKSHAFT 5.6....................................................................................... 366 REMOVAL/DISASSEMBLY..................................................................................... 366 ASSEMBLY/INSTALLATION................................................................................... 367 sm06a.pdf....................................................................................................... 0 SPECIFICATIONS 6.1.......................................................................................... 371 OVERALL GEAR RATIOS..................................................................................... 371 CHAINS AND BELTS........................................................................................ 371 SPROCKETS............................................................................................... 371 CLUTCH.................................................................................................. 371 TORQUE VALUES........................................................................................... 371 PRIMARY CHAIN AND SPROCKETS 6.2............................................................................. 373 PRIMARY CHAIN ADJUSTMENT................................................................................ 373 ADJUSTER SHOE REPLACEMENT............................................................................... 373 DISASSEMBLY............................................................................................. 374 CLEANING AND INSPECTION................................................................................. 374 ASSEMBLY................................................................................................ 374 CLUTCH 6.3.................................................................................................. 375 ADJUSTMENT.............................................................................................. 375 REMOVAL/INSTALLATION.................................................................................... 375 PARTIAL DISASSEMBLY................................................................................. 375 ASSEMBLY............................................................................................ 375 CLEANING AND INSPECTION................................................................................. 375 COMPLETE DISASSEMBLY................................................................................ 377 ASSEMBLY............................................................................................ 378 SECONDARY DRIVE BELT AND SPROCKETS 6.4...................................................................... 380 ADJUSTMENT.............................................................................................. 380 CLEANING AND INSPECTION................................................................................. 380 REPLACEMENT............................................................................................. 381 REMOVAL............................................................................................. 381 INSTALLATION........................................................................................ 381 TRANSMISSION SPROCKET................................................................................... 382 REMOVAL............................................................................................. 382 CLEANING AND INSPECTION............................................................................. 382 INSTALLATION........................................................................................ 382 REAR WHEEL SPROCKET..................................................................................... 383 REMOVAL............................................................................................. 383 CLEANING AND INSPECTION............................................................................. 384 INSTALLATION........................................................................................ 384 PRIMARY CHAINCASE 6.5....................................................................................... 385 GENERAL................................................................................................. 385 LUBRICATION............................................................................................. 385 REMOVAL................................................................................................. 385 INSPECTION AND REPAIR................................................................................... 387 DISASSEMBLY............................................................................................. 388 MAINSHAFT BEARING AND LIP SEAL...................................................................... 388 MAINSHAFT BEARING INNER RACE........................................................................ 389 STARTER JACKSHAFT LIP SEAL AND BUSHING - PRIMARY CHAINCASE.......................................... 390 STARTER JACKSHAFT BUSHING - PRIMARY CHAINCASE COVER................................................. 390 SHIFTER BUSHINGS.................................................................................... 390 INSTALLATION............................................................................................ 391 sm07a.pdf....................................................................................................... 0 SPECIFICATIONS 7.1.......................................................................................... 399 TRANSMISSION DATA....................................................................................... 399 SERVICE WEAR LIMITS..................................................................................... 399 SERVICE WEAR LIMITS (CONT.’D)....................................................................... 400 TORQUE VALUES........................................................................................... 400 TRANSMISSION POWER FLOW 7.2................................................................................. 401 GENERAL................................................................................................. 401 Neutral............................................................................................. 401 1st Gear............................................................................................ 401 2nd Gear............................................................................................ 401 3rd Gear............................................................................................ 401 4th Gear............................................................................................ 401 5th Gear............................................................................................ 401 SHIFT LINKAGE 7.3........................................................................................... 403 ADJUSTMENT.............................................................................................. 403 SHIFT ROD........................................................................................... 403 SHIFTER CAM ASSEMBLY/SHIFTER FORKS 7.4...................................................................... 404 DISASSEMBLY............................................................................................. 404 CLEANING AND INSPECTION................................................................................. 405 ASSEMBLY................................................................................................ 406 CLUTCH RELEASE COVER 7.5.................................................................................... 410 REMOVAL/DISASSEMBLY..................................................................................... 410 CLEANING AND INSPECTION................................................................................. 410 ASSEMBLY/INSTALLATION................................................................................... 410 MAINSHAFT/COUNTERSHAFT 7.6.................................................................................. 413 REMOVAL................................................................................................. 413 DISASSEMBLY............................................................................................. 413 CLEANING AND INSPECTION................................................................................. 414 ASSEMBLY................................................................................................ 416 INSTALLATION............................................................................................ 419 MAIN DRIVE GEAR/BEARING 7.7................................................................................. 421 PRELIMINARY INSTRUCTIONS................................................................................ 421 REMOVAL................................................................................................. 421 CLEANING AND INSPECTION................................................................................. 422 Needle Bearing Replacement.......................................................................... 422 INSTALLATION............................................................................................ 424 FINAL INSTRUCTIONS...................................................................................... 425 Countershaft Needle Bearing Replacement............................................................. 428 TRANSMISSION CASE/OIL PAN 7.8............................................................................... 429 GENERAL................................................................................................. 429 REMOVAL................................................................................................. 429 Transmission Case and Oil Pan....................................................................... 429 Oil Pan Only........................................................................................ 430 CLEANING AND INSPECTION................................................................................. 431 INSTALLATION............................................................................................ 431 Oil Pan Only........................................................................................ 431 Transmission Case and Oil Pan....................................................................... 431 sm08a.pdf....................................................................................................... 0 SPECIFICATIONS 8.1.......................................................................................... 435 IGNITION TIMING......................................................................................... 435 ALTERNATOR SYSTEM....................................................................................... 435 BATTERY................................................................................................. 435 FUSES................................................................................................... 435 SPARK PLUG.............................................................................................. 436 TORQUE VALUES........................................................................................... 436 BULB CHART 8.2.............................................................................................. 437 SYSTEM FUSES 8.3............................................................................................ 439 MAXI-FUSE............................................................................................... 439 REMOVAL............................................................................................. 439 INSTALLATION........................................................................................ 439 MAXI-FUSE HOLDER........................................................................................ 439 REMOVAL............................................................................................. 439 INSTALLATION........................................................................................ 439 SYSTEM FUSES/RELAYS..................................................................................... 439 REMOVAL............................................................................................. 439 INSTALLATION........................................................................................ 440 FUSE BLOCK.............................................................................................. 440 REMOVAL............................................................................................. 440 INSTALLATION........................................................................................ 440 EFI FUSES............................................................................................... 440 ICM (CARBURETED) 8.4........................................................................................ 441 REMOVAL................................................................................................. 441 INSTALLATION............................................................................................ 441 SENSORS (CARBURETED) 8.5.................................................................................... 442 MAP SENSOR.............................................................................................. 442 Removal............................................................................................. 442 Installation........................................................................................ 442 CKP SENSOR.............................................................................................. 442 IGNITION COIL 8.6........................................................................................... 443 REMOVAL................................................................................................. 443 INSTALLATION............................................................................................ 443 SPARK PLUGS/SPARK PLUG CABLES 8.7........................................................................... 444 SPARK PLUGS............................................................................................. 444 REMOVAL............................................................................................. 444 INSPECTION.......................................................................................... 444 CLEANING............................................................................................ 444 ADJUSTMENT.......................................................................................... 444 INSTALLATION........................................................................................ 444 SPARK PLUG CABLES....................................................................................... 445 REMOVAL............................................................................................. 445 INSPECTION.......................................................................................... 445 INSTALLATION........................................................................................ 445 ALTERNATOR/STATOR 8.8....................................................................................... 446 REMOVAL................................................................................................. 446 CLEANING AND INSPECTION................................................................................. 447 INSTALLATION............................................................................................ 447 VOLTAGE REGULATOR 8.9....................................................................................... 449 REMOVAL................................................................................................. 449 INSTALLATION............................................................................................ 449 BATTERY 8.10................................................................................................ 451 GENERAL................................................................................................. 451 BATTERY TESTS........................................................................................... 451 VOLTMETER TEST...................................................................................... 451 CONDUCTANCE TEST.................................................................................... 452 LOAD TEST........................................................................................... 452 DISCONNECTION AND REMOVAL............................................................................... 453 CLEANING AND INSPECTION................................................................................. 453 BATTERY CHARGING........................................................................................ 453 SAFETY PRECAUTIONS.................................................................................. 453 CHARGING BATTERY.................................................................................... 454 BATTERY CABLE ROUTING................................................................................... 455 INSTALLATION AND CONNECTION............................................................................. 455 STORAGE................................................................................................. 456 HEADLAMP (FLHR/C/S, FLHX, FLHT/C/U) 8.11.................................................................... 457 HEADLAMP ASSEMBLY....................................................................................... 457 REMOVAL............................................................................................. 457 INSTALLATION........................................................................................ 457 HEADLAMP BULB REPLACEMENT............................................................................... 457 HEADLAMP ADJUSTMENT..................................................................................... 458 HEADLAMP (FLTR) 8.12........................................................................................ 460 HEADLAMP ASSEMBLY....................................................................................... 460 REMOVAL............................................................................................. 460 INSTALLATION........................................................................................ 460 HEADLAMP BULB REPLACEMENT............................................................................... 461 REMOVAL............................................................................................. 461 INSTALLATION........................................................................................ 461 HEADLAMP ADJUSTMENT..................................................................................... 461 AUXILIARY LAMPS 8.13........................................................................................ 463 AUXILIARY LAMP BULB..................................................................................... 463 REMOVAL............................................................................................. 463 INSTALLATION........................................................................................ 463 AUXILIARY LAMP HOUSING.................................................................................. 464 REMOVAL............................................................................................. 464 INSTALLATION........................................................................................ 465 AUXILIARY LAMP BRACKET.................................................................................. 466 REMOVAL............................................................................................. 466 INSTALLATION........................................................................................ 466 ADJUSTMENT.............................................................................................. 466 TAIL LAMP ASSEMBLY 8.14..................................................................................... 468 TAIL LAMP/TAIL LAMP BULB................................................................................ 468 REMOVAL............................................................................................. 468 INSTALLATION........................................................................................ 468 CIRCUIT BOARD/CHROME BASE............................................................................... 468 REMOVAL............................................................................................. 468 INSTALLATION........................................................................................ 469 REAR FENDER LIGHTS HARNESS.............................................................................. 470 REMOVAL............................................................................................. 470 INSTALLATION........................................................................................ 470 FENDER TIP LAMPS 8.15....................................................................................... 472 FRONT FENDER TIP LAMP................................................................................... 472 REMOVAL............................................................................................. 472 INSTALLATION........................................................................................ 472 FRONT FENDER TIP LAMP JUMPER HARNESS.................................................................... 472 REMOVAL............................................................................................. 472 INSTALLATION........................................................................................ 473 REAR FENDER TIP LAMP.................................................................................... 475 REMOVAL............................................................................................. 475 INSTALLATION........................................................................................ 476 TURN SIGNAL LAMPS 8.16...................................................................................... 477 BULB REPLACEMENT........................................................................................ 477 REMOVAL............................................................................................. 477 INSTALLATION........................................................................................ 477 FRONT TURN SIGNAL LAMP.................................................................................. 477 FLHR/C, FLHT/C/U.................................................................................... 477 FLHRS............................................................................................... 479 FLHX................................................................................................ 481 FLTR................................................................................................ 482 REAR TURN SIGNAL LAMP................................................................................... 483 FLHR/C, FLHT/C/U.................................................................................... 483 FLHRS, FLHX, FLTR................................................................................... 484 REAR TURN SIGNAL LAMPS BRACKET.......................................................................... 485 FLHR/C, FLHT/C/U.................................................................................... 485 FLHRS, FLHX, FLTR................................................................................... 485 INSTALLATION........................................................................................ 485 LICENSE PLATE LAMPS/BRACKET (FLHX) 8.17..................................................................... 486 BULB REPLACEMENT........................................................................................ 486 REMOVAL............................................................................................. 486 INSTALLATION........................................................................................ 486 LICENSE PLATE LAMPS..................................................................................... 486 REMOVAL............................................................................................. 486 INSTALLATION........................................................................................ 486 LICENSE PLATE BRACKET................................................................................... 487 REMOVAL............................................................................................. 487 INSTALLATION........................................................................................ 487 TSM/TSSM 8.18............................................................................................... 488 REMOVAL................................................................................................. 488 INSTALLATION............................................................................................ 488 sm08b.pdf....................................................................................................... 0 IGNITION/LIGHT KEY SWITCH AND FORK LOCK 8.19................................................................ 489 FLHX, FLHT/C/U, FLTR.................................................................................... 489 REMOVAL............................................................................................. 489 INSTALLATION........................................................................................ 490 FLHR/C/S................................................................................................ 492 IGNITION/LIGHT KEY SWITCH........................................................................... 492 FORK LOCK........................................................................................... 493 FAIRING CAP SWITCHES (FLHTC/U) 8.20......................................................................... 494 REMOVAL................................................................................................. 494 INSTALLATION............................................................................................ 495 INSTRUMENT NACELLE SWITCHES (FLTR) 8.21..................................................................... 496 REMOVAL................................................................................................. 496 LEFT SIDE SWITCH.................................................................................... 496 RIGHT SIDE SWITCHES................................................................................. 497 INSTALLATION............................................................................................ 497 LEFT SIDE SWITCH.................................................................................... 497 RIGHT SIDE SWITCHES................................................................................. 498 HANDLEBAR SWITCHES 8.22..................................................................................... 500 GENERAL................................................................................................. 500 REMOVAL................................................................................................. 500 RIGHT HANDLEBAR CONTROLS............................................................................ 500 LEFT HANDLEBAR CONTROLS............................................................................. 501 INSTALLATION............................................................................................ 501 RIGHT HANDLEBAR CONTROLS............................................................................ 501 LEFT HANDLEBAR CONTROLS............................................................................. 503 SWITCH REPAIR/REPLACEMENT............................................................................... 506 RIGHT SIDE HANDLEBAR SWITCHES....................................................................... 506 LEFT SIDE HANDLEBAR SWITCHES........................................................................ 506 SPECIFIC REPAIR PROCEDURES.............................................................................. 506 UPPER SWITCH HOUSINGS............................................................................... 506 LOWER SWITCH HOUSINGS............................................................................... 508 GENERAL REPAIR PROCEDURES............................................................................... 514 RIGHT SIDE HANDLEBAR SWITCHES....................................................................... 516 LEFT SIDE HANDLEBAR SWITCHES........................................................................ 516 STOPLIGHT SWITCHES 8.23..................................................................................... 517 FRONT STOPLIGHT SWITCH.................................................................................. 517 REMOVAL/INSTALLATION................................................................................ 517 REAR STOPLIGHT SWITCH................................................................................... 517 REMOVAL............................................................................................. 517 INSTALLATION........................................................................................ 517 NEUTRAL SWITCH 8.24......................................................................................... 518 REMOVAL................................................................................................. 518 INSTALLATION............................................................................................ 518 OIL PRESSURE SWITCH/SENDER 8.25............................................................................. 519 REMOVAL................................................................................................. 519 INSTALLATION............................................................................................ 519 HORN 8.26................................................................................................... 520 TROUBLESHOOTING......................................................................................... 520 REMOVAL................................................................................................. 520 INSTALLATION............................................................................................ 520 CIGARETTE LIGHTER (FLHX, FLHT/C/U, FLTR) 8.27............................................................... 521 GENERAL................................................................................................. 521 TROUBLESHOOTING......................................................................................... 521 REMOVAL................................................................................................. 521 INSTALLATION............................................................................................ 521 GAUGES/INSTRUMENTS (FLHX, FLHT/C/U, FLTR) 8.28.............................................................. 522 GAUGE/LAMP- 2 INCH DIAMETER............................................................................. 522 REMOVAL............................................................................................. 522 INSTALLATION........................................................................................ 522 GAUGES- 4 INCH DIAMETER................................................................................. 522 TACHOMETER.......................................................................................... 522 REMOVAL............................................................................................. 522 INSTALLATION........................................................................................ 523 VSS..................................................................................................... 523 REMOVAL............................................................................................. 523 INSTALLATION........................................................................................ 524 SPEEDOMETER............................................................................................. 524 REMOVAL............................................................................................. 524 INSTALLATION........................................................................................ 524 INDICATOR LAMPS......................................................................................... 525 REMOVAL............................................................................................. 525 INSTALLATION........................................................................................ 525 GAUGES/INSTRUMENTS (FLHR/C/S) 8.29.......................................................................... 526 FUEL GAUGE.............................................................................................. 526 REMOVAL............................................................................................. 526 INSTALLATION........................................................................................ 526 VSS..................................................................................................... 527 SPEEDOMETER............................................................................................. 527 REMOVAL............................................................................................. 527 INSTALLATION........................................................................................ 528 INDICATOR LIGHTS........................................................................................ 528 REMOVAL............................................................................................. 528 INSTALLATION........................................................................................ 528 IGNITION SWITCH......................................................................................... 529 FUEL LEVEL SENDER (CARBURETED) 8.30......................................................................... 530 FLHX, FLHT CANOPY....................................................................................... 530 REMOVAL............................................................................................. 530 INSTALLATION........................................................................................ 530 FLHR/S CANOPY........................................................................................... 531 REMOVAL............................................................................................. 531 INSTALLATION........................................................................................ 532 FUEL LEVEL SENDER....................................................................................... 533 REMOVAL............................................................................................. 533 INSTALLATION........................................................................................ 533 sm08c.pdf....................................................................................................... 0 CRUISE CONTROL (FLHRC, FLHTCU, FLTR) 8.31................................................................... 535 GENERAL................................................................................................. 535 SYSTEM OPERATION........................................................................................ 535 CABLE ADJUSTMENT........................................................................................ 536 THROTTLE CABLE...................................................................................... 537 IDLE CABLE.......................................................................................... 537 CABLE LASH INITIALIZATION........................................................................... 537 THROTTLE/IDLE CABLES.................................................................................... 538 REMOVAL............................................................................................. 538 INSTALLATION........................................................................................ 538 CRUISE CABLE............................................................................................ 540 REMOVAL............................................................................................. 540 INSTALLATION........................................................................................ 540 CRUISE CONTROL MODULE................................................................................... 541 REMOVAL............................................................................................. 541 INSTALLATION........................................................................................ 542 CRUISE CONTROL SWITCHES................................................................................. 542 FAIRING CAP......................................................................................... 542 HANDLEBAR........................................................................................... 542 ADVANCED AUDIO SYSTEM (FLHX, FLHTC/U, FLTR) 8.32............................................................ 543 RADIO (STORAGE BOX)..................................................................................... 543 REMOVAL............................................................................................. 543 INSTALLATION........................................................................................ 543 FRONT FAIRING SPEAKERS.................................................................................. 544 REMOVAL............................................................................................. 544 INSTALLATION........................................................................................ 544 CONSOLE POD ASSEMBLY.................................................................................... 544 REMOVAL............................................................................................. 544 INSTALLATION........................................................................................ 545 FRONT HEADSET RECEPTACLE................................................................................ 546 REMOVAL............................................................................................. 546 INSTALLATION........................................................................................ 546 REAR HEADSET RECEPTACLE................................................................................. 546 REAR PASSENGER SWITCHES................................................................................. 546 REMOVAL............................................................................................. 546 INSTALLATION........................................................................................ 547 REAR SPEAKERS........................................................................................... 547 REMOVAL............................................................................................. 547 INSTALLATION........................................................................................ 548 CB MODULE............................................................................................... 549 REMOVAL............................................................................................. 549 INSTALLATION........................................................................................ 549 CB LOADING COIL......................................................................................... 549 REMOVAL............................................................................................. 549 INSTALLATION........................................................................................ 549 AUDIO HARNESS........................................................................................... 549 RADIO ANTENNA CABLE..................................................................................... 549 CB ANTENNA CABLE........................................................................................ 549 WIRE TROUGH 8.33............................................................................................ 550 REMOVAL................................................................................................. 550 INSTALLATION............................................................................................ 551 MAIN HARNESS 8.34........................................................................................... 553 REMOVAL................................................................................................. 553 REMOVAL- ALL MODELS (PART I)........................................................................ 553 REMOVAL- FLHR/C/S (PART II)......................................................................... 553 REMOVAL- FLHX, FLHT/C/U (PART II)................................................................... 554 REMOVAL- FLTR (PART II)............................................................................. 556 REMOVAL- ALL MODELS (PART III)...................................................................... 556 INSTALLATION............................................................................................ 561 INSTALLATION- ALL MODELS (PART I)................................................................... 561 INSTALLATION- FLHR/C/S (PART II).................................................................... 564 INSTALLATION- FLHX, FLHT/C/U (PART II).............................................................. 565 INSTALLATION- FLTR (PART II)........................................................................ 565 INSTALLATION- ALL MODELS (PART III)................................................................. 565 FRAME GROUND STUD REPLACEMENT........................................................................... 566 INTERCONNECT HARNESS 8.35................................................................................... 567 FLHX, FLHT/C/U.......................................................................................... 567 REMOVAL............................................................................................. 567 INSTALLATION........................................................................................ 570 FLTR.................................................................................................... 571 REMOVAL............................................................................................. 571 INSTALLATION........................................................................................ 573 RADIO ANTENNA CABLE 8.36.................................................................................... 575 FLHTC/U................................................................................................. 575 REMOVAL............................................................................................. 575 INSTALLATION........................................................................................ 575 FLHX, FLTR.............................................................................................. 577 REMOVAL............................................................................................. 577 INSTALLATION........................................................................................ 577 AUDIO HARNESS (FLHTCU) 8.37................................................................................. 579 REMOVAL................................................................................................. 579 INSTALLATION............................................................................................ 581 CB ANTENNA CABLE (FLHTCU) 8.38.............................................................................. 583 REMOVAL................................................................................................. 583 INSTALLATION............................................................................................ 583 sm09a Fuel injection.pdf........................................................................................ 0 SPECIFICATIONS 9.1.......................................................................................... 587 EFI FUSES............................................................................................... 587 TORQUE VALUES........................................................................................... 587 ELECTRICAL BRACKET ASSEMBLY 9.2............................................................................. 589 DATA LINK CONNECTOR..................................................................................... 589 SETTING ENGINE IDLE SPEED........................................................................... 589 EFI SYSTEM RELAY/EFI FUSES.............................................................................. 590 REMOVAL............................................................................................. 590 INSTALLATION........................................................................................ 590 ECM..................................................................................................... 590 REMOVAL............................................................................................. 590 INSTALLATION........................................................................................ 590 SECURITY SIREN CONNECTOR................................................................................ 590 REMOVAL............................................................................................. 590 INSTALLATION........................................................................................ 591 ELECTRICAL BRACKET...................................................................................... 591 REMOVAL............................................................................................. 591 INSTALLATION........................................................................................ 591 SENSORS 9.3................................................................................................. 592 GENERAL................................................................................................. 592 IAT SENSOR.......................................................................................... 592 TP SENSOR........................................................................................... 592 MAP SENSOR.......................................................................................... 592 BAS................................................................................................. 592 CKP SENSOR.............................................................................................. 592 REMOVAL............................................................................................. 592 INSTALLATION........................................................................................ 593 ET SENSOR............................................................................................... 593 REMOVAL............................................................................................. 593 INSTALLATION........................................................................................ 593 FUEL TANK (FUEL INJECTED) 9.4............................................................................... 594 COMPLETE REMOVAL........................................................................................ 594 FLHXI, FLHT/C/U/I, FLTRI............................................................................ 594 FLHR/C/S/I.......................................................................................... 596 INSTALLATION (AFTER COMPLETE REMOVAL)................................................................... 596 FLHXI, FLHT/C/U/I, FLTRI............................................................................ 596 FLHR/C/S/I.......................................................................................... 598 PARTIAL REMOVAL......................................................................................... 598 FLHXI, FLHT/C/U/I, FLTRI............................................................................ 598 FLHR/C/S/I.......................................................................................... 599 INSTALLATION (AFTER PARTIAL REMOVAL).................................................................... 600 FLHXI, FLHT/C/U/I, FLTRI............................................................................ 600 FLHR/C/S/I.......................................................................................... 600 CONSOLE POD/CANOPY...................................................................................... 601 FLHXI, FLHT/C/U/I, FLTRI............................................................................ 601 REMOVAL............................................................................................. 601 INSTALLATION........................................................................................ 602 INSTRUMENT CONSOLE/CANOPY............................................................................... 604 FLHR/C/S/I.......................................................................................... 604 REMOVAL............................................................................................. 604 INSTALLATION........................................................................................ 604 FUEL FILTER CANISTER.................................................................................... 605 REMOVAL............................................................................................. 605 INSTALLATION........................................................................................ 605 FUEL PRESSURE REGULATOR................................................................................. 606 REMOVAL............................................................................................. 606 INSTALLATION........................................................................................ 606 FUEL PUMP............................................................................................... 607 REMOVAL............................................................................................. 607 INSTALLATION........................................................................................ 607 FUEL PUMP/FUEL LEVEL SENDER WIRING...................................................................... 608 FUEL LEVEL SENDER....................................................................................... 608 REMOVAL............................................................................................. 608 INSTALLATION........................................................................................ 608 FUEL SUPPLY CHECK VALVE/TUBE............................................................................ 608 REMOVAL............................................................................................. 608 INSTALLATION........................................................................................ 609 sm09b.pdf....................................................................................................... 0 INDUCTION MODULE ASSEMBLY 9.5............................................................................... 611 INDUCTION MODULE........................................................................................ 611 REMOVAL............................................................................................. 611 INSTALLATION........................................................................................ 612 FUEL SUPPLY TUBE/FUEL RAIL/ FUEL INJECTORS.............................................................. 613 REMOVAL............................................................................................. 613 INSTALLATION........................................................................................ 614 IAT SENSOR.............................................................................................. 614 REMOVAL............................................................................................. 614 INSTALLATION........................................................................................ 614 TP SENSOR............................................................................................... 615 REMOVAL............................................................................................. 615 INSTALLATION........................................................................................ 615 MAP SENSOR.............................................................................................. 615 REMOVAL............................................................................................. 615 INSTALLATION........................................................................................ 616 IAC..................................................................................................... 617 REMOVAL............................................................................................. 617 INSTALLATION........................................................................................ 617 sm_appa.pdf..................................................................................................... 0 TOOLS A.1................................................................................................... 621 sm_appb1.pdf.................................................................................................... 0 DEUTSCH ELECTRICAL CONNECTORS B.1........................................................................... 641 GENERAL................................................................................................. 641 REMOVING/DISASSEMBLING.................................................................................. 641 REMOVING/INSTALLING SOCKETS............................................................................. 641 REMOVING/INSTALLING PINS................................................................................ 642 ASSEMBLING/INSTALLING................................................................................... 644 CRIMPING INSTRUCTIONS................................................................................... 644 STANDARD TERMINALS.................................................................................. 644 MINI TERMINALS...................................................................................... 646 SOLID BARREL CONTACTS............................................................................... 646 MULTILOCK ELECTRICAL CONNECTORS B.2......................................................................... 648 REMOVING SOCKET/PIN TERMINALS........................................................................... 648 INSTALLING SOCKET/PIN TERMINALS......................................................................... 648 CRIMPING INSTRUCTIONS................................................................................... 652 DELPHI ELECTRICAL CONNECTORS B.3............................................................................ 653 GENERAL................................................................................................. 653 REMOVING SOCKET TERMINALS............................................................................... 653 INSTALLING SOCKET TERMINALS............................................................................. 653 PACKARD ELECTRICAL CONNECTORS B.4........................................................................... 655 150 METRI-PACK SERIES................................................................................... 655 General............................................................................................. 655 Disassembly......................................................................................... 655 Assembly............................................................................................ 655 280 METRI-PACK SERIES................................................................................... 655 General............................................................................................. 655 System Fuse Block................................................................................... 655 480 METRI-PACK SERIES................................................................................... 657 General............................................................................................. 657 Disassembly......................................................................................... 657 Assembly............................................................................................ 658 630 METRI-PACK SERIES................................................................................... 659 General............................................................................................. 659 Disassembly......................................................................................... 659 Assembly............................................................................................ 659 800 METRI-PACK SERIES................................................................................... 659 General............................................................................................. 659 Disassembly......................................................................................... 659 Assembly............................................................................................ 659 PACKARD MICRO 64........................................................................................ 660 General............................................................................................. 660 Disassembly......................................................................................... 660 Assembly............................................................................................ 661 Crimping Instructions............................................................................... 661 PACKARD 100W............................................................................................ 662 General............................................................................................. 662 Disassembly......................................................................................... 662 Assembly............................................................................................ 663 Crimping Instructions............................................................................... 663 AUTOFUSE ELECTRICAL CONNECTOR B.5........................................................................... 665 GENERAL................................................................................................. 665 DISASSEMBLY............................................................................................. 665 ASSEMBLY................................................................................................ 665 SEALED BUTT SPLICE CONNECTORS B.6........................................................................... 666 PROCEDURE............................................................................................... 666 ELECTRICAL CONNECTOR LOCATIONS B.7.......................................................................... 668 FLHX, FLHT/C/U.......................................................................................... 668 FLHX, FLHT/C/U (Continued).......................................................................... 670 FLTR.................................................................................................... 674 FLTR (Continued).................................................................................... 675 FLTR (Continued).................................................................................... 676 FLHR/C/S................................................................................................ 677 FLHR/C/S (Continued)................................................................................ 678 WIRING DIAGRAMS B.8......................................................................................... 679 sm_appc.pdf..................................................................................................... 0 METRIC CONVERSIONS C.1...................................................................................... 705 FLUID CONVERSIONS C.2....................................................................................... 706 UNITED STATES SYSTEM.................................................................................... 706 METRIC SYSTEM........................................................................................... 706 BRITISH IMPERIAL SYSTEM................................................................................. 706 sm_appd.pdf..................................................................................................... 0 JAPANESE MAINSHAFT/COUNTERSHAFT D.1......................................................................... 707 DISASSEMBLY............................................................................................. 707 CLEANING AND INSPECTION................................................................................. 709 ASSEMBLY................................................................................................ 710 sm_appe.pdf..................................................................................................... 0 ACRONYMS AND ABBREVIATIONS E.1.............................................................................. 713 spb01a.pdf...................................................................................................... 0 HYDRAULIC CLUTCH 1.1........................................................................................ 717 GENERAL................................................................................................. 717 CHECKING AND CORRECTING CLUTCH FLUID LEVEL.............................................................. 717 ENGINE LUBRICATION 1.2...................................................................................... 719 GENERAL................................................................................................. 719 CRITICAL FASTENERS 1.3...................................................................................... 720 INSPECTION.............................................................................................. 720 spb02a.pdf...................................................................................................... 0 SPECIFICATIONS 2.1.......................................................................................... 723 TORQUE VALUES 2.2........................................................................................... 724 VEHICLE IDENTIFICATION NUMBER (V.I.N.) 2.3.................................................................. 725 GENERAL................................................................................................. 725 FOOTBOARDS AND CONTROLS 2.4................................................................................. 726 RIDER FOOTBOARDS........................................................................................ 726 Removal............................................................................................. 726 Installation........................................................................................ 726 PASSENGER FOOTBOARDS.................................................................................... 728 Removal............................................................................................. 728 Disassembly......................................................................................... 728 Assembly............................................................................................ 728 Installation........................................................................................ 728 SHIFT LEVER............................................................................................. 728 Replacement......................................................................................... 728 REAR BRAKE PEDAL........................................................................................ 728 Replacement......................................................................................... 728 REAR WHEEL 2.5.............................................................................................. 729 REMOVAL................................................................................................. 729 INSTALLATION............................................................................................ 729 FRONT AXLE COVERS 2.6....................................................................................... 730 REPLACEMENT............................................................................................. 730 LOWER TRIPLE CLAMP COVER 2.7................................................................................ 731 REPLACEMENT............................................................................................. 731 HANDLEBARS 2.8.............................................................................................. 732 REMOVAL................................................................................................. 732 DISASSEMBLY............................................................................................. 734 ASSEMBLY................................................................................................ 735 INSTALLATION............................................................................................ 738 HEATED HANDGRIPS........................................................................................ 740 Initial Disassembly................................................................................. 740 Replacing Left Handgrip............................................................................. 741 Replacing Right Handgrip............................................................................ 742 Final Assembly...................................................................................... 744 CLUTCH MASTER CYLINDER/RESERVOIR 2.9........................................................................ 745 GENERAL................................................................................................. 745 REMOVAL................................................................................................. 745 DISASSEMBLY............................................................................................. 746 ASSEMBLY................................................................................................ 747 INSTALLATION............................................................................................ 748 CLUTCH HAND LEVER 2.10...................................................................................... 749 INSTALLATION............................................................................................ 749 CLUTCH FLUID LINE 2.11...................................................................................... 750 REPLACEMENT............................................................................................. 750 CLUTCH FLUID LINE ROUTING............................................................................... 752 BLEEDING CLUTCH FLUID LINE.............................................................................. 752 SEAT 2.12................................................................................................... 754 GENERAL................................................................................................. 754 REMOVAL................................................................................................. 754 CLEANING AND INSPECTION................................................................................. 755 INSTALLATION............................................................................................ 755 RIDER BACKREST 2.13......................................................................................... 756 GENERAL................................................................................................. 756 REMOVAL................................................................................................. 757 INSTALLATION............................................................................................ 757 ADJUSTMENT.............................................................................................. 757 Vertical Adjustment................................................................................. 757 Tilt Angle.......................................................................................... 757 Forward/Aft Adjustment.............................................................................. 758 TOUR-PAK 2.14............................................................................................... 759 General................................................................................................. 759 REMOVAL................................................................................................. 759 INSTALLATION............................................................................................ 761 AM/FM/WB RADIO ANTENNA.................................................................................. 762 Removal............................................................................................. 762 Installation........................................................................................ 762 CB RADIO ANTENNA........................................................................................ 762 Removal............................................................................................. 762 Installation........................................................................................ 762 SADDLEBAG SUPPORTS 2.15..................................................................................... 763 REMOVAL................................................................................................. 763 INSTALLATION............................................................................................ 763 MUFFLER END CAP 2.16........................................................................................ 765 REPLACEMENT............................................................................................. 765 spb03a.pdf...................................................................................................... 0 SPECIFICATIONS 3.1.......................................................................................... 769 GENERAL................................................................................................. 769 MANUFACTURING TOLERANCES................................................................................ 769 SERVICE WEAR LIMITS 3.2..................................................................................... 771 GENERAL................................................................................................. 771 TORQUE VALUES 3.3........................................................................................... 773 BREATHER ASSEMBLY 3.4....................................................................................... 774 REMOVAL................................................................................................. 774 DISASSEMBLY............................................................................................. 774 CLEANING AND INSPECTION................................................................................. 774 ASSEMBLY................................................................................................ 774 INSTALLATION............................................................................................ 774 ROCKER HOUSING 3.5.......................................................................................... 775 VALVE SPRING TO ROCKER HOUSING CLEARANCE................................................................ 775 CYLINDER HEADS 3.6.......................................................................................... 778 GENERAL................................................................................................. 778 Removal................................................................................................. 778 Disassembly............................................................................................. 778 Cleaning................................................................................................ 780 Inspection.............................................................................................. 781 Cylinder Head....................................................................................... 781 Valve Guides........................................................................................ 781 Valves.............................................................................................. 781 Valve Springs....................................................................................... 781 Tapered Keepers..................................................................................... 781 Valve Seats......................................................................................... 781 VALVE GUIDE REPLACEMENT................................................................................. 782 Removal............................................................................................. 782 Installation........................................................................................ 783 VALVE AND SEAT REFACING................................................................................. 786 Assembly................................................................................................ 789 Installation............................................................................................ 791 PISTONS 3.7................................................................................................. 792 GENERAL................................................................................................. 792 BORING AND HONING CYLINDERS 3.8............................................................................. 793 CYLINDER BORE FINISHED SIZE............................................................................. 793 CAMS AND TIMING MARKS 3.9................................................................................... 794 GENERAL................................................................................................. 794 FLYWHEEL/CONNECTING ROD ASSEMBLY 3.10....................................................................... 795 GENERAL................................................................................................. 795 SPROCKET SHAFT BEARING INNER RACE REPLACEMENT........................................................... 795 OIL VENT LINE 3.11.......................................................................................... 798 REPLACEMENT............................................................................................. 798 OIL COOLER OPERATION 3.12................................................................................... 799 GENERAL................................................................................................. 799 Closed Thermostat................................................................................... 801 Partially Open Thermostat........................................................................... 801 Fully Open Thermostat............................................................................... 801 OIL COOLER 3.13............................................................................................. 802 REMOVAL................................................................................................. 802 INSTALLATION............................................................................................ 802 OIL FILTER MOUNT 3.14....................................................................................... 803 REMOVAL................................................................................................. 803 DISASSEMBLY............................................................................................. 803 ASSEMBLY................................................................................................ 804 INSTALLATION............................................................................................ 804 THERMOSTAT 3.15............................................................................................. 805 TEST PROCEDURE.......................................................................................... 805 REMOVAL................................................................................................. 805 INSTALLATION............................................................................................ 805 spb04a.pdf...................................................................................................... 0 AIR CLEANER COVER 4.1....................................................................................... 809 GENERAL................................................................................................. 809 REMOVAL................................................................................................. 809 INSTALLATION............................................................................................ 809 spb05a.pdf...................................................................................................... 0 SPECIFICATIONS 5.1.......................................................................................... 813 spb06a.pdf...................................................................................................... 0 SPECIFICATIONS 6.1.......................................................................................... 817 TORQUE VALUES 6.2........................................................................................... 818 CLUTCH RELEASE BEARING AND PUSH ROD 6.3..................................................................... 819 GENERAL................................................................................................. 819 REMOVAL................................................................................................. 819 INSTALLATION............................................................................................ 819 Measuring Release Plate Movement.................................................................... 820 Installing Clutch Inspection Cover.................................................................. 820 spb07a.pdf...................................................................................................... 0 SPECIFICATIONS 7.1.......................................................................................... 823 SERVICE WEAR LIMITS 7.2..................................................................................... 824 TORQUE VALUES 7.3........................................................................................... 825 CLUTCH RELEASE COVER 7.4.................................................................................... 826 REMOVAL................................................................................................. 826 INSTALLATION............................................................................................ 827 SECONDARY CLUTCH ACTUATOR 7.5............................................................................... 828 REBUILD................................................................................................. 828 spb08a.pdf...................................................................................................... 0 BULB REQUIREMENTS 8.1....................................................................................... 831 BULB CHART.............................................................................................. 831 HEADLAMP 8.2................................................................................................ 832 GENERAL................................................................................................. 832 REMOVAL................................................................................................. 832 INSTALLATION............................................................................................ 833 AUXILIARY LAMPS AND BRACKETS 8.3............................................................................ 835 LAMP REMOVAL............................................................................................ 835 LAMP BRACKET REMOVAL.................................................................................... 836 LAMP BRACKET INSTALLATION............................................................................... 836 LAMP INSTALLATION....................................................................................... 836 Mounting Lamp....................................................................................... 836 Lamp Alignment...................................................................................... 837 Final Assembly...................................................................................... 837 BULB REPLACEMENT........................................................................................ 838 FRONT TURN SIGNALS 8.4...................................................................................... 839 REMOVAL................................................................................................. 839 INSTALLATION............................................................................................ 840 XM RADIO 8.5................................................................................................ 841 GENERAL................................................................................................. 841 RECEIVER MODULE......................................................................................... 841 Removal............................................................................................. 841 Installation........................................................................................ 841 ANTENNA................................................................................................. 842 Removal............................................................................................. 842 Installation........................................................................................ 842 SOUND SYSTEM AMPLIFIER 8.6.................................................................................. 843 GENERAL................................................................................................. 843 REMOVAL................................................................................................. 843 INSTALLATION............................................................................................ 843 GARAGE DOOR OPENER 8.7...................................................................................... 845 TRANSMITTER............................................................................................. 845 Removal............................................................................................. 845 Installation........................................................................................ 845 RECEIVER................................................................................................ 845 Installation........................................................................................ 845 REMOTE CONTROL GARAGE DOOR OPENER....................................................................... 846 FCC Notices......................................................................................... 846 Program the Receiver and Transmitter................................................................ 846 spb_appa1.pdf................................................................................................... 0 INDEX TO WIRING DIAGRAMS A.1................................................................................ 851 fe08a.pdf....................................................................................................... 0 DEUTSCH ELECTRICAL CONNECTORS 8.1...........................................................................1355 GENERAL.................................................................................................1355 REMOVING/DISASSEMBLING..................................................................................1355 REMOVING/INSTALLING SOCKETS.............................................................................1355 REMOVING/INSTALLING PINS................................................................................1356 ASSEMBLING/INSTALLING...................................................................................1358 CRIMPING INSTRUCTIONS...................................................................................1358 STANDARD TERMINALS..................................................................................1358 MINI TERMINALS......................................................................................1360 SOLID BARREL CONTACTS...............................................................................1360 MULTILOCK ELECTRICAL CONNECTORS 8.2.........................................................................1362 REMOVING SOCKET/PIN TERMINALS...........................................................................1362 INSTALLING SOCKET/PIN TERMINALS.........................................................................1362 CRIMPING INSTRUCTIONS...................................................................................1366 DELPHI ELECTRICAL CONNECTORS 8.3............................................................................1367 GENERAL.................................................................................................1367 REMOVING SOCKET TERMINALS...............................................................................1367 INSTALLING SOCKET TERMINALS.............................................................................1367 PACKARD ELECTRICAL CONNECTORS 8.4...........................................................................1369 150 METRI-PACK SERIES...................................................................................1369 General.............................................................................................1369 Disassembly.........................................................................................1369 Assembly............................................................................................1369 280 METRI-PACK SERIES...................................................................................1369 General.............................................................................................1369 System Fuse Block...................................................................................1369 480 METRI-PACK SERIES...................................................................................1371 General.............................................................................................1371 Disassembly.........................................................................................1371 Assembly............................................................................................1372 630 METRI-PACK SERIES...................................................................................1373 General.............................................................................................1373 Disassembly.........................................................................................1373 Assembly............................................................................................1373 800 METRI-PACK SERIES...................................................................................1373 General.............................................................................................1373 Disassembly.........................................................................................1373 Assembly............................................................................................1373 PACKARD MICRO 64........................................................................................1374 General.............................................................................................1374 Disassembly.........................................................................................1374 Assembly............................................................................................1375 Crimping Instructions...............................................................................1375 PACKARD 100W............................................................................................1376 General.............................................................................................1376 Disassembly.........................................................................................1376 Assembly............................................................................................1377 Crimping Instructions...............................................................................1377 AUTOFUSE ELECTRICAL CONNECTOR 8.5...........................................................................1379 GENERAL.................................................................................................1379 DISASSEMBLY.............................................................................................1379 ASSEMBLY................................................................................................1379 SEALED BUTT SPLICE CONNECTORS 8.6...........................................................................1380 PROCEDURE...............................................................................................1380 ELECTRICAL CONNECTOR LOCATIONS 8.7..........................................................................1382 FLHX, FLHT/C/U..........................................................................................1382 FLHX, FLHT/C/U (Continued)..........................................................................1384 FLTR....................................................................................................1388 FLTR (Continued)....................................................................................1389 FLTR (Continued)....................................................................................1390 FLHR/C/S................................................................................................1391 FLHR/C/S (Continued)................................................................................1392 WIRING DIAGRAMS 8.8.........................................................................................1393 fe08_tc.pdf..................................................................................................... 0 WIRING 8....................................................................................................1353 fe07a.pdf....................................................................................................... 0 CRUISE CONTROL 7.1..........................................................................................1331 GENERAL.................................................................................................1331 SYSTEM OPERATION........................................................................................1331 TROUBLESHOOTING.........................................................................................1332 CRUISE INOPERATIVE DIAGNOSTICS 7.2..........................................................................1333 GENERAL.................................................................................................1333 INOPERATIVE DIAGNOSTICS.................................................................................1333 Diagnostic Notes....................................................................................1333 CRUISE DROPOUT DIAGNOSTICS 7.3..............................................................................1336 GENERAL.................................................................................................1336 DROPOUT DIAGNOSTICS.....................................................................................1336 CRUISE CHART A: INITIAL DIAGNOSTICS 7.4.....................................................................1339 DIAGNOSTICS.............................................................................................1339 Test 7.4 (Part 1 of 2)..............................................................................1339 Test 7.4 (Part 2 of 2)..............................................................................1340 CRUISE CHART B: RESUME SWITCH 7.5...........................................................................1341 DIAGNOSTICS.............................................................................................1341 Test 7.5............................................................................................1341 CRUISE CHART C: CRUISE ENGAGED LAMP 7.6.....................................................................1342 DIAGNOSTICS.............................................................................................1342 Test 7.6............................................................................................1342 CRUISE CHART D: CRUISE POWER 7.7............................................................................1343 DIAGNOSTICS.............................................................................................1343 Test 7.7............................................................................................1343 CRUISE CHART E: CRUISE ENABLE 7.8...........................................................................1345 DIAGNOSTICS.............................................................................................1345 Test 7.8............................................................................................1345 Diagnostic Notes....................................................................................1345 CRUISE CHART F-1: BRAKE LIGHTS ON 7.9.......................................................................1346 DIAGNOSTICS.............................................................................................1346 Test 7.9............................................................................................1346 CRUISE CHART F-2: BRAKE LIGHTS OFF 7.10.....................................................................1347 DIAGNOSTICS.............................................................................................1347 Test 7.10 (Part 1 of 2).............................................................................1347 Test 7.10 (Part 2 of 2).............................................................................1348 Diagnostic Notes....................................................................................1348 CRUISE CHART G: THROTTLE SWITCH 7.11........................................................................1349 DIAGNOSTICS.............................................................................................1349 Test 7.11...........................................................................................1349 CRUISE CHART H: SPEEDOMETER INPUT 7.12......................................................................1350 DIAGNOSTICS.............................................................................................1350 Diagnostic Notes....................................................................................1350 Test 7.12...........................................................................................1350 CRUISE CHART I: TACHOMETER INPUT 7.13.......................................................................1351 DIAGNOSTICS.............................................................................................1351 Test 7.13...........................................................................................1351 fe07_tc.pdf..................................................................................................... 0 CRUISE CONTROL 7............................................................................................1329 fe06a.pdf....................................................................................................... 0 RADIO DIAGNOSTICS 6.1.......................................................................................1221 SYSTEM DESCRIPTION......................................................................................1221 ONBOARD DIAGNOSTICS.....................................................................................1221 General.............................................................................................1221 Radio Diagnostic Display............................................................................1221 RADIO SWITCH DIAGNOSTICS: DTC B2006-B2015 6.2...............................................................1226 GENERAL.................................................................................................1226 DIAGNOSTICS.............................................................................................1226 Diagnostic Notes....................................................................................1226 Test 6.2a...........................................................................................1227 Test 6.2b (Part 1 of 3).............................................................................1228 Test 6.2b (Part 2 of 3).............................................................................1229 Test 6.2b (Part 3 of 3).............................................................................1230 Test 6.2c (Part 1 of 3).............................................................................1231 Test 6.2c (Part 2 of 3).............................................................................1232 Test 6.2c (Part 3 of 3).............................................................................1233 Test 6.2d (Part 1 of 3).............................................................................1234 Test 6.2d (Part 2 of 3).............................................................................1235 Test 6.2d (Part 3 of 3).............................................................................1236 Test 6.2e (Part 1 of 2).............................................................................1237 Test 6.2e (Part 2 of 2).............................................................................1238 Test 6.2f (Part 1 of 2).............................................................................1239 Test 6.2f (Part 2 of 2).............................................................................1240 Test 6.2g (Part 1 of 2).............................................................................1241 Test 6.2g (Part 2 of 2).............................................................................1242 Test 6.2h...........................................................................................1243 Test 6.2i...........................................................................................1244 Test 6.2j...........................................................................................1245 RADIO SPEAKER DIAGNOSTICS: DTC B2016-B2027 6.3..............................................................1246 GENERAL.................................................................................................1246 DIAGNOSTICS.............................................................................................1246 Diagnostic Notes....................................................................................1246 Test 6.3a...........................................................................................1247 Test 6.3b...........................................................................................1249 Test 6.3c...........................................................................................1250 Test 6.3d...........................................................................................1251 Test 6.3e...........................................................................................1252 Test 6.3f...........................................................................................1254 Test 6.3g...........................................................................................1255 Test 6.3h...........................................................................................1256 Test 6.3i...........................................................................................1257 Test 6.3j...........................................................................................1259 Test 6.3k...........................................................................................1260 Test 6.3l...........................................................................................1261 SERIAL DATA BUS DIAGNOSTICS 6.4.............................................................................1262 GENERAL.................................................................................................1262 LOSS OF SERIAL DATA: DTC U1016......................................................................1262 STARTS, THEN STALLS: DTC U1300, U1301...............................................................1262 DIAGNOSTICS.............................................................................................1262 Diagnostic Notes....................................................................................1262 Test 6.4a...........................................................................................1263 Test 6.4b...........................................................................................1266 Test 6.4c (Part 1 of 3).............................................................................1267 Test 6.4c (Part 2 of 3).............................................................................1269 Test 6.4c (Part 3 of 3).............................................................................1270 Test 6.4d...........................................................................................1271 Test 6.4e...........................................................................................1273 Test 6.4f...........................................................................................1275 Test 6.4g...........................................................................................1277 Test 6.4h...........................................................................................1278 ADVANCED AUDIO SYSTEM SYMPTOMS 6.5..........................................................................1280 GENERAL.................................................................................................1280 DIAGNOSTICS.............................................................................................1280 Diagnostic Notes....................................................................................1280 Test 6.5a...........................................................................................1281 Test 6.5b...........................................................................................1283 Test 6.5c...........................................................................................1284 Test 6.5d...........................................................................................1284 Test 6.5e...........................................................................................1285 Test 6.5f...........................................................................................1286 Test 6.5g (Part 1 of 4).............................................................................1287 Test 6.5g (Part 2 of 4).............................................................................1288 Test 6.5g (3 of 4)..................................................................................1289 Test 6.5g (4 of 4)..................................................................................1290 Test 6.5h (1 of 3)..................................................................................1291 Test 6.5h (2 of 3)..................................................................................1293 Test 6.5h (3 of 3)..................................................................................1294 Test 6.5i...........................................................................................1295 Test 6.5j (Part 1 of 2).............................................................................1296 Test 6.5j (Part 2 of 2).............................................................................1297 Test 6.5k...........................................................................................1299 Test 6.5l (1 of 5)..................................................................................1301 Test 6.5l (2 of 5)..................................................................................1302 Test 6.5l (3 of 5)..................................................................................1303 Test 6.5l (4 of 5)..................................................................................1304 Test 6.5l (5 of 5)..................................................................................1305 Test 6.5m (1 of 4)..................................................................................1307 Test 6.5m (2 of 4)..................................................................................1308 Test 6.5m (3 of 4)..................................................................................1309 Test 6.5m (4 of 4)..................................................................................1310 Test 6.5n (Part 1 of 2).............................................................................1312 Test 6.5n (Part 2 of 2).............................................................................1314 Test 6.5o (Part 1 of 2).............................................................................1315 Test 6.5o (Part 2 of 2).............................................................................1316 Test 6.5p...........................................................................................1318 Test 6.5q (Part 1 of 2).............................................................................1320 Test 6.5q (Part 2 of 2).............................................................................1322 Test 6.5r...........................................................................................1323 Test 6.5s...........................................................................................1324 Test 6.5t (Part 1 of 2).............................................................................1325 Test 6.5t (Part 2 of 2).............................................................................1326 Test 6.5u...........................................................................................1327 Test 6.5v...........................................................................................1328 fe06_tc.pdf..................................................................................................... 0 ADVANCED AUDIO SYSTEM 6.....................................................................................1219 fe05b.pdf....................................................................................................... 0 DTC P0107, P0108 5.19.......................................................................................1167 GENERAL.................................................................................................1167 MAP Sensor..........................................................................................1167 DIAGNOSTICS.............................................................................................1167 Diagnostic Tips.....................................................................................1167 Diagnostic Notes....................................................................................1167 Test 5.19 (Part 1 of 2).............................................................................1169 Test 5.19 (Part 2 of 2).............................................................................1170 DTC P0112, P0113 5.20.......................................................................................1171 GENERAL.................................................................................................1171 IAT Sensor..........................................................................................1171 DIAGNOSTICS.............................................................................................1171 Diagnostic Tips.....................................................................................1171 Diagnostic Notes....................................................................................1171 Test 5.20 (Part 1 of 2).............................................................................1173 Test 5.20 (Part 2 of 2).............................................................................1174 DTC P0117, P0118 5.21.......................................................................................1175 GENERAL.................................................................................................1175 ET Sensor...........................................................................................1175 DIAGNOSTICS.............................................................................................1175 Diagnostic Tips.....................................................................................1175 Diagnostic Notes....................................................................................1175 Test 5.21 (Part 1 of 2).............................................................................1177 Test 5.21 (Part 2 of 2).............................................................................1178 DTC P0122, P0123 5.22.......................................................................................1179 GENERAL.................................................................................................1179 TP Sensor...........................................................................................1179 DIAGNOSTICS.............................................................................................1179 Diagnostic Tips.....................................................................................1179 Diagnostic Notes....................................................................................1179 Test 5.22 (Part 1 of 2).............................................................................1181 Test 5.22 (Part 2 of 2).............................................................................1182 DTC P0261, P0262, P0263, P0264 5.23.........................................................................1183 GENERAL.................................................................................................1183 Fuel Injectors......................................................................................1183 DIAGNOSTICS.............................................................................................1183 Diagnostic Notes....................................................................................1183 Test 5.23 (Part 1 of 3).............................................................................1186 Test 5.23 (Part 2 of 3).............................................................................1187 Test 5.23 (Part 3 of 3).............................................................................1188 DTC P0373, P0374 5.24.......................................................................................1189 GENERAL.................................................................................................1189 CKP Sensor..........................................................................................1189 DIAGNOSTICS.............................................................................................1189 Diagnostic Tips.....................................................................................1189 Diagnostic Notes....................................................................................1189 Test 5.24...........................................................................................1191 DTC P0501, P0502 5.25.......................................................................................1192 GENERAL.................................................................................................1192 Vehicle Speed Sensor................................................................................1192 DIAGNOSTICS.............................................................................................1192 Diagnostic Notes....................................................................................1192 Test 5.25 (Part 1 of 2).............................................................................1194 Test 5.25 (Part 2 of 2).............................................................................1195 DTC P0562, P0563 5.26.......................................................................................1196 GENERAL.................................................................................................1196 Battery Voltage.....................................................................................1196 DIAGNOSTICS.............................................................................................1196 Diagnostic Tips.....................................................................................1196 Diagnostic Notes....................................................................................1196 Test 5.26 (Part 1 of 2).............................................................................1199 Test 5.26 (Part 2 of 2).............................................................................1200 DTC P0603, P0605 5.27.......................................................................................1201 GENERAL.................................................................................................1201 ECM Failure.........................................................................................1201 DIAGNOSTICS.............................................................................................1201 DTC P0603...........................................................................................1201 DTC P0605...........................................................................................1201 DTC P1009, P1010 5.28.......................................................................................1202 GENERAL.................................................................................................1202 Password Problem....................................................................................1202 DIAGNOSTICS.............................................................................................1202 Diagnostic Notes....................................................................................1202 Test 5.28...........................................................................................1205 DTC P1351, P1352, P1354, P1355 5.29.........................................................................1206 GENERAL.................................................................................................1206 Ignition Coil.......................................................................................1206 DIAGNOSTICS.............................................................................................1206 Diagnostic Notes....................................................................................1206 Test 5.29 (Part 1 of 2).............................................................................1209 Test 5.29 (Part 2 of 2).............................................................................1210 DTC U1064, U1255 5.30.......................................................................................1211 GENERAL.................................................................................................1211 Loss of TSM/TSSM Serial Data........................................................................1211 DIAGNOSTICS.............................................................................................1211 Diagnostic Notes....................................................................................1211 Test 5.30...........................................................................................1214 DTC U1097, U1255 5.31.......................................................................................1215 GENERAL.................................................................................................1215 Loss of Speedometer Serial Data.....................................................................1215 DIAGNOSTICS.............................................................................................1215 Diagnostic Notes....................................................................................1215 Test 5.31...........................................................................................1218 fe05a.pdf....................................................................................................... 0 SPECIFICATIONS 5.1..........................................................................................1099 EFI SYSTEM 5.2..............................................................................................1101 GENERAL.................................................................................................1101 EFI ENGINE HEAT MANAGEMENT..............................................................................1101 Injected Twin Cam High Temperature Idle.............................................................1101 Phase 1.............................................................................................1101 Phase 2.............................................................................................1101 Phase 3.............................................................................................1101 TROUBLESHOOTING.........................................................................................1101 EFI DIAGNOSTIC INTRODUCTION 5.3.............................................................................1103 SYSTEM PROBLEMS.........................................................................................1103 No Start............................................................................................1103 Poor Performance....................................................................................1103 Check Engine Lamp...................................................................................1103 RESOLVING PROBLEMS......................................................................................1103 CHECKING FOR DIAGNOSTIC TROUBLE CODES: EFI 5.4..............................................................1104 CHECK ENGINE LAMP.......................................................................................1104 CODE TYPES..............................................................................................1105 Current.............................................................................................1105 Historic............................................................................................1105 RETRIEVING DIAGNOSTIC TROUBLE CODES.....................................................................1105 MULTIPLE DIAGNOSTIC TROUBLE CODES.......................................................................1105 INITIAL DIAGNOSTIC CHECK: EFI 5.5...........................................................................1106 GENERAL.................................................................................................1106 Diagnostic Notes....................................................................................1106 Circuit Diagram/Wire Harness Connector Table........................................................1106 Reprogramming ECM...................................................................................1106 INITIAL DIAGNOSTICS.....................................................................................1106 General Information.................................................................................1106 Diagnostic Tips.....................................................................................1106 Diagnostic Notes....................................................................................1106 Other Codes.........................................................................................1106 Diagnostic Check (Part 1 of 2)......................................................................1113 Diagnostic Check (Part 2 of 2)......................................................................1114 SPEEDOMETER SELF DIAGNOSTICS 5.6............................................................................1115 GENERAL.................................................................................................1115 DIAGNOSTICS.............................................................................................1115 Diagnostic Tips.....................................................................................1115 Diagnostic Notes....................................................................................1115 Speedometer Self Diagnostics (chart)................................................................1116 BREAKOUT BOX: EFI 5.7.......................................................................................1117 GENERAL.................................................................................................1117 INSTALLATION............................................................................................1117 REMOVAL.................................................................................................1117 WIGGLE TEST 5.8.............................................................................................1118 GENERAL.................................................................................................1118 PROCEDURE...............................................................................................1118 INTAKE LEAK TEST 5.9........................................................................................1119 GENERAL.................................................................................................1119 LEAK TESTER.............................................................................................1119 Parts List..........................................................................................1119 Tester Assembly.....................................................................................1119 INTAKE LEAK TESTING.....................................................................................1120 ENGINE CRANKS, BUT WILL NOT START 5.10......................................................................1121 GENERAL.................................................................................................1121 DIAGNOSTICS.............................................................................................1121 Diagnostic Notes....................................................................................1121 Diagnostic Tips.....................................................................................1121 Test 5.10 (Part 1 of 4).............................................................................1124 Test 5.10 (Part 2 of 4).............................................................................1125 Test 5.10 (Part 3 of 4).............................................................................1126 Test 5.10 (Part 4 of 4).............................................................................1127 NO ECM POWER 5.11...........................................................................................1128 GENERAL.................................................................................................1128 No Spark/No Check Engine Lamp at Key ON.............................................................1128 DIAGNOSTICS.............................................................................................1128 Diagnostic Notes....................................................................................1128 Test 5.11 (Part 1 of 2).............................................................................1131 Test 5.11 (Part 2 of 2).............................................................................1132 STARTS, THEN STALLS 5.12....................................................................................1133 GENERAL.................................................................................................1133 Diagnostic Trouble Codes U1300, U1301 or “BUS Er”...................................................1133 DIAGNOSTICS.............................................................................................1133 Diagnostic Tips.....................................................................................1133 Diagnostic Notes....................................................................................1133 Test 5.12 (Part 1 of 2).............................................................................1136 Test 5.12 (Part 2 of 2).............................................................................1137 FUEL SYSTEM ELECTRICAL TEST 5.13............................................................................1138 GENERAL.................................................................................................1138 DIAGNOSTICS.............................................................................................1138 Diagnostic Notes....................................................................................1138 Test 5.13 (Part 1 of 4).............................................................................1140 Test 5.13 (Part 2 of 4).............................................................................1141 Test 5.13 (Part 3 of 4).............................................................................1142 Test 5.13 (Part 4 of 4).............................................................................1142 SYSTEM RELAY CHECK 5.14.....................................................................................1143 GENERAL.................................................................................................1143 System Relay........................................................................................1143 DIAGNOSTICS.............................................................................................1143 Diagnostic Notes....................................................................................1143 Test 5.14 (Part 1 of 3).............................................................................1146 Test 5.14 (Part 2 of 3).............................................................................1147 Test 5.14 (Part 3 of 3).............................................................................1147 FUEL PRESSURE TEST 5.15.....................................................................................1148 GENERAL.................................................................................................1148 TESTING.................................................................................................1148 DIAGNOSTICS.............................................................................................1150 Diagnostic Notes....................................................................................1150 Test 5.15...........................................................................................1151 IDLE AIR CONTROL, DTC P0505 5.16............................................................................1152 GENERAL.................................................................................................1152 IAC Operation.......................................................................................1152 Diagnostic Trouble Code P0505: Loss of Idle Speed Control...........................................1152 DIAGNOSTICS.............................................................................................1152 Diagnostic Tips.....................................................................................1152 Diagnostic Notes....................................................................................1153 Test 5.16 (Part 1 of 2).............................................................................1155 Test 5.16 (Part 2 of 2).............................................................................1156 MISFIRE AT IDLE OR UNDER LOAD 5.17..........................................................................1157 GENERAL.................................................................................................1157 Misfire at Idle or Under Load.......................................................................1157 DIAGNOSTICS.............................................................................................1157 Diagnostic Notes....................................................................................1157 Test 5.17 (Part 1 of 3).............................................................................1159 Test 5.17 (Part 2 of 3).............................................................................1160 Test 5.17 (Part 3 of 3).............................................................................1161 COMBUSTION ABSENT/INTERMITTENT 5.18.........................................................................1162 GENERAL.................................................................................................1162 Diagnostic Trouble Codes P1353, P1356, P1357, P1358: No Combustion..................................1162 DIAGNOSTICS.............................................................................................1162 Diagnostic Notes....................................................................................1162 Test 5.18 (Part 1 of 2).............................................................................1165 Test 5.18 (Part 2 of 2).............................................................................1166 fe05_tc.pdf..................................................................................................... 0 ENGINE MANAGEMENT (EFI) 5...................................................................................1097 fe04b.pdf....................................................................................................... 0 DTC P0106, P0107, P0108 4.13................................................................................1065 GENERAL.................................................................................................1065 MAP Sensor..........................................................................................1065 DIAGNOSTICS.............................................................................................1065 Diagnostic Tips.....................................................................................1065 Diagnostic Notes....................................................................................1065 Test 4.13 (Part 1 of 2).............................................................................1067 Test 4.13 (Part 2 of 2).............................................................................1068 DTC P0562, P0563 4.14.......................................................................................1069 GENERAL.................................................................................................1069 Battery Voltage.....................................................................................1069 DIAGNOSTICS.............................................................................................1069 Diagnostic Notes....................................................................................1069 Test 4.14 (Part 1 of 2).............................................................................1071 Test 4.14 (Part 2 of 2).............................................................................1072 DTC P1009, P1010 4.15.......................................................................................1073 GENERAL.................................................................................................1073 Password Problem....................................................................................1073 DIAGNOSTICS.............................................................................................1073 Diagnostic Notes....................................................................................1073 Test 4.15...........................................................................................1076 DTC P1351, P1352, P1354, P1355 4.16.........................................................................1077 GENERAL.................................................................................................1077 Ignition Coil.......................................................................................1077 DIAGNOSTICS.............................................................................................1077 Diagnostic Notes....................................................................................1077 Test 4.16 (Part 1 of 2).............................................................................1079 Test 4.16 (Part 2 of 2).............................................................................1080 DTC P0371, P0372, P0374 4.17................................................................................1081 GENERAL.................................................................................................1081 Crank Position Sensor...............................................................................1081 DIAGNOSTICS.............................................................................................1081 Diagnostic Notes....................................................................................1081 Test 4.17...........................................................................................1083 DTC P0501, P0502 4.18.......................................................................................1084 GENERAL.................................................................................................1084 Vehicle Speed Sensor................................................................................1084 DIAGNOSTICS.............................................................................................1084 Diagnostic Notes....................................................................................1084 Test 4.18 (Part 1 of 2).............................................................................1086 Test 4.18 (Part 2 of 2).............................................................................1087 DTC P0602, P0603, P0604, P0605, P0607 4.19..................................................................1088 GENERAL.................................................................................................1088 ICM Failure.........................................................................................1088 DIAGNOSTICS.............................................................................................1088 DTC P0607 Test......................................................................................1088 DTC P0602, P0603, P0604, P0605 Test.................................................................1088 DTC U1064 4.20..............................................................................................1089 GENERAL.................................................................................................1089 Loss of TSM/TSSM Serial Data........................................................................1089 DIAGNOSTICS.............................................................................................1089 Diagnostic Notes....................................................................................1089 Test 4.20...........................................................................................1092 DTC U1097 4.21..............................................................................................1093 GENERAL.................................................................................................1093 Loss of Speedometer Serial Data.....................................................................1093 DIAGNOSTICS.............................................................................................1093 Diagnostic Notes....................................................................................1093 Test 4.21...........................................................................................1096 fe04a.pdf....................................................................................................... 0 SPECIFICATIONS 4.1..........................................................................................1033 DIAGNOSTIC INTRODUCTION 4.2.................................................................................1034 SYSTEM PROBLEMS.........................................................................................1034 No Start............................................................................................1034 Poor Performance....................................................................................1034 Check Engine Lamp...................................................................................1034 RESOLVING PROBLEMS......................................................................................1034 CHECKING FOR TROUBLE CODES 4.3..............................................................................1035 CHECK ENGINE LAMP.......................................................................................1035 CODE TYPES..............................................................................................1036 Current.............................................................................................1036 Historic............................................................................................1036 RETRIEVING DIAGNOSTIC TROUBLE CODES.....................................................................1036 MULTIPLE DIAGNOSTIC TROUBLE CODES.......................................................................1036 INITIAL DIAGNOSTIC CHECK: ICM 4.4...........................................................................1037 GENERAL.................................................................................................1037 Diagnostic Notes....................................................................................1037 Circuit Diagram/Wire Harness Connector Table........................................................1037 Reprogramming ICM...................................................................................1037 INITIAL DIAGNOSTICS.....................................................................................1037 General Information.................................................................................1037 Diagnostic Tips.....................................................................................1037 Diagnostic Notes....................................................................................1037 Initial Diagnostic Check (Part 1 of 2)..............................................................1042 Initial Diagnostic Check (Part 2 of 2)..............................................................1043 SPEEDOMETER SELF DIAGNOSTICS 4.5............................................................................1044 GENERAL.................................................................................................1044 DIAGNOSTICS.............................................................................................1044 Diagnostic Tips.....................................................................................1044 Diagnostic Notes....................................................................................1044 Speedometer Self Diagnostics (chart)................................................................1045 BREAKOUT BOX: ICM 4.6.......................................................................................1046 GENERAL.................................................................................................1046 INSTALLATION............................................................................................1046 REMOVAL.................................................................................................1046 WIGGLE TEST 4.7.............................................................................................1047 GENERAL.................................................................................................1047 PROCEDURE...............................................................................................1047 INTAKE LEAK TEST 4.8........................................................................................1048 GENERAL.................................................................................................1048 LEAK TESTER.............................................................................................1048 Parts List..........................................................................................1048 Tester Assembly.....................................................................................1048 INTAKE LEAK TESTING.....................................................................................1049 ENGINE CRANKS, BUT WILL NOT START 4.9.......................................................................1050 GENERAL.................................................................................................1050 DIAGNOSTICS.............................................................................................1050 Diagnostic Notes....................................................................................1050 Test 4.9 (Part 1 of 3)..............................................................................1052 Test 4.9 (Part 2 of 3)..............................................................................1053 Test 4.9 (Part 3 of 3)..............................................................................1054 STARTS, THEN STALLS 4.10....................................................................................1055 GENERAL.................................................................................................1055 Diagnostic Trouble Codes U1300, U1301, P1009, P1010 or “BUS Er”.....................................1055 DIAGNOSTICS.............................................................................................1055 Diagnostic Tips.....................................................................................1055 Diagnostic Notes....................................................................................1055 Test 4.10 (Part 1 of 2).............................................................................1058 Test 4.10 (Part 2 of 2).............................................................................1059 NO SPARK/NO ICM POWER 4.11..................................................................................1060 GENERAL.................................................................................................1060 DIAGNOSTICS.............................................................................................1060 Diagnostic Notes....................................................................................1060 Test 4.11...........................................................................................1061 MISFIRE 4.12................................................................................................1062 GENERAL.................................................................................................1062 Misfire at Idle or Under Load.......................................................................1062 DIAGNOSTICS.............................................................................................1062 Diagnostic Notes....................................................................................1062 Test 4.12...........................................................................................1064 fe04_tc.pdf..................................................................................................... 0 ENGINE MANAGEMENT (CARB) 4..................................................................................1031 fe03b.pdf....................................................................................................... 0 KEY FOB SIGNAL TO TSSM WEAK OR FAILS 3.14................................................................... 989 GENERAL................................................................................................. 989 Security Equipped Vehicles Only..................................................................... 989 Job/Time Code Values................................................................................ 989 DIAGNOSTICS............................................................................................. 989 Diagnostic Tips..................................................................................... 989 Diagnostic Notes.................................................................................... 989 Test 3.14........................................................................................... 991 TURN SIGNAL ERRORS 3.15..................................................................................... 992 GENERAL................................................................................................. 992 Job/Time Code Values................................................................................ 992 DIAGNOSTICS............................................................................................. 992 Diagnostic Tips..................................................................................... 992 Diagnostic Notes: All Turn Signal Flow Charts....................................................... 995 Turn Signal Error 1A (Part 1 of 2).................................................................. 996 Turn Signal Error 1A (Part 2 of 2).................................................................. 997 Turn Signal Error 2A................................................................................ 998 Turn Signal Error 2B................................................................................ 999 Turn Signal Error 2C................................................................................1000 Turn Signal Error 2D................................................................................1001 Turn Signal Error 3A................................................................................1002 DTC B0563 3.16..............................................................................................1003 GENERAL.................................................................................................1003 Battery Voltage High................................................................................1003 DIAGNOSTICS.............................................................................................1003 Diagnostic Tips.....................................................................................1003 Diagnostic Notes....................................................................................1003 DTC B1131, B1132 3.17.......................................................................................1004 GENERAL.................................................................................................1004 Alarm Output Low (DTC B1131) or Alarm Output High (DTC B1132).......................................1004 DIAGNOSTICS.............................................................................................1004 Diagnostic Tips.....................................................................................1004 Diagnostic Notes....................................................................................1004 Test 3.17...........................................................................................1006 DTC B1134 3.18..............................................................................................1007 GENERAL.................................................................................................1007 Starter Output High.................................................................................1007 DIAGNOSTICS.............................................................................................1007 Diagnostic Notes....................................................................................1007 Test 3.18...........................................................................................1009 DTC B1135 3.19..............................................................................................1010 GENERAL.................................................................................................1010 Accelerometer Fault.................................................................................1010 DTC B1151, B1152, B1153 3.20................................................................................1011 GENERAL.................................................................................................1011 Sidecar BAS Low (DTC B1151), High (DTC B1152) or Out of Range (DTC B1153)...........................1011 DIAGNOSTICS.............................................................................................1011 Diagnostic Tips.....................................................................................1011 Diagnostic Notes....................................................................................1011 Test 3.20...........................................................................................1013 DTC U1016, U1255 3.21.......................................................................................1014 GENERAL.................................................................................................1014 Loss of ICM/ECM Serial Data.........................................................................1014 DIAGNOSTICS.............................................................................................1014 Diagnostic Notes....................................................................................1014 Test 3.21...........................................................................................1019 DTC U1097, U1255 3.22.......................................................................................1020 GENERAL.................................................................................................1020 Loss of Speedometer Serial Data.....................................................................1020 DIAGNOSTICS.............................................................................................1020 Diagnostic Notes....................................................................................1020 Test 3.22...........................................................................................1025 DTC U1300, U1301 or “BUS ER” 3.23...........................................................................1026 GENERAL.................................................................................................1026 Serial Data Low or Serial data Open/High............................................................1026 DIAGNOSTICS.............................................................................................1026 Diagnostic Tips.....................................................................................1026 PASSWORD LEARN 3.24.........................................................................................1027 GENERAL.................................................................................................1027 PASSWORD LEARNING.......................................................................................1027 TSSM MAINTENANCE 3.25.......................................................................................1029 GENERAL.................................................................................................1029 KEY FOB.................................................................................................1029 Schedule............................................................................................1029 Battery Replacement.................................................................................1029 SIREN (IF INSTALLED)....................................................................................1030 Schedule............................................................................................1030 Battery Replacement.................................................................................1030 fe03a.pdf....................................................................................................... 0 TSM/TSSM OVERVIEW 3.1....................................................................................... 947 GENERAL................................................................................................. 947 TROUBLESHOOTING......................................................................................... 947 TSM/TSSM FEATURES 3.2....................................................................................... 949 GENERAL................................................................................................. 949 TURN SIGNAL FUNCTIONS................................................................................... 949 TSM/TSSM Features................................................................................... 949 BANK ANGLE FUNCTIONS.................................................................................... 949 TSM/TSSM Features................................................................................... 949 SECURITY ALARM AND IMMOBILIZATION FUNCTIONS............................................................. 949 TSSM Only Feature................................................................................... 949 TSM/TSSM VEHICLE DELIVERY 3.3............................................................................... 951 GENERAL................................................................................................. 951 SIDECAR CONFIGURATION................................................................................... 951 POWER DISRUPTION AND CONFIGURING........................................................................ 951 KEY FOB ASSIGNMENT...................................................................................... 952 PERSONAL CODE ENTRY..................................................................................... 952 First Time Code Entry: TSSM Only.................................................................... 952 Modifying Existing Codes: TSSM Only................................................................. 952 TSM/TSSM TURN SIGNAL FUNCTIONS 3.4.......................................................................... 956 GENERAL................................................................................................. 956 AUTOMATIC CANCELLATION.................................................................................. 956 MANUAL CANCELLATION..................................................................................... 956 FOUR-WAY FLASHING....................................................................................... 957 DIAGNOSTICS MODE........................................................................................ 957 TSM/TSSM BANK ANGLE FUNCTION 3.5............................................................................ 958 GENERAL................................................................................................. 958 OPERATION............................................................................................... 958 SECURITY SYSTEM (TSSM) FUNCTIONS 3.6........................................................................ 959 GENERAL................................................................................................. 959 Security System Operation........................................................................... 959 Security System Options............................................................................. 959 Differences By Market Specifications................................................................ 959 ALARM SENSITIVITY....................................................................................... 959 Sensitivity......................................................................................... 959 Transport Mode...................................................................................... 959 AUTO-ARMING FUNCTION.................................................................................... 960 STORAGE MODE............................................................................................ 960 ARMING/DISARMING SECURITY SYSTEM (TSSM) 3.7................................................................. 963 GENERAL................................................................................................. 963 SECURITY LAMP........................................................................................... 963 USING KEY FOB........................................................................................... 963 General............................................................................................. 963 Arming the System................................................................................... 963 Disarming the System................................................................................ 963 Troubleshooting..................................................................................... 963 USING THE PERSONAL CODE................................................................................. 964 General............................................................................................. 964 Disarming the System................................................................................ 964 CHECKING FOR DIAGNOSTIC TROUBLE CODES 3.8................................................................... 965 TSM..................................................................................................... 965 TSSM.................................................................................................... 965 CODE TYPES.............................................................................................. 967 Current............................................................................................. 967 Historic............................................................................................ 967 RETRIEVING DIAGNOSTIC TROUBLE CODES..................................................................... 967 MULTIPLE DIAGNOSTIC TROUBLE CODES....................................................................... 967 INITIAL DIAGNOSTIC CHECK: TSM/TSSM 3.9...................................................................... 968 GENERAL................................................................................................. 968 Diagnostic Notes.................................................................................... 968 Circuit Diagram/Wire Harness Connector Table........................................................ 968 Job/Time Code Values................................................................................ 968 Reprogramming ICM/ECM............................................................................... 968 INITIAL DIAGNOSTICS..................................................................................... 968 Diagnostic Tips..................................................................................... 968 Diagnostic Notes.................................................................................... 968 Other Diagnostic Trouble Codes (DTC’s).............................................................. 968 Initial Diagnostic Check (Part 1 of 3).............................................................. 974 Initial Diagnostic Check (Part 2 of 3).............................................................. 975 Diagnostic Check (Part 3 of 3)...................................................................... 976 SPEEDOMETER SELF DIAGNOSTICS 3.10........................................................................... 977 GENERAL................................................................................................. 977 DIAGNOSTICS............................................................................................. 977 Diagnostic Tips..................................................................................... 977 Diagnostic Notes.................................................................................... 977 Speedometer Self Diagnostics (chart)................................................................ 978 BREAKOUT BOX: TSM/TSSM 3.11................................................................................. 979 GENERAL................................................................................................. 979 INSTALLATION............................................................................................ 979 REMOVAL................................................................................................. 979 NO SECURITY LAMP AT KEY ON 3.12............................................................................. 980 GENERAL................................................................................................. 980 No TSSM Power (Security Equipped Vehicles Only)..................................................... 980 Job/Time Code Values................................................................................ 980 DIAGNOSTICS............................................................................................. 980 Diagnostic Tips..................................................................................... 980 Diagnostic Notes.................................................................................... 980 Test 3.12 (Part 1 of 3)............................................................................. 982 Test 3.12 (Part 2 of 3)............................................................................. 983 Test 3.12 (Part 3 of 3)............................................................................. 984 SECURITY LAMP ON CONTINUOUSLY 3.13.......................................................................... 985 GENERAL................................................................................................. 985 Job/Time Code Values................................................................................ 985 DIAGNOSTICS............................................................................................. 985 Diagnostic Notes.................................................................................... 985 Test 3.13........................................................................................... 987 fe03_tc.pdf..................................................................................................... 0 TSM/TSSM 3.................................................................................................. 945 fe02a.pdf....................................................................................................... 0 CHECKING FOR DIAGNOSTIC TROUBLE CODES 2.1................................................................... 897 CHECK ENGINE LAMP....................................................................................... 897 SECURITY LAMP........................................................................................... 898 CODE TYPES.............................................................................................. 899 Current............................................................................................. 899 Historic............................................................................................ 899 RETRIEVING DIAGNOSTIC TROUBLE CODES..................................................................... 899 MULTIPLE DIAGNOSTIC TROUBLE CODES....................................................................... 899 INITIAL DIAGNOSTIC CHECK: SPEEDOMETER 2.2................................................................... 900 GENERAL................................................................................................. 900 Diagnostic Notes.................................................................................... 900 Circuit Diagram/Wire Harness Connector Table........................................................ 900 INITIAL DIAGNOSTICS..................................................................................... 901 Diagnostic Tips..................................................................................... 901 Diagnostic Notes.................................................................................... 901 Other Codes......................................................................................... 901 Diagnostic Check (Part 1 of 2)...................................................................... 907 Diagnostic Check (Part 2 of 2)...................................................................... 908 SPEEDOMETER SELF DIAGNOSTICS 2.3............................................................................ 909 GENERAL................................................................................................. 909 DIAGNOSTICS............................................................................................. 909 Diagnostic Tips..................................................................................... 909 Diagnostic Notes.................................................................................... 909 Speedometer Self Diagnostics (chart)................................................................ 910 SPEEDOMETER/TACHOMETER 2.4.................................................................................. 911 GENERAL................................................................................................. 911 Reset Switch........................................................................................ 911 SPEEDOMETER THEORY OF OPERATION......................................................................... 912 Job/Time Code Values................................................................................ 912 TACHOMETER THEORY OF OPERATION.......................................................................... 912 DIAGNOSTICS............................................................................................. 912 Diagnostic Notes.................................................................................... 912 Test 2.4 (Part 1 of 2).............................................................................. 913 Test 2.4 (Part 2 of 2).............................................................................. 914 BREAKOUT BOX: SPEEDOMETER 2.5............................................................................... 915 GENERAL................................................................................................. 915 INSTALLATION............................................................................................ 915 REMOVAL................................................................................................. 915 FUEL GAUGE 2.6.............................................................................................. 916 THEORY OF OPERATION..................................................................................... 916 FUEL GAUGE AND SENDER TEST.............................................................................. 916 OIL, AIR AND VOLTMETER GAUGES 2.7........................................................................... 917 Oil Pressure Gauge and Indicator Light.................................................................. 917 Problem............................................................................................. 917 Ambient Air Temperature Gauge........................................................................... 918 Problem............................................................................................. 918 Voltmeter Gauge......................................................................................... 918 Problem............................................................................................. 918 INDICATOR LAMPS: FLHX, FLHT/C/U, FLTR 2.8................................................................... 919 GENERAL................................................................................................. 919 Job/Time Code Values................................................................................ 919 DIAGNOSTICS............................................................................................. 920 Oil Pressure or Neutral Indicator Will Not Function................................................. 920 High Beam or R/L Turn Signal Indicator Will Not Function............................................ 920 INDICATOR LAMPS: FLHR/C/S 2.9............................................................................... 921 GENERAL................................................................................................. 921 Job/Time Code Values................................................................................ 921 DIAGNOSTICS............................................................................................. 922 Oil Pressure or Neutral Indicator Will Not Function................................................. 922 High Beam or R/L Turn Signal Indicator Will Not Function............................................ 922 DTC B1004, B1005 2.10....................................................................................... 923 GENERAL................................................................................................. 923 DIAGNOSTICS............................................................................................. 923 Diagnostic Tips..................................................................................... 923 Diagnostic Notes.................................................................................... 923 Test 2.10: DTC B1004................................................................................ 925 Test 2.10: DTC B1005................................................................................ 926 DTC B1006, B1007 2.11....................................................................................... 927 GENERAL................................................................................................. 927 Accessory Or Ignition Line Overvoltage.............................................................. 927 Test 2.11........................................................................................... 928 DTC B1008 2.12.............................................................................................. 929 GENERAL................................................................................................. 929 Reset Switch Closed................................................................................. 929 DIAGNOSTICS............................................................................................. 929 Diagnostic Notes.................................................................................... 929 Test 2.12........................................................................................... 931 DTC U1016 2.13.............................................................................................. 932 GENERAL................................................................................................. 932 Loss of ICM/ECM Serial Data......................................................................... 932 DIAGNOSTICS............................................................................................. 932 Diagnostic Notes.................................................................................... 932 Test 2.13........................................................................................... 937 DTC U1064, U1255 2.14....................................................................................... 938 GENERAL................................................................................................. 938 Loss of TSM/TSSM Serial Data........................................................................ 938 DIAGNOSTICS............................................................................................. 938 Diagnostic Notes.................................................................................... 938 Test 2.14........................................................................................... 943 DTC U1300, U1301 or “BUS ER” 2.15........................................................................... 944 GENERAL................................................................................................. 944 Serial Data Low or Serial Data Open/High............................................................ 944 DIAGNOSTICS............................................................................................. 944 Diagnostic Tips..................................................................................... 944 fe02_tc.pdf..................................................................................................... 0 INSTRUMENTS 2............................................................................................... 895 fe01a.pdf....................................................................................................... 0 STARTER TROUBLESHOOTING 1.1................................................................................. 873 Table 1-1. Starter Does Not Run or Runs At Very Low Speeds.............................................. 873 Table 1-2. Pinion Does Not Engage With Ring Gear While Starter is Cranked or Engine Cannot Be Cra....... 874 Table 1-3. Starter Does Not Stop Running................................................................ 874 STARTING SYSTEM DIAGNOSIS 1.2............................................................................... 875 Diagnostic Notes........................................................................................ 875 Job/Time Code Values.................................................................................... 875 Starter Testing 1....................................................................................... 875 Starter Testing 2: Solenoid Clicks...................................................................... 876 Starter Testing 3: Relay Clicks......................................................................... 876 Starter Testing 4: Nothing Clicks....................................................................... 877 Starter Testing 5: Starter Spins, But Does Not Engage................................................... 878 Starter Testing 6: Starter Stalls or Spins Too Slowly................................................... 878 STARTER ACTIVATION CIRCUITS 1.3............................................................................. 879 DIAGNOSTICS/TROUBLESHOOTING 1.4............................................................................. 880 STARTER SYSTEM TESTING 1.5.................................................................................. 881 TESTING ASSEMBLED STARTER 1.6............................................................................... 883 CHARGING SYSTEM 1.7......................................................................................... 885 Alternator.............................................................................................. 885 Voltage Regulator....................................................................................... 885 Battery................................................................................................. 885 Wiring.................................................................................................. 886 Voltage Regulator Inspection............................................................................ 886 Job/Time Code Values.................................................................................... 886 Test 1.7 (Part 1 of 2).................................................................................. 887 Test 1.7 (Part 2 of 2).................................................................................. 888 MILLIAMP DRAW TEST...................................................................................... 889 Table 1-4. Milliampere Draw Test (Ignition Switch OFF).................................................. 889 TOTAL CURRENT DRAW TEST................................................................................. 889 CURRENT OUTPUT TEST..................................................................................... 890 VOLTAGE OUTPUT TEST..................................................................................... 890 STATOR CHECK............................................................................................ 890 AC OUTPUT CHECK......................................................................................... 891 BATTERY TESTING 1.8......................................................................................... 892 Table 1-5. Voltmeter Test............................................................................... 892 Table 1-6. Battery Load Test............................................................................ 893 fe01_tc.pdf..................................................................................................... 0 STARTING/CHARGING 1......................................................................................... 871
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