2007 Harley-Davidson Softail Service Manual – PDF DOWNLOAD
DESCRIPTION:
2007 Harley-Davidson Softail Service Manual – PDF DOWNLOAD
FOREWORD
GENERAL
This Service Manual has been prepared with two purposes in mind. First, it will acquaint the user with the construction of the Harley-Davidson product and assist in the performance of basic maintenance and repair. Secondly, it will introduce to the professional Harley-Davidson Technician the latest fieldtested and factory-approved major repair methods. We sincerely believe that this Service Manual will make your association with Harley-Davidson products more pleasant and profitable.
HOWTO USE
YOUR SERVICE MANUAL
Information is arranged as follows:
• Section 1-Maintenance
• Section 2-Ghassis
• Section 3-Engine
• Section 4-Fuel System
• Section 5-Electric Starter
• Section 6-Drive
• Section 7-Transmission
• Section 8-Electrical
• Appendix A-Tools
• Appendix B-Wiring
• Appendix G-Metric Conversions
• Appendix D-Glossary
Use the TABLE OF CONTENTS following this FOREWORD or the INDEX at the back of the book to find the desired subject. Note that each manual section contains sequentially numbered topics. The numbering system allows quick cross references throughout the document.
TABLE OF CONTENTS:
2007 Harley-Davidson Softail Service Manual – PDF DOWNLOAD
SECTION 1-MAINTENANCE
1 1 General
Servicing a New Motorcycle
Safe Operating Maintenance
Shop Practices
Repair Notes
Safety
Removing Parts
Cleaning
Disassembly and Assembly
Repair and Replacement Procedures
Hardware and Threaded Parts
Thread locking Agents
Wiring, Hoses and Lines
Instruments and Gauges
Bearings
Bushings
Exhaust System Leakage
Gaskets
Lip Type Seals
O-Rings (Preformed Packings)
Gears
Shafts
Part Replacement
Cleaning
Part Protectio n
Cleaning Process
Rust or Corrosion Removal
Tool Safety
Air Tools
Wrenches
Pliers/Cutters/Prybars
Hammers
Punches/Chisels
Screwdrivers
Ratchets and Handles
Sockets
Storage Units
1 2 Fuel and Oil
Fuel
Gasoline Blends
Engine Oil
Winter Lubrication
1 3 Maintenance Schedule
First Schedu led Maintenance
1 4 Engine Oil and Filter
Checking and Adding Oil
Type of Oil
Checking Oil Level
Recommended Oil Grades (table)
Changing Oil and Filter
1 5 Battery Maintenance
General
Battery Electro lyte Antidotes (table)
Disconnection and Removal
Installation and Connection
Inspection
Storage
1 6 Brakes
Fluid Inspection
Rear Brake Pedal
Pedal Height
Pedal Lubrication
Pedal Pad
1 7 Bleeding Brakes
General
Procedure
1 8 Brake Pads and Discs
Inspection
Brake Pads
Brake Disc Thickness
Brake Disc Lateral Runout and Warpage :
Brake Pad Replaceme nt
Rear Brake Caliper
Front Brake Caliper: All But FLSTSC
1 9 Tires and Wheels
Tires
Tire Pressures (table)
Tire Replacement
Wheel Bearings
Wheel Spokes
1 10 Primary Chain
General
1 11 Primary Chaincase Lubricant
Changing Lubricant
1 12 CIutch
Adjustment
1 13 Transmission Lubricant
Changing Lubricant
1 14 Rear Belt Deflection
Inspection
Rear Belt Deflection (Table)
Adjustment
1 15 Rear Belt and Sprockets
General
Cleaning
Inspection
Sprockets
Rear Belt
Drive Belt Wear Analysis (table)
1 16 Suspension Adjustments 1-35
Rear Shock Preload 1-35
iii
Page No Page No
1 26 Headlamp Alignment 1-50
Inspection 1-50
Adjustment 1-51
FLSTSC Models 1-51
FLSTC/FLSTF/FLSTN/FXST/FXSTB/FXSTC Models 1-51
FXSTD Models 1-51
1 17 Steering Head Bearings: All But
FLSTSC
Adjustment
Bearing Adjustment (Fall-away)
Lubrication
1 18 Steering Head Bearings:
FLSTSC
General
Lubrication
Adjustment
Adjustment
1 19 Rocker Bearings: FLSTSC
Inspection
1 20 Front Fork Oil
Replacing Fork Oil
1 21 Spark Plugs
Inspection
1 22 Air Cleaner Filter
Removal
Installation
1 23 Cable and Chassis Lubrication
General
Cables and Hand Levers
Jiffy Stand
1 24 Throttle Cables
Cable Inspection, Lubrication and Adjustment
Inspection and Lubrication
Adjustment
1 25 Engine Mounts
Inspection
1 27 Critical Fasteners
Inspection
Critical Fasteners (table)
1 28 Storage
General
Removal From Storage
1 29 Troubleshooting
General
Engine
Starter Motor Does Not Operate or Does Not
Turn Engine Over
Engine Turns Over But Does Not Start
Starts Hard
Starts But Runs Irregularly or Misses
A Spark Plug Fouls Repeatedly
Pre-Ignition or Detonation (Knocks or Pings)
Overheating
Valve Train Noise
Excessive Vibration
Check Engine Light Illuminates During Operation
Lubrication System
Oil Does Not Return To Oil Tank
Engine Uses Too Much Oil Or Smokes Excessively
Engine Leaks Oil From Cases, Push Rods, Hoses
Low Oil Pressure
High Oil Pressure
Electrical System
Alternator Does Not Charge
Alternator Charge Rate Is Below Normal
Speedometer Operates Erratically
Transmission
Shifts Hard –
Jumps Out Of Gear
Clutch Slips
Clutch Drags Or Does Not Release
Clutch Chatters
Handling
Irregularities
Brakes
Brake Does Not Hold Normally
SECTION 2-CHASSIS
2 1 Specifications
Tires
Tire Fitment, Tubeless Cast Wheels (table)
Tire Fitment, Laced Wheels (table)
Tire Pressure, All Models (table)
2 2 Torque Values
2 3 Vehicle Identification
Number (V I N )
General
2 4 Front Wheel: All But
FLSTSCIFXSTD
Removal
Disassembly
Disc Wheel
Laced Wheel
Cleaning and Inspection
Assembly
Disc Wheel
Laced Wheel
Installation
2 14 Vehicle Alignment 2-36
Inspection 2-36
2 5 Front Wheel: FXSTD
Removal
Disassembly
Cleaning and Inspection
Assembly
Installation
2 6 Front Wheel: FLSTSC
Removal
Disassembly
Cleaning and Inspection
Assembly
Installation
2 7 Rear Wheel
Removal
Disassembly
Cleaning and Inspection
Assembly
Installat ion
2 8 Sealed Wheel Bearings
Inspection
Removal
Installation
2 9 Wheel Lacing: 16 In Rim
General
Procedure
2 10 Wheel Lacing: 21 In Rim
Procedure
2 11 Truing Laced Wheel
General
Lateral Truing
Wheel Offset Dimensio ns (table)
Radial Truing
2 12 Disc Rim Runout
General
Lateral Runout
Radial Runout
2 13 Tires
General
Removal
Cleaning, Inspection and Repair
Installation
Tube Type Tires
Tubeless Tires
2 16 Rear Brake Master
Cylinder/Reservoir
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
2 17 Front Brake Caliper:
All But FLSTSC
Removal
Disassembly
Cleaning , Inspection and Repair
Assembly
Installation
2 18 Front Brake Caliper: FLSTSC
Front Brake Caliper
Removal
Disassembly
Cleaning and Inspection
Assembly
Installation
Brake Reaction Link
Removal
Installation
2 19 Rear Brake Caliper: All But
FXSTIFXSTBIFXSTCIFLSTF
Removal :
Disassembly
Cleaning, Inspection and Repair
Assembly
Installation
2 20 Rear Brake Caliper:
FXSTIFXSTBIFXSTCIFLSTF
Removal ·
Disassembly
Cleaning , Inspection and Repair
Assembly
Installation
2 21 Front Forks: All But FLSTSC
General
Removal
Disassembly
Cleaning and Inspection
Assembly
Installation
2 15 Front Brake Master Cylinder 2-37
General 2-37
Removal/Disassembly 2-37
Cleaning and Inspection 2-38
Assembly/Installation 2-40
v
Page No Page No
2 22 Springer Fork: FLSTSC
General
Handlebar and Risers
Removal
Installation
Front Shock Absorber
Removal
Installation
Rigid Fork
Removal
Installation
Spring Fork
Disassembly
Assembly
Fork Rockers
Removal
Installation
Fork Stem Bearings
Removaillnstallation
2 23 Steering Head
Removal
FLSTC, FLSTF, FLSTN Models
FXSTD, FXST, FXSTC, FXSTB Models
FLSTSC Models
Cleaning and Inspection
All Models
Disassembly
Removing Lower Bearings From Fork Stem
Steering Head Bearing Race Removal
Assembly
Installation
FLSTC, FLSTF, FLSTN Models
FXSTD, FXST, FXSTC, FXSTB Models
FLSTSC Models
2 24 Rear Fork
Removal
Cleaning and Inspection
Installation
2 25 Rear Shock Absorbers
General
Removal
Installation
2 26 Throttle ControL
RemovallDisassembly
Cleaning and Inspection
Assembly/Installation
Cable Routing
All Models Except FLSTSC/FXSTD
FLSTSC Models
FXSTD Models
2 27 Handlebars: All but
FLSTFIFLSTSC
Removal
FXSTD
Installation
FXSTD
2 28 Handlebars: FLSTF 2-99
Removal 2-99
Installation 2-100
FXSTD 2-102
2 29 Clutch Hand Control 2-102
Removal 2-102
Installation ; 2-102
2 30 Front Fender: All But FLSTSC 2-103
FXST, FXSTB, FXSTC Models 2-103
Removal 2-103
Installation 2-103
FLSTC, FLSTN Models 2·103
Removal 2-103
Installation 2-103
FLSTF Models 2-104
Removal 2-104
Installation 2-104
FXSTD Models 2-104
Removal 2-104
Installation 2-104
2 31 Front Fender: FLSTSC 2-105
Removal 2-105
Front Fender 2-105
Front Fender Bearing Replacement 2-105
Installation 2-106
2 32 Rear Fender: FLSTC 2-107
Removal 2-107
Installation 2-108
2 33 Rear Fender: FLSTF 2-109
Removal 2-109
Installation 2-110
2 34 Rear Fender:
FXSTIFXSTBIFXSTC 2-111
Removal 2-111
Installation 2-112
2 35 Rear Fender: FXSTD 2-113
Removal 2-113
Disassembly 2-113
Assembly 2-114
Installation 2-114
2 36 Rear Fender: FLSTSC 2-115
Removal 2-115
Disassembly 2-115
Assembly 2-116
Installation 2-116
2 37 Rear Fender: FLSTN 2-117
Removal 2-117
Disassembly 2-117
Assembly 2-119
Installation 2-119
2 38 Rear Fender Wire Conduit:
All But FXSTD 2-120
Installation 2-120
Page No Page No
2 42 SeaVStrap Retention NuL 2-126
Replacement 2-126
2 41 Fork Lock 2-125
Removal 2-125
Installation 2-125
2 40 Jiffy Stand 2-123
Cleaning 2-123
Removal 2-124
Installation 2-124
2 39 Belt Guard/Debris Deflector
Removal
Belt Guard
Debris Deflector
Installation
Belt Guard
Debris Deflector
3 5 Oil Pump Operation
General
Operation
3 6 Breather Operation
General
3 7 Oil Pressure
Oil Pressure Indicator Lamp
Checking Oil Pressure
3 8 How To Use This Section
Top End Repair
Bottom End Repair
Typical Symptoms
3 9 Top End Service
Engine In Chassis
Engine Removed From Chassis
2 43 Seat: FXSTIFXSTB 2-127
Removal/Installation 2-127
Seat Strap 2-127
Seat 2-127
3 10 Bottom End Service
Engine In Chassis : Cam Compartment Service
Engine Removed: Flywheel Compartment
Service or Complete Engine Overhaul
2 44 Seat: FXSTC 2-128
Removal/Installation 2-128
Seat Strap 2-128
Seat 2-128
2 45 Seat: FXSTD 2-129
Removal/Installation 2-129
2 46 Seat: FLSTSCIFLSTNI
FLSTFIFLSTC 2-130
Removal/Installation 2-130
2 47 Luggage Rack: FLSTN 2-131
Removaill nstallation 2-131
2 48 Saddlebags: FLSTC 2-132
Removal 2-132
Installation 2-132
3 11 Troubleshooting 3-20
Diagnosing Valve Train Noise 3-20
Compression Test 3-20
Compression Test Results (table) 3-20
Cylinder Leakage Test 3-21
Diagnosing Smoking Engine or High Oil Consumption 3-21
Check Prior To Cylinder Head Removal 3-21
Check After Cylinder Head Removal 3-21
3 12 Stripping Motorcycle For Service 3-22
Procedure 3-22
3 13 Assembling Motorcycle
After Service 3-23
Procedure 3-23
3 14 Removing Engine From Chassis 3-24
Procedure 3-24
2 49 Windshield: FLSTC 2-133
Removal 2-133
Installation 2-133
SECTION 3-ENGINE
3 1 Specifications 3-1
3 2 Engine Torque Values (table) 3-3
3 3 Service Wear Limits 3-4
General 3-4
3 4 Engine Oil Flow 3-6
Oil Feed 3-6
Top End 3-7
Bottom End 3-7
Chain Guide Bracket 3-11
Oil Return 3-11
3 15 Installing Engine In Chassis
Procedure
3 16 Top End Overhaul: Disassembly
General
Breather Assembly
Rocker Arm Support Plate
Push Rods, Lifters and Covers
Cylinder Head
Cylinder
Piston
3 17 Top End Overhaul: Assembly
General
Piston
Cylinder
Cylinder Head
Push rods, Lifters and Covers
Rocker Arm Support Plate
Breather Assembly
3 18 Bottom End Overhaul:
Disassembly 3-45
General 3-45
Cover and Cam Support Plate 3·45
Crankcase 3-49
Counterbalancer Assembly 3-50
3 19 Bottom End Overhaul: Assembly 3-53
General 3-53
Counterbalancer Assembly 3-53
Balance Sprocket Spacers (table) 3-54
Crankcase 3·56
Cover and Cam Support Plate 3-60
Rear Cam Sprocket Spacers (Table) 3-62
3 27 Oil Pump 3-107
Removal Overview 3-107
Cleaning and Inspection 3-107
Installation and Overview 3-108
3 28 Crankcase 3-109
Removal Overview 3-109
Right Crankcase Half 3-109
Chain Guide Screen 3-109
Crankshaft Bearing 3-109
Piston Jets 3-110
Left Crankcase Half 3-111
Crankshaft (Roller) Bearing 3-111
Cylinder Studs 3-113
Removal 3-113
Installation 3-113
Pipe Plug and Oil Fittings 3-113
Removaillnstallation 3-113
Cleaning and Inspection 3-114
Installation Overview 3-114
3 20 Breather Assembly
Removal Overview
Disassembly
Cleaning and Inspection
Assembly
Installation Overview
3 21 Rocker Arm Support Plate
Removal Overview
Disassembly
Cleaning and Inspection
Assembly
Installation Overview
3 22 Push Rods, Lifters and Covers
Removal Overview
Disassembly
Cleaning and Inspection
Lifter Inspection
Assembly
Installation Overview
3 23 Cylinder Head
Removal Overview
Disassembly
Cleaning
Inspection
Cylinder Head
Valve Guides
Valve Stem To Guide Clearance Service
Wear Limits (table)
Valves
Valve Springs
Tapered Keepers
Valve Seats
Valve Guide Replacement
Removal
Installation
Valve Stem To Guide Clearance (table)
Valve and Seat Refacing
Assembly
Installation Overview
3 24 Cylinder
Removal Overview
Cleaning
Inspection
Deglazing Cylinder
Boring and Honing Cylinder
Installation Overview
Oversize Pistons/Cylinder Bores (table)
3 25 Piston
Removal Overview
Disassembly
Piston Rings
Cleaning
Inspection
Assembly
Piston Rings
Installation Overview
3 26 Cover and Cam Support Plate
Removal Overview
Camshafts
Removal
Assembly
Oil Pressure Relief Valve
Removal
Installation
Cam Needle Bearings
Removal
Installation
Cleaning and Inspection
Oil Pressure Valve
Cam Support Plate
Installation Overview
3 29 Counterbalancer Assembly
Removal Overview
Cleaning, Inspection and Repair
General
Balance Shaft Removal
Balance Shaft Installation
Balance Shaft Support Bearings
Front and Rear Balance Sprockets
Hydraulic Tensioners
Chain Tensioner Guides
Chain Guide Bracket
Balance Chain
Installation Overview
4 8 Engine Temperature Sensor (ET)
GeneraL
Removal
Installation
4 9 Induction Module
Removal
Installation
4 10 Idle Air Control (lAC)
GeneraL
Removal
Installation
3 30 FlywheeVConnecting Rod 3-119
Removal Overview 3-119
Inspection 3-119
Installation Overview 3-119
3 31 Oil Tank 3-120
Removal/Disassembly 3-120
Oil Tank 3-120
Oil Line Fittings/Reta iners 3-122
Installation 3-123
4 11 Manifold Absolute Pressure Sensor
(MAP) 4-22
General 4-22
Removal 4-22
Installation 4-22
4 12 Oxygen Sensor 4-23
GeneraL 4-23
Removal 4-23
Installation 4-23
SECTION 4-FUEL SYSTEM
4 1 Specifications
Torque Values (table)
4 2 Electronic Fuel Injection (EFI)
System
General
Troubleshooting
4 3 Idle Speed
General
4 4 Air Cleaner
Removal
Installation
Backplate Assembly: HDI Models
4 5 Fuel Tank
General
Removal
Cleaning and Inspection
Installation
All But FXSTDL
4 6 Throttle Position Sensor (TP)
General
RemovaL
Installation
4 7 Intake Air Temperature Sensor
(IAT)
General
RemovaL
Installation
4 13 Fuel Injectors
General
Removal
Installation
4 14 Fuel’PumpIFuel Gauge
Sending Unit
GeneraL
Removal
Disassembly/Assembly
Installation
4 15 Fuel Pressure Test
GeneraL
Testing
4 16 Exhaust System: FXSTIFLSTCI
FXSTBIFXSTC
Mufflers
Removal
Assembly
System
Removal
Installation
4 17 Exhaust System: FXSTDIFLSTF
Mufflers
Removal
Assembly
System
Removal
Installation
4 18 Exhaust System: FLSTN
Mufflers
Removal
Assembly
System
Removal
Installation
4 19 Exhaust System: FLSTSC 4-47
Removal 4-47
Installation 4-48
4 20 Intake Leak Test 4-50
General 4-50
Leak Tester 4-50
Parts List 4-50
Tester Assembly 4-50
Tester Adjustment 4-50
Procedure 4-51
4 21 Evaporative Emissions Control: CA
Models 4-52
General 4-52
Charcoal Canister 4-53
Removal 4-53
Installation 4-53
Hose Routing/Replacement 4-54
SECTION 5-ELECTRIC STARTER
5 1 Specifications 5-1
Torque Values 5-1
5 2 Electric Starter System 5-2
General 5-2
Starter Relay 5-2
Operation 5-2
6 3 Drive Components
Primary Chain and Compensating Sprocket
Removal
Installation
6 4 Clutch
Removal/Installation
Clutch Pack Only
Partial Disassembly
Assembly
Cleaning and Inspection
Clutch Pack and Bearing
Complete Disassembly
Assembly
6 5 Transmission Sprocket
Removal
Cleaning and Inspection
Installation
6 6 Drive Belt
Removal
Inspection
Installation
SECTION 7-TRANSMISSION
7 1 Specifications
Torque Values
5 3 Starter Relay
Removal
Installation
5 4 Starter
Removal
Installation
Disassembly, Inspection and Repair
Assembly
5 5 Starter Solenoid
General
Disassembly
Assembly
SECTION 6-DRIVE
6 1 Specifications
Torque Values (Table)
6 2 Primary Chaincase
General
Primary Chaincase Cover
Removal
Installation
Primary Chaincase Housing
Removal
Inspection
Installation
Mainshaft Bearing and Lip Seal
Removal
Shifter Shaft Bushing
7 2 Transmission
General
Neutral
1st Gear
2nd Gear :
3rd Gear
4th Gear
5th Gear
6th Gear
Shifter Linkage Adjustment
7 3 Shifter Forks
Cleaning and Inspection
7 4 Transmission Clutch Release
Cover
Removal/Disassembly
Cleaning and Inspection
Assembly/Installation
7 5 Transmission Assembly
Removal
Disassembly
Countershaft
Cleaning and Inspection
Replacing Side Door Bearings
Assembly
Installation
7 6 Main Drive Gear And Bearing
RemovaL
Cleaning and Inspection
Needle Bearing Replacement
Installation
Installing Main Drive Gear
Installing Main Drive Gear Seal
7 7 Transmission Case
RemovaL
General
Disassembly
Shifter Arm Assembly
Cleaning and Inspection
Assembly
Countershaft Needle Bearing Replacement
Shifter Pawl Lever Assembly
SECTION a-ELECTRICAL
8 10 Main Fuse
Removal
Installation
8 11 Ignition/Light Switch
General
Replacement
Key Switch Functions and Positions (table)
8 12 Alternator
Removal/Disassembly
Cleaning/Inspection
Assembly/Installation
8 13 Voltage Regulator
GeneraL
8 14 Front Electrical Caddy
General
Disassembly
Assembly
8 1 Specifications
Torque Values (table)
8 2 Bulb Requirements
General
Softail Bulb Chart (table)
8 3 Electrical Panel
General
Removal
Installation
8 4 Electronic Control Module (ECM)
General
RemovaL
Installation
8 15 Battery 8-24
Battery Testing 8-24
General 8-24
Voltmeter Test 8-24
Voltmeter Test For Battery Charge Conditions (table) 8-24
Conductance Test 8-24
Load Test 8-25
Battery Load Test (table) 8-25
Charging Battery 8-26
Safety Precautions 8-26
Using a Battery Charger 8-26
Battery Charging RateslTimes (Approximate) (table) 8-26
8 16 Battery Cables 8-28
Routing Procedure 8-28
8 5 Crank Position Sensor (CKP)
General
Removal
Installation
8 6 Spark Plug Cables
General
RemovaL
Inspection
Installation
8 7 Ignition Coil
Removal
Installation
8 8 Fuses
General
Removal
Installation
8 9 Relays
General :
RemovaL
Installation
8 17 Headlamp
GeneraL
Removal/Installation
FXSTD, FXSTS and FLSTSC Models
FXST and FXSTB Models
FLSTC, FLSTF and FLSTN Models
8 18 Tail Lamp: All But FXSTDI
FLSTSCIFLSTN
General
Bulb Replacement
Base Replacement
Tail Lamp Wires (table)
8 19 Tail Lamp: FXSTD
Removal
Installation
8 20 Tail Lamp: FLSTSCIFLSTN
Bulb Replacement
8 22 Front Fender Lamp: FLSTSC 8-46
Removal 8-46
Installation 8-46
8 26 Instrument Console: FXSTD 8-56
Removal 8-56
Installation 8-56
8 27 Speedometer: All But FXSTD 8-57
Removal 8-57
Installation 8-57
8 28 Speedometer: FXSTD 8-58
Removal 8-58
Installation 8-5
8 30 Indicator Lamps: All But FXSTD
General
Removal
Installation
Connector [21] Pins (table)
Indicator Lamp Assembly Wiring (table)
8 31 Indicator Lamps: FXSTD
General
Removal
Installation
8 39 Right Handlebar Switch
Removal
Installation
Disassembly
Switch Repair/Replacement
Upper Housing Repair
Lower Housing Repair
Assembly
8 40 Left Handlebar Switch
Removal
Installation
Disassembly
Switch Repair/Replacement
Upper Housing Repair
Lower Housing Repair
Assembly
8 36 Active Exhaust Module
General
Removal
Repair
Installation
8 33 Oil Pressure Switch
General
Removal
Installation
8 34 Rear Stop Light Switch
General
Removal
Installation
8 38 Handlebar Switch Assemblies
General
Repair Procedures
8 32 Neutral Switch
General
Removal
Installation
8 35 Horn
Inspection
Replacement
8 37 Main Wiring Harness
Removal
Installation
8 21 Auxiliary Lamps: FLSTCIFLSTN
Auxiliary Lamp Bulb
Removal
Installation
FLSTC Models
Auxiliary Lamp Bracket Removal
Auxiliary Lamp Bracket Installation
Auxiliary Lamp Housing Removal
Auxiliary Lamp Housing Installation
FLSTN Models
Auxiliary Lamp Bracket Removal
Auxiliary Lamp Bracket Installation
Auxiliary Lamp Housing Removal
Auxiliary Lamp Housing Installation
Adjustment: FLSTC/FLSTN Models
8 23 Turn Signals/Running Lights 8-47
Bulb Replacement: All But FLSTC 8-47
Bulb Replacement: FLSTC 8-47
Lamp Replacement 8-47
Front Turn Signals: All But FLSTC, FLSTN, FLSTSC,
FXSTS 8-48
Front Turn Signals: FLSTSC, FXSTC 8-49
Rear Turn Signals: All But FXSTD, FLSTSC, FLSTN 8-50
Rear Turn Signals: FXSTD 8-50
Rear Turn Signals: FLSTSC 8-51
Rear Turn Signals: FLSTN 8-51
8 24 TSMlTSSMlHFSM 8-52
General 8-52
Removal 8-52
Installation 8-52
TSMITSSM Configuration 8-53
8 25 Fuel Gauge 8-54
General 8-54
Removal 8-54
Installation 8-55
8 29 Vehicle Speed Sensor: VSS 8-59
General 8~59
Removal 8-59
Installation 8-59
Page No Page No
APPENDIX A-TOOLS
A 1 Tools
APPENDIX B-WIRING
8 1 Amp 1-Place Connector
Pin and Socket Housings
To Separate Housings
To Mate Housings
Wire Terminals
Remove Socket Terminals
Install Socket Terminal
Remove Pin Terminals
Install Pin Terminals
8 2 Amp Multilock
Pin and Socket Housings
Separate Housings
Mate Housings
Wire Terminals
Remove Terminals from Housing
Insert Termina ls into Housings
Terminal Crimps
Prepare Wire Leads
Crimp Terminals to Leads
Inspect Crimp
8 3 Delphi Connectors
Pin and Socket Housings
To Separate Housings
To Mate Housings
Wire Terminals
Remove Socket Terminals
Install Socket Termina ls
Housing
To Separate Housings
To Mate Housings
Wire Terminals
Remove Terminal
Installation
8 5 Deutsch
Pin and Socket Housings
Separate Housings
Mate Housings
Wire Terminals
Remove Socket Terminals
Install Socket Terminals
Remove Pin Terminals
install Pin Terminals
Terminal Crimps
8 6 Standard Deutsch Terminal
Crimps
Terminal Crimps
Prepare Wire Lead
Crimp Terminal to Lead
Inspect Crimp
8 7 Deutsch Mini Terminal Crimps
Terminal Crimps
Prepare Wire Lead
Crimp a Mini Terminal to a Wire Lead
Inspect Crimp
8 8 Deutsch Solid 8arrel Terminal
Crimps
Wire Terminals
Prepare Wire Lead
Adjust Crimper Tool,
Crimp 8arrel Contact to Wire Lead
Inspect Crimp
8 9 Fuse 810cks
Fuse Wire Leads
Remove Socket Terminals
Install Socket Terminals
Terminal Crimps
8 10 150 Metri-Pack
Pin and Socket Housings
Wire Terminals
Remove Terminals
Insert Terminals
Terminal Crimps
8 11 280 Metri-Pack
Pin and Socket Housings
To Separate Housings
To Mate Housings
Wire Terminals
Remove Socket Terminals
Install Socket Terminals
Terminal Crimps :
8 12 480 Metri-Pack
Pin and Socket Housings
To Separate Housings
To Mate Housings
Wire Terminals
Remove Socket Terminal
Install Socket Terminal
8 13 630 Metri-Pack
Pin and Socket Housings
Separate Housings
Mate Housings
Wire Terminals
Remove Socket Terminals
Install Socket Termina ls
8 14 800 Metri-Pack
Fuse and Socket Housing
Remove the Maxi-Fuse
Install Maxi-Fuse
Wire Termina ls
Remove Socket Termina ls
Install Socket Terminals
Terminal Crimps
8 15 Metri-Pack Terminal Crimps 8-30
Match Terminal to Crimper 8-30
Terminal Crimps 8-31
Prepare Wire Lead 8-31
Crimp Wire Core 8-31
Crimp Insulation/Seal 8-31
Inspect Crimp 8-31
8 16 Packard 1OOW 8-32
Socket Housing 8-32
Separate Socket Housing from ECM 8-32
Mate Socket Housing to ECM 8-32
Wire Terminals 8-32
Remove Socket Terminals 8-32
Install Socket Terminals 8-32
8 17 Molex 8-34
Pin and Socket Housings 8-34
Separate the Housings 8-34
Mate the Housings 8-34
Wire Terminals 8-34
Remove Terminals 8-34
Install Terminal 8-35
8 18 Packard Micro 64 8-36
Pin and Socket Housings 8-36
Separate the Housings 8-36
Mate the Housings 8-36
Wire Terminals 8-36
Remove Terminals 8-36
Install Terminals 8-37
Terminal Crimps 8-38
Prepare Wire Lead 8-38
Crimp Terminal 8-38
Inspect Crimp 8-38
8 19 Sealed Splice 8-39
Prepare Wire Leads 8-39
Splicing Wire Leads 8-40
Inspect Seal 8-40
8 20 Connector Locations 8-41
8 21 Index to Wiring Diagrams 8-43
Wire Color Codes 8-43
Wiring Diagram Symbols 8-43
APPENDIX C-METRIC
CONVERSIONS
C 1 Metric Conversions C-1
C 2 Fluid Conversions C-2
United States System C-2
Metric System C-2
8ritish Imperial System C-2
APPENDIX D-GLOSSARY
D 1 Glossary D-I
INDEX
VIDEO PREVIEW OF THE MANUAL:
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
S.V