2011 Harley-Davidson Touring Models Service Manual 99483-11 – PDF DOWNLOAD
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2011 Harley-Davidson Touring Models Service Manual 99483-11 – PDF DOWNLOAD
Language : English
Pages : 724
Downloadable : Yes
File Type : PDF
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2011 Harley-Davidson Touring Models Service Manual 99483-11 – PDF DOWNLOAD
ABOUT THIS MANUAL:
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 field-tested 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.
HOW TO USE YOUR SERVICE MANUAL
Refer to the table below for the content layout of this manual.
NO. CHAPTER
1 Maintenance
2 Chassis
3 Engine
4 Fuel System
5 Drive
6 Transmission
7 Electrical
A Appendix A Connector Repair
B Appendix B Wiring
C Appendix C ABS
D Appendix D Conversions
E Appendix E Glossary
TABLE OF CONTENTS:
2011 Harley-Davidson Touring Models Service Manual 99483-11 – PDF DOWNLOAD
FOREWORD 7
TABLE OF CONTENTS 9
1 MAINTENANCE 25
1 1 FASTENER TORQUE VALUES 27
Fastener Torque Values in this Chapter 27
1 2 GENERAL 29
Servicing a New Motorcycle 29
Safe Operating Maintenance 29
Shop Practices 29
Repair and Replacement Procedures 30
Cleaning 31
Tool Safety 31
1 3 FUEL AND OIL 33
Fuel 33
Gasoline Blends 33
Engine Lubrication 33
Winter Lubrication 34
1 4 BULB REQUIREMENTS 35
General 35
1 5 MAINTENANCE SCHEDULE 37
General 37
1 6 ENGINE OIL AND FILTER 41
Checking Oil Level 41
Changing Oil and Oil Filter 42
1 7 AIR CLEANER AND EXHAUST SYSTEM 44
Removal 44
Installation 44
Exhaust System Leak Check 44
1 8 TIRES AND WHEELS 46
General 46
Tires 46
Tire Replacement 46
Wheel Bearings 47
Wheel Spokes 47
1 9 PRIMARY CHAINCASE LUBRICANT 49
General 49
Changing Primary Chaincase Lubricant 49
1 10 TRANSMISSION LUBRICANT 51
Transmission Lubrication 51
1 11 CLUTCH 53
Adjustment 53
1 12 DRIVE BELT AND SPROCKETS 55
General 55
Cleaning 55
Inspection 55
Checking Drive Belt Deflection 57
Setting Belt Deflection 57
1 13 COMPENSATOR SPROCKET ISOLATOR 60
Inspection 60
1 14 CABLE AND CHASSIS LUBRICATION 61
General 61
Steering Head Bearings 61
Jiffy Stand 61
Miscellaneous Lubrication 61
1 15 BRAKES 62
Fluid Inspection 62
1 16 BRAKE PADS AND DISCS 63
Inspection 63
Brake Pad Replacement 63
1 17 SPARK PLUGS 67
Inspection 67
Spark Plug Cable Inspection 67
1 18 FRONT FORK OIL 69
Replacing Fork Oil 69
1 19 SUSPENSION ADJUSTMENTS 70
General 70
1 20 STEERING HEAD BEARINGS 72
Lubrication 72
Checking 72
Adjustment 73
1 21 HEADLAMP ALIGNMENT 74
Headlamp Alignment 74
Headlamp Adjustment: Single Headlamp Models 74
Headlamp Adjustment: Dual Headlamp Models 75
Auxiliary Lamp Alignment 75
1 22 CRITICAL FASTENERS 77
Inspection 77
1 23 BATTERY MAINTENANCE 79
General 79
Cleaning and Inspection 80
Battery 80
Voltmeter Test 81
Charging Battery 81
Storage 83
1 24 ENGINE MOUNTS 84
Inspection 84
1 25 STORAGE 85
General 85
Placing in Storage 85
Removal from Storage 85
1 26 TROUBLESHOOTING 87
General 87
Engine 87
Lubrication System 88
Electrical System 89
Transmission 89
Handling 89
Brakes 90
2 CHASSIS 91
2 1 FASTENER TORQUE VALUES 93
Fastener Torque Values in this Chapter 93
2 2 SPECIFICATIONS 98
Specifications 98
2 3 VEHICLE IDENTIFICATION NUMBER (V I N ) 101
Vehicle Identification Number: Touring Models 101
2 4 FRONT WHEEL 103
Removal 103
Cleaning and Inspection 104
Installation 104
2 5 REAR WHEEL 106
Removal 106
Cleaning and Inspection 107
Installation 108
2 6 REAR WHEEL COMPENSATOR 110
Isolator Replacement 110
Sprocket Bearing Replacement 110
2 7 WHEEL LACING: FRONT RIM 113
Wheel Lacing: Angle Flange Hub 113
2 8 WHEEL LACING: 16 INCH REAR RIM 115
Wheel Lacing: 16 In Rear Wheel 115
2 9 CHECKING AND TRUING WHEELS 118
General 118
Checking Wheel Runout 118
Laced Wheel Rim Offset 118
Truing Laced Wheels 120
2 10 SEALED WHEEL BEARINGS 122
Inspection 122
Removal 122
Installation 123
2 11 TIRES 125
General 125
Removal 125
Cleaning, Inspection and Repair 126
Installation 126
Checking Tire Runout 127
Wheel Balancing 128
2 12 FRONT BRAKE MASTER CYLINDER 129
General 129
Removal and Disassembly 129
Cleaning and Inspection 131
Assembly and Installation 131
Front Brake Line: Non-ABS Equipped 131
2 13 FRONT BRAKE CALIPER 134
Removal 134
Installation 134
2 14 REAR BRAKE MASTER CYLINDER 135
General 135
Removal and Disassembly 135
Cleaning and Inspection 138
Assembly and Installation 138
Rear Brake Line: Non-ABS Equipped 138
2 15 REAR BRAKE CALIPER 141
Removal 141
Installation 141
2 16 BLEEDING BRAKES 142
General 142
Procedure 142
2 17 FRONT FORK 144
Changing Fork Oil 144
Removal 145
Disassembly 145
Cleaning and Inspection 147
Assembly 148
Installation 148
2 18 STEERING HEAD BEARINGS 150
Removal 150
Inspection 151
Installation 152
2 19 REAR AIR SUSPENSION 153
Check for Air Leaks 153
2 20 REAR SHOCK ABSORBERS 155
Removal 155
Cleaning and Inspection 155
Disassembly and Assembly 155
Installation 155
2 21 REAR FORK 156
Removal 156
Disassembly and Assembly 156
Installation 158
2 22 CLUTCH CABLE 159
Removal 159
Installation 159
2 23 HANDLEBARS 162
Adjustment 162
Removal 162
Installation 163
Left Handgrip 164
Heated Handgrips 164
Rubber Mounts 165
2 24 MIRRORS 167
All Models Except FLHX 167
FLHX 167
2 25 SEAT 168
Seat: Models without Tour-Pak 168
Seat: Models with Tour-Pak 168
Seat: Road King Models 169
Seat Retention Nut Replacement 169
Seat Bumper 170
2 26 SADDLEBAGS 171
Removal 171
Installation 171
2 27 SADDLEBAG SERVICE 172
Saddlebag Hardware 172
Saddlebag Guard/Support Rail 173
2 28 TOUR-PAK 175
Removal/Installation 175
Adjustment 176
Luggage Rack/Tour-Pak Support 176
2 29 TOUR-PAK SERVICE 177
Lockset 177
Hinges 177
Latches/Lockset Catch 178
Catches 178
Tether 178
Tether Brackets 179
Luggage Rack 179
2 30 TOUR-PAK LIGHTS 180
General 180
Side Marker Lights (if equipped) 180
Tour-Pak Lights Harness 180
Wrap-Around Lights (if equipped) 181
2 31 TOUR-PAK BACKREST 183
Passenger Backrest 183
Rubber Isolators 183
Passenger Backrest Flap 184
2 32 TOUR-PAK SPEAKER BOX 185
Speaker Box 185
2 33 LOWER FAIRING AND ENGINE GUARD 186
Lower Fairing 186
Serrated Washer Replacement 187
Engine Guard 187
2 34 UPPER FAIRING AND WINDSHIELD: FORK MOUNTED FAIRING MODELS 189
Outer Fairing and Windshield 189
2 35 FAIRING CAP: FORK MOUNTED FAIRING MODELS 190
Fairing Cap 190
2 36 INNER FAIRING: FORK MOUNTED FAIRING MODELS 191
Removal 191
Installation 193
2 37 AIR DEFLECTORS 195
Air Deflectors 195
Mid-Frame Air Deflectors 195
2 38 UPPER FAIRING AND WINDSHIELD: FRAME MOUNTED FAIRING MODELS 196
Windshield 196
Outer Fairing 196
2 39 INSTRUMENT BEZEL: FRAME MOUNTED FAIRING MODELS 199
Bezel 199
2 40 INSTRUMENT NACELLE: FRAME MOUNTED FAIRING MODELS 201
Instrument Nacelle 201
2 41 INNER FAIRING: FRAME MOUNTED FAIRING MODELS 203
Removal 203
Installation 205
2 42 GLOVE BOX DOOR AND HINGE: FRAME MOUNTED FAIRING MODELS 207
Glove Box Door and Hinge 207
2 43 WINDSHIELD: ROAD KING MODELS 208
Windshield 208
Windshield Window 208
2 44 HEADLAMP NACELLE: ROAD KING MODELS 211
Removal 211
Installation 212
2 45 FRONT FENDER 213
Removal 213
Installation 213
2 46 REAR FENDER 214
Removal 214
Fender Repair 215
Installation 215
2 47 REAR FASCIA 217
Removal 217
Installation 217
Stud Plate 217
Rear Fascia Lamp 217
2 48 REAR FRAME 218
Rear Frame 218
2 49 FOOTBOARDS AND FOOTRESTS 220
Rider Footboards 220
Passenger Footboard 221
Passenger Footrest: FLHX, FLTRX 221
2 50 JIFFY STAND 223
General 223
Leg Removal 223
Leg Installation 223
Jiffy Stand Bracket 224
Jiffy Stand Interlock Sensor 224
2 51 FRONT ENGINE MOUNT 226
Removal 226
Installation 226
3 ENGINE 229
3 1 FASTENER TORQUE VALUES 231
Fastener Torque Values in this Chapter 231
3 2 SPECIFICATIONS 233
Specifications 233
3 3 SERVICE WEAR LIMITS 235
General 235
3 4 ENGINE OIL FLOW 237
Oil Feed 237
Top End 237
Bottom End 239
Oil Return 241
Oil Cooler Operation 242
3 5 OIL PUMP OPERATION 243
General 243
Operation 243
3 6 BREATHER OPERATION 245
General 245
3 7 OIL PRESSURE 246
Oil Pressure Indicator Lamp 246
Checking Oil Pressure 246
3 8 TROUBLESHOOTING 248
Diagnosing Valve Train Noise 248
Compression Test 248
Cylinder Leakdown Test 249
Diagnosing Smoking Engine or High Oil Consumption 249
3 9 OIL COOLER 250
Removal 250
Installation 250
3 10 OIL COOLER ADAPTER 251
Removal 251
Disassembly 251
Assembly 251
Installation 251
3 11 HOW TO USE THIS SECTION 253
Top End Repair 253
Bottom End Repair 253
Typical Symptoms 253
3 12 TOP END SERVICE 254
Engine in Chassis 254
Engine Removed from Chassis 255
3 13 CAM COMPARTMENT SERVICE 256
Engine in Chassis 256
Engine Removed From Chassis 257
3 14 STRIPPING MOTORCYCLE FOR SERVICE 258
Procedure 258
3 15 ASSEMBLING MOTORCYCLE AFTER SERVICE 259
Procedure 259
3 16 REMOVING ENGINE FROM CHASSIS 260
Procedure 260
3 17 INSTALLING ENGINE IN CHASSIS 261
Procedure 261
3 18 TOP END OVERHAUL: DISASSEMBLY 262
General 262
Rocker Covers 262
Rocker Arm Support Plate 262
Push Rods, Lifters and Covers 264
Cylinder Head 265
Cylinder 266
Piston 266
3 19 BREATHER ASSEMBLY 268
Disassembly 268
Cleaning and Inspection 268
Assembly 268
3 20 ROCKER ARM SUPPORT PLATE 270
Disassembly 270
Cleaning and Inspection 270
Assembly 272
3 21 PUSH RODS, LIFTERS AND COVERS 273
Disassembly 273
Cleaning and Inspection 273
Lifter Inspection 274
Assembly 274
3 22 CYLINDER HEAD 275
Disassembly 275
Cleaning 276
Inspection 276
Valve Guide Replacement 277
Valve and Seat Refacing 281
Assembly 283
3 23 CYLINDER 286
Cleaning 286
Inspection 286
Deglazing Cylinder 288
Boring and Honing Cylinder 288
3 24 PISTON 290
Disassembly 290
Cleaning 290
Inspection 290
Assembly 292
3 25 TOP END OVERHAUL: ASSEMBLY 294
General 294
Piston 294
Cylinder 295
Cylinder Head 297
Push Rods, Lifters and Covers 301
Rocker Arm Support Plate 302
Breather and Rocker Cover 303
3 26 CAM COMPARTMENT AND COMPONENTS 305
Cam Support Plate and Cover Removal 305
Cam Support Plate Cleaning and Inspection 307
Camshafts 307
Oil Pressure Relief Valve 309
Cam Needle Bearings 310
Cam Support Plate and Cover Installation 313
3 27 OIL PUMP 317
Removal 317
Cleaning and Inspection 317
Installation 318
3 28 CRANKCASE DISASSEMBLY AND REPAIR 320
Crankcase Disassembly 320
Cleaning and Inspection 320
Right Crankcase Half 321
Left Crankcase Half 322
Sprocket Shaft Bearing Inner Race 324
Cylinder Studs 327
Pipe Plug and Oil Fittings 328
3 29 FLYWHEEL AND CONNECTING RODS 329
Inspection 329
Measuring Crankshaft Runout 329
3 30 CRANKCASE ASSEMBLY 331
Crankcase Assembly 331
3 31 OIL PAN 333
Removal 333
Installation 333
4 FUEL SYSTEM 335
4 1 FASTENER TORQUE VALUES 337
Fastener Torque Values in this Chapter 337
4 2 SPECIFICATIONS: FUEL SYSTEM 339
Specifications 339
4 3 ELECTRONIC FUEL INJECTION (EFI) 340
Troubleshooting 340
4 4 AIR CLEANER ASSEMBLY 341
Removal 341
Installation 342
4 5 FUEL TANK 344
Removal 344
Installation 344
Evaporative Emissions Tube: Non-CA Models 345
Fuel Supply Check Valve/Tube 345
4 6 FUEL TANK TOP PLATE 347
Removal 347
Installation 348
4 7 FUEL FILTER 349
Removal 349
Installation 349
4 8 FUEL PRESSURE REGULATOR 350
Removal 350
Installation 350
4 9 FUEL LEVEL SENDER 351
Removal 351
Installation 351
4 10 TWIST GRIP SENSOR 352
Removal 352
Installation 353
Twist Grip Sensor Jumper Harness 354
4 11 THROTTLE CONTROL ACTUATOR (TCA) 355
General 355
4 12 ENGINE TEMPERATURE SENSOR (ET) 356
Removal 356
Installation 356
4 13 INDUCTION MODULE 357
Removal 357
Installation 358
4 14 TEMPERATURE MANIFOLD ABSOLUTE PRESSURE SENSOR (TMAP) 359
General 359
Removal 359
Installation 359
4 15 OXYGEN SENSORS (O2) 360
General 360
Removal 360
Installation 361
4 16 FUEL INJECTORS 362
General 362
Removal 362
Installation 362
4 17 FUEL PUMP 364
General 364
Removal 364
Installation 364
Fuel Pump and Fuel Level Sender Wire Harness 365
4 18 FUEL PRESSURE TEST 366
General 366
Testing 366
4 19 EXHAUST SYSTEM 368
Mufflers 368
System Removal 368
System Installation 369
4 20 ACTIVE EXHAUST (HDI) 371
Exhaust Valve Actuator 371
Exhaust Valve Actuator Cable 371
Active Exhaust Valve 371
4 21 INTAKE LEAK TEST 372
General 372
Leak Tester 372
Procedure 372
4 22 EVAPORATIVE EMISSIONS CONTROL SYSTEM 374
General 374
Vapor Valve 374
Fuel Vapor Vent Tube 375
Canister-to-Solenoid Tube 375
Solenoid-to-Induction Module Tube 375
Purge Solenoid 376
Charcoal Canister 376
5 DRIVE 379
5 1 FASTENER TORQUE VALUES 381
Fastener Torque Values in this Chapter 381
5 2 SPECIFICATIONS: DRIVE 382
Specifications 382
5 3 PRIMARY CHAINCASE COVER 383
General 383
Removal 383
Installation 383
5 4 DRIVE COMPONENTS 385
Removal 385
Installation 387
5 5 PRIMARY CHAINCASE HOUSING 390
Removal 390
Inspection 390
Mainshaft Bearing and Lip Seal 390
Mainshaft Bearing Inner Race 391
Shifter Shaft Bushings 392
Installation 392
5 6 CLUTCH 394
Removal and Installation 394
Clutch Pack Only 394
Clutch Pack and Bearing 396
5 7 TRANSMISSION SPROCKET 399
Removal 399
Cleaning and Inspection 399
Installation 399
5 8 DRIVE BELT 401
Removal and Adjustment 401
Installation 401
6 TRANSMISSION 403
6 1 FASTENER TORQUE VALUES 405
Fastener Torque Values in this Chapter 405
6 2 SPECIFICATIONS: TRANSMISSION 406
Specifications 406
Service Wear Limits 406
6 3 TRANSMISSION 407
Power Flow 407
6 4 SHIFTER LINKAGE 409
Shifter Rod 409
6 5 CLUTCH RELEASE COVER 410
Removal and Disassembly 410
Cleaning and Inspection 411
Assembly and Installation 411
6 6 TRANSMISSION ASSEMBLY 412
Removal 412
Disassembly 413
Cleaning and Inspection 419
Assembly 419
Installation 423
6 7 MAIN DRIVE GEAR AND BEARING 425
Removal 425
Cleaning and Inspection 426
Mainshaft Seal Replacement 428
Installation 429
6 8 TRANSMISSION CASE 432
Removal 432
Installation 432
Disassembly 433
Cleaning and Inspection 433
Assembly 434
7 ELECTRICAL 437
7 1 FASTENER TORQUE VALUES 439
Fastener Torque Values in this Chapter 439
7 2 SPECIFICATIONS: ELECTRICAL 443
Specifications 443
7 3 VOLTAGE REGULATOR 444
Removal 444
Installation 444
7 4 ELECTRONIC CONTROL MODULE (ECM) 445
ECM 445
7 5 TURN SIGNAL AND SECURITY MODULE (TSM/TSSM/HFSM) 446
General 446
Removal 446
Installation 446
HFSM Antenna 447
7 6 IGNITION COIL 448
Removal 448
Installation 448
7 7 SYSTEM FUSES AND RELAYS 449
Main Fuse 449
Main Fuse Holder 449
System Fuses and Relays 449
Fuse Blocks 450
7 8 ELECTRICAL CADDIES 451
Top Caddy 451
Left Side Caddy 451
Battery Tray 453
7 9 SECURITY SIREN 455
Removal 455
Installation 455
7 10 STARTER 456
General 456
Removal 456
Drive Assembly 456
Solenoid 458
Installation 459
7 11 HEADLAMP: ALL EXCEPT ROAD GLIDE 460
Headlamp: Single Headlamp Models 460
7 12 HEADLAMP: ROAD GLIDE 462
Headlamp Adjuster Assembly 462
Headlamp Bulb Replacement: Dual Headlamp Models 462
7 13 AUXILIARY LAMPS AND BRACKETS 464
Auxiliary Lamp Bulb Replacement 464
Auxiliary Lamp Housing 465
Auxiliary Lamp Bracket 466
Adjustment 467
7 14 TAIL LAMP 468
Tail Lamp Bulb Replacement 468
Circuit Board/Chrome Base 468
Rear Fender Lights Harness: all except FLHX, FLTRX 469
Rear Fender Lights Harness: FLHX, FLTRX 471
7 15 FENDER TIP LAMPS 473
Front Fender Tip Lamp 473
Front Fender Tip Lamp Jumper Harness 473
Rear Fender Tip Lamp 475
7 16 TURN SIGNAL LAMPS 477
Turn Signal Bulb Replacement: Bullet Style 477
Turn Signal Bulb Replacement: Flat Lens Style 477
Front Turn Signal Lamp 477
Rear Turn Signal Lamp 481
Rear Turn Signal Lamps Bracket 484
7 17 IGNITION/LIGHT KEY SWITCH AND FORK LOCK 486
Fairing Models 486
Road King Models 489
7 18 FAIRING CAP SWITCHES: FORK MOUNTED FAIRING MODELS 491
Removal 491
Installation 492
7 19 INSTRUMENT NACELLE SWITCHES: FRAME MOUNTED FAIRING MODELS 493
Removal 493
Installation 494
7 20 CRANKSHAFT POSITION SENSOR (CKP) 497
General 497
Removal 497
Installation 497
7 21 AUTOMATIC COMPRESSION RELEASE (ACR) 498
General 498
Removal 498
Installation 498
7 22 ALTERNATOR 500
Removal 500
Cleaning and Inspection 500
Installation 501
7 23 VEHICLE SPEED SENSOR (VSS) 502
VSS 502
7 24 NEUTRAL SWITCH 503
Removal 503
Installation 503
7 25 OIL PRESSURE SWITCH AND SENDER 504
Removal 504
Installation 504
7 26 STOPLIGHT SWITCHES 505
Front Stoplight Switch 505
Rear Stoplight Switch 505
7 27 HORN 506
Inspection 506
Removal 506
Installation 506
7 28 CIGARETTE LIGHTER: FAIRING MODELS 507
Troubleshooting 507
Removal 507
Installation 507
7 29 GAUGES AND INSTRUMENTS: FAIRING MODELS 508
2 Inch Diameter Gauges: Fuel Level, Ambient Air Temperature, Voltmeter, Oil Pressure 508
Tachometer 508
Speedometer 509
7 30 INDICATOR LAMPS: FAIRING MODELS 510
Indicator Lamps 510
7 31 GAUGES AND INSTRUMENTS: ROAD KING MODELS 511
Fuel Gauge 511
Speedometer 511
7 32 INDICATOR LAMPS: ROAD KING MODELS 513
Indicator Lamps 513
7 33 ADVANCED AUDIO SYSTEM 514
Radio 514
Front Fairing Speakers 515
Front Headset Receptacle 515
Rear Headset Receptacle 516
Rear Passenger Switches 516
Rear Speakers 518
CB Module 518
7 34 WIRE TROUGH 519
Removal 519
Installation 520
7 35 MAIN WIRING HARNESS 521
Removal: All Models (Part 1) 521
Removal: Road King Models (Part 2) 521
Removal: Fork Mounted Fairing Models (Part 2) 522
Removal: Frame Mounted Fairing Models (Part 2) 523
Removal: All Models (Part 3) 523
Installation: All Models (Part 1) 525
Installation: Road King Models (Part 2) 527
Installation: Fork Mounted Fairing Models (Part 2) 528
Installation: Frame Mounted Fairing Models (Part 2) 528
Installation: All Models (Part 3) 528
7 36 INTERCONNECT HARNESS 529
Fork Mounted Fairing Models 529
Frame Mounted Fairing Models 532
7 37 RADIO ANTENNA CABLE 536
Models Equipped with Tour-Pak 536
Models without Tour-Pak 537
7 38 REAR AUDIO HARNESS: ULTRA MODELS 539
Removal 539
Installation 539
7 39 CB ANTENNA CABLE: ULTRA MODELS 541
Removal 541
Installation 541
7 40 HANDLEBAR SWITCH ASSEMBLIES 543
Removal 543
Disassembly 543
Specific Repair Procedures: Upper Switch Housings 544
Specific Repair Procedures: Right Side Lower Switch Housings 546
Specific Repair Procedures: Left Side Lower Switch Housings 549
General Repair Procedures 552
Assembly: Right Side Handlebar Switches 553
Assembly: Left Side Handlebar Switches 554
Installation 554
7 41 TSSM/HFSM MAINTENANCE 559
General 559
Fob Battery 559
Smart Siren (If Installed) 559
7 42 PERSONAL IDENTIFICATION NUMBER (PIN) 561
General 561
Initial Pin Entry 561
Changing the Pin 561
7 43 H-DSSS ACTUATION 563
General 563
Sidecar Configuration 563
Actuation 563
Fob Assignment 563
Power Disruption and Configuring 563
7 44 TSM/HFSM: PASSWORD LEARN 564
General 564
Password Learn 564
A APPENDIX A CONNECTOR REPAIR 567
A 1 AUTOFUSE UNSEALED ELECTRICAL CONNECTORS 569
Autofuse Unsealed Connector Repair 569
A 2 DELPHI 100W MICRO-PACK SEALED CONNECTOR 570
Delphi 100W Micro-Pack Sealed Connector Repair 570
A 3 DELPHI 150 METRI-PACK SEALED CONNECTORS 572
Delphi 150 Metri-Pack Sealed Connector Repair 572
A 4 DELPHI 280 METRI-PACK UNSEALED CONNECTORS 574
Fuse Block Repair 574
A 5 DELPHI 480 METRI-PACK UNSEALED CONNECTORS 575
Delphi 480 Metri-Pack Unsealed Connector Repair 575
A 6 DELPHI 630 METRI-PACK UNSEALED CONNECTORS 576
Delphi 630 Metri-Pack Unsealed Connector Repair 576
A 7 DELPHI 800 METRI-PACK SEALED MAIN FUSE HOUSING 577
Delphi 800 Metri-Pack Sealed Main Fuse Housing Repair 577
A 8 DELPHI METRI-PACK TERMINAL REPAIR 579
Metri-Pack Terminal Crimps 579
A 9 DELPHI MICRO 64 SEALED CONNECTORS 581
Delphi Micro 64 Sealed Connector Repair 581
A 10 DELPHI GT 150 SEALED CONNECTORS 584
Delphi GT 150 Sealed Connector Repair 584
A 11 DELPHI GT 280 SEALED 73-TERMINAL ECM CONNECTOR 586
Delphi GT 280 Sealed 73-Terminal ECM Connector 586
A 12 DEUTSCH DT SEALED CONNECTORS 588
Deutsch DT Sealed Connector Repair 588
A 13 DEUTSCH DT SEALED TERMINAL REPAIR 592
Deutsch DT Sealed Terminal Crimps 592
A 14 DEUTSCH DTM SEALED MINI TERMINAL REPAIR 593
Deutsch DTM Sealed Mini Terminal Crimps 593
A 15 DEUTSCH DTM SEALED SOLID BARREL MINI TERMINAL REPAIR 594
Deutsch DTM Sealed Solid Barrel Terminal Crimps 594
A 16 JAE MX19 SEALED CONNECTORS 596
JAE MX19 Sealed Connectors 596
A 17 MOLEX CMC SEALED CONNECTORS 597
Molex CMC Sealed Connectors 597
A 18 MOLEX MX 150 SEALED CONNECTORS 599
Molex MX 150 Sealed Connector Repair 599
Crimp Terminal to Lead 600
A 19 TYCO 070 MULTILOCK UNSEALED CONNECTOR 603
Tyco 070 Multilock Unsealed Connector Repair 603
A 20 SEALED SPLICE CONNECTORS 607
Sealed Splice Connector Repair 607
B APPENDIX B WIRING 609
B 1 CONNECTORS 611
Connector Locations 611
B 2 WIRING DIAGRAMS 617
Wiring Diagram Information 617
2011 Touring Wiring Diagrams 619
C APPENDIX C ABS 667
C 1 FASTENER TORQUE VALUES 669
Fastener Torque Values in this Chapter 669
C 2 ABS MODULE 670
Hydraulic Control Unit (HCU) 670
Electronic Control Unit (ECU) 671
C 3 WHEEL SPEED SENSORS 673
Front Wheel Speed Sensor 673
Rear Wheel Speed Sensor 674
C 4 ABS BRAKE LINES 675
Front Master Cylinder to ABS Module 675
ABS Module to Front Brake Calipers 676
Rear Master Cylinder to ABS Module 678
ABS Module to Rear Brake Caliper 680
D APPENDIX D CONVERSIONS 681
D 1 METRIC CONVERSION 683
Conversion Table 683
D 2 FLUID CONVERSIONS 684
United States System 684
Metric System 684
British Imperial System 684
D 3 TORQUE CONVERSIONS 685
United States System 685
Metric System 685
E APPENDIX E GLOSSARY 687
E 1 GLOSSARY 689
Acronyms and Abbreviations 689
TOOLS 693
TORQUE VALUES 699
INDEX 715
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