Harley Davidson Touring Models Repair Service Manual 2000-2018

MANUAL LIST (21,080 pages):
Harley Davidson 2003 Touring Models Service Manual
Harley Davidson 2004 Touring Models Service Manual
Harley Davidson 2005 Touring Models Service Manual
Harley Davidson 2012 Touring Models Service Manual
Harley Davidson 2000 Touring Models Service Manual.pdf
Harley Davidson 2002 Touring Models Service Manual.pdf
Harley Davidson 2006 Touring Models Service Manual.pdf
Harley Davidson 2007 Touring Models Electrical Diagnostics.pdf
Harley Davidson 2007 Touring Models Service Manual.pdf
Harley Davidson 2008 FLT Police Models Service Manual Supplement.pdf
Harley Davidson 2008 Touring Models Service Manual.pdf
Harley Davidson 2009 Touring Models Service Manual.pdf
Harley Davidson 2010 Touring Models Service Manual.pdf
Harley Davidson 2011 Touring Models Service Manual.pdf
Harley Davidson 2013 Service Manual.pdf
Harley Davidson 2013 Touring Models Electrical Diagnostics.pdf
Harley Davidson 2015 Touring Models Service Manual.pdf
Harley Davidson 2016 FLHTKSE Models Service Manual Supplement.pdf
Harley Davidson 2017 Touring Models Service Manual.pdf
Harley Davidson 2018 FLHTKSE Models Service Manual Supplement.pdf
Harley Davidson 2018 FLHXSE Models Service Manual Supplement.pdf
Harley Davidson 2018 FLTRXSE Models Service Manual Supplement.pdf
Harley Davidson 2018 Touring Models Electrical Diagnostics.pdf
Harley Davidson 2018 Touring Models Service Manual.pdf
Harley Davidson 2018 Touring Models Wiring Diagrams.pdf
Harley Davidson 2018 Trike Models Service Manual Supplement.pdf

Complete service repair manual with Electrical Wiring Diagrams for Harley Davidson Touring Models 2000-2018, with all the shop information to maintain, diagnostic, repair, refurbish/rebuild like professional mechanics.

Harley Davidson Touring Models workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

PRODUCT DETAILS:
Total Pages/Size: 21,080 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English
Delivery: instant download link displayed on page & emailed to you after checkout
Protection: DRM-free; without any restriction

TABLE OF CONTENTS
1.1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter..1-1
1.2 GENERAL
Servicing a New Motorcycle...1-3
Safe Operating Maintenance..1-3
Shop Practices..1-3
Repair Notes..1-3
Safety..1-3
Removing Parts...1-3
Cleaning..1-3
Disassembly and Assembly..1-4
Checking Torques on Fasteners..1-4
Magnetic Parts Trays...1-4
Repair and Replacement Procedures..1-4
Hardware and Threaded Parts..1-4
Threadlocking Agents..1-4
Wiring, Hoses and Lines...1-4
Instruments and Gauges...1-4
Bearings..1-4
Bushings..1-4
Gaskets...1-4
Lip-Type Seals...1-4
O-Rings...1-5
Gears...1-5
Shafts..1-5
Part Replacement..1-5
Cleaning..1-5
Part Protection...1-5
Cleaning Process..1-5
Rust or Corrosion Removal...1-5
Bearings..1-5
Tool Safety..1-5
Air Tools...1-5
Wrenches..1-5
Pliers/Cutters/Pry Bars..1-6
Hammers...1-6
Punches/Chisels..1-6
Screwdrivers..1-6
Ratchets and Handles...1-6
Sockets..1-6
Storage Units...1-6
1.3 FUEL AND OIL
Fuel...1-7
Gasoline Blends..1-7
Engine Lubrication..1-7
Winter Lubrication...1-8
Installation...1-19
Exhaust System Leak Check..1-20
Exhaust System Leakage..1-20
1.8 TIRES AND WHEELS
General...1-21
Tires..1-21
Tire Replacement...1-22
Inspection..1-22
When To Replace Tires...1-22
Wheel Bearings..1-22
Wheel Spokes...1-22
Identify Wheel Spoke Groups..1-23
Wheel Spoke Adjustment..1-23
1.9 PRIMARY CHAINCASE LUBRICANT
General...1-24
Changing Primary Chaincase Lubricant...1-24
1.10 TRANSMISSION LUBRICANT
Checking Transmission Lubricant...1-26
Changing Transmission Lubricant..1-26
1.11 CLUTCH
Adjustment..1-28
1.12 DRIVE BELT AND SPROCKETS
General...1-29
Cleaning..1-29
Inspection...1-29
Sprockets...1-29
Drive Belt...1-29
Checking Drive Belt Deflection...1-31
Setting Belt Deflection..1-31
Adjustment...1-31
Assembly...1-32
1.13 REAR SPROCKET ISOLATOR
Inspection...1-34
1.14 CABLE AND CHASSIS LUBRICATION
General...1-35
Steering Head Bearings..1-35
Jiffy Stand...1-35
Miscellaneous Lubrication..1-35
Hinges, Latches, Etc..1-35
1.15 BRAKES
Fluid Inspection...1-36
Brake Lines...1-36
1.4 BULB REQUIREMENTS 1.16 BRAKE PADS AND DISCS
General...1-9 Inspection...1-37
Brake Pads..1-37
Brake Disc Thickness..1-37
Brake Disc Lateral Runout..1-37
Brake Pad Replacement...1-37
Rear Brake Caliper..1-37
Front Brake Calipers..1-39
1.5 MAINTENANCE SCHEDULE
General...1-11
1.6 ENGINE OIL AND FILTER
Engine Oil Level..1-16
Oil Level Cold Check...1-16
Oil Level Hot Check...1-16
Changing Oil and Oil Filter..1-17
1.7 AIR CLEANER AND EXHAUST SYSTEM
Removal..1-19
1.17 SPARK PLUGS
Removal..1-41
Inspection...1-41
Cleaning..1-41
Installation...1-41
Spark Plug Cable Inspection..1-42
1.18 STEERING HEAD BEARINGS
Lubrication..1-43
Checking...1-43
Adjustment..1-44
1.19 REAR SUSPENSION ADJUSTMENTS
Air Suspension..1-46
Manual Suspension Preload...1-47
1.20 CRITICAL FASTENERS
Inspection...1-49
Checking Torques on Fasteners..1-49
1.21 BATTERY MAINTENANCE
General...1-50
Cleaning and Inspection...1-51
Battery..1-51
Disconnection and Removal..1-51
Installation and Connection...1-51
Voltmeter Test...1-52
Voltmeter Test..1-52
Charging Battery...1-52
Safety Precautions..1-52
Using a Battery Charger..1-53
Storage...1-53
1.22 HEADLAMP ALIGNMENT
Headlamp Alignment..1-55
Headlamp Adjustment: Single Headlamp Models..1-55
Headlamp Adjustment: Dual Headlamp Models...1-56
Auxiliary/Fog Lamp Alignment..1-57
Oil Does Not Return To Oil Reservoir..1-61
Engine Uses Too Much Oil Or Smokes Excessively..1-61
Engine Leaks Oil From Cases, Push Rods, Hoses,
Etc...1-61
Low Oil Pressure...1-62
High Oil Pressure..1-62
Electrical System..1-62
Alternator Does Not Charge..1-62
Alternator Charge Rate Is Below Normal..1-62
Speedometer Operates Erratically..1-62
Transmission..1-62
Shifts Hard...1-62
Jumps Out Of Gear...1-62
Clutch Slips..1-62
Clutch Drags Or Does Not Release..1-62
Clutch Chatters..1-62
Handling..1-62
Irregularities...1-62
Brakes...1-63
Brake Does Not Hold Normally...1-63
CHASSIS
2.1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter..2-1
2.2 SPECIFICATIONS
Specifications..2-7
Chassis Specifications..2-7
Tire Specifications...2-8
2.3 VEHICLE IDENTIFICATION NUMBER
(V.I.N.)
1.23 ENGINE MOUNTS Vehicle Identification Number: Touring Models...2-11
Inspection...1-58
General..1-58
Stabilizer Link..1-58
Front Engine Mount...1-58
Rear Frame Fasteners..1-58 2.4 FRONT WHEEL
1.24 STORAGE
General...1-59
Placing in Storage...1-59
Removal from Storage..1-59
1.25 TROUBLESHOOTING
General...1-60
Engine...1-60
Starter Motor Does Not Operate or Does Not Turn Engine
Over ..1-60
Engine Turns Over But Does Not Start ..1-60
Starts Hard..1-60
Starts But Runs Irregularly or Misses ...1-60
A Spark Plug Fouls Repeatedly..1-61
Pre-Ignition or Detonation (Knocks or Pings)..1-61
Overheating...1-61
Valve Train Noise...1-61
Excessive Vibration...1-61
Check Engine Light Illuminates During Operation...1-61
Lubrication System...1-61
Oil Does Not Return To Oil Reservoir..1-61
Engine Uses Too Much Oil Or Smokes Excessively..1-61
Engine Leaks Oil From Cases, Push Rods, Hoses,
Etc...1-61
Low Oil Pressure...1-62
High Oil Pressure..1-62
Electrical System..1-62
Alternator Does Not Charge..1-62
Alternator Charge Rate Is Below Normal..1-62
Speedometer Operates Erratically..1-62
Transmission..1-62
Shifts Hard...1-62
Jumps Out Of Gear...1-62
Clutch Slips..1-62
Clutch Drags Or Does Not Release..1-62
Clutch Chatters..1-62
Handling..1-62
Irregularities...1-62
Brakes...1-63
Brake Does Not Hold Normally...1-63
CHASSIS
2.1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter..2-1
2.2 SPECIFICATIONS
Specifications..2-7
Chassis Specifications..2-7
Tire Specifications...2-8
2.3 VEHICLE IDENTIFICATION NUMBER
2.4 FRONT WHEEL
2.5 REAR WHEEL
Removal..2-16
Cleaning and Inspection...2-17
Installation...2-18
2.6 REAR WHEEL COMPENSATOR
Isolator Replacement..2-20
Removal..2-20
Installation...2-20
Sprocket Bearing Replacement..2-20
Removal..2-20
Installation...2-20
2.7 WHEEL LACING: FRONT RIM
Wheel Lacing: Angle Flange Hub...2-22
2.8 WHEEL LACING: 16 INCH REAR RIM
Wheel Lacing: 16 In. Rear Wheel...2-24
2.9 CHECKING AND TRUING WHEELS 2.15 REAR BRAKE CALIPER
General...2-27
Checking Wheel Runout...2-27
Checking Radial Runout..2-27
Checking Lateral Runout...2-27
Laced Wheel Rim Offset...2-28
Truing Laced Wheels..2-30
Radial Runout..2-30
Lateral Runout...2-30 Removal..2-52
Installation...2-52
2.10 SEALED WHEEL BEARINGS Removal..2-55
Disassembly...2-55
Draining...2-55
Disassembly..2-55
Cleaning and Inspection...2-57
Assembly..2-58
Filling...2-59
Installation...2-59
Inspection...2-32
Removal..2-32
Installation...2-33
2.11 TIRES
General...2-35
Removal..2-35
Cleaning, Inspection and Repair..2-35
Installation...2-36
Tube Type Tires...2-36
Tubeless Tires: Cast Wheels...2-36
Tubeless Tires: Laced Wheels..2-37
Checking Tire Runout...2-38
Lateral Runout...2-38
Radial Runout..2-38
Wheel Balancing...2-39
Static vs Dynamic..2-39
Weights..2-39
2.12 FRONT BRAKE MASTER CYLINDER
General...2-40
Removal and Disassembly...2-40
Removal..2-40
Disassembly..2-40
Cleaning and Inspection...2-42
Assembly and Installation...2-42
Assembly...2-42
Installation...2-42
Front Brake Line: Non-ABS Equipped..2-42
Removal..2-42
Installation...2-43
2.13 FRONT BRAKE CALIPER
Removal..2-45
Installation...2-45
2.14 REAR BRAKE MASTER CYLINDER
General...2-46
Removal and Disassembly...2-46
Removal..2-46
Disassembly..2-46
Cleaning and Inspection...2-48
Assembly and Installation...2-48
Assembly...2-48
Installation...2-48
Rear Brake Line: Non-ABS Equipped..2-48
Removal..2-48
Installation...2-50
2.16 BLEEDING BRAKES
General...2-53
Procedure...2-53
2.17 FRONT FORK
2.18 STEERING HEAD BEARINGS
Removal..2-60
Inspection...2-61
Installation...2-62
2.19 REAR AIR SUSPENSION
Check for Air Leaks..2-63
Compression Fitting...2-63
Air Valve Assembly..2-63
Air Tubes...2-63
Shock Absorber Removal...2-64
Cleaning and Inspection...2-64
Disassembly and Assembly..2-64
Shock Absorber Installation..2-64
2.20 REAR SHOCK ABSORBERS: MANUAL
ADJUST
Repair...2-65
2.21 REAR FORK
Removal..2-66
Disassembly and Assembly..2-66
Bearing Removal...2-66
Bearing Installation..2-67
Pivot Shaft/Mount Disassembly...2-67
Installation...2-68
2.22 CLUTCH CABLE
Removal..2-69
Installation...2-69
2.23 HANDLEBARS
Adjustment..2-71
Removal..2-71
Installation...2-72
Left Handgrip..2-73
Removal..2-73
Installation...2-73
Right Handgrip..2-73
Removal..2-73
Installation...2-73
Heated Handgrips...2-73
Remove Left Handgrip..2-73
Install Left Handgrip...2-74
Remove Right Handgrip..2-74
Install Right Handgrip..2-74
Rubber Mounts...2-75
Removal..2-75
Installation...2-75
2.24 MIRRORS
All Models Except FLHX...2-76
Removal..2-76
Installation...2-76
FLHX...2-76
Removal..2-76
Installation...2-76
2.25 SEAT
Seat: Models without Tour-Pak...2-77
Removal..2-77
Installation...2-77
Seat: Models with Tour-Pak..2-78
Removal..2-78
Installation...2-78
Seat: Road King Models...2-78
Removal..2-78
Installation...2-78
Seat Retention Nut Replacement...2-79
Seat Bumper...2-79
2.26 SADDLEBAGS
Removal..2-80
Installation...2-80
2.27 SADDLEBAG SERVICE
Saddlebag Hardware..2-81
Removal..2-81
Installation...2-82
Saddlebag Guard/Support Rail...2-82
Removal..2-82
Installation...2-82
Removal..2-87
Installation...2-87
Tether..2-88
Removal..2-88
Installation...2-88
Tether Brackets...2-88
Removing Tether Bracket from Tour-Pak..2-88
Removing Tether Bracket from Tour-Pak Lid...2-88
Installing Tether Bracket on Tour-Pak Lid..2-88
Installing Tether Bracket on Tour-Pak..2-88
Luggage Rack...2-88
2.30 TOUR-PAK LIGHTS
General...2-90
Side Marker Lights (if equipped)...2-90
Removal..2-90
Installation...2-90
Tour-Pak Lights Harness..2-90
Removal..2-90
Installation...2-90
Wrap-Around Lights (if equipped)...2-91
Bulb Replacement...2-91
Removal..2-91
Installation...2-92
2.31 TOUR-PAK BACKREST
Passenger Backrest..2-93
Removal..2-93
Installation...2-93
Rubber Isolators...2-93
Removal..2-93
Installation...2-93
Passenger Backrest Flap..2-94
Removal..2-94
Installation...2-94
2.32 TOUR-PAK SPEAKER BOX
Speaker Box...2-95
Removal..2-95
Installation...2-95
2.28 TOUR-PAK 2.33 LOWER FAIRING AND ENGINE GUARD
Removal/Installation...2-84
Removal..2-84
Installation...2-84
Adjustment..2-85
Luggage Rack/Tour-Pak Support...2-85
Removal..2-85
Assembly and Installation..2-85 Lower Fairing..2-96
Removal..2-96
Disassembly..2-97
Assembly...2-97
Installation...2-98
Serrated Washer Replacement..2-98
Removal..2-98
Installation...2-98
Engine Guard..2-98
Removal..2-98
Installation...2-98
2.29 TOUR-PAK SERVICE
Lockset...2-86
Removal..2-86
Installation...2-86
Hinges...2-86
Removal..2-86
Installation...2-87
Latches/Lockset Catch...2-87
Removal..2-87
Installation...2-87
Catches...2-87
2.34 UPPER FAIRING AND WINDSHIELD:
FORK MOUNTED FAIRING MODELS
Outer Fairing and Windshield...2-100
Removal..2-100
Installation...2-100
2.35 FAIRING CAP: FORK MOUNTED
FAIRING MODELS
Fairing Cap...2-101
Removal..2-101
Installation...2-101
2.36 INNER FAIRING: FORK MOUNTED
FAIRING MODELS
Removal..2-102
Installation...2-104
2.37 AIR DEFLECTORS
Fairing Air Deflectors..2-106
Removal: Fork Mounted Fairing Models...2-106
Installation: Fork Mounted Fairing Models..2-106
Removal: Frame Mounted Fairing Models..2-106
Installation: Frame Mounted Fairing Models...2-106
Mid-Frame Air Deflectors..2-106
Removal..2-106
Installation...2-106
2.38 UPPER FAIRING AND WINDSHIELD:
FRAME MOUNTED FAIRING MODELS
Windshield..2-108
Removal..2-108
Installation...2-108
Outer Fairing...2-108
Removal..2-108
Installation...2-109
2.39 INSTRUMENT BEZEL: FRAME
MOUNTED FAIRING MODELS
Bezel...2-111
Removal..2-111
Installation...2-111
2.40 INSTRUMENT NACELLE: FRAME
MOUNTED FAIRING MODELS
Instrument Nacelle..2-112
Removal..2-112
Installation...2-113
2.41 INNER FAIRING: FRAME MOUNTED
FAIRING MODELS
Removal..2-114
Inner Fairing..2-114
Fairing Bracket..2-115
Installation...2-116
Fairing Bracket..2-116
Inner Fairing..2-116
2.42 GLOVE BOX DOOR AND HINGE:
FRAME MOUNTED FAIRING MODELS
Glove Box Door and Hinge...2-118
Removal..2-118
Installation...2-118
2.43 WINDSHIELD: ROAD KING MODELS
Windshield..2-119
Removal..2-119
Installation...2-119
Windshield Window..2-119
Removal..2-119
Installation...2-120
2.44 HEADLAMP NACELLE: ROAD KING
MODELS
Removal..2-122
Installation...2-123
2.45 FRONT FENDER
Removal..2-124
Installation...2-125
2.46 REAR FENDER
Removal..2-126
Fender Repair...2-127
Mounting Hardware...2-127
Lights and Harnesses..2-127
Installation...2-128
2.47 REAR FASCIA
Removal..2-129
Installation...2-129
Stud Plate...2-129
Removal..2-129
Installation...2-129
Rear Fascia Lamp..2-129
2.48 REAR FRAME
Rear Frame...2-130
Removal..2-130
Installation...2-131
Thread Repair..2-131
2.49 FOOTBOARDS AND FOOTRESTS
Rider Footboards..2-132
Removal..2-132
Installation...2-132
Disassembly..2-132
Assembly...2-133
Passenger Footboard...2-133
Removal..2-133
Disassembly..2-133
Assembly...2-133
Installation...2-133
Passenger Footrest: FLHX, FLTRX..2-134
Removal..2-134
Disassembly..2-134
Assembly...2-134
Installation...2-134
2.50 JIFFY STAND
General...2-135
Leg Removal...2-135
Leg Installation..2-135
Jiffy Stand Bracket..2-136
Removal..2-136
Installation...2-136
Jiffy Stand Interlock Sensor..2-136
Removal..2-136
Installation...2-137
Assembly..3-21
Installation...3-21
3.11 HOW TO USE THIS SECTION
2.51 FRONT ENGINE MOUNT Top End Repair...3-23
Bottom End Repair...3-23
Typical Symptoms...3-23
Removal..2-138
Installation...2-138 3.12 TOP END SERVICE
2.52 MEDALLIONS, SERIALIZED BADGES
AND TANK EMBLEMS
Removal..2-140
Installation...2-140
ENGINE
3.1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter..3-1
3.2 SPECIFICATIONS
Specifications..3-3
3.3 SERVICE WEAR LIMITS
General...3-5
3.4 ENGINE OIL FLOW
Oil Feed..3-7
Top End...3-7
Bottom End...3-9
Oil Return..3-11
Oil Cooler Operation...3-12
3.5 OIL PUMP OPERATION
General...3-13
Operation..3-13
3.6 BREATHER OPERATION
General...3-15
3.7 OIL PRESSURE
Oil Pressure Indicator Lamp...3-16
Checking Oil Pressure..3-16
3.8 TROUBLESHOOTING
Diagnosing Valve Train Noise...3-18
Compression Test...3-18
Cylinder Leakdown Test...3-19
Diagnosing Smoking Engine or High Oil Consumption...3-19
Check Prior To Cylinder Head Removal..3-19
Check After Cylinder Head Removal...3-19
3.9 OIL COOLER
Removal..3-20
Installation...3-20
3.10 OIL COOLER ADAPTER
Removal..3-21
Disassembly...3-21
VIII TABLE OF CONTENTS
Engine in Chassis...3-24
Engine Removed from Chassis..3-25
3.13 CAM COMPARTMENT SERVICE
Engine in Chassis...3-26
Engine Removed From Chassis...3-27
3.14 STRIPPING MOTORCYCLE FOR
SERVICE
Procedure...3-28
Cam Compartment Service Only...3-28
Top End Service..3-28
3.15 ASSEMBLING MOTORCYCLE AFTER
SERVICE
Procedure...3-29
After Top End Service..3-29
After Cam Compartment Service..3-29
3.16 REMOVING ENGINE FROM CHASSIS
Procedure...3-30
3.17 INSTALLING ENGINE IN CHASSIS
Procedure...3-31
3.18 TOP END OVERHAUL: DISASSEMBLY
General...3-32
Rocker Covers..3-32
Rocker Arm Support Plate..3-32
Pushrods, Lifters and Covers...3-34
Cylinder Head...3-34
Cylinder...3-35
Piston..3-36
3.19 BREATHER ASSEMBLY
Disassembly...3-38
Cleaning and Inspection...3-38
Assembly..3-38
3.20 ROCKER ARM SUPPORT PLATE
Disassembly...3-39
Cleaning and Inspection...3-39
Inspection..3-39
Rocker Shaft Fit...3-39
Rocker Arm Shaft to Bushing..3-40
Replace Rocker Arm Bushings...3-40
Assembly..3-41
3.21 PUSHRODS, LIFTERS AND COVERS
Disassembly...3-42
Cleaning and General Inspection...3-42
Lifter Inspection..3-43
Assembly..3-43 Installation...3-79
Cam Support Plate and Cover Installation...3-80
3.22 CYLINDER HEAD 3.27 OIL PUMP
Disassembly...3-44
Cleaning..3-45
Inspection...3-45
Cylinder Head..3-45
Valve Guides...3-46
Valves..3-46
Valve Springs...3-46
Tapered Keepers...3-46
Valve Seats..3-46
Valve Guide Replacement..3-46
Removal..3-46
Installation...3-47
Valve and Seat Refacing..3-50
Assembly..3-52 Removal..3-84
Cleaning and Inspection...3-84
Installation...3-85
3.23 CYLINDER
Cleaning..3-54
Inspection...3-54
Deglazing Cylinder..3-56
Boring and Honing Cylinder..3-56
3.24 PISTON
Disassembly...3-58
Piston Rings..3-58
Cleaning..3-58
Inspection...3-58
Assembly..3-60
Checking Piston Ring Gap..3-60
Installing Piston Rings...3-60
3.25 TOP END OVERHAUL: ASSEMBLY
General...3-62
Piston..3-62
Cylinder...3-63
Cylinder Head...3-65
Push Rods, Lifters and Covers...3-69
Rocker Arm Support Plate..3-70
Breather and Rocker Cover..3-71
3.26 CAM COMPARTMENT AND
COMPONENTS
Cam Support Plate and Cover Removal..3-72
Prepare Engine..3-72
Cam Chain and Sprockets Removal...3-72
Cam Support Plate Removal...3-73
Cam Support Plate Cleaning and Inspection..3-74
Oil Pressure Valve...3-74
Cam Support Plate..3-74
Camshafts...3-75
Removal..3-75
Installation...3-75
Oil Pressure Relief Valve..3-77
Removal..3-77
Inspection..3-77
Installation...3-77
Cam Needle Bearings...3-77
Removal..3-77
3.28 CRANKCASE DISASSEMBLY AND
REPAIR
Crankcase Disassembly...3-86
Cleaning and Inspection...3-86
Right Crankcase Half..3-87
Main Bearing Removal..3-87
Main Bearing Installation...3-87
Piston Jets Removal..3-88
Piston Jets Installation...3-88
Left Crankcase Half..3-88
Main Bearing Removal..3-88
Main Bearing Installation...3-89
Sprocket Shaft Bearing Inner Race..3-90
Removal..3-90
Installation...3-91
Cylinder Studs..3-93
Removal..3-93
Installation...3-93
Pipe Plug and Oil Fittings...3-94
Removal..3-94
Installation...3-94
3.29 FLYWHEEL AND CONNECTING RODS
General...3-95
Symptoms..3-95
No Oil Pressure...3-95
Vibration..3-95
Inspection...3-95
Measuring Crankshaft Runout..3-95
Crankshaft Installed...3-95
Crankshaft Removed...3-96
3.30 CRANKCASE ASSEMBLY
Crankcase Assembly..3-98
3.31 OIL PAN
Removal..3-100
Installation...3-100
FUEL SYSTEM
4.1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter..4-1
4.2 SPECIFICATIONS: FUEL SYSTEM
Specifications..4-2
4.3 AIR CLEANER ASSEMBLY
Removal..4-3
Installation...4-3
4.4 FUEL TANK
Console...4-5
Removal..4-5
Installation...4-5
Removal..4-5
Purge and Disconnect Fuel Line...4-5
Remove Tank...4-5
Installation...4-6
Vent Tube: Models Without EVAP System...4-6
Removal..4-6
Installation...4-6
Fuel Supply Check Valve/Tube...4-7
Removal..4-7
Installation...4-7
Removal..4-22
Installation...4-22
4.15 FUEL PUMP
General...4-24
Removal..4-24
Installation...4-24
Fuel Pump and Fuel Level Sender Wire Harness..4-25
Removal..4-25
Installation...4-25
4.16 FUEL PRESSURE TEST
General...4-26
Testing..4-26
4.5 FUEL TANK TOP PLATE 4.17 EXHAUST SYSTEM
Removal..4-8
Installation...4-9 Mufflers...4-28
Removal..4-28
Installation...4-28
System Removal...4-28
System Installation..4-30
4.6 FUEL FILTER
Removal..4-10
Installation...4-10
4.7 FUEL PRESSURE REGULATOR
Removal..4-11
Installation...4-11
4.8 FUEL LEVEL SENDER
Removal..4-12
Installation...4-12
4.9 TWIST GRIP SENSOR
Removal..4-13
Installation...4-14
Twist Grip Sensor Jumper Harness..4-15
Removal..4-15
Installation...4-15
4.10 THROTTLE CONTROL ACTUATOR
(TCA)
General...4-16
4.11 INDUCTION MODULE
Removal..4-17
Installation...4-18
4.12 TEMPERATURE MANIFOLD ABSOLUTE
PRESSURE SENSOR (TMAP)
General...4-19
Removal..4-19
Installation...4-19
4.13 OXYGEN SENSORS (O2)
General...4-20
Removal..4-20
Installation...4-21
4.14 FUEL INJECTORS
General...4-22
X TABLE OF CONTENTS
4.18 ACTIVE EXHAUST (HDI)
Exhaust Valve Actuator...4-31
Removal..4-31
Installation...4-31
Exhaust Valve Actuator Cable..4-31
Removal..4-31
Installation...4-31
Active Exhaust Valve..4-31
General..4-31
4.19 INTAKE LEAK TEST
General...4-32
Leak Tester...4-32
Parts List..4-32
Tester Assembly..4-32
Tester Adjustment..4-32
Procedure...4-32
4.20 EVAPORATIVE EMISSIONS CONTROL
SYSTEM
General...4-34
Vapor Valve...4-34
Fuel Vapor Vent Tube...4-35
Removal..4-35
Installation...4-35
Canister-to-Solenoid Tube..4-35
Removal..4-35
Installation...4-35
Solenoid-to-Induction Module Tube..4-35
Removal..4-35
Installation...4-35
Purge Solenoid...4-35
Removal..4-35
Installation...4-36
Charcoal Canister...4-36
Removal..4-36
Installation...4-36
DRIVE
5.1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter..5-1
5.2 SPECIFICATIONS: DRIVE
Specifications..5-2
5.3 PRIMARY CHAINCASE COVER
General...5-3
Removal..5-3
Installation...5-3
5.4 DRIVE COMPONENTS
Removal..5-5
Installation...5-7
5.5 PRIMARY CHAINCASE HOUSING
Removal..5-10
Inspection...5-10
Mainshaft Bearing and Seal...5-10
Removal..5-10
Installation...5-10
Mainshaft Bearing Inner Race..5-11
Removal..5-11
Installation...5-11
Shifter Shaft Bushings..5-12
Installation...5-12
6.3 TRANSMISSION
Power Flow...6-4
Neutral...6-4
1st Gear...6-4
2nd Gear..6-4
3rd Gear..6-4
4th Gear...6-4
5th Gear...6-4
6th Gear...6-4
6.4 SHIFTER LINKAGE
Shifter Rod Adjustment...6-6
Heel-Toe Shift Levers...6-6
Removal..6-6
Repair..6-6
Installation...6-6
Shifter Rod Lever, Front..6-6
Removal..6-6
Installation...6-6
6.5 CLUTCH RELEASE COVER
Removal and Disassembly...6-8
Cleaning and Inspection...6-8
Assembly and Installation...6-9
6.6 TRANSMISSION ASSEMBLY
Removal and Installation..5-14
Clutch Pack Only..5-14
Partial Disassembly...5-14
Cleaning And Inspection...5-14
Assembly...5-15
Clutch Pack and Bearing..5-16
Complete Disassembly..5-16
Assembly...5-17 Removal..6-10
Disassembly...6-11
Shifter Cam/Shifter Forks..6-11
Mainshaft...6-13
Countershaft..6-15
Removing Bearing Housing Bearings...6-16
Cleaning and Inspection...6-17
Assembly..6-17
Installing Bearing Housing Bearings...6-17
Countershaft..6-17
Mainshaft...6-18
Shifter Cam/Shifter Forks..6-18
Installation...6-20
5.7 TRANSMISSION SPROCKET 6.7 MAIN DRIVE GEAR AND BEARING
Removal..5-19
Cleaning and Inspection...5-19
Installation...5-19 Removal..6-22
Cleaning and Inspection...6-23
Needle Bearing Replacement...6-24
Mainshaft Seal Replacement..6-25
Installation...6-26
Installing Main Drive Gear Bearing..6-26
Installing Main Drive Gear...6-26
Installing Main Drive Gear Large Seal...6-27
5.6 CLUTCH
5.8 DRIVE BELT
Removal and Adjustment...5-21
Adjustment...5-21
Removal..5-21
Installation...5-21
TRANSMISSION
6.1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter..6-1
6.2 SPECIFICATIONS: TRANSMISSION
Specifications..6-2
Service Wear Limits..6-2
6.8 TRANSMISSION CASE
Removal..6-29
Installation...6-29
Disassembly...6-30
Shifter Arm Assembly..6-30
Cleaning and Inspection...6-30
Assembly..6-31
Countershaft Needle Bearing Replacement..6-31
Shifter Pawl Lever Assembly...6-31
ELECTRICAL
7.1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter..7-1
7.2 SPECIFICATIONS: ELECTRICAL
Specifications..7-4
7.3 ELECTRONIC CONTROL MODULE (ECM)
ECM..7-5
Removal..7-5
Installation...7-5
7.4 TURN SIGNAL AND SECURITY MODULE
(TSM/TSSM/HFSM)
General...7-6
Removal..7-6
Installation...7-6
HFSM Antenna...7-7
Removal..7-7
Installation...7-7
7.5 IGNITION COIL
Removal..7-8
Installation...7-8
7.6 SYSTEM FUSES AND RELAYS
Main Fuse...7-9
Removal..7-9
Installation...7-9
System Fuses and Relays..7-9
Removal..7-9
Installation...7-9
Main Fuse Holder...7-9
Removal..7-9
Installation...7-10
Fuse Blocks..7-10
Removal..7-10
Installation...7-10
7.7 ELECTRICAL CADDIES
Top Caddy...7-11
Removal..7-11
Installation...7-11
Left Side Caddy..7-11
Removal..7-11
Installation...7-12
Battery Tray..7-14
Removal..7-14
Installation...7-14
7.8 SECURITY SIREN
Removal..7-15
Installation...7-15
7.9 STARTER
General...7-16
Removal..7-16
Drive Assembly...7-16
XII TABLE OF CONTENTS
Disassembly..7-16
Inspection..7-16
Assembly...7-17
Solenoid..7-17
Cover and Plunger Removal...7-17
Short Post Contact: Starter...7-17
Long Post Contact: Battery Positive..7-18
Plunger and Cover Installation..7-18
Installation...7-18
7.10 HEADLAMP: ALL EXCEPT ROAD GLIDE
Headlamp: Single Headlamp Models...7-20
Removal..7-20
Bulb Replacement...7-20
Installation...7-20
7.11 HEADLAMP: ROAD GLIDE
Headlamp Adjuster Assembly..7-22
Removal..7-22
Repair..7-22
Installation...7-22
Headlamp Bulb Replacement: Dual Headlamp Models..7-22
Removal..7-22
Bulb Replacement...7-22
Installation...7-23
7.12 AUXILIARY/FOG LAMPS AND
BRACKETS
Auxiliary/Fog Lamp Bulb Replacement..7-24
Removal..7-24
Installation...7-24
Auxiliary/Fog Lamp Housing...7-25
Removal..7-25
Installation...7-26
Auxiliary/Fog Lamp Bracket..7-27
Removal..7-27
Installation...7-27
Adjustment..7-27
7.13 TAIL LAMP
Tail Lamp Bulb Replacement..7-28
Removal..7-28
Installation...7-28
Circuit Board/Chrome Base..7-28
Removal..7-28
Installation...7-29
Rear Fender Lights Harness: all except FLHX, FLTRX...7-29
Removal..7-29
Installation...7-30
Rear Fascia Lamp..7-31
Removal..7-31
Installation...7-31
Rear Fender Lights Harness: FLHX, FLTRX..7-31
Removal..7-31
Installation...7-31
7.14 FENDER TIP LAMPS
Front Fender Tip Lamp...7-33
Removal..7-33
Installation...7-33
Front Fender Tip Lamp Jumper Harness..7-33
Rear Fender Tip Lamp..7-35
Removal..7-35
Installation...7-35
7.15 TURN SIGNAL LAMPS
Turn Signal Bulb Replacement: Bullet Style...7-37
Turn Signal Bulb Replacement: Flat Lens Style...7-37
Front Turn Signal Lamp..7-37
Removal: Flat Lens Style..7-37
Installation: Flat Lens Style...7-38
Removal: Bullet Style, Fork Mounted..7-39
Installation: Bullet Style, Fork Mounted...7-40
Removal: Bullet Style, Fairing Mounted..7-40
Installation: Bullet Style, Fairing Mounted...7-41
Rear Turn Signal Lamp...7-41
Removal: FLHR/C, FLHTC/U, FLHTK...7-41
Installation: FLHR/C, FLHTC/U, FLHTK..7-42
Removal: FLHX, FLTRX, FLTRU...7-42
Installation: FLHX, FLTRX, FLTRU..7-42
Rear Turn Signal Lamps Bracket..7-44
Removal: FLHR/C, FLHTC/U, FLHTK...7-44
Installation: FLHR/C, FLHTC/U, FLHTK..7-44
Removal: FLHX, FLTRX, FLTRU...7-44
Installation: FLHX, FLTRX, FLTRU..7-45
7.20 ENGINE TEMPERATURE SENSOR (ET)
Removal..7-56
Installation...7-56
7.21 AUTOMATIC COMPRESSION RELEASE
(ACR)
General...7-57
Removal..7-57
Installation...7-57
7.22 VOLTAGE REGULATOR
Removal..7-59
Installation...7-59
7.23 ALTERNATOR
Removal..7-60
Cleaning and Inspection...7-60
Installation...7-61
7.24 VEHICLE SPEED SENSOR (VSS)
VSS...7-62
Removal..7-62
Installation...7-62
7.25 NEUTRAL SWITCH
7.16 IGNITION/LIGHT KEY SWITCH AND
FORK LOCK Removal..7-63
Installation...7-63
Fairing Models..7-46
Removal..7-46
Installation...7-48
Road King Models..7-49
Ignition/Light Key Switch: Removal...7-49
Ignition/Light Key Switch: Installation..7-49
Fork Lock: Removal...7-49
Fork Lock: Installation..7-49 7.26 OIL PRESSURE SWITCH AND SENDER
7.17 FAIRING CAP SWITCHES: FORK
MOUNTED FAIRING MODELS
Removal..7-51
Installation...7-51
7.18 INSTRUMENT NACELLE SWITCHES:
FRAME MOUNTED FAIRING MODELS
Removal..7-53
Left Side Switch...7-53
Right Side Switches...7-53
Installation...7-54
Left Side Switch...7-54
Right Side Switches...7-54
Final Assembly..7-54
7.19 CRANKSHAFT POSITION SENSOR
(CKP)
General...7-55
Removal..7-55
Installation...7-55
Removal..7-64
Installation...7-64
7.27 STOP LAMP SWITCHES
Front Stop Lamp Switch...7-65
Removal/Installation..7-65
Rear Stop Lamp Switch..7-65
Removal..7-65
Installation...7-65
7.28 HORN
Inspection...7-66
Removal..7-66
Installation...7-66
7.29 CIGARETTE LIGHTER: FAIRING
MODELS
Troubleshooting..7-68
Removal..7-68
Installation...7-68
7.30 GAUGES AND INSTRUMENTS: FAIRING
MODELS
2 Inch Diameter Gauges: Fuel Level, Ambient Air Temperature,
Voltmeter, Oil Pressure...7-69
Removal..7-69
Installation...7-69
Tachometer...7-69
Removal..7-69
Installation...7-69
Speedometer..7-70
Removal..7-70
Installation...7-70
7.31 INDICATOR LAMPS: FAIRING MODELS
Indicator Lamps..7-71
Removal..7-71
Installation...7-71
7.32 GAUGES AND INSTRUMENTS: ROAD
KING MODELS
Fuel Gauge...7-72
Removal..7-72
Installation...7-72
Speedometer..7-72
Removal..7-72
Installation...7-73
7.33 INDICATOR LAMPS: ROAD KING
MODELS
Indicator Lamps..7-74
Removal..7-74
Installation...7-74
7.34 ADVANCED AUDIO SYSTEM
Radio..7-75
Removal..7-75
Installation...7-75
Front Fairing Speakers...7-76
Removal..7-76
Installation...7-76
Front Headset Receptacle..7-76
Removal..7-76
Installation...7-76
Rear Headset Receptacle..7-77
Rear Passenger Switches..7-77
Removal..7-77
Installation...7-77
Rear Speakers..7-78
Removal..7-78
Installation...7-78
CB Module..7-79
Removal..7-79
Installation...7-79
7.35 WIRE TROUGH
Removal..7-80
Installation...7-81
7.36 MAIN WIRING HARNESS
Removal: All Models (Part 1)..7-82
Removal: Road King Models (Part 2)...7-82
Removal: Fork Mounted Fairing Models (Part 2)..7-83
Removal: Frame Mounted Fairing Models (Part 2)..7-84
Removal: All Models (Part 3)..7-84
Installation: All Models (Part 1)...7-86
Installation: Road King Models (Part 2)..7-88
Installation: Fork Mounted Fairing Models (Part 2)...7-89
Installation: Frame Mounted Fairing Models (Part 2)...7-89
Installation: All Models (Part 3)...7-89
XIV TABLE OF CONTENTS
7.37 INTERCONNECT HARNESS
Fork Mounted Fairing Models...7-90
Removal..7-90
Installation...7-92
Frame Mounted Fairing Models..7-93
Removal..7-93
Installation...7-95
7.38 RADIO ANTENNA CABLE
Models Equipped with Tour-Pak...7-96
Removal..7-96
Installation...7-96
Models without Tour-Pak..7-97
Removal..7-97
Installation...7-97
7.39 REAR AUDIO HARNESS: ULTRA
MODELS
Removal..7-99
Installation...7-99
7.40 CB ANTENNA CABLE: ULTRA MODELS
Removal..7-101
Installation...7-101
7.41 HANDLEBAR SWITCH ASSEMBLIES
Removal..7-103
Right Handlebar Controls..7-103
Left Handlebar Controls..7-103
Specific Repair Procedures: Upper Switch Housings...7-103
Right Side Handlebar (All Models)..7-103
Left Side Handlebar (All Models)...7-105
Specific Repair Procedures: Right Side Lower Switch
Housings...7-106
Preliminary Instructions...7-106
Turn-Right Signal Switch (All Models)...7-106
Front Stop Lamp Switch (All Models)..7-106
Mode Select Switch (Classic and Ultra Models)..7-106
Cruise Set/Resume Switch (Road King Classic and Ultra
Models)..7-107
Final Instructions...7-108
Specific Repair Procedures: Left Side Lower Switch
Housings...7-109
Preliminary Instructions...7-109
Turn-Left Signal Switch (All Models)...7-109
Clutch Interlock Switch..7-109
Audio Control Switch (Classic and Ultra Models)...7-111
CB Push-To-Transmit Switch (Ultra Models)...7-111
Cruise On/Off Switch (Road King Classic Models)..7-111
Final Instructions...7-112
General Repair Procedures..7-112
Installation...7-114
Right Handlebar Controls..7-114
Left Handlebar Controls..7-115
7.42 TSSM/HFSM MAINTENANCE
General...7-118
Fob Battery...7-118
Battery Replacement Schedule...7-118
Battery Replacement...7-118
Smart Siren (If Installed)...7-118
Battery Replacement Schedule...7-118
Battery Replacement...7-118
Installing Socket Terminals...A-7
Crimping Terminals...A-7
7.43 PERSONAL IDENTIFICATION NUMBER
(PIN) A.6 DELPHI 480 METRI-PACK UNSEALED
CONNECTORS
General...7-119
Initial PIN Entry...7-119
Changing the PIN...7-119
Modifying an Existing PIN...7-119 Delphi 480 Metri-Pack Unsealed Connector Repair..A-8
General...A-8
Separating Pin and Socket Housings...A-8
Mating Pin and Socket Housings..A-8
Removing Socket Terminals...A-8
Installing Socket Terminals...A-8
7.44 H-DSSS ACTUATION
General...7-121
Actuation...7-121
Fob Assignment..7-121
Power Disruption and Configuring..7-121
7.45 TSM/HFSM: PASSWORD LEARN
General...7-122
Password Learn..7-122
APPENDIX A CONNECTOR REPAIR
A.1 AUTOFUSE UNSEALED ELECTRICAL
CONNECTORS
Autofuse Unsealed Connector Repair..A-1
General...A-1
Disassembly..A-1
Assembly...A-1
A.2 BOSCH COMPACT 1.1M CONNECTOR
A.7 DELPHI 630 METRI-PACK UNSEALED
CONNECTORS
Delphi 630 Metri-Pack Unsealed Connector Repair..A-9
Separating Pin and Socket Housings...A-9
Mating Pin and Socket Housings..A-9
Removing Socket Terminal...A-9
Installing Socket Terminal...A-9
A.8 DELPHI 800 METRI-PACK SEALED MAIN
FUSE HOUSING
Delphi 800 Metri-Pack Sealed Main Fuse Housing
Repair...A-10
Removing Socket Terminals...A-10
Installing Socket Terminals...A-10
A.9 DELPHI METRI-PACK TERMINAL
REPAIR
Bosch Compact 1.1M Connector...A-2
General...A-2
Housings...A-2
Removing Socket Terminal...A-2
Installing Socket Terminal...A-2 Metri-Pack Terminal Crimps...A-11
Matching Terminal To Crimper..A-11
Preparing Wire Lead...A-11
Crimping Wire Core...A-11
Crimping Insulation/Seal...A-11
Inspecting Crimps...A-12
A.3 DELPHI 100W MICRO-PACK SEALED
CONNECTOR A.10 DELPHI MICRO 64 SEALED
CONNECTORS
Delphi 100W Micro-Pack Sealed Connector Repair..A-3
General...A-3
Separating Socket Housing From ECM..A-3
Mating Socket Housing To ECM...A-3
Removing Socket Terminal...A-3
Installing Socket Terminal...A-3
Crimping Terminals...A-4 Delphi Micro 64 Sealed Connector Repair...A-13
General...A-13
Separating Pin and Socket Housings...A-13
Mating Pin and Socket Housings..A-13
Removing Terminal...A-13
Installing Terminal...A-14
Preparing Wire Leads for Crimping...A-14
Crimping Terminals...A-14
Inspecting Crimps...A-14
A.4 DELPHI 150 METRI-PACK SEALED
CONNECTORS
Delphi 150 Metri-Pack Sealed Connector Repair..A-5
General...A-5
Separating Pin and Socket Housings...A-5
Mating Pin and Socket Housings..A-5
Removing Socket Terminal...A-5
Inserting Socket Terminal..A-5
A.5 DELPHI 280 METRI-PACK UNSEALED
CONNECTORS
A.11 DELPHI GT 150 SEALED
CONNECTORS
Delphi GT 150 Sealed Connector Repair...A-16
General...A-16
Separating Pin and Socket Housings...A-16
Mating Pin and Socket Housings..A-16
Removing Socket Terminals...A-16
Installing Socket Terminals...A-16
Fuse Block Repair..A-7
Removing Socket Terminals...A-7
A.12 DELPHI GT 280 SEALED 73-TERMINAL
ECM CONNECTOR
Delphi GT 280 Sealed 73-Terminal ECM Connector...A-18
Separating Socket Housing From ECM..A-18
Mating Socket Housing To ECM...A-18
Socket Terminal...A-18
ECM Ground Terminal..A-18
A.13 DEUTSCH DT SEALED CONNECTORS
Deutsch DT Sealed Connector Repair...A-20
General...A-20
Separating Pin and Socket Housings...A-20
Mating Pin and Socket Housings..A-20
Removing Socket Terminals...A-20
Installing Socket Terminals...A-20
Removing Pin Terminals...A-22
Installing Pin Terminals...A-22
Crimping Terminals...A-23
A.14 DEUTSCH DT SEALED TERMINAL
REPAIR
Deutsch DT Sealed Terminal Crimps...A-24
Preparing Wire Leads for Crimping...A-24
Crimping Terminal to Lead..A-24
Inspecting Crimps...A-24
A.15 DEUTSCH DTM SEALED MINI
TERMINAL REPAIR
Deutsch DTM Sealed Mini Terminal Crimps..A-25
Preparing Wire Leads for Crimping...A-25
Crimping a Mini Terminal to Wire Lead...A-25
Inspecting Crimps...A-25
A.16 DEUTSCH DTM SEALED SOLID
BARREL MINI TERMINAL REPAIR
Deutsch DTM Sealed Solid Barrel Terminal Crimps..A-26
Preparing Wire Leads For Crimping...A-26
Adjusting Crimper Tool..A-26
Crimping a Barrel Contact To Wire Lead..A-26
Inspecting Crimps...A-26
A.17 JAE MX19 SEALED CONNECTORS
JAE MX19 Sealed Connectors...A-28
Connector Housings...A-28
Removing Terminals...A-28
Installing Terminals..A-28
Crimping Terminals...A-28
Mating Pin and Socket Housings..A-31
Removing Terminals...A-31
Installing Terminals..A-31
Crimp Terminal to Lead..A-32
Prepare Lead..A-32
Prepare Tool..A-32
Position Terminal in the Punch/Die...A-33
Insert Stripped Lead..A-33
Crimp Terminal to Lead...A-34
Inspect Crimp..A-34
A.20 TYCO 070 MULTILOCK UNSEALED
CONNECTOR
Tyco 070 Multilock Unsealed Connector Repair..A-35
General...A-35
Separating Pin and Socket Housings...A-35
Mating Pin and Socket Housings..A-35
Removing Terminals from Housing...A-35
Inserting Terminals into Housing...A-36
Preparing Wire Leads for Crimping...A-36
Crimping Terminals to Leads..A-37
Inspecting Crimped Terminals...A-38
A.21 TYCO GET 64 SEALED CONNECTOR
Tyco GET 64 Sealed Connector..A-39
General...A-39
Housings...A-39
Removing Socket Terminals...A-39
Installing Socket Terminals...A-39
Crimping Terminals...A-40
A.22 TYCO MCP SEALED CONNECTOR
Tyco MCP Sealed Connector...A-41
General...A-41
Housing...A-41
Removing the Large Terminals...A-41
Removing the Small Terminals...A-41
Installing Terminals..A-42
Crimping Terminals...A-42
A.23 SEALED SPLICE CONNECTORS
Sealed Splice Connector Repair..A-43
General...A-43
Preparing Wire Leads...A-43
Splicing Wire Leads..A-43
Inspecting Seals..A-43
APPENDIX B WIRING
A.18 MOLEX CMC SEALED CONNECTORS B.1 CONNECTORS
Molex CMC Sealed Connectors...A-29
Separating the Connector...A-29
Removing Terminals...A-29
Installing Terminals..A-29
Crimping Terminals...A-30 Connector Locations..B-1
Function/Location..B-1
Place and Color...B-1
Connector Number..B-1
Repair Instructions..B-1
A.19 MOLEX MX 150 SEALED
CONNECTORS B.2 WIRING DIAGRAMS
Molex MX 150 Sealed Connector Repair...A-31
Separating Pin and Socket Housings...A-31
XVI TABLE OF CONTENTS
Wiring Diagram Information..B-7
Wire Color Codes..B-7
Wiring Diagram Symbols..B-7
2013 Touring Wiring Diagrams...B-9
APPENDIX C ABS
C.1 FASTENER TORQUE VALUES
ABS Module to Rear Brake Caliper...C-12
Removal..C-12
Installation...C-12
Fastener Torque Values in this Chapter...C-1 APPENDIX D CONVERSIONS
C.2 ABS MODULE D.1 METRIC CONVERSION
Hydraulic Control Unit (HCU)...C-2
Removal..C-2
Installation...C-3
Electronic Control Unit (ECU)..C-3
Removal..C-3
Installation...C-4 Conversion Table...D-1
C.3 WHEEL SPEED SENSORS
Front Wheel Speed Sensor (WSS)..C-5
Removal..C-5
Installation...C-5
Rear Wheel Speed Sensor..C-6
Removal..C-6
Installation...C-6
C.4 ABS BRAKE LINES
Front Master Cylinder to ABS Module...C-7
Removal..C-7
Installation...C-8
ABS Module to Front Brake Calipers...C-8
Removal..C-8
Installation...C-9
Rear Master Cylinder to ABS Module..C-10
Removal..C-10
Installation...C-11
D.2 FLUID CONVERSIONS
United States System...D-2
Metric System..D-2
British Imperial System..D-2
D.3 TORQUE CONVERSIONS
United States System...D-3
Metric System..D-3
APPENDIX E GLOSSARY
E.1 GLOSSARY
Acronyms and Abbreviations...E-1
REFERENCE MATERIAL
TOOLS...I
TORQUE VALUES...IX
INDEX..XXV