2005 Harley Davidson Sportster XLH Models Electrical Diagnostics + Service Manual – PDF DOWNLOAD
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
2005 Harley Davidson Sportster XLH Models Electrical Diagnostics + Service Manual – PDF DOWNLOAD
SERVICE MANUAL
Part Number 99484-05
ELECTRICAL DIAGNOSTICS
Part Number 99495-05
GENERAL
SERVICING A NEW MOTORCYCLE
- Service operations to be performed before customer delivery are specified in the applicable model year PREDELIVERY AND SETUP MANUAL. The performance of new motorcycle initial service is required to keep warranty in force and to ensure proper emissions systems operation.
- After a new motorcycle has been driven its first 1000 miles (1600 km), and at every 5000 mile (8000 km) interval thereafter, have a Harley-Davidson dealer perform the service operations listed under 1.3 MAINTENANCE SCHEDULE.
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.
TABLE OF CONTENTS:
2005 Harley Davidson Sportster XLH Models Electrical Diagnostics + Service Manual – PDF DOWNLOAD
2005 XLH MODELS..................................................................... 1 SERVICE MANUAL.................................................................. 1 Part Number 99484-05........................................................ 1 ELECTRICAL DIAGNOSTICS.......................................................... 1 Part Number 99495-05........................................................ 1 sm01a.pdf........................................................................... 0 GENERAL 1.1..................................................................... 5 SERVICING A NEW MOTORCYCLE.................................................. 5 SHOP PRACTICES.............................................................. 5 Repair Notes............................................................ 5 Safety.................................................................. 5 Removing Parts.......................................................... 5 Cleaning................................................................ 5 Disassembly and Assembly................................................ 5 REPAIR AND REPLACEMENT PROCEDURES........................................... 6 Hardware and Threaded Parts............................................. 6 Wiring, Hoses and Lines................................................. 6 Instruments and Gauges.................................................. 6 Bearings................................................................ 6 Bushings................................................................ 6 Gaskets................................................................. 6 Lip Type Seals.......................................................... 6 O-Rings (Preformed Packings)............................................ 6 Gears................................................................... 7 Shafts.................................................................. 7 Part Replacement........................................................ 7 CLEANING.................................................................... 7 Part Protection......................................................... 7 Cleaning Process........................................................ 7 Rust or Corrosion Removal............................................... 7 Bearings................................................................ 7 TOOL SAFETY................................................................. 7 Air Tools............................................................... 7 Wrenches................................................................ 7 Pliers/Cutters/Prybars.................................................. 7 Hammers................................................................. 8 Punches/Chisels......................................................... 8 Screwdrivers............................................................ 8 Ratchets and Handles.................................................... 8 Sockets................................................................. 8 Storage Units........................................................... 8 FUEL AND OIL 1.2................................................................ 9 FUEL........................................................................ 9 GASOLINE BLENDS............................................................. 9 ENGINE OIL.................................................................. 9 WINTER LUBRICATION.......................................................... 9 MAINTENANCE SCHEDULE 1.3........................................................ 10 CRITICAL FASTENERS 1.4.......................................................... 14 INSPECTION.................................................................. 14 ENGINE OIL AND FILTER 1.5....................................................... 15 CHECKING AND ADDING OIL..................................................... 15 Removing and Replacing Oil Filler Cap................................... 15 Checking Oil With Cold Engine........................................... 15 Checking Oil With Warm Engine........................................... 15 CHANGING OIL AND FILTER..................................................... 16 General................................................................. 16 Draining Oil Tank....................................................... 16 Removing Oil Filter..................................................... 17 Installing New Oil Filter............................................... 17 Refilling Oil Tank...................................................... 17 BATTERY MAINTENANCE 1.6......................................................... 18 GENERAL..................................................................... 18 LEFT SIDE COVER............................................................. 19 Removal................................................................. 19 Installation............................................................ 19 BATTERY DISCONNECTION AND REMOVAL........................................... 20 BATTERY INSPECTION.......................................................... 20 BATTERY STORAGE............................................................. 21 BATTERY INSTALLATION AND CONNECTION......................................... 21 BRAKES 1.7...................................................................... 22 GENERAL..................................................................... 22 INSPECTION.................................................................. 22 TROUBLESHOOTING............................................................. 22 BLEEDING HYDRAULIC BRAKE SYSTEM 1.8............................................. 23 GENERAL..................................................................... 23 BLEEDING FRONT BRAKE........................................................ 23 BLEEDING REAR BRAKE......................................................... 25 BRAKE PADS AND DISCS 1.9........................................................ 26 INSPECTION.................................................................. 26 Brake Pads.............................................................. 26 Brake Disc Thickness, Lateral Runout and Warpage........................ 26 BRAKE PAD REPLACEMENT....................................................... 26 Front Brake Caliper..................................................... 26 Rear Brake Caliper...................................................... 29 TIRES AND WHEELS 1.10........................................................... 31 TIRES....................................................................... 31 TIRE WEAR INDICATORS........................................................ 31 WHEEL BEARINGS.............................................................. 32 WHEEL SPOKES................................................................ 32 PRIMARY CHAIN 1.11.............................................................. 33 INSPECTION.................................................................. 33 ADJUSTMENT.................................................................. 33 CLUTCH 1.12..................................................................... 34 ADJUSTMENT.................................................................. 34 TRANSMISSION LUBRICANT 1.13..................................................... 36 GENERAL..................................................................... 36 DRAINING LUBRICANT.......................................................... 36 REFILLING LUBRICANT......................................................... 36 REAR BELT DEFLECTION 1.14....................................................... 38 INSPECTION.................................................................. 38 BELT DEFLECTION ADJUSTMENT.................................................. 40 WHEEL ALIGNMENT............................................................. 41 Checking Wheel Alignment................................................ 41 Wheel Alignment Adjustment.............................................. 41 REAR BELT AND SPROCKETS 1.15.................................................... 42 GENERAL..................................................................... 42 CLEANING.................................................................... 42 INSPECTION.................................................................. 42 Sprockets............................................................... 42 Rear Belt............................................................... 42 SHOCK ABSORBER ADJUSTMENT 1.16.................................................. 44 GENERAL..................................................................... 44 PROCEDURE................................................................... 44 STEERING HEAD BEARINGS 1.17..................................................... 45 GENERAL..................................................................... 45 ADJUSTMENT.................................................................. 45 LUBRICATION................................................................. 45 REAR FORK BEARINGS 1.18......................................................... 46 GENERAL..................................................................... 46 PROCEDURE................................................................... 46 sm01b.pdf........................................................................... 0 Front Fork Oil 1.19............................................................. 47 GENERAL..................................................................... 47 CHANGING FORK OIL........................................................... 47 Filling Fork Oil–Forks Assembled, in Frame.............................. 48 Filling Fork Oil - Forks Disassembled, out of Frame..................... 48 SPARK PLUGS 1.20................................................................ 49 GENERAL..................................................................... 49 ADJUSTMENT.................................................................. 49 CLEANING AND INSPECTION..................................................... 49 Inspection.............................................................. 49 Spark Plug Condition.................................................... 49 Cleaning................................................................ 49 INSTALLATION................................................................ 49 CABLE AND CHASSIS LUBRICATION 1.21.............................................. 50 GENERAL..................................................................... 50 CABLES AND HAND LEVERS...................................................... 50 FOOT SHIFT LEVER AND REAR BRAKE PEDAL....................................... 50 JIFFY STAND................................................................. 50 Steering Head Bearings...................................................... 50 AIR FILTER ELEMENT 1.22......................................................... 51 GENERAL..................................................................... 51 REMOVAL..................................................................... 51 CLEANING, INSPECTION AND REPAIR............................................. 52 INSTALLATION................................................................ 52 THROTTLE CABLES AND ENRICHENER 1.23............................................. 53 CABLE INSPECTION, LUBRICATION AND ADJUSTMENT................................ 53 Inspection and Lubrication.............................................. 53 Adjustment.............................................................. 53 ENRICHENER ADJUSTMENT....................................................... 54 IDLE SPEED AND IGNITION TIMING 1.24............................................. 55 IDLE SPEED ADJUSTMENT....................................................... 55 IGNITION TIMING............................................................. 55 FUEL SUPPLY VALVE FILTER 1.25................................................... 56 INSPECTION.................................................................. 56 FUEL SYSTEM LINES AND FITTINGS.............................................. 57 ENGINE MOUNTS AND STABILIZER LINKS 1.26......................................... 58 INSPECTION.................................................................. 58 HEADLAMP ALIGNMENT 1.27......................................................... 59 INSPECTION.................................................................. 59 ADJUSTMENT.................................................................. 59 XL 883C and XL 1200C Models............................................. 59 XL 883, XL 883L and XL 1200R Models..................................... 60 FLUID/LUBRICANT REQUIREMENTS 1.28............................................... 61 BRAKE FLUID................................................................. 61 Brake Component Grease...................................................... 61 FRONT FORK OIL.............................................................. 61 ENGINE OIL.................................................................. 61 PRIMARY DRIVE/TRANSMISSION LUBRICANT........................................ 61 STORAGE 1.29.................................................................... 62 GENERAL..................................................................... 62 REMOVAL FROM STORAGE........................................................ 63 TROUBLESHOOTING 1.30............................................................ 64 GENERAL..................................................................... 64 ENGINE...................................................................... 64 Starting Motor Does Not Operate or Does Not Turn Engine Over............ 64 Engine Turns Over But Does Not Start.................................... 64 Starts Hard............................................................. 64 Starts But Runs Irregularly or Misses................................... 64 Spark Plug Fouls Repeatedly............................................. 65 Pre-Ignition or Detonation (Knocks or Pings)............................ 65 Overheating............................................................. 65 Valve Train Noise....................................................... 65 Excessive Vibration..................................................... 65 ENGINE LUBRICATION SYSTEM................................................... 65 Oil Does Not Return To Oil Tank......................................... 65 Engine Uses Too Much Oil or Smokes Excessively.......................... 65 Engine Leaks Oil From Cases, Push Rods, Hoses, Etc...................... 65 ELECTRICAL SYSTEM........................................................... 65 Alternator Does Not Charge.............................................. 65 Alternator Charge Rate Is Below Normal.................................. 65 Speedometer Operates Erratically........................................ 65 FUEL........................................................................ 66 Carburetor Floods....................................................... 66 TRANSMISSION................................................................ 66 Shifts Hard............................................................. 66 Jumps Out of Gear....................................................... 66 CLUTCH...................................................................... 66 Slips................................................................... 66 Drags or Does Not Release............................................... 66 Chatters................................................................ 66 CHASSIS..................................................................... 66 Irregular/Inadequate Brake Action....................................... 66 Handling Irregularities................................................. 66 sm02a.pdf........................................................................... 0 SPECIFICATIONS 2.1.............................................................. 69 TIRES....................................................................... 70 TORQUE VALUES 2.2............................................................... 71 VEHICLE IDENTIFICATION NUMBER (VIN) 2.3......................................... 74 GENERAL..................................................................... 74 WHEELS 2.4...................................................................... 75 GENERAL..................................................................... 75 TROUBLESHOOTING............................................................. 75 FRONT WHEEL................................................................. 77 Removal................................................................. 77 Disassembly............................................................. 79 Cleaning and Inspection................................................. 79 Assembly................................................................ 79 Installation............................................................ 80 REAR WHEEL.................................................................. 81 Removal................................................................. 81 Disassembly............................................................. 83 Cleaning and Inspection................................................. 83 Assembly................................................................ 83 Installation............................................................ 84 SEALED WHEEL BEARINGS....................................................... 85 Inspection.............................................................. 85 Removal................................................................. 85 Installation............................................................ 85 WHEEL LACING: 16 INCH RIM 2.5................................................... 87 GENERAL..................................................................... 87 Procedure................................................................... 88 WHEEL LACING: 19 INCH RIM 2.6................................................... 90 General..................................................................... 90 PROCEDURE................................................................... 90 WHEEL LACING: 21 INCH RIM 2.7................................................... 94 General..................................................................... 94 PROCEDURE................................................................... 94 TRUING LACED WHEELS 2.8......................................................... 98 PROCEDURE................................................................... 98 CHECKING CAST RIM RUNOUT 2.9....................................................101 CHECKING LATERAL AND RADIAL RUNOUT..........................................101 TIRES 2.10......................................................................102 GENERAL.....................................................................102 REMOVAL.....................................................................102 CLEANING, INSPECTION AND REPAIR.............................................103 INSTALLATION................................................................103 Tube Type Tires.........................................................103 Tubeless Tires..........................................................104 CHECKING TIRE RUNOUT........................................................104 Lateral Runout..........................................................104 Radial Runout...........................................................105 Wheel Balancing.............................................................105 Weights For Laced Wheels................................................105 Weights for Cast Wheels.................................................105 sm02b.pdf........................................................................... 0 FRONT BRAKE MASTER CYLINDER 2.11................................................107 GENERAL.....................................................................107 REMOVAL.....................................................................107 DISASSEMBLY.................................................................108 CLEANING, INSPECTION AND REPAIR.............................................110 ASSEMBLY....................................................................110 INSTALLATION................................................................112 REAR BRAKE MASTER CYLINDER 2.12.................................................114 GENERAL.....................................................................114 REMOVAL.....................................................................114 DISASSEMBLY.................................................................117 CLEANING, INSPECTION AND REPAIR.............................................117 ASSEMBLY....................................................................118 INSTALLATION................................................................120 REAR BRAKE MASTER CYLINDER RESERVOIR 2.13.......................................121 GENERAL.....................................................................121 REMOVAL.....................................................................121 INSTALLATION................................................................122 FRONT BRAKE CALIPER 2.14........................................................123 REMOVAL.....................................................................123 DISASSEMBLY.................................................................124 CLEANING, INSPECTION AND REPAIR.............................................126 ASSEMBLY....................................................................126 LUBRICATING FRONT CALIPER BOLT PINS AND BOOTS...............................128 INSTALLATION................................................................129 REAR BRAKE CALIPER 2.15.........................................................131 REMOVAL.....................................................................131 DISASSEMBLY.................................................................133 CLEANING, INSPECTION AND REPAIR.............................................134 ASSEMBLY....................................................................135 LUBRICATING REAR CALIPER BOLT PINS AND BOOTS................................136 INSTALLATION................................................................137 BRAKE LINES 2.16................................................................140 FRONT BRAKE LINE............................................................140 Removal.................................................................140 Installation............................................................141 REAR BRAKE LINE.............................................................142 Removal.................................................................142 Installation............................................................142 FRONT FORK 2.17.................................................................144 GENERAL.....................................................................144 REMOVAL.....................................................................144 DISASSEMBLY.................................................................144 CLEANING, INSPECTION AND REPAIR.............................................144 ASSEMBLY....................................................................146 INSTALLATION................................................................146 FORK STEM AND BRACKET ASSEMBLY 2.18.............................................147 REMOVAL/DISASSEMBLY.........................................................147 CLEANING, INSPECTION AND REPAIR.............................................147 ASSEMBLY/INSTALLATION.......................................................147 REAR FORK 2.19..................................................................148 REMOVAL.....................................................................148 DISASSEMBLY.................................................................148 CLEANING AND INSPECTION.....................................................149 ASSEMBLY....................................................................149 INSTALLATION................................................................149 REAR SHOCK ABSORBER 2.20........................................................150 GENERAL.....................................................................150 REMOVAL.....................................................................150 CLEANING AND INSPECTION.....................................................150 INSTALLATION................................................................150 sm02c.pdf........................................................................... 0 STABILIZER LINKS 2.21...........................................................151 GENERAL.....................................................................151 UPPER FRONT STABILIZER LINK.................................................151 Removal.................................................................151 Installation............................................................151 LOWER FRONT STABILIZER LINK.................................................152 Removal.................................................................152 Installation............................................................152 REAR STABILIZER LINK........................................................152 Removal.................................................................152 Installation............................................................152 FRONT ENGINE MOUNT/ISOLATOR 2.22................................................153 REMOVAL.....................................................................153 INSTALLATION................................................................153 REAR ENGINE MOUNT/ISOLATOR 2.23.................................................154 REMOVAL.....................................................................154 INSTALLATION................................................................154 THROTTLE CONTROL 2.24...........................................................156 REMOVAL/DISASSEMBLY.........................................................156 CLEANING, INSPECTION AND REPAIR.............................................156 ASSEMBLY/INSTALLATION.......................................................156 HANDLEBARS 2.25.................................................................158 REMOVAL.....................................................................158 All Models..............................................................158 XL 883/XL 883L/XL 1200R.................................................158 XL 883C/XL 1200C........................................................159 INSTALLATION................................................................159 XL 883/XL 883L/XL 1200R.................................................159 XL 883C/XL 1200C........................................................159 All Models..............................................................160 CLUTCH CONTROL 2.26.............................................................161 GENERAL.....................................................................161 REMOVAL/DISASSEMBLY.........................................................161 Clutch Cable–Lower......................................................161 Clutch Lever and Clutch Cable–Upper.....................................162 Clutch Hand Control.....................................................162 ASSEMBLY/INSTALLATION.......................................................163 Clutch Hand Control.....................................................163 Clutch Lever and Clutch Cable–Upper.....................................163 Clutch Cable–Lower......................................................163 EXHAUST SYSTEM 2.27.............................................................164 REMOVAL.....................................................................164 Mufflers and Exhaust Pipes..............................................164 Muffler Interconnect Bracket............................................165 INSTALLATION................................................................166 Muffler Interconnect Bracket............................................166 Exhaust Pipes and Mufflers..............................................166 FRONT FENDER 2.28...............................................................167 REMOVAL.....................................................................167 INSTALLATION................................................................167 REAR FENDER 2.29................................................................168 REMOVAL.....................................................................168 INSTALLATION................................................................170 BELT GUARD/DEBRIS DEFLECTOR 2.30................................................171 REMOVAL.....................................................................171 Belt Guard..............................................................171 Debris Deflector........................................................171 INSTALLATION................................................................171 Belt Guard..............................................................171 Debris Deflector........................................................171 JIFFY STAND 2.31................................................................172 GENERAL.....................................................................172 REMOVAL.....................................................................173 CLEANING AND LUBRICATION....................................................173 INSTALLATION................................................................173 SEAT 2.32.......................................................................174 GENERAL.....................................................................174 REMOVAL.....................................................................174 INSTALLATION................................................................174 RIDER FOOT CONTROLS: XL 883/XL 883L/XL 1200R 2.33...............................176 RIGHT FOOTREST AND REAR BRAKE PEDAL ASSEMBLY................................176 Removal.................................................................176 Installation............................................................176 LEFT FOOTREST AND SHIFT LEVER ASSEMBLY......................................176 Removal.................................................................176 Installation............................................................176 RIDER FOOT CONTROLS: XL 883C/XL 1200C 2.34......................................178 RIGHT FOOTREST AND REAR BRAKE PEDAL ASSEMBLY................................178 Removal.................................................................178 Installation............................................................178 LEFT FOOTREST AND SHIFT LEVER ASSEMBLY......................................180 Removal.................................................................180 Installation............................................................180 ADJUSTING SHIFT PEDAL.......................................................181 PASSENGER FOOTRESTS 2.35........................................................182 GENERAL.....................................................................182 REMOVAL.....................................................................182 INSTALLATION................................................................182 FORK LOCK 2.36..................................................................183 REMOVAL.....................................................................183 INSTALLATION................................................................184 sm03a.pdf........................................................................... 0 SPECIFICATIONS 3.1..............................................................187 SERVICE WEAR LIMITS 3.2.........................................................190 GENERAL.....................................................................190 TORQUE VALUES 3.3...............................................................192 ENGINE 3.4......................................................................194 GENERAL.....................................................................194 TROUBLESHOOTING 3.5.............................................................195 DIAGNOSING VALVE TRAIN NOISE................................................195 COMPRESSION TEST............................................................195 Compression Test Procedure..............................................195 CYLINDER LEAKAGE TEST.......................................................196 Cylinder Leakage Test Procedure.........................................196 DIAGNOSING SMOKING ENGINE OR HIGH OIL CONSUMPTION...........................197 Check Prior To Cylinder Head Removal....................................197 Check After Cylinder Head Removal.......................................197 ADJUSTMENT/TESTING..........................................................197 General.................................................................197 ENGINE LUBRICATION SYSTEM 3.6...................................................198 GENERAL.....................................................................198 OIL PUMP....................................................................198 OIL PRESSURE 3.7................................................................201 GENERAL.....................................................................201 Oil Pressure Indicator Lamp.............................................201 CHECKING OIL PRESSURE.......................................................202 CRANKCASE BREATHING SYSTEM 3.8..................................................203 GENERAL.....................................................................203 HOW TO USE THIS SECTION 3.9.....................................................204 TYPICAL SYMPTOMS............................................................204 TOP END REPAIR..............................................................204 BOTTOM END REPAIR...........................................................204 TOP END SERVICE 3.10............................................................205 ENGINE IN CHASSIS...........................................................205 ENGINE REMOVED FROM CHASSIS.................................................206 BOTTOM END SERVICE 3.11.........................................................207 ENGINE IN CHASSIS: CAM COMPARTMENT SERVICE..................................207 ENGINE REMOVED: FLYWHEEL COMPARTMENT SERVICE OR COMPLETE ENGINE OVERHAUL....208 REMOVING ENGINE FROM CHASSIS 3.12...............................................209 GENERAL.....................................................................209 PROCEDURE...................................................................209 INSTALLING ENGINE IN CHASSIS 3.13...............................................213 GENERAL.....................................................................213 PROCEDURE...................................................................213 sm03b.pdf........................................................................... 0 TOP END OVERHAUL: DISASSEMBLY 3.14..............................................216 GENERAL.....................................................................216 STRIPPING MOTORCYCLE FOR TOP END REPAIR.....................................216 CYLINDER HEAD...............................................................217 Disassembling Rocker Covers.............................................217 Removing Cylinder Head..................................................218 Disassembling Push Rods and Covers......................................220 CYLINDER AND PISTON.........................................................220 CYLINDER HEAD 3.15..............................................................223 REMOVAL.....................................................................223 DISASSEMBLY.................................................................223 CLEANING AND INSPECTION.....................................................224 Cylinder Heads..........................................................224 Rocker Arm Assemblies...................................................225 Valves..................................................................226 Valve Seats.............................................................226 Valve Guides............................................................226 Valve Springs...........................................................226 Spark Plug Threads......................................................227 Push Rods...............................................................227 REPLACING ROCKER ARM BUSHINGS...............................................227 REPLACING VALVE GUIDES......................................................228 Removal.................................................................228 Installation............................................................229 REFACING VALVE SEATS........................................................232 Replacing Valve Seats...................................................234 ASSEMBLY....................................................................235 INSTALLATION................................................................236 CYLINDER AND PISTON 3.16........................................................237 REMOVAL/DISASSEMBLY.........................................................237 CLEANING, INSPECTION, AND REPAIR............................................237 Checking Gasket Surface.................................................237 Measuring Cylinder Bore.................................................238 Measuring Piston to Cylinder Fit........................................239 Boring and Honing Cylinder..............................................239 Fitting Piston Rings....................................................240 CONNECTING ROD BUSHINGS.....................................................241 Removing Upper Connecting Rod Bushing...................................241 Installing Upper Connecting Rod Bushing.................................243 Reaming Upper Connecting Rod Bushing....................................244 Honing Upper Connecting Rod Bushing.....................................244 Repair..................................................................244 ASSEMBLY/INSTALLATION.......................................................244 TOP END OVERHAUL: ASSEMBLY 3.17.................................................245 GENERAL.....................................................................245 PISTON AND CYLINDER.........................................................245 PUSH RODS, COVERS AND RETAINERS.............................................246 CYLINDER HEAD...............................................................247 Rocker Covers...............................................................249 ASSEMBLING MOTORCYCLE AFTER TOP END REPAIR..................................251 BOTTOM END OVERHAUL: DISASSEMBLY 3.18...........................................252 GENERAL.....................................................................252 TAPPETS.....................................................................252 OIL PUMP....................................................................252 GEARCASE COVER AND CAM GEARS................................................252 CRANKCASE...................................................................254 Removing Piston Oil Jets................................................255 Removing Cylinder Base Studs............................................255 VALVE TAPPETS 3.19..............................................................256 GENERAL.....................................................................256 REMOVAL.....................................................................256 CLEANING AND INSPECTION.....................................................256 INSTALLATION................................................................256 sm03c.pdf........................................................................... 0 GEARCASE COVER AND CAM GEARS 3.20...............................................258 GENERAL.....................................................................258 REMOVAL/DISASSEMBLY.........................................................258 CLEANING, INSPECTION AND REPAIR.............................................258 Cam and Pinion Gear Identification, Inspection and Selection............258 Bushing Inspection and Removal..........................................260 BUSHING INSTALLATION........................................................260 Cam Gear Bushings in Right Crankcase Half...............................260 Cam Gear Bushings (Except Rear Intake Bushing) in Gearcase Cover........261 Rear Intake Cam Gear Bushing in Gearcase Cover..........................261 Pinion Shaft Bushing in Gearcase Cover..................................261 BUSHING REAMING.............................................................262 Cam Gear Bushings in Right Crankcase Half...............................262 Cam Gear Bushings (Except Rear Intake Bushing) in Gearcase Cover........263 Rear Intake Cam Gear Bushing in Gearcase Cover..........................263 Pinion Shaft Bushing in Gearcase Cover..................................264 ASSEMBLY/INSTALLATION.......................................................264 OIL PUMP 3.21...................................................................265 GENERAL.....................................................................265 REMOVAL.....................................................................265 DISASSEMBLY.................................................................266 CLEANING, INSPECTION AND REPAIR.............................................266 ASSEMBLY....................................................................266 INSTALLATION................................................................266 OIL FILTER MOUNT 3.22...........................................................267 GENERAL.....................................................................267 DISASSEMBLY.................................................................267 CLEANING AND INSPECTION.....................................................267 ASSEMBLY....................................................................267 CRANKCASE 3.23..................................................................268 GENERAL.....................................................................268 REMOVAL.....................................................................268 DISASSEMBLY.................................................................269 FITTING PINION BEARINGS.....................................................271 Bearing Selection.......................................................272 LAPPING ENGINE MAIN BEARING RACES...........................................276 Assembling Crankcase Halves.................................................276 BOTTOM END OVERHAUL: ASSEMBLY 3.24..............................................277 GENERAL.....................................................................277 CRANKCASE...................................................................277 Installing Piston Oil Jets..............................................277 Installing Pinion Shaft Bearing.........................................278 Installing Left Main Bearing............................................279 Assembling Crankcase Halves.............................................279 Installing Cylinder Base Studs..........................................281 CAM GEARS AND GEARCASE COVER................................................282 TAPPETS.....................................................................285 ASSEMBLING TOP END OF ENGINE................................................285 OIL TANK 3.25...................................................................286 OIL HOSE ROUTING............................................................286 REMOVAL.....................................................................287 INSTALLATION................................................................289 sm04a.pdf........................................................................... 0 SPECIFICATIONS 4.1..............................................................292 TORQUE VALUES 4.2...............................................................293 TROUBLESHOOTING 4.3.............................................................294 ENRICHENER 4.4..................................................................296 GENERAL.....................................................................296 OPERATION...................................................................296 Cool Engine.............................................................296 Warm or Hot Engine......................................................296 CARBURETOR 4.5..................................................................297 GENERAL.....................................................................297 ADJUSTMENT..................................................................297 Float Level.............................................................297 OPERATION CHECK: VACUUM PISTON..............................................299 Opening Malfunction.....................................................299 Closing Malfunction.....................................................299 REMOVAL.....................................................................299 DISASSEMBLY.................................................................301 Vacuum Piston Chamber...................................................301 Carburetor Body.........................................................301 Accelerator Pump........................................................301 CLEANING, INSPECTION AND REPAIR.............................................302 Vacuum Piston Components................................................302 Carburetor Body Components..............................................302 Accelerator Pump........................................................302 ASSEMBLY....................................................................302 Vacuum Piston Chamber...................................................302 Carburetor Body.........................................................302 Accelerator Pump........................................................302 INSTALLATION................................................................303 Carburetor..............................................................303 Carburetor Fuel Overflow/Drain Hose Routing.............................303 AIR CLEANER 4.6.................................................................304 REMOVAL.....................................................................304 CLEANING, INSPECTION AND REPAIR.............................................305 INSTALLATION................................................................305 FUEL SUPPLY VALVE 4.7...........................................................306 GENERAL.....................................................................306 OPERATION...................................................................306 REMOVAL, INSPECTION AND INSTALLATION........................................306 TROUBLESHOOTING.............................................................307 Vacuum Test.............................................................307 FUEL TANK 4.8...................................................................308 GENERAL.....................................................................308 REMOVAL.....................................................................309 CLEANING, INSPECTION AND REPAIR.............................................310 INSTALLATION................................................................310 Console Replacement.........................................................311 Special Tools Needed....................................................311 Removal.................................................................311 Installation............................................................312 EVAPORATIVE EMISSIONS CONTROL–CA MODELS 4.9.....................................314 GENERAL.....................................................................314 REMOVAL.....................................................................315 Charcoal Canister.......................................................315 Vapor Valve.............................................................315 INSTALLATION................................................................316 Charcoal Canister.......................................................316 Vapor Valve.............................................................316 HOSE ROUTING................................................................317 Carburetor..............................................................317 Canister Hose Routings..................................................317 INTAKE LEAK TEST 4.10...........................................................318 GENERAL.....................................................................318 LEAK TESTER.................................................................318 Parts List..............................................................318 Tester Assembly.........................................................318 PROCEDURE...................................................................319 sm05a.pdf........................................................................... 0 SPECIFICATIONS 5.1..............................................................322 TORQUE VALUES 5.2...............................................................323 ELECTRIC STARTER SYSTEM 5.3.....................................................324 GENERAL.....................................................................324 Wiring Diagram..........................................................324 Starter Relay...........................................................324 Operation...................................................................324 STARTER MOTOR 5.4...............................................................327 REMOVAL.....................................................................327 DISASSEMBLY, INSPECTION AND REPAIR..........................................329 ASSEMBLY....................................................................332 INSTALLATION................................................................332 STARTER SOLENOID 5.5............................................................333 GENERAL.....................................................................333 DISASSEMBLY.................................................................333 ASSEMBLY....................................................................333 sm06a.pdf........................................................................... 0 SPECIFICATIONS 6.1..............................................................336 TORQUE VALUES 6.2...............................................................338 PRIMARY CHAIN ADJUSTER 6.3......................................................339 GENERAL.....................................................................339 REMOVAL.....................................................................339 Primary Cover...........................................................339 Primary Chain Adjuster..................................................341 INSTALLATION................................................................341 Primary Chain Adjuster..................................................341 Primary Cover...........................................................341 CLUTCH RELEASE MECHANISM 6.4....................................................343 REMOVAL/DISASSEMBLY.........................................................343 CLEANING, INSPECTION AND REPAIR.............................................344 ASSEMBLY/INSTALLATION.......................................................344 PRIMARY DRIVE/CLUTCH 6.5........................................................345 GENERAL.....................................................................345 REMOVAL.....................................................................347 DISASSEMBLY.................................................................347 INSPECTION AND REPAIR.......................................................348 ASSEMBLY....................................................................349 INSTALLATION................................................................351 SECONDARY DRIVE BELT 6.6........................................................352 REMOVAL.....................................................................352 INSTALLATION................................................................353 TRANSMISSION 6.7................................................................354 OPERATION...................................................................354 CASE DISASSEMBLY FOR TRANSMISSION REMOVAL 6.8...................................355 GENERAL.....................................................................355 RIGHT CRANKCASE REMOVAL.....................................................355 TRANSMISSION REMOVAL AND DISASSEMBLY 6.9........................................358 TRANSMISSION REMOVAL FROM LEFT CRANKCASE....................................358 MAINSHAFT/COUNTERSHAFT......................................................360 MAINSHAFT DISASSEMBLY.......................................................362 Cleaning And Inspection.................................................362 COUNTERSHAFT DISASSEMBLY....................................................363 Cleaning And Inspection.................................................363 TRANSMISSION ASSEMBLY 6.10......................................................364 MAINSHAFT ASSEMBLY..........................................................364 COUNTERSHAFT ASSEMBLY.......................................................365 MAIN DRIVE GEAR 6.11............................................................366 REMOVAL.....................................................................366 DISASSEMBLY.................................................................366 ASSEMBLY....................................................................367 INSTALLATION................................................................367 TRANSMISSION RIGHT CASE BEARINGS 6.12...........................................369 REMOVAL.....................................................................369 INSTALLATION................................................................369 Main Drive Gear Ball Bearing............................................369 Countershaft Needle Bearing.............................................369 Shifter Drum Bushing....................................................369 TRANSMISSION LEFT CASE BEARINGS 6.13............................................370 REMOVAL.....................................................................370 Mainshaft and Countershaft Bearings.....................................370 Shifter Drum Bushing....................................................370 INSTALLATION................................................................370 Mainshaft and Countershaft Bearings.....................................370 Shifter Drum Bushing....................................................370 TRANSMISSION INSTALLATION 6.14..................................................371 INSTALLATION................................................................371 SHIFTER FORKS AND DRUM ASSEMBLY.............................................372 ASSEMBLING CRANKCASES.......................................................373 SHIFTER SHAFT INSTALLATION..................................................375 TRANSMISSION SPROCKET 6.15......................................................376 REMOVAL.....................................................................376 INSTALLATION................................................................377 sm07a.pdf........................................................................... 0 SPECIFICATIONS 7.1..............................................................380 IGNITION....................................................................380 CHARGING SYSTEM.............................................................380 BATTERY.....................................................................380 FUSES.......................................................................380 TORQUE VALUEs 7.2...............................................................381 BULB REQUIREMENTS 7.3...........................................................382 BULB CHART..................................................................382 ELECTRICAL BRACKET 7.4..........................................................383 GENERAL.....................................................................383 REMOVAL.....................................................................383 INSTALLATION................................................................384 IGNITION SYSTEM 7.5.............................................................385 GENERAL.....................................................................385 TROUBLESHOOTING.............................................................385 MANIFOLD ABSOLUTE PRESSURE SENSOR: MAP 7.6......................................387 REMOVAL.....................................................................387 INSTALLATION................................................................387 IGNITION/LIGHT SWITCH 7.7.......................................................388 GENERAL.....................................................................388 REMOVAL.....................................................................389 INSTALLATION................................................................389 IGNITION CONTROL MODULE: ICM 7.8................................................390 GENERAL.....................................................................390 REMOVAL.....................................................................390 INSTALLATION................................................................390 SPARK PLUG CABLES 7.9...........................................................391 GENERAL.....................................................................391 REMOVAL.....................................................................391 INSPECTION..................................................................391 INSTALLATION................................................................391 IGNITION COIL 7.10..............................................................393 GENERAL.....................................................................393 TROUBLESHOOTING.............................................................393 REMOVAL.....................................................................393 INSTALLATION................................................................393 CHARGING SYSTEM 7.11............................................................394 GENERAL.....................................................................394 ALTERNATOR..................................................................394 VOLTAGE REGULATOR...........................................................394 ALTERNATOR 7.12.................................................................395 REMOVAL AND DISASSEMBLY.....................................................395 Rotor...................................................................395 Stator..................................................................395 CLEANING, INSPECTION AND REPAIR.............................................395 ASSEMBLY AND INSTALLATION...................................................396 Stator..................................................................396 Rotor...................................................................397 VOLTAGE REGULATOR 7.13..........................................................398 GENERAL.....................................................................398 REMOVAL.....................................................................398 INSTALLATION................................................................399 BATTERY 7.14....................................................................400 TESTING.....................................................................400 Voltmeter Test..........................................................400 Load Test...............................................................400 BATTERY CHARGING............................................................401 General.................................................................401 Safety Precautions......................................................401 Charging Battery........................................................402 BATTERY CABLES 7.15.............................................................403 REMOVAL.....................................................................403 INSTALLATION................................................................404 sm07b.pdf........................................................................... 0 HEADLAMP 7.16...................................................................406 REPLACEMENT: XL 883C/XL 1200C...............................................406 REPLACEMENT: XL 883/XL 883L/ XL 1200R.......................................409 INDICATOR LAMPS 7.17............................................................411 REPLACEMENT: XL 883C/XL 1200C...............................................411 REPLACEMENT: XL 883/XL 883L.................................................411 REPLACEMENT: XL 1200R.......................................................412 TAIL LAMP 7.18..................................................................413 BULB REPLACEMENT............................................................413 BASE REPLACEMENT............................................................413 TURN SIGNALS 7.19...............................................................415 BULB REPLACEMENT............................................................415 FRONT HOUSING REPLACEMENT...................................................415 REAR HOUSING REPLACEMENT....................................................417 REAR STOP LIGHT SWITCH 7.20.....................................................419 GENERAL.....................................................................419 REPLACEMENT.................................................................419 HANDLEBAR SWITCHES 7.21.........................................................420 GENERAL.....................................................................420 REPAIR PROCEDURES...........................................................420 CONNECTORS..................................................................421 RIGHT HANDLEBAR SWITCH 7.22.....................................................422 REMOVAL.....................................................................422 INSTALLATION................................................................423 DISASSEMBLY.................................................................425 SWITCH REPAIR/REPLACEMENT...................................................426 Upper Switch Housing Repair.............................................426 Lower Switch Housing Repair.............................................427 ASSEMBLY....................................................................428 LEFT HANDLEBAR SWITCH 7.23......................................................429 REMOVAL.....................................................................429 INSTALLATION................................................................429 DISASSEMBLY.................................................................430 SWITCH REPAIR/REPLACEMENT...................................................430 Upper Switch Housing Repair.............................................430 Lower Switch Housing Repair.............................................431 ASSEMBLY....................................................................432 HORN 7.24.......................................................................433 TROUBLESHOOTING.............................................................433 VOLTAGE TEST................................................................433 REPLACEMENT: ALL MODELS EXCEPT XL 1200C.....................................433 REPLACEMENT: XL 1200C.......................................................434 FUSES AND STARTER RELAY 7.25....................................................435 GENERAL.....................................................................435 REPLACING MAXI-FUSE.........................................................435 REPLACING 15-AMP FUSES......................................................436 REPLACING STARTER RELAY.....................................................436 MAXI-FUSE HOLDER 7.26...........................................................437 REPLACEMENT.................................................................437 RELAY/FUSE BLOCK 7.27...........................................................438 REMOVAL.....................................................................438 INSTALLATION................................................................439 SPEEDOMETER: XL 883/XL 883L 7.28................................................440 REMOVAL.....................................................................440 INSTALLATION................................................................440 SPEEDOMETER: XL 883C/XL 1200C 7.29..............................................441 REMOVAL.....................................................................441 INSTALLATION................................................................441 SPEEDOMETER AND TACHOMETER: XL 1200R 7.30.......................................442 TRIP ODOMETER RESET SWITCH REPLACEMENT......................................442 SPEEDOMETER REMOVAL.........................................................443 TACHOMETER REMOVAL..........................................................443 SPEEDOMETER INSTALLATION....................................................444 TACHOMETER INSTALLATION.....................................................444 TURN SIGNAL/SECURITY MODULE: TSM/TSSM 7.31......................................445 GENERAL.....................................................................445 REMOVAL.....................................................................445 TESTING.....................................................................445 INSTALLATION................................................................445 OIL PRESSURE SWITCH 7.32........................................................446 GENERAL.....................................................................446 REMOVAL.....................................................................446 INSTALLATION................................................................446 CRANK POSITION SENSOR: CKP 7.33.................................................447 GENERAL.....................................................................447 REMOVAL.....................................................................447 INSTALLATION................................................................447 VEHICLE SPEED SENSOR: VSS 7.34..................................................448 GENERAL.....................................................................448 REMOVAL.....................................................................448 INSTALLATION................................................................448 NEUTRAL INDICATOR SWITCH 7.35...................................................449 GENERAL.....................................................................449 TEST........................................................................449 REPLACEMENT.................................................................449 BANK ANGLE SENSOR: BAS 7.36.....................................................450 GENERAL.....................................................................450 OPERATION...................................................................450 TESTING.....................................................................450 REPLACEMENT.................................................................450 sm_appa.pdf......................................................................... 0 APPENDIX A–TOOLS A.1............................................................ 0 sm_appb1.pdf........................................................................ 0 APPENDIX B–WIRING AMP MULTILOCK ELECTRICAL CONNECTORS B.1....................... 0 REMOVING SOCKET/PIN TERMINALS............................................... 0 INSTALLING SOCKET/PIN TERMINALS............................................. 0 CRIMPING INSTRUCTIONS....................................................... 0 DEUTSCH ELECTRICAL CONNECTORS B.2............................................... 0 GENERAL..................................................................... 0 REMOVING/DISASSEMBLING...................................................... 0 REMOVING/INSTALLING SOCKETS................................................. 0 REMOVING/INSTALLING PINS.................................................... 0 ASSEMBLING/INSTALLING....................................................... 0 CRIMPING INSTRUCTIONS....................................................... 0 MINI-DEUTSCH CONNECTORS B.3..................................................... 0 GENERAL..................................................................... 0 For Size 20, 16 and 12 Contacts Wire Range 26-12 AWG.................... 0 CRIMPING INSTRUCTIONS....................................................... 0 PACKARD ELECTRICAL CONNECTORS B.4............................................... 0 GENERAL..................................................................... 0 REMOVING PULL-TO-SEAT TERMINALS/EXTERNAL LATCH TYPE......................... 0 INSTALLING PULL-TO-SEAT TERMINALS/EXTERNAL LATCH TYPE....................... 0 SEALED BUTT SPLICE CONNECTORS B.5............................................... 0 INSTALLING SEALED BUTT SPLICE CONNECTORS.................................... 0 CONNECTOR LOCATIONS B.6......................................................... 0 INDEX TO WIRING DIAGRAMS B.7.................................................... 0 sm_appc.pdf......................................................................... 0 APPENDIX C–METRIC CONVERSIONS C.1............................................... 0 FLUID CONVERSIONS C.2........................................................... 0 UNITED STATES SYSTEM........................................................ 0 METRIC SYSTEM............................................................... 0 BRITISH IMPERIAL SYSTEM..................................................... 0 sm_appd.pdf......................................................................... 0 APPENDIX D: COMPENSATING SPROCKET D.1........................................... 0 GENERAL..................................................................... 0 REMOVAL/DISASSEMBLY......................................................... 0 CLEANING, INSPECTION AND REPAIR............................................. 0 ASSEMBLY/INSTALLATION....................................................... 0 xe01a.pdf........................................................................... 0 STARTER TROUBLESHOOTING 1.1.....................................................454 STARTING SYSTEM DIAGNOSIS 1.2...................................................456 DIAGNOSTICS.................................................................456 Diagnostic Notes........................................................456 Starter Testing 1.......................................................457 Starter Testing 2: Solenoid Clicks......................................458 Starter Testing 3: Relay Clicks.........................................458 Starter Testing 4: Nothing Clicks.......................................459 Starter Testing 5: Starter Spins But Does Not Engage....................460 Starter Testing 6: Starter Stalls or Spins Too Slowly...................460 STARTER ACTIVATION CIRCUITS 1.3.................................................461 DIAGNOSTICS/TROUBLESHOOTING 1.4.................................................462 GENERAL.....................................................................462 VOLTAGE DROPS...............................................................462 TESTING STARTER ON MOTORCYCLE 1.5...............................................464 STARTER RELAY TEST..........................................................464 STARTER CURRENT DRAW TEST...................................................464 TESTING STARTER ON BENCH 1.6....................................................465 FREE RUNNING CURRENT DRAW TEST..............................................465 STARTER SOLENOID............................................................465 SOLENOID PULL-IN TEST.......................................................466 SOLENOID HOLD-IN TEST.......................................................466 SOLENOID RETURN TEST........................................................466 CHARGING SYSTEM 1.7.............................................................467 GENERAL.....................................................................467 Alternator..............................................................467 Voltage Regulator.......................................................467 TROUBLESHOOTING.............................................................467 Battery.................................................................467 Wiring..................................................................467 Voltage Regulator Inspection............................................467 Charging System Test 1.7 (Part 1 of 2)..................................469 Charging System Test 1.7 (Part 2 of 2)..................................470 TESTING.....................................................................471 Milliampere Draw Test...................................................471 Total Current Draw Test.................................................471 Current and Voltage Output Test.........................................472 Voltage Output Test.....................................................472 Stator Check............................................................472 AC Output Check.........................................................473 IGNITION COIL 1.8...............................................................474 TROUBLESHOOTING.............................................................474 Primary Circuit Test....................................................474 Secondary Circuit Test..................................................474 Test Results............................................................474 Ignition Coil Substitution..............................................474 BATTERY LOAD TEST 1.9...........................................................475 GENERAL.....................................................................475 xe02a.pdf........................................................................... 0 CHECKING FOR DIAGNOSTIC TROUBLE CODES 2.1.......................................478 CHECK ENGINE LAMP...........................................................478 SECURITY LAMP...............................................................479 Turn Signal Module (TSM)................................................479 Turn Signal Security Module (TSSM)......................................479 CODE TYPES..................................................................480 Current.................................................................480 Historic................................................................480 RETRIEVING DIAGNOSTIC TROUBLE CODES.........................................480 MULTIPLE DIAGNOSTIC TROUBLE CODES...........................................480 INITIAL DIAGNOSTIC CHECK: SPEEDOMETER 2.2.......................................481 GENERAL.....................................................................481 Diagnostic Notes........................................................481 Circuit Diagram/Wire Harness Connector Table............................481 Job/Time Code Values....................................................481 Reprogramming ICM.......................................................481 INITIAL DIAGNOSTICS.........................................................482 Diagnostic Tips.........................................................482 Diagnostic Notes........................................................482 Other Diagnostic Trouble Codes..........................................482 Initial Diagnostic Check (Part 1 of 3)..................................484 Initial Diagnostic Check (Part 2 of 3)..................................485 Initial Diagnostic Check (Part 3 of 3)..................................486 SPEEDOMETER SELF DIAGNOSTICS 2.3................................................487 GENERAL.....................................................................487 DIAGNOSTICS.................................................................487 Diagnostic Tips.........................................................487 Diagnostic Notes........................................................487 Speedometer Self Diagnostics (flow chart)...............................488 SPEEDOMETER/TACHOMETER 2.4......................................................489 GENERAL.....................................................................489 Reset Switch............................................................489 SPEEDOMETER THEORY OF OPERATION.............................................490 TACHOMETER THEORY OF OPERATION..............................................490 DIAGNOSTICS.................................................................490 Diagnostic Notes........................................................490 Test 2.4 (Part 1 of 2)..................................................492 TACHOMETER INOPERATIVE..................................................492 Test 2.4 (Part 2 of 2)..................................................493 BREAKOUT BOX: SPEEDOMETER/TACHOMETER 2.5........................................494 GENERAL.....................................................................494 SPEEDOMETER.................................................................494 Installation............................................................494 Removal.................................................................494 TACHOMETER..................................................................494 Installation............................................................494 Removal.................................................................494 INDICATOR LAMPS 2.6.............................................................495 GENERAL.....................................................................495 Job/Time Code Values....................................................495 Diagnostic Notes........................................................495 DIAGNOSTICS.................................................................497 Oil Pressure or Neutral Indicator Will Not Function.....................497 High Beam or R/L Turn Signal Indicator Will Not Function................497 DTC B1006, B1007 2.7............................................................498 GENERAL.....................................................................498 Accessory Or Ignition Line Overvoltage..................................498 Test 2.7................................................................499 DTC B1008 2.8...................................................................500 GENERAL.....................................................................500 Reset Switch Closed.....................................................500 Diagnostic Notes........................................................500 Test 2.8................................................................501 DTC U1016, U1255 2.9............................................................502 GENERAL.....................................................................502 Loss of ICM Serial Data.................................................502 DIAGNOSTICS.................................................................502 Diagnostic Notes........................................................502 Test 2.9................................................................504 DTC U1064, U1255 2.10...........................................................505 GENERAL.....................................................................505 Loss of TSM/TSSM Serial Data............................................505 DIAGNOSTICS.................................................................505 Diagnostic Notes........................................................505 Test 2.10...............................................................507 DTC U1300, U1301 OR BUS ER 2.11.................................................508 GENERAL.....................................................................508 Serial Data Low or Serial Data Open/High................................508 DIAGNOSTICS.................................................................508 Diagnostic Tips.........................................................508 Diagnostic Notes........................................................508 Test 2.11 (Part 1 of 2).................................................510 Test 2.11 (Part 2 of 2).................................................511 xe03a.pdf........................................................................... 0 TSM/TSSM OVERVIEW 3.1...........................................................514 GENERAL.....................................................................514 TROUBLESHOOTING.............................................................514 TSM/TSSM FEATURES 3.2...........................................................516 GENERAL.....................................................................516 TURN SIGNAL FUNCTIONS.......................................................516 BANK ANGLE FUNCTIONS........................................................516 SECURITY ALARM AND IMMOBILIZATION FUNCTIONS.................................516 TSSM Only Feature.......................................................516 TSM/TSSM VEHICLE DELIVERY 3.3...................................................518 GENERAL.....................................................................518 SIDECAR CONFIGURATION.......................................................518 POWER DISRUPTION AND CONFIGURING............................................518 KEY FOB ASSIGNMENT..........................................................519 PERSONAL CODE ENTRY.........................................................519 First Time Code Entry: TSSM Only........................................519 Modifying Existing Codes: TSSM Only.....................................519 TSM/TSSM TURN SIGNAL FUNCTIONS 3.4..............................................523 GENERAL.....................................................................523 AUTOMATIC CANCELLATION......................................................523 MANUAL CANCELLATION.........................................................523 FOUR-WAY FLASHING...........................................................523 DIAGNOSTICS MODE............................................................523 TSM/TSSM BANK ANGLE FUNCTION 3.5................................................524 GENERAL.....................................................................524 OPERATION...................................................................524 SECURITY SYSTEM (TSSM) FUNCTIONS 3.6............................................525 GENERAL.....................................................................525 Security System Operation...............................................525 Security System Options.................................................525 Differences By Market Specifications....................................525 ALARM SENSITIVITY...........................................................525 Sensitivity.............................................................525 Transport Mode..........................................................525 AUTO-ARMING FUNCTION........................................................526 STORAGE MODE................................................................526 ARMING/DISARMING SECURITY SYSTEM (TSSM) 3.7.....................................529 GENERAL.....................................................................529 SECURITY LAMP...............................................................529 USING KEY FOB...............................................................529 General.................................................................529 Arming the System.......................................................529 Disarming the System....................................................529 Troubleshooting.........................................................529 USING THE PERSONAL CODE.....................................................530 General.................................................................530 Disarming the System....................................................530 CHECKING FOR DIAGNOSTIC TROUBLE CODES 3.8.......................................531 TSM.........................................................................531 TSSM........................................................................531 CODE TYPES..................................................................533 Current.................................................................533 Historic................................................................533 RETRIEVING DIAGNOSTIC TROUBLE CODES.........................................533 MULTIPLE DIAGNOSTIC TROUBLE CODES...........................................533 INITIAL DIAGNOSTIC CHECK: TSM/TSSM 3.9..........................................534 GENERAL.....................................................................534 Diagnostic Notes........................................................534 Circuit Diagram/Wire Harness Connector Table............................534 Job/Time Code Values....................................................534 Reprogramming ICM.......................................................534 INITIAL DIAGNOSTICS.........................................................534 Diagnostic Tips.........................................................534 Diagnostic Notes........................................................534 Other Diagnostic Trouble Codes (DTCs)...................................534 Initial Diagnostic Check (Part 1 of 3)..................................537 Initial Diagnostic Check (Part 2 of 3)..................................538 Initial Diagnostic Check (Part 3 of 3)..................................539 SPEEDOMETER SELF DIAGNOSTICS 3.10...............................................540 GENERAL.....................................................................540 DIAGNOSTICS.................................................................540 Diagnostic Tips.........................................................540 Diagnostic Notes........................................................540 Speedometer Self Diagnostics (chart)....................................541 BREAKOUT BOX: TSM/TSSM 3.11.....................................................542 GENERAL.....................................................................542 INSTALLATION................................................................542 REMOVAL.....................................................................542 NO SECURITY LAMP AT KEY ON 3.12.................................................543 GENERAL.....................................................................543 No TSSM Power (Security Equipped Vehicles Only).........................543 Job/Time Code Values....................................................543 DIAGNOSTICS.................................................................543 Diagnostic Tips.........................................................543 Diagnostic Notes........................................................543 Test 3.12 (Part 1 of 3).................................................545 Test 3.12 (Part 2 of 3).................................................546 Test 3.12 (Part 3 of 3).................................................547 SECURITY LAMP ON CONTINUOUSLY 3.13..............................................548 GENERAL.....................................................................548 Job/Time Code Values....................................................548 DIAGNOSTICS.................................................................548 Diagnostic Notes........................................................548 Test 3.13...............................................................550 xe03b.pdf........................................................................... 0 KEY FOB SIGNAL TO TSSM WEAK OR FAILS 3.14.......................................552 GENERAL.....................................................................552 Security Equipped Vehicles Only.........................................552 Job/Time Code Values....................................................552 DIAGNOSTICS.................................................................552 Diagnostic Tips.........................................................552 Diagnostic Notes........................................................552 Test 3.14...............................................................554 TURN SIGNAL ERRORS 3.15.........................................................555 GENERAL.....................................................................555 Job/Time Code Values....................................................555 DIAGNOSTICS.................................................................555 Diagnostic Tips.........................................................555 Diagnostic Notes: All Turn Signal Flow Charts...........................558 Turn Signal Error 1A (Part 1 of 2)......................................560 Turn Signal Error 1A (Part 2 of 2)......................................561 Turn Signal Error 2A....................................................562 Turn Signal Error 2B....................................................563 Turn Signal Error 2C....................................................564 Turn Signal Error 2D....................................................565 Turn Signal Error 3A....................................................566 DTC B0563 3.16..................................................................567 GENERAL.....................................................................567 Battery Voltage High....................................................567 DIAGNOSTICS.................................................................567 Diagnostic Tips.........................................................567 Diagnostic Notes........................................................567 DTC B1131, B1132 3.17...........................................................568 GENERAL.....................................................................568 Alarm Output Low (DTC B1131) or Alarm Output High (DTC B1132)...........568 DIAGNOSTICS.................................................................568 Diagnostic Tips.........................................................568 Diagnostic Notes........................................................568 Test 3.17...............................................................570 DTC B1134 3.18..................................................................571 GENERAL.....................................................................571 Starter Output High.....................................................571 DIAGNOSTICS.................................................................571 Diagnostic Notes........................................................571 Test 3.18...............................................................573 DTC B1135 3.19..................................................................574 GENERAL.....................................................................574 Accelerometer Fault.....................................................574 DTC U1016, U1255 3.20...........................................................575 GENERAL.....................................................................575 Loss of ICM Serial Data.................................................575 DIAGNOSTICS.................................................................575 Diagnostic Notes........................................................575 Test 3.20...............................................................577 DTC U1097, U1255 3.21...........................................................578 GENERAL.....................................................................578 Loss of Speedometer Serial Data.........................................578 DIAGNOSTICS.................................................................578 Diagnostic Notes........................................................578 Test 3.21...............................................................580 DTC U1300, U1301 OR BUS ER 3.22.................................................581 GENERAL.....................................................................581 DIAGNOSTICS.................................................................581 Diagnostic Tips.........................................................581 Diagnostic Notes........................................................581 PASSWORD LEARN 3.23.............................................................582 GENERAL.....................................................................582 PASSWORD LEARNING...........................................................582 TSSM MAINTENANCE 3.24...........................................................584 GENERAL.....................................................................584 KEY FOB.....................................................................584 Schedule................................................................584 Battery Replacement.....................................................584 SIREN (IF INSTALLED)........................................................585 Schedule................................................................585 Battery Replacement.....................................................585 xe04a.pdf........................................................................... 0 SPECIFICATIONS 4.1..............................................................588 DIAGNOSTIC INTRODUCTION 4.2.....................................................589 SYSTEM PROBLEMS.............................................................589 No Start................................................................589 Poor Performance........................................................589 Check Engine Lamp.......................................................589 RESOLVING PROBLEMS..........................................................589 CHECKING FOR DIAGNOSTIC TROUBLE CODES 4.3.......................................590 CHECK ENGINE LAMP...........................................................590 SECURITY LAMP...............................................................591 CODE TYPES..................................................................591 Current.................................................................591 Historic................................................................591 RETRIEVING DIAGNOSTIC TROUBLE CODES.........................................592 MULTIPLE DIAGNOSTIC TROUBLE CODES...........................................592 INITIAL DIAGNOSTIC CHECK: ICM 4.4...............................................593 GENERAL.....................................................................593 Diagnostic Notes........................................................593 Circuit Diagram/Wire Harness Connector Table............................593 Reprogramming ICM.......................................................593 INITIAL DIAGNOSTICS.........................................................593 General Information.....................................................593 Diagnostic Tips.........................................................593 Diagnostic Notes........................................................593 Other DTCs..............................................................593 Initial Diagnostic Check (Part 1 of 3)..................................597 Initial Diagnostic Check (Part 2 of 3)..................................598 Initial Diagnostic Check (Part 3 of 3)..................................599 SPEEDOMETER SELF DIAGNOSTICS 4.5................................................600 GENERAL.....................................................................600 DIAGNOSTICS.................................................................600 Diagnostic Tips.........................................................600 Diagnostic Notes........................................................600 Speedometer Self Diagnostics (flow chart)...............................601 BREAKOUT BOX: ICM 4.6...........................................................602 GENERAL.....................................................................602 INSTALLATION................................................................602 REMOVAL.....................................................................602 WIGGLE TEST 4.7.................................................................603 GENERAL.....................................................................603 PROCEDURE...................................................................603 Using DVOM (Part No. HD-39978)..........................................603 INTAKE LEAK TEST 4.8............................................................604 GENERAL.....................................................................604 LEAK TESTER.................................................................604 Parts List..............................................................604 Tester Assembly.........................................................604 PROCEDURE...................................................................605 ENGINE CRANKS BUT WILL NOT START 4.9............................................606 GENERAL.....................................................................606 DIAGNOSTICS.................................................................606 Diagnostic Notes........................................................606 Test 4.9 (Part 1 of 3)..................................................608 Test 4.9 (Part 2 of 3)..................................................609 Test 4.9 (Part 3 of 3)..................................................610 STARTS THEN STALLS 4.10.........................................................611 GENERAL.....................................................................611 Serial Data Low or Serial Data Open/High................................611 DIAGNOSTICS.................................................................611 Diagnostic Tips.........................................................611 Diagnostic Notes........................................................611 Test 4.10 (Part 1 of 2).................................................613 Test 4.10 (Part 2 of 2).................................................614 NO SPARK/NO ICM POWER 4.11......................................................615 GENERAL.....................................................................615 DIAGNOSTICS.................................................................615 Diagnostic Notes........................................................615 Test 4.11...............................................................617 MISFIRE 4.12....................................................................618 GENERAL.....................................................................618 Misfire at Idle or Under Load...........................................618 DIAGNOSTICS.................................................................618 Diagnostic Notes........................................................618 Test 4.12...............................................................620 xe04b.pdf........................................................................... 0 DTC P0106, P0107, P0108 4.13....................................................622 GENERAL.....................................................................622 MAP Sensor..............................................................622 DIAGNOSTICS.................................................................622 Diagnostic Tips.........................................................622 Diagnostic Notes........................................................622 Test 4.13 (Part 1 of 2).................................................624 Test 4.13 (Part 2 of 2).................................................625 DTC P0371, P0372, P0374 4.14....................................................626 GENERAL.....................................................................626 Crank Position Sensor...................................................626 DIAGNOSTICS.................................................................626 Diagnostic Notes........................................................626 Test 4.14...............................................................628 DTC P0501, P0502 4.15...........................................................629 GENERAL.....................................................................629 Vehicle Speed Sensor....................................................629 DIAGNOSTICS.................................................................629 Diagnostic Notes........................................................629 Test 4.15 (Part 1 of 2).................................................631 Test 4.15 (Part 2 of 2).................................................632 DTC P0562, P0563 4.16...........................................................633 GENERAL.....................................................................633 Battery Voltage.........................................................633 DIAGNOSTICS.................................................................633 Diagnostic Notes........................................................633 Test 4.16 (Part 1 of 2).................................................635 Test 4.16 (Part 2 of 2).................................................636 DTC P0602, P0603, P0604, P0605, P0607 4.17......................................637 GENERAL.....................................................................637 ICM Failure.............................................................637 DIAGNOSTICS.................................................................637 DTC P0607 Test..........................................................637 DTC P0602, P0603, P0604, P0605 Test.....................................637 DTC P1009, P1010 4.18...........................................................638 GENERAL.....................................................................638 Password Problem........................................................638 DIAGNOSTICS.................................................................638 Diagnostic Notes........................................................638 Test 4.18...............................................................640 DTC P1351, P1352, P1354, P1355 4.19.............................................641 GENERAL.....................................................................641 Ignition Coil...........................................................641 DIAGNOSTICS.................................................................641 Diagnostic Notes........................................................641 Test 4.19 (Part 1 of 2).................................................643 Test 4.19 (Part 2 of 2).................................................644 DTC U1064 4.20..................................................................645 GENERAL.....................................................................645 Loss of TSM/TSSM Serial Data............................................645 DIAGNOSTICS.................................................................645 Diagnostic Notes........................................................645 Test 4.20...............................................................647 DTC U1097 4.21..................................................................648 GENERAL.....................................................................648 Loss of Speedometer Serial Data.........................................648 DIAGNOSTICS.................................................................648 Diagnostic Notes........................................................648 Test 4.21...............................................................650 xe05a.pdf........................................................................... 0 CONNECTOR LOCATIONS 5.1.........................................................654 AMP MULTILOCK ELECTRICAL CONNECTORS 5.2.........................................655 REMOVING SOCKET/PIN TERMINALS...............................................655 INSTALLING SOCKET/PIN TERMINALS.............................................655 CRIMPING INSTRUCTIONS.......................................................658 DEUTSCH ELECTRICAL CONNECTORS 5.3...............................................659 GENERAL.....................................................................659 REMOVING/DISASSEMBLING......................................................659 REMOVING/INSTALLING SOCKETS.................................................659 REMOVING/INSTALLING PINS....................................................660 ASSEMBLING/INSTALLING.......................................................661 CRIMPING INSTRUCTIONS.......................................................662 MINI-DEUTSCH ELECTRICAL CONNECTORS 5.4..........................................664 GENERAL.....................................................................664 For Size 20, 16 and 12 Contacts Wire Range 26-12 AWG....................664 CRIMPING INSTRUCTIONS.......................................................664 SEALED BUTT SPLICE CONNECTORS 5.5...............................................666 INSTALLATION................................................................666 PACKARD ELECTRICAL CONNECTORS 5.6...............................................667 GENERAL.....................................................................667 PULL-TO-SEAT TERMINALS......................................................668 Removing External Latch Type............................................668 Installing External Latch Type..........................................668 PUSH-TO-SEAT TERMINALS......................................................668 Removing Push-to-Seat Terminals.........................................668 Installing Push-to-Seat Terminals.......................................669 CRIMPING INSTRUCTIONS.......................................................669 MICRO 64 TERMINALS..........................................................671 General.................................................................671 Removal.................................................................671 Installation............................................................671 Crimping Instructions...................................................672 INDEX TO WIRING DIAGRAMS 5.7....................................................673 sm_appa.pdf......................................................................... 0 APPENDIX A–TOOLS A.1............................................................694 sm_appb1.pdf........................................................................ 0 APPENDIX B–WIRING AMP MULTILOCK ELECTRICAL CONNECTORS B.1.......................712 REMOVING SOCKET/PIN TERMINALS...............................................712 INSTALLING SOCKET/PIN TERMINALS.............................................714 CRIMPING INSTRUCTIONS.......................................................716 DEUTSCH ELECTRICAL CONNECTORS B.2...............................................717 GENERAL.....................................................................717 REMOVING/DISASSEMBLING......................................................717 REMOVING/INSTALLING SOCKETS.................................................717 REMOVING/INSTALLING PINS....................................................719 ASSEMBLING/INSTALLING.......................................................719 CRIMPING INSTRUCTIONS.......................................................719 MINI-DEUTSCH CONNECTORS B.3.....................................................722 GENERAL.....................................................................722 For Size 20, 16 and 12 Contacts Wire Range 26-12 AWG....................722 CRIMPING INSTRUCTIONS.......................................................722 PACKARD ELECTRICAL CONNECTORS B.4...............................................724 GENERAL.....................................................................724 REMOVING PULL-TO-SEAT TERMINALS/EXTERNAL LATCH TYPE.........................724 INSTALLING PULL-TO-SEAT TERMINALS/EXTERNAL LATCH TYPE.......................725 SEALED BUTT SPLICE CONNECTORS B.5...............................................726 INSTALLING SEALED BUTT SPLICE CONNECTORS....................................726 CONNECTOR LOCATIONS B.6.........................................................727 INDEX TO WIRING DIAGRAMS B.7....................................................728 sm_appc.pdf......................................................................... 0 APPENDIX C–METRIC CONVERSIONS C.1...............................................748 FLUID CONVERSIONS C.2...........................................................749 UNITED STATES SYSTEM........................................................749 METRIC SYSTEM...............................................................749 BRITISH IMPERIAL SYSTEM.....................................................749 sm_appd.pdf......................................................................... 0 APPENDIX D: COMPENSATING SPROCKET D.1...........................................750 GENERAL.....................................................................750 REMOVAL/DISASSEMBLY.........................................................750 CLEANING, INSPECTION AND REPAIR.............................................751 ASSEMBLY/INSTALLATION.......................................................751
VIDEO PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
- The manual can be all yours – Once payment is complete, you will be taken to the download page from where you can download the manual. All in 2-5 minutes time!!
- Need any other service / repair / parts manual, please feel free to contact us at heydownloadss @gmail.com . We may surprise you with a nice offer
S.V