2006 Harley Davidson Sportster XLH Models Electrical Diagnostics + Service Manual – PDF DOWNLOAD
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2006 Harley Davidson Sportster XLH Models Electrical Diagnostics + Service Manual – PDF DOWNLOAD
SERVICE MANUAL
Part Number 99484-06
ELECTRICAL DIAGNOSTICS
Part Number 99495-06
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:
2006 Harley Davidson Sportster XLH Models Electrical Diagnostics + Service Manual – PDF DOWNLOAD
2006 XLH MODELS................................................................. 1 SERVICE MANUAL.............................................................. 1 Part Number 99484-06.................................................... 1 ELECTRICAL DIAGNOSTICS...................................................... 1 Part Number 99495-06.................................................... 1 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................................................ 6 Magnetic Parts Trays.................................................... 6 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)............................................ 7 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.................................................. 8 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 GENERAL..................................................................... 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 LEFT SIDE COVER 1.6............................................................. 18 GENERAL..................................................................... 18 OPENING LEFT SIDE COVER..................................................... 19 CLOSING LEFT SIDE COVER..................................................... 19 REMOVING LEFT SIDE COVER.................................................... 19 INSTALLING LEFT SIDE COVER.................................................. 19 BATTERY MAINTENANCE 1.7......................................................... 20 GENERAL..................................................................... 20 BATTERY DISCONNECTION AND REMOVAL........................................... 21 BATTERY INSPECTION.......................................................... 22 BATTERY STORAGE............................................................. 22 BATTERY INSTALLATION AND CONNECTION......................................... 23 BRAKES 1.8...................................................................... 24 GENERAL..................................................................... 24 INSPECTION.................................................................. 24 TROUBLESHOOTING............................................................. 24 BLEEDING HYDRAULIC BRAKE SYSTEM 1.9............................................. 25 GENERAL..................................................................... 25 BLEEDING FRONT BRAKE........................................................ 25 BLEEDING REAR BRAKE......................................................... 27 BRAKE PADS AND DISCS 1.10....................................................... 28 INSPECTION.................................................................. 28 Brake Pads.............................................................. 28 Brake Disc Thickness, Lateral Runout and Warpage........................ 28 BRAKE PAD REPLACEMENT– FRONT................................................ 29 BRAKE PAD REPLACEMENT–REAR.................................................. 32 TIRES AND WHEELS 1.11........................................................... 35 TIRES....................................................................... 35 TIRE WEAR INDICATORS........................................................ 35 WHEEL BEARINGS.............................................................. 36 WHEEL SPOKES................................................................ 36 PRIMARY CHAIN 1.12.............................................................. 37 INSPECTION.................................................................. 37 ADJUSTMENT.................................................................. 38 CLUTCH 1.13..................................................................... 39 ADJUSTMENT.................................................................. 39 TRANSMISSION LUBRICANT 1.14..................................................... 41 GENERAL..................................................................... 41 DRAINING LUBRICANT.......................................................... 41 REFILLING LUBRICANT......................................................... 41 REAR BELT DEFLECTION 1.15....................................................... 43 INSPECTION.................................................................. 43 BELT DEFLECTION ADJUSTMENT.................................................. 45 WHEEL ALIGNMENT............................................................. 46 Checking Wheel Alignment................................................ 46 Adjusting Wheel Alignment............................................... 46 REAR BELT AND SPROCKETS 1.16.................................................... 47 GENERAL..................................................................... 47 CLEANING.................................................................... 47 INSPECTION.................................................................. 47 Sprockets............................................................... 47 Rear Belt............................................................... 47 SHOCK ABSORBER ADJUSTMENT 1.17.................................................. 49 GENERAL..................................................................... 49 PROCEDURE................................................................... 49 STEERING HEAD BEARINGS 1.18..................................................... 50 GENERAL..................................................................... 50 ADJUSTMENT.................................................................. 50 LUBRICATION................................................................. 50 REAR FORK BEARINGS 1.19......................................................... 51 GENERAL..................................................................... 51 PROCEDURE................................................................... 51 FRONT FORK OIL 1.20............................................................. 53 GENERAL..................................................................... 53 CHANGING FORK OIL........................................................... 53 Filling Fork Oil: Forks Assembled, in Frame............................. 54 Filling Fork Oil: Forks Disassembled, out of Frame...................... 54 SPARK PLUGS 1.21................................................................ 55 GENERAL..................................................................... 55 ADJUSTMENT.................................................................. 55 CLEANING AND INSPECTION..................................................... 55 Inspection.............................................................. 55 Spark Plug Condition.................................................... 55 Cleaning................................................................ 55 INSTALLATION................................................................ 55 CABLE AND CHASSIS LUBRICATION 1.22.............................................. 56 GENERAL..................................................................... 56 CABLES AND HAND LEVERS...................................................... 56 FOOT SHIFT LEVER AND REAR BRAKE PEDAL....................................... 56 JIFFY STAND................................................................. 56 STEERING HEAD BEARINGS...................................................... 56 AIR FILTER ELEMENT 1.23......................................................... 57 GENERAL..................................................................... 57 REMOVAL..................................................................... 57 CLEANING, INSPECTION AND REPAIR............................................. 58 INSTALLATION................................................................ 58 THROTTLE CABLES AND ENRICHENER 1.24............................................. 59 CABLE INSPECTION, LUBRICATION AND ADJUSTMENT................................ 59 Inspection and Lubrication.............................................. 59 Adjustment.............................................................. 59 ENRICHENER ADJUSTMENT....................................................... 60 IDLE SPEED AND IGNITION TIMING 1.25............................................. 61 IDLE SPEED ADJUSTMENT....................................................... 61 IGNITION TIMING............................................................. 61 FUEL SUPPLY VALVE FILTER 1.26................................................... 62 INSPECTION.................................................................. 62 FUEL SYSTEM LINES AND FITTINGS.............................................. 63 ENGINE MOUNTS AND STABILIZER LINKS 1.27......................................... 64 INSPECTION.................................................................. 64 HEADLAMP ALIGNMENT 1.28......................................................... 65 INSPECTION.................................................................. 65 ADJUSTMENT.................................................................. 66 XL 883, XL 883L, XL 883R, XL 1200R...................................... 66 XL 883C, XL 1200C....................................................... 66 FLUID/LUBRICANT REQUIREMENTS 1.29............................................... 67 BRAKE FLUID................................................................. 67 BRAKE COMPONENT GREASE...................................................... 67 FRONT FORK OIL.............................................................. 67 ENGINE OIL.................................................................. 67 PRIMARY DRIVE/TRANSMISSION LUBRICANT........................................ 67 STORAGE 1.30.................................................................... 68 GENERAL..................................................................... 68 REMOVAL FROM STORAGE........................................................ 69 TROUBLESHOOTING 1.31............................................................ 70 GENERAL..................................................................... 70 ENGINE...................................................................... 70 Starting Motor Does Not Operate or Does Not Turn Engine Over............ 70 Engine Turns Over But Does Not Start.................................... 70 Starts Hard............................................................. 70 Starts But Runs Irregularly or Misses................................... 71 Spark Plug Fouls Repeatedly............................................. 71 Pre-Ignition or Detonation (Knocks or Pings)............................ 71 Overheating............................................................. 71 Valve Train Noise....................................................... 71 Excessive Vibration..................................................... 71 ENGINE LUBRICATION SYSTEM................................................... 72 Oil Does Not Return To Oil Tank......................................... 72 Engine Uses Too Much Oil or Smokes Excessively.......................... 72 Engine Leaks Oil From Cases, Push Rods, Hoses, Etc...................... 72 FUEL........................................................................ 72 Carburetor Floods....................................................... 72 ELECTRICAL SYSTEM........................................................... 72 Alternator Does Not Charge.............................................. 72 Alternator Charge Rate Is Below Normal.................................. 72 Speedometer Operates Erratically........................................ 72 TRANSMISSION................................................................ 72 Shifts Hard............................................................. 72 Jumps Out of Gear....................................................... 72 CLUTCH...................................................................... 73 Slips................................................................... 73 Drags or Does Not Release............................................... 73 Chatters................................................................ 73 CHASSIS..................................................................... 73 Irregular/Inadequate Brake Action....................................... 73 Handling Irregularities................................................. 73 SPECIFICATIONS 2.1.............................................................. 77 TIRES....................................................................... 78 TORQUE VALUES 2.2............................................................... 79 VEHICLE IDENTIFICATION NUMBER (VIN) 2.3......................................... 82 GENERAL..................................................................... 82 WHEELS 2.4...................................................................... 84 GENERAL..................................................................... 84 TROUBLESHOOTING............................................................. 85 FRONT WHEEL................................................................. 86 Removal................................................................. 86 Disassembly............................................................. 87 Cleaning and Inspection................................................. 87 Assembly................................................................ 87 Installation............................................................ 90 REAR WHEEL.................................................................. 91 Removal................................................................. 91 Disassembly............................................................. 92 Cleaning and Inspection................................................. 92 Assembly................................................................ 92 Installation............................................................ 94 SEALED WHEEL BEARINGS....................................................... 95 Inspection.............................................................. 95 Removal................................................................. 96 Installation............................................................ 97 WHEEL LACING: 16 INCH RIM 2.5................................................... 98 GENERAL..................................................................... 98 PROCEDURE................................................................... 99 WHEEL LACING: 19 INCH RIM 2.6...................................................101 GENERAL.....................................................................101 PROCEDURE...................................................................101 WHEEL LACING: 21 INCH RIM 2.7...................................................105 GENERAL.....................................................................105 PROCEDURE...................................................................105 TRUING LACED WHEELS 2.8.........................................................109 PROCEDURE...................................................................109 CHECKING CAST WHEEL RUNOUT 2.9..................................................112 CHECKING LATERAL AND RADIAL RUNOUT..........................................112 TIRES 2.10......................................................................113 GENERAL.....................................................................113 REMOVAL.....................................................................113 CLEANING, INSPECTION AND REPAIR.............................................114 INSTALLATION................................................................114 Tube Type Tires.........................................................114 Tubeless Tires..........................................................115 CHECKING TIRE RUNOUT........................................................115 Lateral Runout..........................................................115 Radial Runout...........................................................116 WHEEL BALANCING.............................................................116 Weights For Laced Wheels................................................116 Weights for Cast Wheels.................................................116 FRONT BRAKE MASTER CYLINDER 2.11................................................117 GENERAL.....................................................................117 REMOVAL.....................................................................117 DISASSEMBLY.................................................................120 CLEANING, INSPECTION AND REPAIR.............................................121 ASSEMBLY....................................................................121 INSTALLATION................................................................123 REAR BRAKE MASTER CYLINDER 2.12.................................................125 GENERAL.....................................................................125 INSPECTION..................................................................125 REMOVAL.....................................................................126 DISASSEMBLY.................................................................128 CLEANING, INSPECTION AND REPAIR.............................................130 ASSEMBLY....................................................................130 INSTALLATION................................................................133 REAR BRAKE MASTER CYLINDER RESERVOIR 2.13.......................................134 GENERAL.....................................................................134 REMOVAL.....................................................................134 INSTALLATION................................................................135 FRONT BRAKE CALIPER 2.14........................................................136 REMOVAL.....................................................................136 DISASSEMBLY.................................................................137 CLEANING, INSPECTION AND REPAIR.............................................139 ASSEMBLY....................................................................139 LUBRICATING FRONT CALIPER BOLT PINS AND BOOTS...............................140 INSTALLING BRAKE PADS IN CALIPER............................................141 INSTALLATION................................................................141 REAR BRAKE CALIPER 2.15.........................................................144 REMOVAL.....................................................................144 DISASSEMBLY.................................................................146 CLEANING, INSPECTION AND REPAIR.............................................147 ASSEMBLY....................................................................148 LUBRICATING REAR CALIPER BOLT PINS AND BOOTS................................149 INSTALLATION................................................................150 BRAKE LINES 2.16................................................................153 FRONT BRAKE LINE............................................................153 Removal.................................................................153 Installation............................................................154 REAR BRAKE LINE.............................................................155 Removal.................................................................155 Installation............................................................156 FRONT FORK 2.17.................................................................157 GENERAL.....................................................................157 REMOVAL.....................................................................157 DISASSEMBLY.................................................................157 CLEANING, INSPECTION AND REPAIR.............................................157 ASSEMBLY....................................................................159 INSTALLATION................................................................159 FORK STEM AND BRACKET ASSEMBLY 2.18.............................................160 GENERAL.....................................................................160 REMOVAL/DISASSEMBLY.........................................................160 CLEANING, INSPECTION AND REPAIR.............................................160 ASSEMBLY/INSTALLATION.......................................................160 REAR FORK 2.19..................................................................161 GENERAL.....................................................................161 REMOVAL.....................................................................161 DISASSEMBLY.................................................................162 CLEANING AND INSPECTION.....................................................162 ASSEMBLY....................................................................162 INSTALLATION................................................................163 REAR SHOCK ABSORBERS 2.20.......................................................164 GENERAL.....................................................................164 REMOVAL.....................................................................164 CLEANING AND INSPECTION.....................................................164 INSTALLATION................................................................164 STABILIZER LINKS 2.21...........................................................165 GENERAL.....................................................................165 UPPER FRONT STABILIZER LINK.................................................165 Removal.................................................................165 Installation............................................................165 LOWER FRONT STABILIZER LINK.................................................166 Removal.................................................................166 Installation............................................................166 REAR STABILIZER LINK........................................................166 Removal.................................................................166 Installation............................................................166 FRONT ENGINE MOUNT/ISOLATOR 2.22................................................167 GENERAL.....................................................................167 REMOVAL.....................................................................167 INSTALLATION................................................................168 REAR ENGINE MOUNT/ISOLATOR 2.23.................................................169 GENERAL.....................................................................169 REMOVAL.....................................................................169 INSTALLATION................................................................171 THROTTLE CONTROL 2.24...........................................................172 REMOVAL/DISASSEMBLY.........................................................172 CLEANING, INSPECTION AND REPAIR.............................................172 ASSEMBLY/INSTALLATION.......................................................172 HANDLEBARS 2.25.................................................................174 REMOVAL.....................................................................174 All Models..............................................................174 XL 883, XL 883L, XL 883R, XL 1200R......................................174 XL 883C, XL 1200C.......................................................175 INSTALLATION................................................................175 XL 883, XL 883L, XL 883R, XL 1200R......................................175 XL 883C, XL 1200C.......................................................175 All Models..............................................................176 CLUTCH CONTROL 2.26.............................................................177 GENERAL.....................................................................177 REMOVAL/DISASSEMBLY.........................................................177 Clutch Cable–Lower......................................................177 Clutch Lever and Clutch Cable–Upper.....................................178 Clutch Hand Control.....................................................178 ASSEMBLY/INSTALLATION.......................................................178 Clutch Hand Control.....................................................178 Clutch Lever and Clutch Cable–Upper.....................................179 Clutch Cable–Lower......................................................179 Finish..................................................................179 EXHAUST SYSTEM 2.27.............................................................180 REMOVAL.....................................................................180 Mufflers and Exhaust Pipes..............................................180 Muffler Interconnect Bracket............................................181 INSTALLATION................................................................182 Muffler Interconnect Bracket............................................182 Exhaust Pipes and Mufflers..............................................182 FRONT FENDER 2.28...............................................................183 REMOVAL.....................................................................183 INSTALLATION................................................................183 REAR FENDER 2.29................................................................184 REMOVAL.....................................................................184 INSTALLATION................................................................186 BELT GUARD AND DEBRIS DEFLECTOR 2.30............................................188 REMOVAL.....................................................................188 Belt Guard..............................................................188 Debris Deflector........................................................188 INSTALLATION................................................................188 Belt Guard..............................................................188 Debris Deflector........................................................188 JIFFY STAND 2.31................................................................189 GENERAL.....................................................................189 REMOVAL.....................................................................190 CLEANING AND LUBRICATION....................................................190 INSTALLATION................................................................190 SEAT 2.32.......................................................................191 GENERAL.....................................................................191 REMOVAL.....................................................................191 INSTALLATION................................................................191 RIDER FOOT CONTROLS: XL 883, XL 883L, XL 883R, XL 1200R 2.33....................193 RIGHT FOOTREST AND REAR BRAKE PEDAL ASSEMBLY................................193 Removal.................................................................193 Installation............................................................193 LEFT FOOTREST AND SHIFT LEVER ASSEMBLY......................................193 Removal.................................................................193 Installation............................................................193 RIDER FOOT CONTROLS: XL 883C, XL 1200C 2.34.....................................195 RIGHT FOOTREST AND REAR BRAKE PEDAL ASSEMBLY................................195 Removal.................................................................195 Installation............................................................195 LEFT FOOTREST AND SHIFT LEVER ASSEMBLY......................................197 Removal.................................................................197 Installation............................................................197 ADJUSTING SHIFT PEDAL.......................................................198 PASSENGER FOOTRESTS 2.35........................................................199 GENERAL.....................................................................199 REMOVAL.....................................................................199 INSTALLATION................................................................199 FORK LOCK 2.36..................................................................200 REMOVAL.....................................................................200 INSTALLATION................................................................201 SPECIFICATIONS 3.1..............................................................205 SERVICE WEAR LIMITS 3.2.........................................................208 GENERAL.....................................................................208 TORQUE VALUES 3.3...............................................................210 ENGINE 3.4......................................................................212 GENERAL.....................................................................212 TROUBLESHOOTING 3.5.............................................................213 DIAGNOSING VALVE TRAIN NOISE................................................213 COMPRESSION TEST............................................................213 Compression Test Procedure..............................................213 CYLINDER LEAKAGE TEST.......................................................214 Cylinder Leakage Test Procedure.........................................214 DIAGNOSING SMOKING ENGINE OR HIGH OIL CONSUMPTION...........................215 Check Prior To Cylinder Head Removal....................................215 Check After Cylinder Head Removal.......................................215 ADJUSTMENT/TESTING..........................................................215 General.................................................................215 ENGINE LUBRICATION SYSTEM 3.6...................................................216 GENERAL.....................................................................216 OIL PUMP....................................................................216 OIL PRESSURE 3.7................................................................219 GENERAL.....................................................................219 Oil Pressure Indicator Lamp.............................................219 CHECKING OIL PRESSURE.......................................................219 CRANKCASE BREATHING SYSTEM 3.8..................................................221 GENERAL.....................................................................221 HOW TO USE THIS SECTION 3.9.....................................................222 TYPICAL SYMPTOMS............................................................222 TOP END REPAIR..............................................................222 BOTTOM END REPAIR...........................................................222 TOP END SERVICE 3.10............................................................223 ENGINE IN CHASSIS...........................................................223 ENGINE REMOVED FROM CHASSIS.................................................224 BOTTOM END SERVICE 3.11.........................................................225 ENGINE IN CHASSIS: CAM COMPARTMENT SERVICE..................................225 ENGINE REMOVED: FLYWHEEL COMPARTMENT SERVICE OR COMPLETE ENGINE OVERHAUL....226 REMOVING ENGINE FROM CHASSIS 3.12...............................................227 GENERAL.....................................................................227 PROCEDURE...................................................................227 INSTALLING ENGINE IN CHASSIS 3.13...............................................231 GENERAL.....................................................................231 PROCEDURE...................................................................231 TOP END OVERHAUL: DISASSEMBLY 3.14..............................................234 GENERAL.....................................................................234 STRIPPING MOTORCYCLE FOR TOP END REPAIR.....................................234 CYLINDER HEAD...............................................................235 Disassembling Rocker Covers.............................................235 Removing Cylinder Head..................................................236 Disassembling Push Rods and Covers......................................238 CYLINDER AND PISTON.........................................................238 CYLINDER HEAD 3.15..............................................................241 GENERAL.....................................................................241 REMOVAL.....................................................................241 DISASSEMBLY.................................................................241 CLEANING AND INSPECTION.....................................................242 Cylinder Heads..........................................................242 Rocker Arm Assemblies...................................................243 Valves..................................................................244 Valve Seats.............................................................244 Valve Guides............................................................244 Valve Springs...........................................................244 Spark Plug Threads......................................................245 Push Rods...............................................................245 REPLACING ROCKER ARM BUSHINGS...............................................245 REPLACING VALVE GUIDES......................................................246 Removal.................................................................246 Installation............................................................247 REFACING VALVE SEATS........................................................250 Replacing Valve Seats...................................................252 ASSEMBLY....................................................................253 INSTALLATION................................................................254 CYLINDER AND PISTON 3.16........................................................255 REMOVAL/DISASSEMBLY.........................................................255 CLEANING, INSPECTION, AND REPAIR............................................255 Checking Gasket Surface.................................................255 Measuring Cylinder Bore.................................................256 Measuring Piston to Cylinder Fit........................................257 Boring and Honing Cylinder..............................................257 Fitting Piston Rings....................................................258 CONNECTING ROD BUSHINGS.....................................................260 Removing Upper Connecting Rod Bushing...................................260 Installing Upper Connecting Rod Bushing.................................261 Reaming Upper Connecting Rod Bushing....................................262 Honing Upper Connecting Rod Bushing.....................................263 Repair..................................................................263 ASSEMBLY/INSTALLATION.......................................................263 TOP END OVERHAUL: ASSEMBLY 3.17.................................................264 GENERAL.....................................................................264 PISTON AND CYLINDER.........................................................264 PUSH RODS, COVERS AND RETAINERS.............................................266 CYLINDER HEAD...............................................................267 Rocker Covers...............................................................269 ASSEMBLING MOTORCYCLE AFTER TOP END REPAIR..................................271 BOTTOM END OVERHAUL: DISASSEMBLY 3.18...........................................272 GENERAL.....................................................................272 TAPPETS.....................................................................272 OIL PUMP....................................................................272 GEARCASE COVER AND CAM GEARS................................................273 CRANKCASE...................................................................274 Removing Piston Oil Jets................................................275 Removing Cylinder Base Studs............................................275 VALVE TAPPETS 3.19..............................................................276 GENERAL.....................................................................276 REMOVAL.....................................................................276 CLEANING AND INSPECTION.....................................................276 INSTALLATION................................................................276 GEARCASE COVER AND CAM GEARS 3.20...............................................278 GENERAL.....................................................................278 REMOVAL/DISASSEMBLY.........................................................278 CLEANING, INSPECTION AND REPAIR.............................................278 Cam and Pinion Gear Identification, Inspection and Selection............278 Bushing Inspection and Removal..........................................280 BUSHING INSTALLATION........................................................280 Cam Gear Bushings in Right Crankcase....................................280 Cam Gear Bushings (Except Rear Intake Bushing) in Gearcase Cover........281 Rear Intake Cam Gear Bushing in Gearcase Cover..........................281 Pinion Shaft Bushing in Gearcase Cover..................................281 BUSHING REAMING.............................................................282 Cam Gear Bushings in Right Crankcase....................................282 Cam Gear Bushings (Except Rear Intake Bushing) in Gearcase Cover........283 Rear Intake Cam Gear Bushing in Gearcase Cover..........................283 Pinion Shaft Bushing in Gearcase Cover..................................284 ASSEMBLY/INSTALLATION.......................................................284 OIL PUMP 3.21...................................................................285 GENERAL.....................................................................285 REMOVAL.....................................................................285 DISASSEMBLY.................................................................286 CLEANING, INSPECTION AND REPAIR.............................................286 ASSEMBLY....................................................................286 INSTALLATION................................................................286 OIL FILTER MOUNT 3.22...........................................................287 GENERAL.....................................................................287 DISASSEMBLY.................................................................287 CLEANING AND INSPECTION.....................................................287 ASSEMBLY....................................................................287 CRANKCASE 3.23..................................................................288 GENERAL.....................................................................288 REMOVAL.....................................................................288 DISASSEMBLY.................................................................288 FITTING PINION BEARINGS.....................................................291 Bearing Selection.......................................................292 LAPPING ENGINE MAIN BEARING RACES...........................................296 Assembling Crankcase Halves.................................................296 BOTTOM END OVERHAUL: ASSEMBLY 3.24..............................................297 GENERAL.....................................................................297 CRANKCASE...................................................................297 Installing Piston Oil Jets..............................................297 Installing Pinion Shaft Bearing.........................................298 Installing Left Main Bearing............................................299 Assembling Crankcase Halves.............................................299 Installing Cylinder Base Studs..........................................302 CAM GEARS AND GEARCASE COVER................................................303 TAPPETS.....................................................................306 ASSEMBLING TOP END OF ENGINE................................................306 OIL TANK 3.25...................................................................307 OIL HOSE ROUTING............................................................307 REMOVAL.....................................................................308 INSTALLATION................................................................310 SPECIFICATIONS 4.1..............................................................314 TORQUE VALUES 4.2...............................................................315 TROUBLESHOOTING 4.3.............................................................316 ENRICHENER 4.4..................................................................318 GENERAL.....................................................................318 OPERATION...................................................................318 Cool Engine.............................................................318 Warm or Hot Engine......................................................318 CARBURETOR 4.5..................................................................319 GENERAL.....................................................................319 ADJUSTMENT..................................................................319 Float Level.............................................................319 OPERATION CHECK: VACUUM PISTON..............................................321 Opening Malfunction.....................................................321 Closing Malfunction.....................................................321 REMOVAL.....................................................................321 DISASSEMBLY.................................................................323 Vacuum Piston Chamber...................................................323 Carburetor Body.........................................................323 Accelerator Pump........................................................323 CLEANING, INSPECTION AND REPAIR.............................................324 Vacuum Piston Components................................................324 Carburetor Body Components..............................................324 Accelerator Pump........................................................324 ASSEMBLY....................................................................324 Vacuum Piston Chamber...................................................324 Carburetor Body.........................................................324 Accelerator Pump........................................................324 INSTALLATION................................................................325 Carburetor..............................................................325 Carburetor Fuel Overflow/Drain Hose Routing.............................325 AIR CLEANER 4.6.................................................................326 REMOVAL.....................................................................326 CLEANING, INSPECTION AND REPAIR.............................................327 INSTALLATION................................................................327 FUEL SUPPLY VALVE 4.7...........................................................328 GENERAL.....................................................................328 OPERATION...................................................................328 REMOVAL, INSPECTION AND INSTALLATION........................................328 TROUBLESHOOTING.............................................................329 Vacuum Test.............................................................329 FUEL TANK 4.8...................................................................330 GENERAL.....................................................................330 REMOVAL.....................................................................332 CLEANING, INSPECTION AND REPAIR.............................................332 INSTALLATION................................................................333 CONSOLE REPLACEMENT.........................................................333 Removal.................................................................333 Installation............................................................335 EVAPORATIVE EMISSIONS CONTROL–CA MODELS 4.9.....................................336 GENERAL.....................................................................336 REMOVAL.....................................................................337 Charcoal Canister.......................................................337 Vapor Valve.............................................................338 INSTALLATION................................................................338 Vapor Valve.............................................................338 Charcoal Canister.......................................................339 HOSE ROUTING................................................................340 Carburetor..............................................................340 Canister Hose Routings..................................................340 INTAKE LEAK TEST 4.10...........................................................341 GENERAL.....................................................................341 LEAK TESTER.................................................................341 Parts List..............................................................341 Tester Assembly.........................................................341 Tester Adjustment.......................................................341 PROCEDURE...................................................................342 SPECIFICATIONS 5.1..............................................................346 TORQUE VALUES 5.2...............................................................347 ELECTRIC STARTER SYSTEM 5.3.....................................................348 GENERAL.....................................................................348 Wiring Diagram..........................................................348 Starter Relay...........................................................348 OPERATION...................................................................348 STARTER MOTOR 5.4...............................................................351 REMOVAL.....................................................................351 DISASSEMBLY, INSPECTION AND REPAIR..........................................353 ASSEMBLY....................................................................356 INSTALLATION................................................................357 STARTER SOLENOID 5.5............................................................358 GENERAL.....................................................................358 DISASSEMBLY.................................................................359 ASSEMBLY....................................................................359 FINAL.......................................................................359 SPECIFICATIONS 6.1..............................................................362 TORQUE VALUES 6.2...............................................................364 PRIMARY CHAIN ADJUSTER 6.3......................................................365 GENERAL.....................................................................365 REMOVAL.....................................................................365 Primary Cover...........................................................365 Primary Chain Adjuster..................................................367 INSTALLATION................................................................367 Primary Chain Adjuster..................................................367 Primary Cover...........................................................367 CLUTCH RELEASE MECHANISM 6.4....................................................369 REMOVAL/DISASSEMBLY.........................................................369 CLEANING, INSPECTION AND REPAIR.............................................370 ASSEMBLY/INSTALLATION.......................................................370 PRIMARY DRIVE/CLUTCH 6.5........................................................371 GENERAL.....................................................................371 REMOVAL.....................................................................373 DISASSEMBLY.................................................................374 INSPECTION AND REPAIR.......................................................375 ASSEMBLY....................................................................376 INSTALLATION................................................................377 SECONDARY DRIVE BELT 6.6........................................................379 REMOVAL.....................................................................379 INSTALLATION................................................................381 TRANSMISSION 6.7................................................................382 OPERATION...................................................................382 CASE DISASSEMBLY FOR TRANSMISSION REMOVAL 6.8...................................383 GENERAL.....................................................................383 ENGINE REMOVAL AND DISASSEMBLY..............................................383 TRANSMISSION REMOVAL AND DISASSEMBLY 6.9........................................386 TRANSMISSION REMOVAL FROM LEFT CRANKCASE....................................386 MAINSHAFT/COUNTERSHAFT......................................................388 MAINSHAFT DISASSEMBLY.......................................................390 Cleaning And Inspection.................................................390 COUNTERSHAFT DISASSEMBLY....................................................391 Cleaning And Inspection.................................................391 TRANSMISSION ASSEMBLY 6.10......................................................392 GENERAL.....................................................................392 MAINSHAFT ASSEMBLY..........................................................392 COUNTERSHAFT ASSEMBLY.......................................................393 MAIN DRIVE GEAR AND BEARING 6.11................................................394 GENERAL.....................................................................394 REMOVAL.....................................................................395 Main Drive Gear.........................................................395 Main Drive Gear Ball Bearing............................................396 DISASSEMBLY.................................................................396 ASSEMBLY....................................................................397 INSTALLATION................................................................398 Main Drive Gear Ball Bearing............................................398 Main Drive Gear.........................................................399 Main Drive Gear Seal....................................................400 TRANSMISSION RIGHT CASE BEARINGS 6.12...........................................402 REMOVAL.....................................................................402 Countershaft Needle Bearing.............................................402 Shifter Drum Bushing....................................................402 INSTALLATION................................................................402 Countershaft Needle Bearing.............................................402 Shifter Drum Bushing....................................................402 TRANSMISSION LEFT CASE BEARINGS 6.13............................................403 REMOVAL.....................................................................403 Mainshaft and Countershaft Bearings.....................................403 Shifter Drum Bushing....................................................403 INSTALLATION................................................................403 Mainshaft and Countershaft Bearings.....................................403 Shifter Drum Bushing....................................................403 TRANSMISSION INSTALLATION 6.14..................................................404 GENERAL.....................................................................404 INSTALLATION................................................................404 SHIFTER FORKS AND DRUM ASSEMBLY.............................................405 ASSEMBLING CRANKCASES.......................................................406 SHIFTER SHAFT INSTALLATION..................................................408 TRANSMISSION SPROCKET 6.15......................................................409 REMOVAL.....................................................................409 INSTALLATION................................................................410 SPECIFICATIONS 7.1..............................................................414 IGNITION....................................................................414 CHARGING SYSTEM.............................................................414 BATTERY.....................................................................414 FUSES.......................................................................414 TORQUE VALUES 7.2...............................................................415 BULB REQUIREMENTS 7.3...........................................................416 BULB CHART..................................................................416 BATTERY TRAY 7.4................................................................417 GENERAL.....................................................................417 REMOVAL.....................................................................417 INSTALLATION................................................................418 IGNITION SYSTEM 7.5.............................................................419 GENERAL.....................................................................419 TROUBLESHOOTING.............................................................419 MANIFOLD ABSOLUTE PRESSURE SENSOR (MAP) 7.6.....................................421 REMOVAL.....................................................................421 INSTALLATION................................................................421 IGNITION/LIGHT SWITCH 7.7.......................................................422 GENERAL.....................................................................422 REMOVAL.....................................................................423 INSTALLATION................................................................423 IGNITION CONTROL MODULE (ICM) 7.8...............................................424 GENERAL.....................................................................424 REMOVAL.....................................................................424 INSTALLATION................................................................424 SPARK PLUG CABLES 7.9...........................................................425 GENERAL.....................................................................425 REMOVAL.....................................................................425 INSPECTION..................................................................426 INSTALLATION................................................................426 IGNITION COIL 7.10..............................................................427 GENERAL.....................................................................427 TROUBLESHOOTING.............................................................427 REMOVAL.....................................................................427 INSTALLATION................................................................427 CHARGING SYSTEM 7.11............................................................428 GENERAL.....................................................................428 ALTERNATOR..................................................................428 VOLTAGE REGULATOR...........................................................428 ALTERNATOR 7.12.................................................................429 REMOVAL AND DISASSEMBLY.....................................................429 Rotor...................................................................429 Stator..................................................................429 CLEANING, INSPECTION AND REPAIR.............................................429 ASSEMBLY AND INSTALLATION...................................................430 Stator..................................................................430 Rotor...................................................................431 Final Assembly..........................................................431 VOLTAGE REGULATOR 7.13..........................................................432 GENERAL.....................................................................432 REMOVAL.....................................................................432 INSTALLATION................................................................433 BATTERY 7.14....................................................................434 GENERAL.....................................................................434 VOLTMETER TEST..............................................................434 CONDUCTANCE TEST............................................................434 LOAD TEST...................................................................435 CHARGING....................................................................436 General.................................................................436 Safety Precautions......................................................436 Charging Battery........................................................436 BATTERY CABLES 7.15.............................................................438 REMOVAL.....................................................................438 INSTALLATION................................................................439 HEADLAMP 7.16...................................................................442 REPLACEMENT–XL 883, XL 883L, XL 883R, XL 1200R..............................442 REPLACEMENT–XL 883C, XL 1200C...............................................443 INDICATOR LAMPS 7.17............................................................446 REPLACEMENT–XL 883, XL 883L, XL 883R........................................446 REPLACEMENT–XL 1200R........................................................446 REPLACEMENT–XL 883C, XL 1200C...............................................447 TAIL LAMP 7.18..................................................................448 BULB REPLACEMENT............................................................448 BASE REPLACEMENT............................................................448 TURN SIGNALS 7.19...............................................................450 BULB REPLACEMENT............................................................450 FRONT HOUSING REPLACEMENT...................................................450 REAR HOUSING REPLACEMENT....................................................451 REAR STOP LAMP SWITCH 7.20......................................................454 GENERAL.....................................................................454 REPLACEMENT.................................................................454 HANDLEBAR SWITCHES 7.21.........................................................455 GENERAL.....................................................................455 REPAIR PROCEDURES...........................................................455 CONNECTORS..................................................................456 RIGHT HANDLEBAR SWITCH 7.22.....................................................457 REMOVAL.....................................................................457 INSTALLATION................................................................458 DISASSEMBLY.................................................................460 SWITCH REPAIR/REPLACEMENT...................................................461 Upper Switch Housing Repair.............................................461 Lower Switch Housing Repair.............................................462 ASSEMBLY....................................................................463 LEFT HANDLEBAR SWITCH 7.23......................................................464 REMOVAL.....................................................................464 INSTALLATION................................................................464 DISASSEMBLY.................................................................465 SWITCH REPAIR/REPLACEMENT...................................................466 Upper Switch Housing Repair.............................................466 Lower Switch Housing Repair.............................................467 ASSEMBLY....................................................................467 HORN 7.24.......................................................................468 TROUBLESHOOTING.............................................................468 VOLTAGE TEST................................................................468 REPLACEMENT: ALL MODELS EXCEPT XL 1200C.....................................468 REPLACEMENT: XL 1200C.......................................................469 MAXI-FUSE 7.25..................................................................470 GENERAL.....................................................................470 REMOVING....................................................................470 INSTALLING..................................................................470 SYSTEM FUSES AND STARTER RELAY 7.26.............................................471 GENERAL.....................................................................471 REPLACING 15-AMP FUSES......................................................471 REPLACING STARTER RELAY.....................................................471 MAXI-FUSE HOLDER 7.27...........................................................472 REPLACEMENT.................................................................472 RELAY/FUSE BLOCK 7.28...........................................................473 GENERAL.....................................................................473 REMOVAL.....................................................................473 INSTALLATION................................................................474 SPEEDOMETER: XL 883, XL 883L, XL 883R 7.29......................................475 REMOVAL.....................................................................475 INSTALLATION................................................................475 SPEEDOMETER AND TACHOMETER: XL 1200R 7.30.......................................476 TRIP ODOMETER RESET SWITCH REPLACEMENT......................................476 SPEEDOMETER REMOVAL.........................................................477 TACHOMETER REMOVAL..........................................................477 SPEEDOMETER INSTALLATION....................................................478 TACHOMETER INSTALLATION.....................................................478 SPEEDOMETER: XL 883C, XL 1200C 7.31.............................................479 REMOVAL.....................................................................479 INSTALLATION................................................................480 TURN SIGNAL/SECURITY MODULE (TSM/TSSM) 7.32.....................................481 GENERAL.....................................................................481 TESTING.....................................................................481 REMOVAL.....................................................................481 INSTALLATION................................................................482 OIL PRESSURE SWITCH 7.33........................................................483 GENERAL.....................................................................483 REMOVAL.....................................................................483 INSTALLATION................................................................483 CRANK POSITION SENSOR (CKP) 7.34................................................484 GENERAL.....................................................................484 REMOVAL.....................................................................484 INSTALLATION................................................................484 VEHICLE SPEED SENSOR (VSS) 7.35.................................................485 GENERAL.....................................................................485 REMOVAL.....................................................................485 INSTALLATION................................................................485 NEUTRAL INDICATOR SWITCH 7.36...................................................486 GENERAL.....................................................................486 TEST........................................................................486 REPLACEMENT.................................................................487 Optional Security Siren 7.37....................................................489 GENERAL.....................................................................489 REMOVAL.....................................................................489 DISASSEMBLY.................................................................489 Battery Replacement.........................................................490 ASSEMBLY....................................................................491 INSTALLATION................................................................491 BANK ANGLE SENSOR (BAS) 7.38....................................................492 GENERAL.....................................................................492 OPERATION...................................................................492 TESTING.....................................................................492 REPLACEMENT.................................................................492 APPENDIX A–TOOLS A.1............................................................494 APPENDIX B–WIRING AMP MULTILOCK ELECTRICAL CONNECTORS B.1.......................512 REMOVING SOCKET/PIN TERMINALS...............................................512 INSTALLING SOCKET/PIN TERMINALS.............................................514 CRIMPING INSTRUCTIONS.......................................................516 DEUTSCH ELECTRICAL CONNECTORS B.2...............................................517 GENERAL.....................................................................517 REMOVING/DISASSEMBLING......................................................517 REMOVING/INSTALLING SOCKETS.................................................517 REMOVING/INSTALLING PINS....................................................519 ASSEMBLING/INSTALLING.......................................................519 CRIMPING INSTRUCTIONS.......................................................519 MINI-DEUTSCH CONNECTORS B.3.....................................................522 GENERAL.....................................................................522 For Size 20, 16 and 12 Contacts Wire Range 26-12 AWG....................522 CRIMPING INSTRUCTIONS.......................................................522 PACKARD ELECTRICAL CONNECTORS B.4...............................................524 GENERAL.....................................................................524 REMOVING PULL-TO-SEAT TERMINALS/EXTERNAL LATCH TYPE.........................524 INSTALLING PULL-TO-SEAT TERMINALS/EXTERNAL LATCH TYPE.......................525 SEALED BUTT SPLICE CONNECTORS B.5...............................................526 INSTALlation................................................................526 CONNECTOR LOCATIONS B.6.........................................................527 INDEX TO WIRING DIAGRAMS B.7....................................................528 2006 ALL SPORTSTER DOM. and INT. MODELS, LIGHTS, PAGE 2 OF 2....................560 2006 ALL SPORTSTER DOM. and INT. MODELS, MAIN HARNESS, PAGE 2 OF 2..............550 STARTING........................................................................554 2006 ALL SPORTSTER DOM. and INT. MODELS, STARTING AND CHARGING, PAGE 1 OF 1.....554 2006 ALL SPORTSTER DOM. and INT. MODELS, HORN AND INSTRUMENTS, PAGE 1 OF 1......556 2006 ALL SPORTSTER DOM. and INT. MODELS, MAIN HARNESS, PAGE 1 OF 2..............548 2006 ALL SPORTSTER DOM. and INT. MODELS, SECURITY, PAGE 1 OF 2..................562 2006 ALL SPORTSTER DOM. and INT. MODELS, SECURITY, PAGE 2 OF 2..................564 2006 ALL SPORTSTER DOM. and INT. MODELS, IGNITION CIRCUIT, PAGE 1 OF 1..........552 2006 ALL SPORTSTER DOM. and INT. MODELS, LIGHTS, PAGE 1 OF 2....................558 APPENDIX C–METRIC CONVERSIONS C.1...............................................566 FLUID CONVERSIONS C.2...........................................................567 UNITED STATES SYSTEM........................................................567 METRIC SYSTEM...............................................................567 BRITISH IMPERIAL SYSTEM.....................................................567 APPENDIX D: COMPENSATING SPROCKET D.1...........................................568 GENERAL.....................................................................568 REMOVAL/DISASSEMBLY.........................................................568 CLEANING, INSPECTION AND REPAIR.............................................569 ASSEMBLY/INSTALLATION.......................................................569 APPENDIX E–GLOSSARY E.1.........................................................570 STARTER TROUBLESHOOTING 1.1.....................................................576 STARTING SYSTEM DIAGNOSIS 1.2...................................................578 DIAGNOSTICS.................................................................578 Diagnostic Notes........................................................578 Starter Testing 1.......................................................579 Starter Testing 2: Solenoid Clicks......................................580 Starter Testing 3: Relay Clicks.........................................580 Starter Testing 4: Nothing Clicks.......................................581 Starter Testing 5: Starter Spins But Does Not Engage....................582 Starter Testing 6: Starter Stalls or Spins Too Slowly...................582 STARTER ACTIVATION CIRCUITS 1.3.................................................583 DIAGNOSTICS/TROUBLESHOOTING 1.4.................................................584 GENERAL.....................................................................584 VOLTAGE DROPS...............................................................584 TESTING STARTER ON MOTORCYCLE 1.5...............................................586 STARTER RELAY TEST..........................................................586 STARTER CURRENT DRAW TEST...................................................586 TESTING STARTER ON BENCH 1.6....................................................587 FREE RUNNING CURRENT DRAW TEST..............................................587 STARTER SOLENOID............................................................587 SOLENOID PULL-IN TEST.......................................................588 SOLENOID HOLD-IN TEST.......................................................588 SOLENOID RETURN TEST........................................................588 CHARGING SYSTEM 1.7.............................................................589 GENERAL.....................................................................589 Alternator..............................................................589 Voltage Regulator.......................................................589 TROUBLESHOOTING.............................................................589 Battery.................................................................589 Wiring..................................................................589 Voltage Regulator Inspection............................................589 Charging System Test 1.7 (Part 1 of 2)..................................591 Charging System Test 1.7 (Part 2 of 2)..................................592 TESTING.....................................................................593 Milliampere Draw Test...................................................593 Total Current Draw Test.................................................593 Current and Voltage Output Test.........................................594 Stator Check............................................................595 AC Output Check.........................................................596 IGNITION COIL 1.8...............................................................597 TROUBLESHOOTING.............................................................597 Primary Circuit Test....................................................597 Secondary Circuit Test..................................................597 Test Results............................................................597 Ignition Coil Substitution..............................................597 BATTERY TESTING 1.9.............................................................598 GENERAL.....................................................................598 VOLTMETER TEST..............................................................598 CONDUCTANCE TEST............................................................598 LOAD TEST...................................................................599 CHECKING FOR DIAGNOSTIC TROUBLE CODES 2.1.......................................602 CHECK ENGINE LAMP...........................................................602 SECURITY LAMP...............................................................603 Turn Signal Module (TSM)................................................603 Turn Signal Security Module (TSSM)......................................603 CODE TYPES..................................................................604 Current.................................................................604 Historic................................................................604 RETRIEVING DIAGNOSTIC TROUBLE CODES.........................................604 MULTIPLE DIAGNOSTIC TROUBLE CODES...........................................604 INITIAL DIAGNOSTIC CHECK: SPEEDOMETER 2.2.......................................605 GENERAL.....................................................................605 Diagnostic Notes........................................................605 Circuit Diagram/Wire Harness Connector Table............................605 Job/Time Code Values....................................................605 Reprogramming ICM.......................................................605 INITIAL DIAGNOSTICS.........................................................606 Diagnostic Tips.........................................................606 Diagnostic Notes........................................................606 Other Diagnostic Trouble Codes..........................................606 Initial Diagnostic Check (Part 1 of 3)..................................608 Initial Diagnostic Check (Part 2 of 3)..................................609 Initial Diagnostic Check (Part 3 of 3)..................................610 SPEEDOMETER SELF DIAGNOSTICS 2.3................................................611 GENERAL.....................................................................611 DIAGNOSTICS.................................................................611 Diagnostic Tips.........................................................611 Diagnostic Notes........................................................611 Speedometer Self Diagnostics (flow chart)...............................612 SPEEDOMETER/TACHOMETER 2.4......................................................613 GENERAL.....................................................................613 Reset Switch............................................................613 SPEEDOMETER THEORY OF OPERATION.............................................614 TACHOMETER THEORY OF OPERATION..............................................614 DIAGNOSTICS.................................................................614 Diagnostic Notes........................................................614 Test 2.4 (Part 1 of 2)..................................................616 TACHOMETER INOPERATIVE..................................................616 Test 2.4 (Part 2 of 2)..................................................617 BREAKOUT BOX: SPEEDOMETER/TACHOMETER 2.5........................................618 GENERAL.....................................................................618 SPEEDOMETER.................................................................618 Installation............................................................618 Removal.................................................................618 TACHOMETER..................................................................618 Installation............................................................618 Removal.................................................................618 INDICATOR LAMPS 2.6.............................................................619 GENERAL.....................................................................619 Job/Time Code Values....................................................619 Diagnostic Notes........................................................619 DIAGNOSTICS.................................................................621 Oil Pressure or Neutral Indicator Will Not Function.....................621 High Beam or R/L Turn Signal Indicator Will Not Function................621 DTC B1006, B1007 2.7............................................................622 GENERAL.....................................................................622 Accessory Or Ignition Line Overvoltage..................................622 Test 2.7................................................................623 DTC B1008 2.8...................................................................624 GENERAL.....................................................................624 Reset Switch Closed.....................................................624 Diagnostic Notes........................................................624 Test 2.8................................................................625 DTC U1016, U1255 2.9............................................................626 GENERAL.....................................................................626 Loss of ICM Serial Data.................................................626 DIAGNOSTICS.................................................................626 Diagnostic Notes........................................................626 Test 2.9................................................................628 DTC U1064, U1255 2.10...........................................................629 GENERAL.....................................................................629 Loss of TSM/TSSM Serial Data............................................629 DIAGNOSTICS.................................................................629 Diagnostic Notes........................................................629 Test 2.10...............................................................631 DTC U1300, U1301 OR BUS ER 2.11.................................................632 GENERAL.....................................................................632 Serial Data Low or Serial Data Open/High................................632 DIAGNOSTICS.................................................................632 Diagnostic Tips.........................................................632 Diagnostic Notes........................................................632 Test 2.11 (Part 1 of 2).................................................634 Test 2.11 (Part 2 of 2).................................................635 TSM/TSSM OVERVIEW 3.1...........................................................638 GENERAL.....................................................................638 TROUBLESHOOTING.............................................................638 TSM/TSSM FEATURES 3.2...........................................................640 GENERAL.....................................................................640 TURN SIGNAL FUNCTIONS.......................................................640 BANK ANGLE FUNCTIONS........................................................640 SECURITY ALARM AND IMMOBILIZATION FUNCTIONS.................................640 TSSM Only Feature.......................................................640 TSM/TSSM VEHICLE DELIVERY 3.3...................................................642 GENERAL.....................................................................642 SIDECAR CONFIGURATION.......................................................642 POWER DISRUPTION AND CONFIGURING............................................642 KEY FOB ASSIGNMENT..........................................................643 PERSONAL CODE ENTRY.........................................................643 First Time Code Entry: TSSM Only........................................643 Modifying Existing Codes: TSSM Only.....................................643 TSM/TSSM TURN SIGNAL FUNCTIONS 3.4..............................................647 GENERAL.....................................................................647 AUTOMATIC CANCELLATION......................................................647 MANUAL CANCELLATION.........................................................647 FOUR-WAY FLASHING...........................................................647 DIAGNOSTIC MODE.............................................................647 TSM/TSSM BANK ANGLE FUNCTION 3.5................................................648 GENERAL.....................................................................648 OPERATION...................................................................648 SECURITY SYSTEM (TSSM) FUNCTIONS 3.6............................................649 GENERAL.....................................................................649 Security System Operation...............................................649 Security System Options.................................................649 Differences By Market Specifications....................................649 ALARM SENSITIVITY...........................................................649 Sensitivity.............................................................649 Transport Mode..........................................................649 AUTO-ARMING FUNCTION........................................................650 STORAGE MODE................................................................650 ARMING/DISARMING SECURITY SYSTEM (TSSM) 3.7.....................................653 GENERAL.....................................................................653 SECURITY LAMP...............................................................653 USING KEY FOB...............................................................653 General.................................................................653 Arming the System.......................................................653 Disarming the System....................................................653 Troubleshooting.........................................................653 USING THE PERSONAL CODE.....................................................654 General.................................................................654 Disarming the System....................................................654 CHECKING FOR DIAGNOSTIC TROUBLE CODES 3.8.......................................655 TSM.........................................................................655 TSSM........................................................................655 CODE TYPES..................................................................657 Current.................................................................657 Historic................................................................657 RETRIEVING DIAGNOSTIC TROUBLE CODES.........................................657 MULTIPLE DIAGNOSTIC TROUBLE CODES...........................................657 INITIAL DIAGNOSTIC CHECK: TSM/TSSM 3.9..........................................658 GENERAL.....................................................................658 Diagnostic Notes........................................................658 Circuit Diagram/Wire Harness Connector Table............................658 Job/Time Code Values....................................................658 Reprogramming ICM.......................................................658 INITIAL DIAGNOSTICS.........................................................658 Diagnostic Tips.........................................................658 Diagnostic Notes........................................................658 Other Diagnostic Trouble Codes (DTCs)...................................658 Initial Diagnostic Check (Part 1 of 3)..................................661 Initial Diagnostic Check (Part 2 of 3)..................................662 Initial Diagnostic Check (Part 3 of 3)..................................663 SPEEDOMETER SELF DIAGNOSTICS 3.10...............................................664 GENERAL.....................................................................664 DIAGNOSTICS.................................................................664 Diagnostic Tips.........................................................664 Diagnostic Notes........................................................664 Speedometer Self Diagnostics (chart)....................................665 BREAKOUT BOX: TSM/TSSM 3.11.....................................................666 GENERAL.....................................................................666 INSTALLATION................................................................666 REMOVAL.....................................................................666 NO SECURITY LAMP AT KEY ON 3.12.................................................667 GENERAL.....................................................................667 No TSSM Power (Security Equipped Vehicles Only).........................667 Job/Time Code Values....................................................667 DIAGNOSTICS.................................................................667 Diagnostic Tips.........................................................667 Diagnostic Notes........................................................667 Test 3.12 (Part 1 of 3).................................................669 Test 3.12 (Part 2 of 3).................................................670 Test 3.12 (Part 3 of 3).................................................671 SECURITY LAMP ON CONTINUOUSLY 3.13..............................................672 GENERAL.....................................................................672 Job/Time Code Values....................................................672 DIAGNOSTICS.................................................................672 Diagnostic Notes........................................................672 Test 3.13...............................................................674 KEY FOB SIGNAL TO TSSM WEAK OR FAILS 3.14.......................................676 GENERAL.....................................................................676 Security Equipped Vehicles Only.........................................676 Job/Time Code Values....................................................676 DIAGNOSTICS.................................................................676 Diagnostic Tips.........................................................676 Diagnostic Notes........................................................676 Test 3.14...............................................................678 TURN SIGNAL ERRORS: DTC B1121, B1122, B1141 3.15................................679 GENERAL.....................................................................679 Job/Time Code Values....................................................679 DIAGNOSTICS.................................................................679 Diagnostic Tips.........................................................679 Diagnostic Notes: All Turn Signal Flow Charts...........................682 Turn Signal Error 1A (Part 1 of 2)......................................684 Turn Signal Error 1A (Part 2 of 2)......................................685 Turn Signal Error 2A....................................................686 Turn Signal Error 2B....................................................687 Turn Signal Error 2C....................................................688 Turn Signal Error 2D....................................................689 Turn Signal Error 3A....................................................690 DTC B0563 3.16..................................................................691 GENERAL.....................................................................691 Battery Voltage High....................................................691 DIAGNOSTICS.................................................................691 Diagnostic Tips.........................................................691 Diagnostic Notes........................................................691 DTC B1131, B1132 3.17...........................................................692 GENERAL.....................................................................692 Alarm Output Low (DTC B1131) or Alarm Output High (DTC B1132)...........692 DIAGNOSTICS.................................................................692 Diagnostic Tips.........................................................692 Diagnostic Notes........................................................692 Test 3.17...............................................................694 DTC B1134 3.18..................................................................695 GENERAL.....................................................................695 Starter Output High.....................................................695 DIAGNOSTICS.................................................................695 Diagnostic Notes........................................................695 Test 3.18...............................................................697 DTC B1135 3.19..................................................................698 GENERAL.....................................................................698 Accelerometer Fault.....................................................698 DTC U1016, U1255 3.20...........................................................699 GENERAL.....................................................................699 Loss of ICM Serial Data.................................................699 DIAGNOSTICS.................................................................699 Diagnostic Notes........................................................699 Test 3.20...............................................................701 DTC U1097, U1255 3.21...........................................................702 GENERAL.....................................................................702 Loss of Speedometer Serial Data.........................................702 DIAGNOSTICS.................................................................702 Diagnostic Notes........................................................702 Test 3.21...............................................................704 DTC U1300, U1301 OR BUS ER 3.22.................................................705 GENERAL.....................................................................705 DIAGNOSTICS.................................................................705 Diagnostic Tips.........................................................705 Diagnostic Notes........................................................705 PASSWORD LEARN 3.23.............................................................706 GENERAL.....................................................................706 PASSWORD LEARNING...........................................................706 TSSM MAINTENANCE 3.24...........................................................708 GENERAL.....................................................................708 KEY FOB.....................................................................708 Schedule................................................................708 Battery Replacement.....................................................708 SECURITY SIREN (IF INSTALLED)...............................................709 Schedule................................................................709 Battery Replacement.....................................................709 SPECIFICATIONS 4.1..............................................................712 DIAGNOSTIC INTRODUCTION 4.2.....................................................713 SYSTEM PROBLEMS.............................................................713 No Start................................................................713 Poor Performance........................................................713 Check Engine Lamp.......................................................713 RESOLVING PROBLEMS..........................................................713 CHECKING FOR DIAGNOSTIC TROUBLE CODES 4.3.......................................714 CHECK ENGINE LAMP...........................................................714 SECURITY LAMP...............................................................715 CODE TYPES..................................................................715 Current.................................................................715 Historic................................................................715 RETRIEVING DIAGNOSTIC TROUBLE CODES.........................................716 MULTIPLE DIAGNOSTIC TROUBLE CODES...........................................716 INITIAL DIAGNOSTIC CHECK: ICM 4.4...............................................717 GENERAL.....................................................................717 Diagnostic Notes........................................................717 Circuit Diagram/Wire Harness Connector Table............................717 Reprogramming ICM.......................................................717 INITIAL DIAGNOSTICS.........................................................717 General Information.....................................................717 Diagnostic Tips.........................................................717 Diagnostic Notes........................................................717 Other DTCs..............................................................717 Initial Diagnostic Check (Part 1 of 3)..................................721 Initial Diagnostic Check (Part 2 of 3)..................................722 Initial Diagnostic Check (Part 3 of 3)..................................723 SPEEDOMETER SELF DIAGNOSTICS 4.5................................................724 GENERAL.....................................................................724 DIAGNOSTICS.................................................................724 Diagnostic Tips.........................................................724 Diagnostic Notes........................................................724 Speedometer Self Diagnostics (flow chart)...............................725 BREAKOUT BOX: ICM 4.6...........................................................726 GENERAL.....................................................................726 INSTALLATION................................................................726 REMOVAL.....................................................................726 WIGGLE TEST 4.7.................................................................727 GENERAL.....................................................................727 PROCEDURE...................................................................727 Using DVOM (Part No. HD-39978)..........................................727 INTAKE LEAK TEST 4.8............................................................728 GENERAL.....................................................................728 LEAK TESTER.................................................................728 Parts List..............................................................728 Tester Assembly.........................................................728 Tester Adjustment.......................................................728 PROCEDURE...................................................................729 ENGINE CRANKS BUT WILL NOT START 4.9............................................730 GENERAL.....................................................................730 DIAGNOSTICS.................................................................730 Diagnostic Notes........................................................730 Test 4.9 (Part 1 of 3)..................................................732 Test 4.9 (Part 2 of 3)..................................................733 Test 4.9 (Part 3 of 3)..................................................734 STARTS THEN STALLS 4.10.........................................................735 GENERAL.....................................................................735 Serial Data Low or Serial Data Open/High................................735 DIAGNOSTICS.................................................................735 Diagnostic Tips.........................................................735 Diagnostic Notes........................................................735 Test 4.10 (Part 1 of 2).................................................737 Test 4.10 (Part 2 of 2).................................................738 NO SPARK/NO ICM POWER 4.11......................................................739 GENERAL.....................................................................739 DIAGNOSTICS.................................................................739 Diagnostic Notes........................................................739 Test 4.11...............................................................741 MISFIRE 4.12....................................................................742 GENERAL.....................................................................742 Misfire at Idle or Under Load...........................................742 DIAGNOSTICS.................................................................742 Diagnostic Notes........................................................742 Test 4.12...............................................................744 DTC P0106, P0107, P0108 4.13....................................................746 GENERAL.....................................................................746 MAP Sensor..............................................................746 DIAGNOSTICS.................................................................746 Diagnostic Tips.........................................................746 Diagnostic Notes........................................................746 Test 4.13 (Part 1 of 2).................................................748 Test 4.13 (Part 2 of 2).................................................749 DTC P0371, P0372, P0374 4.14....................................................750 GENERAL.....................................................................750 Crank Position Sensor...................................................750 DIAGNOSTICS.................................................................750 Diagnostic Notes........................................................750 Test 4.14 (Part 1 of 2).................................................752 Test 4.14 (Part 2 of 2).................................................753 DTC P0501, P0502 4.15...........................................................754 GENERAL.....................................................................754 Vehicle Speed Sensor....................................................754 DIAGNOSTICS.................................................................754 Diagnostic Notes........................................................754 Test 4.15 (Part 1 of 2).................................................756 Test 4.15 (Part 2 of 2).................................................757 DTC P0562, P0563 4.16...........................................................758 GENERAL.....................................................................758 Battery Voltage.........................................................758 DIAGNOSTICS.................................................................758 Diagnostic Notes........................................................758 Test 4.16 (Part 1 of 2).................................................760 Test 4.16 (Part 2 of 2).................................................761 DTC P0602, P0603, P0604, P0605, P0607 4.17......................................762 GENERAL.....................................................................762 ICM Failure.............................................................762 DIAGNOSTICS.................................................................762 DTC P0607 Test..........................................................762 DTC P0602, P0603, P0604, P0605 Test.....................................762 DTC P1009, P1010 4.18...........................................................763 GENERAL.....................................................................763 Password Problem........................................................763 DIAGNOSTICS.................................................................763 Diagnostic Notes........................................................763 Test 4.18...............................................................765 DTC P1351, P1352, P1354, P1355 4.19.............................................766 GENERAL.....................................................................766 Ignition Coil...........................................................766 DIAGNOSTICS.................................................................766 Diagnostic Notes........................................................766 Test 4.19 (Part 1 of 2).................................................768 Test 4.19 (Part 2 of 2).................................................769 DTC U1064 4.20..................................................................770 GENERAL.....................................................................770 Loss of TSM/TSSM Serial Data............................................770 DIAGNOSTICS.................................................................770 Diagnostic Notes........................................................770 Test 4.20...............................................................772 DTC U1097 4.21..................................................................773 GENERAL.....................................................................773 Loss of Speedometer Serial Data.........................................773 DIAGNOSTICS.................................................................773 Diagnostic Notes........................................................773 Test 4.21...............................................................775 CONNECTOR LOCATIONS 5.1.........................................................778 AMP MULTILOCK ELECTRICAL CONNECTORS 5.2.........................................779 REMOVING SOCKET/PIN TERMINALS...............................................779 INSTALLING SOCKET/PIN TERMINALS.............................................779 CRIMPING INSTRUCTIONS.......................................................782 DEUTSCH ELECTRICAL CONNECTORS 5.3...............................................783 GENERAL.....................................................................783 REMOVING/DISASSEMBLING......................................................783 REMOVING/INSTALLING SOCKETS.................................................783 REMOVING/INSTALLING PINS....................................................784 ASSEMBLING/INSTALLING.......................................................785 CRIMPING INSTRUCTIONS.......................................................786 MINI-DEUTSCH ELECTRICAL CONNECTORS 5.4..........................................788 GENERAL.....................................................................788 For Size 20, 16 and 12 Contacts Wire Range 26-12 AWG....................788 CRIMPING INSTRUCTIONS.......................................................788 SEALED BUTT SPLICE CONNECTORS 5.5...............................................790 INSTALLATION................................................................790 PACKARD ELECTRICAL CONNECTORS 5.6...............................................791 GENERAL.....................................................................791 PULL-TO-SEAT TERMINALS......................................................792 Removing External Latch Type............................................792 Installing External Latch Type..........................................792 PUSH-TO-SEAT TERMINALS......................................................792 Removing Push-to-Seat Terminals.........................................792 Installing Push-to-Seat Terminals.......................................793 CRIMPING INSTRUCTIONS.......................................................793 MICRO 64 TERMINALS..........................................................795 General.................................................................795 Removal.................................................................795 Installation............................................................795 Crimping Instructions...................................................796 INDEX TO WIRING DIAGRAMS 5.7....................................................797 APPENDIX A–GLOSSARY A.1.........................................................816
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