HARLEY DAVIDSON VRSCA V-ROD 1131cc 2002-2009 SERVICE REPAIR SHOP MANUAL
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LANGUAGE:ENGLISH
PAGES:446
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DESCRIPTION:
HARLEY DAVIDSON VRSCA V-ROD 1131cc 2002-2009 SERVICE REPAIR SHOP MANUAL
GENERAL:
This Service Manual has been prepared with two purposes in mind. First, it will acquaint the user with the construction of the Harley—Davidson product and assist in the performance of basic maintenance and repair. Secondly, it will introduce to the professional Harley-Davidson Technician the latest field- tested and factory-approved major repair methods. We sin- cerely believe that this Service Manual will make your association with Harley-Davidson products more pleasant and profitable.
Safety
Safety is always the most important consideration when per- forming 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 posi- tioned 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:
HARLEY DAVIDSON VRSCA V-ROD 1131cc 2002-2009 SERVICE REPAIR SHOP MANUAL
Index............................................... 2 Table of Contents................................... 5 1. Maintenance...................................... 13 Fuel and Oil.................................... 18 Airbox and Air Filter........................... 22 Cooling System.................................. 25 Engine Oil and Filter........................... 26 Battery Maintenance............................. 28 Brakes.......................................... 31 Bleeding Brakes................................. 33 Brake Pads and Discs............................ 34 Tires and Wheels................................ 37 Clutch.......................................... 38 Bleeding Clutch................................. 39 Rear Belt Deflection............................ 41 Rear Belt and Sprockets......................... 43 Suspension Adjustments.......................... 45 Steering Head Bearings.......................... 46 Front Fork Oil.................................. 47 Spark Plug/Coil................................. 49 Cable and Chassis Lubrication................... 51 Throttle Cables................................. 52 Valve Lash...................................... 53 Verify Cam Tiiming.............................. 57 Lash Adjustment................................. 58 Secondary Cam Chain............................. 63 Headlamp Alignment.............................. 66 Critical Fasteners.............................. 67 Storage......................................... 68 Troubleshooting................................. 70 2. Chassis.......................................... 74 Specifications.................................. 75 Torque Values................................... 76 V.I.N........................................... 79 Frame/Lower Frame Rails......................... 80 Front Engine Mount.............................. 82 Exhaust System.................................. 85 Rear Engine Mounts.............................. 87 Engine Replacement.............................. 88 Jiffy Stand..................................... 97 Footrests/Foot Controls......................... 99 Throttle Cables.................................101 Clutch Master Cylinder/Reservoir................103 Clutch Hand Lever...............................106 Clutch Fluid Line...............................107 Secondary Clutch Actuator.......................108 Front Brake Master Cylinder/Reservoir...........110 Front Brake Calipers............................114 Rear Brake Master Cylinder/Reservoir............119 Rear Brake Caliper..............................125 Handlebars......................................130 Front Wheel.....................................132 Rear Wheel......................................136 Sealed Wheel Bearings...........................141 Disc Rim Runout.................................144 Tires...........................................145 Front Fender....................................150 Front Fork......................................151 Steering Head...................................156 Fork Lock.......................................159 Belt Guard/Debris Deflector.....................160 Rear Shock Absorbers............................161 Rear Fork.......................................163 Seat Latch......................................166 Seat............................................167 Rear Fender/Supports............................169 3. Engine...........................................171 Specifications..................................172 Service Wear Limits.............................177 Engine Torque Values............................178 Oil Flow........................................179 Oil Pressure....................................183 Troubleshooting.................................185 Stripping Motorcycle For Service................187 Throttle Body...................................189 Top End Disassembly.............................191 Cylinder Head Service...........................197 Oil Pump........................................207 Clutch..........................................209 Upper and Lower Crankcase Service...............221 Counterbalancer Bearing Replacement.............236 Crankshaft Bearing Replacement..................242 Shift Shaft and Seal............................244 Crankshaft, Piston and Cylinder Liner...........246 Oil Filter Mount................................260 Cam Drive.......................................261 Cylinder Heads..................................264 Installing and Timing the Cams..................266 4. Fuel System......................................272 Specifications..................................273 Fuel Pump/Filters/Fuel Level Sender Assembly....274 Suction Side Fuel Filter........................277 Fuel Pump.......................................278 Fuel Tank.......................................279 Vapor Valve.....................................281 Evaporative Emissions Control - CA Models.......282 Purge Solenoid/Vapor Valve......................283 Charcoal Canister...............................284 Hose Routing/Replacement........................285 5. Electric Starter.................................286 Specifications..................................287 Electric Starter System.........................288 Starter Relay...................................290 Starter.........................................292 Starter Solenoid................................293 6. Cooling System...................................295 Specifications..................................296 Coolant Flow....................................297 Troubleshooting.................................299 Pressure Cap Test...............................300 System Pressure Test............................301 Leak Detection Dye Test?Blown Gasket............302 Engine Coolant..................................303 Thermostat......................................305 Water Pump......................................307 Coolant Pipes and Hoses.........................309 Oil Line Fittings...............................312 Radiator/Oil Cooler.............................313 Oil Cooler......................................316 7. Transmission.....................................318 Specifications..................................319 Output Shaft....................................320 Input Shaft.....................................329 8. Electrical.......................................335 Specifications..................................336 Torque Values...................................337 Bulb Requirements...............................338 Relay/Fuse Block................................339 Crank Position Sensor: CKP......................341 Maxi-Fuse.......................................342 Ignition/Light Switch...........................343 Alternator......................................344 Voltage Regulator...............................346 Battery.........................................348 Battery Cables..................................353 Headlamp........................................354 Tail Lamp.......................................356 Turn Signal/Running Lights......................358 Turn Signal Security Module:TSSM................360 Instrument Cluster..............................361 Vehicle Speed Sensor:VSS........................363 Neutral Switch..................................364 Oil Pressure Switch.............................365 Stop Light Switch...............................367 Horn............................................368 Cooling Fans....................................369 9. Fuel Injection...................................371 Specifications..................................372 Torque Values...................................373 Electronic Fuel Injection:EFI...................374 Electronic Control Module:ECM...................376 Throttle Position Sensor:TP.....................377 Intake Air Temperature Sensor:IAT...............378 Engine Coolant Temperature Sensor:ECT...........379 Idle Air Control:IAC............................380 Manifold Absolute Pressure Sensor:MAP...........382 Fuel Rail/Fuel Injectors........................383 Fuel Pressure Test..............................385 Intake Leak Test................................387 Appendix............................................389 Appendix A - Tools..............................390 Appendix B - Wiring.............................402 Appendix C - Conversions........................423 Index...............................................438
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
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