Generalinstallation

Cylinder head removal is part of top end disassembly. See 3.10 TOP END DISASSEMBLY. Clean and examine heads carefully before installation. If heads, values, guides or springs require service, see 3.11 CYLINDER HEAD SERVICE. If heads have been serviced, remove cam journal caps and cams prior to cylinder head installation. The cams will be reinstalled after the heads have been installed and the head bolts torqued to specifications. See 3.22 INSTALLING AND TIMING THE CAMS. Initial valve lash...

Awarning

Use care not to damage the new races' tapered surface. The race should be firmly seated against the shoulder in the bore. If it is loose, the steering head adjustment will become loose, adversely affecting the motorcycle's handling, which may lead to an accident which could result in death or serious injury. 5. When bearing races are fully seated in bore of steering head, pack new bearings with HARLEY-DAVIDSON SPECIAL PURPOSE GREASE (HD-99857-97). Do not use a sleeve that is larger than the...

Specifications

Gerotor, internal oil pump, wet sump 3-6.5 bar (43-94 psi) at 3000 rpm and normal operating temperature of 70 C (158 F) 10 micron media between pump & engine Impeller type, thermostat controlled bypass Valve-to-guide running clearance - intake Valve-to-guide running clearance - exhaust Table 3-11. Cylinder Heads (continued) Table 3-11. Cylinder Heads (continued) Maximally compressed (intake and exhaust) Pittings to be smaller than 16 mm in length, Maximum depth of tensioner show wear 0.8 mm....

Cable and Chassis Lubrication 138

General Jiffy 1.21 Throttle Cable Inspection, Lubrication and Adjustment 1-39 Fuel System Lines and 1.22 Valve Lash Verify Cam Lash 1.23 Secondary Cam Chain 1-50 1.24 Headlamp Alignment 1-53 1.25 Critical Preparation for Removal from General Engine Starter Motor Does Not Operate Turn Over 1-57 Engine Turns Over But Does Not Start 1-57 Starts Starts But Runs Irregularly or A Spark Plug Fouls Pre-lgnition or Detonation (Knocks or Pings) 1-58 Valve Train Excessive Check Engine Light Illuminates...

Harley V Rod Bearing Race Tool

Steering head bearing race installer 1. Lubricate outside of new steering head bearing races with lubricant provided or engine oil. 2. See Figure 2-97. Assemble STEERING HEAD BEARING RACE INSTALLER (HD-39302) and bearing races on tool's draw down bolt through steering head. Orient races so lettered edges are at bottom of steering head bore in steering head. 3. Continue to thread nut on draw down bolt until races fit, and are parallel to steering head bore. 4. Slowly tighten nut while stopping...

Cleaning And Inspection

Inspect all components for wear or damage. 2. Clean underside of pillion and seat. Clean fender and frame mounting surfaces. Do not use ordinary soap to clean the seat. Thoroughly clean with a quality saddle soap. Once the seat is dry it can be treated with HARLEY-DAVIDSON LEATHER CARE DRESSING (Part No. 98261-91V). Pillion Grabstrap Mounting bolt and washer Rider's seat 1. If necessary, install grabstrap. Tighten to 11-17 Nm (97-150 in-lbs). 2. Push pillion toward front of motorcycle until...

Replacement

With oil pump on engine, loosen bypass fastener and front cover fasteners. 3. See Figure 3-69. Remove bypass valve assembly. Examine valve piston and valve piston bore in pump housing. There should be no scoring and valve piston should move freely in the bore without sticking. 4. See Figure 3-70. Examine gerotor. Replace parts showing scoring. Note assembly marks on the gerotor. Marks must be on the same side when assembling. 2. See Figure 3-68. Remove three fasteners holding...

Head Assembly

Thoroughly clean head before beginning assembly. 2. See Figure 3-61. Insert lower spring collar. 3. Lubricate valve with Harley-Davidson Motorcycle Oil 20W50 and position in head. 4. See Figure 3-62. Place VALVE GUIDE SEAL INSTALLER (HD-45322) tapered pin over valve stem and position new seal on the tapered pin. Drive seal into position. Figure 3-62. Valve Seal Installation Figure 3-65. Cam Journal Caps 9.7 Nm (85 in-lbs) 12. See Figure 3-65. Install cams and cam journal caps. Tighten cam...

Gasoline Blends

Using gasoline that has an alcohol additive, such as methanol, may cause fuel system rubber components' failure and or engine damage. Harley-Davidson motorcycles were designed to give the best performance using unleaded gasoline. Some fuel suppliers sell gasoline alcohol blends as a fuel. The type and amount of alcohol added to the fuel is important. DO NOT USE GASOLINES CONTAINING METHANOL. Using gasoline methanol blends will result in starting and driveability deterioration and damage to...

Rod Lock Ring Fuel Module

Fuel Pump Filters Fuel Level Sender Assembly 3. See Figure 4-3. Orient the pointer (6) on the lock ring to point 90 degrees to the left side of the motorcycle. In this position the start of the lock ring threads match the start of the threads on the collar of the opening in the fuel tank. Thread on lock ring. Use FUEL CAP REMOVER INSTALLER (HD-45324) to tighten the lock ring to 54-61 Nm (40-45 ft-lbs). 4. Connect the fuel module connector (5) while supporting the top plate connector...

Preparation For Service

Gasoline is extremely flammable and highly explosive. Always stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near the work site. Inadequate safety precautions could result in death or serious injury. Good preparation is very important for efficient service work. A clean work area at the start of each job will allow you to perform the repair as easily and quickly as possible, and will reduce the incidence of misplaced tools and parts. A...

Info

2.1 Specifications 2.2 Torque 2.3 Vehicle Identification Number 2.4 Frame Lower Frame 2.5 Front Engine 2.6 Front Engine Mount Assembly 2.7 Exhaust 2.8 Rear Engine Mounts 2.9 Engine 2.10 Jiffy Stand 2.11 Footrests Foot 2.12 Throttle Cables 2.13 Clutch Master Cylinder Reservoir 2.14 Clutch Hand 2.15 Clutch Fluid Line 2.16 Secondary Clutch Actuator 2.17 Front Brake Master 2.18 Front Brake Calipers 2.19 Rear Brake Master Cylinder Reservoir 2.20 Rear Brake Caliper 2.21 Handlebars 2.22 Front 2.23...

Brake Does Not Hold Normally

Master cylinder reservoir low on fluid. 2. Brake system contains air bubbles. 3. Master or wheel cylinder piston worn or parts damaged. 4. Brake pads contaminated with grease or oil. 6. Brake disc badly worn or warped. 7. Brake drags -brake pedal and master cylinder piston not returning completely. 8. Brake fades due to heat build up - brake pads dragging or excessive braking.

Irregularities

Non-standard equipment on the front end such as heavy radio receivers, extra lighting equipment or luggage tends to cause unstable handling. 2. Damaged tire(s) or improper front-rear tire combination. 3. Irregular or peaked front tire tread wear. 4. Incorrect tire pressure. See 1.11 TIRES AND WHEELS. 5. Shock absorber not functioning normally. 6. Loose wheel axle nuts. Tighten to recommended torque specification. 7. Excessive wheel hub bearing play. 8. Rear wheel...

General

The troubleshooting section of this manual is intended solely as a guide to diagnosing problems. Carefully read the appropriate sections of this manual before performing any work. Observe all cautions and warnings. Failure to observe cautions and warnings could result in death or serious injury. The following check list of possible operating troubles and their probable causes will be helpful in keeping a motorcycle in good operating condition. More than one of these conditions may be causing...

Adjustment

Turn the cable adjusters (2, 4) and jam-nuts (3) as short as they will go. Both cables should have zero adjustment at the start of this procedure. 2. Point the front wheel straight ahead. a. Turn the throttle grip wide open and hold it there. b. Turn the throttle cable adjuster (2), lengthening the sleeve, until the throttle cam just touches the cam stop. c. Tighten the adjuster jamnut (3) and release the throttle. 3. Turn the front wheel full right. 4. Turn the idle cable...

Removalinspection

Inspect at every 8000 km (5000 mile) service interval. Replace every 16,000 km (10,000 mile) service interval. 1. After the engine has cooled to room temperature remove airbox assembly. See 1.4 AIRBOX AND AIR FILTER. 2. Lift fuse block off the retaining bracket and move to side. 3. See Figure 1-49. Remove rear coil fasteners (1). 4. Detach connector (2) 83R at rear coil, 83F at front coil. 5. Pull coil and boot assembly straight up to disconnect spark plug. 6. Using a spark plug socket with...

Inspection

Harley Davidson Drive Belt Teeth

If chrome chips or gouges to rear sprocket are large enough to be harmful, they will leave a pattern on the belt face. 1. See Figure 1-39. Inspect each tooth (1) of rear sprocket for b. Large chrome chips with sharp edges. c. Gouges caused by hard objects. d. Excessive loss of chrome plating (see step 2). 2. To check if chrome plating has worn off, drag a scribe or sharp knife point across the bottom of a groove (2) (between two teeth) with medium pressure. a. If scribe or knife point slides...

Bleeding Brakes

Hydraulic brake fluid bladder-type pressure equipment can be used to fill brake master cylinder through the bleeder valve. Remove master cylinder reservoir cover so that system cannot pressurize. Do not use pressure bleeding equipment when the hydraulic system is sealed with master cylinder reservoir cover and gasket in place. 1. Bleed front and rear brakes separately. Remove bleeder valve cap. Install end of a length of clear plastic tubing over caliper bleeder valve. Place opposite end in a...

Pedal Adjustment

With a wrench holding the push rod (1), loosen jam nut (2). 2. Turn push rod (1) to set threaded rod end (3) length (5) to 18-22 mm (0.690-0.890 in.). Measure pedal adjustment from the centerline of the clevis pin (4) to the backside of the jam nut (2). 3. With a wrench holding the push rod (1), tighten jam nut (2).

Installationconnection

Attach the cables to the correct battery terminals using the proper torque. Overtightening bolts can damage battery terminals and incorrect connections may damage the motorcycle's electrical system. Always connect the positive battery cable first. If the positive cable should contact ground with the negative cable installed, the resulting sparks may cause a battery explosion that could result in death or serious injury. Figure 1-22. Position Hold-down Strap 1. See Figure 1-22. Stretch rubber...

Disconnectionremoval

Always disconnect the negative battery cable first. If the positive battery cable should contact ground with the negative cable installed, the resulting sparks may cause a battery explosion that could result in death or serious personal injury. 1. See Figure 1-21. Remove fastener (1) and remove right side cover (2). 3. Remove airbox. See 1.4 AIRBOX AND AIR FILTER. 4. See Figure 1-20. Remove negative terminal bolt (1) and positive terminal bolt (2). 5. Release battery strap clip (3) and remove...

Installation

To replace, press a new pressure side filter into its bracket up against the bracket stop, replace the fuel crossover hose and the pressure fuel line, and install a new clamp over the crossover hose using side of HOSE CLAMP PLIERS (HD-41137). 3. Rheostatic slide and fuel level sender float Figure 4-6. Fuel Pump Filters Fuel Level Sender Assembly Some gasoline will drain from the individual components when disconnected from the fuel pump filters fuel level sender assembly. Thoroughly wipe up any...

Fluid Inspection

Check brake fluid reservoir level and condition At the first scheduled service interval. At every 5000 mile (8000 km) service interval thereafter. When storing or removing the motorcycle for the season. Also, check for fluid leaks at every service interval. Direct contact of D.O.T. 5 brake fluid with eyes may cause eye irritation, swelling, and redness. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 5...

Crimping Instructions

Strip wire lead removing 5 32 in. (4 mm) of insulation. 2. Compress handles until ratchet automatically opens. Always perform core crimp before insulation seal crimp. 3. Determine the correct dye or nest for the core crimp by checking with the appropriate crimp table. When the word TIP appears in the Crimp Table, use the tip of the tool specified to perform the core crimp procedure. See 4. Lay the back of the core crimp tails on the appropriate nest. Be sure the core crimp tails are pointing...

Installing Pushto Seat Terminals

For wire location purposes, alpha characters are stamped onto the secondary locks or onto the wire end of the connector housing. 1. To install a terminal back into the chamber of the connector housing, use a thin flat blade, like that on an X-Acto knife, and carefully bend the tang outward away from the terminal body. 2. Push the lead into the chamber at the wire end of the connector. A click is heard when the terminal is properly seated. 3. Gently tug on the wire end to verify that the...

Removing External Latch Type

To remove a pull-to-seat terminal from connectors with external latches, proceed as follows 1. Remove the connector from the retaining device, if present. 2. Bend back the external latch(es) slightly and separate the pin and socket halves of the connector. 3. To free a pull-to-seat terminal from the connector housing, first look into the mating end of the connector to find the locking tang. See A in Figure B-20. The tangs are always positioned in the middle of the chamber and are on the same...

Assemblinginstalling

Insert socket housing into pin housing until it snaps in place. Two-, three-, four- and six-pin Deutsch connectors have one external latch on the socket half of the connector. To fit the halves of the connector together, the latch on the socket side must be aligned with the latch cover on the pin side. For those connectors with two external latches (8-pin and 12-pin), a different system is used to prevent improper assembly. Align the tabs on the socket housing with the grooves on the pin...

Removinginstalling Pins

Use the hooked end of a stiff piece of mechanics wire a needle nose pliers, or a suitable pick tool (Part No. HD-41475-100). See Figure B-10. 2. Gently depress terminal latches inside pin housing and back out pins through holes in wire seal. Figure B-9. Depress Terminal Latches Back Out Pins An ELECTRICAL TERMINAL CRIMP TOOL (Part No. HD- 39965) is used to install Deutsch pin and socket terminals on wires. If new terminals must be installed, see Crimping 3....

Removinginstalling Sockets

Remove the secondary locking wedge. Insert the blade of a small screwdriver between the socket housing and locking wedge in line with the groove (in line with the pin holes if the groove is absent). Turn the screwdriver 90 degrees to pop the wedge up. 2. See Figure B-8. Gently depress terminal latches inside socket housing and back out sockets through holes in rear wire seal. Figure B-6. Remove Secondary Locking Wedge Figure B-6. Remove Secondary Locking Wedge An ELECTRICAL...

Removingdisassembling

Attachment clips are attached to the pin housings of most connectors. The clips are then attached to T-studs on the motorcycle frame. T-studs give positive location to electrical connectors and wire harness. Consistent location reduces electrical problems and improves serviceability. 1. Push the connector to disengage small end of slot on attachment clip from T-stud. Lift connector off T-stud. 2. Depress the external latch(es) on the socket housing side and use a rocking motion to separate the...

Adanger

Propane is an extremely flammable liquid and vapor. Vapor may cause flash fire. Keep away from heat, sparks and flame. Keep container closed. Use only with adequate ventilation. Do not direct propane stream toward front of engine. If propane enters air horn, a false reading will be obtained. 4. See Figure 9-24. Aim nozzle toward possible sources of leak such as fuel injectors and intake tract. 5. See Figure 9-23. Push valve (4) to release propane. Tone of engine will change when propane enters...

Testing

Fuel Pump Connector 141 Figure 9-19. Fuel Pressure Gauge Valves 1 8 in. pipe thread 90 elbow Fuel valve Figure 9-20. Schr der Valve Location Figure 9-21. Fuel Pressure Gauge Installed Connect fuel pressure gauge to Schr der valve. Reconnect connector 141 . Start and idle engine to pressurize the fuel system. Open the fuel valve to allow the flow of fuel down the hose of the pressure gauge. Position the clear air bleed tube in a suitable container and open and close the air bleed...

Fuel Tubes

Install washers (3) over fuel tube. 2. Apply clean engine oil to new fuel tube o-rings (2). 3. Install feed and return fuel tubes into proper holes in fuel rail. 4. See Figure 9-16. Install fuel pressure regulator clip over fuel tubes. 5. Install screws (5, 9). Tighten to 2.0-2.8 Nm (18.0-25.0 in-lbs).

British Imperial System

Fluid volume measurements in this Service Manual do not include the British Imperial (Imp.) system equivalents. The following conversions exist in the British Imperial system 1 pint (Imp.) 20 fluid ounces (Imp.) 1 quart (Imp.) 2 pints (Imp.) 1 gallon (Imp.) 4 quarts (Imp.) Although the same unit-of-measure terminology as the U.S. system is used in the British Imperial (Imp.) system, the actual volume of each British Imperial unit-of-measure differs from its U.S. counterpart. The U.S. fluid...

Metric System

Fluid volume measurements in this Service Manual include the metric system equivalents. In the metric system, 1 liter (L) 1,000 milliliters (mL). Should you need to convert from U.S. units-of-measure to metric units-of-measure (or vice versa), refer to the following fluid ounces (U.S.) x 29.574 milliliters pints (U.S.) x 0.473 liters quarts (U.S.) x 0.946 liters gallons (U.S.) x 3.785 liters milliliters x 0.0338 fluid ounces (U.S.) liters x 2.114 pints (U.S.) liters x 1.057 quarts (U.S.) liters...

Caution

Damaged pistons or piston bores will leak when reassembled. Do not use metal objects to remove or install objects from piston bores. Prevent damage to bores by only using a wooden toothpick when servicing calipers. 6. See Figure 2-44. Using a wooden toothpick (1), remove a wiper (2) and square seal (3) from each caliper bore. Discard all removed parts. 7. Repeat for opposite caliper. Figure 2-44. Wipers and Square Seals Figure 2-44. Wipers and Square Seals Figure 2-46. Crossover O-rings and...

Disassembly

Remove pad pins (10), brake pads (7) and bridge bolts (11) to separate caliper housings (1, 8). 2. Remove anti-rattle spring (6). If necessary, remove bleeder valve (12). 3. See Figure 2-45. Remove pistons. a. Place BRAKE CALIPER PISTON REMOVER (Part No. HD-43293) between caliper housings. b. Insert two bridge bolts (2) and tighten securely. c. If the bleeder valve was removed, loosely reinstall or place a gloved finger over the bleeder valve hole on the outside caliper...

Removal

If only replacing brake pads, see 1.10 BRAKE PADS AND DISCS. Damaged banjo bolt surfaces will leak when reassembled. Prevent damage to seating surfaces by carefully removing 1. See Figure 2-42. Remove banjo bolt (1) and both steel rubber washers (2) to detach front brake line (3) from caliper. Discard washers. 2. Remove both upper (4) and lower (5) mounting bolts. Lift caliper upward to remove from brake disc. 3. Repeat for opposite side caliper. Figure 2-42. Front Brake Caliper Mounting...

Assembly

Coat cylinder bore, piston, o-ring, boot, and bleeder screw with lubricant from service kit. 2. Orient a new seal (6) with square split lip toward rider side of actuator and fit to piston (7). 3. Insert spring into cylinder bore and insert piston into cylinder bore. Compress and guide seal lip as piston is pressed into bore. 4. Install a new o-ring (4) into groove at base of secondary clutch actuator housing (1). 5. Fit boot (8) to piston (7) and push edge of boot over machined...

Warning

Always wear proper eye protection when removing retaining rings. Use the correct retaining ring pliers. Verify that the tips of the pliers are not damaged or excessively worn. Slippage could propel the ring with force which could cause death or serious injury. 3. Remove retaining ring from pivot pin groove. To take the piston spring load off the pin and remove the pivot pin, gently force the clutch lever toward the piston (as if operating the clutch). 4. Remove pivot pin through top of housing....

Removaldisassembly

Loosen cable adjuster jam nuts (1). Screw throttle cable adjuster until it is a short as possible. 2. Remove screws that hold handlebar housing together to separate the upper and lower housings. 3. Use a screwdriver to rotate cable ferrules in throttle grip notches. Remove cables from notches on inboard side of throttle grip and remove cables from throttle grip and lower housing. 4. Remove airbox. See 1.4 AIRBOX AND AIR FILTER. 5. Remove throttle cable housings from guides at...

Jiffy Stand And Lower Frame Rail Improvement For V

Wear gloves and protective eyeglasses (or face shield) when performing the following procedure. The jiffy stand spring tension could cause the spring, attached components and or hand tools to fly outward at great speed and could cause death or serious injury. 3. With leg in the retracted position, detach spring (6) from jiffy stand leg (5), and anchor (7). 4. Remove clevis pin (2) by gently tapping on pin from bottom to drive pin up through mounting bracket. 5. Pull out jiffy stand leg and...

Jiffy Stand

Without the weight of the motorcycle resting on the jiffy stand, any vehicle movement could cause the jiffy stand to retract slightly from the full forward position. If the jiffy stand is not in the full forward or lock position when vehicle weight is rested on it, the vehicle could fall over which could result in death or serious injury.

Iat Connector Vrod

Inspect IAT o-ring (1). Replace IAT sensor if o-ring is worn or damaged. 2. Apply clean engine oil to IAT sensor o-ring. 3. Install IAT sensor into upper airbox. 4. Connect IAT sensor connector 89B , 5. Replace airbox cover. See 1.4 AIRBOX AND AIR FILTER. Figure 9-6. Intake Air Temperature Sensor Location

Harley Davidson V Rod Connector To

Rod Frame Pics Only

See 8.5 MAXI-FUSE. 2. Remove exhaust system. See 2.7 EXHAUST SYSTEM. 3. See Figure 8-13. Remove fasteners (1) and left and right radiator trim covers (2). Before removing wiring harnesses, carefully note wire routing. In particular, pay close attention to locations of cable straps that must be replaced. 4. See Figure 8-16. Pull rear brake master cylinder reservoir straight away from its mounting slots in right side of radiator cover. 5. See Figure 8-42. Clip cable straps...

Bulb Replacement

Locate notch on edge of front or rear turn signal lens cap. 2. Insert coin in notch. Carefully twist coin until lens pops out of turn signal housing. a. Push bulb in and turn counterclockwise. b. Pull bulb from socket when tab on bulb clears opening on socket. c. Push new light bulb in and turn clockwise to lock in place. 4. Snap lens back into turn signal housing with the notch facing down. If after replacing a bulb, the turn signal or running lamp will not light, check the wiring, the ground...

Tail Lamp812

Insert a small screwdriver into middle hole of license plate light cover. Push forward with screwdriver to release tail lamp housing retaining clip. 2. Lift rear of tail lamp housing up and slide housing 3. See Figure 8-25. To replace tail lamp bulb a. Turn bulb socket assembly (2) clockwise (CW) and pull outward from tail lamp housing. b. Remove bulb by turning counterclockwise (CCW) and pulling from bulb socket assembly. c. Push new bulb into bulb socket assembly and turn...

License Lamp V

Do NOT force the connector onto the headlamp bulb socket. The two headlamp connectors are not interchangeable. Forcing the wrong connector onto the bulb will damage the connector pins and or bulb socket. 3. Gently push the headlamp wiring connector onto the headlamp bulb socket until it clicks into place. Figure 8-24. Releasing Tail Lamp Retaining Clip

Headlamp Bulb

It Is not necessary to disassemble the headlamp assembly in 1. See Figure 8-23. To replace the low beam (5) or high beam (7) headlamp bulb, reach behind the headlamp bucket (4) and grasp the appropriate headlamp bulb socket connector. 2. Squeeze the release latches on the connector and pull the connector away from the headlamp bulb. 3. While facing the headlamp from behind (looking toward the front of the motorcycle), twist the headlamp bulb approximately 45 degrees counterclockwise (ccw) and...

Battery Charging

Never charge a battery without first reviewing the instructions for the charger being used. In addition to the manufacturer's instructions, follow these general safety precautions Always wear proper eye, face and hand protection. Always charge batteries in a well-ventilated area. Turn the charger OFF before connecting the leads to the battery to avoid dangerous sparks. Never try to charge a visibly damaged or frozen battery. Connect the charger leads to the battery red positive (+) lead to the...

Harley Davidson V-rod Vrsca Alternator Stator Cover

How Install Harley Jiffy Stand

Stator-to-Regulator Connector 4. Alternator cover remover installer tool (HD-45304) Figure 8-9. Removing Alternator Cover 1. Thoroughly clean alternator cover and gasket sealing surface on engine case. Remove any sealing material from gasket sealing surfaces. 2. See Figure 8-10. Install stator assembly (2) in alternator cover (1). Make sure to orient stator so that wiring harness exits stator housing at approximately 3 O'clock position. Line up three fastener holes in stator with...

Alternator

Alternator cover remover installer tool (HD-45304) Figure 8-8. Stator-to-Regulator Connector The alternator is located behind the alternator cover, on the lower left side of the engine. The alternator cover is secured with 14 fasteners. The derby cover is located on the alternator cover, secured with two fasteners. For diagnostic information, see the VRSCA Electrical Diagnostic Manual.

Vrsc Ignition Switch Removal

See 8.5 MAXI-FUSE. 3. See Figure 8-7. Remove two fasteners (1), washers (3) and seat latch mechanism (4) from frame. 4. Remove fastener (2), washer (3) and ignition light switch (5) from frame. 5. Using IGNITION SWITCH CONNECTOR REMOVAL TOOL (HD-45961), carefully release latching tab securing wiring harness connector to back of ignition light switch. Pull connector out of ignition light switch socket. 6. Insert wiring harness connector into new ignition light switch socket....

Rod Crank Sensor

The new CKP o-ring has a blue teflon coating that provides lubrication during installation. It is not necessary to coat the o-ring with engine oil to install it. 1. See Figure 8-5. Install new CKP sensor (1) and o-ring with fastener and captive washer (2). Tighten to 8.2-10.7 Nm (73-95 in-lbs). 2. Route CKP sensor wiring harness through cable clip (3) on top of jiffy stand bracket. Latch cable clip. 3. Route CKP sensor wiring harness to wiring harness on left side of radiator and attach to...

Relayfuse Block Installation

Slide each relay fuse block assembly back into relay fuse block cover. Push relay fuse block assembly into the cover until cover release tab locks into place. 2. Replace airbox cover. See 1.4 AIRBOX AND AIR FILTER. 3. Turn ignition switch to the FUEL position and close seat. Then turn ignition switch to the LOCK position. When closing the seat, make sure the ignition switch is in the FUEL position. If the ignition switch is in any other position when the seat is closed, the seat...

Relayfuse Block

Relay Fuse Block Assembly 1. See Figure 8-3. Grasp the suspect fuse and gently pull straight out of the fuse socket. 2. Inspect the fuse element. Replace the fuse if the element is burned or broken. 3. Line up the pins of the fuse with the socket holes in the relay fuse block. Push gently down on the fuse body until it bottoms out in the socket. Two spare fuses are located in the left relay fuse block. Always use replacement fuses that are of the correct type and amperage rating....

Disassembly 1st Gear

Figure 7-55.1st Gear Bearing Removal 9. See Figure 7-55. Remove 1st gear crankcase bearing. Bearing Removal - 1st Gear End Bearing Installation - 1st Gear End Figure 7-55.1st Gear Bearing Removal 9. See Figure 7-55. Remove 1st gear crankcase bearing. Figure 7-56.1st Gear Bearing Replacement 10. See Figure 7-56. Install new bearing, with bearing alignment pin offset toward the gears. Use a pressing ring so installation force is on the inner race only.

Oil Cooler

Do not remove the filler cap when the engine is hot. The cooling system is under pressure and hot coolant and steam may escape causing severe burns. Allow engine to cool before servicing the cooling system. 1. Allow cooling system to cool. 2. Remove right side cover and maxi-fuse. See 8.5 MAXI-FUSE. To protect against shock and accident start-up of vehicle, disconnect the negative battery cable before proceeding. Inadequate safety precautions could result in death or serious injury. 3. Remove...

How To Open Vrod Radiator Housing

The thermostat is a valve that remains closed until the engine reaches operating temperature. The thermostat opens allowing engine coolant to flow out of the engine to the radiator when the coofant temperature exceeds 85 C (185 F). The thermostat is fully open at 100 C (212 F). Do not remove the pressure filler cap when the engine is hot. The cooling system is under pressure and hot coolant and steam may escape causing severe burns. Allow engine to coot before servicing the cooling system. 1....

Troubleshooting

The pressure cap and radiator filler neck pressurize the coolant system. The pressure cap's upper spring diaphragm gasket seals to the upper sealing seat in the filler neck. The lower pressure limiting valve in the pressure cap seals to the lower seat. The filler neck has an overflow tube between and upper and lower sealing seat. The troubleshooting section of this manual is intended solely as a guide to diagnosing problems. Carefully read the appropriate sections of this manual before...

Flow Description

To warm the engine up quickly, the ethylene-glycol coolant is re-circulated through the cylinders (13) and combustion chamber (12) in the cylinder heads. The thermostat (4) blocks the passage to the radiator (11) to recirculate the coolant. As coolant exits the pump (3), it flows through the crankcase and around the cylinder liners (13) removing the heat build-up caused by the motion of the piston rings. From the cylinder liners (13), the coolant flows up through the cylinder...

Coolant Flow

The VRSCA engine is cooled by a an ethylene-glycol coolant and the lubricating engine oil. The ethylene-glycol coolant is pressurized and circulated through the engine and a cooling radiator by an impeller type water pump utilizing a thermostat controlled bypass. The coolant pressure determines the coolant boiling point. The boiling point rises as the pressure increases and drops as the pressure decreases. At the rated system pressure of 103 kPa (15 psi), the boiling point rises to over 121 C...

Removalinstallation

Replace the radiator oil cooler assembly. See 6.8 RADIATOR OIL COOLER. 3. While holding each crankcase fitting (oil in & oil out) with an angled wrench, install and tighten oil line sleeves to 53-58 Nm (39-42 ft-lbs). 4. Check oil level and add oil if required. 5. Replace the negative battery cable. Tighten to 6.8-10.8 Nm (60-96 in-lbs). 6. Install maxi-fuse and right side cover. a. Inspect oil sleeves and fittings for oil leaks. b. Check oil level and add oil if required. c. Check coolant...

Oil Line Fittings

Oil line sleeve 53-58 Nm (39-42 ft-lbs) 2. Oil in fitting 25-30 nm (19-22 ft-lbs) Do not remove the filler cap when the engine is hot. The cooling system is under pressure and hot coolant and steam may escape causing severe burns. Allow engine to cool before servicing the cooling system. 1. Allow cooling system to cool. 2. Remove right side cover and maxi-fuse.

Acaution

Direct contact of D.O.T. 5 SILICONE BRAKE FLUID with eyes may cause eye irritation, swelling, and redness. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 5 SILICONE BRAKE FLUID may cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. 8. See Figure 2-54. Add D.O.T. 5 SILICONE BRAKE FLUID to the master cylinder reservoir until the...

How To Remove Pin From Sportster Brake Pedal

Damaged banjo bolt surfaces will leak when reassembled. Prevent damage to seating surfaces by carefully removing 1. Remove right side cover and maxi-fuse. See 8.5 MAXI-FUSE. 2. Remove radiator left side cover. 3. See Figure 2-49. With a suitable container under the master cylinder, remove the banjo bolt (1). Discard the two steel rubber washers (7). 4. Remove the cotter key from the clevis pin (4). 5. See Figure 2-50. Cover the outside face of clevis pin with cardboard and using a large pliers,...

Topping Off Harley Vrod Antifreeze

Coolant & battery tester - Fahrenheit Coolant & battery tester - Celsius Do not remove the pressure filler cap when the engine is hot. The cooling system is under pressure and hot coolant and steam may escape causing severe burns. Allow engine to cool before servicing the cooling system. 1. Allow cooling system to cool. 2. Remove right side cover and maxi-fuse. 3. Open seat. Using a cloth over pressure cap, turn cap 1 4 turn counterclockwise (CCW) to safety stop. Let pressure escape....

Packard Ecm Connector

Packard 100w Connector Harley Davidson

Depress tabs (3) on the sides of connector and remove clear plastic cover (4). 3. See Figure B-24. Pry three tabs to separate connector halves. 4. Push on desired wire from back of connector to expose wire terminal. A series of Packard Electrical Terminal Crimp Tools are available to install Packard socket terminals on wires. If new terminals must be installed, see CRIMPING INSTRUCTIONS below.

Assembly And Installation

Apply a light coating of graphite to handlebar and inside surface of housings. 2. See Figure 2-29. Attach control cable assemblies to lower housing. a. Push silver insert of the cable housing into hole in front of tension adjuster screw. Snap in retaining ring. b. Push gold insert of idle cable housing into hole at rear of tension adjuster screw. Snap in retaining ring. c. Install adjusting screw, spring and friction pad in lower housing if they were removed. 3. Position throttle grip on the...

Rod Main Fuse

Harley-Davidson No. 10R12A (no substitute) Ignition coil primary resistance at room temperature Ignition coil secondary resistance at room temperature The fuse labeled Security provides basic turn signal functionality on vehicles without a factory-installed security system. Do not remove this fuse or use it as a replacement fuse for other systems. Electronic control module (ECM) mounting bolts Engine coolant temperature sensor (ECT) use new screws or LOCTITE THREADLOCKER 243 (blue), page 9-10...

Suspension Adjustments

The rear shock absorber springs can be adjusted for the weight the motorcycle is to carry. There is a spanner wrench for this purpose. Both shock absorber adjuster plates must be adjusted to the same position. Not having the springs adjusted to the same length could adversely affect handling. This may lead to a loss of control of the motorcycle and could result in death or serious injury.

Throttle Body

Loosen Throttle Body Clamps Figure 3-12. Fuel Rail intake Seal Fasteners 1. Disconnect the idle speed control (IAC) connector. 2. Disconnect the throttle position (TP) sensor. 3. See Figure 3-11. Loosen throttle body clamps. 4. Detach throttle body from rubber seals by pulling up with a gentle rocking motion. If engine is in chassis, it is not necessary to disconnect throttle cables. Move throttle body and cables aside and secure away from engine. 5. See Figure 3-12. Remove fuel...

System Pressure Test

The cooling system can be pressure tested to identify a leak and to verify a blown engine gasket. 1. Before troubleshooting cooling system, be sure engine coolant level is at COLD FULL mark on overflow bottle when the motorcycle is on the jiffy stand. 2. Using a cloth over pressure cap, turn cap 1 4 turn counterclockwise (CCW) to safety stop. Let pressure escape. Press down and turn cap to pass over safety stops and remove. 3. See Figure 6-3. Clean and inspect filler neck, upper (1) and lower...

Disassembly 2nd Gear

Always wear proper eye protection when installing retaining rings. Use the correct retaining ring pliers. Verify that the tips of the pliers are not damaged or excessively worn. Slippage may propel the ring with enough force to cause eye injury. 1. See Figure 7-36. Remove retaining ring at 2nd gear crankcase bearing. 2. See Figure 7-37. Use puller to remove 2nd gear bearing. To protect the end of the shaft use END CAP (HD-34902), part of BIG-TWIN MAINSHAFT PRIMARY BEARING RACE REMOVER AND...

Checking Oil Pressure

Operating oil pressure is checked as follows 1. Fill crankcase to proper level. 2. Remove oil pressure switch from crankcase. 3. Attach OIL PRESSURE GAUGE 1 HD-45308 to ADAPTER 2 HD-45309 . 4. Install in oil pressure switch mounting hole. Engine oil should be at normal operating temperature 70 C 158 F for an accurate reading. 5. Oil pressure should be 3-6.5 bar 43-94 psi at 3000 rpm and normal operating temperature of 70 C 158 F . Figure 3-4. Oil Pressure Indicator Lamp Figure 3-5. Oil Pressure...

Wheel Bearings

Inspect any time the wheels are removed. Replace when bearings exceed end play service wear limit of 0.051 mm 0.002 in. . Check wheel bearings and axle spacers for wear and corrosion. Excessive play or roughness indicates worn bearings. Replace bearings in sets only. See 2.24 SEALED WHEEL BEARINGS.

Vrsca Throttle Cable Installstion

Recondition Battery Guide

Do not apply excessive heat to idle air control. Apply only enough heat to break LOCTITE patch on screws. Excessive heat will cause damage to idle air control. 6. See Figure 9-12. Using heat gun, apply heat to idle air control screws 2 to break LOCTITE patch. Remove screws. 7. Pull IAC 1 and o-ring from throttle body 3 . 1. Inspect IAC o-ring, replace if damaged. 2. Apply clean engine oil to IAC o-ring. 3. Place idle air control and o-ring into throttle body. Be sure o-ring is properly seated...

Pressure Cap Test

The pressure cap should be tested for the correct operating range every time the antifreeze is changed or any cooling system maintenance performed. Do not remove the pressure cap when the engine is hot. The cooling system is under pressure and hot coolant and steam may escape causing severe burns. Allow engine to cool before servicing the cooling system. 1. See Figure 6-3. Using a cloth over pressure cap, turn cap 1 4 turn counterclockwise CCW to safety stop 2 . Let pressure escape. Press down...

Wheel Balancing

Wheels must be balanced to improve handling and reduce vibration, especially at high road speeds. Static balancing using WHEEL TRUING STAND HD-95599-80 will produce satisfactory results. Dynamic balancing, utilizing a wheel spinner, should be used to produce finer tolerances for best high speed handling characteristics. Follow the instructions supplied with the balance machine you are using. Cast aluminum wheels require the special self adhesive balance weights listed below. 1. Use a balancing...

Starts Hard

Spark plugs in bad condition or have improper gap or are partially fouled. 3. Loose wire connection at one of the battery terminals, coil, or plug between ECM or ignition module. 4. Water or dirt in fuel system. 6. Fuel tank vent hose and vapor valve plugged, or fuel line closed off, restricting fuel flow. 7. Engine lubricant too heavy winter operation . For cold weather starts, always disengage clutch. 8. Ignition not functioning properly possible sensor failure . 10. Valves sticking or...

Adjustment Fallaway

At the 1600 km 1000 mile service interval, adjust steering head bearing fall away. At every 48,280 km 30,000 mile service interval, disassemble, inspect and repack the steering head bearing. See 2.29 STEERING HEAD. 1. Support motorcycle in an upright position so the front end is completely suspended and the vehicle is level. 2. Remove all accessory weight and P amp A parts, such as a windshield, or any part that may influence the way the front end swings. 3. See Figure 1-42. Place masking tape...

Excessive Vibration

Wheels and or tires worn or damaged. 2. Engine transmission rear wheel not aligned properly. 3. Upper engine mounting bracket loose broken or mounting bracket pre-loaded. 4. Ignition timing advanced due to faulty sensor inputs MAP, CKP poorly tuned engine. 7. Engine counterbalancer out of time or bearing failed. 8. Exhaust system binding or hitting frame.

Tire Runout

Mounted tires should be checked for both lateral and radial tire runout. See Figure 2-84. Check tire runout by turning wheel on axle, measuring tire lateral runout. 1. See Figure 2-85. With a tire centered and mounted on the rim, check runout by turning wheel on axle, measuring amount of radial displacement from a fixed point near the tire. Make sure bead is properly seated on rim. Deflate and reseat 2. Maximum tire tread runout is 2.29 mm 0.090 in. . If tire tread runout exceeds 2.29 mm 0.090...

How To Change Water Cooling System Vrod

Rod Cooling System

Cut shrink clamps 9 from the coolant inlet and the coolant outlet pipes 2, 3 and hoses 10, 13, 21 . To remove shrink clamps without cutting, use a soldering iron and, carefully, melt a slice through the band without damaging the hose. 2. Loosen overflow hose clamp 17 and remove overflow hose 23 from filler neck. 3. Remove hose cover 22 and loosen upper clamp 19 from the water pump to coolant inlet pipe hose. 4. Clean hose mounting stems on the engine coolant inlet pipe 2 and...

Remove Fuel Tank Vrsca

Hybeam Flashlight Picture

Remove fuel cap, remove fuel filler boot, and replace fuel cap. Gasoline is extremely flammable and highly explosive. Always stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near the work site. Inadequate safety precautions could result in death or serious injury. 4. Vapor valve frame clip 13. Fuel pump filters fuel level sender assembly

Harley Davidson Vrsc Oil Cooler

Vrod Radiator Drain Plug

To protect against shock and accident start-up of vehicle, disconnect the negative battery cable before proceeding. Inadequate safety precautions could result in death or serious injury. 3. Remove negative battery cable. 4. Remove airbox decorative cover, airbox cover, air filter cover and air filter. See 1.4 AIRBOX AND AIR FILTER. 5. See Figure 6-19. Remove fasteners 11 and left and right radiator side covers 10 . 6. Cover front fender with shop towel or protective cover. Remove fasteners and...

Diagnosing Smoking Engine Or High Oil Consumption

Perform COMPRESSION TEST or CYLINDER LEAKAGE TEST as described. If further testing is needed, remove suspect head s and inspect for the following Check Prior to Cylinder Head Removal 2. Valve guide to valve stem clearance. 3. Gasket surface of both head and cylinder. 4. Cylinder head casting's porosity allowing oil to drain into Fastener Side cover Maxi-fuse 40 amp If cylinder head, crankcase, or transmission work needs to be performed, engine must be removed from chassis. See 2.9 ENGINE...

Rear Engine Mounts

Support motorcycle under fuel tank frame weldment and lock the front wheel so that the engine can be removed. To provide clearance and alignment, locate a scissors style jack under the fuel tank frame extensions to raise or lower the motorcycle throughout the procedure. 2. Remove right side cover and maxi-fuse. See 8.5 MAXI-FUSE. 4. Remove airbox cover. See 1.4 AIRBOX AND AIR FILTER.

Tests For Blown Gasket

Coolant fluorescent leak detection dye If the coolant overflow bottle is empty when the engine is cold, it is possible that air has been drawn into the coolant system. The system must be purged of any trapped air and refilled with coolant. 1. Before troubleshooting cooling system be sure engine coolant level is at COLD FULL mark on overflow bottle when the motorcycle is on the jiffy stand.

Starts But Runs Irregularly or Misses

Spark plugs in bad condition or partially fouled. 2. Spark plug gap too close or too wide. 3. Faulty ignition coil, module, or sensor. 5. Damaged wire or loose connection at battery terminals, coil, or plug between ignition sensor and module. 6. Intermittent short circuit due to damaged wire insulation. 7. Water or dirt in fuel system or filter. 8. Fuel tank vent system plugged or closed off. 9. Air leak at intake manifold or air filter. 11. Loose or dirty ignition module or ECM connector at...

Inspection and Lubrication

Turn the cable adjusters 2, 4 and jam-nuts 3 as short as they will go. 2. Remove two screws 1 to separate the upper handlebar housing from the lower housing. 3. Use a screwdriver to rotate each ferrule and remove cable from the throttle grip. 4. Slide the throttle grip off the handlebar. 5. Apply a light coat of graphite to the handlebar and replace throttle grip. 6. Put one or two drops of SUPER OIL Part No. HD-94968-85TV into the housing of each cable. 7. Assembling the...

Cylinder Head Service

Harley Davidson Rod Head Cylinder

Cylinder Head Fasteners Cam chain tensioner guide pin remover installer If TAPPET COMPRESSING TOOL HD-45491 is in place from the cam drive removal process, remove it before proceeding. Removing the head with valves extended could result in damage. 1. See Figure 3-41. Remove seven fasteners retaining head. The four main headbolts are external TORX E14. Use Snap-on tool 1MFLE140 to remove main headbolts. 3. See Figure 3-40. Use CYLINDER HEAD HOLDING FIXTURE HD-39786 and CYLINDER HEAD...

Servicing A New Motorcycle

Always follow the listed service and maintenance recommendations, since they affect the safe operation of the motorcycle and the personal welfare of the rider. Failure to follow recommendations could result in death or serious injury. 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...

Verify Cam Timing

Top Dead Center Positioning Tool HD-45653 Figure 1-64. Crankshaft Locking Pin HD-45306 . Note position of cam lobes and alignment of the cam gear marks. Note position of cam lobes and alignment of the cam gear marks. Copper colored links are for initial assembly of complete cam drive system and may not appear in the illustrated position, even though the timing is correct.

Installing Socketpin Terminals

For wire location purposes, numbers are stamped into the secondary locks of both the socket and pin housings. See Figure B-2. 1. From the secondary lock side of the connector, insert the terminal into its respective numbered chamber until it snaps in place. For proper fit, the slot in the terminal must face the tang in the chamber. Figure B-1.10-Place Amp Multilock Connector Figure B-1.10-Place Amp Multilock Connector Figure B-2. Release Tang and Back Out Terminals See Figure B-3. The tang in...

Electric Starter System

The electric starter system is made up of the starter relay, starter solenoid, and starter motor. The starter drive gear engages a geared limiter assembly which engages a starter ring gear whose hub rotates inside a ball clutch on the rotor assembly. The rotation of the starter is transferred to the crankshaft of the engine through the ball clutch. The starter motor torque is multiplied through the gear reduction of the starter drive gear to the limiter assembly gear and to the starter ring...

Valve Lash

2003 Harley Rod Radiator Vent Hose

See 1.4 AIRBOX AND AIR FILTER. 2. Remove battery. See 1.7 BATTERY MAINTENANCE. IAC sensor connector 87B Idle air control IAC Throttle position TP sensor connector 88B Air intakes covered 3. See Figure 1-53. Remove fuel lines. Figure 1-55. Intake Clamps, Throttle Body Removed Ground strap Radiator hose P clamp Front cylinder breather hose Rear cylinder breather hose Cable straps Ground strap Radiator hose P clamp Front cylinder breather hose Rear cylinder breather hose...

Negative Cable Replacement

See 1.4 AIRBOX AND AIR FILTER. 3. See Figure 8-22. Remove battery negative terminal 1 fastener. 4. Remove nut 3 securing negative battery cable 2 to stud on adapter bracket 4 and negative battery cable. 5. Install new battery cable. Secure with nut on adapter bracket stud. Tighten to 6-10 Nm 53-88 in-lbs . 6. Secure other end of battery cable to battery negative terminal with fastener. Tighten to 6.8-10.8 Nm 60-96 in-lbs . 7. Turn ignition switch to the FUEL position and...

Table B5 Wiring Diagrams

2003 VRSCA MODEL, MAIN HARNESS PAGE 1 OF 2 2003 VRSCA MODEL, MAIN HARNESS PAGE 2 OF 2 2003 VRSCA MODEL, IGNITION CIRCUIT PAGE 1 OF 1 2003 VRSCA MODEL, CHARGING CIRCUIT PAGE 1 OF 1 2003 VRSCA MODEL, STARTING CIRCUIT PAGE 1 OF 1 2003 VRSCA MODEL, LIGHTING CIRCUIT PAGE 1 OF 1 2003 VRSCA MODEL, HORN AND INSTRUMENT CIRCUIT PAGE 1 OF 1 2003 VRSCA MODEL, SECURITY CIRCUIT PAGE 1 OF 1