Harley Davidson Dyna Models (2003) - Repair, Service Manual and Electrical Wiring Diagrams

HARLEY DAVIDSON DYNA MODELS (2003) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS

- English Service Manual and Wiring Diagrams, to motorcycles Harley Davidson Dyna Models (2003).


MODELS COVERED:

- Harley-Davidson Dyna FXD Model
- Harley-Davidson Dyna FXDL Model
- Harley-Davidson Dyna FXDX Model
- Harley-Davidson Dyna FXDXT Model
- Harley-Davidson Dyna FXDWG Model


CONTENTS:

SECTION 1-MAINTENANCE

11 General 1-1
- Servicing a New Motorcycle1-1
- Safe Operating Maintenance 1-1
- Shop Practices 1-1
- Repair Notes 1-1
- Safety 1-1
- Removing Parts 1-1
- Cleaning1-1
- Disassembly and Assembly 1-2
- Repair and Replacement Procedures1-2
- Hardware and Threaded Parts1-2
- Wiring, Hoses and Lines 1-2
- Instruments and Gauges1-2
- Bearings 1-2
- Bushings 1-2
- Gaskets1-2
- Lip Type Seals 1-2
- 0-Rings (Preformed Packings) 1-2
- Gears 1-3
- Shafts 1-3
- Part Replacement 1-3
- Cleaning1-3
- Part Protection 1-3
- Cleaning Process 1-3
- Rust or Corrosion Removal1-3
- Bearings 1-3
- Tool Safety 1-3
- Air Tools1-3
- Wrenches 1-3
- Pliers/Cutters/Prybars1-3
- Hammers 1-4
- Punches/Chisels 1-4
- Screwdrivers 1-4
- Ratchets and Handles1-4
- Sockets 1-4
- Storage Units 1-4
12 Fuel and Oil
- Fuel
- Gasoline Blends
- Engine Oil
- Winter Lubrication
13 Maintenance Schedule
14 Engine Oil and Filter
- Checking and Adding Oil
- Type of Oil
- Checking With Cold Engine
- Checking With Warm Engine
- Recommended Oil Grades (Table)
- Changing Oil and Filter
15 Battery Maintenance 1-13
- General 1-13
- Battery Electrolyte Antidotes (Table)1-13
- Disconnection and Removal1-14
- Installation and Connection 1-14
- Inspection 1-15
- Storage 1-15
16 Brakes 1-16
- Fluid Inspection 1-16
- Rear Pedal Height 1-17
17 Bleeding Brakes1-18
- General 1-18
- Procedure 1-18
18 Brake Pads and Discs 1-19
- Inspection 1-19
- Brake Pads 1-19
- Brake Disc Thickness1-19
- Brake Disc Lateral Runout and Warpage1-19
- Brake Pad Replacement 1-19
- Rear Brake Caliper 1-19
- Front Brake Caliper 1-21
19 Tires and Wheels1-22
- Tires 1-22
- Tire Pressures (Table) 1-22
- Tire Replacement 1-22
- Wheel Bearings 1-23
- Wheel Spokes 1-23
110 Primary Chain1-24
- Inspection 1-24
111 Primary Chain case Lubricant 1-26
- Changing Lubricant 1-26
112 Clutch 1-28
- Adjustment 1-28
113 Transmission Lubricant 1-30
- Changing Lubricant 1-30
114 Rear Belt Deflection 1-31
- Inspection 1-31
- Adjustment 1-32
115 Rear Belt and Sprockets1-33
- General1-33
- Cleaning 1-33
- Inspection 1-33
- Sprockets 1-33
- Rear Belt 1-33
- Drive Belt Wear Analysis (Table) 1-34
116 Suspension Adjustments
- All Models But FXDX/FXDXT
- FXDX/FXDXT Models
- General
- Preload Adjustment
- Rear Suspension Adjustments
- Front Suspension Adjustments
- FXDX/FXDXT Factory Suspension Settings {Table)
117 Steering Head Bearings
- Adjustment
- Bearing Adjustment, Fall-away
- Lubrication
118 Front Fork Oil
- Replacing Fork Oil
- Type E Fork Oil Amounts (Table)
119 Spark Plugs
- Inspection
120 Air Cleaner Filter
- Removal
- Installation
121 Cable and Chassis Lubrication
- General
- Cables and Hand Levers
- Foot Shift Lever
- Jiffy Stand
122 Throttle Cables and Enrichener
- Cable Inspection, Lubrication and Adjustment
- Inspection and Lubrication
- Adjustment
- Enrichener Adjustment
123 Idle Speed and Ignition Timing 1-46
- Idle Speed Inspection1-46
- Ignition Timing 1-46
124 Fuel Supply Valve Filter 1-47
- Inspection 1-47
- Fuel System Lines and Fittings 1-48
125 Engine Mounts 1-49
- Inspection 1-49
126 Headlamp Alignment 1-50
- Inspection 1-50
- Adjustment 1-51
- All Models But FXDWG/FXDXT 1-51
- FXDWG Model 1-51
- FXDXT Model 1-51
127 Critical Fasteners 1-52
- Inspection 1-52
128 Storage1-53
- General 1-53
- Removal From Storage 1-54
129 Troubleshooting
- General:
- Engine
- Starter Motor Does Not Operate/Turn Over
- Engine Turns Over But Does Not Start
- Starts Hard             
- Starts But Runs Irregularly or Misses
- A Spark Plug Fouls Repeatedly
- Pre-Ignition or Detonation (Knocks or Pings)
- Overheating
- Valve Train Noise
- Excessive Vibration
- Check Engine Light Illuminates During Operation
- Lubrication System
- Oil Does Not Return To Oil Pan
- Engine Uses Too Much Oil Or Smokes Excessively
- Engine Leaks Oil From Cases, Push Rods, Hoses
- Low Oil Pressure
- High Oil Pressure
- Electrical System
- Alternator Does Not Charge
- Alternator Charge Rate Is Below Normal
- Speedometer Operates Erratically
- Carburetor
- Floods
- Transmission
- Shifts Hard
- Jumps Out Of Gear
- Clutch Slips
- Clutch Drags Or Does Not Release
- Clutch Chatters
- Handling
- Irregularities
- Brakes
- Brake Does Not Hold Normally

SECTION 2-CHASSIS

21 Specifications 2-1
22 Torque Values 2-2
23 Vehicle Identification Number 2-4
- General 2-4
24 Front Wheel 2-5
- Removal 2-5
- Disassembly 2-7
- Cast Wheel 27
- Laced Wheel 2-7
- Cleaning and Inspection 2-7
- Assembly 2-7
- Cast Wheel 2-7
- Laced Wheel 2-7
- Installation 2-8
25 Rear Wheel 2-9
- Removal 2-9
- Disassembly 29
- Cleaning and Inspection 2-10
- Assembly 2-1 O
- Installation 2-11
26 Sealed Wheel Bearings 2-12
27 Rear Brake Caliper2-42
- Inspection 2-12 Removal 2-42
- Removal 2-12 Disassembly 2-42
- Installation2-13 Cleaning, Inspection and Repair 2-44
27 Wheel Lacing: 16 In Rim 2-14
- Assembly2-44
- Installation 2-45
- General 2-14
- Procedure 2-14 218 Front Fork: FXD and FXDL2-46
28 Wheel Lacing: 19 In Rim 2-16
- Procedure 2-16
- Removal 2-46
- Disassembly 2-46
- Cleaning and Inspection2-46
29 Wheel Lacing: 21 In Rim 2-20
- General 2-20
- Assembly2-46
- Installation 2-48
- Procedure 2-20
219 Front Fork: FXDWG2-49
210 Truing Laced Wheel 2-22
- General 2-22
- lateral Truing2-22
- Radial Truing2-23
- Removal 2-49
- Disassembly 2-49
- Cleaning and Inspection 2-49
- Assembly 2-51
- Installation 2-51
211 Cast Wheel Run out 2-24
220 Front Fork: FXDX and FXDXT2-52
- General 2-24
- Lateral Runout 2-24
- Radial Runout 2-24
- Removal 2-52
- Disassembly 2-52
- Cleaning and Inspection2-54
212 Tires2-25
- General 2-25
- Assembly 2-54
- Installation 2-56
- Removal2-25
- Cleaning and Inspection 2-25
- Replacement 2-25
- Installation 2-26
- Checking Tire Runout 2-27
- Radial Runout 2-27
- Lateral Runout 2-27
- Wheel Balancing 2-27
- Wheel Weights and Colors (Table) 2-27
221 Steering Head2-57
- Removal 2-57
- All Models Except FXDWG2-57
- FXDWG Models 2-57
- Cleaning and Inspection 2-58
- Disassembly 2-58
- Steering Head Bearing Race Removal 2-58
- Assembly2-59
- Installation 2-59
213 Vehicle Alignment 2-28
- Inspection 2-28
- All Models Except FXDWG 2-59
- FXDWG Models2-59
214 Front Brake Master Cylinder 2-30
- General 2-30
- Removal/Disassembly 2-30
- Cleaning and Inspection2-32
- Assembly/Installation 2-32
222 Rear Shock Absorbers 2-60
- General2-60
- FXD, FXDL, FXDWG Models 2-60
- Removal 2-60
- Installation 2-60
- FXDX, FXDXT Models 2-61
215 Rear Brake Master Cylinder 2-34
- Removal 2-34
- Removal 2-61
- Installation 2-61
- Disassembly 2-35
- Cleaning and Inspection 2-35
- Assembly 2-35
- Installation 2-36
223 Rear Fork 2-62
- Removal 2-62
- Disassembly 2-63
- Cleaning and Inspection2-63
216 Front Brake Caliper 2-37
- Removal2-37
- Assembly2-63
- Installation 2-63
- Disassembly 2-37
- Cleaning, Inspection and Repair2-39
- Assembly 2-39
- Installation 2-40
- 224 Belt Guard 2-64
- Removal 2-64
- Installation 2-64
225 Debris Deflector 2-65
- Removal 2-65
- Installation 2-65
226 Throttle Control 2-66
- Removal/Disassembly 2-66
- Cleaning and Inspection2-66
- Assembly/Installation 2-66
- Throttle Cable Routing 2-67
227 Clutch Control 2-68
- Removal 2-68
- Installation 2-68
228 Front Fender 2-69
- Removal 2-69
- Installation 2-69
229 Rear Fender 2-70
- General 2-70
- Removal 2-70
- Tail Lamp/Turn Signal Harness Routing 2-70
- Installation 2-71
- FXDWG Model 2-71
- Removal 2-71
- Installation 2-71
- FXD, FXDX and FXDL Models 2-72
- Removal 2-72
- Installation 2-72
- FXDXT Model 2-72
- Removal 2-72
- Installation 2-72
230 Jiffy Stand 2-73
- Cleaning 2-73
- Removal 2-73
- Installation 2-73
231 Fork Lock 2-74
- Removal 2-74
- Installation 2-74
232 Seat 2-75
- Removal 2-75
- Installation 2-75
233 Engine Mounts 2-76
- Removal 2-76
- F rant Isolator 2-76
- Rear Isolator 2-76
- Installation 2-76
- Front Isolator 2-76
- Rear Isolator 2-76
234 Saddlebags: FXDXT 2-77
- General 2-77
- Removal
- Installation
235 Windshield: FXDXT 2-78
- Removal 2-78
- Disassembly 2-78
- Assembly2-80
- Installation 2-81

SECTION 3-ENGINE

31 Specifications3-1
32 Torque Values 3-3
33 Service Wear Limits3-5
- General 3-5
34 Engine Oil Flow 3-7
- Oil Feed 3-7
- Top End 3-8
- Bottom End 3-8
- Oil Return 3-12
35 Oil Pump Operation 3-13
- General 3-13
- Operation 3-13
36 Breather Operation 3-14
- General 3-14
37 Oil Pressure 3-15
- Oil Pressure Indicator Lamp 3-15
- Checking Oil Pressure 3-15
38 How To Use This Section 3-16
- Top End Repair 3-16
- Bottom End Repair 3-16
- Typical Symptoms 3-16
39 Top End Service 3-17
- Engine In Chassis 3-17
- Engine Removed From Chassis 3-18
310 Bottom End Service 3-19
- Engine In Chassis: Cam Compartment Service 3-19
- Engine Removed: Flywheel Compartment Service
- or Complete Engine Overhaul 3-20
311 Troubleshooting 3-21
- Diagnosing Valve Train Noise 3-21
- Compression Test 3-21
- Compression Test Results (Table) 3-21
- Cylinder Leakage Test 3-22
- Diagnosing Smoking Engine or High Oil Consumption 3-22
- Check Prior To Cylinder Head Removal 3-22
- Check After Cylinder Head Removal 3-22
312 Stripping Motorcycle For Service 3-23
- Procedure 3-23
313 Assembling Motorcycle
- After Service3-24
- Procedure 3-24
314 Removing Engine From Chassis 3-25
- Procedure 3-25
315 Installing Engine In Chassis 3-26
- Procedure 3-26
 316 Top End Overhaul: Disassembly 3-28 323 Cylinder Head3-61
- General 3-28 Removal Overview 3-61
- Breather Assembly 3-28 Disassembly 3-61
- Rocker Arm Support Plate 3-29 Cleaning 3-62
- Push rods, Lifters and Covers3-30 Inspection 3-63
- Cylinder Head 3-30 Cylinder Head3-63
- Cylinder 3-31 Valve Guides 3-63
- Piston 3-32 Valve Stem To Guide Clearance Service Wear Limits (Ta-
317 Top End Overhaul: Assembly 3-33 ble) 3-63
- Valves 3-63
- General 3-33
- Piston 3-33
- Cylinder3-34
- Valve Springs 3-63
- Tapered Keepers 3-64
- Valve Seats 3-64
- Cylinder Head 3-36 Valve Guide Replacement3-64
- Pushrods, Lifters and Covers3-39 Removal 3-64
- Push Rod/Lifter Locations (Table) 3-39 Installation 3-65
- Rocker Arm Support Plate 3-40 Valve Stem To Guide Clearance (Table) 3-67
- Breather Assembly3-41 Refacing Valve Seats 3-67
318 Bottom End Overhaul: Disassembly 3-42
- General 3-42
- Assembly 3-70
- Installation Overview 3-72
324 Cylinder3-73
- Cover and Cam Support Plate 3-42 Removal Overview 3-73
- Crankcase3-45 Cleaning:,- 3-73
319 Bottom End Overhaul: Assembly 3-46
- Inspection: 3-74
- Deglazing Cylinder 3-75
- General 3-46 Boring and Honing Cylinder 3-76
- Crankcase3-46 Installation Overview 3-76
- Cover and Cam Support Plate 3-49 Oversize Pistons/Cylinder Bores (Table) 3-76
- Rear Cam Sprocket Spacers (Table) 3-51
325 Piston 3-77
320 Breather Assembly3-55
- Removal Overview 3-77
- Removal Overview3-55 Disassembly 3-77
- Disassembly 3-55 Piston Rings 3-77
- Inspection 3-55 Cleaning 3-77
- Assembly 3-55 Inspection 3-78
- Installation Overview3-55 Assembly 3-80
321 Rocker Arm Support Plate 3-56
- Removal Overview3-56
- Piston Rings 3-80
- Ring End Gap (Table) 3-80
- Installation Overview 3-81
- Disassembly 3-56
- Cleaning and Inspection3-56
326 Upper Connecting Rod 3-82
- Assembly 3-58 Removal Overview 3-82
- Installation Overview 3-58 Disassembly/Assembly 3-82
322 Pushrods, Lifters and Covers 3-59
- Removal Overview 3-59
- Disassembly 3-59
- Cleaning and Inspection 3-59
- Removing Upper Connecting Rod Bushing3-82
- Installing Upper Connecting Rod Bushing3-83
- Reaming Upper Connecting Rod Bushing3-84
- Honing Upper Connecting Rod Bushing 3-85
- Installation Overview 3-85
- Lifter Inspection3-60
- Assembly 3-60
- Installation Overview3-60
327 Cover and Cam Support Plate 3-87
- Removal Overview
- Disassembly/Assembly
- Crankshaft Bushing
- Removal
- Installation
- Reaming Crankshaft Bushing
- Camshafts and Camshaft Bearings
- Removal
- Installation
- Cam Chain Tensioners
- Removal
- Installation
- Oil Pressure Relief Valve
- Removal
- Installation
- Cam Needle Bearings
- Removal
- Installation
- Cleaning and Inspection
- Installation Overview
328 Oil Pump3-102
- Removal Overview 3-102
- Cleaning and Inspection 3-102
- Installation Overview 3-102
329 Oil Filter Mount and Adapter 3-103
- Removal 3-103
- Installation 3-103
330 Crankcase3-104
- Removal Overview
- Right Crankcase Half
- Crankshaft (Roller) Bearing
- Piston Jets
- Left Crankcase Half
- Crankshaft (Roller) Bearing
- Cylinder Studs
- Removal
- Installation
- Pipe Plug and Oil Fittings
- Removal
- Installation
- Cleaning and Inspection
- Installation Overview
331 Flywheel/Connecting Rod3-109
- Removal Overview 3-1 09
- Inspection 3-109
- Installation Overview 3-1 09
332 Oil Pan3-110
- Removal 3-11 O
- Installation3-111

SECTION 4-FUEL SYSTEM

41 SpecificationsTorque
- Values (Table)
42 Fuel System Troubleshooting
- Carburetor
- Overflow Troubleshooting (Table)
- Poor Idling (Table)
- Poor Fuel Economy (Table)
- Poor Acceleration (Table)
- Hard Starting (Table)
- Poor Performance On Road (Table)
- Poor High Speed Performance (Table)
- Vacuum Piston Assembly
- Piston Does Not Raise Properly (Table)
- Piston Does Not Close Properly (Table)
43 Enrichener
- General
- Operation
- Cool Engine
- Warm Climate or Hot Engine
44 Carburetor
- Removal
- Disassembly
- Vacuum Piston Chamber
- Carburetor Body
- Accelerator Pump
- Cleaning and Inspection
- Vacuum Piston Components
- Carburetor Body Components
- Float Replacement
- Accelerator Pump
- Assembly
- Vacuum Piston Chamber
- Carburetor Body
- Accelerator Pump
- Installation
45 Carburetor Adjustments
- Operation Check: Vacuum Piston
- Opening Malfunction
- Closing Malfunction
- Float Bowl
- Float Bowl Inlet (Needle) Valve Replacement
- Float Level
46 Fuel Supply Valve
- General
- Operation
- Removal, Inspection and Installation
- Troubleshooting
- Troubleshooting Fuel Supply Valve (Table)
- Vacuum Test
47 Fuel Tank 4-17

SECTION 6-DRIVE

- General4-17
- Removal 4-17
- Cleaning and Inspection 4-18
61 Specifications 6-1
- Installation 4-18 Torque Values {Table) 6-1
- Vapor Valve4-18
48 Air Cleaner 4-19
62 Primary Chaincase6-2
- General6-2
- Removal4-19 Primary Chaincase Cover 6-2
- Installation4-19 Removal 6-2
- Backplate Assembly: California Models 4-20 Installation 6-3
49 Exhaust System4-21
- Primary Chaincase Housing6-3
- Removal 6-3
- Removal 4-21 Inspection 6-4
- Disassembly 4-21
- Mainshaft Bearing and Lip Seal6-4
- Assembly 4-21 Removal 6-4
- Installation4-21 Installation 6-5
410 Evaporative Emissions Control: 63 Drive Components 6-6
- CA Models4-23
- Primary Chain and Compensating Sprocket 6-6
- General 4-23 Removal 6-6
- Charcoal Canister 4-24 Installation 6-7
- Removal4-24 Sprocket Alignment 6-9
- Installation4-24 Spacer Thickness {Table) 6-9
- Hose Routing/Replacement 4-25 Chain Tensioner Shoe 6-9

SECTION 5-ELECTRIC STARTER

64 Clutch6-10
- Removal/Installation 6-1 0
- Clutch Pack Only 6-10
51 Specifications 5-1
- Starter {Table) 5-1
- Service Wear Limits {Table) 5-1
- Torque Values {Table) 5-1
- Partial Disassembly 6-10
- Assembly 6-1 O
- Cleaning and Inspection 6-12
- Clutch Pack and Bearing 6-12
- Complete Disassembly 6-12
- 52 Electric Starter System 5-2 Assembly 6-13
- General 5-2
- Wiring Diagrams 5-2
- Starter Relay 5-2
- Operation 5-2
65 Transmission Sprocket 6-15
- Removal 6-15
- Cleaning and Inspection 6-15
- Installation 6-15
53 Starter Relay 5-5
- Removal 5-5
- Installation 5-5
66 Drive Belt 6-17
- Removal 6-17
- Inspection 6-17
- 54 Starter5-6 Installation 6-17
- Removal5-6
- Installation5-6
- Disassembly, Inspection and Repair 5-8
- Assembly 5-11
55 Starter Solenoid5-13
- General 5-13
- Disassembly5-13
- Assembly 5-13
56 Starter Jackshaft 5-14
- Removal/Disassembly 5-14
- Assembly/Installation 5-15

SECTION 7-TRANSMISSION

71 Specifications 7-1
- Torque Values 7-2
72 Transmission 7-3
- General 7-3
- General 8-3
- Neutral7-3
- Dyna Glide Bulb Chart (Table) 8-3
- 1st Gear 7-3
- Dyna Glide Indicator Bulb Chart (Table) 8-3
- 2nd Gear 7-3
- 3rd Gear 7-3
- 4th Gear 7-3
- General 8-4
- 5th Gear 7-3
- Troubleshooting 8-4
- Shifter Linkage Adjustment 7-5
73 Shifter Cam Assembly 7-6
- Removal8-6
- Removal/Disassembly7-6
- Cleaning and Inspection 7-7
- Assembly/Installation 7-8
- Removing Cover and Bracket 8-6
- Removing Panel For Ignition Module Access 8-7
- Installation 8-8
74 Shifter Forks 7-10
- Removal 7-10 General 8-9
- Cleaning and Inspection 7-10
- Installation 7-11
- Ignition Timing8-9
- Removal8-9
- Installation 8-9
75 Transmission Clutch Release Cover 7-12
- Removal/Disassembly7-12
- Cleaning and Inspection 7-13
- Assembly/Installation 7-13
76 Mainshaft and Countershaft7-15
- Removal 7-15
- Disassembly 7-16
- Cleaning and Inspection 7-16
- General 8-11
- Removal 8-11
- Replacing Side Door Bearings 7-16
- Assembly7-16
- Installation 7-23
- Installation8-12
- Crank Position Sensor Terminals (Table) 8-12
- Oil Pressure Switch Sensor Terminals (Table) 8-12
77 Transmission Case 7-25
- Removal 7-25 General 8-13
- General7-25 Removal 8-13
- Main Drive Gear and Bearing 7-25
- Installation 8-13
- Installation 7-25
- Main Drive Gear and Bearing 7-25
- Disassembly 7-28
- Shifter Arm Assembly 7-28

SECTION 8-ELECTRICAL

81 Specifications8-1
- Torque Values 8-2
82 Bulb Requirements8-3
83 Ignition System 8-4
84 Electrical Panel 8-6
85 Ignition Module 8-9
86 Manifold Absolute PressureSensor (MAP) 8-10
- General 8-10
- Removal 8-10
- Installation 8-10
87 Crank Position Sensor (CKP) 8-11
88 Spark Plug Cables 8-13
89 Ignition Coil 8-14
- Removal8-14
- Installation 8-14
- Cleaning and Inspection7-28
810 Fuses 8-15
- Assembly 7-29
- Shifter Pawl Lever Assembly 7-29
- General 8-15
- Replacement8-15
811 Main Circuit Breaker 8-16
- General 8-16
- Removal8-16
- Installation 8-17
812 Ignition/Light Switch 8-18
822 Speedometer and Tachometer 8-41
- General 8-18
- Replacement8-18
823 Instruments: FXDWG8-42
- FXD, FXDL, FXDX, FXDXT Models 8-18
- Removal 8-42
- Key Switch Functions and Positions (Table) 8-18
- Speedometer 8-42
- FXDWG Models 8-19
- Installation 8-42
813 Alternator 8-20
- Removal/Disassembly 8-20
- Speedometer8-42
824 Instruments: FXDL8-43
- Cleaning/Inspection 8-20 Removal 8-43
- Assembly/Installation 8-20 General8-43
814 Voltage Regulator 8-21
- Speedometer8-43
- Tachometer 8-43
- Removal 8-21 Installation 8-43
- Installation 8-22 General 8-43
815 Battery 8-23
- Speedometer8-43
- Tachometer 8-43
- Battery Testing8-23
- General 8-23
825 Instruments: FXD, FXDX, FXDXT 8-44
- Voltmeter Test 8-23 Removal 8-44
- Load Test 8-23 Speedometer 8-44
- Voltmeter Test For Battery Charge Conditions (Table) 8-23
- Tachometer: FXDX, FXDXT Only 8-44
- Battery Load Test (Table) 8-23
- Installation 8-44
- Charging Battery 8-24
- General 8-44
- Safety Precautions8-24
- Speedometer 8-44
- Using a Battery Charger 8-24
- Tachometer: FXDX, FXDXT Only 8-44
- Battery Charging Rates/Times (Table) 8-24
816 Battery Cables 8-26
826 Speedometer Speed Sensor 8-45
- General 8-45
- Routing Procedure 8-26 Removal 8-45
817 Headlamp 8-27
- General 8-27
- Installation 8-45
827 Indicator Lamps: All But FXDWG 8-46
- Removal8-27 Bulb Replacement 8-46
- FXD, FXDL, FXDX Models8-27 FXD, FXDX and FXDXT Models 8-46
- FXDWG, FXDXT Models 8-27 FXDL Models 8-46
- Installation8-27 Lamp Housing Replacement 8-46
818 Tail Lamp 8-29
- General 8-29
- FXD, FXDX, FXDXT Connector [20] Pins (Table) 8-47
828 Indicator Lamps: FXDWG8-48
- Bulb Replacement8-29 General8-48
- Base Replacement 8-29 Removal 8-48
- Tail Lamp Wires (Table) 8-30 Installation 8-48
819 Turn Signals/Running Lights 8-31
- Bulb Replacement 8-31
- Lamp Housing Replacement 8-31
- FXDWG Connector [21] Pins (Table) 8-48
- LED Assembly Wiring (Table) 8-48
829 Neutral Switch 8-49
- FXDXT Turn Signals 8-31 General 8-49
- FXD, FXDX, FXDL, FXDWG Turn Signals 8-32 Removal 8-49
820 TSM/TSSM Module 8-34
- Installation 8-49
- Removal8-34
830 Oil Pressure Switch 8-50
- Installation 8-35 General 8-50
821 Fuel Gauge8-39
- Removal 8-50
- Installation 8-50
- General 8-39
- FXDL, FXDWG Models8-39
831 Rear Stoplight Switch8-51
- Removal 8-39 General 8-51
- Installation8-39 Removal 8-51
- FXD, FXDX, FXDXT Models: 8-40 Installation 8-51
- Removal8-40
- Installation8-40
832 Horn 8-52
- Inspection 8-52
- Replacement 8-52
833 Main Wiring Harness 8-53
- General8-53
- Removal 8-53
- Installation 8-54
834 Handlebar Switch Assemblies 8-56
- General 8-56
- Repair Procedures 8-56
835 Right Handlebar Switch8-57
- Removal 8-57
- Installation 8-57
- Disassembly 8-59
- Switch Repair/Replacement 8-60
- Upper Housing Repair8-60
- Lower Housing Repair 8-61
- Assembly8-62
836 Left Handlebar Switch 8-63
- Removal 8-63
- Installation 8-63
- Disassembly 8-64
- Switch Repair/Replacement 8-64
- Upper Housing Repair8-64
- Lower Housing Repair8-65
- Assembly8-65

APPENDIX A-TOOLS

A1 Tools A-1

APPENDIX 8-WIRING

B1 Amp Multilock Electrical Connectors 8-1
- Removing Socket/Pin Terminals
- Installing Socket/Pin Terminals
- Crimping Instructions
B2 Deutsch Electrical Connectors 8-5
- General B-5
- Removing/Disassembling B-5
- Removing/Installing Sockets B-5
- Removing/Installing Pins B-6
- Assembling/Installing B-7
- Crimping Instructions B-8
B3 Mini-Deutsch Connectors B-10
- General B-1 O
- Mini-Deutsch Connectors For Size 20, 16 and 12
- Contacts Wire Range 26-12 AWG B-10
- Crimping Instructions B-10
84 Sealed Butt Splice Connectors B-12
- InstallationB-12
85 Packard Electrical Connectors B-13
- General B-13
- Pull-to-Seat Terminals B-14
- Removing External Latch Type B-14
- Installing External Latch Type B-14
- Push-to-Seat Terminals B-14
- Removing Push-to-Seat Terminals B-14
- Installing Push-to-Seat Terminals B-15
- Crimping Instructions B-15
86 Connector Locations B-17
87 Index to Wiring Diagrams B-19

APPENDIX METRIC CONVERSIONS

C1 Metric ConversionsC-1
C2 Fastener Torque Values C-2
- C3 Fluid ConversionsC-4
- United States System C-4
- Metric System C-4
- British Imperial System C-4