ABOUT THIS MANUAL GENERAL instruments and any parts needed for the job should be gathered before work is started. Interrupting a job to locate tools or parts is a distraction and causes needless delay. 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 pro- fessional Harley-Davidson Technician the latest field-tested and factory-approved major repair methods. We sincerely believe that this Service Manual will make your association with Harley-Davidson products more pleasant and profitable.
NOTES • To avoid unnecessary disassembly, carefully read all rel- ative service information before repair work is started. • In figure legends, the number which follows the name of a part indicates the quantity necessary for one complete assembly. HOW TO USE YOUR SERVICE MANUAL • When servicing a vehicle equipped with the Harley-Dav- idson Smart Security System (H-DSSS), you must first disarm the security system. Either keep the fob in close Refer to the table below for the content layout of this manual. FOREWORD Use the TABLE OF CONTENTS (which follows this FORE- WORD) and the INDEX (at the back of this manual) to quickly locate subjects.
Sections and topics in this manual are sequentially numbered for easy navigation. To ensure satisfactory and lasting repairs, carefully follow the Service Manual instructions and use only genuine Harley- Davidson replacement parts. Behind the emblem bearing the words GENUINE HARLEY-DAVIDSON stand more than 100 years of design, research, manufacturing, testing and inspecting experience.This is your assurance that the parts you are using will fit right, operate properly and last longer. For example, a cross-reference shown as 2.1 SPECIFICA- TIONS refers to chapter 2 CHASSIS, heading 2.1 SPECIFIC- ATIONS.
For quick and easy reference, all pages contain a section number followed by a page number. For example, page 3-5 refers to page 5 in section 3. WARNINGS AND CAUTIONS A number of acronyms and abbreviations are used in this document. See the F.1 GLOSSARY for a list of acronyms, abbreviations and definitions. Statements in this service manual preceded by the following words are of special significance. PREPARATION FOR SERVICE WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. (00119a) Stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near gasoline.
Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00002a) CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. (00139a) 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 motorcycle that is excessively dirty should be cleaned before work starts. Cleaning will occasionally uncover sources of trouble.
Tools, CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage. (00140a) I NO. CHAPTER Maintenance Chassis Engine Fuel System Cooling System Transmission Electrical Appendix A Connector Repair Appendix B Wiring proximity to the vehicle, or use Digital Technician II to disable the security system while the vehicle is being ser- viced and re-enable the system after service is completed. SERVICE BULLETINS In addition to the information presented in this Service Manual, Harley-Davidson Motor Company will periodically issue Service Bulletins to Harley-Davidson dealers.
Service Bulletins cover interim engineering changes and supplementary information. Consult the Service Bulletins to keep your product knowledge current and complete. USE GENUINE REPLACEMENT PARTS 1 2 3 4 5 6 7 A B C Appendix C ABS D Appendix D Valve Las h E Appendix E Conversio ns F Appendix F Glossary