Harley Davidson 1986-2003 XL/XLH Sportster. Service Manual — page 12

is in the diagnostic mode. All codes will be cleared whether
they have been displayed or not.

8. To exit the diagnostic mode, turn the ignition switch
from on to off and then to on again. Do not press the reset
switch while doing so. Diagnostic codes are also cleared
when the vehicle speed reaches 5 mph.

Speedometer/Tachometer Troubleshooting
(1995-1998 Models, Except 1998 883 Models)

Find the symptom that best describes the condition in

Figure 93 or Figure 94 and perform the indicated test pro-
cedures. Some test procedures, however, require the use of
the speedometer tester (part No. HD-41354). Take the mo-
torcycle to a dealership when indicated to do so in the trou-
bleshooting chart.

TURN SIGNAL MODULE

(1991-1996 MODELS)

Performance Test
(1991-1993 Models)

If the turn signals are not working properly, perform the

following performance test. A jumper wire, ohmmeter and
voltmeter will be required.
1. Remove the turn signal module as described in Chapter
Twelve.
2. After removing the module, identify the socket connec-
tor and module pin connectors using the diagram in Figure
98.
3. With ignition switch off, check for ground at pin No. 1.
4. Turn the ignition switch on.
5. Check for voltage at pin No. 2. Voltmeter should read 12
volts.
6. Connect a jumper wire between pins No. 2 and No. 4.
The right front and rear turn signal lights should illuminate.

TROUBLESHOOTING

101

2

98

TURN SIGNAL MODULE CONNECTORS

(1991-1993 MODELS)

Speedometer

Left turn

signal switch

Right turn

signal switch

Left turn

signal light

Right turn

signal light

Module

Power

Orange

Brown

Violet

White/
brown

White/
violet

Black

White/
green

Socket connector

Pin

Module pin
connector

102

CHAPTER TWO

99

TURN SIGNAL MODULE CONNECTORS (1994-1996 MODELS)

Socket housing alignment tabs

Pin housing alignment tabs

Speedometer

Module

Power

Left turn

signal switch

Right turn

signal switch

Left turn

signal light

Right turn

signal light

Pin

number

Wire

color

Description/function

1

Black

Module ground to motorcycle

2

Orange/white

12vdc input from accessory circuit breaker

3

White/green

Speedometer reed switch input

4

Brown

Pulsed 12 vdc for flashing right turn signal lights

5

Violet

Pulsed 12 vdc for flashing left turn signal lights

6

White/brown

12 vdc from right turn signal switch (when pressed)

7

White/violet

12 vdc from left turn signal switch (when pressed)

8

–

Not used

7. Connect a jumper wire between pins No. 2 and No. 6.
The left front and rear turn signal lights should illuminate.

8. Connect a jumper wire between pins No. 4 and No. 8
and depress the right turn signal switch button. The right
front and rear turn signal lights should illuminate.

9. Connect a jumper wire betweens pins No. 6 and No. 10
and depress the left turn signal switch button. The left front
and rear turn signal lights should illuminate.

10. Remove the jumper wire and turn the ignition switch
off.

11. If the module passed all six tests, the module is service-
able. If the module failed one or more tests, refer to

Trou-

bleshooting

in this section.

Performance Test
(1994-1996 Models)

If the turn signals are not working properly, perform the

following performance test. A jumper wire, ohmmeter and
voltmeter will be required.

1. Remove the turn signal module as described in Chapter
Twelve.

2. After removing the module, identify the socket connec-
tor and module pin connectors using the diagram in Figure
99.

3. With ignition switch off, check for ground at pin No. 1.

4. Turn the ignition switch on.

5. Check for voltage at pin No. 2. Voltmeter should read 12
volts.

6. Connect a jumper wire between pins No. 2 and No. 4.
The right front and rear turn signal lights should illuminate.

7. Connect a jumper wire between pins No. 2 and No. 5.
The left front and rear turn signal lights should illuminate.

CAUTION

Do not use a jumper on 1996 models in Steps
8 or 9. The turn signal switch will be dam-
aged.

8A. On 1994-1995 models, connect a jumper wire between
pins No. 4 and No. 6 and depress the right turn signal switch
button. The right turn signal lights should illuminate.

8B. On 1996 models, depress the right turn signal button
and check for 12 volts at pin No. 6.

9A. On 1994-1995 models, connect a jumper wire between
pins No. 5 and No. 7 and depress the left turn signal switch
button. The Left turn signal lights should illuminate.

9B. On 1996 models, depress the left turn signal button and
check for 12 VDC at pin No. 7.

10. Remove the jumper wire and turn the ignition switch
off.

11. If the module passed all six tests, the module is service-
able. If the module failed one or more tests, refer to

Trou-

bleshooting

in this section.

Troubleshooting

The following troubleshooting procedures help isolate

specific problems to the module. If it is necessary to access
the turn signal module, remove it as described in Chapter
Twelve.

Refer to Figure 98 or Figure 99 for socket and module

pin connector identification.

One or both turn signals do not flash. Light on front or
rear side is lit, but does not flash

1. Remove the lens and check for a burned out bulb. Re-
place bulb if necessary.
2. If the bulb is good, check for the following:

a. Check the bulb socket contacts for corrosion. Clean

contacts and recheck. If corrosion consistently builds
on the contacts, wipe the contacts with a dielectric
grease before installing the bulb.

b. Check for a broken bulb wire. Repair the wire or con-

nector.

c. Check for a loose bulb socket where it is staked to the

housing. If the bulb socket is loose, replace the light
assembly.

d. Check for a poor ground connection. If the ground is

poor, scrape the ground mounting area or replace
damaged ground wire(s), as required.

Turn signals do not operate on one side

1. Perform the checks listed under

One or both turns sig-

nals do not flash. Light on front or rear side is lit, but does
not flash

in this section. If these checks do not locate the

problem, proceed to Step 2.
2. Inoperative handlebar directional switch. Perform the
following:

a. Turn the ignition switch on.
b. Disconnect the turn signal module electrical connec-

tor.

c. Locate pin No. 8 or No. 10 (1991-1993 models) or

pin No. 6 or No. 7 (1994-1996 models ) on the socket
connector.

d. With a voltmeter set on the DC scale, connect the

negative lead to a good ground and the positive lead
to one of the pin numbers specified in substep c and
press the turn signal switch. The voltmeter should
read 12 volts when the switch is pressed in.

e. If there is a 12 volt reading, proceed to Step 3.
f. If there is no voltage reading, proceed to Step 4.

3. If 12 volts were recorded in Step 2, and the lights and
connecting wires are in good condition, the module may be
damaged. Replace the module and retest.
4. If no voltage was recorded in Step 2, check the handle-
bar switch and related wiring for damage. Further tests can
be made by performing continuity and voltage checks.
5. Reconnect the turn signal module electrical connector.

TROUBLESHOOTING

103

2

Turn signals/hazard lights do not operate on both sides

1. If none of the turn signals or hazard flashers operate,
check the turn signal module for proper ground with an
ohmmeter. Using the wiring diagram at the end of this man-
ual, trace the ground connection from the module to the
frame tab. If a ground is not present, remove the ground
wire at the frame and scrape the frame and clean the con-
nector. Check the ground wire for breaks. Repair as re-
quired. If a ground is present, perform Step 2.

CAUTION

Do not operate the module without pin No. 1
grounded. Otherwise, the module will burn
out.

2. Refer to the appropriate wiring diagram and locate the
accessory circuit breaker. Turn the ignition switch on and
check for voltage on the hot or load side of the circuit
breaker with a voltmeter. If there is no voltage, refer to
Chapter Twelve and check the following components:

a. Accessory circuit breaker.

b. Main circuit breaker.

c. Starter relay.

d. Ignition switch.

e. Circuit wiring.

Turn signals do not cancel

1. Support the motorcycle so that the front wheel clears the
ground.

2A. On 1994 models, connect an ohmmeter to the speed-
ometer white/green wire and ground. Spin the front wheel
and watch the ohmmeter scale. The ohmmeter should alter-
nate between 0 ohms and infinity.

a. If ohmmeter reading is correct, disconnect the mod-

ule pin connector. With a voltmeter set on the DC
scale, connect the negative lead to a good ground and
the positive lead to the No. 3 pin (white/green) socket
connector. The voltmeter should read 12 volts. If ohm
and volt readings are correct, the module is damaged.

b. If ohmmeter reading is incorrect, check for damaged

wiring from the speedometer white/green wire to the
module. If wiring is okay, the reed switch in the
speedometer may be damaged.

2B. On 1995-1996 models, set a voltmeter to the DC scale.
Connect the positive meter lead to pin 3 and connect the
negative meter lead to a good ground. Turn the ignition on
and spin the rear wheel. The voltmeter readings should al-
ternate between 0-1 volts and 8-12 volts. If the voltage is
within specification, replace the turn signal module. If the
readings are not within specification, check the speedome-
ter wiring and the speedometer.

TURN SIGNAL MODULE

(1997-2003 MODELS)

Use the following troubleshooting charts (Figures

100-103) to help isolate specific turn signal problems. Find
the particular symptom and follow the procedures until the
problem is corrected. If it is necessary to access the turn sig-
nal module, remove it as described in Chapter Twelve.

The troubleshooting charts refer to various connectors by

code numbers. The connectors are identified in the wiring
diagrams located at the end of this manual.

Refer to Figure 104 to identify the socket and pin con-

nectors in the turn signal module connector.

EXCESSIVE VIBRATION

Excessive vibration is usually caused by loose engine

mounting hardware. High speed vibration may be due to a
bent axle shaft or loose or faulty suspension components.
Vibration can also be caused by the following conditions:
1. Improperly balanced wheel(s).
2. Defective or damaged tire(s).
3. Defective or damaged wheel(s).
4. Tight primary chain links.
5. Severely worn primary chain.
6. Loose or damaged engine mounting bracket.
7. Internal engine wear or damage.
8. Broken frame.

FRONT SUSPENSION AND STEERING

Poor handling may be caused by improper tire pressure, a

damaged or bent frame or front steering components, worn
wheel bearings or dragging brakes.

Irregular or Wobbly Steering

1. Loose wheel axle nut(s).
2. Loose or worn steering head bearings.
3. Excessive wheel hub bearing play.
4. Damaged cast wheel.
5. Spoke wheel out of alignment.
6. Unbalanced wheel assembly.
7. Worn hub bearings.
8. Incorrect wheel alignment.
9. Bent or damaged steering stem or frame (at steering
neck).
10. Tire incorrectly seated on rim.
11. Excessive front end loading from non-standard
equipment.

Stiff Steering

1. Low front tire air pressure.
2. Bent or damaged steering stem or frame at the steering
neck.

104

CHAPTER TWO

TROUBLESHOOTING

105

2

100

TURN SIGNALS WILL NOT CANCEL

(1997-1998 MODELS, EXCEPT LATE-MODEL 1998 833 MODELS)*

Turn the ignition on. Check for voltage on the white/green terminal on the harness side of the turn
signal module connector [30] while it is still connected to the turn signal module. The voltage should
fluctuate between 0-1 volts and 6-12 volts while the rear wheel is being turned. Does it?

Replace the turn
signal module.

Disconnect the turn signal module
connector [30] and remove the
white/green speedometer harness
wire from the back of thespeedom-
eter. Check for continuity to
ground on the white/green wire. Is
there continuity present?

Check for continuity between
the white/green speedometer
harness wire on the back of
the speedometer and
white/green wire in the turn
signal module connector [30].
Is there continuity present?

Replace the
turn signal
module.

Repair
short to
ground on
white/green
wire.

Repair open
in white/green
wire.

Yes

No

No

Yes

Yes

No voltage

No fluctuation

*Late model 1998 883 models are equipped with a speedometer
featuring self-diagnostic capabilities.

Is battery
voltage pres-
ent on
white/green
wire with the
connector
[30] still dis-
connected?

Yes

No

Repair the short
to voltage.

Refer to speedome-
ter troubleshooting.

106

CHAPTER TWO

101

TURN SIGNALS WILL NOT CANCEL

(LATE MODEL 1998 883CC AND 1999-2003 MODELS)

Turn the ignition on. Check for voltage on the white/green terminal on the harness
side of the turn signal module connector [30] while it is still connected to the turn sig-
nal module. The meter should read 3-6 volts when the wheel is turned faster than 3
mph, and it should read 9-11 volts when the wheel is stationary. Does it?

Replace the turn
signal module.

Replace the
turn signal
module.

Repair
short to
ground on
white/green
wire.

Repair open in
white/green
wire.

No

Yes

No voltage

No fluctuation

Yes

No

Yes

No

Repair the short
to voltage.

Refer to speedome-
ter troubleshooting.

Is battery
voltage pres-
ent on
white/green
wire with the
connector
[30] still dis-
connected?

Yes

Disconnect connector [30] and re-
move the speedometer harness con-
nector at the back of the
speedometer. Check for continuity be-
tween the white/green speedometer
harness connector at the back of the
speedometer and white/green wire in
the turn signal module connector [30].
Is there continuity?

Disconnect connector [30] and
remove the speedometer har-
ness connector at the back of
the speedometer. Check for con-
tinuity to ground on the
white/green wire. Is there conti-
nuity?

Use this chart for speedometer trouble
codes 9 (speed output shorted high) and 10
(speed output shorted low or open).

TROUBLESHOOTING

107

2

102

TURN SIGNALS WILL NOT FLASH RIGHT, WILL NOT FLASH LEFT

(1997-2003 MODELS, EXCEPT LATE-MODEL 1998 883 MODELS)

Does the turn signal indicator illumi-
nate on the side that will not flash?

Perform the diagnostic proce-
dure in Figure 103.

Replace the bulbs as necessary.

With the bulbs removed, check
for continuity between the termi-
nal in the bulb socket and
terminal 3. Is there continuity?

Repair the
open ground
circuit.

Repair the
open in the
wire.

Repair the
open
ground
circuit.

No

Yes

Yes

No

Yes

Inspect the bulbs on the side that will
not flash. Have the bulbs failed?

No

Yes

No

Yes

No

Disconnect the turn signal module
connector [30] from the turn signal
module. Place a jumper wire across
terminals 2 and 3 in the connector,
and turn the ignition on. Both right
side turn signal lamps should be on.
Are they?

Disconnect the turn signal module
connector [30] from the turn signal
module. Place a jumper wire across
terminals 2 and 4 in the connector,
and turn the ignition on. Both left
side turn signal lamps should be on.
Are they?

Replace
the turn
signal
module.

No

With the bulbs re-
moved, check for
continuity between
terminal in the bulb
socket and terminal
4. Is there continuity?

Repair the
open in the
wire.

Yes

108

CHAPTER TWO

103

TURN SIGNALS WILL NOT FLASH, 4-WAY FLASHES INOPERABLE

Inspect the bulbs on a side that will
not flash. Has a bulb failed?

Replace the bulbs as necessary.

Check for 12 volts at
both terminals of the
15 amp accessory
circuit breaker. Is 12
volts present at both
terminals?

Yes

No

Disconnect the turn signal module
connector [30] Turn the ignition on.
Measure the voltage between termi-
nals 1 and 2 on the connector. Does
the meter read 12 volts?

No

Check the resistance to ground at terminal 1
of the turn signal module connector. Is the
resistance less than 1 ohm?

Yes

No

Repair poor ground
connection.

Repair the open in the
orange/white wire be-
tween the accessory
circuit breaker terminal
and turn the signal
module.

Yes

No

One

terminal

Neither

terminal

Repair the
open be-
tween the
ignition
switch and
the circuit
breaker
block.

Replace
the circuit
breaker.

Keep the ignition on. Measure the volt-
age between terminals 1 and 7 of the
turn signal module connector when the
right turn signal switch is pressed.
Does the meter read 12 volts?

Yes

Repair the open
between the han-
dlebar connector
[22] and the turn
signal module.

No

Depress the right turn signal switch,
and check the voltage at the
white/brown terminal in the harness
side of the right handlebar connector
[22] while it is connected to the con-
trols. Does the meter read 12 volts?

Yes

No

Check for conti-
nuity at the or-
ange/white wire
to ground. Is
there continuity?

Yes

No

Repair the short
to ground.

Is 12 volts present
at orange/white
wire in connector
[22]?

No

Yes

Replace the turn
signal switch.

Repair the open
between the
connector [22]
and the circuit
breaker block.

Yes

TROUBLESHOOTING

109

2

Keep the ignition on. Measure the voltage be-
tween terminals 1 and 8 of the turn signal mod-
ule connector when the left turn signal switch
is pressed. Does the meter read 12 volts?

Depress the left turn signal switch
and check the voltage at the
white/violet terminal in the harness
side of the left handlebar connector
[24] while it is connected to the con-
trols. Does the meter read 12 volts?

Replace the turn
signal switch.

No

Is 12 volts present at the
orange/white wire in
connector [24]?

No

No

Repair the open
between the
connector [24]
and the circuit
breaker block.

No

Repair open between
connector [24] and
turn signal module.

Yes

Yes

Repair
open
ground
circuit.

Repair the open between
the lamps and turn sig-
nal module connector
[30].

Yes

No

Check for continuity
between terminal 3
and the lamps. Is
continuity present?

No

Repair the
open be-
tween the
lamps and
turn signal
module con-
nector [30].

Yes

Yes

Yes

Replace
the turn
signal
module.

No

No

Yes

Check for conti-
nuity between
terminal 4 and
the lamps. Is
there continuity?

Repair the open
ground circuit.

Place a jumper across terminals 2 and 3 in the turn
signal module connector, and turn the ignition on.
Both right turn signal lamps should turn on. Do they?

Place a jumper
across terminals 2
and 4 in the turn
signal module con-
nector, and turn the
ignition ON. Both
left turn signal
lamps should turn
on. Do they?

Check continuity at the
white/violet wire to ground.
Is continuity present?

Yes

Repair the short
to ground.

110

CHAPTER TWO

104

TURN SINGLA MODULE CONNECTORS

(1994-2003 MODELS)

Power

Module

Right turn
signal switch

Right turn
signal light

Left turn
signal switch

Left turn
signal light

Speedometer

Pin housing alignment tabs

Socket housing alignment tabs

Pin

number

Wire

color

Description/function

1

Black

Module ground to motorcycle

2

Orange/white

12vdc input from accessory circuit breaker

3

White/green

Speedometer reed switch input

4

Brown

Pulsed 12 vdc for flashing right turn signal lights

5

Violet

Pulsed 12 vdc for flashing left turn signal lights

6

–

Not used

7

White/brown

12 vdc from right turn signal switch (when pressed)

8

White/violet

12 vdc from left turn signal switch (when pressed)

3. Loose or worn steering head bearings.

Stiff or Heavy Fork Operation

1. Incorrect fork oil viscosity.
2. Excessive amount of fork oil.
3. Bent fork tubes.
4. Incorrect fork springs.

Poor Fork Operation

1. Low fork oil level
2. Contaminated fork oil.
3. Worn or damaged fork tubes.
4. Bent or damaged fork tubes.
5. Incorrect fork springs.
6. Heavy front end loading from non-standard equipment.

Poor Rear Shock Absorber Operation

1. Rear shocks adjusted incorrectly.
2. Incorrect loading.
3. Heavy rear end loading from non-standard equipment.
4. Weak or worn springs.
5. Damper unit leaking.
6. Shock shaft worn or bent.
7. Incorrect rear shock springs.

BRAKE PROBLEMS

All models are equipped with front and rear disc brakes.

Perform the maintenance specified in Chapter Three to
minimize brake system problems. Brake system service is
covered in Chapter Sixteen. When refilling the front and
rear master cylinders, use only DOT 5 silicone-based brake
fluid.

Insufficient Braking Power

Worn brake pads or disc, air in the hydraulic system,

glazed or contaminated pads, low brake fluid level, or a
leaking brake line or hose can cause this problem. Visually
check for leaks. Check for worn brake pads. Also check for
a leaking or damaged primary cup seal in the master cylin-
der. Bleed and adjust the brakes. Rebuild a leaking master
cylinder or brake caliper. Brake drag will result in excessive
heat and brake fade. See

Brake Drag

in this section.

Spongy Brake Feel

This problem is generally caused by air in the hydraulic

system. Bleed and adjust the brakes as described in Chapter
Sixteen.

Brake Drag

Check brake adjustment. Check for insufficient brake

pedal and/or hand lever free play. Also check for worn,
loose or missing parts in the brake calipers. Check the brake
disc for warp or excessive runout.

Brakes Squeal or Chatter

Check brake pad thickness and disc condition. Make sure

that the pads are not loose. Check that the anti-rattle springs
are properly installed and in good condition. Clean off any
dirt on the pads. Loose components can also cause this.
Check for:
1. Warped brake disc.
2. Loose brake disc.
3. Loose caliper mounting bolts.
4. Loose front axle nut.
5. Worn wheel bearings.
6. Damaged hub.

TROUBLESHOOTING

111

2

Table 1 and Table 2 are on the following page.

Table 1 STARTER SPECIFICATIONS

Current draw

Normal

160-200 amps

Maximum

250 amps

Maximum no-load current @ 11.5 volts

90 amps

Minimum no-load speed @ 11.5 volts

3000 rpm

Table 2 ELECTRICAL SPECIFICATIONS

Alternator

Stator coil resistance

0.2-0.4 ohms

AC voltage output

19-26 Vac per 1000 rpm

Battery capacity

12 volt, 19 amp hr.

Ignition coil

Primary resistance

1200S models

0.4-0.6 ohms

All other models

2.5-3.1 ohms

Secondary resistance

1986-1992 models

11,250-13.750 ohms

1993-2003 models

1200S models

11,700-12,700 ohms

All other models

10,000-12,500 ohms

Spark plug cable resistance (1998-2003 1200S)

Front left cable (No. 1)

5039-11,758 ohms

Rear center cable (No.2)

4665-10,886 ohms

Rear left cable (No. 3)

5787-13,504 ohms

Front center cable (No. 4)

4882-11,392 ohms

Voltage regulator

Voltage output

1986-1993 models

13.8-15 VDC @ 75° F (24° C)

1994-2003 models

14.3-14.7 VDC @75° F (24° C)

Amps @ 3600 rpm

1986-1990 models

19 amps

1991-2003 models

22 amps

112

CHAPTER TWO

CHAPTER THREE

LUBRICATION, MAINTENANCE

AND TUNE-UP

This chapter covers lubrication, maintenance and tune-

up procedures.

To maximize the service life of the motorcycle, and gain

maximum safety and performance, it is necessary to per-
form periodic inspections and maintenance. Minor prob-
lems found during routine service can be corrected before
they develop into major ones.

Consider the maintenance schedule a guide. Harder than

normal use and exposure to mud, water or high humidity in-
dicates the need for more frequent servicing of most main-
tenance items. Record all service and repairs in the
maintenance log at the back of this manual. A running re-
cord will make it easier to evaluate future maintenance re-
quirements and maintain the motorcycle in top condition.

Maintenance intervals, capacities, recommendations and

specification are listed in Tables 1-9 at the end of this
chapter.

FUEL TYPE

The recommended pump octane number is 89 or higher

for 1986-1990 models and 87 or higher for 1991-2003
models. Using fuel with a lower octane number can cause
pinging or spark knock, and lead to engine damage.

When choosing gasoline and filling the fuel tank, note

the following:

1. When filling the tank, do not overfill it. There should be
no fuel in the filler neck (tube located between the fuel cap
and tank).
2. Because oxygenated fuels can damage plastic and paint,
do not spill fuel onto the fuel tank during filling.
3. DO NOT use gasoline containing methanol (methyl or
wood alcohol).
4. DO NOT use gasoline containing more than 10% of eth-
anol (ethyl or grain alcohol).

MAINTENANCE SCHEDULE

Refer to Table 1 for a recommended maintenance sched-

ule. If the motorcycle is operated under extreme conditions,
perform the appropriate maintenance more frequently.

Most of the services in Table 1 are described in this chap-

ter. However, some procedures, which require more than
minor disassembly or adjustment, are covered in the appro-
priate chapter.

ROUTINE SAFETY CHECKS

Pre-ride Inspection

1. Check wheel and tire condition. Check tire pressure. Re-
fer to

Tires and Wheels

in this chapter.

3

2. Make sure all lights work. Refer to the

Lights and Horn

section.
3. Check engine, transmission and primary drive chaincase
for oil leaks. If necessary, add oil as described in this chap-
ter.
4. Check brake fluid level and condition. If necessary, add
fluid as described in this chapter.
5. Check the operation of the front and rear brakes.
6. Check clutch operation. If necessary, adjust the clutch as
described in this chapter.
7. Check the throttle operation. The throttle should move
smoothly and return quickly when released. If necessary,
adjust throttle free play as described in this chapter.
8. Inspect the front and rear suspension. They should have
a solid feel with no looseness.
9. Check the exhaust system for leaks or damage.
10. Inspect the fuel system for leaks.
11. Check the fuel level in fuel tank.
12. If equipped with a drive chain, check chain free play as
described in this chapter.
13. If equipped with a drive belt, check drive belt tension
as described in this chapter.

CAUTION

When checking the tightness of the exposed
fasteners, do not check the cylinder head
bolts without following the procedure de-
scribed in Chapter Four.

14. Check the tightness of exposed fasteners.

Lights and Horn

Turn the ignition switch on, and check the following:

1. Pull the front brake lever and make sure the brake light
works.
2. Push the rear brake pedal down and verify the brake
light operation.
3. Make sure the headlight and taillight work.
4. Move the dimmer switch between the high and low posi-
tions, and make sure both headlight elements are working.
5. Push the turn signal switch to the left and right positions,
and make sure all four turn signal lights are working.
6. Make sure all accessory lights work properly, if so
equipped.
7. Check the horn button operation.
8. If the horn or any light fails to work properly, refer to
Chapter Twelve.

TIRES AND WHEELS

Tire Pressure

Check the tire pressure often to maintain tire profile, trac-

tion and handling, and to get the maximum life out of the
tire. Carry a tire gauge in the motorcycle’s tool kit. Table 2
lists the cold tire pressures for the original equipment tires.

NOTE

Always reinstall the air valve caps after
checking and adjusting the air pressure.
These caps prevent debris from collecting in
the valve stems and causing air leaks or in-
correct tire pressure readings.

Tire Inspection

Inspect the tires periodically for excessive wear, deep

cuts and imbedded objects such as stones or nails. If a nail
or other object is found in a tire, mark its location with a
light crayon prior to removing it. This will help locate the
hole for repair.

Measure the tread depth (Figure 1) with a gauge or a small

ruler. As a guideline, replace tires when the tread depth is
1/16 in. (1.6 mm.) or less. On original equipment tires, wear
bars on the tire will first appear flush with the surrounding
rubber when wear depth reaches 1/32 in. (0.8 mm). Replace
the tire before wear reaches the wear bars. Refer to Chapter
Thirteen for tire changing and repair information.

Laced Wheel Spoke Tension

On models with laced wheels, check for loose or dam-

aged spokes. Refer to Chapter Thirteen for wheel service.

Rim Inspection

Check the rims for cracks and other damage. Refer to

Chapter Thirteen for wheel service.

PERIODIC LUBRICATION

NOTE

Never dispose of oil in the trash, on the
ground or down a storm drain. Many service
stations and oil retailers accept used oil for

114

CHAPTER THREE

1

recycling. Do not combine other fluids with
motor oil to be recycled.

Oil Tank and Oil Line Inspection

Before inspecting the oil level, inspect the oil tank for

cracks or other damage. If oil leaks are evident on or near
the oil tank, locate and repair the problem. Check the oil
tank mounting bolts for loose or missing fasteners; replace
or tighten all fasteners. Check all oil line connections on the
tank and the engine crankcase (Figures 2-4). Replace dam-
aged oil lines as described in

Oil Tank

in Chapter Four.

Engine Oil Level Check

1. Run the engine until normal operating temperature is
reached. Stop the engine and allow the oil to settle in the oil
tank.

CAUTION

Allowing the motorcycle to rest on the
sidestand will result in an incorrect oil level
reading.

2. Place the motorcycle on a level surface and hold the mo-
torcycle upright so it is not resting on the sidestand.

3. Wipe the area around the oil filler cap (Figure 5) with a
clean rag. Remove the cap by pulling it up.

4. Wipe the dipstick with a clean rag, then reinstall the oil
filler cap. Be sure the cap is fully seated.

5. Remove the filler cap and check the oil level on the dip-
stick (Figure 6). The oil level should be between the full
(upper) and fill (lower) indicator grooves on the dipstick
(Figure 7). If the oil level is even with or below the fill
groove, continue with Step 6. If the oil level is correct, go to
Step 7.

6. Add the recommended engine oil listed in Table 3.

CAUTION

Do not overfill the oil level in the oil tank. If
the engine is cold, do not add oil so oil level
reaches the full groove. Oil may be forced
into the air cleaner causing engine malfunc-
tion or damage.

7. Inspect the oil filler cap O-ring for cracks or other dam-
age. Replace the O-ring if necessary.

8. Reinstall the oil filler cap. Be sure the cap is fully seated.

LUBRICATION, MAINTENANCE AND TUNE-UP

115

3

2

OIL HOSE ROUTING (1986-1990 MODELS)

Air cleaner

Oil tank

Transmission
vent line

Oil filter
Main oil feed
Oil tank return

Vent line

Oil pump

Frame (front)

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CHAPTER THREE

3

OIL HOSE ROUTING (1991-1993 MODELS)

Oil tank

Transmission

Feed

Vent

Return

Starter

Gear case cover

Oil pump

Oil filter
mount

4

OIL HOSE ROUNTING (1994-2003 MODELS)

Filler cap
and dipstick

Oil tank

Transmission

Gear case cover

To “A”

Return

Vent

Feed

Oil pump

Starter

Oil filter