Harley Davidson 1986-2003 XL/XLH Sportster. Service Manual — page 36

b. Examine the flange for distortion or other damage;

the flange must be flat to fit properly onto the exhaust
studs. Distortions may be flattened out, but make sure
the edges or holes in the flange are not deformed
when straightening it. Replace a damaged or bent
flange.

c. Check the fit of the flange on the cylinder head studs

before installing it onto the pipe.

d. Clean the end of the pipe to remove all rust and other

debris. If reinstalling a used flange, clean the inside
of the flange thoroughly.

e. Slide the flange on the exhaust pipe so the shoulder

on the flange faces toward the snap ring groove. In-
stall a new snap ring and check its fit; it must be se-
cure in its groove.

f. Repeat for the other exhaust pipe and flange, if re-

quired.

5. Replace worn or damaged heat shield clamps as re-
quired.
6. Store the exhaust pipes in a safe place until they are rein-
stalled.

EXHAUST SYSTEM

(883R MODELS)

Removal

Refer to Figure 113.

1. Secure the motorcycle on a suitable stand.
2. Remove the heat shields.
3. Remove the nuts and washers securing the front and rear
exhaust pipes to the cylinder heads (Figure 101, typical).
4. Remove the bolts securing the muffler to the support
bracket.

CAUTION

A bowed exhaust flange (

Figure 105

) may

wedge against the exhaust studs preventing
removal. If a flange is tight, remove one of the
cylinder head studs; refer to

Service Methods

in Chapter One. Replace or flatten a distorted
flange.

5. Slide the exhaust pipe flanges (Figure 106) away from
the cylinder head studs.
6. Remove the exhaust as an assembly.
7. Remove and discard the exhaust port gaskets (Figure
108).
8. Loosen the muffler clamp bolts and remove the muffler
from the exhaust pipes.
9. Inspect the exhaust system as described in this section.

Installation

1. Before installing the new exhaust port gaskets, remove
all carbon residue from the pipe fitting surfaces in the ex-
haust port. Wipe the port with a rag, then align the new gas-

ket with the port and push it into place. The new gasket
should fit snugly in the port (Figure 109). Repeat for the
other exhaust port and gasket.
2. If an exhaust stud was removed, install the stud now. Re-
fer to the

Service Methods

in Chapter One.

3. Before installing the exhaust pipes, check that the snap
rings (Figure 110) holding the flanges on the exhaust pipes
fit tightly in the pipe grooves.
4. Position the exhaust pipe assembly, without the muffler,
so the front and rear exhaust pipes fit into the front and rear
cylinder head exhaust pipes. Slide the flanges onto the
mounting studs and install a washer and nut onto each stud
(Figure 101). Install the nuts finger-tight only.
5. Install a new muffler clamp and fastener onto the end of
the exhaust pipes.
6. Slide the muffler onto the exhaust pipe.
7. Turn the muffler so that mounting holes in the muffler
align with the bolt holes in the support bracket. Install, but
do not tighten, the mounting bolts.
8. Tighten the fasteners in the following order:

a. Tighten the cylinder head flange nuts (Figure 101) to

72-96 in.-lb. (8-11 N•m).

b. Tighten the Torca clamp bolt on the muffler to 35-40

ft.-lb. (48-54 N•m).

c. Tighten the muffler mounting bolts to 120-180 in.-lb.

(14-20 N•m).

9. Wipe the exhaust pipes and mufflers with a clean rag to
remove all traces of oil and grease.
10. Install the heat shields and secure with the mounting
clamps.
11. Start the engine and check for leaks. Some smoke will
be evident after starting, especially if rust penetrant was
used on the hose clamps or if oil and grease residue was not
wiped off the exhaust pipes and mufflers.

Inspection

Follow the steps described in

Exhaust System (All Mod-

els Except 883R Models)

in this chapter.

EVAPORATIVE EMISSION CONTROL SYSTEM

(CALIFORNIA MODELS)

All of the California models covered by this manual are

equipped with an evaporative emission control system.
This system is used to prevent gasoline vapors from escap-
ing into the atmosphere. When the engine is not running,
fuel vapor from the fuel tank is routed through the vapor
valve and stored in a carbon canister. When the engine is
running, these vapors are drawn through a purge hose and
into the carburetor where they are burned in the combustion
chambers. The vapor valve also prevents gasoline vapors
from escaping from the carbon canister if the motorcycle
should fall onto its side.

Two evaporative emission control systems are used on

the California models covered by this manual.

378

CHAPTER ELEVEN

FUEL, EMISSION CONTROL AND EXHAUST SYSTEMS (1988-2003 MODELS)

379

11

113

EXHAUST SYSTEM (883R MODELS)

1. Muffler
2. Clamp
3. Rear heat shield
4. Nut
5. Flange
6. Snap ring
7. Gasket
8. Exhaust pipe
9. Front head shield

10. Collector heat shield
11. Torca clamp
12. Support bracket
13. Bolt

Refer to Figure 114 or Figure 115 for the components

and the hose routing to the various parts. Before removing
the hoses from any of the parts, label the hose and the fit-
ting to identify the hose location.

Inspection/Replacement

WARNING

Make sure the fuel tank vapor hoses are
routed so they cannot contact hot engine or
exhaust components. These hoses contain
flammable vapors. If a hose melts from con-
tacting a hot part, leaking vapors may ignite,
causing severe motorcycle damage and rider
injury.

1. Check all emission control lines or hoses to make sure
they are correctly routed and properly connected.

2. Make sure there are no kinks in the lines or hoses and
that there are no signs of excessive wear or burning on lines
routed near engine hot spots.

3. Check the physical condition of all lines and hoses in the
system for cuts, tears or loose connections. Damaged lines
or hoses should be replaced.

4. Check all components in the emission control system for
signs of damage, such as broken fittings or broken nipples
on the component.

5. When replacing one or more lines or hoses, refer to the
appropriate diagram. Disconnect one end of the line from
the component, then connect one end of the new line to the
component fitting. Disconnect the other end of the line
and connect the other end of the new line. This method
lessens the possibility of incorrectly connected and routed
hoses.

Vapor Valve Replacement

The vapor valve (Figure 116) is mounted on the frame

tube between the battery and oil tank.

1. Remove the battery as described in Chapter Twelve.

2. Label the hoses at the vapor valve and then disconnect
them.

380

CHAPTER ELEVEN

114

EVAPORATIVE EMISSION CONTROL SYSTEM

(1988-1991 CALIFORNIA MODELS)

Air filter
backplate

Carburetor

Reed valve

Vacuum operated
vacuum switch (VOVS)

Vacuum operated
electrical switch (VOES)

Fuel tank

Carbon canister

Vapor

valve

3. Note that one end of the vapor valve is longer than the
other end. The longer end must point up when the vapor valve
is installed on the motorcycle. Remove and replace the vapor
valve.

CAUTION

The vapor valve must be installed in a verti-
cal position with the longer end pointing up
or excessive pressure will build in the fuel
tank.

4. Install by reversing the removal steps.

Carbon Canister Replacement

Refer to Figure 117 or Figure 118.
The carbon canister is mounted on the bottom side of the

swing arm.
1. Remove the canister guard mounting screws and re-
move the guard.
2. On 1990-2003 models, cut the canister cable strap. Dis-
card the strap.
3. Label and then disconnect the hoses from the canister.
Plug the open end of each hose to prevent contamination.

FUEL, EMISSION CONTROL AND EXHAUST SYSTEMS (1988-2003 MODELS)

381

11

115

EVAPORATIVE EMISSION CONTROL SYSTEM

(1992-2003 CALIFORNIA MODELS)

Carburetor

Vacuum hose

Fuel tank

Overflow
vent hose

Vacuum
operated electric
switch (VOES)

Purge hose

Vapor valve

Carbon

canister

Air filter
backplate

Solenoid-operated
butterfly valve

Canister clean
air inlet hose

1992-1994 MODELS

Carburetor

Vacuum hose

Fuel tank

Air filter backplate

Solenoid-
operated
butterfly valve

Cannister clean air inlet hose

Overflow
vent hose

Vacuum-
operated
electric switch
(VOES)

Carbon

cannister

Vapor
valve

Purge
hose

1995-2003
MODELS

4. Press the canister bracket locking tab and slide the canis-
ter toward the left side of the motorcycle and off the bracket.
5. If necessary, remove the canister bracket mounting fas-
teners and mounting plate assembly and remove the canis-
ter bracket.

CAUTION

Do not alter the carbon canister position. The
canister must be mounted below the carbure-
tor to work correctly.

6. Install by reversing the removal steps.

Reed Valves Replacement (1988-1991 Models)

Whenever the air filter backplate is removed from the

motorcycle, check the reed valve assembly for broken reed
valves. To replace damaged reed valves, perform the fol-
lowing:
1. Remove the air filter backplate as described in this
chapter.
2. Remove the screws securing the reed cover to the reed
support and remove the cover (Figure 119).
3. Refer to Figure 120. Remove the screws securing the
reed bottom to the reed support. Then remove the following
parts:

a. Reed bottom.
b. Reed top.
c. Reed stop.

4. Check the reeds for cracks or debris that would prevent
the reed from closing. Replace worn or damaged parts as
required.
5. Refer to Figure 120. Attach the reed bottom, reed top
and the reed stop to the reed support cover. Secure with the
attaching screws.
6. Install the reed support cover onto the reed support and
secure with the attaching screws (Figure 119).
7. Install the air filter backplate as described in this chapter.

Vacuum Operated Valve Switch
Testing/Replacement (1988-1991 Models)

The vacuum-operated vacuum switch (VOVS) closes off

the carburetor float bowl vent passage when the engine is
not running. This prevents fuel vapor from escaping when
the engine is off.

A hand-operated vacuum pump (part No. HD-23738 or

equivalent) is required to test the VOVS.
1. Label and then disconnect the hoses from the VOVS;
see Figure 114 and Figure 121.
2. Attach a vacuum pump to port A in Figure 121.
3. Apply 1-2 in. HG vacuum to the valve while watching
the pump gauge. The vacuum should remain steady. If vac-
uum reading decreases rapidly, the diaphragm is damaged.
4. If vacuum remains constant, blow into port C; air should
pass through the VOVS. If air cannot pass through, the
VOVS is damaged.

5. Remove the vacuum pump and blow into port B; air
should not pass through the VOVS. If air can pass through,
the VOVS is damaged.

6. If the VOVS failed to react as described in Steps 3-5, re-
place it with a new one.

Solenoid-Operated Butterfly Valve
Troubleshooting (1992-2003 Models)

On 1992-2003 California models, a solenoid-operated

butterfly valve is installed in the air filter backplate to seal
off the backplate when the ignition switch is off. This valve
prevents fuel vapors from escaping into the atmosphere.
Turning the ignition switch to the on or ignition position en-
ergizes the solenoid hold-in windings. When the start
switch is operated, the solenoid pull-in windings are ener-
gized. The hold-in windings will keep the butterfly valve
open until the ignition switch is turned off.

Test the solenoid-operated butterfly valve if the engine

suffers from sluggish acceleration and the engine’s top
speed is 40 mph.

1. Make sure all of the hoses are properly connected; see
Figure 115.

2. If the butterfly valve is not opening and closing properly
due to mechanical problem perform the following:

a. Check the mechanical linkage assembly (Figure

122) for corroded, loose, broken or missing compo-
nents. The butterfly valve linkage and plunger should
be cleaned every 5000 miles as described in this
section.

b. Check for a broken solenoid spring (Figure 122). If

the spring is broken, replace the solenoid assembly.
The spring cannot be replaced separately. Replace the
assembly as described in this chapter.

Solenoid-Operated Butterfly Valve
Electrical Testing (1992-2003 Models)

Prior to testing the solenoid valve, fabricate the test har-

ness shown in Figure 123.

382

CHAPTER ELEVEN

116

FUEL, EMISSION CONTROL AND EXHAUST SYSTEMS (1988-2003 MODELS)

383

11

117

CARBON CANISTER (1988-1989 CALIFORNIA MODELS)

1. Guard
2. Screw
3. Nut
4. Washer
5. Rubber mount
6. Bracket
7. Nuts
8. Washer
9. Bracket

10. Bracket
11. Bolts
12. Carbon canister

118

CARBON CANISTER (1990-2003 CALIFORNIA MODELS)

1. Screw
2. Guard
3. Bolt
4. Mounting bracket
5. Wellnut
6. Locknut
7. Washer
8. Mounting plate
9. Bracket

10. Bolt
11. Carbon canister

Solenoid winding resistance test

1. Remove the air filter backplate as described in this chapter.
2. Disconnect the solenoid valve electrical connector (Fig-
ure 122).
3. Check for dirty or loose-fitting terminals and connec-
tors.
4. Connect the solenoid test connector to the solenoid con-
nector (Figure 124).
5. Refer to Figure 125 for test connections and values and
compare your meter readings to the stated values. If any of
the meter readings differ from the specified values, replace
the solenoid as described in this section.
6. If the resistance readings are correct, perform the pull-in
coil test as described in this section.

Pull-in coil test

A fully charged 12-volt battery is required for this test.

1. Remove the air filter backplate as described in this
chapter.
2. Disconnect the solenoid valve electrical connector (Fig-
ure 122).
3. Check for dirty or loose-fitting terminals and connectors.
4. Connect the solenoid test connector to the solenoid con-
nector (Figure 124).
5. Connect a 12-volt battery to the two solenoid test con-
nector wires shown in Figure 126. The butterfly valve
should open when battery voltage is applied. Disconnect
the battery connections and note the following:

a. If the butterfly valve now opens but did not open

when originally connected to the wiring harness, per-
form Step 6.

b. If the butterfly valve did not open, check the linkage

for corroded, missing or damaged parts. If the linkage
assembly appears okay, retest with a new solenoid.

6. Perform the following:

a. Make sure the ohmmeter is set to the appropriate

scale. On 1992-1994 models, check for ground at the
gray/black lead in the solenoid connector. On 1995-
2003 models, check for ground at the black lead in

384

CHAPTER ELEVEN

119

Reed top

Screw

Reed support

Reed support cover

120

REED SUPPORT ASSEMBLY

(1988-1991 MODELS)

Reed support cover

Screw

Reed
bottom

Reed stop

Reed support
cover

Reed support

121

CARBURETOR/EMISSION

HOSE ROUTING

(1988-1991 MODELS)

1. Carburetor
2. Purge hose-to-the carbon canister
3. Vacuum-operated electric switch (VOES)
4. Vacuum-operated vacuum switch (VOVS)

lead in the solenoid connector. The ohmmeter should
read 1 ohm or less.

b. Reconnect the solenoid 4-prong connector.
c. Switch a voltmeter to the 12 VDC scale.
d. On 1992-1994 models, connect the positive voltme-

ter lead to the black/red lead in the solenoid connec-
tor. On 1995-2003 models, connect the positive
voltmeter lead to the green lead in the solenoid con-
nector. Connect the negative voltmeter lead to a good
engine ground. Press the start button while reading
the voltage indicated on the voltmeter. It should be 12
volts.

7. If any of the meter readings differ from those specified
in Step 6, there is a problem in the solenoid wiring harness.
Use voltage and resistance checks to locate the damaged
wire(s). After repairing the wire(s), repeat the above
checks.

8. If the meter readings were correct as performed in Step
7, perform the hold-in test as described in this section.

Hold-in coil test

A fully charged 12-volt battery is required for this test.

FUEL, EMISSION CONTROL AND EXHAUST SYSTEMS (1988-2003 MODELS)

385

11

122

SOLENOID/BUTTERFLY VALVE ASSEMBLY

(1992-2003 CALIFORNIA MODELS)

1. Air filter backplate
2. Screw
3. Connector
4. Solenoid
5. Spring
6. Plastic washer
7. Setscrew
8. Clamp
9. Screw

10. E-clip

11. Plunger
12. Plastic link
13. Setscrew
14. Lever arm
15. Shaft
16. Rivet
17. Housing
18. Housing
19. Butterfly plate

386

CHAPTER ELEVEN

123

SOLENOID TEST CONNECTOR

Part No. 70292-89

Part No. 72038-71

Black

Black/red

Grey/black

White

Part No. 70292-89

Part No. 72038-71

Black

Green

Black

White/black

Part No. 73103-96BK

Part No. 73190-96

Green

White/black

Black

TEST HARNESS
1992-1993 MODELS

TEST HARNESS
1994-1996 MODELS

TEST HARNESS
1997-2003 MODELS

124

RESISTANCE TEST

4 place socket connector

Solenoid

Test

connector

Solenoid

Test

connector

Solenoid

Test

connector

Black

Black/red

Gray/black

White

Black

Green

Black

White/black

Green

Black

To motorcycle
harness

Green

White/black

Black

1992-1993 MODELS

1994-1996 MODELS

1997-2003 MODELS

Black

White/black

FUEL, EMISSION CONTROL AND EXHAUST SYSTEMS (1988-2003 MODELS)

387

11

125

TEST

POSITIVE

PROBE

(+)

NEGATIVE

PROBE

(–)

RESISTANCE

Pull-in

Black/Red

Gray/Black

4-6 Ohms

Hold-in

White

Black

21-27 Ohms

Pull-in

Green

Black

4-6 Ohms

Hold-in

White/Black

Black

21-27 Ohms

126

SOLENOID PULL-IN COIL TEST

Solenoid

Test

connector

12 volt

battery

Solenoid

Test

connector

12 volt

battery

Solenoid

Test

connector

12 volt

battery

Grey/black

White

Black

Green

Black

White

Green

White/black

Black

1992-1993 MODELS

1994-1996 MODELS

1997-2003 MODELS

Black/red

Black

1. Remove the air filter backplate as described in this chapter.
2. Disconnect the solenoid valve electrical connector (

Fig-

ure 122

).

3. Check for dirty or loose-fitting terminals and connectors.
4. Connect the solenoid test connector to the solenoid con-
nector (

Figure 124

).

5. Connect a 12-volt battery to the two solenoid test con-
nector wires shown in

Figure 127

and perform the follow-

ing:

a. Open the butterfly valve carefully with a screwdriver by

pushing inward on the top side of the butterfly valve.

b. Remove the screwdriver. The butterfly valve should

remain open as long as the solenoid hold-in windings
are energized.

c. Disconnect the negative battery cable from the sole-

noid test connector. The butterfly valve should close.

d. If the butterfly valve operated as described in

substeps b and c, the solenoid hold-in windings are
operating correctly.

e. If the butterfly valve failed to operate properly, per-

form Step 6.

f. Disconnect the positive battery cable from the sole-

noid test connector.

6. If the butterfly valve did not remain open in Step 5,
substep b, perform the following:

a. Switch an ohmmeter to R × 1 and cross the test leads.

Check for ground at the black connector pin in the so-
lenoid connector. The ohmmeter should read 1 ohm
or less.

b. Reconnect the solenoid connector.

c. Switch a voltmeter to the 12 VDC scale.

388

CHAPTER ELEVEN

127

SOLENOID HOLD-IN COIL TEST

Solenoid

Test

connector

12 volt

battery

Solenoid

Test

connector

12 volt

battery

Solenoid

Test

connector

12 volt

battery

Black

Black/red

Grey/black

White

Black

Green

Black

Black/white

Green

White/black

Black

1992-1993 MODELS

1994-1996 MODELS

1997-2003 MODELS

d. On 1992-1994 models, connect the positive voltme-

ter lead to the white lead in the solenoid connector.
On 1995-2003 models, connect the positive voltme-
ter lead to the white/black lead in the solenoid con-
nector. Connect the voltmeter negative lead to a good
engine ground.Turn the ignition switch to the on or
ignition position and read the voltage indicated on the
voltmeter. It should be 12 volts.

7. If any of the meter readings differ from those specified
in Step 6, there is a problem in the solenoid wiring harness.
Use voltage and resistance checks to locate the damaged
wire(s). After repairing the wire(s), repeat the above
checks.
8. If the solenoid test readings were correct but the butter-
fly valve does not work properly, perform the tests in the

Solenoid-Operated Butterfly Valve Mechanical (1992-
2003)

in this section.

9. Remove all test equipment and reconnect the solenoid
connector.

Solenoid-Operated Butterfly Valve
Cleaning and Lubrication (1992-2003 Models)

Refer to Figure 122.

1. Remove the air filter backplate as described in this chap-
ter.
2. At every 2500 mile (4022 km) interval, inspect the but-
terfly valve and solenoid for proper operation.
3. At every 5000 mile (8045 km) interval, spray the butter-
fly valve and plunger with carburetor cleaner. Then, after

the carburetor cleaner evaporates, lubricate the linkage and
plunger with a dry film spray lubricant.
4. Reinstall the air filter backplate as described in this
chapter.

Solenoid-Operated Butterfly Valve
Removal/Installation/Adjustment (1992-2003 Models)

Refer to Figure 122.

1. Remove the air filter backplate as described in this chap-
ter.
2. Remove the plunger mounting screw.
3. Loosen the lever arm setscrew.
4. Slide the solenoid up to free it from the clamp and re-
move it.

NOTE

An original equipment replacement solenoid
does not include the connector housing, pin
terminals (3,

Figure 122

) or the conduit.

When replacing the solenoid, install the pin
terminals (part No. HD 72039-71) onto the
solenoid wires, and reuse the connector hous-
ing and conduit from the old solenoid. Make
sure each pin terminal is properly seated in
the connector housing.

5. Slide the solenoid into the clamp.
6. Apply threadlock (Loctite 242 or equivalent) to the
plunger mounting screw and lever arm setscrew threads.

NOTE

When assembling the plunger and plastic
link, the slot in the plastic link must face to-
ward the pin on the lever arm.

7. Align the deep flat side on the plunger with the plastic
link, then install the plunger mounting screw. Tighten the
screw securely.
8. Loosen the solenoid setscrew.
9. Push the plunger up until the butterfly valve opens fully
and hold it in this position. Then position the solenoid body
inside the clamp.
10. While still lifting the plunger up so the butterfly valve
is fully open, press down on top of the solenoid until the
bottom of the solenoid just touches the plastic washer.
Tighten the solenoid setscrew securely.
11. Release the plunger and check that the solenoid spring
closes the butterfly valve completely. If not, readjust the
plunger and solenoid.
12. Install the air filter backplate as described in this chap-
ter.

Emission/Carburetor Hose Routing (All Models)

Refer to Figure 121 or Figure 128 for emission hose

routing at the carburetor.

FUEL, EMISSION CONTROL AND EXHAUST SYSTEMS (1988-2003 MODELS)

389

11

128

CARBURETOR/EMISSION

HOSE ROUTING

(1992-2003 MODELS)

1. Carburetor
2. Purge hose to canister
3. Vacuum-operated electric switch (VOES)
4. Vent hose to air filter backplate

Table 1 CARBURETOR SPECIFICATIONS

883 models

1200 models

Carburetor jet sizes

U.S. models (except California)

Main jet

1988 models

170

200

1989-1991 models

175

175

1992-1995 models

160

170

1996 models

160

179

1997 models

160

170

1998-2003 models

160

1200 and 1200C

170

200S

195

Pilot jet

1988 models

35

35

1989-1991 models

45

45

1992-1995 models

40

40

1996-2003 models

42

42

California

Main jet

1988 models

165

180

1989 models

155

160

1990-1991 models

160

160

1992 models

160

170

1993-1997 models

170

185

1998-2003 models

170

1200 and 1200C

185

1200S

195

Pilot jet

1988 models

35

35

1989 models

42

42

1990-1991 models

42

42

1992-1995 models

40

40

1996-2003 models

42

42

HDI models

Main jet

1993-1994 models

160

160

1995-1997 models

190

190

1998 models

190

1200 and 1200C

190

1200S

195

1999-2003 models

190

200

Pilot jet

1993-1994 models

40

40

1995-2003 models

42

42

Swiss models

Main jet

1995 models

160

160

1996-1997 models

190

190

1998 models

190

1200 and 1200C

190

1200S

195

1999-2003 models

190

200

Pilot jet

1995 models

40

40

1996-2003 models

42

42

Float height

1988-1991 models

0.725-0.730 in.

0.725-.730 in.

(18.4-18.5 mm)

(18.4-18.5 mm)

1992-2003 models

0.413-0.453 in.

0.413-0.453 in.

(10.5-11.5 mm)

(10.5-11.5 mm)

390

CHAPTER ELEVEN

Table 2 FUEL SYSTEM TORQUE SPECIFICATIONS

ft.-lb.

in.-lb.

N•m

Air filter retaining screws

(HDI models)

–

20

2

Backplate-to-carburetor screws

–

36-60

4-7

Backplate-to-cylinder head bolts

–

120-144

14-16

Fuel tank mounting bolts

1988-1992 models

–

108

12

1993-2003 models

–

96-192

11-22

Intake manifold mounting

bolts and nuts

–

72-120

8-14

Table 3 EXHAUST SYSTEM TORQUE SPECIFICATIONS

ft.-lb.

in.-lb.

N•m

Cylinder head exhaust flange

nuts

–

72-96

8-11

Front muffler locknut

1991-1992 models

50-60

–

68-81

1993-2003 models

20-40

–

27-54

Muffler clamp nut

1988-1993 models

–

84

9

Muffler mounting bolts

–

120-180

14-20

Rear master cylinder

mounting bolts

–

155-190

18-21

Torca muffler clamp bolt

1994-2003 models

35-40

–

48-54

FUEL, EMISSION CONTROL AND EXHAUST SYSTEMS (1988-2003 MODELS)

391

11

CHAPTER TWELVE

ELECTRICAL SYSTEM

This chapter covers the electrical system. Refer to Chap-

ter Three for spark plug maintenance information.

Tables 1-4 are located at the end of this chapter. Wiring

diagrams are located at the end of this manual.

ELECTRICAL COMPONENT REPLACEMENT

Most motorcycle dealerships and parts suppliers will not

accept the return of any electrical part. If the exact cause of
an electrical system malfunction cannot be determined, have
a dealership retest that specific system to verify the test re-
sults. This may help avert the possibilty of purchasing an ex-
pensive, unreturnable part that does not fix the problem.

Consider any test results carefully before replacing a

component that tests only slightly out of specification, es-
pecially resistance. A number of variables can affect test re-
sults dramatically. These include: the testing meter’s
internal circuitry, ambient temperature and conditions un-
der which the machine has been operated. All instructions
and specifications have been checked for accuracy; how-
ever, successful test results depend to a great degree upon
individual accuracy.

ELECTRICAL CONNECTORS

Many electrical problems can be traced to damaged wir-

ing, or contaminated or loose connectors.

The locations of the connectors vary by model. Also, if

the motorcycle has been serviced previously, the connector
may be in a different location.

The electrical system uses three types of connectors. If

individual wires or terminals of a particular connector re-
quire repair or replacement, refer to

Electrical Connectors

in this chapter.

Always check the wire colors listed in the procedure or

wiring diagrams to verify the location of the components.

Perform the following steps first if an electrical system

fault is encountered:

1. Inspect all wiring for fraying, burning and other visual
damage.

2. Check the main fuse and make sure it is not blown. Re-
place it if necessary.

3. Check the individual fuse(s) for each circuit. Make sure
it is not blown. Replace it if necessary.

4. Inspect the battery as described in this chapter. Make
sure it is fully charged and the battery cables are clean and
securely attached to the battery terminals.
5. Clean connectors with an aerosol electrical contact
cleaner. After a thorough cleaning, pack multi-pin electri-
cal connectors with dielectric grease to seal out moisture.
6. Disconnect electrical connectors in the suspect circuits
and check for bent or damaged terminals. The male and fe-
male terminals must connect or an open circuit will result.
7. Make sure the terminals are pushed all the way into the
plastic connector. If they are not, carefully push them in
with a narrow-blade screwdriver.
8. After everything is checked, push the connectors together
and make sure they are fully engaged and locked together.
9. Never pull on the electrical wires when disconnecting an
electrical connector. Only pull on the connector plastic
housing.

BATTERY

(1986-1996 MODELS)

WARNING

Always wear safety glasses when working
with batteries. If electrolyte is splashed into
the eyes, call a physician immediately, force
the eyes open and flood with cool, clean wa-
ter for approximately 15 minutes.

WARNING

When performing the following procedures,
protect eyes, skin and clothing.

CAUTION

Do not to spill battery electrolyte on painted or
polished surfaces. The liquid is highly corro-
sive and will damage the finish. If it is spilled,
wash it off immediately with soapy water and
thoroughly rinse with clean water.

Clean and inspect the battery at periodic intervals. The

original equipment battery on 1986-1996 models is a con-
ventional lead-acid battery.

On all models in this manual, the negative side is the

ground. When removing the battery, disconnect the nega-
tive cable first, then the positive cable. This minimizes the
chance of a tool shorting to ground when disconnecting the
battery positive cable.

Safety Precautions

When working with lead-acid batteries, use extreme care

to avoid spilling or splashing the electrolyte. This solution
contains sulfuric acid, which can ruin clothing and cause
serious chemical burns. If any electrolyte is spilled or
splashed on clothing or skin, immediately neutralize with a
solution of baking soda and water, then flush with clean
water.

While batteries are being charged, explosive hydrogen

gas forms in each cell. Some of this gas escapes through
filler cap openings and may form an explosive atmosphere
in and around the battery. This condition can persist tor sev-
eral hours. Sparks, open flame or a lighted cigarette can ig-
nite the gas causing an internal battery explosion and
possible serious personal injury.

Take the following precautions to prevent an explosion:

1. Do not smoke or permit any open flame near any battery
being charged or which has been recently charged.
2. Do not disconnect live circuits at battery terminals be-
cause a spark can occur.
3. Take care when connecting or disconnecting any battery
charger. Be sure the charger power switch is off before
making or breaking connections. Poor connections are a
common cause of electrical arcs which cause explosions.
4. Keep all children and pets away from charging equip-
ment and batteries.

For maximum battery life, check the battery periodically

for electrolyte level, state of charge and corrosion. During
hot weather periods, frequent checks are recommended. If
the electrolyte level is below the bottom of the vent well in
one or more cells, add distilled water as required–tap water
will shorten battery life. To assure proper mixing of the wa-
ter and acid, operate the engine immediately after adding
water.

Never

add battery acid instead of water.

Cable Service

1. If the electrical cable terminals are corroded, disconnect
them from the electrical system.
2. Clean each connector with a wire brush and a baking
soda solution. Rinse thoroughly with clean water and wipe
dry with a clean cloth.
3. After cleaning, apply a thin layer of dielectric grease to
the battery terminals before reattaching the cables.
4. Reconnect the electrical cables to the electrical system if
they were disconnected.
5. After connecting the electrical cables, apply a light coat
of dielectric grease to the terminals to retard corrosion and
decomposition of the terminals.

Removal

1. Remove the seat (Chapter Seventeen).
2. Remove the battery strap (A, Figure 1).
3. Remove the battery top cover (B, Figure 1).
4. Disconnect the negative battery cable from the battery
(Figure 2).
5A. On 1986-1993 models, remove the positive battery ca-
ble bolt, red wire running from the main circuit breaker,
positive battery cable and spacer (Figure 3).
5B. On 1994-1996 models, remove the positive battery ca-
ble bolt, positive battery cable and spacer (Figure 4).
6. Disconnect the battery vent tube from the battery.
7. Remove the battery.

ELECTRICAL SYSTEM

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