Harley Davidson 1999-2005 Harley Dyna Models. Repair Manual — page 17

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320

CHAPTER EIGHT

ignition module where the module adjusts the igni-

tion timing advance curve for maximum perfor-

33

mance.

On 1999-2000 models, the camshaft position

sensor (CMP) (Figure 33) is located in the cam-

shaft cover on the right side of the crankcase. The

raised ridge on the rotor operates at one-half crank-

shaft speed and it breaks the magnetic field of the

Hall-effects device on the camshaft position sen-

sor. The logic-type signal of the Hall-effect device

gives accurate timing information to the ignition

module.

The bank angle sensor mounts on a

2. Insert a clean shop cloth into the spark plug hole

frame-mounted panel behind the electric panel, on

in the cylinder head to lessen the chance of gasoline

the left side of the motorcycle on 1999-2000 mod-

vapors being emitted from the hole.

els. On 2001-on models, the bank angle sensor is

an integral part of the turn signal/turn signal secu-

3. Insert the spark plug (Figure 40), or spark tester

rity module (TSM/TSSM) that is mounted onto the

(Figure 41), into its cap and touch the spark plug

electrical panel. The sensor consists of a small

base against the cylinder head to ground it. Position

magnetic disc that rides within a V-shaped chan-

the spark plug so the electrode is visible.

nel. If the motorcycle is tilted over at an angle of

55° on 1999-2000 models or 45° on 2001 models,

NOTE

for more than one second, the ignition system is

If not using a spark tester, always use

a new spark plug for this test proce-

shut off. Once the sensor is activated, the motorcy-

dure.

cle must be placed upright and the ignition turned

OFF and then ON again. Once this is done, the ig-

nition system is operational and the engine can be

WARNING

restarted.

Mount the spark plug, or tester, away

from the spark plug hole in the cylin-

Electrical diagrams of the ignition systems are

der so that the spark or tester cannot

shown in Figures 34-38 for 1999-2001 models. Re-

ignite the gasoline vapors in the cylin-

fer to the wiring diagrams at the end of the manual

der. If the engine is flooded, do not

for 2002-on models.

perform this test. The firing of the

spark plug can ignite fuel that is

ejected through the spark plug hole.

Ignition Coil

Performance test

4. Turn the engine over with the electric starter. A

fat blue spark should be evident across the spark

1. Disconnect the plug wire and remove one of the

plug electrode. If there is strong sunlight on the

spark plugs as described in Chapter Three.

plug, shade the plug so the spark is more visible.

Repeat for the other cylinder.

NOTE

A spark tester is a useful tool for test-

WARNING

ing the ignition system’s spark output.

If necessary, hold onto the spark plug

Figure 39 shows the Motion Pro Igni-

wire with a pair of insulated pliers.

tion System Tester (part No. 08-0122).

Do not hold the spark plug, wire or

This tool is inserted in the spark plug

connector or a serious electrical

cap and its base is grounded against

shock may result.

the cylinder head. The tool’s air gap is

adjustable, and it allows the visual in-

spection of the spark while testing the

5. If a fat blue spark occurs, the ignition coil is

intensity of the spark.

good. If not, perform the following resistance test.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

ELECTRICAL SYSTEM

321

34

IGNITION SYSTEM

FXDWG MODELS 1999-2000

Crank

Cam

Engine

Ignition

position

position

stop/run

Manifold

sensor

sensor

fuse 15A

switch

air

Bank

Diagram Key

pressure

angle

sensor

sensor

Connectors

Ground

Frame ground

Connection

No connection

Electronic

speedometer

B/Y

8

R/W

V/W

G/W

R

B

B/W

G/R

V/R

Ignition

module

W/B

B

B/Y

L/O

Y/L

G/Gr

Battery

B

B

Color Code

B

Black

R

Red

Off

Gr

Gray

Acc.

Starter

B/W

Black/White

Data

Ignition

B/Y

Black/Yellow

link

Circuit

Ignition

W/B

White/Black

breaker

R/B

Red/Black

switch

30 A

R/W

Red/White

G/W

Green/White

G/R

Green/Red

G/Gr

Green/Gray

L/O

Blue/Orange

Y/L

Yellow/Blue

V/W

Violet/White

V/R

Violet/Red

-------------------------------------------------------------------------------------------------------------------------------------------------------------

322

CHAPTER EIGHT

35

IGNITION SYSTEM

FXDX, FXDS-CONV,

FXDL, FXD MODELS 1999-2000

Crank

Cam

Engine

Ignition

position

position

stop/run

fuse 15A

Manifold

sensor

sensor

switch

air

Bank

Diagram Key

pressure

angle

sensor

sensor

Connectors

Ground

Frame ground

Connection

No connection

Tachometer

P

Electronic

B/Y

speedometer

R/W

V/W

G/W

R

B

B/W

G/R

V/R

Ignition

module

W/B

B

B/Y

L/O

Y/L

G/Gr

P

B

Battery

B

Color Code

B

Black

R

Red

Gr

Gray

Off

P

Pink

Acc.

Starter

B/W

Black/White

Data

Ignition

B/Y

Black/Yellow

link

Circuit

Ignition

W/B

White/Black

breaker

R/B

Red/Black

switch

30 A

R/W

Red/White

G/W

Green/White

G/R

Green/Red

G/Gr

Green/Gray

L/O

Blue/Orange

Y/L

Yellow/Blue

V/W

Violet/White

V/R

Violet/Red

-------------------------------------------------------------------------------------------------------------------------------------------------------------

ELECTRICAL SYSTEM

323

36

IGNITION SYSTEM

FXDWG MODELS 2001*

Crank

Engine

position

Ignition

stop/run

fuse 15A

Manifold

sensor

switch

air

Turn signal/

pressure

security

Diagram Key

sensor

module

Connectors

Ground

Frame ground

Connection

No connection

P

8

Speedometer

B/Y

R/W

V/W

R

B

B/W

G/R

V/R

Ignition

module

W/B

B

B/Y

L/O

Y/L

G/Gr

P

B

Battery

B

Color Code

B

Black

R

Red

Gr

Gray

Off

P

Pink

Acc.

Starter

B/W

Black/White

Data

Ignition

B/Y

Black/Yellow

link

Circuit

W/B

White/Black

Ignition

breaker

R/B

Red/Black

switch

30 A

R/W

Red/White

G/W

Green/White

G/R

Green/Red

G/Gr

Green/Gray

L/O

Blue/Orange

Y/L

Yellow/Blue

V/W

Violet/White

*Refer to the wiring diagrams at the end of this manual for 2002-on models

V/R

Violet/Red

-------------------------------------------------------------------------------------------------------------------------------------------------------------

324

CHAPTER EIGHT

37

IGNITION SYSTEM

FXDX, FXDXT, FXDL, FXD MODELS 2001*

Crank

Engine

position

Ignition

stop/run

fuse 15A

Manifold

sensor

switch

air

Turn signal/

security

Diagram Key

pressure

sensor

module

Connectors

Ground

Frame ground

Connection

No connection

Tachometer

P

Speedometer

B/Y

R/W

V/W

R

B

B/W

G/R

V/R

Ignition

module

W/B

B

B/Y

L/O

Y/L

G/Gr

P

B

Battery

B

Color Code

B

Black

R

Red

Gr

Gray

Off

P

Pink

Acc.

Starter

B/W

Black/White

Data

Ignition

B/Y

Black/Yellow

link

Circuit

W/B

White/Black

Ignition

breaker

R/B

Red/Black

switch

30 A

R/W

Red/White

G/W

Green/White

G/R

Green/Red

G/Gr

Green/Gray

L/O

Blue/Orange

Y/L

Yellow/Blue

V/W

Violet/White

V/R

Violet/Red

*Refer to the wiring diagrams at the end of this manual for 2002-on models

-------------------------------------------------------------------------------------------------------------------------------------------------------------

ELECTRICAL SYSTEM

325

38

IGNITION SYSTEM

FXDP MODELS 2001-2004

Crank

Engine

position

stop/run

Manifold

sensor

switch

air

Turn signal/

security

Diagram Key

pressure

sensor

module

Connectors

Ground

Frame ground

Connection

No connection

8

Gr

Ignition

Speedometer

B/Y

R/B

fuse 15A

R/W

V/W

Br/Gr

Security

R

fuse 15A

R

B

B/W

G/R

V/R

Ignition

module

W/B

B

B/Y

L/O

Y/L

G/Gr

B

Battery

B

Color Code

B

Black

R

Red

Gr

Gray

Off

B/W

Black/White

Acc.

Starter

B/Y

Black/Yellow

Data

Ignition

W/B

White/Black

link

Circuit

R/B

Red/Black

Ignition

breaker

R/W

Red/White

switch

30 A

G/W

Green/White

G/R

Green/Red

G/Gr

Green/Gray

L/O

Blue/Orange

Y/L

Yellow/Blue

V/W

Violet/White

V/R

Violet/Red

Br/Gr

Brown/Gray

-------------------------------------------------------------------------------------------------------------------------------------------------------------

326

CHAPTER EIGHT

Resistance test

39

NOTE

Refer to the Basic Information sec-

tion at the beginning of this chapter.

1. Remove the ignition coil as previously de-

scribed.

2. Disconnect the secondary wires from the igni-

tion coil.

3. Use an ohmmeter set at R × 1 and measure the

primary coil resistance between terminals A and B

and then terminals B and C (Figure 42) at the back-

side of the ignition coil. The specified resistance

40

value is listed in Table 1.

4. Using an ohmmeter set at R × 1000, measure the

secondary coil resistance between the spark plug

leads of the secondary coil terminals (Figure 42).

The specified resistance value is listed in Table 1.

5. If the resistance values are less than specified,

there is most likely a short in the coil windings. Re-

place the coil.

6. If the resistance values are more than specified,

this may indicate corrosion or oxidation of the coil’s

terminals. Thoroughly clean the terminals, then

spray with an aerosol electrical contact cleaner. Re-

41

peat Step 3 and Step 4 and if the resistance value is

still high, replace the coil.

7. If the coil resistance does not meet (or come

close to) either of these specifications, the coil must

be replaced. If the coil exhibits visible damage, it

should be replaced as described in this chapter.

8. Install the ignition coil as described in this chap-

ter.

Removal/installation

Refer to Figure 43.

42

NOTE

Always disarm the optional TSSM se-

curity system prior to disconnecting

the battery or the siren will sound.

1. Disconnect the negative battery cable as de-

scribed in this chapter.

TERMINAL-A

TERMINAL-C

rear coil

TERMINAL-B

front coil

2. Remove the fuel tank as described in Chapter

+12 V

Seven.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

ELECTRICAL SYSTEM

327

43

IGNITION SYSTEM

45

COMPONENTS

NOTE

Label all wiring connectors prior to

disconnecting them in the following

steps.

3. Disconnect the secondary lead (A, Figure 44)

from each spark plug.

4. Disconnect the front cylinder’s secondary lead

8

from the clip on the frame.

5. Disconnect the primary wire connector (Figure

45) from the backside of the ignition coil.

6A. On models with a chrome cover, remove the Al-

1.

Ignition module

len bolts and washers securing the ignition coil and

2.

Screw

cover to the frame.

3.

Nut

4.

Bracket

6B. On all other models, remove the Allen bolts (B,

5.

Ignition coil

Figure 44) securing the ignition coil to the frame.

6.

Allen bolt

7. Remove the ignition coil (C, Figure 44).

7.

Washer

8. Install the ignition coil by reversing these steps.

8.

Cover (on models so

equipped)

9.

Collar

Ignition Module

10.

Spark plug cable-rear

Removal/Installation

cylinder

11.

Spark plug cable-front

The ignition module mounts behind the electric

cylinder

12.

Spark plugs

panel cover, on the left side of the motorcycle.

NOTE

Always disarm the optional TSSM se-

curity system prior to disconnecting

44

the battery or the siren will sound.

1. Disconnect the negative battery cable as de-

scribed in this chapter.

2. Refer to Electrical Panel in this chapter and re-

move the outer and inner panel to gain access to the

ignition module.

3. Remove the two screws securing the ignition

module to the backside of the inner panel.

4. Disconnect the 12-pin black and 12-pin gray

electrical connectors from the ignition module.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

328

CHAPTER EIGHT

46

INTAKE MANIFOLD

1. Manifold seal

2. Flange

3. Intake manifold

4. Screw

5. Clip

6. MAP sensor

7. Seal

8. Bolt

9. Seal

5. Remove the ignition module.

1. Disconnect the negative battery cable as de-

6. Install the ignition module by reversing these

scribed in this chapter.

steps while noting the following:

2. Remove the fuel tank as described in Chapter

a. Apply a light coat of dielectric compound to

Seven.

the electrical connectors prior to installing

3. Remove the carburetor as described in Chapter

them.

Seven. Place a lint-free shop cloth into the intake

b. Make sure the electrical connectors are

manifold opening (A, Figure 47) to prevent the en-

pushed tightly onto the ignition module.

try of debris.

4. Remove the screw and clip (B, Figure 47) secur-

ing the MAP sensor to the top of the intake mani-

Manifold Absolute Pressure (MAP) Sensor

fold.

Removal/Installation

5. Pull the MAP sensor (C, Figure 47) straight up

out of the seal in the intake manifold.

The MAP sensor (Figure 32) is located on top of

6. Disconnect the electrical connector from the

the intake manifold. Refer to Figure 46.

MAP sensor and remove the sensor.

7. Install the MAP sensor by reversing these steps

NOTE

while noting the following:

Always disarm the optional TSSM se-

curity system prior to disconnecting

a. Apply a light coat of dielectric compound to

the battery or the siren will sound.

the electrical connector prior to installing it.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

ELECTRICAL SYSTEM

329

b. Make sure the electrical connector is pushed

47

tightly onto the MAP sensor.

c. If necessary, replace the seal in the intake

manifold.

Crankshaft Position Sensor (CKP)

Sensor Removal/installation

The crankshaft position sensor (CKP) (Figure

31) is mounted on the front left side of the crankcase

next to the oil filter.

The CKP and the oil pressure switch are included

in one wiring harness. If one of the components is

defective, both must be replaced.

48

1. Remove the seat as described in Chapter Thir-

teen.

NOTE

Always disarm the optional TSSM se-

curity system prior to disconnecting

8

the battery or the siren will sound.

2. Disconnect the negative battery cable as de-

scribed in this chapter.

3. Remove the fuel tank as described in Chapter

Seven.

4. Remove the exhaust system as described in

49

Chapter Seven.

5. Remove the T20 Torx screw, then open the

clamp (A, Figure 48) securing the electrical harness

to the engine.

6. Disconnect the single green/yellow wire from

the oil pressure switch (B, Figure 48).

7. Remove the Allen screw and withdraw the CKP

sensor (Figure 49) and O-ring from the crankcase.

8. Move the CKP sensor and wiring over the right

side of the engine.

NOTE

The following electrical connector(s)

50

are not visible in Figure 50 as they

are located under the frame

cross-member.

9A. On 1999 models, the following Mini-Deutsch

connector, located under the seat, must be discon-

nected. The single connector has three wires with

one red, one black and one green/yellow wire.

9B. On

2000-on models, the following

Mini-Deutsch connectors, located under the seat,

must be disconnected:

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330

CHAPTER EIGHT

a. CKP connector has two wires with one red

and one black wire.

51

b. Oil pressure connector has a single green/yel-

low wire.

10. Carefully pull the electrical connector(s), noted

in Step 9, out from under the frame cross-member.

Disconnect the secondary locks on the

Mini-Deutsch connector(s) (Figure 50) and discon-

nect the connector(s).

11. Tie a piece of string to the electrical connec-

tor(s). Tie the other end of the string to the frame

cross-member. If necessary, make a drawing of the

wire routing through the frame. It is easy to forget

the routing path after removing the wire.

52

12. Carefully pull the wiring harness, connector(s)

and string out of the frame on the right side. If the

wire becomes tight or stuck, do not force it.

13. Untie the string from the wiring harness.

14. Install by reversing these removal steps while

noting the following:

a. Tie the string to the wiring harness and con-

nector(s).

b. Carefully pull the string and the wiring har-

ness and connector(s) through the right side

of the frame and into position under the seat.

Untie and remove the string.

c. Apply a light coat of dielectric compound to the

53

electrical connector(s) prior to installing them.

d. Apply clean engine oil to the new O-ring on

the CKP sensor prior to installation. Install

the sensor and tighten the Allen screw to the

specification in Table 6.

Camshaft Position Sensor

(CMP) (1999-2000) Removal/installation

The camshaft position sensor (CMP) (Figure 33)

is located in the camshaft cover on the right side of

the crankcase.

connector has three wires with one red/white, one

1. Remove the seat as described in Chapter Thir-

black/white and one green/white wire.

teen.

NOTE

NOTE

The electrical Mini-Deutsch connec-

Always disarm the optional TSSM se-

tor is not visible in Figure 50. It is lo-

curity system prior to disconnecting

cated under the frame cross-member.

the battery or the siren will sound.

2. Disconnect the negative battery cable as de-

4. Carefully pull the electrical connector out from

scribed in this chapter.

under the frame cross-member. Disconnect the sec-

3. The following Mini-Deutsch connector, located

ondary locks on the Mini-Deutsch connector (Fig-

under the seat, must be disconnected. The single

ure 50).

-------------------------------------------------------------------------------------------------------------------------------------------------------------

ELECTRICAL SYSTEM

331

11. Remove the screw and clamp (Figure 52) se-

54

curing the wiring harness to the crankcase.

12. Remove the T20 Torx screws securing the in-

spection cover (Figure 53) and remove the cover.

13. Tie a different piece of string onto the end of the

wiring harness.

14. Remove the screw and washer securing the

CMP sensor (Figure 54) to the camshaft cover. Re-

move the sensor and O-ring from the cover.

NOTE

Figure 55 is shown with the camshaft

cover removed to better illustrate the

step.

55

15. Carefully pull the electrical harness, along with

the piece of string, out through both openings in the

camshaft cover (Figure 55).

16. Untie the string and retie it to the new CMP

8

sensor wiring harness.

17. Carefully pull the new wiring harness back

through the two openings in the camshaft cover

(Figure 55). Untie and remove the string.

18. Apply a light coat of new engine oil to the CMP

sensor O-ring.

5.

Note the location of each of the three individual

wires within the Mini-Deutsch connector, then dis-

19. Carefully push the new sensor into place in the

connect the three wires.

camshaft cover and install the screw and washer.

6. Tape a piece of string to the three individual

Tighten the screw to the specification in Table 6.

electrical wires in the harness. Tie the other end of

20. Tie the piece of string onto the end of the new

the string to the frame cross-member. If necessary,

CMP sensor wire harness.

make a drawing of the wire routing through the

21. Carefully pull the string and the wiring harness

frame. It is easy to forget the routing path after re-

and connectors through the right side of the frame

moving the wire.

and into position under the seat. Untie and remove

7. Carefully pull the wiring harness out of the

the string.

frame on the right side. If the wire becomes tight or

22. Apply a light coat of dielectric compound to the

stuck, do not force it.

electrical connectors prior to connecting them.

8. Untie the string from the wiring harness, but

23. Refer to the notes made in Step 5 and connect

leave it within the frame.

the three individual wires into the correct location

9. Remove the exhaust system (A, Figure 51) as

within the Mini-Deutsch connector. Lock the sec-

described in Chapter Seven.

ondary lock on the Mini-Deutsch connector.

10. Tie the rear brake pedal (B, Figure 51) down to

24. Install the inspection cover and the T20 Torx

gain access to the inspection cover (C, Figure 51)

screws. Tighten the screw to the specification in Ta-

on the camshaft cover.

ble 6.

NOTE

25. Install the exhaust system as described in

The following photographs are shown

Chapter Seven.

with the engine removed and partially

26. Unhook the rear brake pedal.

disassembled to better illustrate the

steps.

27. Install the seat

-------------------------------------------------------------------------------------------------------------------------------------------------------------

332

CHAPTER EIGHT

Bank Angle (BAS) Sensor (1999-2000)

Removal/installation

56

The bank angle sensor mounts onto a

frame-mounted panel behind the electric panel, on

the left side of the motorcycle.

NOTE

The bank angle sensor is an integral

part of the turn signal module/turn

signal security module (TSM/TSSM)

on the 20001 models. This sensor is

covered under Turn Signal Module

in this chapter.

Troubleshooting

1. Remove the seat as described in Chapter Thir-

Refer to Chapter Two.

teen.

NOTE

Starter Removal

Always disarm the optional TSSM se-

curity system prior to disconnecting

1. Remove the seat as described in Chapter Thir-

the battery or the siren will sound.

teen.

2. Disconnect the negative battery cable as de-

NOTE

scribed in this chapter.

Always disarm the optional TSSM se-

3. Remove the screw securing the bank angle sen-

curity system prior to disconnecting

sor to the backside of the frame panel.

the battery or the siren will sound.

4. Carefully disconnect the 3-pin electrical connec-

tor (Figure 56) containing one black wire, one gray

2. Disconnect the negative battery cable as de-

wire and one light green/gray wire.

scribed in this chapter.

5. Remove the bank angle sensor.

3. Remove the primary cover as described in Chap-

6. Install the bank angle sensor by reversing these

ter Five.

steps while noting the following:

NOTE

a. Apply a light coat of dielectric compound

The following photographs are shown

to the electrical connector prior to install-

with the clutch assembly removed to

ing it.

better illustrate the steps.

b. Make sure the electrical connector is pushed

tightly onto the bank angle sensor.

4. Straighten the tab on the lockplate (Figure 62).

5. Wrap the pinion gear with a cloth to protect the

STARTING SYSTEM

finish, then secure it with locking pliers (A, Figure

63).

Electrical diagrams of the starting systems are

6. Loosen and remove the bolt (B, Figure 63),

shown in Figures 57-61 for 1999-2001 models. Re-

lockplate and thrust washer from the starter

fer to the wiring diagrams at the end of the manual

jackshaft assembly at the end of the starter motor.

for 2002-on models.

7. Remove the rear exhaust pipe as described in

Chapter Seven.

CAUTION

8. Remove the bolt and the cover (A, Figure 64)

Do not operate the starter for more

from the end of the starter motor.

than five seconds at a time. Let it cool

approximately 10 seconds before op-

9. Disconnect the solenoid electrical connector (B,

erating it again.

Figure 64) from the starter motor.

-------------------------------------------------------------------------------------------------------------------------------------------------------------

ELECTRICAL SYSTEM

333

57

STARTING SYSTEM

FXDWG MODELS 1999-2000

Engine

Ignition

stop/run

Start

fuse 15A

switch

switch

Start

Diagram Key

relay

Connectors

Ground

Frame ground

Connection

No connection

8

B

Battery

B

Color Code

Off

Acc.

Starter

B

Black

Ignition

R

Red

Circuit

G

Green

Ignition

breaker

Gr

Gray

switch

B/R

Black/Red

30 A

R/B

Red/Black

W/B

White/Black

-------------------------------------------------------------------------------------------------------------------------------------------------------------

334

CHAPTER EIGHT

58

STARTING SYSTEM

FXDX, FXDS-CONV, FXDL, FXD MODELS 1999-2000

Engine

Ignition

stop/run

Start

fuse 15A

switch

switch

Start

Diagram Key

relay

Connectors

Ground

Frame ground

Connection

No connection

B

Battery

B

Color Code

Off

Acc.

Starter

B

Black

Ignition

R

Red

Circuit

G

Green

Ignition

Gr

Gray

breaker

switch

B/R

Black/Red

30 A

R/B

Red/Black

R/Gr

Red/Gray

W/B

White/Black

-------------------------------------------------------------------------------------------------------------------------------------------------------------

ELECTRICAL SYSTEM

335

59

STARTING SYSTEM

FXDWG MODELS 2001*

Security

Ignition

Engine

fuse 15A

fuse 15A

stop/run

Start

switch

switch

Start

Diagram Key

relay

Connectors

Ground

Frame ground

Connection

No connection

8

B

Battery

B

Turn signal/

Off

Color Code

Acc.

security

Starter

Ignition

B

Black

module

Circuit

R

Red

Ignition

breaker

G

Green

switch

30 A

Gr

Gray

B/R

Black/Red

R/B

Red/Black

T/G

Tan/Green

Br/Gr

Brown/Gray

W/B

White/Black

*Refer to the wiring diagrams at the end of this manual for 2002-on models

-------------------------------------------------------------------------------------------------------------------------------------------------------------

336

CHAPTER EIGHT

60

STARTING SYSTEM

FXDX, FXDL, FXDXT, FXD MODELS 2001*

Security

Ignition

Engine

fuse 15A

fuse 15A

stop/run

Start

switch

switch

Start

Diagram Key

relay

Connectors

Ground

Frame ground

Connection

No connection

B

Battery

B

Turn signal/

Off

Color Code

Acc.

security

Starter

Ignition

module

B

Black

Circuit

R

Red

Ignition

breaker

G

Green

switch

30 A

Gr

Gray

B/R

Black/Red

R/B

Red/Black

T/G

Tan/Green

Br/Gr

Brown/Gray

W/B

White/Black

*Refer to the wiring diagrams at the end of this manual for 2002-on models

-------------------------------------------------------------------------------------------------------------------------------------------------------------

ELECTRICAL SYSTEM

337

61

STARTING SYSTEM

FXDP MODELS 2001-2004

Security

Ignition

Engine

fuse 15A

fuse 15A

stop/run

Start

switch

switch

Start

Diagram Key

relay

Connectors

Ground

Frame ground

Connection

No connection

Br/Gr

Turn

Gr

signal/

security

T/G

module

8

B

B

Battery

B

Off

Color Code

Acc.

Starter

Ignition

B

Black

Clutch

Circuit

R

Red

Ignition

lockout

breaker

G

Green

switch

switch

30 A

Gr

Gray

B/R

Black/Red

R/B

Red/Black

T/G

Tan/Green

Br/Gr

Brown/Gray

W/B

White/Black

62

63

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338

CHAPTER EIGHT

64

65

66

STARTER MOTOR

1. Screw

2. Lockwasher

11. Ball

20. Field coil assembly

3. Drive housing

12. Return spring

21. Brushes

4. O-ring

13. Solenoid housing

22. Brush springs

5. Drive assembly

14. Tab

23. Brush holder

6. Idler gear bearing

15. Nut

24. End cap

7. Bearing rollers (5)

16. Nut

25. O-ring

8. Idler gear

17. Bearing

26. Washer

9. Drive spring

18. Armature

27. Screw

10. Clutch shaft

19. O-ring

28. Through bolt

-------------------------------------------------------------------------------------------------------------------------------------------------------------

ELECTRICAL SYSTEM

339

washer. Tighten the bolts to the specification in Ta-

67

ble 6.

4. Connect the solenoid electrical connector (B,

Figure 64) onto the starter motor.

5. Connect the positive cable (C, Figure 64) onto

the starter motor terminal and tighten the nut to the

specification in Table 6. Slide the rubber boot back

over the connection.

6. Install the cover and the bolt (A, Figure 64) onto

the end of the starter motor. Tighten the bolt se-

curely.

7. Install the bolt (B, Figure 65), lockplate (C), and

thrust washer (D) through the pinion gear (A) and

onto the jackshaft.

68

8. Align the lockplate tab with the thrust washer,

then insert the tab into the notch in the end of the

jackshaft.

9. Screw the bolt into the starter motor shaft by

hand.

10. Wrap the pinion gear with a cloth to protect the

8

finish, then secure it with locking pliers (A, Figure

63).

11. Tighten the bolt (B, Figure 63) onto the starter

motor to the specification in Table 6. Bend the outer

lockplate tab against the bolt head (Figure 62).

10. Slide back the rubber boot, remove the nut and

12. Install the primary cover as described in Chap-

disconnect the positive cable (C, Figure 64) from

ter Five.

the starter motor terminal.

13. Install the rear exhaust pipe as described in

Chapter Seven.

11. Remove the starter motor mounting bolts and

washers (D, Figure 64). Note the location of the

14. Connect the negative battery cable.

negative ground cable (E) under the front bolt and

15. Install the seat.

washer.

12. Pull the starter motor straight out of the crank-

Disassembly

case and remove it.

13. If necessary, service the starter motor as de-

Refer to Figure 66.

scribed in this chapter.

NOTE

If only the solenoid assembly requires

Installation

service, refer to Solenoid Housing in

this chapter.

1. If the jackshaft coupling was removed or if it

was removed after the starter motor was removed,

1. Clean all grease, dirt and carbon from the exte-

install the coupling

(A, Figure

65) onto the

rior of the starter assembly.

jackshaft before installing the starter motor.

2. Remove the two through bolts (Figure 67).

2. Install the starter motor straight into the crank-

3. Remove the two drive housing Phillips screws

case from the right side. Carefully engage the starter

(Figure 68) and lockwashers.

motor shaft with the jackshaft coupling.

4. Tap the drive housing and remove it from the

3. Install the starter motor mounting bolts and

starter assembly (Figure 69).

washers (D, Figure 64). Be sure to install the nega-

5. Disconnect the C terminal field wire (A, Figure

tive ground cable (E) under the front bolt and

70) from the solenoid housing.