Harley Davidson Softail 2000-2005. Service manual — page 31

d. Carefully withdraw the top plate (C, Figure 123)

and sending unit while moving it back and forth,
and while lifting and turning it in either direction.

e. Remove the gasket from the fuel tank and discard it.

6. Install by reversing these removal steps while noting
the following:

NOTE

not

apply any type of gasket sealer to the

top plate gasket.

a. Install

new

gaskets between the fuel gauge and fuel

tank.

b. Install the sending unit

carefully

to avoid damage to

the float arm.

c. Tighten all screws securely.

2001-On Models (Except FXSTD)
Removal/Installation

Refer to Figure 124.

1. Remove the seat as described in Chapter Fourteen.

2. Disconnect the negative battery cable as described in
Chapter Eight.

3. Remove the fuel tank as described in this chapter.

NOTE

The fuel gauge sending unit electrical wires
are routed through a tube in the fuel tank
and are secured with a clamp at the bottom

306

CHAPTER SEVEN

122

FUEL LEVEL SENDING UNIT

(2000-ON FXSTD MODELS)

1. Fuel level sending unit and harness
2. Gasket
3. Electrical connector
4. O-ring
5. Screw
6. Top plate
7. Terminal socket
8. Terminal socket
9. Wiring harness

10. Ground lead
11. Clip
12. Gasket
13. Pin terminal
14. Pin housing

123

of the fuel tank. Loosen the clamp (

Figure

116

) and make sure there is enough slack in

the wires to allow the gauge to be pulled up
and out of the fuel tank.

4. To remove the fuel gauge only, perform the following:

CAUTION

Do not twist the fuel gauge in Step 3 as the
fuel gauge will be damaged.

a. Carefully pull straight up and partially withdraw the

fuel gauge from the fuel tank.

b. Disconnect the sending unit and fuel gauge wiring

electrical connectors.

c. Remove the fuel gauge and gasket.

5. To remove the fuel gauge sending unit, perform the
following:

a. Remove the fuel gauge as described in Step 3.
b. Remove the screws securing the fuel gauge sending

unit plate.

CAUTION

Do not bend the float arm during removal of
the sending unit. If bent, the gauge will give
inaccurate readings.

c. Carefully withdraw the sending unit while moving

it back and forth, and while lifting and turning it in
either direction.

d. Remove the gasket from the fuel tank and discard it.

6. Install by reversing these removal steps while noting
the following:

NOTE

not

apply any type of gasket sealer to the

top plate gasket.

a. Install

new

gaskets between the fuel gauge and fuel

tank.

b. Install the sending unit

carefully

to avoid damage to

the float arm.

c. Tighten all screws securely.

EXHAUST SYSTEM

(FLSTF AND FXSTD MODELS)

Removal

Refer to Figure 125.

NOTE

If the system joints are corroded or rusty,
spray all connections with WD-40, or an
equivalent, and allow the penetrating oil to
soak in sufficiently to free the rusted joints.

1. Support the motorcycle on a work stand. See

Motorcy-

cle Stands

in Chapter Nine.

2. On models so equipped, remove the footboards as de-
scribed in Chapter Fourteen.
3. Label the heat shields prior to removal for aid during
installation. They look very similar but all have slight dif-
ferences. Use the numbers assigned to these parts in Fig-
ure 125.

FUEL, EXHAUST AND EMISSION CONTROL SYSTEMS

307

124

FUEL LEVEL SENDING UNIT

(2001-ON MODELS EXCEPT FXSTD)

1. Fuel level gauge
2. Gasket
3. Pin terminal
4. Socket terminal
5. Pin terminal
6. Screw
7. Sending unit
8. Pin terminal
9. Socket terminal

10. Clip (adhesive backed)
11. Gasket

308

CHAPTER SEVEN

125

EXHAUST SYSTEM (FLSTF AND FXSTD MODELS)

1. Clamp (HDI models only)
2. Heat shield
3. Muffler (rear cylinder)
4. Clamp
5. Exhaust pipe (rear cylinder)
6. Heat shield
7. Muffler support
8. Muffler (front cylinder)
9. Heat shield

10. Bolt
11. Washer
12. Mounting bracket
13. Washer
14. Bolt

15. Mounting bracket
16. Bolt
17. Seal
18. Washer
19. Bolt
20. Mounting bracket
21. Flange locknut
22. Heat shield
23. Exhaust pipe (front cylinder)
24. Heat shield
25. Gasket
26. Circlip
27. Retaining ring
28. Nut

4. To remove the muffler assembly, perform the following:

a. Remove the carriage bolt and nut securing the Torca

clamp to the lower muffler-to-exhaust pipe mount-
ing bracket.

b. Remove the screws and washers on both muffler

brackets.

c. Pull the muffler assembly toward the rear and dis-

connect both mufflers from the front and rear ex-
haust pipes. Leave the mufflers attached to the
interconnect fittings on both mufflers.

5. To remove the exhaust pipes, perform the following:

a. Remove the mufflers as described in Step 4.
b. Loosen the clamps and remove both heat shields.
c. At each cylinder head, loosen and remove the two

flange nuts securing both the front and rear exhaust
pipes to the cylinder heads.

d. Slide the exhaust flange and retaining ring off the

cylinder head studs.

e. Remove the exhaust pipes from the cylinder heads.
f. Remove the circlip, then remove the exhaust port

gaskets.

6. Inspect the exhaust system as described in this chapter.
7. Store the exhaust system components in a safe place
until they are reinstalled.

Installation

NOTE

New Torca clamps must be installed to en-
sure correct sealing integrity. The new Torca
clamps eliminate the need for graphite or sil-
icone tape during installation of the mufflers.

NOTE

To prevent exhaust leaks, do not tighten any
of the mounting bolts and nuts or the Torca
clamps until all exhaust components are in
place.

1. Scrape the exhaust port surfaces to remove all carbon
residue. Then wipe the port with a rag.
2. Install a

new

exhaust port gasket into each exhaust port

with the tapered side facing out. Install the circlips to se-
cure the gaskets.
3. To install the exhaust pipes, perform the following:

a. Install the front header pipe onto the front cylinder

head exhaust port. Install the flange nuts and tighten
them finger-tight.

b. Install the rear header pipe onto the rear cylinder

head exhaust port. Install the flange nuts and tighten
them finger-tight.

c. Move the open end of the exhaust pipes into posi-

tion to accept the muffler assembly.

d. Install the

new

Torca clamps onto the end of the ex-

haust pipes.

4. To install the muffler assembly, perform the following:

a. Move the muffler assembly into position and attach

them to the exhaust pipes.

b. Install the screws and washers securing the mufflers

to the mounting brackets. Tighten the screws fin-
ger-tight.

c. Move the Torca clamps into position and tighten

finger-tight.

5. Check the entire exhaust system to make sure none of
the exhaust components are touching the frame. If neces-
sary, make slight adjustments to avoid any contact that
would transmit vibrations to the rider through the frame.
6. Check the exhaust assembly alignment, then tighten
the mounting bolts and nuts as follows:

a. Front cylinder head flange nuts. Tighten the upper

nut to 60-80 in-lbs. (7-9 N•m), then tighten the
lower nut to 60-80 in-lbs. (7-9 N•m).

b. Rear cylinder head flange nuts. Tighten the upper

nut to 60-80 in-lbs. (7-9 N•m), then tighten the
lower nut to 60-80 in-lbs. (7-9 N•m).

c. Tighten the carriage bolt and nut securing the Torca

clamp to the lower muffler-to-exhaust pipe mount-
ing bracket to 45-60 ft.-lbs. (61-81 N•m).

d. Tighten the screws and washers on both muffler

brackets to 15-19 ft.-lbs. (20-25 N•m).

7. Open the heat shield clamps completely. Position the
clamp so the screw is on the outboard side in the most ac-
cessible position. Install the heat shields in the locations
marked during removal. Tighten the clamps securely.
8. Check all heat shields to make sure none are touching
the frame. If necessary, make slight adjustments to avoid
any contact that would transmit vibrations to the rider
through the frame.
9. Start the engine and check for leaks.
10. On models so equipped, install the footboards as de-
scribed in Chapter Fourteen.

EXHAUST SYSTEM (FLSTS MODELS)

Removal

Refer to Figure 126.

NOTE

If the system joints are corroded or rusty,
spray all connections with WD-40, or an
equivalent, and allow the penetrating oil to
soak in sufficiently to free the rusted joints.

1. Support the motorcycle on a work stand. See

Motorcy-

cle Stands

in Chapter Nine.

FUEL, EXHAUST AND EMISSION CONTROL SYSTEMS

309

310

CHAPTER SEVEN

126

EXHAUST SYSTEM (FLSTS MODELS)

1. Muffler* (left side)
2. Mounting bracket
3. Washer
4. Bolt
5. Washer
6. Lockwasher
7. Bolt
8. Muffler support tube
9. Lockwasher

10. Bolt
11. Clamp
12. Clamp

13. Washer
14. Bolt
15. Heat shield
16. Crossover pipe
17. Heat shield
18. Gasket
19. Washer
20. Heat shield
21. Locknut
22. Mounting bracket
23. Bolt
24. Bolt

25. Mounting bracket
26. Locknut
27. Rear cylinder exhaust pipe
28. Heat shield
29. Heat shield
30. Muffler* (right side)
31. Gasket
32. Circlip
33. Retaining ring
34. Nut
35. Clamp

*Mufflers on California models are equipped with a catalytic converter.

On HDI models, the right side muffler is equipped with a catalytic converter.

2. Remove both saddlebags as described in Chapter
Fourteen.
3. Remove the footboards as described in Chapter Four-
teen.
4. Label the heat shields prior to removal for aid during
installation. They look very similar but all have slight dif-
ferences. Use the numbers assigned to these parts in Fig-
ure 126.
5. Loosen the clamps and remove the heat shields.
6. To remove the mufflers, perform the following:

a. Loosen the Torca clamp securing the muffler to the

exhaust pipe.

b. Remove the bolts, lockwashers and washers secur-

ing the muffler to the muffler support tube.

c. Pull the muffler toward the rear and disconnect the

muffler from the exhaust pipe.

d. Repeat for the other muffler.

7. To remove the exhaust pipes, perform the following:

a. On the right side, loosen the clamp securing the

front cylinder exhaust pipe to the rear cylinder ex-
haust pipe.

b. Remove the bolt and locknut securing the rear por-

tion of the rear cylinder exhaust pipe to the mount-
ing bracket on the frame.

c. Remove the screw and washer securing the cross

over clamp to the passenger footboard.

d. Remove the cross over pipe from the rear exhaust

pipe.

e. At each cylinder head, loosen and remove the two

flange nuts securing both the front and rear exhaust
pipes to the cylinder heads.

f. Slide the exhaust flange and retaining ring off the

cylinder head studs.

g. Remove the exhaust pipes from the cylinder heads.
h. Remove the circlip, then remove the exhaust port

gaskets.

8. Inspect the exhaust system as described in this chapter.
9. Store the exhaust system components in a safe place
until they are reinstalled.

Installation

NOTE

New Torca clamps must be installed to en-
sure correct sealing integrity. The new
Torca clamps eliminate the need for graph-
ite or silicone tape during installation of the
mufflers.

NOTE

To prevent exhaust leaks, do not tighten any
of the mounting bolts and nuts or the Torca

clamps until all exhaust components are in
place.

1. Scrape the exhaust port surfaces to remove all carbon
residue, then wipe the port with a rag.
2. Install a

new

exhaust port gasket into each exhaust port

with the tapered side facing out. Install the circlips to se-
cure the gaskets.
3. To install the exhaust pipes, perform the following:

a. Install the front header pipe onto the front cylinder

head exhaust port. Install the flange nuts and tighten
them finger-tight.

b. Install the rear header pipe onto the rear cylinder

head exhaust port. Install the flange nuts and tighten
them finger-tight.

c. Install the

new

Torca clamps onto the end of the ex-

haust pipes.

d. Connect the front cylinder head exhaust pipe to the

rear cylinder head exhaust pipe. Push them together
until they bottom.

e. Install the bolt and locknut securing the rear portion

of the rear cylinder exhaust pipe to the mounting
bracket on the frame.

f. Install a

new

washer and gasket onto the cross over

pipe.

g. Install the cross over pipe to the rear cylinder ex-

haust pipe and push it on until it bottoms.

h. Install the screw and washer securing the cross over

clamp to the passenger footboard.

i. Move the open end of the exhaust pipes into posi-

tion to accept the mufflers.

4. To install the mufflers, perform the following:

a. Install the

new

Torca clamp onto the end of the ex-

haust pipe.

b. Move the muffler into position and attach it to the

exhaust pipe.

c. Install the bolts, lockwashers and washers securing

the muffler to the muffler support tube. Tighten the
bolts finger-tight.

d. Move the Torca clamps into position and tighten

finger-tight.

e. Repeat for the other muffler.

a. Front cylinder head flange nuts. Tighten the upper

nut to 9-18 in.-lbs. (1-2 N•m). Tighten the lower nut
to 120 in.-lbs. (14 N•m) then tighten the upper nut to
120 in.-lbs. (14 N•m).

FUEL, EXHAUST AND EMISSION CONTROL SYSTEMS

311

312

CHAPTER SEVEN

127

EXHAUST SYSTEM (FLSTC, FXST, FXSTS AND FXSTB MODELS)

1. Clamp (HDI models only)
2. Muffler (rear cylinder)
3. Washer
4. Screw
5. Interconnecting tube
6. Flange locknut
7. Washer
8. Spacer stud
9. Gasket

10. Heat shield
11. Clamp

12. Exhaust pipe (rear cylinder)
13. Heat shield
14. Muffler (front cylinder)
15. Gasket
16. Heat shield
17. Exhaust pipe (front cylinder)
18. Nut
19. Gasket
20. Circlip
21. Retaining ring

b. Rear cylinder head flange nuts. Tighten the upper

nut to 9-18 in.-lbs. (1-2 N•m). Tighten the lower nut
to 120 in.-lbs. (14 N•m) then tighten the upper nut to
120 in.-lbs. (14 N•m).

c. Tighten the bolts securing the mufflers to the sup-

port tube securely.

d. Tighten the screw securing the cross over pipe

clamp to the passenger footboard securely.

e. Tighten the bolts and locknut securing the rear por-

tion of the rear cylinder exhaust pipe to the mount-
ing brackets securely.

f. Tighten the Torca clamp securing the front cylinder

exhaust pipe to the rear cylinder exhaust pipe to
45-60 ft.-lbs. (61-81 N•m).

7. Open the heat shield clamps completely. Position the
clamp so the screw is on the outboard side in the most ac-
cessible position. Install the heat shields in the locations
marked during removal. Tighten the clamps securely.
8. Check all heat shields to make sure none are touching
the frame. If necessary, make slight adjustments to avoid
any contact that would transmit vibrations to the rider
through the frame.
9. Start the engine and check for leaks.
10. Install the footboards as described in Chapter Four-
teen.
11. Install both saddlebags as described in Chapter Four-
teen.

EXHAUST SYSTEM

(FXST, FLSTC, FXSTS AND FXSTB MODELS)

Removal

Refer to Figure 127.

NOTE

If the system joints are corroded or rusty,
spray all connections with WD-40, or an
equivalent, and allow the penetrating oil to
soak in sufficiently to free the rusted joints.

1. Support the motorcycle on a work stand. See

Motorcy-

cle Stands

in Chapter Nine.

2. On models so equipped, remove the footboards as de-
scribed in Chapter Fourteen.
3. On models so equipped, remove the saddlebags as de-
scribed in Chapter Fourteen.
4. Label the heat shields prior to removal for aid during
installation. They look very similar but all have slight dif-
ferences. Use the numbers assigned to these parts in Fig-
ure 127.
5. Loosen the clamps and remove the heat shields.

6. To remove the muffler assembly, perform the follow-
ing:

a. Remove the flange locknuts securing the intercon-

necting tube to the frame.

b. Loosen the clamps securing the mufflers to the ex-

haust pipes.

c. Pull the muffler assembly toward the rear and dis-

connect both mufflers from the front and rear ex-
haust pipes. Leave the mufflers attached to the
interconnect tube on both mufflers.

7. To remove the exhaust pipes, perform the following:

a. Remove the mufflers as described in Step 6.
b. Loosen the clamps and remove both heat shields.
c. At each cylinder head, loosen and remove the two

flange nuts securing both the front and rear exhaust
pipes to the cylinder heads.

d. Slide the exhaust flange and retaining ring off the

cylinder head studs.

e. Remove the exhaust pipes from the cylinder heads.
f. Remove the circlip, then remove the exhaust port

gaskets.

8. Inspect the exhaust system as described in this chapter.
9. Store the exhaust system components in a safe place
until they are reinstalled.

Installation

NOTE

To prevent exhaust leaks, do not tighten any
of the mounting bolts and nuts or the Torca
clamps until all exhaust components are in
place.

1. Scrape the exhaust port surfaces to remove all carbon
residue. Then wipe the port with a rag.
2. Install a

new

exhaust port gasket into each exhaust port

with the tapered side facing out. Install the circlips to se-
cure the gaskets.
3. To install the exhaust pipes, perform the following:

a. Install the front header pipe onto the front cylinder

head exhaust port. Install the flange nuts and tighten
them finger-tight.

b. Install the rear header pipe onto the rear cylinder

head exhaust port. Install the flange nuts and tighten
them finger-tight.

c. Move the open end of the exhaust pipes into posi-

tion to accept the muffler assembly.

d. Install the

new

clamps onto the end of the exhaust

pipes.

4. To install the muffler assembly, perform the following:

a. Move the muffler assembly into position and attach

them to the exhaust pipes.

FUEL, EXHAUST AND EMISSION CONTROL SYSTEMS

313

b. Install the flange locknuts securing the intercon-

necting tube to the frame and tighten them fin-
ger-tight.

c. Move the clamps into position and tighten fin-

ger-tight

6. Check the exhaust assembly alignment, then tighten
the mounting bolts and nuts as follows:

a. Front cylinder head flange nuts. Tighten the lower

nut to 10 in.-lbs. (1 N•m). Tighten the upper nut to
60-80 in.-lbs. (7-9 N•m), then tighten the lower nut
to 60-80 in.-lbs. (7-9 N•m).

b. Rear cylinder head flange nuts. Tighten the lower

nut to 10 in.-lbs. (1 N•m). Tighten the upper nut to
60-80 in.-lbs. (7-9 N•m), then tighten the lower nut
to 60-80 in.-lbs. (7-9 N•m).

c. Tighten the flange locknuts securing the intercon-

necting tube to the frame to 30-33 ft.-lbs. (41-45
N•m).

EXHAUST SYSTEM

Inspection (All Models)

1. Replace rusted or damaged exhaust system compo-
nents.
2. Inspect all pipes for rust or corrosion.
3. Remove all rust from exhaust pipes and muffler mating
surfaces.

314

CHAPTER SEVEN

128

EVAPORATIVE EMISSION CONTROL SYSTEM

(CALIFORNIA MODELS)

Backplate

Clean air
inlet hose

Carburetor or
fuel induction
module

Charcoal
canister

Vacuum hose

Vapor valve

Fuel tank

Fuel
valve

Vent hose

Purge hose

Trap door

4. The Torca clamps are not reusable.

5. Replace damaged exhaust pipe retaining rings.

6. Replace worn or damaged heat shield clamps as re-
quired.

7. Check the mounting bracket bolts and nuts for tight-
ness.

EVAPORATIVE EMISSION CONTROL SYSTEM

(CALIFORNIA MODELS)

The evaporative emission control system prevents gas-

oline vapor from escaping into the atmosphere.

When the engine is not running, the system directs the

fuel vapor from the fuel tank through the vapor valve and
into the charcoal canister. Also, when the engine is not
running, the gravity-operated trap door in the air filter
backplate blocks the inlet port of the air filter. This pre-
vents hydrocarbon vapors from the carburetor venturi, or
fuel injection induction module, from escaping into the at-
mosphere.

When the engine is running, these vapors are drawn

through a purge hose and into the carburetor, or fuel injec-
tion induction module, where they burn in the combustion
chambers. The vapor valve also prevents gasoline vapor
from escaping from the carbon canister if the motorcycle
falls onto its side.

Also, when the engine is running, the engine vacuum

pulls the air filter backplate trap door open, allowing air to
enter.

Charcoal Canister

Inspection

Refer to Figure 128 for component placement and hose

routing. Before removing the hoses from any of the parts,
mark the hose and fitting with a piece of masking tape to
identify them.

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

WARNING

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

2. Make sure there are no kinks in the lines or hoses. Also
inspect the hoses and lines routed near engine hot spots
for excessive wear or burning.
3. Check the physical condition of all lines and hoses in
the system. Check for cuts, tears or loose connections.
These lines and hoses are subjected to various tempera-
tures and operating conditions, and eventually become
brittle and crack. Replace damaged lines and hoses.
4. Check all components in the emission control system
for damage, such as broken fittings.

Replacement

1. Support the motorcycle on a work stand with the rear
wheel off the ground. See

Motorcycle Stands

in Chapter

Nine.
2. Remove the rear wheel as described in Chapter Nine.
3. Remove the bolts securing the rear fender panel and re-
move the panel.
4. On the left side of the canister, use a screwdriver and
lift up on the tang of the canister bracket on the frame.
5. On the left side of the canister, mark the two hoses (A,
Figure 129) and the canister fittings prior to disconnect-
ing the hoses from the fittings.
6. Slide the canister (B, Figure 129) to the left until it is
free from the bracket, then lower it from the frame.
7. On carbureted models, disconnect the breather hose
from the fitting on the right side of the canister.
8. Disconnect the hoses from the canister fittings and re-
move the canister.
9. Installation is the reverse of removal. Ensure that all
hoses are connected to the correct fittings and are secure.

Vapor Valve Replacement

The vapor valve is an integral part of the fuel pressure

relief system. The fuel tank vapor expands as the fuel tank
temperature rises. This pressure must be relived to avoid
excessive vapor buildup within the fuel tank.

FUEL, EXHAUST AND EMISSION CONTROL SYSTEMS

315

129

The lower hose is vented to the atmosphere or on Cali-

fornia models it is connected to the evaporation canister.

Refer to Figures 130-132.

1. Remove the rear wheel as described in Chapter Nine.

2. Label the upper hose and lower hose where they are
connected to the vapor valve fittings.

3. Disconnect the hoses from the vapor valve (Figure
133).

4. Remove the vapor valve from the clip on the mounting
bracket.

WARNING

The vapor valve must be mounted in the clip
in a

vertical position

in order to operate

316

CHAPTER SEVEN

130

131

132

VAPOR VALVE

(CALIFORNIA MODELS)

133

Vapor
valve

Vapor valve

To fuel tank

1. Upper hose
2. Vapor valve
3. Clamp
4. Lower hose
5. Screw
6. Mounting bracket

correctly. If installed incorrectly, excessive
pressure can build up in the fuel tank that
could result in a fire or an explosion result-
ing in serious injury.

5. Correctly position the vapor valve with the long neck
fitting at the top and install the vapor valve into the clip on
the mounting bracket.
6. Connect the upper and lower hoses to the vapor valve.

Table 1 CARBURETOR SPECIFICATIONS

Item

Specification

Main jet

190

Pilot jet

Float level

0.413-0.453 in. (10.5-11.5 mm)

Table 2 FUEL SYSTEM TORQUE SPECIFICATIONS

Item

ft.-lb.

in.-lb.

N•m

Air filter

Backplate screws

–

20-40

2-4

Cover screw

–

36-60

4-7

Breather hollow bolts

–

120-144

14-16

Fuel valve adapter (FXSTD)

22-26

30-35

Fuel shutoff valve hex fitting

15-20

–

20-27

Fuel tank mounting bolts (FXSTD)

Front

28-32

–

38-43

Rear

14-18

–

19-24

Fuel tank mounting bolts

(all models except FXSTD)

Front

28-32

–

38-43

Rear

18-22

–

24-30

Intake manifold bolts

–

97-141

11-16

Induction module bolts (EFI)

–

71-124

8-14

Table 3 EXHAUST SYSTEM TORQUE SPECIFICATIONS

Item

ft.-lb.

in.-lb.

N•m

Exhaust flange nuts

Refer to procedure in text.

Torca clamp nuts

45-60

–

61-81

FUEL, EXHAUST AND EMISSION CONTROL SYSTEMS

317

CHAPTER EIGHT

ELECTRICAL SYSTEM

This chapter contains service and test procedures for

the electrical and ignition system components. Spark plug
maintenance is in Chapter Three.

The electrical system includes the following systems:

1. Charging system.

2. Ignition system.

3. Starting system.

4. Lighting system.

5. Switches and other electrical components.

Refer to Tables 1-7 at the end of the chapter for specifica-

tions. 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 you cannot
determine the

exact

cause of any electrical system mal-

function, have a Harley-Davidson dealership retest that
specific system to verify your test results. If you purchase
a new electrical component(s), install it, and then find that
the system still does not work properly, you will probably
be unable to return the unit for a refund.

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
results dramatically. These include: the testing meter’s in-
ternal circuitry, ambient temperature and conditions under
which the machine has been operated. All instructions and
specifications have been checked for accuracy; however,
successful test results depend to a great degree upon indi-
vidual accuracy.

ELECTRICAL CONNECTORS

Many electrical problems can be traced to damaged

wiring, or contaminated or loose connectors.

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

the motorcycle has been serviced previously, the connec-
tor 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 Connector

Service

at the end of this chapter.

Always check the wire colors listed in the procedure or

wiring diagrams to verify the location of the components.

TE:

Ref

er t

o th

e S

upp

lem

ent

the

bac

k o

f th

is m

anu

al f

info

rma

tion

uni

que

to 2

004

-20

del

inc

lud

ing

Scr

eam

in’

Eag

le m

ode

ls.

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 dielectic grease to seal out moisture.
6. Disconnect electrical connectors in the suspect circuits
and check for bent or damaged terminals. The male and
female terminals must connect or an open circuit will re-
sult.
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 to-
gether 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

The battery is important to the motorcycle’s electrical sys-

tem, yet most electrical system problems can be traced to
battery neglect. Clean and inspect the battery at periodic in-
tervals. The original equipment battery is a maintenance-free
sealed battery and the electrolyte level cannot be checked.

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.

Negative Cable

Some of the component replacement procedures and

test procedures in this chapter require disconnecting the
negative battery cable as a safety precaution.

NOTE

Always disarm the optional TSSM security
system prior to disconnecting the battery or
the siren will sound.

1. Remove the seat as described in Chapter Fourteen.
2. Remove the bolt or nut (Figure 1) securing the nega-
tive cable to the frame. Move the cable away from the bat-
tery to avoid making accidental contact with the battery
post.
3. Connect the negative cable to the frame post. Reinstall
the nut and tighten it securely.
4. Install the seat.

Cable Service

To ensure good electrical contact between the battery

and the electrical cables, the cables must be clean and free
of corrosion.
1. If the electrical cable terminals are badly corroded, dis-
connect them from the motorcycle’s electrical system.
2. Thoroughly 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 motorcycle’s
electrical system if they were disconnected.
5. After connecting the electrical cables, apply a light
coat of dielectric grease to the terminals to retard corro-
sion and decomposition of the terminals.

Removal/Installation

NOTE

Always disarm the optional TSSM security
system prior to disconnecting the battery or
the siren will sound.

1. Remove the seat as described in Chapter Fourteen.
2. Remove the bolt or nut and disconnect the negative
battery cable (Figure 1).

ELECTRICAL SYSTEM

319

3. Remove the bolt and disconnect the positive battery
cable (A, Figure 2).
4. Carefully lift the battery (B, Figure 2) up and out of the
frame.
5. Inspect the battery tray and compartment (Figure 3)
for corrosion or damage. Replace it if necessary.
6. Position the battery with the negative cable terminal on
the right side of the frame.
7. Reinstall the battery onto the battery tray in the frame.
8. Install the battery, hold down and tighten the Torx bolt
securely.
9. Connect the positive battery cable (A, Figure 2).
Tighten the bolt securely.
10. Connect the negative battery cable (Figure 1).
Tighten the bolt securely.
11. After connecting the electrical cables, apply a light
coat of dielectric grease to the electrical terminals of the
battery to retard corrosion and decomposition of the ter-
minals.
12. Install the seat.

Inspection and Testing

The battery electrolyte level cannot be serviced in a

maintenance-free battery.

Never

attempt to remove the

sealing bar cap from the top of the battery. The battery
does not require periodic electrolyte inspection or water
refilling. Refer to the label (A, Figure 4) on top of the bat-
tery.

Even though the battery is sealed, protect eyes, skin and

clothing. The corrosive electrolyte may have spilled out
and can cause severe chemical skin burns and permanent
injury. The battery case may be cracked and leaking elec-
trolyte. If electrolyte is spilled or splashed on clothing or
skin, immediately neutralize it with a baking soda and wa-
ter solution, then flush with an abundance of clean water.

WARNING

Electrolyte is extremely harmful to the eyes.
Always wear safety glasses while working
with a battery. If electrolyte gets into the
eyes, call a physician immediately and force
the eyes open and flood them with cool,
clean water for approximately 15 minutes.

1. Remove the battery as described in this chapter. Do not
clean the battery while it is mounted in the frame.
2. Set the battery on a stack of newspapers or shop cloths
to protect the surface of the workbench.
3. Check the entire battery case (Figure 5) for cracks or
other damage. If the battery case is warped, discolored or
has a raised top, the battery has been overcharged and
overheated.

4. Check the battery terminal bolts, spacers and nuts (B,
Figure 4) for corrosion or damage. Clean parts thor-
oughly with a baking soda and water solution. Replace
corroded or damaged parts.

5. If the top of the battery is corroded, clean it with a stiff
bristle brush using the baking soda and water solution.

6. Check the battery cable ends for corrosion and dam-
age. If corrosion is minor, clean the battery cable ends
with a stiff wire brush. Replace worn or damaged cables.

7. Connect a digital voltmeter between the battery nega-
tive and positive leads. Note the following:

a. If the battery voltage is 13.0-13.2 volts (at 20° C

[68° F]) the battery is fully charged.

b. If the battery voltage is 12.0 to 12.5 volts (at 20° C

[68° F]), or lower, the battery is undercharged and
requires charging.

8. If the battery is undercharged, recharge it as described
in this chapter. Then test the charging system as described
in Chapter Two.

9. Inspect the battery case for contamination or damage.
Clean it with a baking soda and water solution.

10. Install the battery as described in this chapter.

320

CHAPTER EIGHT

Charging

Refer to

Battery Initialization

in this chapter if the bat-

tery is new.

To recharge a maintenance-free battery, a digital volt-

meter and a charger with an adjustable amperage output
are required. If this equipment is not available, have the
battery charged by a shop with the proper equipment. Ex-
cessive voltage and amperage from an unregulated
charger can damage the battery and shorten service life.

The battery should only self-discharge approximately

one percent of its given capacity each day. If a battery not
in use, without any loads connected, loses its charge
within a week after charging, the battery is defective.

If the motorcycle is not used for long periods of time, an

automatic battery charger with variable voltage and am-
perage outputs is recommended for optimum battery ser-
vice life.

WARNING

During charging, highly explosive hydrogen
gas is released from the battery. Only
charge the battery in a well-ventilated area
away from open flames, including pilot
lights on appliances. Do not allow smoking
in the area. Never check the charge of the

battery by arcing across the terminals; the
resulting spark can ignite the hydrogen gas.

CAUTION

Always disconnect the battery cables from
the battery. If the cables are left connected
during the charging procedure, the charger
may damage the diodes within the voltage
regulator/rectifier.

1. Remove the battery from the motorcycle as described
in this chapter.
2. Set the battery on a stack of newspapers or shop cloths
to protect the surface of the workbench.
3. Make sure the battery charger is turned off prior to at-
taching the charger leads to the battery.
4. Connect the positive charger lead to the positive bat-
tery terminal and the negative charger lead to the negative
battery terminal.
5. Set the charger at 12 volts. If the output of the charger
is variable, select the low setting.
6. The charging time depends on the discharged condi-
tion of the battery. Refer to Table 2 for the suggested
charging time. Normally, a battery should be charged at
1/10 its given capacity.

CAUTION

If the battery emits an excessive amount of
gas during the charging cycle, decrease the
charge rate. If the battery becomes hotter
than 110° F (43° C) during the charging cy-
cle, turn the charger off and allow the bat-
tery to cool. Then continue with a reduced
charging rate and continue to monitor the
battery temperature.

7. Turn the charger to the ON position.
8. After the battery has been charged for the predeter-
mined time, turn the charger off, disconnect the leads and
measure the battery voltage. Refer to the following:

a. If the battery voltage is 13.0-13.2 volts (at 20° C

[68° F]), the battery is fully charged.

b. If the battery voltage is 12.5 volts (at 20° C [68° F]),

or lower, the battery is undercharged and requires
additional charging time.

9. If the battery remains stable for one hour, the battery is
charged.
10. Install the battery into the motorcycle as described in
this chapter.

Battery Initialization

A new battery must be

fully

charged before installation.

To bring the battery to a full charge, give it an initial

ELECTRICAL SYSTEM

321

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