Instant Harley Manuals

HARLEY DAVIDSON SERVICE MANUALS 

FULL ACCESS SERVICE MANUALS BELOW

 

1

 

Sportster Models

Touring Models

Dyna Models


 

 

 


HARLEY DAVIDSON SERVICE & REPAIR MANUALS AVAILABLE FOR DOWNLOAD
 
 
TOURING MODELS
 
 
2001 Harley Davidson Touring H-D Service Manual & 2001 H-D Electrical Diagnostics Manual for Harley Models: FLHTCUI Ultra Classic Electra Glide (2001), FLHTC/I Electra Glide Classic (2001), FLHT  Electra Glide Standard (2001), FLTR/I Road Glide (2001), FLHRCI Road King Classic (2001), FLHR/I Road King (2001) and also contains the 2001 H-D FLT Police Model Service Manual Supplement and 2001 H-D FLTRSEI2 Service Manual Supplement.
 
2002 Harley Davidson Touring Service Manual & 2002 H-D Touring Electrical Diagnostic Manual for models: FLHTCUI Ultra Classic Electra Glide (2002), FLHTC/FLHTCI Electra Glide Classic (2002), FLHT Electra Glide Standard (2002), FLHTCUI Ultra Classic Electra Glide (2002), FLTR/I Road Glide (2002), FLHRCI Road King Classic (2002), FLHR Road King (2002), 2002 FLT Police Models Service Manual Supplement and 2002 FLTRSEI2 Model Service Manual Supplement.
 
2003 Harley Davidson Touring 2003 H-D Touring Service Manual, 2003 H-D Electrical Diagnostics Manual, 2003 H-D Police Model Service Manual Supplement and 2003 H-D FLHRSEI2 Service Manual Supplement for: 2003 Harley-Davidson FLHTCUI Ultra Classic- Electra Glide, 2003 Harley-Davidson FLHR/FLHRI Road King, 2003 Harley-Davidson FLHT Electra Glide -Standard, 2003 Harley-Davidson FLHRCI Road King -Classic, 2003 Harley-Davidson FLTR/FLTRI Road Glide, 2003 Harley-Davidson FLHTC/FLHTCI Electra Glide- Classic, 2003 FLHP, FLHTP and FLHRSEI2.
 
2004 Harley Touring Service Repair Manual & Electrical Diagnostics Manual For: 2004 H-D FLT Police Model, 2004 H-D FLHTCSE, FLHRS/I Road King Custom (2004), FLHTCUI Ultra Classic Electra Glide (2004), FLHTC/I Electra Glide Classic (2004), FLHT/I  Electra Glide Standard (2004), FLTRI Road Glide (2004), FLHRCI Road King Classic (2004), FLHR/I Road King (2004).
 
2005 Harley Davidson Touring  Service Repair Manual & Electrical Diagnostics Manual For: FLHRS/FLHRSI Road King Custom (2005) FLHTCUI Ultra Classic Electra Glide (2005), FLHTC/FLHTCI Electra Glide Classic (2005), FLHT/FLHTI  Electra Glide Standard (2005), FLHTCUI Ultra Classic Electra Glide (2005), FLTRI Road Glide (2005), FLHRCI Road King Classic (2005), FLHR/FLHRI Road King (2005), 2005 H-D Touring Electrical Diagnostic Manual (800+ pages), 2005 FLT Police Models Service Manual Supplement and 2005 FLHTCSE 2 Model Service Manual Supplement.
 
2006 Harley Davidson Touring Motorcycle Service Manual for:  2006 FLHX Street Glide,  2006 FLHT Electra Glide Standard, 2006 FLHTC Electra Glide Classic, 2006 FLHTCU Electra Glide Ultra Classic, 2006 FLTR Road 2006 Glide, FLTRI Road Glide.
 
2007 Harley Davidson Touring Service Repair Manual & Electrical Diagnostics Manual For: (2007) FLHT Electra Glide Standard (2007), FLHR Road King (2007), FLHTC Electra Glide Classic (2007), FLHRS Road King Custom (2007), FLHTCU  Ultra Classic Electra Glide (2007), FLHRC  Road King Classic (2007), FLTR Road Glide (2007), FLHX Street Glide (2007).
 
2008 Harley Davidson Touring Motorcycle Factory Service Manual for: FLHT Electra Glide Standard, FLHR Road King, FLHTC Electra Glide Classic, FLHRC Road King Classic, FLHTCU Ultra Classic Electra Glide, FLHTCU ANV 105th Anniversary Ultra Classic Electra Glide, FLHRC ANV 105th Anniversary Road King Classic, FLTR Road Glide, FLHX Street Glide, 2008 FLT Police Models Service Manual Supplement, 2008 FLHTCUSE 3 Model Service Manual Supplement.
 
2009 Harley Davidson Touring Motorcycle Factory Service Manual for: 2009 FLHT Electra Glide, 2009 FLHTC/U Ultra Classic*Electra Glide with Side Car, 09 FLTR Road Glide, 09 FLHX Street Glide, 09 FLHR Road King Shrine, FLHRC Road King classic, FLHTC Electra Glide Classic.
 
SPORTSTER MODELS
 
1986-2003 Harley Davidson Sportster Motorcycle Service Reapir Manual for: XL & XLH models, including XLH883, XL883R, XLH1100, XL1200, XLH1200 (883/1100/1200), Custom, Sportster Deluxe, Hugger, Custom and Sport model years 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002 and 2003.
 
2005 H-D Sportster XL Service Manual & 2005 H-D Sportster XL Electrical Diagnostics Manual for: 2005 Harley-Davidson XL 1200C Sportster 1200 Custom, 2005 Harley-Davidson XL 1200R Sportster 1200 Roadster, 2005 Harley-Davidson XL 883C Sportster 883 Custom, 2005 Harley-Davidson XL 883 Sportster 883, 2005 Harley-Davidson XL Sportster 883L, 2005 Harley-Davidson XL883R Sportster (XL883, XL883L, 883R, XL883C, XL1200C, XL1200R, XL1200).
 
2006 Harley-Davidson Sportster Motorcycle Factory Service Manual for: 2006 XL 883 Sportster, 2006 XL883, 2006 XL 883L 883 Low, 2006 XL 883C Sportster 883C Custom , XL 883R Sportster 883R, XL 1200C Sportster 1200 Custom, XL 1200R Sportster 1200 Roadster, XL 1200L Sportster 1200 Low.
 
2007 H-D Sportster XL Service Manual & 2007 Harley Davidson Electrical Diagnostics Manual for Harley Models: 2007 XL SPORTSTER 883 (XL883), 2007 XL SPORTSTER 883L (883-L), 2007 XL SPORTSTER 883R (883-R), 2007 XL SPORTSTER 1200L (1200-L), 2007 XL SPORTSTER 1200 N (1200N), 2007 XL SPORTSTER 1200 R (1200R), 2007 XL SPORTSTER 883C/XL 1200C, 2007 XL SPORTSTER 50 motorcycles.
 
2008 Harley Davidson Sportster Motorcycle Factory Service Manual for: 2008 XL 883 Sportster, 2008 XL 883C Sportster, 2008 XL 883L Sportster, XL 1200L Sportster, XL 1200R Sportster, XL 1200N Sportster, Harley Davidson XL 1200C Sportster, XL 1200C Sportster Custom 105th Anniversary Edition. 08 Harley Custom, 08 Harley Nightster, 08 Roadster, Sportster Low.
2009 Harley Davidson Sportster XL-XR 883-1200 Service Manual Application: H-D (HD) Harley-Davidson XL883 Sportster 883, 2009 Harley-Davidson XL XL883C Sportster 883 C Custom, 2009 Harley-Davidson XL883L Sportster 883 Low, 2009 Harley-Davidson XL883R Sportster 883R, 2009 Harley-Davidson XL1200C Sportster 1200 Custom, 2009 Harley-Davidson XL1200R Sportster 1200 Roadster, 09 H-D XL1200L Sportster 1200 Low, 09 H-D Harley-Davidson XL1200N Sportster 1200 Nightster, 09 HD XR1200 Sportster 1200, 2009 Harley-Davidson XL883N Sportster 883N.
 
DYNA MODELS
 
2001 Dyna Service manual, Diagnostics manual & Supplement manual application: 2001 "01" Harley Davidson, Dyna Wide Glide (FXDWG), 2001 "01" HD Dyna Super Glide (FXD), 2001 "01" H-D Dyna Super Glide Sport (FXDX), 2001 "01" H-D Dyna Low Rider (FXDL), 2001 "01" H-D CONV (FXDS), 2001 "01" H-D Dyna Super Glide T-Sport (FXDXT) & FXDP Police model motorcycles.
 
2002 Dyna Service manual, Diagnostics manual & Supplement manual application: 2002 "02" Harley Davidson, Dyna Wide Glide (FXDWG), 2002 "02" HD Dyna Super Glide (FXD), 2002 "02" H-D Dyna Super Glide Sport (FXDX), 2002 "02" H-D Dyna Low Rider (FXDL), 2002 "02" H-D CONV (FXDS), 2002 "02" H-D Dyna Super Glide T-Sport (FXDXT) & 2002 "02" FXDP Police model motorcycles.
 
2004 Harley Service manual, Diagnostics manual & Supplement manual application: 2004 "04" Harley Davidson, 2004 Harley-Davidson Dyna Super Glide Wide Glide FXDWG/FXDWG, 2004 Harley-Davidson Dyna Super Glide Low Rider FXDL, 2004 Harley-Davidson Dyna Glide Super Glide Custom FXDC, 2004 Harley-Davidson Dyna Super Glide Sport FXDX, 2004 Harley-Davidson Dyna Glide Super Glide FXD/FXDI model motorcycles.
 
2006 Harley Dyna FXD Service Repair Manual & 2006 Dyna FXD Electrical Diagnostics Manual For: 2006 Harley-Davidson FXD/I Dyna Super Glide, 2006 Harley-Davidson FXDCI Dyna Super Glide Custom, 2006 Harley-Davidson FXDI35 Dyna 35th Anniversary Super Glide, 2006 Harley-Davidson FXDBI Dyna Street Bob, 2006 Harley-Davidson FXDLI Dyna Low Rider, 2006 Harley-Davidson FXDWGI Dyna Wide Glide.
 
2007 Harley-Davidson Dyna Motorcycle Factory Service Manual for: FXD Dyna Super Glide, FXDB Dyna Street Bob, FXDL Dyna Low Rider, 2007 Harley-Davidson FXDC Dyna Super Glide Custom, 2007 H-D FXDWG Dyna Wide Glide, 2007 H-D Dyna FXDSE Screamin' Eagle Dyna Service Supplement Motorcycles.
 
2008 Harley Davidson Dyna FXD motorcycle service manual are: FXDWG ANV 105th Anniversary Dyna Wide Glide (2008), FXDF Dyna Fat Bob (2008), FXD Dyna Super Glide (2008), FXDB Dyna Street Bob (2008), FXDC Dyna Super Glide Custom (2008), FXDL Dyna Low Rider (2008), FXDC ANV 105th Anniversary Dyna Super Glide Custom ( 2008).
2009 Harley Davidson Dyna FXD motorcycle service manual & diagnostic manual application: 2009 (09) H-D (HD) Harley-Davidson FXD Dyna Super Glide (Dyna), 2009 Harley-Davidson FXDC Dyna Super Glide Custom (Dyna), 2009 Harley-Davidson FXDL Dyna Low Rider (Dyna), 2009 Harley-Davidson FXDB Street Bob (Dyna), 2009 Harley-Davidson FXDF Fat Bob (Dyna), 2009 Harley-Davidson FXDFSE Custom Vehicle Operations Dyna Fat Bob
 
SOFTAIL MODELS
  

1985-1990 Softail Service Manual Application: 1985, 1986, 1987, 1988, 1989, 1990 Harley Davidson (H-D, HD) FXSB (Low Rider, LowRider), FXEF (Fat Bob, FatBob) , FXWG (Wide Glide), FXST (Softail Stardard), FXSTC (Softail Custom), FLST (Heritage Softail) , FXSTS (Softail Springer), FLSTC (Heritage Softail Classic), FLSTF (Fat Boy), 85, 86, 87, 88, 89, 90 H-D motorcycle models.

1991-1992 H-D Harley Davidson Softail Service Manual Application: FLSTC (Heritage Softail Classic), FLSTF (Fat Boy), FXSTC (Softail Custom ), FXSTS (Softail Springer).

2001 Service Repair Manual Applictation: This Softail Service Manual covers all 2001 Harley-Davidson FLSTS Heritage Springer, 2001 Harley-Davidson FXSTS Springer Softail, 2001 Harley-Davidson FLSTC Heritage Softail Classic, 2001 Harley-Davidson FLSTF Fat Boy, 2001 Harley-Davidson FXSTB Night, 2001 Harley-Davidson FXST Softail Standard, 2001 Harley-Davidson FXSTD Softail Deuce Motorcycles.

2002 Softail Service manual & Diagnostics manual application: 2002 "02" H-D (HD) Harley-Davidson FXST/FXSTI Softail Standard, 2002 Harley-Davidson FXSTB/FXSTBI Night Train, 2002 Harley-Davidson FXSTS/FXSTSI Springer Softail, 2002 Harley-Davidson FLSTF/FLSTFI Fat Boy, 2002 Harley-Davidson FXSTD/FXSTDI Softail Deuce, 02 Harley-Davidson FLSTS/FLSTSI Heritage Springer, 02 Harley-Davidson FLSTC/FLSTCI Heritage Softail Classic model motorcycles.

2004 Softail Service Manual, Supplement Manual & Diagnostics Manual application: - 2004 H-D (HD) Heritage Softail Classic FLSTC/FLSTCIM, 2004 Harley-Davidson Softail Springer Classic FLSTSC, 2004 Harley-Davidson Softail Deluxe FLSTN/FLSTNI, 2004 Harley-Davidson Softail Fat Boy FLSTF/FLSTFI, 2004 Harley-Davidson Softail Deuce FXSTD/FXSTDI, 2004 Harley-Davidson Softail Springer Softail FXSTS, 2004 Harley-Davidson Softail Night Train FXSTB, 2004 Harley-Davidson Softail Standard FXST, 2004 Harley-Davidson FLSTFI Fat Boy, 2004 Harley Davidson Softail FLSTDSE2 model motorcycles.

2005 Softail Service Manual, Supplement Manual & Diagnostics Manual application: - 20005 H-D (HD) Heritage Softail Classic FLSTC 2005 Harley-Davidson Softail Springer Classic FLSTSC, 2005 Harley-Davidson Softail Deluxe FLSTN/FLSTNI, 2005 Harley-Davidson Softail Fat Boy FLSTF/FLSTFI, 2005 Harley-Davidson Softail Deuce FXSTD/FXSTDI, 2005 Harley-Davidson Softail Springer Softail FXSTS, 2005 Harley-Davidson Softail Night Train FXSTB, 2005 Harley-Davidson Softail Standard FXST, 2005 Harley-Davidson FLSTFI Fat Boy, 2005 Harley Davidson Softail FLSTFSE model motorcycles.

2006 Softail Service Manual Application: 2006 (06) FLSTSC Softail Springer Classic, 2006 (06) FXSTS Springer Softail, 2006 (06) FXSTD Softail Deuce, 2006 (06) FLSTN Softail Deluxe , 2006 (06) FLSTC Heritage Softail Classic , 2006 (06) FLSTF H-D Fat Boy , 2006 (06) FXSTB Softail Night Train , 2006 (06) FXST Softail Standard & 2006 (06)FLST Heritage Softail motorcycle including both EFI & Carburetor models.

2007 Harley Davidson Softail Motorcycle Service Manual for : 2007 FLSTSC Softail Springer Classic, 2007 FLSTF Fat Boy, 2007 FLSTN Softail Deluxe, 2007 FXST Softail Standard, 2007 FXSTB Night Train, 2007 FXSTC Softail Custom & 2007 FXSTD Softail Deuce.
 
2008 Harley Davidson Softail Motorcycle Factory Service Manual & 2008 H-D Softail Electrical Diagnostics Manual for: 2008 Softail FXCW Rocker, 2008 Softail FXCWC Rocker C, 2008 Softail FLSTC Heritage Classic, 08 Sfotail FLSTC ANV 105th Anniversary Heritage Classic, 08 Softail FLSTF Fat Boy, 2008 Softail FLSTSB Cross Bones, 08 Softail FLSTN Deluxe,  08 FXSTB Night Train, 08 FXSTC Custom, 08 FXSTC ANV 105th Anniversary Custom.

1.1 Starter Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

 

 

2.2 Initial Diagnostic Check: Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2.3 Speedometer Self Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2.4 Speedometer/Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

2.5 Breakout Box: Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

2.6 Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

2.7 Oil, Air and Voltmeter Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

2.8 Indicator Lamps: FLTR, FLHT/C/U . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

2.9 Indicator Lamps: FLHR/C/S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

2.10 DTC B1004, B1005 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

2.11 DTC B1006, B1007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

2.12 DTC B1008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

2.13 DTC U1016 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

2.14 DTC U1064, U1255 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

2.15 DTC U1300, U1301 or "BUS Er" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48

GENERAL

 

 

 

 

The troubleshooting tables beginning on page 1-1 contain

detailed procedures to solve and correct problems. Follow the

1.2 STARTING SYSTEM DIAGNOSIS diagram to diagnose

starting system problems. The VOLTAGE DROPS procedure

below will help you to locate poor connections or components

with excessive voltage drops.

 

 

 

VOLTAGE DROPS

 

 

Check the integrity of all wiring, switches, circuit breakers and

connectors between the source and destination.

The voltage drop test measures the difference in potential or the

actual voltage dropped between the source and destination.

1. See ITEM A in Figure 1-1. Attach your red meter lead to

the most positive part of the circuit, which in this case

would be the positive post of the battery.

2. See ITEM B in Figure 1-1. Attach the black meter lead to

the final destination or component in the circuit (solenoid

terminal from relay).

3. Activate the starter and observe the meter reading. The

meter will read the voltage dropped or the difference in

potential between the source and destination.

4. An ideal circuit’s voltage drop would be 0 volts or no voltage

dropped, meaning no difference in potential.

5. See ITEM C in Figure 1-1. An open circuit should read

12 volts, displaying all the voltage dropped, and the

entire difference in potential displayed on the meter.

 

NOTE

Open circuits on the ground side will read zero.

 

 

 

 

 

CHECK ENGINE LAMP

To diagnose electronic control module (ECM) or ignition control

module (ICM) system problems, start by observing the

behavior of the check engine lamp.

 

 

 

NOTES

 

 

 

See Figure 2-2. “Key ON” means that the ignition key is

turned to ON and the engine stop switch is set to RUN

(although the engine is

not

running).

When the ignition switch is turned ON, the check engine

lamp will illuminate for approximately four seconds and

then turn off.

If the check engine lamp is not illuminated at Key ON.

See 2.2 INITIAL DIAGNOSTIC CHECK: SPEEDOMETER.

If the check engine lamp comes on late (after 20 seconds).

See 2.2 INITIAL DIAGNOSTIC CHECK: SPEEDOMETER.

If the check engine lamp fails to turn OFF after the initial

four second period. See 2.2 INITIAL DIAGNOSTIC

CHECK: SPEEDOMETER.

1. See Figure 2-3. After lamp turns off after being illuminated

for the first four second period, one of three situations

may occur.

a. The lamp remains off. This indicates there are no

current fault conditions or stored diagnostic trouble

codes (DTC) currently detected by the ignition control

module (ICM) or electronic control module

(ECM).

b. The lamp stays off for only four seconds and then

comes back on for an eight second period. This indicates

an diagnostic trouble code is stored, but no

current diagnostic trouble code exists.

c. If the lamp remains on beyond the eight second

period, then a current diagnostic trouble code exists.

2. See CODE TYPES which follows for a complete description

of diagnostic trouble code formats.

 

 

 

 

 

 

 

 

 

 

SYSTEM PROBLEMS

All system problems fall into at least one of three general categories.

No Start

The engine cranks over freely, but will not start. This does not

include situations where the engine will not crank, such as a

bad starter, dead battery, etc. This condition assumes that all

obvious checks (fuel in tank, etc.) have been made.

 

Poor Performance

The engine starts but there are performance problems. These

problems may include poor fuel economy, rough idle, engine

misfire, engine hesitation, severe spark knock, etc.

Check Engine Lamp

See Figure 4-2. The check engine lamp indicates the ignition

control module (ICM) has determined a fault condition exists.

There may also be starting or performance problems.

RESOLVING PROBLEMS

To resolve system problems, five basic steps are involved. In

order of occurrence, they are:

1. Check for diagnostic trouble codes (DTCs) by observing

check engine lamp. See 4.3 CHECKING FOR TROUBLE

CODES.

2. Retrieve DTCs using speedometer self diagnostics. See

4.5 SPEEDOMETER SELF DIAGNOSTICS.

3. Diagnose system problems. This involves using special

tools and the diagnostic flow charts in this section.

4. Correct problems through the replacement and/or repair

of the affected components.

5. After repairs are performed, the work must be validated.

This involves clearing the DTCs and confirming proper

vehicle operation as indicated by the behavior of the

check engine lamp.

 

 

1.1 Starter Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

 

1.2 Starting System Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.3 Starter Activation Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

1.4 Diagnostics/Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1.5 Starter System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

1.6 Testing Assembled Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

1.7 Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

1.8 Battery Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

2.1 Checking For Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1