Harley Davidson Softail 2000-2005. Service manual

charge. Using a new battery without an initial charge will
cause permanent battery damage. The battery will never
be able to hold more than an 80% charge. Charging a new
battery after it has been used will not bring its charge to
100%. When purchasing a new battery, verify its charge
status.

NOTE

Recycle the old battery

. When a new battery

is purchased, turn in the old one for recy-
cling. Most motorcycle dealerships will ac-
cept the old battery in trade for a new one.
Never place an old battery in the household
trash since it is illegal, in most states, to
place any acid or lead (heavy metal) con-
tents in landfills.

Load Testing

A load test checks the battery’s performance under full

current load and is the best indication of battery condition.

A battery load tester is required for this procedure.

When using a load tester, follow the manufacturer’s in-
structions. Figure 6 shows a typical load tester and bat-
tery arrangement.
1. Remove the battery from the motorcycle as described
in this chapter.

NOTE

Let the battery stand for at least one hour af-
ter charging prior to performing this test.

2. The battery must be fully charged before beginning
this test. If necessary, charge the battery as described in
this section.

WARNING

The battery load tester must be turned OFF
prior to connecting or disconnecting the test
cables to the battery. Otherwise, a spark
could cause the battery to explode.

CAUTION

To prevent battery damage during load test-
ing, do not load test a discharged battery
and do not load test the battery for more
than 20 seconds. Performing a load test on a
discharged battery can cause permanent
battery damage.

3. Load test the battery as follows:

a. Connect the load tester cables to the battery follow-

ing its manufacturer’s instructions.

b. Load the battery at 50% of the cold cranking amper-

age (CCA) or 135 amperes.

c. After 15 seconds, the voltage reading with the load

still applied must be 9.6 volts or higher at 70° F (21°
C). Now quickly remove the load and turn the tester
OFF.

4. If the voltage reading was 9.6 volts or higher, the bat-
tery output capacity is good. If the reading was below 9.6
volts, the battery is defective.

5. With the tester OFF, disconnect the cables from the
battery.

6. Install the battery as described in this chapter.

CHARGING SYSTEM

Refer to Figures 7-10. The charging system consists of

the battery, alternator and a voltage regulator/rectifier. Al-
ternating current generated by the alternator is rectified to
direct current. The voltage regulator maintains the voltage
to the battery and additional electrical loads, such as the
lights and ignition system, at a constant voltage regardless
of variations in engine speed and load.

A malfunction in the charging system generally causes

the battery to remain undercharged. To prevent damage to
the alternator and the regulator/rectifier when testing and
repairing the charging system, note the following precau-
tions:

NOTE

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

1. Always disconnect the negative battery cable, as de-
scribed in this chapter, before removing a component
from the charging system.

2. To charge the battery, remove the battery from the mo-
torcycle and recharge it as described in this chapter.

322

CHAPTER EIGHT

LOAD TEST

Load
tester

Battery

ELECTRICAL SYSTEM

323

- +

Alternator

Diagram key

Connectors

Ground

Frame ground

Connection

No connection

Color code

Black

Circuit

breaker

Starter

Battery

Voltage

regulator

CHARGING SYSTEM 2000 MODELS

- +

Alternator

Diagram key

Connectors

Ground

Frame ground

Connection

No connection

Color code

Black
Red
Green

B
R
G

starter

relay

Circuit

breaker

Starter

solenoid/

Motor

Battery

Voltage

regulator

CHARGING SYSTEM (2001-ON MODELS)

3. Inspect the battery case (Figure 5). Look for bulges or
cracks in the case, leaking electrolyte or corrosion
build-up.

4. Check the charging system wiring for signs of chafing,
deterioration or other damage.

5. Check the wiring for corroded or loose connections.
Clean, tighten or reconnect wiring as required.

Battery Current Draw Test

This test measures the current draw or drain on the bat-

tery when all electrical systems and accessories are off.
Perform this test if the battery will not hold a charge when
the motorcycle is not being used. A current draw that ex-
ceeds 5.5 mA will discharge the battery. The ECM (1
mA), voltage regulator (0.5 mA), TSM (0.5 mA), TSSM

disarmed (0.5 mA) and TSSM armed (3.0 mA) account
for a 5.0 mA current draw. The battery must be fully
charged to perform this test.

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

2. Connect an ammeter between the negative battery termi-
nal and the battery ground cable as shown in Figure 11.

3. With the ignition switch, lights and all accessories turned
off, read the ammeter. If the current drain exceeds 5.5 mA,
continue with Step 4.

4. Refer to the wiring diagrams at the end of the manual for
the necessary model. Check the charging system wires and
connectors for shorts or other damage.

5. Unplug each electrical connector separately and check
for a reduction in the current draw. If the meter reading
changes after a connector is disconnected, the source of the

324

CHAPTER EIGHT

CHARGING SYSTEM COMPONENTS (2000 MODELS)

1. Stator
2. Torx bolt
3. Rotor
4. Mounting bracket
5. Ground wire
6. Screw
7. Washer
8. Screw
9. Washer

10. Locknut
11. Voltage regulator
12. Cable seal
13. Pin terminal
14. Pin housing
15. Pin terminal lock
16. Socket terminal lock
17. Socket housing

current draw has been found. Check the electrical connectors
carefully before testing the individual component.
6. After completing the test, disconnect the ammeter and re-
connect the negative battery cable.

Testing

A malfunction in the charging system generally causes

the battery to remain undercharged. Perform the follow-
ing visual inspection to determine the cause of the prob-
lem. If the visual inspection proves satisfactory, test the
charging system as described under

Charging System

Chapter Two.
1. Make sure the battery cables are connected properly
(Figure 12). If polarity is reversed, check for a damaged
voltage regulator/rectifier.
2. Inspect the terminals for loose or corroded connec-
tions. Tighten or clean them as required.
3. Inspect the battery case. Look for bulges or cracks in
the case, leaking electrolyte or corrosion buildup.
4. Carefully check all connections at the alternator to
make sure they are clean and tight.
5. Check the circuit wiring for corroded or loose connec-
tions. Clean, tighten or connect wiring as required.

ALTERNATOR

Rotor Removal/Installation

NOTE

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

1. Disconnect the negative battery cable as described in
this chapter.
2. Remove the primary chain case cover and housing as
described in Chapter Five.

ELECTRICAL SYSTEM

325

CHARGING SYSTEM

COMPONENTS

(2001-ON MODELS)

1. Stator
2. Torx bolt
3. Rotor
4. Terminal socket
5. Wiring harness
6. Anchor connector

Ammeter

Battery
ground
cable

7. Mounting bracket
8. Screw
9. Retainer

10. Ground wire
11. Voltage regulator
12. Screw

3. Remove the primary chain, clutch assembly, chain
tensioner assembly and compensating sprocket compo-
nents as an assembly. Refer to Chapter Five.
4. If still in place, remove the shaft extension and washer
from the crankshaft.

CAUTION

The holes in the rotor face are not threaded.
Push the bolts in just enough to grasp the
sides of the rotor holes. Do not push the
bolts in too far as they will contact the stator
coils and damage them.

5. Insert two bolts into the rotor face (Figure 13), then
push outward to press the threads against the holes. Slide
the rotor off the crankshaft.
6. Inspect the rotor magnets (Figure 14) for small bolts,
washers or other metal debris that may be attached the
magnets. Any debris will cause severe damage to the al-
ternator stator assembly.
7. Check the inner splines (Figure 15) for wear or dam-
age. Replace the rotor if necessary.
8. Install by reversing these removal steps. Align the ro-
tor splines with the crankshaft splines and push the rotor
on until it bottoms.

Stator Removal

1. Remove the rotor as described in this chapter.
2. Unplug the alternator rotor electrical connector (Fig-
ure 16) from the voltage regulator.
3. Insert a small screwdriver between the socket housing
side of connector going to the alternator stator and the
locking wedge on the socket housing. Gently pivot the
screwdriver tip and pop the wedge loose.
4. Lift the terminal latches inside the socket housing and
back the sockets through the wire end of connector.
5. Remove the three Torx screws (A, Figure 17) securing
the stator assembly to the crankcase. New Torx screws
must be used on installation.

NOTE

necessary,

spray

electrical

contact

cleaner or glass cleaner around the wiring
harness grommet to help ease it out of the
crankcase boss receptacle.

6. Use an awl to carefully lift the capped lip on the grommet
(Figure 18) from the crankcase and push it into the bore.
7. Carefully push the stator wires and grommet (B, Fig-
ure 17) through the crankcase bore and remove the stator
assembly.

326

CHAPTER EIGHT

8. Inspect the stator mounting surface on the crankcase for
oil residue from a damaged oil seal. Clean it off if necessary.
9. Inspect the stator wires (A, Figure 19, typical) for
fraying or damage.
10. Inspect the rubber grommet (B, Figure 19) for deteri-
oration or hardness.
11. Check the stator connector pins (Figure 20, typical)
for looseness or damage.

Stator Installation

1. Apply a light coat of electrical contact cleaner or glass
cleaner to the wiring harness grommet to help ease it into
the crankcase boss receptacle.
2. Insert the electrical harness and grommet into the
crankcase boss receptacle and carefully pull it through un-
til the grommet is correctly seated.

CAUTION

New Torx screws must be installed. The
threadlocking compound originally applied
to the Torx screws is for one time use only. If
a used Torx screw is installed, it can work
loose and cause engine damage.

3. Move the stator into position on the crankcase and in-
stall four

new

Torx screws (A, Figure 17). Tighten the

screws to the specification in Table 5.
4. Move the wires to the right side of the motorcycle.
5. Apply a light coat of dielectric compound to the electri-
cal connector prior to assembling it. Reassemble the elec-
trical connector socket by reversing Steps 4 and 5 of

Stator

Removal

. Make sure it has locked together securely.

6. Install the rotor as described in this chapter.

VOLTAGE REGULATOR

Removal/Installation

Refer to Figure 9 and Figure 10.

1. Disconnect the negative battery cable as described in
this chapter.
2. Remove the rear fender inner panel as described in
Chapter Fourteen.
3. Disconnect the voltage regulator lead (Figure 21)
from the silver post on the main circuit breaker.

NOTE

Prior to removing the voltage regulator
wires, note the routing of the wires through
the frame. Note the location of cable straps
and tie wraps. The wires must be rerouted in
the same path.

ELECTRICAL SYSTEM

327

After disconnecting any straps, leave them in place on

the frame as a reference for installation of the wiring.

4. Disconnect the voltage regulator electrical connector
from the alternator stator (Figure 16).

5A. On 2000 models, perform the following:

a. Remove the two nuts and washers securing the volt-

age regulator to the mounting bracket.

b. Remove the screw and disconnect the ground strap

from the backside of the voltage regulator. Do

not

disconnect it from the mounting bracket.

5B. On 2001-on models, perform the following:

a. Remove the two bolts securing the voltage regulator

(A, Figure 22) to the mounting bracket.

b. Remove the screw and disconnect the ground strap

(B, Figure 22) from the mounting bracket.

6. Unhook the wire retainer from the mounting bracket.

7. Remove the voltage regulator (A, Figure 22) and re-
lated wiring from the frame.

8. Install by reversing these removal steps. Note the fol-
lowing:

328

CHAPTER EIGHT

ENGINE SENSORS

1. Screw
2. Clamp
3. MAP sensor
4. Seal
5. Engine temperature sensor (ET)

(2001-on fuel injected models)

6. O-ring
7. Crankshaft position sensor (CKP)

(2001-on)

8. Screw
9. Screw*

10. Washer*
11. Camshaft position sensor (CMP)*
12. O-ring*
13. Clamp
14. Screw
15. Oil pressure switch
16. Anchor connector
17. Anchor connector

*Camshaft position sensor on 2000

models only

a. Secure the ground strap to the voltage regulator (2000

models) or mounting bracket (2001-on models).

b. Tighten the mounting nut or bolts securely.

c. Apply a light coat of dielectric compound to the

electrical connectors prior to installing them.

d. Install new cable straps and tie wraps securing elec-

trical wires to the frame.

IGNITION SYSTEM

The ignition system consists of an ignition coil, two spark

plugs, the ignition module (carburetted models), electronic
control module (EFI models), crankshaft position sensor
(CKP) (2001-on models), manifold absolute pressure sensor
(MAP), camshaft position sensor (CMP) (2000 models
only) and the bank angle sensor (BAS). Refer to Figure 23
for the locations of the majority of the sensors.

The ignition module (carbureted models) or electronic

control module (EFI models) is located behind the frame
right side panel. It determines the spark advance for cor-
rect ignition timing based on signals from the CKP, MAP,
BAS and CMP. The ignition system fires the spark plugs
near top dead center for starting, then varies the spark ad-
vance from 0

to 50

depending on engine speed, crank-

shaft position and intake manifold pressure. It also
regulates the low-voltage circuits between the battery and
the ignition coil. The ignition module is not repairable and
must be replaced if defective.

The MAP sensor is located on top of the intake mani-

fold or throttle housing (Figure 24). This sensor monitors
the intake manifold vacuum and sends this information to
the ignition module (carbureted models) or electronic
control module (EFI models). The module adjusts the ig-
nition timing advance curve for maximum performance.

The rotor and camshaft position sensor (CMP) is lo-

cated in the camshaft cover on the right side of the crank-
case. The raised ridge on the rotor operates at one-half
crankshaft speed and it breaks the magnetic field of the
Hall-effect device on the camshaft position sensor. The
logic-type signal of the Hall-effect device gives accurate
timing information to the ignition module.

The bank angle sensor mounts on a frame-mounted

panel behind the rear fender inner fender on 2000 mod-
els. On 2001-on models, the bank angle sensor is an inte-
gral part of the turn signal/turn signal security module
(TSM/TSSM) and is also mounted on a frame-mounted
panel behind the rear fender inner fender. The sensor
consists of a small magnetic disc that rides within a
V-shaped channel. If the motorcycle is tilted at a 45

an-

gle, for more than one second, the ignition system is shut
off. Once the sensor is activated, the motorcycle must be
up-righted and the ignition turned OFF then ON. Then,
the ignition system is operational and the engine can be
restarted.

The basic components of a typical ignition system are

shown in Figure 25 for carbureted models or Figure 26

ELECTRICAL SYSTEM

329

IGNITION SYSTEM

COMPONENTS

(CARBURETED MODELS)

1. Ignition module
2. Washer
3. Allen screw
4. Pad
5. Cover (FXSTB)
6. Screw
7. Cover

(all models except FXSTB)

8. Ignition coil
9. Bolt

10. Spark plug cable (rear cylinder)
11. Spark plug
12. Spark plug cable (front cylinder)

for EFI models. When servicing the ignition system, refer
to the wiring diagrams located at the end of the manual.

Ignition Coil

Performance test

1. Disconnect the plug wire and remove one of the spark
plugs as described in Chapter Three.

NOTE

A spark tester is useful for testing the igni-
tion system spark output.

Figure 27

shows

the Motion Pro Ignition System Tester (part
No. 08-0122). This tool is inserted in the spark

plug cap and its base is grounded against the
cylinder head. The tool’s air gap is adjustable
and it allows the visual inspection of the spark
while testing the intensity of the spark.

2. Insert a clean shop cloth into the spark plug hole in the
cylinder head to reduce gasoline vapors emitting from the
hole.

3. Insert the spark plug (

Figure 28

), or spark tester (

Fig-

ure 29

), into its cap and touch the spark plug base against

the cylinder head to ground it. Position the spark plug so
the electrode is visible.

330

CHAPTER EIGHT

IGNITION SYSTEM

COMPONENTS

(EFI MODELS)

1. ECM
2. Bolt

(all models except FXSTDI)

3. Nut (FXSTDI)
4. Washer
5. Bolt
6. Cover (FXSTB)
7. Pad
8. Screw
9. Cover

(all models except FXSTB)

10. Ignition coil
11. Spark plug cable (rear cylinder)
12. Spark plug cable (front cylinder)
13. Spark plug

WARNING

Mount the spark plug, or tester, away from
the spark plug hole in the cylinder so the
spark or tester cannot ignite the gasoline
vapors in the cylinder. If the engine is
flooded, do not perform this test. The firing
of the spark plug can ignite fuel ejected
through the spark plug hole.

NOTE

When not using a spark tester, always use a
new spark plug for this test procedure.

4. Crank the engine over with the starter. A fat blue spark
should be evident across the spark plug electrode or spark
tester. If there is strong sunlight on the plug, or tester,

shade it so the spark is more visible. Repeat for the other
cylinder.

WARNING

If necessary, hold onto the spark plug wire
with a pair of insulated pliers. Do

not

hold

the spark plug, wire or connector or a seri-
ous electrical shock could occur.

5. If there is a fat blue spark, the ignition coil is good. If
there is not, perform the following resistance test.

Resistance test (carbureted models)

NOTE

Refer to

Electrical System Fundamentals

in Chapter One.

1. Remove the ignition coil as previously described.
2. Disconnect the secondary wires from the ignition coil.
3. Use an ohmmeter set at R × 1 to measure the primary
coil resistance between terminals A and B, then terminals
B and C (

Figure 30

) at the backside of the ignition coil.

The specified resistance is in

Table 1

4. Use an ohmmeter set at R × 1000 to measure the sec-
ondary coil resistance between terminals B and R, then
terminals B and F (

Figure 30

) at the backside of the igni-

tion coil. The specified resistance is in

Table 1

5. If the resistance is less than specified, there is probably
a short in the coil windings. Replace the coil.
6. If the resistance is more than specified, this may indi-
cate corrosion or oxidation of the coil’s terminals. Thor-
oughly clean the terminals, then spray them with an
aerosol electrical contact cleaner. Repeat Steps 3 and 4. If
the resistance is still high, replace the coil.
7. If the coil resistance does not meet (or come close to)
either of these specifications, replace the coil. If the coil
is visibly damaged, replace it as described in this chap-
ter.
8. Install the ignition coil as described in this chapter.

Resistance test (EFI models)

NOTE

Refer to

Electrical System Fundamentals

in Chapter One.

Figure 31

) at the backside of the ignition coil.

The specified resistance is in

Table 1

ELECTRICAL SYSTEM

331

Terminal A
rear coil

Terminal C
front coil

Terminal B
+12 V

Terminal D
front coil

Terminal C
rear coil

Terminal

Terminal B

+12V

4. Use an ohmmeter set at R × 1000 to measure the sec-
ondary coil resistance between terminals B and C, then
terminals B and D (

Figure 31

) at the backside of the igni-

tion coil. The specified resistance is in

Table 1

5. If the resistance is less than specified, there is probably
a short in the coil windings. Replace the coil.

6. If the resistance is more than specified, this may indi-
cate corrosion or oxidation of the coil’s terminals. Thor-
oughly clean the terminals, then spray them with an
aerosol electrical contact cleaner. Repeat Steps 3 and 4. If
the resistance is still high, replace the coil.

7. If the coil resistance does not meet (or come close to)
either of these specifications, replace the coil. If the coil
is visibly damaged, replace it as described in this chap-
ter.

8. Install the ignition coil as described in this chapter.

Removal/installation

NOTE

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

1. Disconnect the negative battery cable as described in
this chapter.

NOTE

Label all wiring connectors prior to discon-
necting them in the following steps.

2. If necessary, disconnect the secondary lead from each
spark plug.

3. Remove the small screw securing the cover and re-
move the cover.

4. Disconnect the secondary leads (

Figure 32

) from the

coil towers.

NOTE

On FLSTS models, to avoid removing the
rear exhaust pipe, use a swivel socket and
ball ended Allen wrenches to remove the
coil fasteners.

5. Remove the bolts and lockwashers (

Figure 33

) secur-

ing the ignition coil to the seat post.

6. Move the ignition coil away from the seat post and dis-
connect the primary wire connector (

Figure 34

) from the

ignition coil.

7. Remove the ignition coil.

8. Install the ignition coil by reversing these steps.

Ignition Module (Carbureted Models)
Removal/Installation

The ignition module is located under the seat.

NOTE

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

1. Disconnect the negative battery cable as described in
this chapter.

332

CHAPTER EIGHT

2. Remove the seat as described in Chapter Fourteen.

3. Remove the screws securing the ignition module to the
mounting bracket.

4. Depress the external latches on the two multi-pin elec-
trical connectors. Gently pull and disconnect the black
and gray electrical connectors from the ignition module.

5. Remove the ignition module from the frame.

6. Install the ignition module by reversing these steps.
Note the following:

a. Apply a light coat of dielectric compound to the

electrical connectors prior to installing them.

b. Make sure the electrical connectors are pushed

tightly onto the ignition module.

Electronic Control Module (ECM)
(EFI Models) Removal/Installation

The ECM is located under the seat.

NOTE

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

1. Disconnect the negative battery cable as described in
this chapter.

2. Remove the seat as described in Chapter Fourteen.

3. Remove the nuts and washers (FXSTDI models), or
screws (all models except FXSTDI) securing the ECM
(A,

Figure 35

) to the mounting bracket.

4. Depress the external latch and use a rocking motion to
disconnect the 36-pin electrical connector (B,

Figure 35

)

from the ECM.

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

a. Apply a light coat of dielectric compound to the

electrical connector prior to installing them.

b. Make sure the electrical connector is pushed tightly

onto the ECM.

Manifold Absolute Pressure (MAP) Sensor
(Carbureted Models)
Removal/Installation

The MAP sensor (

Figure 23

) is located on top of the in-

take manifold.

NOTE

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

1. Disconnect the negative battery cable as described in
this chapter.

2. Remove the fuel tank as described in Chapter Seven.

3. Remove the carburetor as described in Chapter Seven.
Place a lint-free shop cloth into the intake manifold open-
ing (A,

Figure 36

) to prevent the entry of debris.

4. Remove the screw and clip (B,

Figure 36

) securing the

MAP sensor to the top of the intake manifold.

5. Pull the MAP sensor (C,

Figure 36

) straight up out of

the seal in the intake manifold.

6. Disconnect the electrical connector from the MAP sen-
sor and remove the sensor.

7. Install the MAP sensor by reversing these steps. Note
the following:

a. Apply a light coat of dielectric compound to the

electrical connector prior to installing it.

b. Make sure the electrical connector is pushed tightly

onto the MAP sensor.

c. If necessary, replace the seal in the intake manifold.

ELECTRICAL SYSTEM

333

Manifold Absolute Pressure (MAP) Sensor
(EFI Models)
Removal/Installation

The MAP sensor (Figure 23) is located on top of the in-

duction module.

CAUTION

Do not try to remove the MAP sensor with
the induction module installed on the engine
as the sensor will be damaged.

1. Remove the induction module as described in Chapter
Seven.

CAUTION

Do not apply excessive heat to the idle air
control unit as it will be damaged.

3. Remove the throttle housing screw.

4. Carefully pry the MAP sensor up and out of the intake
manifold. The grommet may come out with the sensor or
may stay in the intake manifold. Remove the grommet and
discard it.

5. Install a

new

grommet onto the sensor and press it into

the intake manifold until it bottoms.

NOTE

The

new

screw

coated

with

threadlocking compound. Do

not

add addi-

tional compound.

6. Install a

new

screw securing the idle air control valve

and the throttle housing stop to the throttle body. Tighten
the screw finger-tight at this time.

7. Install the throttle housing screw and tighten to 18
in.-lbs. (2 N•m).

8. Tighten the throttle housing stop screw to 25 in.-lbs. (3
N•m).

9. Install the induction module as described in Chapter
Seven.

Idle Air Control (IAC) Valve (EFI Models)
Removal/Installation

The IAC valve (Figure 37) is located on top of the in-

duction module.

CAUTION

Do not try to remove the IAC valve with the
induction module installed on the engine as
the sensor will be damaged.

1. Remove the induction module as described in Chapter
Seven.

CAUTION

Do not apply excessive heat to the idle air
control unit as it will be damaged.

2. Use a heat gun and apply sufficient heat to the front
screw securing both the idle air control valve and the
throttle housing stop to the throttle body. Heat the front
screw to break loose the thread locking compound. Re-
move the front screw and discard it.
3. Remove the throttle housing screw.
4. Remove the IAC valve and O-ring out of the intake
manifold.
5. Install a

new

O-ring onto the sensor and press it into

the intake manifold until it bottoms.

334

CHAPTER EIGHT

IAC VALVE

1. Induction module
2. O-ring
3. Idle air control valve (IAC)
4. Screw
5. Screw
6. Screw
7. Throttle housing stop

NOTE

The

new

screw

coated

with

threadlocking compound. Do

not

add addi-

tional compound.

6. Install a

new

screw securing the idle air control valve

and the throttle housing stop to the throttle body. Tighten
the screw finger-tight at this time.
7. Install the throttle housing screw and tighten to 18
in.-lbs. (2 N•m).
8. Tighten the throttle housing stop screw to 25 in.-lbs. (3
N•m).
9. Install the induction module as described in Chapter
Seven.

Crankshaft Position Sensor (CKP) (2001-on Models)
Removal/Installation

The CKP sensor (

Figure 38

) is mounted on the front

left side of the crankcase next to the oil filter.
1. Remove the seat as described in Chapter Fourteen.

NOTE

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

2. Disconnect the negative battery cable from the battery
as described in this chapter.
3. Remove the voltage regulator (A,

Figure 39

) as de-

scribed in this chapter.
4. Remove the voltage regulator mounting bracket (B,

Figure 39

5. Disconnect the sensor’s two-pin electrical connector
(one red, one black wire) from the harness.
6. On the left side of the motorcycle, remove the Allen
screw (

Figure 38

) and withdraw the CKP sensor and

O-ring from the crankcase.
7. Install by reversing these removal steps. Note the fol-
lowing:

a. Apply a light coat of dielectric compound to the

electrical connector prior to installing them.

b. 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 20-30 in.-lb. (2-3
N•m).

Camshaft Position Sensor (CMP) (2000 Models)
Removal/Installation

The CMP sensor is located in the camshaft cover on the

right side of the crankcase.
1. Remove the seat as described in Chapter Fourteen.

NOTE

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

2. Disconnect the negative battery cable as described in
this chapter.
3. Remove the exhaust system as described in Chapter
Seven.
4. Locate the CMP sensor harness three-pin Mini-Deutsch
electrical connector at the right side of the frame adjacent to
the rear brake line.
5. Remove the cable straps on the protective sheath to un-
cover the three-pin CMP and three-pin CKP electrical
connectors. Detach the electrical connectors from the sup-
port bracket on the rear brake line.
6. Disconnect the three-pin CMP Mini-Deutsch connec-
tor (one red/white, one green/white, one black/white)
from the wiring harness.
7. Use needle nose pliers to remove the secondary lock-
ing wedge from the pin side of the electrical connector.
8. Gently depress the terminal latches inside the pin
housing and back the pins out through the holes in the
wire seal. Remove the red/white, green/white and
black/white wires.

ELECTRICAL SYSTEM

335

9. Remove the T20 Torx screws securing the inspection
cover and remove the cover.
10. Tie a piece of string to the end of the wiring harness.
11. Remove the screw and washer securing the CMP sen-
sor to the camshaft cover. Remove the sensor and O-ring
from the cover.
12. Tape a piece of string to the three individual electrical
connectors in the CMP harness. Tie the other end of the
string to the frame cross-member.

NOTE

Figure 40

is shown with the camshaft cover

removed to better illustrate the step.

13. Carefully pull the electrical harness, with the piece of
string, out through both openings in the camshaft cover
(

Figure 40

14. Install by reversing these removal steps. Note the fol-
lowing:

a. Attach the string to the new CMP electrical connec-

tors.

b. Slowly pull the wires and connectors back through

both openings in the camshaft cover. Remove the
string.

c. Apply a light coat of dielectric compound to the

electrical connector(s) prior to installing them.

d. Apply clean engine oil to the

new

O-ring on the

CMP sensor prior to installation. Install the sensor
and tighten the Allen screw to 20-30 in.-lb. (2-3
N•m).

Engine Temperature Sensor
(2001-on EFI Models)
Removal/Installation

The engine temperature sensor (

Figure 41

) is located in

the rear left side of the front cylinder head.

NOTE

All carbureted engines are not equipped
with the engine temperature sensor circuit.

1. Remove the seat as described in Chapter Fourteen.

NOTE

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

2. Disconnect the negative battery cable as described in
this chapter.
3. Remove the fuel tank as described in Chapter Seven.
4. On the left side of the front cylinder head, pull the rub-
ber boot back off the sensor (

Figure 41

5. Pull on the external latch and disconnect the electrical
connector from the sensor.
6. Use a 3/4 in. deep socket and loosen the sensor. When
the socket turns easily, remove the socket and completely
unscrew the sensor by hand.
7. Install a new sensor and start it by hand. Use the socket
to tighten the sensor to 10-14 ft.-lb. (14-20 N•m).
8. Apply a light coat of dielectric compound to the elec-
trical connector prior to installing it.
9. Install the electrical connector and push it on until it
locks into place.
10. Pull the rubber boot back over the electrical connector.
11. Attach the negative battery cable.
12. Install the seat as described in Chapter Fourteen.

Bank Angle Sensor (BAS) (2000)
Removal/Installation

The bank angle sensor mounts on a frame-mounted

panel behind the rear fender inner fender on 2000 models.
On 2001-on models, the BAS is an integral part of the turn
signal/turn signal security module (TSM/TSSM) and is
also mounted on a frame-mounted panel behind the rear
fender inner fender.

336

CHAPTER EIGHT

NOTE

On 2001-on models, the bank angle sensor
is an integral part of the turn signal mod-
ule/turn signal security module (TSSM). Re-
fer to

Turn Signal Security Module

in this

chapter.

1. Remove the seat as described in Chapter Fourteen.

NOTE

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

2. Disconnect the negative battery cable from the battery
as described in this chapter.
3. Refer to

Electrical Panel

in this chapter to gain access

to the BAS.
4. Remove the mounting screw (A,

Figure 42

) and par-

tially remove the sensor (B) from the electrical panel.
5. Pull the external latch outward and disconnect the
electrical connector from the bank angle sensor.
6. Install by reversing these removal steps. Note the fol-
lowing:

a. Apply a light coat of dielectric compound to the

electrical connector prior to installing it.

b. Tighten the screw securely.

STARTING SYSTEM

When servicing the starting system, refer to the wiring

diagrams located at the end of the manual.

CAUTION

Do not operate the starter for more than five
seconds at a time. Let it cool approximately
ten seconds before operating it again.

Troubleshooting

Refer to Chapter Two.

Starter Removal

1. Remove the seat as described in Chapter Fourteen.

NOTE

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

2. Disconnect the negative battery cable as described in
this chapter.
3. Remove the primary drive outer cover as described in
Chapter Five.
4. Remove the oil tank (A,

Figure 43

) as described in

Chapter Four.
5. Remove the bolt and cover (B,

Figure 43

) from the end

of the starter.
6. Straighten the tab on the lockplate (

Figure 44

7. Wrap the pinion gear with a cloth to protect the finish,
then secure it with pliers (A,

Figure 45

8. Loosen and remove the bolt (B,

Figure 45

), lockplate

and thrust washer from the starter jackshaft assembly at
the end of the starter.

ELECTRICAL SYSTEM

337

Harley Davidson Softail 2000-2005. Service manual - page 32