Harley Davidson Softail 2000-2005. Service manual

Do not consider a tripped circuit breaker a minor an-

noyance; it indicates something is wrong in the electrical
system and must be corrected immediately.

Replacement

The circuit breaker is located on the electrical pan for-

ward of the rear wheel.
1. Remove the seat as described in Chapter Fourteen.
2. Turn the ignition switch OFF.
3. Disconnect the negative battery cable as described in
this chapter.
4. Refer to

Electrical Panel

in this chapter to gain access

to the circuit breaker.

NOTE

Record the wire’s colors and the terminal to
which they are connected. The wires must be
reinstalled onto the correct terminal.

5. Remove the nuts and wire connections at the circuit
breaker (Figure 145).
6. Remove the circuit breaker from the mounting bracket
on the electrical panel.
7. Install the circuit breaker by reversing these steps.

ELECTRICAL CONNECTOR SERVICE

A variety of electrical connectors are used throughout

the electrical system. The following procedures are for
disassembly of the connector in order to replace an indi-
vidual electrical wire in the connector.

These connectors are designed for a superior seal to

prevent dirt and moisture from entering the connector and
damaging a pin connector.

Deutsch Electrical Connectors Socket Terminal
Removal/Installation

This procedure shows how to remove and install the

socket terminals from the socket housing connector half.
This procedure is shown on a 12-pin Duetsch connector
and is the same for two-, three-, four- and six-pin Duetsch
connectors.

Refer to Figure 146 and Figure 147.

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. Disconnect the connector housing.
4. Remove the secondary locking wedge (7, Figure 147)
as follows:

a. Locate the secondary locking wedge in Figure 146

or Figure 147.

b. Insert a wide-blade screwdriver between the socket

housing and the locking wedge. Turn the screw-
driver 90

to force the wedge up (Figure 148).

c. Remove the secondary locking wedge (7, Figure

147).

5. Lightly press the terminal latches inside the socket
housing and remove the socket terminal (14, Figure 147)
through the holes in the rear wire seal.
6. Repeat Step 5 for each socket terminal.
7. If necessary, remove the wire seal (12, Figure 147).
8. Install the wire seal (12, Figure 147) into the socket
housing if it was removed.
9. Hold onto the socket housing and insert the socket ter-
minals (14, Figure 147) through the holes in the wire seal
so they enter their correct chamber hole. Continue until
the socket terminal locks into place. Then lightly tug on
the wire to make sure it is locked into place.
10. Set the internal seal (8, Figure 147) onto the socket
housing if it was removed.

NOTE

With the exception of the three-pin Duetsch
connector, all of the secondary locking
wedges are symmetrical. When assembling
the three-pin connector, install the connec-
tor so the arrow on the secondary locking
wedge is pointing toward the external latch
as shown in

Figure 149

NOTE

If the secondary locking wedge does not
slide into position easily, one or more of the

370

CHAPTER EIGHT

145

socket terminals are not installed correctly.
Correct the problem at this time.

11. Install the secondary locking wedge into the socket
housing as shown in Figure 146 or Figure 147. Press the
secondary locking wedge down until it locks into place.

Deutsch Electrical Connectors Pin Terminal
Removal/Installation

This procedure shows how to remove and install the pin

terminals from the pin housing connector half. This pro-
cedure is shown on a 12-pin Duetsch connector and re-
lates to all of the Duetsch connectors (two-, three-, four-
and six-pin).

Refer to Figure 146 and Figure 147.

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. Disconnect the connector housing.
4. Use needlenose pliers to remove the locking wedge (6,
Figure 147).
5. Lightly press the terminal latches inside the pin hous-
ing and remove the pin terminal(s) (1, Figure 147)
through the holes in the rear wire seal.
6. Repeat Step 5 for each socket terminal.
7. If necessary, remove the wire seal (2, Figure 147).
8. Install the wire seal (2, Figure 147) into the socket
housing if it was removed.
9. Hold onto the pin housing and insert the pin terminals
(1, Figure 147) through the holes in the wire seal so they
enter their correct chamber hole. Continue until the pin
terminal locks into place. Then lightly tug on the wire to
make sure it is locked into place.

NOTE

Figure 149

NOTE

If the locking wedge does not slide into po-
sition easily, one or more of the pin termi-

nals are not installed correctly. Correct the
problem at this time.

10. Install the locking wedge into the pin housing as
shown in Figure 146 or Figure 147. Press the secondary
locking wedge down until it locks into place. When prop-

372

CHAPTER EIGHT

148

Secondary
locking wedge

149

Pin housing

Socket housing

Arrow points to
external latch

THREE-PIN

WEDGE ALIGNMENT

erly installed, the wedge will fit into the pin housing cen-
ter groove.

Packard Electrical Connectors External
Latch Type Removal/Installation

This procedure shows how to remove and install the

electrical terminals from the external latch type connec-
tors with pull-to-seat terminals (Figure 150).
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. Bend back the external latch(es) slightly and separate
the connector.
4. Look into the mating end of the connector and locate
the locking tang (1, Figure 151) in the middle chamber

ELECTRICAL SYSTEM

373

150

151

PACKARD CONNECTORS

EXTERNAL LATCH TYPE

IAT sensor connector

Two-place

ET sensor connector

Two-place

TP sensor connector

Three-place

IAC valve connector

Four-place

PACKARD TERMINALS

1. Locate tang on latch side of chamber

2. Pivot end of pin to depress tang

3. Push on wire end of lead to remove terminal

4. Raise tang and reinstall terminal

and on the external latch side of connector. On locking ear
connectors, the tang is on the side opposite the ear.
5. Insert the point of a one-inch safety pin about 1/8 in.
into the middle chamber (2, Figure 151). Pivot the end of
the safety pin up toward the terminal body until a click is
heard. Repeat this step several times. The click is the tang
returning to the locked position as it slips from the point of
the safety pin. Continue to pick at the tang until the click-
ing stops and the safety pin seems to slide in at a slightly
greater depth indicating the tang has been depressed.
6. Remove the safety pin, push the wire end of the lead
and remove the lead from the connector (3, Figure 151).
If additional slack is necessary, pull back on the harness
conduit and remove the wire seal at the back of the con-
nector.
7. To install the terminal and wire back into the connec-
tor, use a thin flat blade of an X-Acto knife to carefully
bend the tang away from the terminal (4, Figure 151).
8. Carefully pull the lead and terminal into the connector
until a click is heard indicating the terminal is seated cor-
rectly within the connector. Gently push on the lead to en-
sure the terminal is correctly seated.
9. If necessary, install the wire seal and push the harness
conduit back into position on the backside of the connec-
tor.
10. Push the socket halves together until the latch(es) are
locked together.

Packard Electrical Connectors Wire Form Type
Removal/Installation

This procedure shows how to remove and install the

electrical terminals from the wire form type latch connec-
tors with pull-to-seat terminals (Figure 152).
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. Depress the wire form and separate the connector.
4. Hold the connector so the wire form is facing down.
5. Look into the mating end of the connector and locate
the plastic rib that separates the wire terminals. The termi-
nal is on each side of the rib with the tang at the rear.
6. Use the thin flat blade of an X-Acto knife to depress
the tang. Tilt the blade at an angle and place the tip at the
inboard edge of the terminal. Push down slightly until the
spring tension is relieved and a click is heard. Repeat this

step several times. The click represents the tang returning
to the locked position as it slips from the point of the knife
blade. Continue to push down until the clicking stops indi-
cating the tang has been depressed.
7. Remove the knife blade, push the wire end of the lead
and remove the lead from the connector. If additional
slack is necessary, pull back on the harness conduit and re-
move the wire seal at the back of the connector.
8. To install the terminal and wire back into the connec-
tor, use a thin flat blade of an X-Acto knife to carefully
bend the tang away from the terminal.
9. Carefully pull the lead and terminal into the connector
until a click is heard indicating the terminal is seated cor-
rectly within the connector. Gently pull on the lead to en-
sure the terminal is correctly seated.
10. If necessary, install the wire seal and push the harness
conduit back into position on the backside of the connec-
tor.
11. Push the socket halves together until the latch(es) are
locked together.

Amp Electrical Connectors Socket and Pin Terminals
Removal/Installation

This procedure shows how to remove and install the

socket and pin terminals from the pin and socket housing
connector. This procedure relates to all of the Amp con-
nectors (three-, six- and ten-pin).

Refer to Figure 153.

1. Remove the seat as described in Chapter Fourteen.

374

CHAPTER EIGHT

152

PACKARD CONNECTOR

WIRE FORM TYPE

Two-place

Fuel injector connector

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. Press the button on the socket on the terminal side and
pull the connector apart.

4. Slightly bend the latch back and free one side of the
secondary lock. Repeat this step for the other side.

5. Rotate the secondary lock (Figure 154) out on the
hinge to access the terminals within the connector.

NOTE

Do not pull too hard on the wire until the
tang is released or the terminal will be diffi-
cult to remove.

376

CHAPTER EIGHT

154

155

AMP MULTILOCK

TERMINALS SERVICE

Socket terminal

Secondary lock open

Pin housing

Socket housing

Tang

Button

Pin housing

Pick tool

Secondary lock open

Pin terminal

Socket housing

Three-place connector

Six-place connector

Ten-place connector

Pick tool

6. Insert a pick tool (2, Figure 154) into the flat edge of
the terminal cavity until it stops. Pivot the pick tool away
(3) from the terminal and gently pull on the wire to pull
the terminal (4) from the terminal cavity. Note the wire lo-
cation number on the connector (Figure 155).

NOTE

The release button used to separate the con-
nectors is at the top of the connector.

7. The tang in the chamber engages the pin terminal slot
to lock the terminal into position. The tangs (Figure 154)
are located as follows:

a. Pin housing side—the tangs are located at the bot-

tom of each chamber. The pin terminal slot, on the
side opposite the crimp tails, must face downward.

b. Socket housing side—the tangs are located at the

top of each chamber. The pin terminal slot, on the
same side as the crimp tails, must face upward.

8. On the secondary lock side of the connector, push the
wire and terminal into the correct location until it snaps
into place. Gently pull on the lead to ensure the terminal is
correctly seated.

9. Rotate the hinged secondary lock down and inward un-
til the tabs are fully engaged with the latches on both sides
of the connector. Pull upward to make sure the tabs are
locked in place.

10. Insert the socket housing into the pin housing and
push it in until it locks into place.

WIRING DIAGRAMS

Wiring diagrams are located at the end of this manual.

Table 1 ELECTRICAL SPECIFICATIONS

Item

Specification

Battery capacity

12 volts, 19 amp hour/270 CCA*

Maximum current draw

5.5 mA

Alternator

AC voltage output

Carbureted

16-20 volts per 1000 rpm

EFI

19-26 VAC per 1000 rpm

Stator coil resistance

0.1-0.3 ohm

Voltage regulator

Voltage output @ 3600 rpm

14.3-14.7 @ 75

F (24

Amps @ 3000 rpm

Carbureted

34-40 amps

EFI

41-48 amps

Ignition coil

Primary resistance

0.5-0.7 ohm

Secondary resistance

5500-7500 ohms

Spark plug cable resistance

Short cable (7.25 in./184 mm)

1812-4375 ohms

Long cable (19.0 in./483 mm)

4750-11,230 ohms

Circuit breaker

30 amp

Fuses

Ignition

15 amp

Lighting

15 amp

Accessory

15 amp

Instrument

15 amp

Security

15 amp

Fuel pump (EFI)

15 amp

Electronic control module (EFI)

15 amp

* CCA. Cold cranking amperage

ELECTRICAL SYSTEM

377

Table 2 BATTERY CHARGING RATES/TIMES (APPROXIMATE)

% of

3 amp

6 amp

10 amp

20 amp

Voltage

charge

charger

12.8

100%

–

12.6

75%

1.75 hours

50 minutes

30 minutes

15 minutes

12.3

50%

3.5 hours

1.75 hours

1 hour

30 minutes

12.0

25%

5 hours

2.5 hours

1.5 hours

45 minutes

11.8

6 hours and

3 hours and

2 hours

1 hour

40 minutes

20 minutes

Table 3 STARTER MOTOR SPECIFICATIONS

Minimum no-load speed @ 11.5 volts

3000 rpm

Maximum no-load current @ 11.5 volts

90 amp

Current draw

normal

160-180 amps

maximum

200 amps

Brush length (minimum)

0.433 in. (11.0 mm)

Commutator diameter (minimum)

1.141 in. (28.981)

Table 4 REPLACEMENT BULBS

Item

wattage × quantity

Headlamp

FLS models

40/60

FXS models

60/55

Position lamp

Passing lamps

Fog lamps

Tail lamp

Stop lamp

License plate lamp

FLST/I

4.2

All models except FLST

Front turn signal/running light

27/7 ×2

Front turn signal

21 ×2

Rear turn signal

27 ×2

Rear turn signal

21 ×2

Fender tip lamps

FLSTC

FLSTS

4.2

1. Indicates bulb specification for HD International models.

378

CHAPTER EIGHT

Table 5 ELECTRICAL SYSTEM TORQUE SPECIFICATIONS

Item

ft.-lb.

in.-lb.

N•m

Alternator stator Torx screws

2000

–

30-40

3-5

2001-on

–

55-75

6-9

Camshaft position sensor (2000 only)

Inspection cover screws

–

20-30

2-3

Sensor mounting screw

–

20-30

2-3

Crankshaft position sensor (CKP)

Allen screw

–

90-120

10-14

Engine temperature sensor (EFI)

10-15

–

14-20

Fuel gauge sending unit

Plate screws

–

16-22

2-3

Fuel tank console nut

–

80-100

9-11

Handlebar switch housing screws

–

35-45

4-5

Headlight adjust bolts

FXSTS, FLSTS

25-35

–

34-48

FLSTC, FXSTB, FXST

Horizontal bolt

30-35

–

41-48

Vertical bolt

35-45

–

48-61

FXSTD

25-30

–

34-41

Horn

Mounting nut

–

110-120

12-14

Screws

–

23-28

2.6-3

Ignition coil bolts

10-15

–

14-20

Ignition module

Mounting screws

–

15-21

1.7-2.4

Mounting nuts

–

30-35

3.4-4.0

Mounting plate nuts

–

70-80

8-9

Ignition switch Allen bolts

(all FLHT models)

–

40-50

5-6

MAP sensor screw

–

25-35

3-4

Speed sensor screw

–

84-108

10-12

Starter

Jackshaft bolt

–

84-108

9-12

Mounting bolts

13-20

–

18-27

Positive terminal nut

–

65-80

7-9

Switches

Neutral

–

120-180

14-20

Oil pressure

–

96-144

11-16

Rear brake light

–

96-120

11-14

Tail/brake light

Base screws

–

40-48

5-6

Lens screws

–

20-24

2-3

Voltage regulator

Mounting bracket bolt

–

70-100

8-11

Mounting bolt

–

50-80

6-9

Table 6 TURN SIGNAL DISTANCE TEST (2000 ONLY)

Range

MPH

0-34

35-44

45-60

61+

KMH

0-56

56-71

72-97

98+

Feet

221

339

680

1051

Miles

0.04

0.06

0.13

0.20

Meters

103

207

320

ELECTRICAL SYSTEM

379

CHAPTER NINE

WHEELS, HUBS AND TIRES

This chapter includes procedures for disassembly and

repair of the front and rear wheels, and hubs and tire ser-
vice. For routine maintenance, see Chapter Three.

Tables 1-3 are at the end of the chapter.

MOTORCYCLE STANDS

Many procedures in this chapter require the front or rear

wheel to be lifted off the ground. A quality motorcycle
front end stand (Figure 1), swing arm stand or suitable
size jack is required. Before purchasing or using a stand,
check the manufacturer’s instructions to make sure the
stand will work with the specific model being worked on.
If any adjustments or accessories are required, perform
the necessary adjustments and install the correct parts be-
fore lifting the motorcycle. When using the stand, have an
assistant standing by to help. Some means to tie down one
end of the motorcycle may also be required. Make sure the
motorcycle is properly supported on the stand.

If a motorcycle stand is not available, use a scissor jack

(Figure 2) with adapters that securely fit onto the frame
tubes (Figure 3).

FRONT WHEEL

Removal (Non-Springer Fork Models)

1. Support the motorcycle with the front wheel off the
ground. See

Motorcycle Stands

in this chapter.

2. Remove the caliper mounting bolts and remove the
caliper (A, Figure 4) as described in Chapter Thirteen.

NOTE

Place a plastic or wooden spacer between
the brake pads in place of the disc. Then, if
the brake lever is inadvertently applied, the
pistons will not be forced out of the caliper.
If the pistons are forced out, disassemble the
caliper to reseat the pistons.

3. On all models except FXSTD, insert a drift or screw-
driver through the front axle hole on the right side to pre-
vent it from rotating in the next step.

NOTE

On FXSTD models, the front axle is
equipped with two axle nuts. Loosen and re-
move only the left side axle nut.

4A. On FXSTD models, loosen and remove the

left side

axle nut, lockwasher and flat washer.
4B. On all other models, loosen and remove the axle nut
(B, Figure 4), lockwasher and flat washer.
5. On the right side, loosen the fork slider axle clamp nuts
(Figure 5, typical).
6. Prior to removing the front axle, note the location of
the right side spacer and left side spacer. The spacers must
be reinstalled on the correct sides during installation.
7. Withdraw the front axle (Figure 6) from the fork slid-
ers and front wheel.

NOT

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els.

16. Remove the stand and lower the front wheel to the
ground.

Removal
(Springer Fork [FXSTS Models])

Refer to Figure 12.

1. Support the motorcycle with the front wheel off the
ground. See

Motorcycle Stands

in this chapter.

2. Remove the front fender as described in Chapter Four-
teen.
3. Remove the caliper as described in Chapter Thirteen.

NOTE

Place a plastic or wooden spacer between
the brake pads in place of the disc. Then, if
the brake lever is inadvertently applied, the
pistons will not be forced out of the calipers.
If the pistons are forced out, disassemble the
caliper to reseat the pistons.

4. On the left side, loosen and remove the axle nut (Fig-
ure 13) and flat washer (Figure 14). Discard the axle nut.
5. Prior to removing the front axle, note the location of
the right side spacer and left side spacer. The spacers must
be reinstalled on the correct sides during installation.

384

CHAPTER NINE

FRONT WHEEL (FXSTS)

1. Front axle
2. Rocker (right side)
3. Washer—outside (small

inside diameter)

4. Brake caliper mount
5. Washer—inside (large

inside diameter)

6. Wave washer
7. Bearing spacer (right side)
8. Bearing spacer (left side)
9. Rocker (left side)

10. Washer
11. Axle nut

NOTE

There are several small washers located be-
tween the wheel hub and the brake caliper
mount and the fork rockers. Do not misplace
them.

6. On the right side,

slowly

withdraw the front axle (A,

Figure 15) from the left side fork rocker, front wheel,
brake caliper mount (B) and right side fork rocker (C).

7. Roll the front wheel away from the fork rockers and re-
move the brake caliper mount (Figure 16).

NOTE

The right and left side wheel bearing spac-
ers are different. Label the spacers before
removing them.

8. On the right side of the wheel, perform the following:

a. Remove the outside washer (small inner diameter)

from between the rocker and the brake caliper
mount.

b. Remove the inside washer (large inner diameter)

(Figure 17) and wave washer (Figure 18) from the
bearing spacer.

c. Remove the bearing spacer (Figure 19) from the

hub.

CAUTION

Do not set the wheel down on the brake disc
surface, as it may be damaged.

9. Inspect the front wheel assembly as described in this
chapter.

Installation
(Springer Fork [FXSTS Models])

1. Clean the axle in solvent and dry it thoroughly. Make
sure the axle bearing surfaces on both fork rockers, the

WHEELS, HUBS AND TIRES

385

Harley Davidson Softail 2000-2005. Service manual - page 35