Content      ..      1      2      3      ..

Harley Davidson 1999-2005 Harley Dyna Models. Repair Manual - page 2

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

20

CHAPTER ONE

37

Vernier scale

Sleeve

1. Reading on upper sleeve line

4.0 mm

Thimble

2. Reading on lower sleeve line

0.5 mm

3. Thimble is between 0.15 and 0.16

Vernier scale

mm on the sleeve line

0.15 mm

4. Vernier line coinciding with

thimble line

0.008 mm

Total reading

4.658 mm

Sleeve

Thimble

38

39

b. If the adjustment is correct, the 0 mark on the

c. Follow the manufacturer’s instructions to ad-

thimble will align exactly with the 0 mark on

just the micrometer.

the sleeve line. If the marks do not align, the

micrometer is out of adjustment.

Micrometer Care

c. Follow the manufacturer’s instructions to ad-

just the micrometer.

Micrometers are precision instruments. They

2B. To check a micrometer larger than 1 in. or 25

must be used and maintained with great care. Note

mm use the standard gauge supplied by the manu-

the following:

facturer. A standard gauge is a steel block, disc or

1. Store micrometers in protective cases or separate

rod that is machined to an exact size.

padded drawers in a toolbox.

a. Place the standard gauge between the spindle

2. When in storage, make sure the spindle and anvil

and anvil, and measure its outside diameter or

faces do not contact each other or an other object. If

length. If the micrometer has a ratchet stop,

they do, temperature changes and corrosion may

use it to ensure that the proper amount of

damage the contact faces.

pressure is applied.

b. If the adjustment is correct, the 0 mark on the

3. Do not clean a micrometer with compressed air.

thimble will align exactly with the 0 mark on

Dirt forced into the tool will cause wear.

the sleeve line. If the marks do not align, the

4. Lubricate micrometers with WD-40 to prevent

micrometer is out of adjustment.

corrosion.

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

GENERAL INFORMATION

21

the movable post in position. Remove the gauge and

40

1

measure the length of the posts. Telescoping gauges

are typically used to measure cylinder bores.

To use a small-bore gauge, select the correct size

gauge for the bore. Carefully insert the gauge into

the bore. Tighten the knurled end of the gauge to

carefully expand the gauge fingers to the limit

within the bore. Do not overtighten the gauge, as

there is no built-in release. Excessive tightening can

damage the bore surface and damage the tool. Re-

move the gauge and measure the outside dimension

(Figure 40). Small hole gauges are typically used to

measure valve guides.

41

Dial Indicator

A dial indicator (Figure 41) is a gauge with a dial

face and needle used to measure variations in di-

mensions and movements. Measuring brake rotor

runout is a typical use for a dial indicator.

Dial indicators are available in various ranges and

graduations and with three basic types of mounting

bases: magnetic, clamp, or screw-in stud. When

purchasing a dial indicator, select the magnetic

stand type with a continuous dial.

42

Cylinder Bore Gauge

A cylinder bore gauge is similar to a dial indica-

tor. The gauge set shown in Figure 42 consists of a

dial indicator, handle, and different length adapters

(anvils) to fit the gauge to various bore sizes. The

bore gauge is used to measure bore size, taper and

out-of-round. When using a bore gauge, follow the

manufacturer’s instructions.

Telescoping and

Small Bore Gauges

Compression Gauge

Use telescoping gauges (Figure

38) and small

A compression gauge (Figure 43) measures com-

hole gauges (Figure 39) to measure bores. Neither

bustion chamber (cylinder) pressure, usually in psi

gauge has a scale for direct readings. An outside mi-

or kg/cm². The gauge adapter is either inserted or

crometer must be used to determine the reading.

screwed into the spark plug hole to obtain the read-

To use a telescoping gauge, select the correct size

ing. Disable the engine so it will not start and hold

gauge for the bore. Compress the movable post and

the throttle in the wide-open position when per-

carefully insert the gauge into the bore. Carefully

forming a compression test. An engine that does not

move the gauge in the bore to make sure it is cen-

have adequate compression cannot be properly

tered. Tighten the knurled end of the gauge to hold

tuned. See Chapter Three.

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

22

CHAPTER ONE

43

44

Multimeter

Voltage

A multimeter (Figure 44) is an essential tool for

Voltage is the electrical potential or pressure in an

electrical system diagnosis. The voltage function

electrical circuit and is expressed in volts. The more

indicates the voltage applied or available to various

pressure (voltage) in a circuit, the more work that

electrical components. The ohmmeter function tests

can be performed.

circuits for continuity, or lack of continuity, and

Direct current (DC) voltage means the electricity

measures the resistance of a circuit.

flows in one direction. All circuits powered by a

Some manufacturers’ specifications for electrical

battery are DC circuits.

components are based on results using a specific

Alternating current (AC) means that the electric-

test meter. Results may vary if a meter not recom-

ity flows in one direction momentarily then

mend by the manufacturer is used. Such require-

switches to the opposite direction. Alternator output

ments are noted when applicable.

is an example of AC voltage. This voltage must be

changed or rectified to direct current to operate in a

battery powered system.

Ohmmeter (analog) calibration

Each time an analog ohmmeter is used or if the

Measuring voltage

scale is changed, the ohmmeter must be calibrated.

Unless otherwise specified, perform all voltage

Digital ohmmeters do not require calibration.

tests with the electrical connectors attached. When

1. Make sure the meter battery is in good condition.

measuring voltage, select the meter range that is one

2. Make sure the meter probes are in good condi-

scale higher than the expected voltage of the circuit

tion.

to prevent damage to the meter. To determine the

3. Touch the two probes together and observe the

actual voltage in a circuit, use a voltmeter. To sim-

needle location on the ohms scale.

ply check if voltage is present, use a test light.

The needle must align with the 0 mark to obtain

accurate measurements.

NOTE

When using a test light, either lead

4. If necessary, rotate the meter ohms adjust knob

can be attached to ground.

until the needle and 0 mark align.

1. Attach the negative meter test lead to a good

ELECTRICAL SYSTEM FUNDAMENTALS

ground (bare metal). Make sure the ground is not in-

sulated with a rubber gasket or grommet.

A thorough study of the many types of electrical

2. Attach the positive meter test lead to the point

systems used in today’s vehicles is beyond the

being checked for voltage (Figure 45).

scope of this manual. However, a basic understand-

3. Turn on the ignition switch. The test light should

ing of electrical basics is necessary to perform sim-

light or the meter should display a reading. The

ple diagnostic tests.

reading should be within one volt of battery voltage.

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

GENERAL INFORMATION

23

45

46

1

Voltage drop

Voltmeter

Battery

If the voltage is less, there is a problem in the cir-

Resistance is measured in an inactive circuit with

cuit.

an ohmmeter. The ohmmeter sends a small amount

of current into the circuit and measures how diffi-

cult it is to push the current through the circuit.

Voltage drop test

An ohmmeter, although useful, is not always a

good indicator of a circuit’s actual ability under op-

Resistance causes voltage to drop. This resistance

erating conditions. This is due to the low voltage

can be measured in an active circuit by using a volt-

(6-9 volts) that the meter uses to test the circuit. The

meter to perform a voltage drop test. A voltage drop

voltage in an ignition coil secondary winding can be

test compares the difference between the voltage

several thousand volts. Such high voltage can cause

available at the start of a circuit to the voltage at the

the coil to malfunction, even though it tests accept-

end of the circuit while the circuit is operational. If

able during a resistance test.

the circuit has no resistance, there will be no voltage

Resistance generally increases with temperature.

drop. The greater the resistance, the greater the volt-

Perform all testing with the component or circuit at

age drop will be. A voltage drop of one volt or more

room temperature. Resistance tests performed at

indicates excessive resistance in the circuit.

high temperatures may indicate high resistance

1. Connect the positive meter test lead to the elec-

readings and result in the unnecessary replacement

trical source (where electricity is coming from).

of a component.

2. Connect the negative meter test lead to the elec-

trical load (where electricity is going). See Figure

46.

Measuring resistance and continuity testing

3. If necessary, activate the component(s) in the

CAUTION

circuit.

Only use an ohmmeter on a circuit

4. A voltage reading of 1 volt or more indicates ex-

that has no voltage present. The meter

cessive resistance in the circuit. A reading equal to

will be damaged if it is connected to a

battery voltage indicates an open circuit.

live circuit. An analog meter must be

calibrated each time it is used or the

scale is changed. See Multimeter in

Resistance

this chapter.

Resistance is the opposition to the flow of elec-

A continuity test can determine if the circuit is

tricity within a circuit or component and is mea-

complete. This type of test is performed with an

sured in ohms. Resistance causes a reduction in

ohmmeter or a self-powered test lamp.

available current and voltage.

1. Disconnect the negative battery cable.

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

24

CHAPTER ONE

2. Attach one test lead (ohmmeter or test light) to

one end of the component or circuit.

47

3. Attach the other test lead to the opposite end of

the component or circuit (Figure 47).

Ohmmeter

4. A self-powered test light will come on if the cir-

cuit has continuity or is complete. An ohmmeter

will indicate either low or no resistance if the circuit

has continuity. An open circuit is indicated if the

meter displays infinite resistance.

Amperage

Component

Amperage is the unit of measure for the amount

of current within a circuit. Current is the actual flow

of electricity. The higher the current, the more work

that can be performed up to a given point. If the cur-

rent flow exceeds the circuit or component capacity,

ing any operation involving major disassembly of

the system will be damaged.

the engine.

1. Front, in this manual, refers to the front of the ve-

hicle. The front of any component is the end closest

Measuring amps

to the front of the vehicle. The left and right sides re-

An ammeter measures the current flow or amps

fer to the position of the parts as viewed by the rider

of a circuit (Figure 48). Amperage measurement re-

sitting on the seat facing forward.

quires that the circuit be disconnected and the am-

2. Whenever servicing an engine or suspension

meter be connected in series to the circuit. Always

component, secure the vehicle in a safe manner.

use an ammeter that can read higher than the antici-

3. Tag all similar parts for location and mark all

pated current flow to prevent damage to the meter.

mating parts for position. Record the number and

Connect the red test lead to the electrical source and

thickness of any shims as they are removed. Iden-

the black test lead to the electrical load.

tify parts by placing them in sealed and labeled

plastic sandwich bags.

4. Tag disconnected wires and connectors with

SPECIAL TOOLS

masking tape and a marking pen. Do not rely on

memory alone.

Some of the procedures in this manual require

5. Protect finished surfaces from physical damage

special tools (Table 9). These are described in the

or corrosion. Keep gasoline and other chemicals off

appropriate chapter and are available from either

painted surfaces.

the manufacturer or a tool supplier.

6. Use penetrating oil on frozen or tight bolts.

In many cases, an acceptable substitute may be

Avoid using heat where possible. Heat can warp,

found in an existing tool kit. Another alternative is

melt or affect the temper of parts. Heat also dam-

to make the tool. Many schools with a machine shop

ages the finish of paint and plastics.

curriculum welcome outside work that can be used

7. When a part is a press fit or requires a special

as practical shop applications for students.

tool for removal, the information or type of tool is

identified in the text. Otherwise, if a part is difficult

BASIC SERVICE METHODS

to remove or install, determine the cause before pro-

ceeding.

Most of the procedures in this manual are

8. To prevent objects or debris from falling into the

straightforward and can be performed by anyone

engine, cover all openings.

reasonably competent with tools. However, con-

9. Read each procedure thoroughly and compare

sider personal capabilities carefully before attempt-

the illustrations to the actual components before

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

GENERAL INFORMATION

25

14. If special tools are required, have them avail-

48

1

able before starting the procedure. When special

tools are required, they will be described at the be-

ginning of the procedure.

Ammeter

15. Make diagrams of similar-appearing parts. For

Connected

in series

instance, crankcase bolts are often not the same

lengths. Do not rely on memory alone. It is possible

that carefully laid out parts will become disturbed,

Measures

making it difficult to reassemble the components

current

correctly without a diagram.

flow

16. Make sure all shims and washers are reinstalled

in the same location and position.

17. Whenever rotating parts contact a stationary

part, look for a shim or washer.

18. Use new gaskets if there is any doubt about the

condition of old ones.

19. If self-locking fasteners are used, replace them

with new ones. Do not install standard fasteners in

place of self-locking ones.

starting the procedure. Perform the procedure in se-

20. Use grease to hold small parts in place if they

quence.

tend to fall out during assembly. Do not apply

10. Recommendations are occasionally made to

grease to electrical or brake components.

refer service to a dealership or specialist. In

these cases, the work can be performed more

economically by the specialist than by the home

Removing Frozen Fasteners

mechanic.

11. The term replace means to discard a defective

If a fastener cannot be removed, several methods

part and replace it with a new part. Overhaul means

may be used to loosen it. First, apply penetrating oil

to remove, disassemble, inspect, measure, repair

such as Liquid Wrench or WD-40. Apply it liberally

and/or replace parts as required to recondition an as-

and let it penetrate for 10-15 minutes. Rap the fas-

sembly.

tener several times with a small hammer. Do not hit

12. Some operations require the use of a hydraulic

it hard enough to cause damage. Reapply the pene-

press. If a press is not available, have these opera-

trating oil if necessary.

tions performed by a shop equipped with the neces-

For frozen screws, apply penetrating oil as de-

sary equipment. Do not use makeshift equipment

scribed, then insert a screwdriver in the slot and rap

that may damage the vehicle.

the top of the screwdriver with a hammer. This loos-

ens the rust so the screw can be removed in the nor-

13. Repairs are much faster and easier if the vehi-

mal way. If the screw head is too damaged to use

cle is clean before starting work. Degrease the ve-

this method, grip the head with locking pliers and

hicle with a commercial degreaser; follow the

twist the screw out.

directions on the container for the best results.

Clean all parts with cleaning solvent as they are re-

Avoid applying heat unless specifically in-

moved.

structed, as it may melt, warp or remove the temper

from parts.

CAUTION

Do not direct high-pressure water at

Removing Broken Fasteners

steering bearings, carburetor hoses,

wheel bearings, suspension and elec-

If the head breaks off a screw or bolt, several

trical components, or drive belt. The

water will force the grease out of the

methods are available for removing the remaining

bearings and possibly damage the

portion. If a large portion of the remainder projects

seals.

out, try gripping it with locking pliers. If the pro-

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

26

CHAPTER ONE

49

50

REMOVING BROKEN

SCREWS AND BOLTS

Filed

Slotted

1. Center punch broken stud

2. Drill hole in stud

jecting portion is too small, file it to fit a wrench or

cut a slot in it to fit a screwdriver (Figure 49).

If the head breaks off flush, use a screw extractor.

To do this, centerpunch the exact center of the re-

maining portion of the screw or bolt. Drill a small

hole in the screw and tap the extractor into the hole.

3. Tap in screw extractor

4. Remove broken

Back the screw out with a wrench on the extractor

stud

(Figure 50).

Repairing Damaged Threads

51

Occasionally, threads are stripped through care-

lessness or impact damage. Often the threads can be

repaired by running a tap (for internal threads on

nuts) or die (for external threads on bolts) through

the threads (Figure 51). To clean or repair spark

plug threads, use a spark plug tap.

If an internal thread is damaged, it may be neces-

sary to install a Helicoil or some other type of thread

insert. Follow the manufacturer’s instructions when

installing their insert.

If it is necessary to drill and tap a hole, refer to Ta-

ble 8 for American tap and drill sizes.

Stud Removal/Installation

A stud removal tool is available from most tool

suppliers. This tool makes the removal and installa-

tion of studs easier. If one is not available, thread

3. Remove the stud by turning the stud remover or

two nuts onto the stud and tighten them against each

the lower nut.

other. Remove the stud by turning the lower nut

4. Remove any threadlocking compound from the

(Figure 52).

threaded hole. Clean the threads with an aerosol

1. Measure the height of the stud above the surface.

parts cleaner.

2. Thread the stud removal tool onto the stud and

5. Install the stud removal tool onto the new stud or

tighten it, or thread two nuts onto the stud.

thread two nuts onto the stud.

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

GENERAL INFORMATION

27

Removing Hoses

1

52

When removing stubborn hoses, do not exert ex-

cessive force on the hose or fitting. Remove the

hose clamp and carefully insert a small screwdriver

or pick tool between the fitting and hose. Apply a

spray lubricant under the hose and carefully twist

the hose off the fitting. Clean the fitting of any cor-

rosion or rubber hose material with a wire brush.

Clean the inside of the hose thoroughly. Do not use

any lubricant when installing the hose (new or old).

The lubricant may allow the hose to come off the fit-

ting, even with the clamp secure.

Bearings

Bearings are used in the engine and transmission

53

assembly to reduce power loss, heat and noise re-

sulting from friction. Because bearings are preci-

sion parts, they must be maintained by proper

lubrication and maintenance. If a bearing is dam-

aged, replace it immediately. When installing a new

bearing, take care to prevent damaging it. Bearing

Bearing puller

replacement procedures are included in the individ-

ual chapters where applicable; however, use the fol-

lowing sections as a guideline.

NOTE

Spacer

Unless otherwise specified, install

bearings with the manufacturer’s

Shaft

mark or number facing outward.

Bearing

Removal

While bearings are normally removed only when

damaged, there may be times when it is necessary to

remove a bearing that is in good condition. How-

ever, improper bearing removal will damage the

bearing and maybe the shaft or case half. Note the

following when removing bearings.

1. When using a puller to remove a bearing from a

6. Apply threadlocking compound to the threads of

shaft, take care that the shaft is not damaged. Al-

the stud.

ways place a piece of metal between the end of the

shaft and the puller screw. In addition, place the

7. Install the stud and tighten with the stud removal

puller arms next to the inner bearing race. See Fig-

tool or the top nut.

ure 53.

2. When using a hammer to remove a bearing from

8. Install the stud to the height noted in Step 1 or its

a shaft, do not strike the hammer directly against the

torque specification.

shaft. Instead, use a brass or aluminum rod between

9. Remove the stud removal tool or the two nuts.

the hammer and shaft (Figure 54) and make sure to

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

28

CHAPTER ONE

54

55

Press ram

Shaft

Bearing

Spacer

Spacer

Shaft

Press bed

Bearing

Blocks

56

Bearing

support both bearing races with wooden blocks as

shown.

3. A hydraulic press is the ideal method of bearing

removal. Note the following when using a press:

Housing

a. Always support the inner and outer bearing

races with a suitable size wooden or alumi-

num ring (Figure 55). If only the outer race is

supported, pressure applied against the balls

and/or the inner race will damage them.

b. Always make sure the press arm (Figure 55)

bearing

directly

with

a

hammer or the bearing

aligns with the center of the shaft. If the arm is

will be damaged. When installing a bearing, use a

not centered, it may damage the bearing

piece of pipe or a driver with a diameter that

and/or shaft.

matches the bearing race. Figure 58 shows the

c. The moment the shaft is free of the bearing, it

correct way to use a socket and hammer to install

will drop to the floor. Secure or hold the shaft

a bearing.

to prevent it from falling.

3. Step 1 describes how to install a bearing in a case

half or over a shaft. However, when installing a

Installation

bearing over a shaft and into a housing at the same

time, a tight fit will be required for both outer and

1. When installing a bearing in a housing, apply

inner bearing races. In this situation, install a spacer

pressure to the outer bearing race (Figure 56).

underneath the driver tool so that pressure is applied

When installing a bearing on a shaft, apply pressure

evenly across both races. See Figure 59. If the outer

to the inner bearing race (Figure 57).

race is not supported as shown in Figure 59, the

2. When installing a bearing as described in Step

balls will push against the outer bearing race and

1, some type of driver is required. Never strike the

damage it.

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

GENERAL INFORMATION

29

57

59

1

Bearing

Shaft

Driver

Spacer

Bearing

Shaft

Housing

58

c. Fill a suitable pot or beaker with clean min-

eral oil. Place a thermometer rated above

120° C (248° F) in the oil. Support the ther-

mometer so that it does not rest on the bottom

or side of the pot.

d. Remove the bearing from its wrapper and se-

Socket

cure it with a piece of heavy wire bent to hold

it in the pot. Hang the bearing in the pot so it

does not touch the bottom or sides of the pot.

e. Turn the heat on and monitor the thermome-

ter. When the oil temperature rises to approxi-

mately 120° C (248° F), remove the bearing

Bearing

from the pot and quickly install it. If neces-

sary, place a socket on the inner bearing race

Shaft

and tap the bearing into place. As the bearing

chills, it will tighten on the shaft, so installa-

tion must be done quickly. Make sure the

bearing is installed completely.

Interference Fit

2. Follow this step when installing a bearing in a

1. Follow this procedure when installing a bearing

housing. Bearings are generally installed in a hous-

over a shaft. When a tight fit is required, the bearing

ing with a slight interference fit. Driving the bearing

inside diameter will be smaller than the shaft. In this

into the housing using normal methods may damage

case, driving the bearing on the shaft using normal

the housing or cause bearing damage. Instead, heat

methods may cause bearing damage. Instead, heat

the housing before the bearing is installed. Note the

the bearing before installation. Note the following:

following:

a. Secure the shaft so it is ready for bearing in-

CAUTION

stallation.

Before heating the housing in this pro-

b. Clean all residues from the bearing surface of the

cedure, wash the housing thoroughly

shaft. Remove burrs with a file or sandpaper.

with detergent and water. Rinse and

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

30

CHAPTER ONE

rewash the cases as required to re-

move all traces of oil and other chem-

60

ical deposits.

Spring

a.

Heat the housing to approximately 212° F

(100° C) in an oven or on a hot plate. An easy

Dust lip

way to check that it is the proper temperature

is to place tiny drops of water on the housing;

Main

if they sizzle and evaporate immediately, the

lip

Oil

temperature is correct. Heat only one housing

at a time.

Reinforcement

CAUTION

Do not heat the housing with a pro-

pane or acetylene torch. Never bring

a flame into contact with the bearing

or housing. The direct heat will de-

stroy the case hardening of the bear-

ing and will likely warp the housing.

Seal Replacement

b.

Remove the housing from the oven or hot

plate, and hold onto the housing with a

kitchen potholder, heavy gloves or heavy

Seals (Figure 60) are used to contain oil, water,

shop cloth. It is hot!

grease or combustion gasses in a housing or shaft.

Improper removal of a seal can damage the housing

NOTE

or shaft. Improper installation of the seal can dam-

Remove and install the bearings with

age the seal. Note the following:

a suitable size socket and extension.

1. Prying is generally the easiest and most effective

c.

Hold the housing with the bearing side down

method of removing a seal from a housing. How-

and tap the bearing out. Repeat for all bear-

ever, always place a rag underneath the pry tool

ings in the housing.

(Figure 61) to prevent damage to the housing.

d.

Before heating the bearing housing, place the

2. Pack waterproof grease in the seal lips before the

new bearing in a freezer if possible. Chilling a

seal is installed.

bearing slightly reduces its outside diameter

3. In most cases, install seals with the manufac-

while the heated bearing housing assembly is

turer’s numbers or marks face out.

slightly larger due to heat expansion. This

will make bearing installation easier.

4. Install seals with a socket placed on the outside

of the seal as shown in Figure 62. Drive the seal

NOTE

squarely into the housing. Never install a seal by

Always install bearings with the man-

hitting against the top of the seal with a hammer.

ufacturer’s mark or number facing

outward.

STORAGE

e.

While the housing is still hot, install the new

bearing(s) into the housing. Install the bear-

ings by hand, if possible. If necessary, lightly

Several months of non-use can cause a general

tap the bearing(s) into the housing with a

deterioration of the vehicle. This is especially true

socket placed on the outer bearing race (Fig-

in areas of extreme temperature variations. This de-

ure 56). Do not install new bearings by driv-

terioration can be minimized with careful prepara-

ing on the inner-bearing race. Install the

tion for storage. A properly stored vehicle will be

bearing(s) until it seats completely.

much easier to return to service.

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

GENERAL INFORMATION

31

length of non-use, storage area conditions and per-

61

1

sonal preference. Consider the following list the

minimum requirement:

1. Wash the vehicle thoroughly. Make sure all dirt,

mud and road debris are removed.

2. Start the engine and allow it to reach operating

temperature. Drain the engine oil and transmission

oil, regardless of the riding time since the last ser-

vice. Fill the engine and transmission with the rec-

ommended type of oil.

3. Drain all fuel from the fuel tank, run the engine

until all the fuel is consumed from the lines and car-

buretor.

4. Remove the spark plugs and pour a teaspoon of

62

engine oil into the cylinders. Place a rag over the

openings and slowly turn the engine over to distrib-

ute the oil. Reinstall the spark plugs.

5. Remove the battery. Store the battery in a cool

and dry location.

6. Cover the exhaust and intake openings.

7. Reduce the normal tire pressure by 20%.

8. Apply a protective substance to the plastic and

rubber components, including the tires. Make sure

to follow the manufacturer’s instructions for each

type of product being used.

9. Place the vehicle on a stand or wooden blocks,

Storage Area Selection

so the wheels are off the ground. If this is not possi-

When selecting a storage area, consider the fol-

ble, place a piece of plywood between the tires and

lowing:

the ground. Inflate the tires to the recommended

1. The storage area must be dry. A heated area is

pressure if the vehicle can not be elevated.

best, but not necessary. It should be insulated to

10. Cover the vehicle with old bed sheets or some-

minimize extreme temperature variations.

thing similar. Do not cover it with any plastic mate-

2. If the building has large window areas, mask

rial that will trap moisture.

them to keep sunlight off the vehicle.

3. Avoid buildings in industrial areas where corro-

Returning the Vehicle to Service

sive emissions may be present. Avoid areas close to

saltwater.

The amount of service required when returning a

4. Consider the area’s risk of fire, theft or vandal-

vehicle to service after storage depends on the

ism. Check with an insurer regarding vehicle cover-

length of non-use and storage conditions. In addi-

age while in storage.

tion to performing the reverse of the above proce-

dures, make sure the brakes, clutch, throttle and

engine stop switch work properly before operating

Preparing the Vehicle for Storage

the vehicle. Refer to Chapter Three and evaluate the

The amount of preparation a vehicle should un-

service intervals to determine which areas require

dergo before storage depends on the expected

service.

Tables 1-9 are on the following pages

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

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

GENERAL INFORMATION

33

Table 2 GENERAL DIMENSIONS (continued)

1

Item/model

in.

mm

Saddle height (continued)

FXDL

26.50

673.10

FXD

26.50

673.10

FXDX

27.00

685.80

FXDXT T-Sport

27.25

692.20

FXDP

31.00

787.40

Table 3 VEHICLE WEIGHT (DRY)

Model

lbs.

kg

FXDWG

612.0

277.8

FXDS-CONV

640.0

290.6

FXDL

614.0

278.8

FXD

612.0

277.8

FXDX

619.0

281.1

FXDXT T-Sport

619.0

281.1

FXDP

697.4

316.3

Table 4 DECIMAL AND METRIC EQUIVALENTS

Fractions

Decimal in.

Metric mm

Fractions

Decimal in.

Metric mm

1/64

0.015625

0.39688

33/64

0.515625

13.09687

1/32

0.03125

0.79375

17/32

0.53125

13.49375

3/64

0.046875

1.19062

35/64

0.546875

13.89062

1/16

0.0625

1.58750

9/16

0.5625

14.28750

5/64

0.078125

1.98437

37/64

0.578125

14.68437

3/32

0.09375

2.38125

19/32

0.59375

15.08125

7/64

0.109375

2.77812

39/64

0.609375

15.47812

1/8

0.125

3.1750

5/8

0.625

15.87500

9/64

0.140625

3.57187

41/64

0.640625

16.27187

5/32

0.15625

3.96875

21/32

0.65625

16.66875

11/64

0.171875

4.36562

43/64

0.671875

17.06562

3/16

0.1875

4.76250

11/16

0.6875

17.46250

13/64

0.203125

5.15937

45/64

0.703125

17.85937

7/32

0.21875

5.55625

23/32

0.71875

18.25625

15/64

0.234375

5.95312

47/64

0.734375

18.65312

1/4

0.250

6.35000

3/4

0.750

19.05000

17/64

0.265625

6.74687

49/64

0.765625

19.44687

9/32

0.28125

7.14375

25/32

0.78125

19.84375

19/64

0.296875

7.54062

51/64

0.796875

20.24062

5/16

0.3125

7.93750

13/16

0.8125

20.63750

21/64

0.328125

8.33437

53/64

0.828125

21.03437

11/32

0.34375

8.73125

27/32

0.84375

21.43125

23/64

0.359375

9.12812

55/64

0.859375

22.82812

3/8

0.375

9.52500

7/8

0.875

22.22500

25/64

0.390625

9.92187

57/64

0.890625

22.62187

13/32

0.40625

10.31875

29/32

0.90625

23.01875

27/64

0.421875

10.71562

59/64

0.921875

23.41562

7/16

0.4375

11.11250

15/16

0.9375

23.81250

29/64

0.453125

11.50937

61/64

0.953125

24.20937

15/32

0.46875

11.90625

31/32

0.96875

24.60625

31/64

0.484375

12.30312

63/64

0.984375

25.00312

1/2

0.500

12.70000

1

1.00

25.40000

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

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

GENERAL INFORMATION

35

Table 6 GENERAL TORQUE SPECIFICATIONS (FT.-LB.)¹

1

Type²

1/4

5/16

3/8

7/16

1/2

9/16

5/8

3/4

7/8

1

SAE 2

6

12

20

32

47

69

96

155

206

310

SAE 5

10

19

33

54

78

114

154

257

382

587

SAE 7

13

25

44

71

110

154

215

360

570

840

SAE 8

14

29

47

78

119

169

230

380

600

700

1. Convert ft.-lb. specification to N•m by multiplying by 1.3558.

2. Fastener strength of SAE bolts can be determined by the bolt head grade markings. Unmarked bolt heads

and cap screws are usually mild steel. More grade markings indicate higher fastener quality.

SAE 2

SAE 5

SAE 7

SAE 8

Table 7 TECHNICAL ABBREVIATIONS

ABDC

After bottom dead center

ATDC

After top dead center

BBDC

Before bottom dead center

BDC

Bottom dead center

BTDC

Before top dead center

C

Celsius (Centigrade)

cc

Cubic centimeters

cid

Cubic inch displacement

CDI

Capacitor discharge ignition

CKP

Crankshaft position sensor

CMP

Camshaft position sensor

cu. in.

Cubic inches

ECM

Electronic control module

ET

Engine temperature sensor

F

Fahrenheit

ft.

Feet

ft.-lb.

Foot-pounds

gal.

Gallons

H/A

High altitude

hp

Horsepower

IAC

Idle air control valve

IAT

Intake air temperature sensor

in.

Inches

in.-lb.

Inch-pounds

I.D.

Inside diameter

kg

Kilograms

kgm

Kilogram meters

km

Kilometer

kPa

Kilopascals

L

Liter

m

Meter

MAG

Magneto

MAP

Manifold absolute pressure

ml

Milliliter

mm

Millimeter

(continued)

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

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

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

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

TROUBLESHOOTING

39

OPERATING REQUIREMENTS

1

An engine needs three basics to run properly: cor-

2

rect fuel/air mixture, compression and a spark at the

right time. If one basic requirement is missing, the

engine will not run. Four-stroke engine operating

principles are described in Chapter Four under En-

gine Principles.

If the motorcycle has been sitting for any time

and refuses to start, check and clean the spark plugs.

If the plugs are not fouled, look to the fuel delivery

system. This includes the fuel tank, fuel shutoff

valve, fuel filter and fuel lines. If the motorcycle sat

2

for a while with fuel in the carburetor, fuel deposits

may have gummed up carburetor jets and air pas-

sages. Gasoline tends to lose its potency after stand-

ing for long periods. Condensation may

contaminate it with water. Drain the old gas and try

starting with a fresh tankful.

STARTING THE ENGINE

Engine Fails to Start

(Spark Test)

ample, note whether the engine lost power gradu-

ally or all at once, what color smoke came from the

Perform the following spark test to determine if

exhaust, etc.

the ignition system is operating properly.

After defining the symptoms, follow the proce-

dure that most closely relates to the condition(s).

CAUTION

Guessing at the cause of the problem may provide a

Before removing the spark plugs in

solution, but it can easily lead to wasted time and

Step 1, clean all dirt and debris away

unnecessary parts replacement.

from the plug base. Dirt that falls into

Expensive equipment or complicated test gear is

the cylinder will cause rapid engine

wear.

not required to determine whether repairs can be at-

tempted at home. A few simple checks could save a

large repair bill and lost time while the motorcycle

1. Refer to Chapter Three and disconnect the spark

sits in a dealership’s service department. On the

plug wire and remove the spark plug.

other hand, be realistic and do not attempt repairs

beyond personal capabilities. Dealership service

NOTE

departments tend to charge heavily when working

A spark tester is a useful tool for test-

ing the spark output. Figure 2 shows

on equipment that has been abused. Some will not

the Motion Pro Ignition System Tester

even take on such a job. Use common sense to avoid

(part No. 08-122). This tool is in-

getting involved in a procedure that cannot be com-

serted in the spark plug cap and its

pleted satisfactorily.

base is grounded against the cylinder

If the decision has been made to refer trouble-

head. The tool’s air gap is adjustable,

shooting to a repair facility, describe problems ac-

and it allows the visual inspection of

curately and fully.

the spark while testing the intensity of

Table 1 and Table 2 list electrical specifications.

the spark. This tool is available

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

through motorcycle repair shops.

Content      ..      1      2      3      ..