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Harley Davidson 1999-2005 Harley Dyna Models. Repair Manual - page 16

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300

CHAPTER SEVEN

3. Remove the five screws securing the fuel gauge

retainer (B, Figure 100). Remove the retainer.

100

4. Withdraw the fuel gauge (C, Figure 100) from

the sending unit,

5. Remove the five screws and washers securing

the sending unit to the fuel tank.

6. Remove the trim panel ring.

CAUTION

Do not bend the float arm during re-

moval of the sending unit. If bent, the

gauge will give inaccurate readings.

7. Carefully withdraw the sending unit while mov-

ing it back and forth, lifting and turning it in either

101

FUEL GAUGE ASSEMBLY

direction.

(FXDL, FXDWG, FXDP 2001)

8. Remove the gasket from the fuel tank.

9. Install by reversing these removal steps while

noting the following:

a. Lubricate the rubber surface on the base of

the fuel gauge flange with rubbing alcohol or

glass cleaner.

b. Position the electrical terminals in between

the posts on the bottom of the fuel gauge.

c. Align the fuel gauge with the first scribe mark

on the sending unit, then turn it clockwise to

align with the second scribe mark on the

sending unit.

d. Install a new gasket between the sending unit

and fuel tank.

e. Carefully install the sending unit to avoid

damage to the float arm.

f. Tighten all screws securely.

Removal/Installation

(FXDX, FXDWG, FXDP [2001])

Refer to Figure 101.

1. Remove the fuel tank as described in this chap-

ter.

NOTE

The fuel gauge electrical wires are

1.

Fuel gauge

routed through a tube in the fuel tank

2.

Gasket

and are secured with a clamp at the

3.

Screw

bottom of the fuel tank. Loosen the

4.

Pin terminal

clamp and make sure there is enough

5.

Pin housing

6.

Sending unit

slack in the wires to allow the gauge

7.

Gasket

to be pulled up and out of the fuel

tank.

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FUEL, EXHAUST AND EMISSION SYSTEMS

301

2. Pull straight up on the gauge and partially re-

102

move it from the tank.

3. Disconnect the electrical connector from the

wires within the fuel tank. Do not disconnect the

electrical wires from the fuel gauge.

4. Remove the fuel gauge and the gasket.

5. Remove the five screws securing the sending

unit to the fuel tank.

CAUTION

Do not bend the float arm during re-

moval of the sending unit. If bent, the

gauge will give inaccurate readings.

103

6. Carefully withdraw the sending unit while mov-

ing it back and forth and lifting and turning it in ei-

ther direction.

7. Remove the gasket from the fuel tank.

7

8. Install by reversing these removal steps while

noting the following:

a. Install a new gasket between the fuel gauge

and fuel tank.

b. Carefully install the sending unit to avoid

damage to the float arm.

c. Tighten all screws securely.

104

EXHAUST SYSTEM

Removal

1. Support the motorcycle on a work stand. See mo-

torcycle Stands in Chapter Nine.

2. At each cylinder head, loosen and remove the

two flange nuts (Figure 102) securing both the front

and rear exhaust pipes to the cylinder heads.

3. Slide the exhaust flange and retaining ring off

the cylinder head studs.

4. Remove the nut and bolt (Figure 103) securing

the front exhaust pipe to the frame bracket.

105

5. Remove the nut and bolt (Figure 104) securing

the rear exhaust pipe to the frame bracket.

6. Carefully pull the exhaust assembly

(Figure

105) away from the motorcycle and remove it as an

assembly.

7. Remove the exhaust port gaskets (Figure 106).

8. Inspect the exhaust system as described in this

chapter.

9. Store the exhaust system in a safe place until it is

reinstalled.

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302

CHAPTER SEVEN

106

107

108

EXHAUST SYSTEM

1. Gasket

2. Retaining ring

3. Exhaust pipe-front

cylinder

4. Nut

5. Clamp

6. Heat shield

7. Bracket-front

8. Nut

9. Bolt

10. Heat shield

11. Ring gasket

12. Gasket

13. Bracket-front

14. Nut

15. Muffler-front cylinder

16. Clamp

17. Clamp

18. Exhaust pipe-rear

cylinder

19. Heat shield

20. Heat shield

21. Clamp

22. Acorn nut

23. Nut

24. Nut

25. Muffler-rear cylinder

26. Heat shield

27. Bracket-rear

28. Washer

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FUEL, EXHAUST AND EMISSION SYSTEMS

303

9. If removed, install the heat shields and tighten

109

the clamps securely.

10. Start the engine and check for leaks.

Inspection

Refer to Figure 108.

1. Replace rusted or damaged exhaust system com-

ponents.

2. Inspect the crossover pipe (Figure 109) for rust

or corrosion.

3. Remove all rust from exhaust pipe and muffler

mating surfaces.

Installation

4. The muffler clamps are not reusable. Replace the

muffler clamps if they are removed.

NOTE

If the mufflers were removed from the

5. Replace damaged exhaust pipe retaining rings

exhaust pipes, new clamps must be in-

(Figure 107).

7

stalled to ensure correct sealing in-

6. Replace all worn or damaged heat shield clamps

tegrity. The new clamps eliminate the

as required.

need for graphite or silicone tape dur-

7. Check the mounting bracket bolts and nuts for

ing installation of the mufflers.

tightness.

1. Before installing the new exhaust port gaskets,

scrape the exhaust port surfaces to remove all car-

EVAPORATIVE EMISSION CONTROL

bon residue—removing the carbon will ensure a

SYSTEM (CALIFORNIA MODELS)

good gasket fit. Then wipe the port with a rag.

2. Position the new gasket with the wider diameter

An evaporative emission control system prevents

end facing out toward exhaust pipe.

gasoline vapor from escaping into the atmosphere.

3. Before installing the exhaust pipes, check that

When the engine is not running, the system di-

the retaining rings (Figure 107) fit tightly against

rects the fuel vapor from the fuel tank through the

the pipe flanges.

vapor valve and into the charcoal canister. Also

4. Position the exhaust pipe assembly so that the

when the engine is not running, the grav-

front and rear exhaust pipes fit into the front and

ity-operated trap door in the air filter backplate

rear cylinder head ports. Slide the retaining ring and

blocks the inlet port of the air filter. This prevents

exhaust flange over the mounting studs and install

hydrocarbon vapors emanating from the carburetor

the lock nuts. Tighten the nuts finger-tight only.

venturi from escaping into the atmosphere.

When the engine is running, these vapors are drawn

5. Position the rear exhaust pipe clamp onto the frame

through a purge hose and into the carburetor where they

bracket and install the nut and bolt (Figure 104).

burn in the combustion chambers. The vapor valve also

6. Position the front exhaust pipe clamp onto the

prevents gasoline vapor from escaping from the carbon

frame bracket and install the nut and bolt (Figure

canister if the motorcycle falls on its side.

103).

Also when the engine is running, the engine vac-

7. Check the exhaust assembly alignment, then

uum pulls the air filter backplate trap door open, al-

tighten the cylinder head stud nuts as follows:

lowing air to enter.

a. Tighten the upper nut finger-tight.

b. Tighten the lower nut to 10 in-lbs. (1 N•m).

c. Tighten the upper nut to 60-80 in-lbs. (7-9

Inspection/Replacement

N•m).

d. Tighten the lower nut to 60-80 in-lbs. (7-9

Refer to Figure 110 for component and hose

N•m).

routing. Before removing the hoses from any of

8. Tighten the front and then the rear exhaust pipe

the parts, mark the hose and the fitting with a piece

clamp bolts and nuts to the specification in Table 3.

of masking tape to identify where the hose goes.

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304

CHAPTER SEVEN

110

Carburetor

Backplate

Vacuum hose

Clean air

inlet hose

Purge hose

Fuel valve

Trap door

Fuel tank

Vent hose

Charcoal

canister

1. Check all emission control lines and hoses to

make sure that they are correctly routed and con-

111

nected.

WARNING

Make sure the fuel tank vapor hoses

are routed so they cannot contact any

hot engine or exhaust component.

These hoses contain flammable vapor.

If a hose melts from contacting a hot

part, leaking vapor may ignite, caus-

ing severe motorcycle damage and

rider injury.

5. When replacing one or more lines or hoses, refer

2. Make sure there are no kinks in the lines or

to the diagram for the specific model being worked

hoses. Also inspect the hose and lines for excessive

on.

wear or burning on lines that are routed near engine

hot spots.

Vapor Valve Replacement

3. Check the physical condition of all lines and

hoses in the system. Check for cuts, tears or loose

The vapor valve (Figure 111) is connected in the

connections. These lines and hoses are subjected to

vent hose between the fuel tank and carbon canister.

various temperature and operating conditions and

1. Label the hoses at the vapor valve, then discon-

eventually become brittle and crack. Replace dam-

nect them.

aged lines and hoses.

2. Remove the vapor valve.

4. Check all components in the emission control

CAUTION

system for damage, such as broken fittings or bro-

The vapor valve must be installed in

ken nipples on the component.

the vent hose in a vertical position

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FUEL, EXHAUST AND EMISSION SYSTEMS

305

with the longer end facing up toward

112

the fuel tank.

3. Install the vapor valve and secure both hoses.

Carbon Canister

Replacement

1. Prior to disconnecting any of the hoses, label the

hoses and the canister fittings. Plug the open end of

each hose to prevent contamination.

2. Disconnect the clean air hose (Figure 112) from

the right side of the canister.

3. Disconnect the purge hose and the vent hose (A,

113

Figure 113) from the left side of the canister.

4. Using a flat-blade screwdriver, lift up the tang on

the base of the canister, slide the canister toward the

left side and remove the canister (B, Figure 113)

7

from the mounting bracket.

5. Install the carbon canister by reversing these

steps while noting the following:

a. Slide the canister into the mounting bracket

until it clicks.

b. Attach the hoses to the correct fittings as

noted during removal.

Table 1 CARBURETOR JET SIZES

Year and model

Main jet

Pilot jet

All years and models

190

45

Table 2 FUEL SYSTEM TORQUE SPECIFICATIONS

Item

ft.-lb.

in.-lb.

N·m

Air filter cover screw

-

36-60

4-7

Air filter backplate screws

-

20-40

2-5

Breather hollow bolts

-

124-142

14-16

Fuel shutoff valve

Mounting hex fitting

15-20

-

20-27

Diaphragm screws

-

18.5

2.1

Fuel tank mounting bolts

10-18

-

14-24

Intake manifold Allen bolts

15-17

-

20-23

Table 3 EXHAUST SYSTEM TORQUE SPECIFICATIONS

Item

ft.-lb.

in.-lb.

N·m

Exhaust flange nuts

Refer to text procedure

Muffler clamp nuts

45-60

-

61-81

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308

CHAPTER EIGHT

tive (+) cable. This minimizes the chance of a tool

shorting to ground when disconnecting the battery

1

positive cable.

Negative Cable

Some of the component replacement procedures

and some of the test procedures in this chapter re-

quire disconnecting the negative battery cable as a

safety precaution.

NOTE

Always disarm the optional TSSM se-

curity system prior to disconnecting

2

the battery or the siren will sound.

1. Remove the seat as described in Chapter Thir-

teen.

2. Remove the nut (Figure 1) securing the negative

cable to the frame. Move the cable away from the

battery to avoid making accidental contact with the

battery post.

3. Connect the negative cable onto the frame post,

reinstall the nut (Figure 1) and tighten securely.

4. Install the seat.

3

Battery Cable Service

To ensure good electrical contact between the

battery and the electrical cables, the cables must be

clean and free of corrosion.

1. If the electrical cable terminals are badly cor-

roded, disconnect them from the motorcycle’s elec-

trical system.

2. Thoroughly clean each connector with a wire

brush and then with a baking soda solution. Rinse

thoroughly with clean water and wipe dry with a

4

clean cloth.

3. After cleaning, apply a thin layer of dielectric

grease to the battery terminals before reattaching

the cables.

4. If disconnected, attach the electrical cables to the

motorcycle’s electrical system.

5. After connecting the electrical cables, apply a

light coat of dielectric grease to the terminals to re-

tard corrosion and decomposition of the terminals.

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ELECTRICAL SYSTEM

309

Battery and Tray

5

Removal/Installation

NOTE

Always disarm the optional TSSM se-

curity system prior to disconnecting

the battery or the siren will sound.

1. Remove the seat as described in Chapter Thir-

teen.

2. Remove the nut (Figure 1) securing the negative

cable to the frame.

3. Disconnect the negative cable from the frame

post and reinstall the nut to avoid misplacing it.

6

4. Remove the bolt (Figure 2) securing the positive

cable to the battery. Disconnect the cable.

5. Remove the bolt (Figure 3), at the rear of the

battery case, securing the battery tray to the chassis.

6. Carefully tilt the battery and tray down and re-

move the top cover (Figure 4).

8

7. Remove the battery (Figure 5) from the tray and

frame.

8. If necessary, unhook the tab on the backside of

the battery tray (A, Figure 6) from the frame mount

and remove the battery tray (B) from the frame.

9. Inspect the battery tray for corrosion or damage.

Replace if necessary.

7

10. If removed, hook the front of the battery tray

onto the frame mount (Figure 7) and install the bat-

tery tray (B, Figure 6) onto the frame. Correctly lo-

cate the battery positive cable (C, Figure 6) behind

the battery tray.

11. If removed, install the negative battery cable as

shown in A, Figure 8. Do not wait until the battery

is installed, since there is limited working room af-

ter the battery is installed.

12. Position the battery with the cable terminal side

going in first.

13. Reinstall the battery onto the battery tray in the

frame (Figure 5). Direct the negative cable through

8

the frame and into position on the frame mount.

14. Install the battery top cover (Figure 4).

15. Install the bolt (Figure 3) securing the battery

tray to the chassis and tighten securely.

16. Connect the positive cable (Figure 2) to the

battery. Tighten the bolt securely.

17. Connect the negative cable onto the frame post,

reinstall the nut (Figure 1) and tighten securely.

18. After connecting the electrical cables, apply a

light coat of dielectric grease to the battery termi-

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310

CHAPTER EIGHT

nals to prevent corrosion and deterioration of the

terminals.

9

19. Install the seat.

Inspection and Testing

The battery electrolyte level cannot be serviced.

Never attempt to remove the sealing bar cap (B,

Figure 8) from the top of the battery. This bar cap

was removed for the initial filling of electrolyte

prior to delivery of the motorcycle, or the installa-

tion of a new battery, and is not to be removed there-

after. The battery does not require periodic

6. Check the battery cable ends (C, Figure 10) for

electrolyte inspection or water refilling. Refer to the

corrosion and damage. If corrosion is minor, clean

label (Figure 9) on top of the battery.

the battery cable ends with a stiff wire brush. Re-

Even though the battery is a sealed type, protect

place worn or damaged cables.

eyes, skin and clothing; electrolyte, which is very

7. Connect a digital voltmeter between the battery

corrosive, may have spilled out and can cause se-

negative and positive leads. Note the following:

vere chemical skin burns and permanent injury. The

a. If the battery voltage is 12.6 volts (at 20° C

battery case may be cracked and leaking electrolyte.

[68° F]), or greater, the battery is fully

If any electrolyte is spilled or splashed on clothing

charged.

or skin, immediately neutralize with a solution of

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

baking soda and water, then flush with an abun-

20° C [68° F]), or lower, the battery is under-

dance of clean water.

charged and requires charging.

8. If the battery is undercharged, recharge it as de-

WARNING

scribed in this chapter. Then test the charging sys-

Electrolyte splashed into the eyes is

tem as described in Chapter Two.

extremely harmful. Always wear

safety glasses while working with a

9. Inspect the battery case for contamination or

battery. If electrolyte gets into the

damage. Clean with a solution of baking soda and

eyes, call a physician immediately

water.

and force the eyes open and flood

them with cool, clean water for ap-

proximately 15 minutes.

Charging

1. Remove the battery as described in this chapter.

Refer to Battery Initialization in this chapter if

Do not clean the battery while it is mounted in the

the battery is new.

frame.

If recharging is required on a maintenance-free

2. Set the battery on a stack of newspapers or shop

battery, a digital voltmeter and a charger with an ad-

cloths to protect the surface of the workbench.

justable amperage output are required. If this equip-

3. Check the entire battery case (A, Figure 10) for

ment is not available, it is recommended that battery

cracks or other damage. If the battery case is

charging be entrusted to a shop with the proper

warped, discolored or has a raised top, the battery

equipment. Excessive voltage and amperage from

has been overcharged and overheated.

an unregulated charger can damage the battery and

4. Check the battery terminal bolts, spacers and

shorten service life.

nuts (B, Figure 10) for corrosion or damage. Clean

The battery should only self-discharge approxi-

parts thoroughly with a solution of baking soda and

mately one percent each day. If a battery not in use,

water. Replace corroded or damaged parts.

with no loads connected, loses its charge within a

5. If corroded, clean the top of the battery with a

week after charging, the battery is defective.

stiff bristle brush using the baking soda and water

If the motorcycle is not used for long periods of

solution.

time, an automatic battery charger with variable

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ELECTRICAL SYSTEM

311

CAUTION

10

If the battery emits an excessive

amount of gas during the charging cy-

cle, decrease the charge rate. If the

battery becomes hotter than 110° F

(43° C) during the charging cycle,

turn the charger to the OFF position

and allow the battery to cool. After

cooling down, continue with a re-

duced charging rate and continue to

monitor the battery temperature.

7. Turn the charger to the ON position.

8. After the battery has been charged for the

voltage and amperage outputs is recommended for

pre-determined time, turn the charger to the OFF

optimum battery service life.

position, disconnect the leads and measure the bat-

WARNING

tery voltage. Refer to the following:

During charging, highly explosive hy-

a. If the battery voltage is 12.6 volts (at 20° C

drogen gas is released from the bat-

[68° F]), or greater, the battery is fully

tery. The battery should be charged

charged

only in a well-ventilated area away

8

from open flames

(including pilot

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

lights on some gas home appliances).

[68° F]), or lower, the battery is undercharged

Do not allow any smoking in the area.

and requires additional charging time.

Never check the charge of the battery

9. If the battery remains stable for one hour, the

by arcing across the terminals; the re-

battery is charged.

sulting spark can ignite the hydrogen

gas.

10. Install the battery into the motorcycle as de-

scribed in this chapter.

CAUTION

Always disconnect the battery cables

from the battery. If the cables are left

Battery Initialization

connected during the charging proce-

dure, the charger may destroy the di-

A new battery must be fully charged to a specific

odes in the voltage regulator/rectifier.

gravity of 1.260-1.280 before installation. To bring

the battery to a full charge, give it an initial charge.

1. Remove the battery from the motorcycle as de-

Using a new battery without an initial charge will

scribed in this chapter.

cause permanent battery damage. That is, the bat-

2. Set the battery on a stack of newspapers or shop

tery will never be able to hold more than an 80%

cloths to protect the surface of the workbench.

charge. Charging a new battery after it has been

3. Make sure the battery charger is turned to the

used will not bring its charge to 100%. When pur-

OFF position, prior to attaching the charger leads to

chasing a new battery, verify its charge status.

the battery.

4. Connect the positive charger lead to the positive

NOTE

(+) battery terminal and the negative charger lead to

Recycle the old battery. When a new

the negative (-) battery terminal.

battery is purchased, turn in the old

one for recycling. Most motorcycle

5. Set the charger at 12 volts. If the output of the

dealerships will accept the old battery

charger is variable, select the low setting.

in trade when purchasing a new one.

6. The charging time depends on the discharged

Never place an old battery in the

condition of the battery. Refer to Table 3 for the

household trash since it is illegal, in

suggested charging time. Normally, a battery

most states, to place any acid or lead

should be charged at 1/10th its given capacity.

(heavy metal) contents in landfills.

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312

CHAPTER EIGHT

Load Testing

11

LOAD TEST

A load test checks the battery’s performance un-

der full current load and is the best indication of bat-

tery condition.

A battery load tester is required for this proce-

+

dure. When using a load tester, follow the manufac-

Load

Battery

turer’s instructions. Figure 11 shows a typical load

tester

tester and battery arrangement.

-

1. Remove the battery from the motorcycle as de-

scribed in this chapter.

NOTE

If the battery required charging, let

the battery stand for at least one hour

CHARGING SYSTEM

prior to performing this test.

An electrical diagram of the charging system is

2. The battery must be fully charged before begin-

shown in Figure 12 for 1999-2001 models. Refer to

ning this test. If necessary, charge the battery if nec-

the wiring diagrams at the end of the manual for

essary as described in this section.

2002-on models. The charging system consists of the

battery, alternator and voltage regulator/rectifier

WARNING

(Figure 13 and Figure 14). Alternating current gen-

The battery load tester must be turned

erated by the alternator is rectified to direct current.

to the OFF position prior to connect-

The voltage regulator maintains a constant voltage to

ing or disconnecting the test cables to

the battery. Otherwise, a spark could

the battery and additional electrical loads, such as the

cause the battery to explode.

lights and ignition system, at a constant voltage re-

gardless of variations in engine speed and load.

CAUTION

A malfunction in the charging system generally

To prevent battery damage during

causes the battery to remain undercharged. To pre-

load testing, observe these two re-

vent damage to the alternator and the regulator/rec-

quirements: Do not load test a dis-

tifier when testing and repairing the charging

charged battery and do not load test

system, note the following precautions:

the battery for more than 20 seconds.

1. Disarm the optional TSSM security system prior

Performing a load test on a dis-

to disconnecting the battery or the siren will sound.

charged battery can result in perma-

nent battery damage.

2. Always disconnect the negative battery cable, as

described in this chapter, before removing a compo-

3.

Load test the battery as follows:

nent from the charging system.

a. Connect the load tester cables to the battery

3. When it is necessary to charge the battery, re-

following its manufacturer’s instructions.

move the battery from the motorcycle and recharge

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

it as described in this chapter.

amperage (CCA), or 135 amperes.

4. Inspect the battery case. Look for bulges or cracks

c. After 15 seconds, the voltage reading (with

in the case, leaking electrolyte or corrosion build-up.

the load still applied) must be 9.6 volts or

5. Check the charging system wiring for signs of

higher at 70° F (21° C). Now quickly remove

chafing, deterioration or other damage.

the load and turn the tester OFF.

6. Check the wiring for corroded or loose connec-

4.

If the voltage reading is 9.6 volts or higher, the

tions. Clean, tighten or reconnect as required.

battery output capacity is good. If the reading is be-

low 9.6 volts, the battery is defective.

Battery Drain

5. With the tester in the OFF position, disconnect

the cables from the battery.

Perform this test prior to performing the output

6. Install the battery as described in this chapter.

test.

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ELECTRICAL SYSTEM

313

12

CHARGING SYSTEM (1999-2001 MODELS)

Stator

Circuit

breaker

Diagram Key

30 A

Voltage

regulator

Connectors

Ground

Frame ground

Connection

No connection

8

-

+

Starter

Color Code

B Black

Battery

*Refer to the wiring diagrams at the end of this manual for 2002-on models

13

CHARGING SYSTEM COMPONENTS (FXDP)

1. Stator coil assembly

2. Allen bolt

3. Rotor

4. Washer

5. Cable seal

6. Terminal socket

7. Socket housing

8. Primary lock

9. Rubber boot

10. Secondary lock

11. Connector

12. Terminal pin

13. Heat sink tubing

14. Bolt

15. Voltage regulator

16. Nut

17. Mounting bracket

18. Washer

19. Lockwasher

20. Allen bolt

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314

CHAPTER EIGHT

14

CHARGING SYSTEM COMPONENTS

(ALL MODELS EXCEPT FXDP)

1. Stator coil assembly

2. Allen bolt

3. Inner washer

4. Rotor

5. Outer washer

6. Cable seal

7. Terminal socket

To main

8. Socket housing

circuit

9. Primary lock

breaker

10. Rubber boot

(silver stud)

11. Secondary lock

12. Connector

13. Terminal socket

14. Bolt

15. Terminal pin

16. Voltage regulator

17. Heat sink tubing

18. Terminal pin

19. Heat sink tubing

20. Terminal pin

21. Bolt

22. Heat sink tubing

1. Turn the ignition switch OFF.

2. Remove the seat.

15

Ammeter

NOTE

Always disarm the optional TSSM se-

curity system prior to disconnecting

the battery or the siren will sound.

3. Disconnect the battery negative lead as de-

scribed in this chapter.

4. Switch the ammeter from its highest to lowest

amperage scale while reading the meter scale.

CAUTION

Battery

Before connecting the ammeter into

ground

the circuit in Step 4, set the meter to its

cable

highest amperage scale. This will pre-

vent a possible large current flow

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ELECTRICAL SYSTEM

315

b. Short circuit in the system.

16

c. Loose, dirty or faulty electrical system con-

nectors in the charging system wiring har-

ness.

7. Disconnect the ammeter test leads and reconnect

the battery negative lead.

Testing

A malfunction in the charging system generally

causes the battery to remain undercharged. Perform

the following visual inspection to determine the

cause of the problem. If the visual inspection proves

satisfactory, test the charging system as described

17

under Charging System in Chapter Two.

1. Make sure the battery cables (Figure 16) are

connected properly. If polarity is reversed, check

for a damaged rectifier.

2. Inspect the terminals for loose or corroded con-

8

nections. Tighten or clean 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

18

connections. Clean, tighten or connect as re-

quired.

ALTERNATOR

Rotor Removal/Installation

NOTE

Always disarm the optional TSSM se-

curity system prior to disconnecting

the battery or the siren will sound.

1. Disconnect the negative battery cable as de-

from damaging the meter or blowing

the meter’s fuse, if so equipped.

scribed in this chapter.

2. Remove the primary chain case cover and inner

5.

Connect the ammeter between the negative bat-

housing as described in Chapter Five.

tery cable and the negative terminal of the battery

3. If still in place, remove the shaft extension (A,

(Figure 15). If the needle swings even the slightest

Figure 17) and outer spacer (B) from the crank-

amount when the meter is connected, there is a cur-

shaft.

rent draw in the system that will discharge the bat-

4. Slide the rotor (A, Figure 18) off the crankshaft.

tery.

If necessary, insert two wire hooks into the holes in

6. If the current draw is excessive, the probable

the face of the rotor. Slide the rotor off.

causes are:

5. On 1999 models, remove the inner spacer (Fig-

a. Damaged battery.

ure 19) from the crankshaft.

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316

CHAPTER EIGHT

6. Inspect the rotor magnets (Figure 20) for small

bolts, washers or other metal debris that may have

19

been picked up by the magnets. These small metal

bits can cause severe damage to the alternator stator

assembly.

7. Check the inner splines (Figure 21) for wear or

damage. Replace the rotor if necessary.

8. Install by reversing these removal steps.

Stator Removal

1. Remove the rotor as described in this chapter.

2. Disconnect the stator electrical connector (B,

Figure 18) from the wiring harness.

20

NOTE

The following photographs are shown

with the engine removed to better il-

lustrate the steps.

3. Remove the four T27 Torx screws securing the

stator assembly (Figure 22). New Torx screws must

be used on installation.

NOTE

If necessary, spray electrical contact

cleaner or glass cleaner around the

wiring harness grommet to help ease

21

it out of the crankcase boss recepta-

cle.

4. Carefully pull the stator wiring harness and

grommet out of the crankcase boss receptacle (A,

Figure 23) and remove the stator assembly (B).

5. Inspect the stator mounting surface on the crank-

case (Figure 24) for any oil residue that may have

passed by a damaged oil seal. Clean off if necessary.

6. Inspect the stator wires (A, Figure 25) for fray-

ing or damage.

7. Inspect the rubber grommet (B, Figure 25) for

deterioration or hardness.

22

8. Check the stator connector pins (Figure 26) 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

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ELECTRICAL SYSTEM

317

23

27

through until the grommet is correctly seated (Fig-

24

ure 27).

CAUTION

New T27 Torx screws must be in-

stalled. The threadlocking compound

originally applied to the Torx screws

is sufficient for one time use only. If a

8

used Torx screw is installed, it can

work loose and cause engine damage.

3. Move the stator into position on the crankcase

and install four new T27 Torx screws. Tighten the

screws to the specifications in Table 6.

4. Connect the stator electrical connector (B, Fig-

25

ure 18) onto the wiring harness.

5. Install the rotor as described in this chapter.

VOLTAGE REGULATOR

Removal/Installation

NOTE

Always disarm the optional TSSM se-

curity system prior to disconnecting

the battery or the siren will sound.

1. Disconnect the negative battery cable from the

battery as described in this chapter.

26

2. Remove the fuel tank as described in Chapter

Seven.

3. Refer to Electrical Panel in this chapter. Re-

move the cover and outer panel to gain access to the

circuit breaker.

4. Disconnect the voltage regulator black wire

(Figure 28) from the main circuit breaker.

5. Disconnect and remove any cable straps and

clips securing the voltage regulator black wire to the

frame.

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318

CHAPTER EIGHT

28

29

30

ENGINE SENSORS AND SWITCHES

1. Screw

7. Allen bolt

12. Connector-oil pressure

2. Clip

8. Oil pressure switch

switch

3. MAP sensor

9. Oil pressure switch

13. Connector-camshaft

4. Seal

harness connector

position sensor

5. O-ring seal

10. Harness sleeve

(1999-2000)

6. Crankshaft position

11. Connector-crankshaft

14. Camshaft position

sensor

position sensor

sensor (1999-2000)

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ELECTRICAL SYSTEM

319

d. Remove the electrical wires from the connec-

31

tor.

9. Remove the bolts securing the voltage regulator

to the frame. Note the location of the ground strap

on the left side mounting bolt (B, Figure 29).

10. Remove the voltage regulator (C, Figure 29).

Untie the string from the black wire.

11. Install by reversing these removal steps while

noting the following:

a. Tie the string to the voltage regulator black

wire.

b. Carefully pull the string and black wire back

through the frame to the electrical panel. Un-

tie and remove the string.

32

c. Be sure to install the ground wire under the

left side mounting screw (B, Figure 29).

IGNITION SYSTEM

8

The ignition system consists of an ignition coil,

two spark plugs, the ignition module, crankshaft po-

sition sensor

(CKP), manifold absolute pressure

sensor (MAP) and the bank angle sensor (BAS).

The 1999-2000 models are also equipped with the

camshaft position sensor (CMP) that was elimi-

6.

Tie a piece of string to the voltage regulator wire

nated on 2001-on models. Refer to Figure 30 for

at the electrical panel. Tie the other end of the string

the location of all sensors.

to the frame next to the electrical panel. If neces-

The ignition module is located behind the electri-

sary, make a drawing of the wire routing through the

cal panel. It determines the spark advance for cor-

frame. It is easy to forget the routing path after re-

rect ignition timing based on signals from the CKP,

moving the wire.

MAP and BAS (and CMP on 1999-2000 models).

The ignition system fires the spark plugs near top

7. Carefully pull the black wire and string to-

dead center for starting, then varies the spark ad-

ward the front of the motorcycle and through the

vance from 0 to 50° depending on engine speed,

frame. If the wire becomes tight or stuck, do not

crankshaft position, and intake manifold pressure. It

force it.

also regulates the low-voltage circuits between the

NOTE

battery and the ignition coil. The ignition module is

On California models, the connector

a non-repairable item and, if defective, must be re-

is located behind the evaporation

placed.

emission charcoal canister (A, Figure

The crankshaft position sensor (CKP) (Figure

29).

31) is mounted on the front left side of the crankcase

next to the oil filter. The CKP provides engine speed

8. Disconnect the voltage regulator electrical con-

and position data to the ignition module. The sensor

nector from the wiring harness as follows:

is an induction-type pulse generator that generates

a. Remove the screw securing the rubber boot

an alternating current (AC) signal as the 30 teeth of

and electrical connector from the front engine

the flywheel (speed) and the two-tooth gap (refer-

mount.

ence position TDC) pass by the sensor.

b. Slide the rubber boot off the connector.

The MAP sensor (Figure 32) is located on top of

c. Remove the secondary lock off the electrical

the intake manifold. This sensor monitors the intake

wire connectors.

manifold vacuum and sends this information to the

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