Harley Davidson 1999-2005 Harley Dyna Models. Repair Manual - page 29

 

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Harley Davidson 1999-2005 Harley Dyna Models. Repair Manual - page 29

 

 

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560
SUPPLEMENT
The fuse ratings are identical to prior years. Refer to
2. Disconnect the negative battery cable as described
Figure 86 or Figure 87 for fuse location on the panel.
in Chapter Eight.
3. Hold onto both sides of the cover, pull straight out
Fuse Replacement
and remove the cover (Figure 83) from the electrical
panel.
NOTE
4. Insert a small flat blade screwdriver under the
On models so equipped, always disarm
blown fuse and disengage it from the fuse panel.
the optional TSSM security system
prior to disconnecting the battery or the
5. Install a new fuse and press it into the fuse panel
siren will sound.
until it bottoms.
1. Remove the seat as described in Chapter Thirteen.
6. Install the cover onto the electrical panel.
Table 11 REPLACEMENT BULBS
Item
Size (all 12 volt) × quantity
Headlamp
55/60
Position lamp*
3.9
Indicator lamps
FXDL, FXDLI
1.1 × 4
FXDP
2.1 × 4
All models except FXDL and FXDP
2.2 × 3
Fuel gauge
FXDL FXDLI, FXDWG, FXDWGI
2.7
FXD, FXDI, FXDC, FXDCI, FXDX,
FXDXI, FXDX-CONV, FXDXT
3.7
FXDP
NA
Front turn signal/running light
27/7 × 2
Front turn signal*
21 × 2
Rear turn signal
27 ×2
Rear turn signal
21 × 2
Tail/brake lamp
2003
7/27
2004-on
7/25
Tail/brake lamp*
5/21
* Indicates bulb specification for HD International models.
Table 12 ELECTRICAL SYSTEM TORQUE SPECIFICATIONS
Item
ft.-lb.
in.-lb.
N•m
Crankshaft Allen screws
-
90-120
10.2-13.6
Electrical panel
Long screws
-
50
5.6
Short screw
-
100
11.3
Ignition coil screws
-
50
5.6
Starter jackshaft bolt
-
60-80
6.8-9.0
Stator screws
-
55-75
6.2-8.4
Voltage regulator bolts
-
60-80
6.8-9.0

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2002-2005 MODEL SERVICE INFORMATION
561
CHAPTER TEN
FRONT SUSPENSION AND STEERING
FRONT FORK
STEERING HEAD AND STEM
Front Fork Service
Removal/Installation
(2002-On FXDL)
(2005 FXDC and FXDCI Models)
Removal and installation of the steering stem is
Service to the front fork is the same as on prior
the same as on prior models with the exception of
FXDL models with the exception of the fork oil
the handlebar holder that is also the speedometer
quantity and oil level.
mounting bracket (Figure 88).
Assemble the front fork as described in Chapter
Remove the bolts securing the handlebar
Ten. Add 10.6 oz. (314 ml) and adjust the fork oil
holder/speedometer mounting bracket. Secure the
level so it is 6.69 in. (169.9 mm) from the top sur-
speedometer and mounting bracket to the lower
face of the fork tube.
stem after removal.
Table 13 FRONT FORK OIL CAPACITY AND OIL LEVEL DIMENSION
Oil level dimension
Model
Capacity oz. (ml)
in. (mm)
1999 models
FXDWG
10.2
(302)
-
All models except FXDWG
9.2 (272)
-
2000-on models
FXD, FXDI
10.6
(314)
6.69
(169.9)
FXDC, FXDCI
10.6 (314)
6.69
(169.9)
FXDL, FXDLI
10.7
(316)
7.20
(182.0)
FXDS-CONV
11.5 (341)
6.10
(154.9)
FXDWG, FXDWGI
12.0 (356)
7.28
(184.9)
FXDX, FXDXI, FXDXT
NA
14
FXDP
NA
NA = Information not available from the manufacturer.

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562
SUPPLEMENT
CHAPTER ELEVEN
REAR SUSPENSION
SHOCK ABSORBERS
Shock Absorber Busing
Inspection and Replacement
Shock absorber inspection is the same as on prior
models with the exception of the bushings. The bush-
ings are no longer available and cannot be replaced, if
worn or damaged, replace the shock absorber.
CHAPTER TWELVE
BRAKES
FRONT BRAKE PAD REPLACEMENT
91
Front brake pad removal and installation is the
same as on previous models with the following ex-
ception.
The brake pads are not symmetrical. The pad with
one tab (A, Figure 91) must be installed on the in-
board side of the left side caliper and on the out-
board side of the right side caliper. The pad with
two tabs (B, Figure 91) must be installed on the out-
board side of the left side caliper and on the inboard
side of the right side caliper.
REAR BRAKE PEDAL
REAR BRAKE PAD REPLACEMENT
(2003-ON FXDWG MODELS)
Rear brake pad removal and installation is the
same as on previous models with the following ex-
Removal/Lubrication/Installation
ception.
The brake pads are not symmetrical. The pad with
Refer to Figure 92.
one tab (A, Figure 91) must be installed on the out-
board side. The pad with two tabs (B, Figure 91)
1. Remove the exhaust system as described in
must be installed on the inboard side of the caliper.
Chapter Seven of the main body of this manual.

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2002-2005 MODEL SERVICE INFORMATION
563
92
REAR BRAKE PEDAL
1. Nut
8. Mounting bracket
2. Push rod
9. Bolt
3. Clevis pin
10. Pad
4. Bolt
11. Washer
5. Footrest mount
12. Cotter pin
6. Brake pedal
13. Acorn nut
7. Pivot shaft
2. Remove the bolt and nut securing the footrest to
8. Inspect the pivot shaft where the pedal rides for
the footrest mount. Remove the footrest.
wear.
3. Remove the cotter pin, washer and clevis pin se-
9. Lubricate the bushing and bracket shoulder with
curing the push rod to the brake pedal. Disconnect
waterproof grease.
the pushrod.
4. Remove the bolt securing the footrest mount and
10. Install the pedal by reversing these removal
14
the brake pedal to the mounting bracket. Remove
steps. Note noting the following:
the brake pedal.
a. Tighten the special bolt securely.
5. If necessary, remove the bolts securing the
mounting bracket to the frame and remove the
b. Install a new cotter pin and bend the ends over
mounting bracket.
completely.
6. Inspect the brake pedal for fractures or damage
c. Adjust the rear brake pedal height as de-
and replace if necessary.
scribed in Chapter Three of the main body of
7. Inspect the bushing within the pedal for wear.
this manual.
Replace if necessary.

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INDEX
A
rear caliper
Abbreviations, technical
35-36
1999 models
476-480
Air filter backplate
273-275, 525
2000-on models
480-483
Alignment, vehicle
402-404
rear pad replacement
562
Alternator
315-317, 546-548
1999 models
471-474
American tap and drill sizes
36
2000-2001 models
474-476
2002-2005 models
562
rear pedal
497
B
2003-on FXDWG models
562-563
Basic service methods
24-30
rear master cylinder
484-489
Battery
307-312
service
449-450
charging rates/times, approximate
373
system
voltage readings, maintenance free
373
Bearing
specifications
497
torque specifications
497-498
end play check, 1999 models,
front and rear wheel
387
race replacement, steering head
431-433
C
spacer shim
Caliper
1999, front and rear wheel
405
front brake
camshaft left side
197-198
1999 models
457-461
Bleeding the system
494-497
2000-on models
461-465
Body
rear brake
saddlebags
500
1999 models
476-480
seat
499
2000-on models
480-483
windshield
499-500
Camshaft support plate
155, 516
Brakes
bearing replacement
170-172
bleeding the system
494-497
disc
492-494
cleaning plug removal/installation
174
front caliper
installation
160-163
1999 models
457-461
oil pressure relief valve
2000-on models
461-465
removal/installation
173
front pad replacement
562
primary and secondary
1999 models
451-454
chain tensioner
174-175
2000-2001 models
454-457
rear
2002-2005 models
562
sprocket and crankshaft
front master cylinder
465-471
drive sprocket alignment
163-165
hose and line replacement
489-492
sprocket spacers
197
problems
64
support plate and camshafts
165-170

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565
INDEX
Carburetor
275-287
Driven sprocket assembly
391-392
jet sizes
305
operation
272-273
Case, transmission
264-269
E
Cast wheels
395
Electrical system,
Chaincase outer cover, primary
199-203
alternator
315-317, 546-548
Charging system
50-54, 312-315
basic information
306-307
Circuit breaker
372
battery
307-312
Clutch
62
charging rates/times, approximate
373
and primary chaincase
charging system
312-315
torque specifications
227
circuit breaker
372
assembly, 2005 models
522
diagnostic trouble codes
372
cable replacement
225-226
electric panel
359
plates and friction discs
203-208
2004-on models
552-554
release mechanism, transmission
electronic fuel injection (EFI)
525-527
side cover
261-263
fundamentals
22-24
shell
fuses
371-372
compensating sprocket and
and maxi-fues, 2004-on models
557-560
primary drive chain
208-212
horn
358-359
hub and sprocket
212-215
ignition system
319-332
specifications and sprocket sizes
226
instruments
366-371, 556-557
torque specifications
522
lighting system
346-350, 550
Compensating sprocket
maintenance free battery
and primary drive chain clutch shell . . . 208-212
voltage readings
373
inspection
217
panel
359
Conversion tables
34
replacement bulbs
374, 560
Crankcase and crankshaft
175, 516-520
specifications
65, 373
and connecting rods
speedometer speed sensor
365-366
cleaning and inspection
180-182
starter
cleaning and inspection
179-180
motor specifications
373
cylinder stud replacement
192-193
relay replacement, 2004-on fuel
end play inspection
187-191
injected models
555-556
disassembly
175-179
relay switch replacement
366
left side
2004 models
554-555
main bearing replacement
183-191
starting system
42-50, 332-346, 550
oil seal replacement
191-192
switches
351-358, 550
right side main bearing replacement . . . 182-183
torque specifications
374-375, 560
Crankshaft left side bearing spacer shim
197-198
turn signal
Cylinder
133-138
15
and security modules,
head
119-123, 507
2001 models
364-365
module
1999-2000 models
359-363
D
Decimal
2004-on models
554
and metric equivalents
33
speed and distance test
375
place values
16
speed and time test
375
Diagnostic trouble codes
65, 372
voltage regulator
317-319, 548
Drive
wiring diagrams
571-590
belt
392-393
Electronic fuel injection (EFI)
525-527
sprocket
392
Emission control system
transmission
263-264
air filter backplate
525

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566
INDEX
Emission control system (continued)
service
evaporative
precautions
100-102
California models
303-304
specifications
194-196, 521
service
304-305
servicing engine in frame
103
Engine
103-107, 506
special tools
102
and primary drive/transmission
torque specifications
196-197, 521
oil capacities
98
valve
break-in
193
and components
123-133
camshaft
2005 models
507-515
bearing replacement
170-172
lifters
147-150
cleaning plug removal/installation
174
Evaporative emission control system
installation
160-163
service
304-305
oil pressure relief valve
California models
303-304
removal/installation
173
Excessive vibration
63
primary and secondary
Exhaust system
301-303
chain tensioner
174-175
torque specifications
305
rear camshaft sprocket and crankshaft
External shift mechanism
260-261
drive sprocket alignment
163-165
support plate
155, 516
F
support plate and camshafts
165-170
Fasteners
4-7
crankcase and crankshaft
175, 516-520
Fluids and lubricants, recommended
98
and connecting rods
Fork
cleaning and inspection
180-182
front
561
cleaning and inspection
179-180
FXD, FXDL, FXDS-con, FXDWG,
cylinder stud replacement
192-193
FXDP and 1999 FXDX
408-415
disassembly
175-179
FXDXT, 2000-on FXDX
415-427
left side main bearing
oil capacity and oil level dimension
434
replacement
183-191
specifications, FXDXT and
left side oil seal replacement
191-192
2000-on FXDX
434
right side main bearing
Friction discs, clutch plates
203-208
replacement
182-183
crankshaft left side bearing
Front hubs
spacer shim
197-198
and rear
1999
383-387
cylinder
133-138
head
119-123, 507
2000-on
387-391
general specifications
193-194
brake pad replacement
lubrication
61-62
1999 models
451-454
noises
61
2000-2001 models
454-457
oil
2002-2005 models
562
filter mount
154-155
fork oil capacity and oil level dimension
99
pump
150-154
suspension and steering
63-64
specifications
98
wheel
377-379
performance
41-42
Fuel
pistons and piston rings
138-145, 515-516
air filter backplate
273-275
principles
100
carburetor
275-287
pushrods
145-146
jet sizes
305
and lifter location
196
operation
272-273
and rocker arms
107-119
depressuring fuel injected models
527
rear camshaft sprocket spacers
197, 521
induction module, fuel injected models . 528-531
rocker arms and pushrods . . . 107-119, 506-507
intake manifold
287-289

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INDEX
567
pump and fuel filter,
sprocket
392
2004-on fuel injected models
542-545
driven sprocket assembly
391-392
shutoff valve
296-297
front and rear
starting enrichment valve (choke)
1999
383-387
cable replacement
292
2000-on
387-391
system
58-61
sprocket and shell
212-215
torque specifications
305, 545
tank
293-296
I
2004-on
Idle speed adjustment
95-96, 506
carbureted models
535-540
Ignition system
54-58, 319-332
fuel injected models
540-542
2004-on models
548-550
console
533-535
Instruments
366-371
gauge
298-301
Intake manifold
287-289
top plate and fuel gauge sending unit,
2004-on all models
542
L
throttle and idle cable
Lifter and pushrod
fuel injected models
531-533
location
196
replacement
289-292
Lighting system
63, 346-350, 550
Fuses
371-372
Lubrication
and maxi-fuse, 2004-on models
557-560
and maintenance schedule
96-97
engine
G
oil, specifications
98
General information
primary drive/transmission
American tap and drill sizes
36
oil capacities
98
basic
front fork, oil capacity and
service methods
24-30
oil level dimension
99
tools
9-14
periodic
68-77, 504-506
conversion tables
34
recommended lubricants
decimal
and fluids
98
and metric equivalents
33
place values
16
dimensions
32-33
M
electrical system fundamentals
22-24
Main drive gear
257-260
fasteners
4-7
Maintenance
model designation
32, 502
and lubrication schedule
96-97
precision measuring tools
14-22
idle speed adjustment
506
serial numbers
4
intervals
67
shop supplies
7-9
periodic
77-90, 505-506
15
special tools
24, 36-37
routine safety checks
66-67
storage
30-31
tires
technical abbreviations
35-36
and wheels
67-68, 504
torque specifications, ft.-lb
35
inflation pressure, cold
98
vehicle weight, dry
33, 503
tune-up
specifications
99
H
torque specifications
98-99, 506
Handlebar
406-408
Master cylinder
Horn
358-359
front
465-471
Hubs
rear
484-489
drive
Model designation
32
belt
392-393
Motorcycle stands
376-377

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INDEX
568
Serial numbers
4
O
Oil
Service precautions, engine
100-102
filter mount
154-155
Servicing engine in frame
103
level dimension and
Shafts, transmission
243-257
front fork oil capacity
99
Shift
pan, transmission
269
forks
239-241
pump
150-154
mechanism, external
260-261
Operating requirements
39
Shifter
adjustment, transmission
228-232
2003-on models
523
P
cam
Pistons and piston rings
138-145,
515-516
1999-2000
233-237
Primary drive
2001
237-239
chain
Shock absorbers
435-439, 562
alignment
215-217
adjustment
439-440
and guide inspection
215
Shop supplies
7-9
chaincase
Shutoff valve, fuel
296-297
inner housing
217-222
Special tools
36-37
outer cover
199-203
engine
102
clutch and primary chain case
Specifications
torque specifications
227
battery charging rates/times,
compensating sprocket
approximate
373
inspection
217
brake system
497
sprocket alignment spacers
227
torque
497-498
starter jackshaft
223-225
carburetor jet sizes
305
Pushrods
145-146
clutch
and
and primary chain case torque
227
lifter location
196
and sprocket sizes
226
rocker arms
107-119
crankshaft left side
bearing spacer shim
197-198
R
electrical
65, 373
Rear
system torque
374-375
brake
engine
pad replacement
and primary drive/transmission
1999 models
471-474
oil capacities
98
2000-2001 models
474-476
oil
98
2002-2005 models
562
specifications
pedal
497
service
194-196
hubs, and front
torque
196-197
1999
383-387
exhaust system torque
305
2000-on
387-391
front and rear wheel bearing
wheel
380-383
spacer shims, 1999
405
Replacement bulbs
374
front fork
Rim and laced wheel service
394-395
FXDXT and 2000-on FXDX
434
Rocker arms and pushrods
107-119
oil capacity and oil
Routine safety checks
66-67
level dimension
99, 434
front suspension torque
433-434
S
fuel system torque
305
Saddlebags
500
general
Seat
499
dimensions
32-33

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569
INDEX
engine
193-194
fork
561
torque, ft.-lb
35
FXDXTand 2000-on FXDX
434
maintenance
fork, FXD, FXDL, FXDS-con,
and tune-up
99
FXDWG, FXDP and 1999 FXDX . . 408-415
and tune-up torque
98-99
FXDXT, 2000-on FXDX
415-427
free battery voltage readings
373
steering head and stem
561
push rod and lifter location
196
torque specifications
433-434
rear
rear
camshaft sprocket spacers
197-197
swing arm
440-448
suspension torque
448
shock absorber adjustment
439-440
recommended lubricants and fluids
98
shock absorbers
435-439, 562
sprocket alignment spacers
227
torque specifications
448
starter motor
373
Swing arm, rear
440-448
Switches
351-358, 550
test
64
tire inflation pressure, cold
98, 405
transmission
269
T
service
269-270
Tap and drill sizes, American
36
torque
271
Technical abbreviations
35-36
vehicle weight, dry
33
Throttle and idle cable
wheel
404
replacement
289-292
torque
404
Tires
396
Speedometer speed sensor
365-366
and wheels
67-68, 503
Sprocket
inflation pressure, cold
405
alignment spacers
227
inspection
68, 504
sizes, and clutch specifications
226
repairs
400-402
Starter
tubeless changing
397-400
jackshaft
223-225
Tools
motor
basic
9-14
specifications
373
precision measuring
14-22
test specifications
64
special
24, 36, 102
relay switch replacement
366
Top cover, transmission
232-233
2004-models
554-555
Torque specifications
Starting
brake system
497-498
enrichment valve (choke)
clutch
522
cable replacement
292
electrical system
374-375, 560
system
332-346, 550
engine
196-197, 521
the engine
39-41
exhaust system
305
Steering
fuel system
305, 545
15
handlebar
406-408
general
35
head
maintenance
506
and stem
428-431, 561
suspension,
bearing race replacement
431-433
front
433-434
play adjustment
433
rear
448
Storage
30-31
transmission
271
Suspension
wheel
404
front
Transmission
62-63
adjustment, FXDXT,
case
264-269
2000-on FXDX
427-428
2003-on models
523
fork oil capacity and
drive sprocket
263-264
oil level dimension
434, 561
electronic fuel injection (EFI)
525-527

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570
INDEX
Transmission (continued)
transmission
62-63
external shift mechanism
260-261
Tune-up
90-95
main drive gear
257-260
idle speed adjustment
95-96
oil pan
269
specifications, maintenance
99
service specifications
269-270
torque specifications
98-99
shafts
243-257
Turn signal
shift forks
239-241
and security modules,
shifter adjustment
228-232
1999-2000 models
359-363
2003 models
523
2001-on models
364-365
shifter cam
speed
1999-2000
233-237
and distance test
375
2001
237-239
and time test
375
side
cover and clutch release
mechanism
261-263
V
door and transmission
Valve
shaft assemblies
241-243
lifters
147-150
specifications
269
and components
123-133
top cover
232-233
2005 models
508-515
torque specifications
271
Vehicle
Troubleshooting
alignment
402-404
brake problems
64
weight, dry
33
charging system
50-54
Voltage regulator
317-319
clutch
62
diagnostic trouble codes
65
W
electric starting system
42-50
Wheels
Troubleshooting (continued)
and tires
67-68
electrical specifications
65
balance
396
engine
lubrication
61-62
cast
395
noises
61
front
377-379
performance
41-42
and rear bearing end
excessive vibration
63
play check, 1999 models
387
front suspension
spacer shims, 1999
405
and steering
63-64
rear
380-383
fuel system
58-61
rim and laced
394-395
ignition system
54-58
runout
393-394
lighting system
63
specifications
404
operating requirements
39
torque specifications
404
starter motor test
vehicle alignment
402-404
specifications
64
Windshield
499-500
starting the engine
39-41
Wiring diagrams
571-590

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

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

572
WIRING DIAGRAMS
1999-2000 FXDWG MODELS
Ignition
Crank
Cam
switch
Engine
Right
position
position
Stoplight
Off
stop/run
Start
turn
sensor
sensor
switch
Acc.
switch
switch
switch
Ignition
Manifold
Turn signal
air
module
pressure
Bank
sensor
angle
sensor
Rear
stoplight
R/Y
switch
O/W
Right
B
turn
Br
L
Position
O/W
lamp
B
(HDI only)
B
Headlamp
W
Y
Domestic
only
L
Left
V
turn
B
Function/
O/W
tripmeter
reset switch
B/Y
W/G
Electronic
B
speedometer
R
Speed
W
sensor
B
*Pink wire located at
speedometer connector
P
and is taped back to
the wire harness.
O
Fuel gauge
B
w/ backlight
P
B
Fuel level
sending
unit
Neutral
switch
Y/B
Horn
B
Hi
Low
Ignition module
Left
Headlamp
Horn
Left
High Oil
Right
turn
Hi/Lo
switch
turn
beam
turn
switch switch
indicator
Neutral
indicator

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

WIRING DIAGRAMS
573
Diagram Key
Connectors
Stator
Circuit
Start relay
Voltage
breaker
Battery
regulator
30A
Ground
Frame ground
Connection
No connection
G
B
Starter
B
Running light
(International)
V/Br
Right
B
turn
B
L
B
R/Y
R/Y
Tail
B
O/W
lamp
B
L
BV
Running light
O/W
(Domestic)
Br
V/Br
Left
B
turn
Color Code
B
Black
W
White
R
Red
G
Green
L
Blue
Y
Yellow
O
Orange
P
Pink
V
Violet
T
Tan
Br
Brown
Gr
Gray
B/W
Black/White
B/R
Black/Red
B/Y
Black/Yellow
W/B
White/Black
W/G
White/Green
W/V
White/Violet
16
W/Br
White/Brown
R/B
Red/Black
R/W
Red/White
R/Y
Red/Yellow
R/Gr
Red/Gray
G/W
Green/White
G/R
Green/Red
G/Y
Green/Yellow
G/Gr
Green/Gray
Data
L/O
Blue/Orange
link
Y/B
Yellow/Black
Y/L
Yellow/Blue
O/W
Orange/White
Oil
V/W
Violet/White
pressure
V/R
Violet/Red
sending
unit

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

574
WIRING DIAGRAMS
1999-2000 FXDS-CONV, FXDL, FXDX, FXD MODELS
Ignition
Crank
Cam
switch
Engine
Right
position
position
Off
stop/run
Start
turn
Stoplight
sensor
sensor
switch
Acc.
switch
switch
switch
Ignition
Manifold
Turn signal
air
module
pressure
Bank
sensor
angle
sensor
Rear
R/Y
stoplight
switch
O/W
B
Right
Br
turn
L
Position
O/W
lamp
B
(HDI only)
B
Headlamp
W
Y
Domestic
only
L
Left
V
turn
B
Function/
O/W
tripmeter
reset switch
B/Y
W/G
Electronic
B
speedometer
R
Speed
W
sensor
B
P
B
Tachometer
O
O
Fuel gauge
B
w/ backlight
P
B
Fuel level
sending
unit
Neutral
switch
Y/B
Horn
B
Hi
Low
Ignition module
Left
Headlamp
Horn
Left
High Oil
Right
turn
Hi/Lo
switch
turn
beam
turn
switch switch
indicator
Neutral
indicator

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

WIRING DIAGRAMS
575
Diagram Key
Connec
Circuit
Stator
Battery
Start relay
Voltage
breaker
regulator
30A
Ground
Frame gro
Connection
No connect
G
B
Starter
B
Running light
(International)
V/Br
Right
B
turn
B
L
B
R/Y
R/Y
Tail
B
O/W
lamp
B
L
BV
O/W
Running light
(Domestic)
Br
V/Br
Left
B
turn
Color Code
B
Black
W
White
R
Red
G
Green
L
Blue
Y
Yellow
O
Orange
P
Pink
V
Violet
T
Tan
Br
Brown
Gr
Gray
B/W
Black/White
B/R
Black/Red
B/Y
Black/Yellow
W/B
White/Black
W/G
White/Green
W/V
White/Violet
16
W/Br
White/Brown
R/B
Red/Black
R/W
Red/White
R/Y
Red/Yellow
R/Gr
Red/Gray
G/W
Green/White
G/R
Green/Red
G/Y
Green/Yellow
G/Gr
Green/Gray
Data
L/O
Blue/Orange
link
Y/B
Yellow/Black
Y/L
Yellow/Blue
O/W
Orange/White
Oil
V/W
Violet/White
pressure
V/R
Violet/Red
sending
unit

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

576
WIRING DIAGRAMS
2001-2003 FXDWG MODELS
Crank
Cam
Engine
Right
position
position
Stoplight
stop/run
Start
turn
sensor
sensor
switch
switch
switch
switch
Manifold
Turn signal
air
module
pressure
sensor
Rear
R/Y
stoplight
switch
O/W
B
Right
Br
turn
L
Position
O/W
lamp
B
(HDI only)
B
Headlamp
W
Y
Domestic
only
L
Left
V
turn
B
Function/
Gr
O/W
tripmeter
Gr
W/G
reset switch
B/Y
Br/V
Electronic
speedometer
R
B
Speed
W
sensor
B
*Pink wire located at
speedometer connector
P
and is taped back to
the wire harness.
B
Fuel gauge
O
w/ backlight
B
Y/W
Fuel level
sending
unit
Neutral
switch
Y/B
Horn
B
Hi
Low
Ignition module
Left
Headlamp
Horn
Left
High
Oil
Right
turn
Hi/Lo
switch
turn
beam
turn
switch switch
indicator
Neutral
indicator

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

WIRING DIAGRAMS
577
Diagram Key
Connector
Circuit
Stator
Battery
Start relay
Voltage
breaker
regulator
30A
Ground
Frame ground
Connection
No connection
G
B
Starter
B
Running light
(International)
V/Br
Right
B
turn
B
L
B
R/Y
R/Y
Tail
B
O/W
lamp
B
L
BV
Running light
O/W
(Domestic)
Br
V/Br
Left
B
turn
Color Code
B
Black
W
White
R
Red
G
Green
L
Blue
Y
Yellow
O
Orange
P
Pink
V
Violet
T
Tan
Br
Brown
Gr
Gray
B/W
Black/White
B/R
Black/Red
B/Y
Black/Yellow
W/B
White/Black
W/G
White/Green
W/V
White/Violet
16
W/Br
White/Brown
R/B
Red/Black
R/W
Red/White
R/Y
Red/Yellow
R/Gr
Red/Gray
G/W
Green/White
G/R
Green/Red
Off
G/Y
Green/Yellow
Acc.
G/Gr
Green/Gray
Ignition
Data
L/O
Blue/Orange
link
Y/B
Yellow/Black
Ignition
Y/L
Yellow/Blue
switch
O/W
Orange/White
Security
Oil
V/W
Violet/White
(optional)
pressure
V/R
Violet/Red
sending
unit

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

578
WIRING DIAGRAMS
2001-2003 FXDX, FXDXT, FXDL & FXD MODELS
Crank
Cam
Engine
Right
position
position
Stoplight
stop/run
Start
turn
sensor
sensor
switch
switch
switch
switch
Manifold
Turn signal
air
module
pressure
sensor
Rear
stoplight
R/Y
switch
O/W
Right
B
turn
Br
L
Position
O/W
lamp
B
(HDI only)
B
Headlamp
W
Y
Domestic
only
L
Left
V
turn
B
O/W
Function/
tripmeter
reset switch
B/Y
Electronic
W/G
speedometer
B
R
Speed
W
sensor
B
P
Tachometer
B
O
B
Fuel gauge
O
w/ backlight
B
Y/W
Fuel level
sending
unit
Neutral
switch
Y/B
Horn
B
Hi
Low
Ignition module
Left
Headlamp
Horn
Left
High Oil
Right
turn
Hi/Lo
switch
turn
beam
turn
switch switch
indicator
Neutral
indicator

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

WIRING DIAGRAMS
579
Diagram Key
Connectors
Stator
Circuit
Start relay
Voltage
breaker
Battery
regulator
30A
Ground
Frame ground
Connection
No connection
G
B
Starter
B
Running light
(International)
V/Br
Right
B
turn
B
L
B
R/Y
R/Y
Tail
B
O/W
lamp
B
L
BV
Running light
O/W
(Domestic)
Br
V/Br
Left
B
turn
Color Code
B
Black
W
White
R
Red
G
Green
L
Blue
Y
Yellow
O
Orange
P
Pink
V
Violet
T
Tan
Br
Brown
Gr
Gray
B/W
Black/White
B/R
Black/Red
B/Y
Black/Yellow
W/B
White/Black
W/G
White/Green
W/V
White/Violet
W/Br
White/Brown
R/B
Red/Black
16
R/W
Red/White
R/Y
Red/Yellow
R/Gr
Red/Gray
G/W
Green/White
G/R
Green/Red
Off
G/Y
Green/Yellow
Acc.
G/Gr
Green/Gray
Ignition
Data
L/O
Blue/Orange
link
Y/B
Yellow/Black
Ignition
Y/L
Yellow/Blue
switch
O/W
Orange/White
Security
Oil
V/W
Violet/White
(optional)
pressure
V/R
Violet/Red
sending
unit

 

 

 

 

 

 

 

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