H-D Job Codes 2010

All Harley-Davidson Models
JOB TIME/CODE MANUAL 2010
2009 H-D. ALL RIGHTS RESERVED

Binder 99998-88 Contents 99997-10 DOWNLOAD FREE ADDITIONAL COPIES FROM THE H-DNET WEB SITE https://www.h-dnet.com
CMI - X.xM - MM/YY
Printed in the U.S.A.
JOB TIME/CODE UPDATE FORM

_____ Job Change _____ Job Addition
Update requested based on this experience:
MODEL AND YEAR
JOB DESCRIPTION
JOB TIME JOB/CODE NUMBER (IF ANY)
Name: Street: City: Email:
Date: Dealership Number: State and Zip: Phone Number:
99997-10 2010 Harley-Davidson Job Time/Codes Please clip out and mail to: Harley-Davidson Motor Company P.O. Box 653 Milwaukee, WI 53201 USA
GENERAL INFORMATION
2010 MODEL PREFIXES
All 2010 model prefixes are listed at the top of each page in each section. Please note that these flat rates only apply to the 2010 model year. They do not apply to any previous model year vehicles.
CODE
Chapter 4. VRSC Models

NAME
HFH HFJ HHH HHJ HPH HPJ
VRSCAW VRSCAW 105 VRSCDX VRSCDX 105 VRSCF VRSCF 105
Chapter 1. Softail Models

CODE NAME
BV5 BW5 BX5 JD5 JE5 JG5 JH5 JK5 JL5 JM5 JN5
FXST FLSTC FLSTF FLSTN FLST FLSTF Shrine FLSTC Shrine FXCWC FXSTC FLSTSB FLSTFB
Chapter 5. FLHT/FLTR Models

CODE NAME
FC4 FF4 FG4 FL4 FMM FV4 KB4 KEM KH4
FLHTCU FLHTC FLHTCU w/Sidecar FLHTCU Shrine FLHTP FLHT FLHX FLHTK FLTRX
Chapter 2. Dyna Models

CODE NAME
GM4 GN4 GP4 GV4 GX4 GY4
FXD FXDL FXDWG FXDC FXDB FXDF

CODE
Chapter 6. FLHR Models

NAME
FB4 FHM FR4 FTM FW4
FLHR FLHP Police FLHRC FLHPE FLHR Shrine
Chapter 3. Sportster Models

CODE NAME
Chapter 7. Trike Models

CODE NAME
CP2 CR2 CS2 CT3 CX3 CZ3 LA6 LD6 LE2
XL883C XL883L XL883R XL1200C XL1200L XL1200N XR1200 XR1200X XL883N
MAM MBM
FLHTCUTG FLHXXX
Chapter 8. Sidecar Models

CODE NAME
SKX SZX
TLEU TLE
Chapter 9. CVO: FLHTCUSE5

CODE NAME
PR8
FLHTCUSE5
Chapter 10. CVO: FLHXSE

CODE NAME CODE
Chapter 12. CVO: FXDFSE2

NAME
PZ8
FLHXSE
PX4 PX8
FXDFSE2 FXDFSE2
Chapter 11. CVO: FLSTSE

CODE NAME
Chapter 13. Harley Accessories

CODE NAME
PY9
FLSTSE
---
See previous tables for model-to-name matching.
SOFTAIL MODELS
1.1 SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 NEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 REGULAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.2 CHASSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 PAINT REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 DRIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 HANDLEBARS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 FRAME/SWING ARM/FRONT FORK. . . . . . . . . . . . 1-3 BRAKES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 SEATS/FENDERS/TANKS. . . . . . . . . . . . . . . . . . . . . 1-6 BELT GUARDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 EXHAUST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . 1-7 1.3 ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 CYLINDER AND PISTON. . . . . . . . . . . . . . . . . . . . 1-10 CAM COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 CRANKCASE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 BALANCER SYSTEM. . . . . . . . . . . . . . . . . . . . . . . 1-13 FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 EVAPORATIVE EMISSIONS SYSTEM. . . . . . . . . . 1-14 1.4 DRIVE AND CLUTCH. . . . . . . . . . . . . . . . . . . . . . . 1-15 DRIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 1.5 TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 TRANSMISSION CASE. . . . . . . . . . . . . . . . . . . . . 1-16 1.6 OEM ACCESSORIES. . . . . . . . . . . . . . . . . . . . . . . 1-17 ACCESSORIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 1.7 ELECTRICAL - GENERAL. . . . . . . . . . . . . . . . . . . 1-18 INSTRUMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18 WIRING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18 SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18 LIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18 BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19 1.8 SOFTAIL DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . 1-20 DIAGNOSTICS GENERAL. . . . . . . . . . . . . . . . . . . 1-20 SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20 FUSES AND RELAYS. . . . . . . . . . . . . . . . . . . . . . . 1-21 CHARGING CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . 1-22 STARTER CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . 1-22 IGNITION CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . 1-22 AIR INTAKE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23 FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23 SENSORS AND ECM. . . . . . . . . . . . . . . . . . . . . . . 1-24 HDI ACTIVE EXHAUST. . . . . . . . . . . . . . . . . . . . . . 1-25 TURN SIGNALS/INSTRUMENTS/SECURITY. . . . 1-25
DYNA MODELS
2.1 SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 NEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 REGULAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.2 CHASSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 PAINT REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 DRIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 HANDLEBARS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 FRAME/SWING ARM/FRONT FORK. . . . . . . . . . . . 2-3 BRAKES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 SEATS/FENDERS/TANKS. . . . . . . . . . . . . . . . . . . . . 2-5 BELT GUARDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 EXHAUST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . 2-6 2.3 ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 CYLINDER HEAD. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 CYLINDER AND PISTON. . . . . . . . . . . . . . . . . . . . . 2-8 CAM COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 CRANKCASE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 EVAPORATIVE EMISSIONS SYSTEM. . . . . . . . . . 2-11 2.4 DRIVE AND CLUTCH. . . . . . . . . . . . . . . . . . . . . . . 2-12 DRIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 2.5 TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 TRANSMISSION CASE. . . . . . . . . . . . . . . . . . . . . 2-13 2.6 OEM ACCESSORIES. . . . . . . . . . . . . . . . . . . . . . . 2-14 ACCESSORIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 2.7 ELECTRICAL - GENERAL. . . . . . . . . . . . . . . . . . . 2-15 INSTRUMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 WIRING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 LIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 2.8 DYNA DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . . . . 2-17 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 FUSES AND RELAYS. . . . . . . . . . . . . . . . . . . . . . . 2-18 CHARGING CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . 2-19 STARTER CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . 2-19 IGNITION CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . 2-19 AIR INTAKE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 SENSORS AND ECM. . . . . . . . . . . . . . . . . . . . . . . 2-21 HDI ACTIVE EXHAUST. . . . . . . . . . . . . . . . . . . . . . 2-22 TURN SIGNALS/INSTRUMENTS/SECURITY. . . . 2-22 I
TABLE OF CONTENTS
TABLE OF CONTENTS SPORTSTER MODELS

3.1 SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 REGULAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.2 CHASSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 PAINT REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 DRIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 HANDLEBARS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 FRAME/SWING ARM/FRONT FORK. . . . . . . . . . . . 3-3 BRAKES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 SEATS/FENDERS/TANKS. . . . . . . . . . . . . . . . . . . . . 3-5 BELT GUARDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 EXHAUST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . 3-7 3.3 ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 CYLINDER HEAD. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 CYLINDER AND PISTON. . . . . . . . . . . . . . . . . . . . . 3-9 GEARCASE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 CRANKCASE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 EVAPORATIVE EMISSIONS SYSTEM. . . . . . . . . . 3-12 3.4 DRIVE AND CLUTCH. . . . . . . . . . . . . . . . . . . . . . . 3-13 DRIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 3.5 TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 TRANSMISSION CASE. . . . . . . . . . . . . . . . . . . . . 3-14 3.6 OEM ACCESSORIES. . . . . . . . . . . . . . . . . . . . . . . 3-15 ACCESSORIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 3.7 ELECTRICAL - GENERAL. . . . . . . . . . . . . . . . . . . 3-16 INSTRUMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 WIRING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 LIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 3.8 SPORTSTER DIAGNOSTICS. . . . . . . . . . . . . . . . . 3-18 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 FUSES AND RELAYS. . . . . . . . . . . . . . . . . . . . . . . 3-19 CHARGING CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . 3-20 STARTER CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . 3-20 IGNITION CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . 3-20 AIR INTAKE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 SENSORS AND ECM. . . . . . . . . . . . . . . . . . . . . . . 3-21 TURN SIGNALS/INSTRUMENTS/SECURITY. . . . 3-22
VRSC MODELS
4.1 SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 NEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 REGULAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.2 CHASSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 PAINT REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 DRIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 HANDLEBARS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 FRAME/SWING ARM/FRONT FORK. . . . . . . . . . . . 4-3 BRAKES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 SEATS/COSMETIC COVERS/FUEL TANK/VISOR KIT. 4-6 BELTS GUARDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 EXHAUST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . 4-7 4.3 ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 CYLINDER HEAD. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 CYLINDER AND PISTON. . . . . . . . . . . . . . . . . . . . . 4-9 CAM COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 CRANKCASE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 BALANCER SYSTEM. . . . . . . . . . . . . . . . . . . . . . . 4-10 FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 EVAPORATIVE EMISSIONS SYSTEM. . . . . . . . . . 4-11 4.4 CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 4.5 TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 4.6 OEM ACCESSORIES. . . . . . . . . . . . . . . . . . . . . . . 4-14 ACCESSORIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 4.7 COOLING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 COOLING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 4.8 ELECTRICAL - GENERAL. . . . . . . . . . . . . . . . . . . 4-16 INSTRUMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 WIRING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 LIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 4.9 VRSC DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . . . . 4-17 DIAGNOSTICS GENERAL. . . . . . . . . . . . . . . . . . . 4-17 SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 FUSES AND RELAYS. . . . . . . . . . . . . . . . . . . . . . . 4-18
II TABLE OF CONTENTS
TABLE OF CONTENTS
CHARGING CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . 4-19 STARTER CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . 4-19 IGNITION CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . 4-19 AIR INTAKE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 SENSORS AND ECM. . . . . . . . . . . . . . . . . . . . . . . 4-20 TURN SIGNALS/INSTRUMENTS/SECURITY SYSTEM. 4-22 ABS BRAKES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 5.8 FLHT/FLTR DIAGNOSTICS. . . . . . . . . . . . . . . . . . 5-23 DIAGNOSTICS GENERAL. . . . . . . . . . . . . . . . . . . 5-23 SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 FUSES AND RELAYS. . . . . . . . . . . . . . . . . . . . . . . 5-24 CHARGING CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . 5-25 STARTER CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . 5-25 IGNITION CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . 5-26 AIR INTAKE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 SENSORS AND ECM. . . . . . . . . . . . . . . . . . . . . . . 5-27 HDI ACTIVE EXHAUST. . . . . . . . . . . . . . . . . . . . . . 5-29 TURN SIGNALS/INSTRUMENTS/SECURITY/CRUISE. 5-29 AUTOMATIC COMPRESSION RELEASE. . . . . . . . 5-31 ABS BRAKES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31 HEATED GRIPS. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31 SOUND SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
FLHT/FLTR MODELS
5.1 SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 NEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 REGULAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5.2 CHASSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 PAINT REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 DRIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 HANDLEBARS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 FRAME/SWING ARM/FRONT FORK. . . . . . . . . . . . 5-3 BRAKES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 SEATS/FENDERS/TANKS. . . . . . . . . . . . . . . . . . . . . 5-6 BELT GUARDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 EXHAUST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . 5-7 5.3 ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 CYLINDER HEAD. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 CYLINDER AND PISTON. . . . . . . . . . . . . . . . . . . . 5-10 CAM COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 CRANKCASE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 EVAPORATIVE EMISSIONS SYSTEM. . . . . . . . . . 5-14 5.4 DRIVE AND CLUTCH. . . . . . . . . . . . . . . . . . . . . . . 5-15 DRIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 5.5 TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 TRANSMISSION CASE. . . . . . . . . . . . . . . . . . . . . 5-16 5.6 OEM ACCESSORIES. . . . . . . . . . . . . . . . . . . . . . . 5-17 ACCESSORIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 5.7 ELECTRICAL - GENERAL. . . . . . . . . . . . . . . . . . . 5-19 INSTRUMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 WIRING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 LIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 SOUND SYSTEM REPAIR. . . . . . . . . . . . . . . . . . 5-21
FLHR MODELS
6.1 SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 NEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 REGULAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.2 CHASSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 PAINT REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 DRIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 HANDLEBARS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 FRAME/SWING ARM/FRONT FORK. . . . . . . . . . . . 6-3 BRAKES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 SEATS/FENDERS/TANKS. . . . . . . . . . . . . . . . . . . . . 6-6 BELT GUARDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 EXHAUST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . 6-7 6.3 ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 CYLINDER HEAD. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 CYLINDER AND PISTON. . . . . . . . . . . . . . . . . . . . . 6-9 CAM COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 CRANKCASE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 EVAPORATIVE EMISSIONS SYSTEM. . . . . . . . . . 6-13 6.4 DRIVE AND CLUTCH. . . . . . . . . . . . . . . . . . . . . . . 6-14 DRIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 6.5 TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 TRANSMISSION CASE. . . . . . . . . . . . . . . . . . . . . 6-15 6.6 OEM ACCESSORIES. . . . . . . . . . . . . . . . . . . . . . . 6-16
TABLE OF CONTENTS III
TABLE OF CONTENTS
ACCESSORIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 6.7 ELECTRICAL - GENERAL. . . . . . . . . . . . . . . . . . . 6-18 INSTRUMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 WIRING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 LIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 6.8 FLHR DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . . . . 6-20 DIAGNOSTICS GENERAL. . . . . . . . . . . . . . . . . . . 6-20 SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 FUSES AND RELAYS. . . . . . . . . . . . . . . . . . . . . . . 6-21 CHARGING CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . 6-22 STARTER CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . 6-23 IGNITION CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . 6-23 AIR INTAKE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 SENSORS AND ECM. . . . . . . . . . . . . . . . . . . . . . . 6-24 HDI ACTIVE EXHAUST. . . . . . . . . . . . . . . . . . . . . . 6-26 TURN SIGNALS/INSTRUMENTS/SECURITY. . . . 6-26 AUTOMATIC COMPRESSION RELEASE. . . . . . . . 6-27 ABS BRAKES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28 7.8 TRI GLIDE DIAGNOSTICS. . . . . . . . . . . . . . . . . . . 7-22 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22 SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22 FUSES AND RELAYS. . . . . . . . . . . . . . . . . . . . . . . 7-23 CHARGING CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . 7-24 STARTER CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . 7-24 IGNITION CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . 7-25 AIR INTAKE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25 FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25 SENSORS AND ECM. . . . . . . . . . . . . . . . . . . . . . . 7-26 TURN SIGNALS/INSTRUMENTS/SECURITY. . . . 7-28 7.2 CHASSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 PAINT REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 DRIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 HANDLEBARS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 FRAME/REAR FORK/FRONT FORK. . . . . . . . . . . . 7-3 BRAKES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 PARKING BRAKE. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 SEATS/FENDERS/TANKS. . . . . . . . . . . . . . . . . . . . . 7-5 EXHAUST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . 7-6 BODY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 7.3 ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 CYLINDER HEAD. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 CYLINDER AND PISTON. . . . . . . . . . . . . . . . . . . . . 7-9 CAM COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 CRANKCASE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11 FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 EVAPORATIVE EMISSIONS SYSTEM. . . . . . . . . . 7-12 AUTOMATIC COMPRESSION RELEASE. . . . . . . . 7-29 SOUND SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . 7-29 REVERSE CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . 7-31 7.4 DRIVE AND CLUTCH. . . . . . . . . . . . . . . . . . . . . . . 7-14 DRIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 DIFFERENTIAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 7.5 TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16 TRANSMISSION CASE. . . . . . . . . . . . . . . . . . . . . 7-16 7.6 OEM ACCESSORIES. . . . . . . . . . . . . . . . . . . . . . . 7-17 ACCESSORIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17 7.7 ELECTRICAL - GENERAL. . . . . . . . . . . . . . . . . . . 7-19 INSTRUMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19 WIRING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19 SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19 LIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20 BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20 SOUND SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
TRIKE MODELS
7.1 SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 NEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 REGULAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
SIDECAR MODELS
8.1 ALL TIMES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 PAINT REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 ACCESSORY SIDECAR. . . . . . . . . . . . . . . . . . . . . . 8-1 ELECTRICAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
CVO: FLHTCUSE5
9.1 SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 NEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 REGULAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 9.2 CHASSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 PAINT REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 HANDLEBARS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 FRAME/SWING ARM/FRONT FORK. . . . . . . . . . . . 9-2
IV TABLE OF CONTENTS
TABLE OF CONTENTS
BRAKES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 SEATS/FENDERS/TANKS. . . . . . . . . . . . . . . . . . . . . 9-2 EXHAUST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . 9-2 9.3 ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 CRANKCASE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 9.4 DRIVE AND CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . 9-5 CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 9.5 TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 9.6 OEM ACCESSORIES. . . . . . . . . . . . . . . . . . . . . . . . 9-7 ACCESSORIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7 9.7 ELECTRICAL - GENERAL. . . . . . . . . . . . . . . . . . . . 9-8 WIRING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 LIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 9.8 FLHTCUSE5 DIAGNOSTICS. . . . . . . . . . . . . . . . . . 9-9 AUTOMATIC COMPRESSION RELEASE. . . . . . . . . 9-9 POWER LOCK SYSTEM. . . . . . . . . . . . . . . . . . . . . . 9-9 HEATED SEAT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9 HEATED GRIPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9 SOUND SYSTEM DIAGNOSIS, REPAIR. . . . . . . . 9-9 NAVIGATION MODULE. . . . . . . . . . . . . . . . . . . . . . 9-10 WIRING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7 10.8 FLHXSE DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . 10-8 AUTOMATIC COMPRESSION RELEASE. . . . . . . . 10-8
CVO: FLSTSE
11.1 SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 NEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 REGULAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 11.2 CHASSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2 PAINT REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2 HANDLEBARS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2 FRAME/SWING ARM/FRONT FORK. . . . . . . . . . . 11-2 SEATS/FENDERS/TANKS. . . . . . . . . . . . . . . . . . . . 11-2 ACCESSORIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2 11.3 ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4 FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4 11.4 DRIVE AND CLUTCH. . . . . . . . . . . . . . . . . . . . . . 11-5 CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5 11.5 TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . 11-6 TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6 11.6 ELECTRICAL - GENERAL. . . . . . . . . . . . . . . . . . 11-7 HANDLEBARS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7 INSTRUMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7 11.7 FLSTSE DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . 11-8 AUTOMATIC COMPRESSION RELEASE. . . . . . . . 11-8
CVO: FLHXSE
10.1 SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 NEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 REGULAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 10.2 CHASSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 PAINT REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 HANDLEBARS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 FRAME/SWING ARM/FRONT FORK. . . . . . . . . . . 10-2 BRAKES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 SEATS/FENDERS/TANKS. . . . . . . . . . . . . . . . . . . . 10-2 EXHAUST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . 10-2 10.3 ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 CRANKCASE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 10.4 DRIVE AND CLUTCH. . . . . . . . . . . . . . . . . . . . . . 10-4 CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 10.5 TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . 10-5 TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5 10.6 OEM ACCESSORIES. . . . . . . . . . . . . . . . . . . . . . 10-6 ACCESSORIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6 10.7 ELECTRICAL - GENERAL. . . . . . . . . . . . . . . . . . 10-7
CVO: FXDFSE2
12.1 SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1 NEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1 REGULAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1 12.2 CHASSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2 PAINT REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2 HANDLEBARS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2 FRAME/SWING ARM/FRONT FORK. . . . . . . . . . . 12-2 12.3 ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3 EVAPORATIVE EMISSIONS SYSTEM. . . . . . . . . . 12-3 12.4 DRIVE AND CLUTCH. . . . . . . . . . . . . . . . . . . . . . 12-4 CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4 12.5 TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . 12-5 TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5 12.6 ELECTRICAL - GENERAL. . . . . . . . . . . . . . . . . . 12-6 ELECTRICAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6 12.7 FXDFSE2 DIAGNOSTICS. . . . . . . . . . . . . . . . . . . 12-7
TABLE OF CONTENTS V
TABLE OF CONTENTS
DIAGNOSTIC TROUBLE CODES. . . . . . . . . . . . . . 12-7 AUTOMATIC COMPRESSION RELEASE. . . . . . . . 12-7 13.4 PERFORMANCE. . . . . . . . . . . . . . . . . . . . . . . . . 13-4 13.5 ELECTRICAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5 13.6 ADVANCED AUDIO SYSTEM. . . . . . . . . . . . . . . . 13-6 HANDS FREE MODULE. . . . . . . . . . . . . . . . . . . . . 13-6 XM MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6 13.2 FUNCTIONAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2 13.3 DECORATIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3 NAVIGATION MODULE. . . . . . . . . . . . . . . . . . . . . . 13-6
HARLEY ACCESSORIES
13.1 CHASSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
VI TABLE OF CONTENTS
SUBJECT..............................................................................................................PAGE NO. 1.1 Service........................................................................................................................1-1 1.2 Chassis.......................................................................................................................1-2 1.3 Engine.........................................................................................................................1-9 1.4 Drive and Clutch........................................................................................................1-15 1.5 Transmission.............................................................................................................1-16 1.6 OEM Accessories......................................................................................................1-17 1.7 Electrical - General....................................................................................................1-18 1.8 Softail Diagnostics.....................................................................................................1-20
SOFTAIL MODELS
Unless otherwise specified, Job Times shown include all operations necessary to complete the listed job.
BV5 = FXST JM5 = FLSTSB
BW5 = FLSTC JG5 = FLSTF Shrine
BX5 = FLSTF JH5 = FLSTC Shrine
JD5 = FLSTN JE5 = FLST
JL5 = FXSTC JN5 = FLSTFB
JK5 = FXCWC
Table 1-1. Service

ITEM DESCRIPTION LABOR CODE MODELS BW5 JH5 JE5 JD5 BV5 BX5 JG5 JN5 JL5 JK5 JM5
NEW Set-up and pre-delivery 1000 (1,600 km) mile service REGULAR 5,000 (8,000 km) mile maintenance 10,000 (16,000 km) mile maintenance 15,000 (24,000 km) mile maintenance 20,000 (32,000 km) mile maintenance 25,000 (40,000 km) mile maintenance 30,000 (48,000 km) mile maintenance Addition to any maintenance- required every 2 years Addition to 1,000, 5,000 and 20,000 mile (1,600, 8,000, and 32,000 km) maintenance and every 15,000 mile (24,000 km) interval there after Tighten spoke wheels if equipped, time per wheel --0.5 0.5 0.5 0.5 0.5 0.5 0.5 flush/fill D.O.T 4 brake fluid- front and rear --------------1.0 1.5 1.0 1.5 1.5 1.5 0.4 1.0 1.5 1.0 1.5 1.5 1.5 0.4 1.0 1.5 1.0 1.5 1.5 1.5 0.4 1.0 1.5 1.0 1.5 1.5 1.5 0.4 1.0 1.5 1.0 1.5 1.5 1.5 0.4 1.0 1.5 1.0 1.5 1.5 1.5 0.4 1.0 2.0 1.0 2.0 2.0 2.0 0.4 ----2.1 1.5 2.1 1.5 2.1 1.5 2.1 1.5 2.1 1.5 2.1 1.5 2.1 2.0
2010 Softail Models
1-1
JK5 = FXCWC
Table 1-2. Chassis

PAINT REPAIR NOTE: Use these codes when repairing any painted part on vehicle with the Kent Moore finesse kit or other paint repair methods Light scuff/scratch - buff Light sanding/buff/blend Buff entire part Repair build up in clear/paint Color blend/paint/buff DRIVE Adjust secondary belt at PDI only Replace secondary belt Replace rear wheel sprocket WHEELS Replace tire - includes balancing Replace tire - includes balancing Replace wheel assembly - includes disc and sprocket exchange and balancing Replace wheel assembly - includes disc and sprocket exchange and balancing Replace rim, hub or spokes (includes truing wheel) front Replace rim, hub or spokes (includes truing wheel) rear Replace wheel bearings Replace wheel bearings Check or true spoke wheel Replace wheel weight HANDLEBARS Replace handlebars 2206 0.5 0.5 0.5 2.2 0.5 --0.5 front rear each wheel 2116 2121 2136 2141 2155 2119 2.3 2.3 0.5 1.0 0.5 0.1 2.3 2.3 0.5 1.0 0.5 0.1 2.3 2.3 0.5 1.0 0.5 0.1 ----0.5 1.0 --0.1 2.3 2.3 0.5 1.0 0.5 0.1 ----0.5 1.1 0.5 0.1 2.3 2.3 0.5 0.6 0.5 0.1 rear 2114 1.2 1.4 1.2 1.4 1.2 1.3 0.9 front rear front 2106 2111 2113 0.5 0.8 0.8 0.5 0.8 0.8 0.5 0.8 0.8 0.5 1.3 0.8 0.5 0.8 0.8 0.5 1.3 0.8 0.7 1.3 0.8 2010 2011 2021 0.3 4.7 0.8 0.3 4.7 0.8 0.3 4.7 0.8 0.3 4.7 0.8 0.3 4.7 0.8 0.3 4.7 0.8 0.3 4.7 0.8 1102 1104 1106 1108 1110 0.2 0.4 0.6 0.8 1.0 0.2 0.4 0.6 0.8 1.0 0.2 0.4 0.6 0.8 1.0 0.2 0.4 0.6 0.8 1.0 0.2 0.4 0.6 0.8 1.0 0.2 0.4 0.6 0.8 1.0 0.2 0.4 0.6 0.8 1.0
2010 Softail Models
1-2
JK5 = FXCWC
Table 1-2. Chassis

ITEM DESCRIPTION LABOR CODE MODELS BW5 JH5 JE5
----0.2 0.2 0.4 0.6 0.5 0.2 0.4 0.1
JD5
----0.2 0.2 0.4 0.6 0.5 0.2 0.4 0.1
BV5
----0.2 0.2 0.4 0.6 0.5 0.2 0.4 0.1
BX5 JG5 JN5

----0.2 0.2 0.4 0.6 0.5 0.2 0.4 0.1
JL5
----0.2 0.2 0.4 0.6 0.5 0.2 0.4 0.1
JK5
1.2 1.2 0.2 0.2 0.4 0.6 0.5 0.2 0.4 0.3
JM5
----0.2 0.2 0.4 0.6 0.4 0.2 0.2 0.1
Replace handlebars Replace handlebars Replace clutch hand lever Replace clutch hand lever bracket Replace throttle control Replace and adjust throttle control cables Replace both rubber handlebar mounts Replace rubber handlebar grip Replace handlebar riser Replace handlebar clamp FRAME/SWING ARM/FRONT FORK Replace frame
left side right side
2211 2212 2221 2226 2231
one or both
2241 2246 2251
one or both one or both
2253 2254
includes removal and installation of all accessories and motorcycle components
2306
12.4
12.4
12.4
12.4
12.4
12.4
12.4
Replace top fork clamp Replace front fork assembly Replace lower fork bracket and stem Replace steering head cups and bearings, including bearing adjustment Replace upper fork bracket Replace fork lock Replace steering bearings Replace rigid fork Replace spring fork Adjust steering head bearing Change front fork oil
2309 2311 2316 2321
--2.3 2.4 1.9
--2.3 2.4 1.9
--2.2 2.3 1.8
--2.3 2.4 1.9
--2.2 2.3 1.8
--2.2 2.3 1.8
0.3 -------
2326 2330 2332 2334 2285 2290 ---
1.3 1.0 1.4 ----0.4 0.5
1.3 1.0 1.4 ----0.4 0.5
1.2 0.8 1.4 ----0.4 0.5
1.3 1.0 1.4 ----0.4 0.5
1.2 0.8 1.4 ----0.4 0.5
2.0 0.8 1.4 ----0.4 0.7
--1.1 2.0 2.1 1.4 0.4 ---
2010 Softail Models
1-3
JK5 = FXCWC
Table 1-2. Chassis

---------
JD5
---------
BV5
---------
BX5 JG5 JN5

---------
JL5
---------
JK5
---------
JM5
0.1 0.3 0.1 1.4
Replace shock Replace one or more rebound spring(s) Replace upper spring bridge Replace lower (compression) spring or spring reaction rod assembly (one or more) or spring fork Replace strut assembly (front fender) Replace lower rocker Replace lower rocker Replace rocker bearings (rocker removed) Service fork slider and/or seal includes removal, one side disassembly, cleaning, inspection, replacing parts, servicing damper tube, replacing bushings, assembly and installation Service fork slider and/or seal includes removal, both sides disassembly, cleaning, inspection, replacing parts, servicing damper tube, replacing bushings, assembly and installation Replace fork side Replace fork side one side both sides one both
2335 2336 2338 2348
2284 2350 2353 2355 2341
--------0.8
--------0.8
--------0.7
--------0.8
--------0.7
--------0.7
0.3 0.6 0.7 0.2 ---
2342
1.2
1.2
1.1
1.2
1.1
1.1
---
2346 2351 2356
0.7 0.8 0.8
0.7 0.8 0.8
0.6 0.8 0.7
0.7 0.8 0.8
0.6 0.8 0.7
0.6 0.8 0.7
-------
Replace fork tube includes removal, disassembly, one side cleaning, inspection, replacing parts, servicing damper tube, replacing bushings, assembly and installation Replace fork tube includes removal, disassembly, both sides cleaning, inspection, replacing parts, servicing damper tube, replacing bushings, assembly and installation Replace rear swing arm and/or bearings or rear fork pivot shaft
2361
1.2
1.2
1.1
1.2
1.1
1.1
---
2366
1.2
1.2
1.2
1.2
1.2
1.2
1.4
2010 Softail Models
1-4
JK5 = FXCWC
Table 1-2. Chassis

0.6 1.2 0.8 1.6 0.4 0.1 0.4 0.2 0.1
JD5
0.6 1.2 0.8 1.6 0.4 0.1 0.4 0.2 0.1
BV5
0.6 1.2 0.8 1.6 0.4 0.1 0.4 0.2 ---
BX5 JG5 JN5

0.6 1.2 0.8 1.6 0.4 0.1 0.4 0.2 0.1
JL5
0.6 1.2 0.8 1.6 0.4 0.1 0.4 0.2 ---
JK5
0.6 1.2 0.8 1.6 0.4 0.1 0.4 0.2 ---
JM5
0.6 1.2 0.8 1.6 0.4 0.1 0.4 0.2 0.1
Replace rear shock absorber assembly Replace rear shock absorber assembly
one side both sides
2371 2376 2382 2383 2396 2399 2286 2394 2299
Replace shock bushing includes removing shock one Replace shock bushing includes removing shock both Replace jiffy stand Replace jiffy stand Replace jiffy stand Replace footboard or foot peg Replace footboard insert BRAKES Replace hydraulic brake line includes filling/bleeding brakes Replace hydraulic brake line includes filling/bleeding brakes Replace brake pads Replace brake pads Replace brake reaction rod Replace brake caliper includes filling/bleeding brakes Replace brake caliper includes filling/bleeding brakes Replace rear brake caliper mount Replace brake disc Replace brake disc Bleed brake caliper Bleed brake caliper front rear front rear rear front front rear rear front spring and/or stand rubber bumper bushings and or pin
2406
0.4
0.4
0.4
0.4
0.4
0.4
0.4
2411
0.4
0.4
0.4
0.4
0.4
0.4
0.4
2416 2421 2423 2426
0.1 0.3 --0.4
0.1 0.6 --0.4
0.1 0.3 --0.4
0.1 0.6 --0.4
0.1 0.3 --0.4
0.1 0.3 --0.4
0.1 0.3 0.1 0.4
2431
0.5
0.5
0.5
0.5
0.5
0.5
0.5
2408 2436 2441 2442 2443
0.7 0.3 0.8 0.2 0.2
0.7 0.3 0.8 0.2 0.2
0.7 0.3 0.8 0.2 0.2
0.7 0.3 0.8 0.2 0.2
0.7 0.3 0.8 0.2 0.2
0.7 0.3 0.8 0.2 0.2
0.6 0.3 0.9 0.2 0.2
2010 Softail Models
1-5
JK5 = FXCWC
Table 1-2. Chassis

0.6
JD5
0.6
BV5
0.6
BX5 JG5 JN5

0.6
JL5
0.6
JK5
0.6
JM5
0.6
Overhaul brake caliper includes filling/bleeding brakes Overhaul brake caliper includes filling/bleeding brakes Replace master cylinder assembly includes filling/bleeding brakes Replace master cylinder assembly includes filling/bleeding brakes Rebuild master cylinder assembly includes filling/bleeding brakes Rebuild master cylinder assembly includes filling/bleeding brakes Replace brake master cylinder cover/gasket Replace rear brake pedal Replace front brake lever SEATS/FENDERS/TANKS Replace seat only Replace seat mount bushings Rplace seat hinge Replace frame mounting pivot bracket Replace spring seat support bracket Replace seat spring (each) Replace spring bushing Replace spring base seat bracket Replace frame fairing (battery cover) Replace pillion/passenger seat Replace seat support
front
2451
rear
2456
0.8
0.8
0.8
0.8
0.8
0.8
0.8
front
2461
0.4
0.4
0.4
0.4
0.4
0.4
0.4
rear
2466
0.5
0.5
0.5
0.5
0.5
0.5
0.5
front
2471
0.6
0.6
0.6
0.6
0.6
0.6
0.6
rear
2476
0.6
0.6
0.6
0.6
0.6
0.6
0.6
2479 2492 2494
0.1 0.3 0.1
0.1 0.3 0.1
0.1 0.3 0.1
0.1 0.3 0.1
0.1 0.3 0.1
0.1 0.3 0.1
0.1 0.3 0.1
2506 2608 2630 2632 2633 2634 2635 2639 2641 2502 either side 2701
0.1 ----------------0.1 ---
0.1 ----------------0.1 ---
0.1 ---------------------
0.1 ----------------0.1 ---
0.1 ---------------------
0.1 ----------------0.1 0.6
0.3 0.2 0.1 0.1 0.1 0.1 0.1 0.1 0.1 -----
2010 Softail Models
1-6
JK5 = FXCWC
Table 1-2. Chassis

------0.1 1.1 1.6 0.3 0.9 0.5 0.5 2.3
JD5
------0.1 1.1 1.6 0.3 0.9 0.5 0.5 2.8
BV5
------0.1 0.3 1.2 0.3 0.9 0.5 0.5 2.3
BX5 JG5 JN5

------0.1 0.3 1.2 0.3 0.9 0.5 0.5 2.8
JL5
------0.1 0.3 1.2 0.3 0.9 0.5 0.5 2.3
JK5
0.5 0.2 0.1 0.1 0.8 1.0 --0.9 0.5 0.5 2.3
JM5
--------0.7 1.0 0.3 0.8 0.2 0.3 2.5
Replace pillion support Replace locking hardware Replace seat bracket/cover Replace ignition switch name plate Replace fender Replace fender Replace rear fender support/cover one only Replace fuel tank assembly Replace fuel gauge Replace fuel gauge sending unit Replace oil tank and/or one or more rubber mount(s) Replace any single oil hose Replace license plate bracket BELT GUARDS Replace clutch cover and/or o-ring Replace debris deflector (belt guard) Replace fender extension EXHAUST SYSTEM Replace complete exhaust system and/or gaskets/inter-connect Replace exhaust pipe dual exhaust system Replace exhaust pipe dual exhaust system Replace exhaust pipe shotgun Replace muffler front rear front rear per side
2702 2703 2704 5130 2526 2531 2536 2541 2563 2564 2566
2576 2590
0.5 ---
0.5 ---
0.5 0.5
0.5 ---
0.5 0.5
0.5 0.1
0.5 ---
2607 2616 2707
0.1 0.2 ---
0.1 0.2 ---
0.1 0.2 ---
0.1 0.2 ---
0.1 0.2 ---
0.1 0.2 0.1
0.1 0.2 ---
2626
0.8
0.8
0.8
0.8
0.8
0.8
1.4
2631 2636 2615 2646
0.7 0.5 --0.2
----0.8 0.6
0.7 0.5 --0.2
----0.8 0.6
0.7 0.5 0.7 0.2
0.7 0.5 --0.2
1.2 0.3 --0.2
2010 Softail Models
1-7
JK5 = FXCWC
Table 1-2. Chassis

0.1 0.1 0.8
JD5
0.1 0.1 0.8
BV5
0.1 0.1 0.8
BX5 JG5 JN5

0.1 0.1 0.8
JL5
0.1 0.1 0.8
JK5
0.1 0.1 0.8
JM5
0.1 0.1 0.2
Check for exhaust leaks Replace any exhaust shield Replace muffler support
--2661 2666
2010 Softail Models
1-8
JK5 = FXCWC
Table 1-3. Engine

GENERAL Remove and install engine Remove and install engine Remove and replace oil tank for inspection/contamination Recondition cylinder head includes removal of head and gasket, remove carbon, service valve guides, grind valves and seats, test springs and install head and gaskets. Recondition cylinder head includes removal of head and gasket, remove carbon, service valve guides, grind valves and seats, test springs and install head and gaskets. Recondition cylinder head includes removal of head and gasket, remove carbon, service valve guides, grind valves and seats, test springs and install head and gaskets. Replace cylinder head Replace cylinder head Replace valve seal or spring after cylinder head removal Replace valve seal or spring after cylinder head removal Replace cylinder head gasket/o-ring Replace cylinder head gasket/o-ring Replace cylinder head gasket/o-ring Replace rocker arm covers and/or gaskets Replace rocker arm covers and/or gaskets front cylinder rear cylinder both cylinders front cylinder rear cylinder 3140 3142 3143 3144 3145 2.2 2.2 2.6 0.7 0.7 2.6 2.6 3.0 0.7 0.7 2.2 2.2 2.6 0.7 0.7 2.6 2.6 3.0 0.7 0.7 2.2 2.2 2.6 0.7 0.7 2.6 2.6 3.0 0.7 0.7 2.6 2.6 3.0 0.7 0.7 both seals or springs (intake or exhaust) 3132 0.2 0.2 0.2 0.2 0.2 0.2 0.2 one head both heads one seal or spring (intake or exhaust) 3106 3108 3131 3.1 4.0 0.1 3.5 4.4 0.1 3.1 4.0 0.1 3.5 4.4 0.1 3.1 4.0 0.1 3.5 4.4 0.1 3.2 3.8 0.1 both heads 3104 4.7 5.1 4.7 5.1 4.7 5.1 5.1 rear head 3103 4.1 4.5 4.1 4.5 4.1 4.5 4.5 front head 3101 3.5 3.5 3.5 3.5 3.5 3.5 3.5 California vehicles only 3006 3006 3009 5.4 5.3 2.8 5.4 5.3 2.8 5.4 5.3 2.8 5.4 5.3 2.8 5.3 5.4 2.8 5.4 5.3 2.8 5.4 5.3 2.8
2010 Softail Models
1-9
JK5 = FXCWC
Table 1-3. Engine

0.8 1.1
JD5
0.8 1.1
BV5
0.8 1.1
BX5 JG5 JN5

0.8 1.1
JL5
0.8 1.1
JK5
0.8 1.1
JM5
0.8 1.1
Replace rocker arm covers and/or gaskets
both cylinders
3148 3147
Replace lower rocker arm cover/gasket, or rocker front cylinder arms and /or shafts/rocker arm support Replace lower rocker arm cover/gasket, or rocker rear cylinder arms and /or shafts/rocker arm support Replace lower rocker arm cover/gasket, or rocker both cylinders arms and /or shafts/rocker arm support Recondition rocker arms after heads are removed one head Recondition rocker arms after heads are removed both heads Replace cylinder o-ring/drain o-ring Replace cylinder o-ring/drain o-ring Replace cylinder o-ring/drain o-ring Replace crankcase umbrella valve Replace crankcase umbrella valve CYLINDER AND PISTON Recondition top end - includes disassembly, replacement of piston and sizing cylinder (.005 pistons), replacing piston rings and all items listed under recondition cylinder head and assembly. Recondition top end - includes disassembly, replacement of piston and sizing cylinder (.005 pistons), replacing piston rings and all items listed under recondition cylinder head and assembly. Recondition top end - includes disassembly, replacement of piston and bore and hone, resizing cylinder (.010 oversize or above), replacing piston rings and all items listed under recondition cylinder head and assembly. one piston and cylinder both pistons and cylinders one piston and cylinder one cylinder rear cylinder both cylinders one both
3152
1.1
1.1
1.1
1.1
1.1
1.1
1.1
3153
1.6
1.6
1.6
1.6
1.6
1.6
1.5
3149 3150 3161 3163 3168 3172 3174
0.7 1.4 2.4 2.4 2.8 1.0 1.1
0.7 1.4 2.8 2.8 3.2 1.0 1.1
0.7 1.4 2.4 2.4 2.8 1.0 1.1
0.7 1.4 2.8 2.8 3.2 1.0 1.1
0.7 1.4 2.4 2.4 2.8 1.0 1.1
0.7 1.4 2.8 2.8 3.2 1.0 1.1
0.7 1.4 2.8 2.8 3.2 1.0 1.1
3202
5.1
5.5
5.1
5.5
5.1
5.5
4.5
3203
5.7
6.1
5.7
6.1
5.7
6.1
5.1
3211
5.5
5.9
5.5
5.9
5.5
5.9
5.9
2010 Softail Models
1-10
JK5 = FXCWC
Table 1-3. Engine

6.1
JD5
6.5
BV5
6.1
BX5 JG5 JN5

6.5
JL5
6.1
JK5
6.5
JM5
6.5
Recondition top end - includes disassembly, replacement of piston and bore and hone, resizing cylinder (.010 oversize or above), replacing piston rings and all items listed under recondition cylinder head and assembly. Recondition top end includes disassembly, deglazing cylinder and replacing rings, or replacing cylinder and piston, all items listed under recondition cylinder head and assembly. Recondition top end includes disassembly, deglazing cylinder and replacing rings, or replacing cylinder and piston, all items listed under recondition cylinder head and assembly.
both pistons and cylinders
3212
one piston and cylinder
3207
4.9
5.3
4.9
5.3
4.9
5.3
4.3
3208
5.5
5.9
5.5
5.9
5.5
5.9
5.9
Replace piston rings includes deglazing cylinder one cylinder Replace piston rings includes deglazing cylinder both cylinders Replace piston and piston rings includes removal one cylinder of cylinder head and cylinder, fitting new piston with rings, resizing cylinder and assembly Replace piston and piston rings includes removal both cylinders of cylinder head and cylinder, fitting new piston with rings, resizing cylinder and assembly Replace cylinder and piston Replace cylinder and piston Replace one cylinder stud Replace all eight cylinder studs Replace Crank positions senson o-ring. CAM COVER Replace lifter cover/gasket or lifter/and, or antirotation pin one or two same cylinder one cylinder both cylinders cylinder removed cylinders removed
3206 3216 3221
2.7 3.3 3.3
3.1 3.7 3.7
2.7 3.3 3.3
3.1 3.7 3.7
2.7 3.3 3.3
3.1 3.7 3.7
3.1 3.7 3.7
3231
4.5
4.9
4.5
4.9
4.5
4.9
4.9
3236 3246 3253 3254 3403
2.6 3.1 0.1 0.5 0.1
3.0 3.5 0.1 0.5 0.1
2.6 3.1 0.1 0.5 0.1
3.0 3.5 0.1 0.5 0.1
2.6 3.1 0.1 0.5 0.1
3.0 3.5 0.1 0.5 0.1
3.0 3.5 0.1 0.5 0.1
3307
1.3
1.3
1.3
1.3
1.3
1.3
1.3
2010 Softail Models
1-11
JK5 = FXCWC
Table 1-3. Engine

1.6
JD5
1.6
BV5
1.6
BX5 JG5 JN5

1.6
JL5
1.6
JK5
1.6
JM5
1.6
Replace lifter cover/gasket or lifter/and, or antirotation pin
both on both cylinders
3310
Replace push rod, push rod cover and/or o-ring or one or two same cylinder quad seal Replace push rod, push rod cover and/or o-ring or one each cylinder quad seal Replace cam cover and/or gasket Replace primary cam chain, sprockets and/or fastener Replace primary cam chain tensioner Replace cam support plate o-rings Replace cam support plate Replace cam support /cams/secondary cam chain/tensioner Replace oil pump and/or o-ring Replace cam bearing crankcase Replace cam bearing crankcase By pass valve inspection CRANKCASE Replace crankcases California vehicles only includes remove and install engine Replace crankcases Seal crankcase only Replace flywheels Replace left or right side main bearing Replace left or right side main bearing Piston jet/o-ring one includes remove and install engine California vehicles only includes remove and install engine one bearing two bearings
3317
1.3
1.3
1.3
1.3
1.3
1.3
1.3
3318
1.5
1.5
1.5
1.5
1.5
1.5
1.5
3325 3327
0.9 1.0
0.9 1.0
0.9 1.0
0.9 1.0
0.9 1.0
0.9 1.0
0.9 1.0
3328 3335 3337 3338
1.0 2.1 3.0 3.2
1.0 2.1 3.0 3.2
1.0 2.1 3.0 3.2
1.0 2.1 3.0 3.2
1.0 2.1 3.0 3.2
1.0 2.1 3.0 3.2
1.0 2.1 3.0 3.2
3341 3342 3343 3354
2.0 2.7 3.0 2.0
2.0 2.7 3.0 2.0
2.0 2.7 3.0 2.0
2.0 2.7 3.0 2.0
2.0 2.7 3.0 2.0
2.0 2.7 3.0 2.0
2.0 2.7 3.0 2.0
3406
7.6
7.6
7.6
7.6
7.6
7.6
7.6
3406 3407 3411 3412 3412 3413
7.5 6.6 6.7 6.7 6.6 2.2
7.5 6.6 6.7 6.7 6.6 2.2
7.5 6.6 6.7 6.7 6.6 2.2
7.5 6.6 6.7 6.7 6.6 2.2
7.5 6.6 6.7 6.7 6.6 2.2
7.5 6.6 6.7 6.7 6.6 2.2
7.3 6.6 6.7 6.7 6.6 2.2
2010 Softail Models
1-12
JK5 = FXCWC
Table 1-3. Engine

2.6 0.1
JD5
2.6 0.1
BV5
2.6 0.1
BX5 JG5 JN5

2.6 0.1
JL5
2.6 0.1
JK5
2.6 0.1
JM5
2.6 0.1
Piston jet/o-ring Check flywheel trueness before assembly or after removal Recondition cylinder heads head removed (for non-related repairs Recondition cylinder heads head removed (for non-related repairs Replace piston rings
both
3414 3420
one head
3425
1.0
1.0
1.0
1.0
1.0
1.0
1.0
both heads
3426
2.0
2.0
2.0
2.0
2.0
2.0
2.0
cylinders removed (for non-related repairs deglaze only)
3428
0.3
0.3
0.3
0.3
0.3
0.3
0.3
Replace pistons
cylinders removed (for non-related repairs) includes resizing cylinders
3430
1.4
1.4
1.4
1.4
1.4
1.4
1.4
BALANCER SYSTEM Replace balancer shaft/crankcase bearing Replace balancer bearing/support Replace balancer system chain Replace balancer crankshaft sprocket Replace balancer shaft sprocket/nut/spacer Replace balancer bracket assembly Replace balancer blade guide - front, rear, long Replace viton oil interconnect FUEL SYSTEM Replace air cleaner backing plate Replace air cleaner cover Replace induction module seal Replace external fuel supply hose- EFI 3501 3502 3510 3514 0.2 0.1 0.7 0.2 0.2 0.1 0.7 0.2 0.2 0.1 0.7 0.2 0.2 0.1 0.7 0.2 0.2 0.1 0.7 0.2 0.2 0.1 0.7 0.5 0.2 0.1 0.7 0.2 3450 3452 3454 3456 3458 3460 3462 3464 7.8 7.5 7.4 7.6 7.5 7.4 7.0 6.9 7.8 7.5 7.4 7.6 7.5 7.4 7.0 6.9 7.8 7.5 7.4 7.6 7.5 7.4 7.0 6.9 7.8 7.5 7.4 7.6 7.5 7.4 7.0 6.9 7.8 7.5 7.4 7.6 7.5 7.4 7.0 6.9 7.8 7.5 7.4 7.6 7.5 7.4 7.0 6.9 7.8 7.5 7.4 7.6 7.3 7.5 7.0 6.9
2010 Softail Models
1-13
JK5 = FXCWC
Table 1-3. Engine

EVAPORATIVE EMISSIONS SYSTEM Replace canister Replace vapor valve Replace any one hose California vehicles only 3527 3528 3529 0.2 0.1 0.1 0.2 0.1 0.1 0.2 0.1 0.1 0.2 0.1 0.1 0.2 0.1 0.1 0.5 0.1 0.1 0.2 0.1 0.1
2010 Softail Models
1-14
JK5 = FXCWC
Table 1-4. Drive and Clutch

DRIVE Replace primary chain Replace primary chain tensioner Replace engine sprocket Replace engine sprocket seal Replace primary cover Replace primary cover gasket Replace primary inspection cover and/or O-ring Replace inner primary case, mainshaft bearing, or primary to crankcase gasket CLUTCH Adjust clutch Replace release cable assembly Service the clutch includes disassembly, cleaning, inspection, repair, assembly, and adjustment Replace clutch release bearing and/or push rod end Replace clutch release mechanism (ball ramp) and/or cover 4018 0.6 0.6 0.6 0.6 0.6 0.6 0.5 4016 0.4 0.4 0.4 0.4 0.4 0.4 0.4 --4006 4011 0.2 0.8 1.3 0.2 0.8 1.3 0.2 0.8 1.3 0.2 0.8 1.3 0.2 0.8 1.3 0.2 0.8 1.3 0.2 0.8 1.3 4002 4033 4003 4005 4007 4009 4001 4008 0.9 0.7 0.9 1.2 0.4 0.4 0.1 2.3 0.9 0.7 0.9 1.2 0.4 0.4 0.1 2.3 0.7 0.7 0.9 1.1 0.3 0.3 0.1 2.3 0.9 0.7 0.9 1.1 0.4 0.4 0.1 2.3 0.7 0.7 0.9 1.1 0.3 0.3 0.1 2.3 0.7 0.7 0.9 1.1 0.3 0.3 0.1 2.3 0.9 0.7 0.9 1.1 0.4 0.4 0.1 2.3
2010 Softail Models
1-15
JK5 = FXCWC
Table 1-5. Transmission

TRANSMISSION CASE Replace transmission case Replace transmission complete Overhaul transmission includes disassembly, cleaning, inspection, replacing parts (transmission case in frame) Replace transmission sprocket Replace main drive gear oil seal Replace mainshaft oil seal Replace side door gasket Replace shifter drum Replace shifter arm assembly or springs Replace transmission top cover and/or gasket Replace shifter forks and/or shaft Replace side door bearing Replace side door bearing Replace transmission case countershaft bearing Replace main drive gear and/or bearing Replace side cover gasket Replace shift pedal and/or lever Replace transmission shifter shaft seal Replace vehicle speed sensor o-ring Ream shifter lever bearing sleeve (after installation) one or both includes removal and installation includes adjusting gear engagement includes oil tank and starter removal includes checking gear engagement one both in transmission case in main drive gear 4309 4311 4316 4321 4331 4336 4341 4343 4348 4351 4361 4366 4368 4372 4390 4380 4393 2.4 2.5 2.4 3.4 3.5 3.5 2.6 3.5 3.7 3.8 3.5 5.6 1.1 0.1 2.2 0.6 0.2 2.4 2.5 2.4 3.8 3.9 3.9 3.0 3.9 4.1 4.2 3.9 6.0 1.5 0.1 2.2 0.6 0.2 2.4 2.5 2.4 3.4 3.5 3.5 2.6 3.5 3.7 3.8 3.5 5.6 1.1 0.1 2.2 0.6 0.2 2.4 2.5 2.4 3.8 3.9 3.9 3.0 3.9 4.1 4.2 3.9 6.0 1.5 0.1 2.2 0.6 0.2 2.4 2.5 2.4 3.4 3.5 3.5 2.6 3.5 3.7 3.8 3.5 5.6 1.1 0.1 2.2 0.6 0.2 2.4 2.5 2.4 3.8 3.9 3.9 3.0 3.9 4.1 4.2 3.9 6.0 1.5 0.1 2.2 0.6 0.2 2.4 2.5 2.4 3.4 3.5 3.5 2.6 3.5 3.7 3.8 3.9 5.0 1.1 0.1 2.2 0.6 0.2 4304 4305 4306 5.7 4.3 5.2 6.1 4.7 5.6 5.7 4.3 5.2 6.1 4.7 5.6 5.7 4.3 5.2 6.1 4.7 5.6 5.1 3.7 4.6
2010 Softail Models
1-16
JK5 = FXCWC
Table 1-6. OEM Accessories

ACCESSORIES Replace tank trim Replace sissy bar (Except FLST) Replace mirror Replace backrest (Except FLST) Replace windshield (Except FLST) Replace windshield (Except FLST) Replace one saddlebag (Except FLST) Replace one saddlebag bracket (Except FLST) Replace one saddlebage insulator (Except FLST) Replace luggage Rack Replace fender tip Replace fender tip front rear window only 6507 6511 6513 6515 6204 6517 6518 6519 6538 6453 6302 6304 --0.8 0.1 0.2 0.3 0.3 0.1 0.2 0.1 --0.1 0.1 --0.8 0.1 0.2 --0.3 0.1 0.2 0.1 0.1 0.1 0.1 ----0.1 ----------------------0.1 ----------------------0.1 ----------------------0.1 ------------------0.1 --0.1 -------------------
2010 Softail Models
1-17
JK5 = FXCWC
Table 1-7. Electrical - General

INSTRUMENTS Replace speedometer Replace console Replace trip switch boot WIRING Replace connector housing Replace connector anchor Replace main wiring harness Replace rear fender wiring harness Replace electrical box Replace fuse Replace fuse block SWITCHES Replace ignition switch Replace passing lamp switch Replace right upper handlebar switch Replace left upper handlebar switch housing Replace left lower handlebar switch housing Replace right upper handlebar switch housing Replace right lower handlebar switch housing LIGHTS Replace headlight bracket Replace headlight housing Replace rear turn signal bar Replace fender tip lamp assembly Front Includes adjustment Includes adjustment 5181 5189 5207 5225 0.2 0.5 0.3 0.7 0.2 0.5 0.7 --0.2 0.5 ----0.2 0.5 ----0.2 0.5 ----0.2 0.5 ----0.2 0.5 ----5129 5167 5173 5177 5178 5179 5180 0.2 0.1 0.7 0.2 0.2 0.2 0.4 0.2 0.1 0.7 0.2 0.2 0.2 0.4 0.2 --0.7 0.2 0.2 0.2 0.4 0.2 --0.7 0.2 0.2 0.2 0.4 0.2 --0.7 0.2 0.2 0.2 0.4 0.2 --0.7 0.2 0.2 0.2 0.4 0.2 --0.7 0.2 0.2 0.2 0.4 5022 5023 5026 5036 5047 5145 5196 0.1 0.1 2.1 0.8 0.2 0.2 0.4 0.1 0.1 2.1 0.8 0.2 0.2 0.4 0.1 0.1 2.0 0.8 0.2 0.2 0.3 0.1 0.1 2.0 0.8 0.2 0.2 0.3 0.1 0.1 2.0 0.8 0.2 0.2 0.3 0.1 0.1 2.0 0.8 0.2 0.2 0.3 0.1 0.1 2.1 0.8 0.2 0.2 0.4 Cosmetic issue 6003 6012 6043 0.3 0.2 0.1 0.3 0.2 0.1 0.3 0.2 0.1 0.3 0.2 0.1 0.3 0.2 0.1 0.3 0.2 0.1 0.3 0.2 0.1
2010 Softail Models
1-18
JK5 = FXCWC

0.1 0.1 0.4 0.6 --1.0 0.3
JD5
----0.4 0.6 --0.7 0.7
BV5
----------0.5 0.3
BX5 JG5 JN5

----------0.5 0.3
JL5
----------0.5 0.3
JK5
--------0.1 0.5 0.3
JM5
----------1.0 0.3
Replace fender tip lamp assembly Replace fender tip lamp bulb Replace passing lamp assembly Replace passing lamp bracket Replace license plate bracket Replace turn signal (cosmetic issue) Replace turn signal (cosmetic issue) BATTERY Replace the battery
Rear Includes diagnosis
5229 5228 5230 5232 5237
Front Rear
5201 5205
5705
0.3
0.3
0.3
0.3
0.3
0.3
0.3
2010 Softail Models
1-19
JK5 = FXCWC
Table 1-8. Softail Diagnostics

NOTE: Unless otherwise noted, all codes include diagnostic time and replacement time if required. The codes must be used in conjunction with the diagnostic/repair procedures listed in the current Softail Service Manual and Softail Electrical Diagnostic Manual. DIAGNOSTICS GENERAL Repair any single wire Repair any single wire Repair any single wire Replace position lamp Replace headlight Replace indicator lamp assembly Light circuit Accessory circuit All wires except lighting and accessory circuits Position lamp inoperative Headlamp inoperative High beam indicator inoperative, neutral lamp inoperative, oil pressure lamp inoperative, turn signal indicator inoperative Replace tail lamp bulb or lens Replace tail lamp assembly or circuit board Replace auxiliary lamp bulb Replace horn and/or bracket Running lamps inoperative Headlamp inoperative, stop lamp inoperative Auxiliary lamp inoperative Horn inoperative 5197 5215 5227 5765 7210 0.1 0.2 0.2 0.1 0.5 0.1 0.6 0.2 0.1 0.5 0.1 0.2 --0.1 0.5 0.1 0.2 --0.1 0.5 0.1 0.2 --0.1 0.5 0.1 0.2 --0.1 0.5 0.1 0.2 --0.1 0.5 5039 5043 5041 5143 5185 5191 0.5 0.5 0.5 0.1 0.1 0.2 0.5 0.5 0.5 0.1 0.1 0.2 0.5 0.5 0.5 0.1 0.1 0.2 0.5 0.5 0.5 0.1 0.1 0.2 0.5 0.5 0.5 0.1 0.1 0.2 0.5 0.5 0.7 0.1 0.1 0.2 0.5 0.5 0.5 0.1 0.1 0.2
Repair engine compression; use in conjunction with Engine cranks but will not start additional code(s) Code not present SWITCHES Replace rear stoplight switch, includes filling and bleeding brakes Replace neutral switch Nothing clicks, neutral lamp always on, neutral lamp inoperative, B1155 Replace oil pressure switch Oil pressure lamp always on, oil pressure lamp inoperative Replace clutch switch Nothing clicks, B1154 Stop lamp inoperative B1006, B1007, B0563, P0562, P0563, P0603
7770
0.2
0.2
0.2
0.2
0.2
0.2
0.2
5141
0.4
0.4
0.4
0.4
0.4
0.4
0.4
5157
0.6
0.6
0.6
0.6
0.6
0.6
0.6
5161
0.3
0.3
0.3
0.3
0.3
0.3
0.3
5168
0.8
0.8
0.8
0.8
0.8
1.0
0.8
2010 Softail Models
1-20
JK5 = FXCWC

0.5
JD5
0.5
BV5
0.5
BX5 JG5 JN5

0.5
JL5
0.5
JK5
0.5
JM5
0.5
Replace left upper handlebar switch
Horn always on, horn inoperative, headlamp inoperative
5171
Replace front brake light switch Replace start button Replace trip switch Replace trip switch boot Replace turn signal switch Replace engine stop switch Replace engine stop switch Replace ignition switch
Stop lamp inoperative Starter inoperative B1008 B1008 Both lamps on one side inoperative Serial data missing No check engine lamp Starter testing, serial data missing, no check engine lamp, stop lamp inoperative, IM inoperative
5176 5818 6001 6002 6811 6730 7295 7287
0.6 0.9 0.3 0.2 1.1 0.9 0.7 0.4
0.6 0.9 0.3 0.2 1.1 0.9 0.7 0.4
0.6 0.9 0.3 0.2 1.1 0.9 0.7 0.4
0.6 0.9 0.3 0.2 1.1 0.9 0.7 0.4
0.6 0.9 0.3 0.2 1.1 0.9 0.7 0.4
0.6 0.9 0.3 0.2 1.3 1.2 1.0 0.4
0.6 0.9 0.3 0.2 1.1 0.9 0.7 0.4
FUSES AND RELAYS Replace battery fuse Inspect/access main wire harness and electrical panel/wiggle test/replace ignition fuse Replace main fuse Serial data missing 6733 6766 0.5 0.3 0.5 0.3 0.5 0.3 0.5 0.3 0.5 0.3 0.5 0.5 0.5 0.3 U1064 Serial data missing 6713 6729 0.5 0.4 0.5 0.4 0.5 0.4 0.5 0.4 0.5 0.4 0.7 0.7 0.5 0.4
Access instruments\wiggle test\replace instrument U1097, U1255 fuse Replace starter relay Replace starter relay Inspect/access electrical panel/main wiring harness/replace battery fuse Replace 15 amp fuse Replace system relay Replace system relay Replace system relay Engine cranks but will not start, starts hard Serial data missing, P1001, P1003 P1002 P1004 Starter inoperative B1134 No check engine lamp, U1255
5832 6841 7159
0.2 0.2 0.5
0.2 0.2 0.5
0.2 0.2 0.5
0.2 0.2 0.5
0.2 0.2 0.5
0.2 0.4 0.7
0.2 0.2 0.5
7181 7904 7909 7911
0.3 0.3 0.3 0.2
0.3 0.3 0.3 0.2
0.3 0.3 0.3 0.2
0.3 0.3 0.3 0.2
0.3 0.3 0.3 0.2
0.3 0.6 0.3 0.5
0.3 0.3 0.3 0.2
2010 Softail Models
1-21
JK5 = FXCWC

0.4
JD5
0.4
BV5
0.4
BX5 JG5 JN5

0.4
JL5
0.4
JK5
0.7
JM5
0.4
Harness inspection/wiggle test/electrical panel removal/replace system relay Harness inspection/wiggle test/electrical panel removal/replace ECM fuse CHARGING CIRCUIT Milliamp draw Replace stator Total current draw Replace voltage regulator Replace voltage regulator Replace rotor Replace battery
P1004
7918
P1003, P1351, P1354
7937
0.5
0.5
0.5
0.5
0.5
0.8
0.5
Low battery after extended ignition off Low or no charging Diagnose charging system No or low charging, overcharging Serial data missing No or low charging engine cranks but will not start
5308 5309 5310 5316 6724 5319 7185 7771
0.2 2.6 0.2 0.7 0.4 2.5 0.5 0.2
0.2 2.6 0.2 0.7 0.4 2.5 0.5 0.2
0.2 2.6 0.2 0.7 0.4 2.5 0.5 0.2
0.2 2.6 0.2 0.7 0.4 2.5 0.5 0.2
0.2 2.6 0.2 0.7 0.4 2.5 0.5 0.2
0.2 2.6 0.2 0.7 0.4 2.5 0.5 0.2
0.2 2.6 0.2 0.7 0.4 2.5 0.5 0.2
Repair charging system/accompanies other codes B0563, B1006, B1007, P0562, P0563 STARTER CIRCUIT Replace starter motor Replace starter motor Replace starter clutch Replace starter solenoid Repair starting system, use in conjunction with additional code(s) IGNITION CIRCUIT Replace spark plugs Hesitates - poor driveability, misfire at idle or under load, rough or rolling idle, engine cranks but will not start, starts - then stalls, starts hard Replace spark plug P1353, P1356, P1357, P1358 Solenoid clicks Starter spins but does not engage Starter spins but does not engage Starter testing, starter relay clicks Engine cranks but will not start
5817 5825 5837 5845 7166
1.6 1.2 1.4 1.4 0.2
1.6 1.2 1.4 1.4 0.2
1.5 1.1 1.3 1.3 0.2
1.5 1.1 1.3 1.3 0.2
1.5 1.1 1.3 1.3 0.2
1.5 1.1 1.3 1.3 0.2
1.6 1.6 1.8 1.4 0.2
7134
0.4
0.4
0.4
0.4
0.4
0.4
0.4
7548
0.2
0.2
0.2
0.2
0.2
0.2
0.2
2010 Softail Models
1-22
JK5 = FXCWC

0.3
JD5
0.3
BV5
0.3
BX5 JG5 JN5

0.3
JL5
0.3
JK5
0.3
JM5
0.3
Replace spark plug Wire
Hesitates - poor driveability, misfire at idle or under load, rough or rolling idle, engine cranks but will not start, starts - then stalls, starts hard
7138
Replace spark plug Wire Replace ignition coil Replace ignition coil Replace ignition coil
P1353, P1356, P1357, P1358 Engine cranks but will not start, starts hard P1353, P1356, P1357, P1358 Hesitates - poor driveability, misfire at idle or under load, rough or rolling idle, P1351, P1352, P1354, P1355,
7549 7226 7547 7856
0.2 0.4 0.5 0.5
0.2 0.4 0.5 0.5
0.2 0.4 0.5 0.5
0.2 0.4 0.5 0.5
0.2 0.4 0.5 0.5
0.2 0.4 0.8 0.8
0.2 0.4 0.8 0.8
AIR INTAKE Repair intake leak FUEL SYSTEM Replace fuel level sender Replace fuel gauge Replace fuel filter or clean fuel pump screen Repair/replace fuel pump/pressure regulator/fuel line/fuel filter Replace fuel filter screen Hesitates - poor driveability, misfire at idle or under load, rough or rolling idle, engine cranks but will not start, starts hard, P0131, P0151, Repair/replace fuel pump/pressure regulator/fuel line/fuel filter Hesitates - poor driveability, misfire at idle or under load, rough or rolling idle, engine cranks but will not start, starts hard, P0131, P0132, P0151, P0152 Replace fuel injector Hesitates - poor driveability, misfire at idle or under load, rough or rolling idle, P0131, P0132, P0151, P0152 Replace fuel injector Replace fuel injector Emits black smoke P0261, P0262, P0263, P0264 7596 7795 1.0 0.7 1.0 0.7 1.0 0.7 1.0 0.7 1.0 0.7 1.0 1.0 1.0 0.7 7144 0.9 0.9 0.9 0.9 0.9 1.2 0.9 7164 1.0 1.0 1.0 1.0 1.0 1.3 1.0 7163 1.0 1.0 1.0 1.0 1.0 1.3 1.0 B1004, B1005 U1255 Starts - then stalls, P1353, P1356, P1357, P1358 Starts - then stalls, P1353, P1356, P1357, P1358 6035 6775 7013 7014 0.6 0.4 0.8 1.0 0.6 0.4 0.8 1.0 0.6 0.4 0.8 1.0 0.6 0.4 0.8 1.0 0.6 0.4 0.8 1.0 0.6 0.6 0.8 1.0 0.6 0.4 0.8 1.0 P0131, P0151 7486 1.0 1.0 1.0 1.0 1.0 1.3 1.0
2010 Softail Models
1-23
JK5 = FXCWC

0.9 0.9 1.2 0.7
JD5
0.9 0.9 1.2 0.7
BV5
0.9 0.9 1.2 0.7
BX5 JG5 JN5

0.9 0.9 1.2 0.7
JL5
0.9 0.9 1.2 0.7
JK5
0.9 0.9 1.5 0.7
JM5
0.9 0.9 1.2 0.7
Replace fuel injector Replace fuel pump Replace fuel pump Replace fuel pressure regulator SENSORS AND ECM Replace Jiffy Stand Sensor IAC system OK, may use with other codes Replace idle air control (IAC) Replace throttle position sensor
Engine cranks but will not start, starts hard Engine cranks but will not start, starts hard P1003 Emits black smoke
7992 7415 7924 7480
P1501, P1502 P0505 P0505 Engine cranks but will not start, starts hard, P0122, P0123,
5085 7028 7490 7595
0.4 0.5 0.5 1.2
0.4 0.5 0.5 1.2
0.4 0.5 0.5 1.2
0.4 0.5 0.5 1.2
0.4 0.5 0.5 1.2
0.7 0.5 0.8 1.2
0.4 0.5 0.5 1.2
Replace engine temperature (ET) sensor Replace engine temperature (ET) sensor Replace vehicle speed sensor (VSS) Replace oxygen sensor Replace intake air temperature (IAT) sensor Replace crankshaft position (CKP) sensor Clean or repair crankshaft position (CKP) sensor Replace MAP sensor
Emits black smoke P0117, P0118 P0502 P0131, P0132, P0134, P0151, P0152, P0154 P0112, P0113 P0373, P0374 P0373, P0374 Hesitates - poor driveability, misfire at idle or under load, rough or rolling idle
7598 7710 7639 7667 7725 7981 7982 7152
1.2 0.4 0.4 0.6 0.9 0.4 0.3 0.7
1.2 0.4 0.4 0.6 0.9 0.4 0.3 0.7
1.2 0.4 0.4 0.6 0.9 0.4 0.3 0.7
1.2 0.4 0.4 0.6 0.9 0.4 0.3 0.7
1.2 0.4 0.4 0.6 0.9 0.4 0.3 0.7
1.2 0.7 0.7 0.9 0.9 0.7 0.6 1.0
1.2 0.4 0.4 0.6 0.9 0.4 0.3 0.7
Replace MAP sensor Replace MAP sensor Replace MAP sensor Clean or repair vehicle speed sensor (VSS) Replace vehicle speed sensor (VSS) Replace ECM
Emits black smoke P0107 P0107, P0108, P0122 P0501 P0122, P0501, P0502 Hesitates - poor driveability, misfire at idle or under load, rough or rolling idle, P1009
7597 7630 7650 7939 7967 6703
1.1 0.3 0.6 0.4 0.6 1.0
1.1 0.3 0.6 0.4 0.6 1.0
1.1 0.3 0.6 0.4 0.6 1.0
1.1 0.3 0.6 0.4 0.6 1.0
1.1 0.3 0.6 0.4 0.6 1.0
1.1 0.3 0.9 0.7 0.9 1.3
1.1 0.3 0.6 0.4 0.6 1.0
2010 Softail Models
1-24
JK5 = FXCWC

0.6 1.6 0.9 0.4 0.8
JD5
0.6 1.6 0.9 0.4 0.8
BV5
0.6 1.6 0.9 0.4 0.8
BX5 JG5 JN5

0.6 1.6 0.9 0.4 0.8
JL5
0.6 1.6 0.9 0.4 0.8
JK5
0.9 1.6 1.2 0.7 1.1
JM5
0.6 1.6 0.9 0.4 0.8
Replace ECM Replace ECM Replace ECM Replace ECM Replace ECM
P0122, P0501, P0502, P0505, U1064 Emits black smoke P0107, P0108, P0661, P0662, P1010 P0117, P1001, P1002 Engine cranks but will not start, starts - then stalls, starts hard, serial data missing, P0118, P0131, P0132, P0134, P0151, P0152, P0154, P0262, P0264, U1300, U1301
7565 7601 7641 7680 7685
Replace ECM
No check engine lamp, P0112, P0123, P0373, P0374, P0605, P1351, P1352, P1354, P1355
7735
0.5
0.5
0.5
0.5
0.5
0.8
0.5
Replace ECM
Serial data missing, no check engine lamp, P0113, P0261, P0263, P0603, P1353, P1356, P1357, P1358, P1475, P1477, P1478, P1501, P1502
7740
0.7
0.7
0.7
0.7
0.7
1.0
0.7
HDI ACTIVE EXHAUST Replace active intake solenoid Replace exhaust actuator Replace exhaust actuator valve Replace exhaust actuator cable Replace engine control fuse TURN SIGNALS/INSTRUMENTS/SECURITY Perform ECM/TSM/TSSM/HFSM module replace- P1009 ment procedure Replaced TSM/TSSM/HFSM , system now ok Replaced TSM/TSSM/HFSM , system now ok Replace FOB battery Replace FOB P1009 P1010 Fails to disarm Fails to disarm 6702 6707 6755 6756 0.5 0.6 0.1 0.1 0.5 0.6 0.1 0.1 0.5 0.6 0.1 0.1 0.5 0.6 0.1 0.1 0.5 0.6 0.1 0.1 0.7 0.9 0.1 0.1 0.5 0.6 0.1 0.1 6701 0.5 0.5 0.5 0.5 0.5 0.8 0.5 P0661, P0662, P1475 P1475, P1477, P1478 P1475 P1475 P1475 7064 7811 7812 7814 7826 0.5 0.8 0.7 0.8 0.3 0.5 1.0 0.7 0.8 0.3 0.5 0.8 0.7 0.8 0.3 0.5 0.8 0.7 0.8 0.3 0.5 1.0 0.7 0.8 0.3 0.5 1.1 0.7 0.8 0.6 0.5 1.0 0.7 0.8 0.3
2010 Softail Models
1-25
JK5 = FXCWC

0.2
JD5
0.2
BV5
0.2
BX5 JG5 JN5

0.2
JL5
0.2
JK5
0.2
JM5
0.2
Replace Bulb
Both lamps on one side inoperative, flash at double normal rate, B1121, B1122
6796
Remove corrosion Remove corrosion/replace bulb Replace lamp assembly/bulb connections
Flash at double normal rate Flash at double normal rate Flash at double normal rate, one lamp inoperative, B1121, B1122
6821 6822 6823
0.2 0.6 0.5
0.2 0.6 0.5
0.2 0.6 0.5
0.2 0.6 0.5
0.2 0.6 0.5
0.2 0.6 0.7
0.2 0.6 0.5
Replace speedometer
No security lamp during bulb check, security lamp on continuously after bulb check, no check engine lamp, B1008
6020
0.3
0.3
0.3
0.3
0.3
0.3
0.3
Replace speedometer
Serial data missing, no check engine lamp, U1016, U1064,
6072
0.5
0.5
0.5
0.5
0.5
0.8
0.5
Replace speedometer Replace TSM/TSSM/HFSM Replace TSM/TSSM/HFSM Replace TSM/TSSM/HFSM Replace TSM/TSSM/HFSM Replace TSM/TSSM/HFSM Replace TSM/TSSM/HFSM
U1097, U1255, U1300, U1301, Nothing clicks B1143, B1144, B1145, B1154, B1155 U1016, U1064, U1255 Fails to disarm Will not cancel upon turn completion Starter inoperative, flash at double normal rate, B1121- B1126, B1134, B1141
6765 5838 5863 6717 6757 6773 6791
0.6 0.6 0.5 0.7 0.6 1.1 0.7
0.6 0.6 0.5 0.7 0.6 1.1 0.7
0.6 0.6 0.5 0.7 0.6 1.1 0.7
0.6 0.6 0.5 0.7 0.6 1.1 0.7
0.6 0.6 0.5 0.7 0.6 1.1 0.7
0.9 0.8 0.7 1.0 0.8 1.3 0.9
0.6 0.6 0.5 0.7 0.6 1.1 0.7
Replace TSM/TSSM/HFSM Replace TSM/TSSM/HFSM Replace TSM/TSSM/HFSM Replace TSM/TSSM/HFSM Replace siren Replace siren Replace security antenna Replace security antenna harness
Flash at double normal rate Neutral lamp always on, B1135, B1136, B1142 No check engine lamp Serial data missing, U1300, U1301 B1131, B1132 No check engine lamp Fails to disarm, B1143-B1145 B1145
6824 6845 7306 7998 6832 7161 6878 6881
0.9 0.3 0.6 0.9 0.3 0.3 0.2 0.4
0.9 0.3 0.6 0.9 0.3 0.3 0.2 0.4
0.9 0.3 0.6 0.9 0.3 0.3 0.2 0.4
0.9 0.3 0.6 0.9 0.3 0.3 0.2 0.4
0.9 0.3 0.6 0.9 0.3 0.3 0.2 0.4
1.1 0.5 1.0 1.2 0.5 0.4 0.4 0.6
0.9 0.3 0.6 0.9 0.3 0.3 0.2 0.4
2010 Softail Models
1-26
SUBJECT..............................................................................................................PAGE NO. 2.1 Service........................................................................................................................2-1 2.2 Chassis.......................................................................................................................2-2 2.3 Engine.........................................................................................................................2-7 2.4 Drive and Clutch........................................................................................................2-12 2.5 Transmission.............................................................................................................2-13 2.6 OEM Accessories......................................................................................................2-14 2.7 Electrical - General....................................................................................................2-15 2.8 Dyna Diagnostics......................................................................................................2-17 Unless otherwise specified, Job Times shown include all operations necessary to complete the listed job.
DYNA MODELS
GM4 = FXD
GN4 = FXDL
GV4 = FXDC
GX4 = FXDB
GY4 = FXDF
GP4 = FXDWG
Table 2-1. Service

ITEM DESCRIPTION LABOR CODE MODELS GM4 GV4 GX4 GN4 GY4 GP4
NEW Set-up and predelivery 1,000 mile (1,600 km) service REGULAR 5,000 mile (8,000 km) maintenance 10,000 mile (16,000 km) maintenance 15,000 mile (24,000 km) maintenance 20,000 mile (32,000 km) maintenance 25,000 mile (40,000 km) maintenance 30,000 mile (48,000 km) maintenance Addition to any maintenance- required every 2 years Addition to 1,000, 5,000 and 20,000 mile (1,600, 8,000, and 32,000 km) maintenance and every 15,000 mile (24,000 km) interval there after Tighten spoke wheels if equipped, time per wheel --0.5 0.5 0.5 0.5 0.5 0.5 flush/fill D.O.T 4 brake fluid- front and rear --------------2.1 3.1 2.1 2.2 2.1 2.7 0.4 2.1 3.1 2.1 2.2 2.1 2.7 0.4 2.1 3.1 2.1 2.2 2.1 2.7 0.4 2.1 3.1 2.1 2.2 2.1 2.7 0.4 2.1 3.1 2.1 2.2 2.1 2.7 0.4 2.1 3.1 2.1 2.2 2.1 2.7 0.4 ----2.1 2.0 2.1 2.0 2.1 2.0 2.1 2.0 2.1 2.0 2.1 2.0
2010 Dyna Models
2-1
GM4 = FXD
GN4 = FXDL
GV4 = FXDC
GX4 = FXDB
GY4 = FXDF
GP4 = FXDWG
Table 2-2. Chassis

PAINT REPAIR NOTE: use these codes when repairing any painted part on vehicle with the Kent Moore finesse kit or other paint repair methods Light scuff/scratch - buff Light sanding/buff/blend Buff entire part Repair build up in clear/paint Color blend/paint/buff DRIVE Adjust secondary belt Replace secondary belt Replace rear wheel sprocket WHEELS Replace tire includes balancing Replace tire includes balancing Replace wheel assembly - includes disc and sprocket exchange and balancing Replace wheel assembly - includes disc and sprocket exchange and balancing Replace rim, hub or spokes-includes truing wheel front Replace rim, hub or spokes-includes truing wheel rear Replace wheel bearings Replace wheel bearings Check or true spoked wheel HANDLEBARS Replace handlebars Replace clutch hand lever 2206 2221 0.5 0.2 0.5 0.2 1.2 0.2 0.5 0.2 1.2 0.2 1.2 0.2 front rear each wheel 2116 2121 2136 2141 2155 2.3 2.3 0.5 0.6 0.5 2.3 2.3 0.5 0.6 0.5 2.3 2.3 0.5 0.6 0.5 2.3 2.3 0.5 0.6 0.5 2.2 2.3 0.5 0.6 0.5 2.2 2.3 0.5 0.6 0.5 rear 2114 0.9 0.9 0.9 0.9 0.9 0.9 front rear front 2106 2111 2113 0.6 0.7 0.8 0.6 0.7 0.8 0.6 0.7 0.8 0.6 0.7 0.8 0.6 0.7 0.8 0.6 0.7 0.8 --2011 2021 0.2 2.1 0.8 0.2 2.1 0.8 0.2 2.1 0.8 0.2 2.1 0.8 0.2 2.1 0.8 0.2 2.1 0.8 1102 1104 1106 1108 1110 0.2 0.4 0.6 0.8 1.0 0.2 0.4 0.6 0.8 1.0 0.2 0.4 0.6 0.8 1.0 0.2 0.4 0.6 0.8 1.0 0.2 0.4 0.6 0.8 1.0 0.2 0.4 0.6 0.8 1.0
2010 Dyna Models
2-2
GM4 = FXD
GN4 = FXDL
GV4 = FXDC
GX4 = FXDB
GY4 = FXDF
GP4 = FXDWG
Table 2-2. Chassis

ITEM DESCRIPTION LABOR CODE
2226 2231 one or both 2241 2246 2251 one or both one or both 2253 2254
MODELS GM4
0.2 0.4 0.6 0.5 0.2 0.4 0.1
GV4
0.2 0.4 0.6 0.5 0.2 0.4 0.1
GX4
0.2 0.4 0.6 --0.2 --0.1
GN4
0.2 0.4 0.6 0.5 0.2 0.4 0.1
GY4
0.2 0.4 0.6 0.5 0.2 0.4 0.1
GP4
0.2 0.4 0.6 0.5 0.2 0.4 0.1
Replace clutch hand lever bracket Replace throttle control Replace and adjust throttle control cables Replace both rubber handlebar mounts Replace rubber handlebar grip Replace handlebar riser Replace handlebar clamp FRAME/SWING ARM/FRONT FORK Replace frame includes removal and installation of all accessories and motorcycle components Replace foot pegs Replace foot peg mount (to frame/swingarm) Replace front fork assembly Replace lower fork bracket and stem Replace steering head cups and bearings, including bearing adjustment Replace upper fork bracket Replace fork lock Adjust steering head bearings Change front fork oil at PDI Only both sides each
2306
10.0
10.0
10.0
10.0
10.0
10.0
2307 2308 2311 2316 2321
0.1 0.2 2.1 2.1 2.1
0.1 0.2 2.1 2.1 2.1
0.1 0.2 2.1 2.1 2.1
0.1 0.2 2.1 2.1 2.1
0.1 0.2 2.1 2.1 2.1
0.1 0.2 2.1 2.1 2.1
2326 2330 2290 --2341
0.7 0.3 0.3 0.8 0.9
0.7 0.3 0.3 0.8 0.9
0.7 0.3 0.3 0.8 0.9
0.7 0.3 0.3 0.8 0.9
0.7 0.3 0.3 0.8 0.9
0.7 0.3 0.3 0.8 0.9
Service or replace fork slider and/or seal includes one side removal, disassembly, cleaning, inspection, replacing bushings, assembly and installation Service or replace fork slider and/or seal includes both sides removal, disassembly, cleaning, inspection, replacing bushings, assembly and installation Replace fork side one side
2342
1.5
1.5
1.5
1.5
1.5
1.5
2346
0.6
0.6
0.6
0.6
0.6
0.6
2010 Dyna Models
2-3
GM4 = FXD
GN4 = FXDL
GV4 = FXDC
GX4 = FXDB
GY4 = FXDF
GP4 = FXDWG
Table 2-2. Chassis

2351 2356
MODELS GM4
0.8 0.9
GV4
0.8 0.9
GX4
0.8 0.9
GN4
0.8 0.9
GY4
0.8 0.9
GP4
0.8 0.9
Replace fork side
both sides
Replace fork tube includes removal, disassembly, one side cleaning, inspection, replacing parts, servicing damper tube, assembly and installation Replace fork tube includes removal, disassembly, both sides cleaning, inspection, replacing parts, servicing damper tube, assembly and installation Replace rear swing arm and/or bushings Replace rear fork pivot shaft Replace rear shock absorber assembly Replace rear shock absorber assembly Replace rear shock absorber component(s) Replace rear shock absorber component(s) Replace jiffy stand Replace jiffy stand Replace motor rubber mount Replace motor rubber mount BRAKES Replace hydraulic brake line includes filling/bleeding brakes Replace hydraulic brake line includes filling/bleeding brakes Replace rear master cylinder Replace brake pads Replace brake pads Replace brake caliper includes filling/bleeding brakes front each caliper rear front rear front one side both sides one side both sides spring and/or stand rubber bumper rear front
2361
1.5
1.5
1.5
1.5
1.5
1.5
2366 2368 2371 2376 2381 2386 2396 2399 2395 2398
2.0 0.5 0.2 0.4 0.3 0.6 0.3 0.1 0.5 0.2
2.0 0.5 0.2 0.4 0.3 0.6 0.3 0.1 0.5 0.2
2.0 0.5 0.2 0.4 0.3 0.6 0.3 0.1 0.5 0.2
2.0 0.5 0.2 0.4 0.3 0.6 0.3 0.1 0.5 0.2
2.0 0.5 0.2 0.4 0.3 0.6 0.3 0.1 0.5 0.2
2.0 0.5 0.2 0.4 0.3 0.6 0.3 0.1 0.5 0.2
2406
0.3
0.3
0.3
0.3
0.3
0.3
2411
0.3
0.3
0.3
0.3
0.3
0.3
2414 2416 2421 2426
0.5 0.1 0.1 0.4
0.5 0.1 0.1 0.4
0.5 0.1 0.1 0.4
0.5 0.1 0.1 0.4
0.5 0.1 0.1 0.4
0.5 0.1 0.1 0.4
2010 Dyna Models
2-4
GM4 = FXD
GN4 = FXDL
GV4 = FXDC
GX4 = FXDB
GY4 = FXDF
GP4 = FXDWG
Table 2-2. Chassis

2431
MODELS GM4
0.4
GV4
0.4
GX4
0.4
GN4
0.4
GY4
0.4
GP4
0.4
Replace brake caliper includes filling/bleeding brakes Replace brake disc Replace brake disc Bleed brake caliper Overhaul brake caliper includes filling/bleeding brakes Overhaul brake caliper includes filling/bleeding brakes Replace master cylinder assembly includes filling/bleeding brakes Replace master cylinder assembly includes filling/bleeding brakes Rebuild master cylinder assembly includes filling/bleeding brakes Rebuild master cylinder assembly includes filling/bleeding brakes replace master cylinder cover (front or rear) Replace rear brake pedal Replace front brake lever SEATS/FENDERS/TANKS Replace seat Replace fender Replace fender Replace wire conduit Replace rear fender chrome support cover Replace fuel tank assembly
rear
front each side rear one or two front calipers or rear caliper front each caliper
2436 2441 2446 2451
0.3 0.8 0.2 0.6
0.3 0.8 0.2 0.6
0.3 0.8 0.2 0.6
0.3 0.8 0.2 0.6
0.3 0.8 0.2 0.6
0.3 0.8 0.2 0.6
rear
2456
0.8
0.8
0.8
0.8
0.8
0.8
front
2461
0.4
0.4
0.4
0.4
0.4
0.4
rear
2466
0.5
0.5
0.5
0.5
0.5
0.5
front
2471
0.6
0.6
0.6
0.6
0.6
0.6
rear
2476
0.7
0.7
0.7
0.7
0.7
0.7
2479 2492 2494
0.1 0.3 0.1
0.1 0.3 0.1
0.1 0.3 0.1
0.1 0.3 0.1
0.1 0.3 0.1
0.1 0.3 0.1
2506 front rear (includes replacing wire conduit) 2526 2531 2533 one only 2536 2541
0.1 0.3 1.1 0.2 0.3 0.9
0.1 0.3 1.1 0.2 0.3 0.9
0.1 0.3 1.1 0.2 --0.9
0.1 0.3 1.1 0.2 0.3 0.9
0.1 0.3 1.1 0.2 0.3 0.9
0.1 0.3 1.1 0.2 0.3 0.9
2010 Dyna Models
2-5
GM4 = FXD
GN4 = FXDL
GV4 = FXDC
GX4 = FXDB
GY4 = FXDF
GP4 = FXDWG
Table 2-2. Chassis

2561 2563 2557 2549 2564 2576 2582 2590 3480
MODELS GM4
0.7 0.3 0.2 0.6 0.6 0.3 0.1 0.2 0.1
GV4
0.7 0.2 0.2 0.6 0.6 0.3 0.1 0.2 0.1
GX4
0.7 0.3 0.2 0.6 0.6 0.3 0.1 0.2 0.1
GN4
0.7 0.2 0.2 0.6 0.6 0.3 0.1 0.2 0.1
GY4
0.7 0.2 0.2 0.6 0.6 0.3 0.1 0.2 0.1
GP4
0.7 0.2 0.2 0.6 0.6 0.3 0.1 0.5 0.1
Replace fuel tank valve Replace fuel tank gauge Replace fuel tank console/fuel filler trim ring Replace fuel tank top plate/gasket Replace fuel tank gauge sending unit Replace any hose Replace oil filter Replace license plate holder Replace dipstick BELT GUARDS Replace debris deflector Replace belt guard EXHAUST SYSTEM Replace complete exhaust system and/or gaskets Replace exhaust pipe Replace exhaust pipe Replace exhaust actuator cable Replace any muffler Replace any exhaust shield Replace muffler support front rear HDI only
2616 2620
0.2 0.2
0.2 0.2
0.2 0.2
0.2 0.2
0.2 0.2
0.2 0.2
2626 2631 2636 2637 2646 2661 2666
0.6 0.3 0.3 0.2 0.2 0.1 0.2
0.6 0.3 0.3 0.2 0.2 0.1 0.2
0.6 0.3 0.3 0.2 0.2 0.1 0.2
0.6 0.3 0.3 0.2 0.2 0.1 0.2
0.6 ----0.3 0.2 0.1 0.2
0.6 ----0.3 0.2 0.1 0.2
2010 Dyna Models
2-6
GM4 = FXD
GN4 = FXDL
GV4 = FXDC
GX4 = FXDB
GY4 = FXDF
GP4 = FXDWG
Table 2-3. Engine

GENERAL Remove and install engine- includes remove, replace, install oil passage gasket Remove and install engine- includes remove, replace, install oil passage gasket Replace and adjust stabilizer CYLINDER HEAD Recondition cylinder head includes removal of head and gasket, remove carbon, service valve guides, grind valves and seats, test springs and install head and gaskets. Recondition cylinder head includes removal of head and gasket, remove carbon, service valve guides, grind valves and seats, test springs and install head and gaskets. Recondition cylinder head includes removal of head and gasket, remove carbon, service valve guides, grind valves and seats, test springs and install head and gaskets. Replace cylinder head Replace cylinder head Replace valve seal or spring after cylinder head removal Replace valve seal or spring after cylinder head removal Replace cylinder head gasket/o-ring Replace cylinder head gasket/o-ring Replace cylinder head gasket/o-ring Replace rocker arm covers and/or gaskets front cylinder rear cylinder both cylinders front cylinder 3140 3142 3143 3144 1.6 1.6 2.0 0.7 1.6 1.6 2.0 0.7 1.6 1.6 2.0 0.7 1.6 1.6 2.0 0.7 1.6 1.6 2.0 0.7 1.6 1.6 2.0 0.7 both seals or springs (intake or exhaust) 3132 0.2 0.2 0.2 0.2 0.2 0.2 one head both heads one seal or spring (intake or exhaust ) 3106 3108 3131 2.5 3.4 0.1 2.5 3.4 0.1 2.5 3.4 0.1 2.5 3.4 0.1 2.5 3.4 0.1 2.5 3.4 0.1 both heads 3104 4.1 4.1 4.1 4.1 4.1 4.1 rear head 3103 3.5 3.5 3.5 3.5 3.5 3.5 front head 3101 3.5 3.5 3.5 3.5 3.5 3.5 top 3005 0.7 0.7 0.7 0.7 0.7 0.7 3006 4.0 4.0 4.0 4.0 4.0 4.0 California vehicles only 3006 4.1 4.1 4.1 4.1 4.1 4.1
2010 Dyna Models
2-7
GM4 = FXD
GN4 = FXDL
GV4 = FXDC
GX4 = FXDB
GY4 = FXDF
GP4 = FXDWG
Table 2-3. Engine

3145 3148 3149 3150 3147
MODELS GM4
0.7 0.8 0.7 1.4 1.1
GV4
0.7 0.8 0.7 1.4 1.1
GX4
0.7 0.8 0.7 1.4 1.1
GN4
0.7 0.8 0.7 1.4 1.1
GY4
0.7 0.8 0.7 1.4 1.1
GP4
0.7 0.8 0.7 1.4 1.1
Replace rocker arm covers and/or gaskets Replace rocker arm covers and/or gaskets
rear cylinder both cylinders
Recondition rocker arms after heads are removed one head Recondition rocker arms after heads are removed both heads Replace lower rocker arm cover/gasket, or rocker front cylinder arms and /or shafts/rocker arm support Replace lower rocker arm cover/gasket, or rocker rear cylinder arms and /or shafts/rocker arm support Replace lower rocker arm cover/gasket, or rocker both cylinders arms and /or shafts/rocker arm support Replace cylinder o-ring/drain o-ring Replace cylinder o-ring/drain o-ring Replace cylinder o-ring/drain o-ring Replace crankcase umbrella valve Replace crankcase umbrella valve CYLINDER AND PISTON Recondition top end - includes disassembly, replacement of piston and sizing cylinder (.005 pistons), replacing piston rings and all items listed under recondition cylinder head and assembly. Recondition top end - includes disassembly, replacement of piston and sizing cylinder (.005 pistons), replacing piston rings and all items listed under recondition cylinder head and assembly. Recondition top end - includes disassembly, replacement of piston and bore and hone, resizing cylinder (.010 oversize or above), replacing piston rings and all items listed under recondition cylinder head and assembly. one piston and cylinder both pistons and cylinders one piston and cylinder one cylinder rear cylinder both cylinders one both
3152
1.1
1.1
1.1
1.1
1.1
1.1
3153
1.8
1.8
1.8
1.8
1.8
1.8
3161 3163 3168 3172 3174
1.8 1.8 2.2 1.0 1.1
1.8 1.8 2.2 1.0 1.1
1.8 1.8 2.2 1.0 1.1
1.8 1.8 2.2 1.0 1.1
1.8 1.8 2.2 1.0 1.1
1.8 1.8 2.2 1.0 1.1
3202
4.5
4.5
4.5
4.5
4.5
4.5
3203
5.1
5.1
5.1
5.1
5.1
5.1
3211
4.9
4.9
4.9
4.9
4.9
4.9
2010 Dyna Models
2-8
GM4 = FXD
GN4 = FXDL
GV4 = FXDC
GX4 = FXDB
GY4 = FXDF
GP4 = FXDWG
Table 2-3. Engine

3212
MODELS GM4
5.5
GV4
5.5
GX4
5.5
GN4
5.5
GY4
5.5
GP4
5.5
Recondition top end - includes disassembly, replacement of piston and bore and hone, resizing cylinder (.010 oversize or above), replacing piston rings and all items listed under recondition cylinder head and assembly. Recondition top end includes disassembly, deglazing cylinder and replacing rings, or replacing cylinder and piston, all items listed under reconditioning cylinder head and assembly. Recondition top end includes disassembly, deglazing cylinder and replacing rings, or replacing cylinder and piston, all items listed under reconditioning cylinder head and assembly.
3207
4.3
4.3
4.3
4.3
4.3
4.3
3208
4.9
4.9
4.9
4.9
4.9
4.9
Replace piston rings includes deglazing cylinder one cylinder Replace piston rings includes deglazing cylinder both cylinders Replace piston and piston rings includes removal one cylinder of cylinder head and cylinder, fitting new piston with rings, resizing cylinder and assembly Replace piston and piston rings includes removal both cylinders of cylinder head and cylinder, fitting new piston with rings, resizing cylinder and assembly Replace cylinder and piston Replace cylinder and piston Replace upper connecting rod bushing during upper end repair Replace one cylinder stud Replace all eight cylinder studs CAM COVER Replace lifter cover/gasket or lifter/and, or antirotation pin one cylinder removed cylinders removed one cylinder both cylinders
3206 3216 3221
2.1 2.7 2.7
2.1 2.7 2.7
2.1 2.7 2.7
2.1 2.7 2.7
2.1 2.7 2.7
2.1 2.7 2.7
3231
3.9
3.9
3.9
3.9
3.9
3.9
3236 3246 3251
2.0 2.5 0.4
2.0 2.5 0.4
2.0 2.5 0.4
2.0 2.5 0.4
2.0 2.5 0.4
2.0 2.5 0.4
3253 3254
0.1 0.5
0.1 0.5
0.1 0.5
0.1 0.5
0.1 0.5
0.1 0.5
3307
1.3
1.3
1.3
1.3
1.3
1.3
2010 Dyna Models
2-9
GM4 = FXD
GN4 = FXDL
GV4 = FXDC
GX4 = FXDB
GY4 = FXDF
GP4 = FXDWG
Table 2-3. Engine

3310
MODELS GM4
1.6
GV4
1.6
GX4
1.6
GN4
1.6
GY4
1.6
GP4
1.6
both
Replace push rod, push rod cover and/or o-ring or one or two same cylinder quad seal Replace push rod, push rod cover and/or o-ring or one each cylinder quad seal Replace cam cover and/or gasket Replace primary cam chain, sprockets and/or fastener Replace primary cam chain tensioner Replace cam support plate o-rings Replace cam support plate Replace cams/secondary cam chain/tensioner Replace oil pump and/or o-rings Replace cam bearing crankcase Replace cam bearing crankcase By pass valve inspection CRANKCASE Replace crankcases California vehicles only includes remove and install engine Replace crankcases Seal crankcase only Replace flywheels Replace right side main bearing Replace right side main bearing Replace left side main bearing Replace left side main bearing California vehicles only includes remove and install engine California vehicles only includes remove and install engine one bearing two bearings
3317
1.3
1.3
1.3
1.3
1.3
1.3
3318
1.5
1.5
1.5
1.5
1.5
1.5
3325 3327
0.9 1.0
0.9 1.0
0.9 1.0
0.9 1.0
0.9 1.0
0.9 1.0
3328 3335 3337 3338 3341 3342 3343 3354
1.0 2.1 3.0 3.2 2.0 2.7 3.0 2.0
1.0 2.1 3.0 3.2 2.0 2.7 3.0 2.0
1.0 2.1 3.0 3.2 2.0 2.7 3.0 2.0
1.0 2.1 3.0 3.2 2.0 2.7 3.0 2.0
1.0 2.1 3.0 3.2 2.0 2.7 3.0 2.0
1.0 2.1 3.0 3.2 2.0 2.7 3.0 2.0
3406
7.0
7.0
7.0
7.0
7.0
7.0
3406 3407 3411 3412 3412 3410 3410
6.9 6.2 6.5 6.5 6.4 6.4 6.3
6.9 6.2 6.5 6.5 6.4 6.4 6.3
6.9 6.2 6.5 6.5 6.4 6.4 6.3
6.9 6.2 6.5 6.5 6.4 6.4 6.3
6.9 6.2 6.5 6.5 6.4 6.4 6.3
6.9 6.2 6.5 6.5 6.4 6.4 6.3
2010 Dyna Models
2-10
GM4 = FXD
GN4 = FXDL
GV4 = FXDC
GX4 = FXDB
GY4 = FXDF
GP4 = FXDWG
Table 2-3. Engine

3413 3414 3403 3420
MODELS GM4
2.0 2.4 0.1 0.1
GV4
2.0 2.4 0.1 0.1
GX4
2.0 2.4 0.1 0.1
GN4
2.0 2.4 0.1 0.1
GY4
2.0 2.4 0.1 0.1
GP4
2.0 2.4 0.1 0.1
Piston jet/o-ring Piston jet/o-ring Replace crank position sensor o-ring Check flywheel trueness before assembly or after removal Recondition cylinder heads head removed (for non-related repairs ) Recondition cylinder heads head removed (for non-related repairs ) Replace piston rings
one both
one head
3425
1.0
1.0
1.0
1.0
1.0
1.0
both heads
3426
2.0
2.0
2.0
2.0
2.0
2.0
3428
0.3
0.3
0.3
0.3
0.3
0.3
Replace pistons
3430
1.4
1.4
1.4
1.4
1.4
1.4
FUEL SYSTEM Replace air cleaner backing plate Replace air cleaner cover Replace induction module/ seal Replace intake gasket Replace external fuel hose-EFI EVAPORATIVE EMISSIONS SYSTEM Replace canister Replace vapor valve Replace any one hose California vehicles only 3527 3528 3529 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 one or both 3501 3502 3510 3511 3514 0.2 0.1 0.7 0.3 0.2 0.2 0.1 0.7 0.3 0.2 0.2 0.1 0.7 0.3 0.2 0.2 0.1 0.7 0.3 0.2 0.2 0.1 0.7 0.3 0.2 0.2 0.1 0.7 0.3 0.2
2010 Dyna Models
2-11
GM4 = FXD
GN4 = FXDL
GV4 = FXDC
GX4 = FXDB
GY4 = FXDF
GP4 = FXDWG

DRIVE Replace primary chain Replace primary chain tensioner or pad Replace engine sprocket Replace engine sprocket seal Replace primary cover Replace primary cover gasket Replace inner primary housing and/or gasket /mainshaft bearing Replace or hone forward control shift shaft bushing Replace starter-primary o-ring CLUTCH Adjust clutch Replace release cable assembly Service the clutch includes disassembly, cleaning, inspection repair, assembly and adjustment Replace clutch release bearing and/or push rod Replace clutch release mechanism (ball ramp) and/or side cover 4016 4018 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 --4006 4011 0.2 0.8 1.3 0.2 0.8 1.3 0.2 0.8 1.3 0.2 0.8 1.3 0.2 0.8 1.3 0.2 0.8 1.3 4393 4034 --0.3 --0.3 --0.3 --0.3 0.3 0.3 0.3 0.3 4002 4033 4003 4005 4007 4009 4008 0.9 0.5 0.9 2.4 0.4 0.4 2.1 0.9 0.5 0.9 2.4 0.4 0.4 2.1 0.9 0.5 0.9 2.4 0.4 0.4 2.1 0.9 0.5 0.9 2.4 0.4 0.4 2.1 0.9 0.5 0.9 2.4 0.4 0.4 2.1 0.9 0.5 0.9 2.4 0.4 0.4 2.1
2010 Dyna Models
2-12
GM4 = FXD
GN4 = FXDL
GV4 = FXDC
GX4 = FXDB
GY4 = FXDF
GP4 = FXDWG

TRANSMISSION CASE Replace transmission case Replace transmission complete- Includes remove, replace, install oil passage gasket Overhaul transmission includes disassembly, cleaning, inspection, replacing parts, assembly (transmission case in frame) Replace transmission sprocket Replace main drive gear oil seal (in transmission case) Replace mainshaft oil seal (in main drive gear) Replace side door gasket Replace shifter drum Replace shifter arm assembly or springs Replace transmission top cover and/or gasket Replace shifter forks and/or shaft Replace side door bearing Replace side door bearing Replace transmission case countershaft bearing Replace main drive gear and/or bearing Replace side cover gasket Remove oil pan and/or gasket and/or baffle Replace oil fill tube and/or o-ring Replace vehicle speed sensor o-ring Replace transmission shift shaft seal Replace shift lever includes checking gear engagement one both 4316 4321 4331 4336 4341 4343 4348 4351 4361 4366 4368 4378 4379 4380 4390 4012 2.2 2.8 2.9 2.9 0.6 2.9 3.1 3.2 2.9 3.2 0.2 0.6 0.3 0.4 2.2 0.1 2.2 2.8 2.9 2.9 0.6 2.9 3.1 3.2 2.9 3.2 0.2 0.6 0.3 0.4 2.2 0.1 2.2 2.8 2.9 2.9 0.6 2.9 3.1 3.2 2.9 3.2 0.2 0.6 0.3 0.4 2.2 0.1 2.2 2.8 2.9 2.9 0.6 2.9 3.1 3.2 2.9 3.2 0.2 0.6 0.3 0.4 2.2 0.1 2.2 2.8 2.9 2.9 0.6 2.9 3.1 3.2 2.9 3.2 0.2 0.6 0.3 0.4 2.2 0.1 2.2 2.8 2.9 2.9 0.6 2.9 3.1 3.2 2.9 3.2 0.2 0.6 0.3 0.4 2.2 0.1 4309 4311 2.4 2.5 2.4 2.5 2.4 2.5 2.4 2.5 2.4 2.5 2.4 2.5 4306 4.6 4.6 4.6 4.6 4.6 4.6 4304 4305 5.3 4.9 5.3 4.9 5.3 4.9 5.3 4.9 5.3 4.9 5.3 4.9
2010 Dyna Models
2-13
GM4 = FXD
GN4 = FXDL
GV4 = FXDC
GX4 = FXDB
GY4 = FXDF
GP4 = FXDWG

ACCESSORIES Replace electrical caddie/coil cover Replace fuel tank trim/or medallion Replace sissy bar Replace mirror 6263 6507 6511 6513 0.2 ----0.1 0.2 0.2 0.2 0.1 0.2 ----0.1 0.2 ----0.1 0.2 0.2 --0.1 0.2 0.2 0.7 0.1
2010 Dyna Models
2-14
GM4 = FXD
GN4 = FXDL
GV4 = FXDC
GX4 = FXDB
GY4 = FXDF
GP4 = FXDWG

INSTRUMENTS Replace speedometer Replace tachometer Replace instrument housing assembly (speedo/tach); h-bar mounted Replace speedometer wiring harness WIRING Replace connector housing Replace connector anchor Replace main wiring harness Replace electrical caddie/ Battery support Replace main fuse connector Replace fuse/main fuse Replace fuse block SWITCHES Replace ignition switch Replace left upper handlebar switch housing Replace left lower handlebar switch housing Replace right upper handlebar switch housing Replace right lower handlebar switch housing Replace sidestand switch LIGHTS Replace headlight bracket Replace headlight housing Replace turn signal light assembly Replace turn signal light assembly Includes adjustment Includes adjustment Front Rear 5181 5189 5201 5205 0.1 0.5 0.7 0.3 0.1 0.5 0.7 0.3 0.1 0.5 0.7 0.3 0.1 0.5 0.7 0.3 0.1 0.5 0.7 0.3 0.1 0.5 0.7 0.3 HDI only 5129 5177 5178 5179 5180 5164 0.3 0.2 0.2 0.2 0.2 0.4 0.2 0.2 0.2 0.2 0.2 0.4 0.3 0.2 0.2 0.2 0.2 0.4 0.3 0.2 0.2 0.2 0.2 0.4 0.2 0.2 0.2 0.2 0.2 0.4 0.2 0.2 0.2 0.2 0.2 0.4 5022 5023 5026 5047 5158 5145 5148 0.1 0.1 2.0 0.3 0.4 0.1 0.4 0.1 0.1 2.0 0.3 0.4 0.1 0.4 0.1 0.1 2.0 0.3 0.4 0.1 0.4 0.1 0.1 2.0 0.3 0.4 0.1 0.4 0.1 0.1 2.0 0.3 0.4 0.1 0.4 0.1 0.1 2.0 0.3 0.4 0.1 0.4 5046 0.8 --0.8 0.8 ----Cosmetic issue Cosmetic issue 6003 6009 6019 0.3 --0.3 0.3 ----0.3 ----0.3 0.3 0.5 0.3 ----0.3 -----
2010 Dyna Models
2-15
GM4 = FXD
GN4 = FXDL
GV4 = FXDC
GX4 = FXDB
GY4 = FXDF
GP4 = FXDWG

BATTERY Replace the battery Replace battery tray Replace battery cable 5705 5767 5769 0.2 0.3 0.2 0.2 0.3 0.2 0.2 0.3 0.2 0.2 0.3 0.2 0.2 0.3 0.2 0.2 0.3 0.2
2010 Dyna Models
2-16
GM4 = FXD
GN4 = FXDL
GV4 = FXDC
GX4 = FXDB
GY4 = FXDF
GP4 = FXDWG
Table 2-8. Dyna Diagnostics

NOTE: Unless otherwise noted, all codes include diagnostic time and replacement time if required. The codes must be used in conjunction with the diagnostic/repair procedures listed in the current year Dyna Service Manual and Electrical Diagnostic Manual. GENERAL Repair any single wire Repair any single wire Repair any single wire Replace position lamp Replace headlight bulb Replace indicator lamp assembly Light circuit Accessory circuit All wires except lighting and accessory circuits Position lamp inoperative Headlamp inoperative High beam indicator inoperative, neutral lamp inoperative, oil pressure lamp inoperative, turn signal indicator inoperative Replace tail lamp bulb or lens Replace tail lamp assembly or circuit board Replace horn and/or bracket Running lamps inoperative Headlamp inoperative, stop lamp inoperative Horn inoperative 5197 5215 5765 7210 0.1 0.2 0.1 0.5 0.7 0.3 0.1 0.5 --0.5 0.1 0.5 0.1 0.2 0.1 0.5 0.7 0.3 0.1 0.5 0.7 0.3 0.1 0.5 5039 5043 5041 5143 5185 5191 0.5 0.5 0.5 0.1 0.1 0.5 0.5 0.5 0.5 0.1 0.1 0.2 0.5 0.5 0.5 0.1 0.1 0.5 0.5 0.5 0.5 0.1 0.1 0.5 0.5 0.5 0.5 0.1 0.1 0.2 0.5 0.5 0.5 0.1 0.1 0.2
Repair engine compression, use in conjunction with Engine cranks but will not start, starts hard additional code(s) Code not present B1006, B1007, B0563, P0562, P0563, P0603, P0605 SWITCHES Replace rear stoplight switch- includes bleeding brakes Replace rear stoplight switch- includes bleeding brakes Replace neutral switch Nothing clicks, neutral lamp always on, neutral lamp inoperative, B1155 Replace oil pressure switch Oil pressure lamp always on, oil pressure lamp inoperative Replace clutch switch Nothing clicks, B1154 U1097, U1255 Stop lamp inoperative
7770
0.2
0.2
0.2
0.2
0.2
0.2
5141
0.4
0.4
0.4
0.4
0.4
0.4
6787
0.6
0.6
0.6
0.6
0.6
0.6
5157
0.4
0.4
0.4
0.4
0.4
0.4
5161
0.2
0.2
0.2
0.2
0.2
0.2
5168
0.7
0.7
0.7
0.7
0.7
0.7
2010 Dyna Models
2-17
GM4 = FXD
GN4 = FXDL
GV4 = FXDC
GX4 = FXDB
GY4 = FXDF
GP4 = FXDWG

5171
MODELS GM4
0.5
GV4
0.5
GX4
0.5
GN4
0.5
GY4
0.7
GP4
0.7
Replace front brake light switch Replace start button Replace odometer reset switch Replace odometer reset switch boot Replace turn signal switch Replace engine stop switch Replace engine stop switch Replace ignition switch Replace ignition switch FUSES AND RELAYS Replace battery fuse Inspect/access main wire harness and electrical panel/wiggle test/replace ignition fuse
Stop lamp inoperative Starter inoperative B1008 B1008 Both lamps on one side inoperative Serial data missing No check engine lamp Serial data missing U1097, U1255
5176 5818 6001 6002 6811 6730 7295 7287 6782
0.5 0.6 0.3 0.1 0.7 1.0 1.2 0.4 0.7
0.5 0.6 0.3 0.1 0.7 1.0 1.2 0.4 0.7
0.5 0.6 0.3 0.1 0.7 1.0 1.2 0.4 0.7
0.5 0.6 0.3 0.1 0.7 1.0 1.2 0.4 0.7
0.5 0.6 0.3 0.1 0.6 1.0 1.2 0.5 0.7
0.5 0.6 0.3 0.1 0.7 1.0 1.2 0.4 0.7
U1064 Serial data missing
6713 6729
0.3 1.3
0.3 1.3
0.3 1.3
0.3 1.3
0.3 1.3
0.3 1.3
Inspect/access electrical panel/wiggle test/replace Serial data missing main fuse Access instruments\wiggle test\replace instrument U1097, U1255 fuse Access instruments\wiggle test\replace accessory U1097, U1255 fuse Replace starter relay Replace starter relay Inspect/access electrical panel/main wiring harness/replace battery fuse Replace 15 amp fuse Replace system relay Replace system relay Engine cranks but will not start, starts hard Serial data missing, P1001, P1003 P1002 Starter inoperative B1134 No check engine lamp, U1255
6733
0.5
0.5
0.5
0.5
0.5
0.5
6766
0.7
0.7
0.7
0.7
0.7
0.7
6781
0.7
0.7
0.7
0.7
0.7
0.7
5832 6841 7159
0.4 0.2 0.8
0.4 0.2 0.8
0.4 0.2 0.8
0.4 0.2 0.8
0.4 0.2 0.8
0.4 0.2 0.8
7181 7904 7909
0.3 0.3 0.4
0.3 0.3 0.4
0.3 0.3 0.4
0.3 0.3 0.4
0.3 0.3 0.4
0.3 0.3 0.4
2010 Dyna Models
2-18
GM4 = FXD
GN4 = FXDL
GV4 = FXDC
GX4 = FXDB
GY4 = FXDF
GP4 = FXDWG

7911 7918
MODELS GM4
0.2 0.9
GV4
0.2 0.9
GX4
0.2 0.9
GN4
0.2 0.9
GY4
0.2 0.9
GP4
0.2 0.9
Replace system relay Harness Inspection/wiggle test/electrical panel removal/replace system relay Replace engine control fuse Harness inspection/wiggle test/electrical panel removal/replace ECM fuse CHARGING CIRCUIT Milliamp draw Replace stator Total current draw Replace voltage regulator Replace voltage regulator Replace rotor Replace battery
P1004 P1004
P1475 P1003, P1351, P1354
7826 7937
0.3 0.8
0.3 0.8
0.3 0.8
0.3 0.8
0.3 0.8
0.3 0.8
Low battery after extended ignition off Low or no charging Diagnose charging system No or low charging, overcharging Serial data missing No or low charging Engine cranks but will not start, starts hard
5308 5309 5310 5316 6724 5319 7185 7771
0.2 2.6 0.2 0.7 0.4 2.5 0.5 0.2
0.2 2.6 0.2 0.7 0.4 2.5 0.5 0.2
0.2 2.6 0.2 0.7 0.4 2.5 0.5 0.2
0.2 2.6 0.2 0.7 0.4 2.5 0.5 0.2
0.2 2.6 0.2 0.7 0.4 2.5 0.5 0.2
0.2 2.6 0.2 0.7 0.4 2.5 0.5 0.2
Repair charging system/accompanies other codes B0563, B1006, B1007, P0562, P0563 STARTER CIRCUIT Replace starter Replace starter Replace starter Replace starter clutch Replace starter solenoid Repair starting system; use in conjunction with additional code(s) IGNITION CIRCUIT Replace spark plugs Misfire at idle or under load, rough or rolling idle, engine cranks but will not start, starts hard Replace spark plug P1353, P1356-P1358 Solenoid clicks Starter spins but does not engage Slow starter crank or starter stalls Starter spins but does not engage Starter testing, starter relay clicks Engine cranks but will not start, starts hard
5817 5825 5836 5837 5845 7166
0.6 0.5 0.3 0.8 0.8 0.2
0.6 0.5 0.3 0.8 0.8 0.2
0.6 0.5 0.3 0.8 0.8 0.2
0.6 0.5 0.3 0.8 0.8 0.2
0.6 0.5 0.3 0.8 0.8 0.2
0.6 0.5 0.3 0.8 0.8 0.2
7134
0.4
0.4
0.4
0.4
0.4
0.4
7548
0.2
0.2
0.2
0.2
0.2
0.2
2010 Dyna Models
2-19
GM4 = FXD
GN4 = FXDL
GV4 = FXDC
GX4 = FXDB
GY4 = FXDF
GP4 = FXDWG

7138
MODELS GM4
0.3
GV4
0.3
GX4
0.3
GN4
0.3
GY4
0.3
GP4
0.3
Replace spark plug wire
Misfire at idle or under load, rough or rolling idle, engine cranks but will not start, starts hard
Replace spark plug wire Replace ignition coil Replace ignition coil Replace ignition coil Replace ignition coil AIR INTAKE Repair intake leak FUEL SYSTEM Replace fuel level sender Replace fuel gauge Replace fuel filter or clean fuel pump screen Repair/replace fuel pump/pressure regulator/fuel line/fuel filter Replace fuel filter screen
P1353, P1356-P1358 Misfire at idle or under load, rough or rolling idle Engine cranks but will not start, starts hard P1353, P1356-P1358 P1351, P1352, P1354, P1355
7549 7139 7226 7547 7856
0.2 0.3 0.4 0.3 0.3
0.2 0.3 0.4 0.3 0.3
0.2 0.3 0.4 0.3 0.3
0.2 0.3 0.4 0.3 0.3
0.2 0.3 0.4 0.3 0.3
0.2 0.3 0.4 0.3 0.3
P0131, P0151
7486
1.0
1.0
1.0
1.0
1.0
1.0
B1004, B1005 U1097, U1255 Starts - then stalls, P1353, P1356-P1358 Starts - then stalls, P1353, P1356-P1358
6035 6775 7013 7014
1.0 0.4 0.8 1.0
1.0 0.4 0.8 1.0
1.0 0.4 0.8 1.0
1.0 0.4 0.8 1.0
1.0 0.4 0.8 1.0
1.0 0.4 0.8 1.0
Misfire at idle or under load, rough or rolling idle, engine cranks but will not start, starts hard, P0131, P015
7163
1.0
1.0
1.0
1.0
1.0
1.0
Repair/replace fuel pump/pressure regulator/fuel line/fuel filter
Misfire at idle or under load, rough or rolling idle, engine cranks but will not start, starts hard, P0131, P0132, P0151, P0152
7164
1.0
1.0
1.0
1.0
1.0
1.0
Replace fuel injector
Misfire at idle or under load, rough or rolling idle, P0131, P0132, P0151, P0152
7144
0.9
0.9
0.9
0.9
0.9
0.9
Replace fuel injector Replace fuel injector Replace fuel injector Replace fuel pump Replace fuel pump
Emits black smoke P0261-P0264 Engine cranks but will not start, starts hard Engine cranks but will not start, starts hard P1003
7596 7795 7992 7415 7924
1.0 1.3 0.9 0.9 1.5
1.0 1.3 0.9 0.9 1.5
1.0 1.3 0.9 0.9 1.5
1.0 1.3 0.9 0.9 1.5
1.0 1.3 0.9 0.9 1.5
1.0 1.3 0.9 0.9 1.5
2010 Dyna Models
2-20
GM4 = FXD
GN4 = FXDL
GV4 = FXDC
GX4 = FXDB
GY4 = FXDF
GP4 = FXDWG

7480
MODELS GM4
0.9
GV4
0.9
GX4
0.9
GN4
0.9
GY4
0.9
GP4
0.9
Replace fuel pressure regulator SENSORS AND ECM Replace jiffy stand sensor IAC system OK, may use with other Codes Replace idle air control (IAC) Replace throttle position sensor Replace throttle position sensor
Emits black smoke
P1501, P1502 P0505 P0505 P0122 Engine cranks but will not start, starts hard, P0122, P0123
5085 7028 7490 7590 7595
0.7 0.5 0.5 1.7 1.2
0.7 0.5 0.5 1.7 1.2
0.7 0.5 0.5 1.7 1.2
0.7 0.5 0.5 1.7 1.2
0.7 0.5 0.5 1.7 1.2
0.7 0.5 0.5 1.7 1.2
Replace engine temperature (ET) sensor Replace engine temperature (ET) sensor Replace oxygen sensor Replace intake air temperature (IAT) sensor Replace intake air temperature (IAT) sensor Replace crankshaft position (CKP) sensor Replace MAP sensor
Emits black smoke P0117, P0118 P0131, P0132, P0134, P0151, P0152, P0154 P0112, P0113 P0112, P0113 P0373, P0374 Hesitates - poor driveability, misfire at idle or under load, rough or rolling idle
7598 7710 7667 7725 7760 7981 7152
0.8 0.7 0.5 0.9 1.1 0.5 0.8
0.8 0.7 0.5 0.9 1.1 0.5 0.8
0.8 0.7 0.5 0.9 1.1 0.5 0.8
0.8 0.7 0.5 0.9 1.1 0.5 0.8
0.8 0.7 0.5 0.9 1.1 0.5 0.8
0.8 0.7 0.5 0.9 1.1 0.5 0.8
Replace MAP sensor Replace MAP sensor Replace MAP sensor Clean or repair vehicle speed sensor (VSS) Replace vehicle speed sensor (VSS) Replace ECM Replace ECM Replace ECM
Emits black smoke P0107 P0107, P0108, P0122 P0501, P0502 P0501, P0502 P1009 U1064 Engine cranks but will not start, starts-then stalls, starts hard
7597 7630 7650 7939 7967 6703 6716 7450
1.2 0.7 1.0 1.0 0.7 1.0 0.8 1.1
1.2 0.7 1.0 1.0 0.7 1.0 0.8 1.1
1.2 0.7 1.0 1.0 0.7 1.0 0.8 1.1
1.2 0.7 1.0 1.0 0.7 1.0 0.8 1.1
1.2 0.7 1.0 1.0 0.7 1.0 0.8 1.1
1.2 0.7 1.0 1.0 0.7 1.0 0.8 1.1
Replace ECM
P0107, P0122, P0501, P0502
7565
1.2
1.2
1.2
1.2
1.2
1.2
2010 Dyna Models
2-21
GM4 = FXD
GN4 = FXDL
GV4 = FXDC
GX4 = FXDB
GY4 = FXDF
GP4 = FXDWG

7601 7641
MODELS GM4
1.5 0.9
GV4
1.5 0.9
GX4
1.5 0.9
GN4
1.5 0.9
GY4
1.5 0.9
GP4
1.5 0.9
Replace ECM Replace ECM
Emits black smoke Serial data missing, misfire at idle or under load, rough or rolling idle, P0108, P0112, P0261, P0263, P0373, P0374, P0661, P0662, P1475, P1477, P1478, P1501, P1502, U1300, U1301
Serial data missing, P0117, P0603, P0605 No check engine lamp, P0118, P0123, P0131, P0132, P0134, P0151, P0152, P0154, P0262, P0264, P1001, P1002, P1351-P1355, P1356P1358
7680 7685
0.7 0.8
0.7 0.8
0.7 0.8
0.7 0.8
0.7 0.8
0.7 0.8
Replace ECM HDI ACTIVE EXHAUST Replace active intake solenoid Replace exhaust actuator Replace exhaust actuator valve Replace exhaust actuator cable TURN SIGNALS/INSTRUMENTS/SECURITY
P0113, P0505, P1010
7740
1.0
1.0
1.0
1.0
1.0
1.0
P0661, P0662, P1475 P1475, P1477, P1478 P1475 P1475
7064 7811 7812 7814
0.5 0.4 0.6 0.4
0.5 0.4 0.6 0.4
0.5 0.4 0.6 0.4
0.5 0.4 0.6 0.4
0.5 0.4 0.6 0.4
0.5 0.4 0.6 0.4
Perform ECM/TSM/TSSM/HFSM module replace- P1009 ment procedure Replaced TSM/TSSM/HFSM, system now ok Replaced TSM/TSSM/HFSM, system now ok Replace FOB battery Replace FOB Replace bulb P1009 P1010 Fails to disarm Fails to disarm Both lamps on one side inoperative, flash at double normal rate, B1121, B1122 Replace turn signal converter module Remove corrosion/replace bulb Flash at double normal rate, B1123-B1126 Bulbs flash at double normal rate
6701
0.4
0.4
0.4
0.4
0.4
0.4
6702 6707 6755 6756 6796
0.4 0.6 0.1 0.1 0.3
0.4 0.6 0.1 0.1 0.3
0.4 0.6 0.1 0.1 0.3
0.4 0.6 0.1 0.1 0.3
0.4 0.6 0.1 0.1 0.3
0.4 0.6 0.1 0.1 0.3
6809 6822
--0.5
--0.5
0.7 0.5
--0.5
--0.5
0.7 0.5
2010 Dyna Models
2-22
GM4 = FXD
GN4 = FXDL
GV4 = FXDC
GX4 = FXDB
GY4 = FXDF
GP4 = FXDWG

6823
MODELS GM4
0.4
GV4
0.4
GX4
0.4
GN4
0.4
GY4
0.4
GP4
0.4
Replace lamp assembly
Flash at double normal rate, one lamp inoperative, B1121, B1122
Replace speedometer
No security lamp during bulb check, security lamp on continuously after bulb check, no check engine lamp, B1008
6020
0.3
0.3
0.3
0.3
0.3
0.3
Replace speedometer
Serial data missing, no check engine lamp, U1016, U1064
6072
0.5
0.5
0.5
0.5
0.5
0.5
Replace speedometer Replace TSSM\HFSM
U1097, U1255, U1300, U1301 Starter inoperative, nothing clicks, flash at double normal rate, no check engine lamp, B1121-B1126, B1135, B1136, B1142, B1141, U1016, U1064, U1255
6765 5838
0.7 0.5
0.7 0.5
0.7 0.5
0.7 0.5
0.7 0.5
0.7 0.5
Replace TSSM\HFSM Replace TSSM\HFSM Replace TSSM\HFSM Replace TSSM\HFSM Replace TSSM\HFSM Replace TSSM\HFSM Replace TSSM\HFSM Replace tachometer
B1143, B1144, B1145, B1154, B1155 Fails to disarm Will not cancel upon turn completion Flash at double normal rate B1131, B1132, B1134 Neutral lamp always on, B1135, B1136, B1142 Serial data missing, U1300, U1301 Serial data missing, no check engine lamp, U1016, U1097, U1255
5863 6757 6773 6824 6833 6845 7998 6772
0.4 0.3 0.9 0.6 0.7 0.3 0.8 ---
0.4 0.3 0.9 0.6 0.7 0.3 0.8 ---
0.4 0.3 0.9 0.6 0.7 0.3 0.8 ---
0.4 0.3 0.9 0.6 0.7 0.3 0.8 0.5
0.4 0.3 0.5 0.3 0.7 0.3 0.8 ---
0.4 0.3 0.5 0.3 0.7 0.3 0.8 ---
Replace tachometer Replace siren Replace siren Replace security antenna Replace security antenna harness
U1300, U1301 B1131, B1132 No check engine lamp Fails to disarm, B1143, B1144, B1145 B1145
6803 6832 7161 6878 6881
--0.7 0.6 0.2 0.4
--0.7 0.6 0.2 0.4
--0.7 0.6 0.2 0.4
0.7 0.7 0.6 0.2 0.4
--0.7 0.6 0.2 0.4
--0.7 0.6 0.2 0.4
2010 Dyna Models
2-23
NOTES
SUBJECT..............................................................................................................PAGE NO. 3.1 Service........................................................................................................................3-1 3.2 Chassis.......................................................................................................................3-2 3.3 Engine.........................................................................................................................3-8 3.4 Drive and Clutch........................................................................................................3-13 3.5 Transmission.............................................................................................................3-14 3.6 OEM Accessories......................................................................................................3-15 3.7 Electrical - General....................................................................................................3-16 3.8 Sportster Diagnostics................................................................................................3-18 Unless otherwise specified, Job Times shown include all operations necessary to complete the listed job.
SPORTSTER MODELS
CP2 = XL883C CX3 = XL1200L
CR2 = XL883L CZ3 = XL1200N
CS2 = XL883R LA6 = XR1200
LE2 = XL883N LD6 = XR1200X
CT3 = XL1200C
Table 3-1. Service

ITEM DESCRIPTION LABOR CODE MODELS CR2 CS2 LE2 CX3 CZ3 CP2 CT3 LA6 LD6
GENERAL Set-up and predelivery 1,000 mile service (1,600 km) REGULAR 5,000 mile maintenance (8,000 km) 10,000 mile maintenance (16,000 km) 15,000 (24,000 km) mile maintenance 20,000 (32,000 km) mile maintenance 25,000 (40,000 km) mile maintenance 30,000 (48,000 km) mile maintenance Addition to any maintenance- required every 2 years Addition to 1,000, 5,000 and 20,000 mile (1,600, 8,000, and 32,000 km) maintenance and every 15,000 mile (24,000 km) interval there after Tighten spoke wheels if equipped, time per wheel --0.5 0.5 0.5 --flush/fill D.O.T 4 brake fluid- front and rear --------------1.8 2.3 1.8 2.3 5.3 2.3 0.4 1.8 2.3 1.8 2.3 5.3 2.3 0.4 1.8 2.3 1.8 2.3 5.3 2.3 0.4 2.0 2.5 2.0 2.5 5.9 2.5 0.4 ----1.3 2.1 1.3 2.1 1.3 2.1 1.3 2.3
2010 Sportster Models
3-1
CP2 = XL883C CX3 = XL1200L
CR2 = XL883L CZ3 = XL1200N
CS2 = XL883R LA6 = XR1200
LE2 = XL883N LD6 = XR1200X
CT3 = XL1200C
Table 3-2. Chassis

PAINT REPAIR NOTE: Use these codes when repairing any painted part on vehicle with the Kent Moore finesse kit or other paint repair methods Light scuff/scratch - buff Light sanding/buff/blend Buff entire part Repair build up in clear/paint Color blend/paint/buff DRIVE Adjust secondary belt Replace idler bracket assembly Replace idler pulley Replace secondary belt Replace rear wheel sprocket Replace transmission sprocket cover WHEELS Replace rim, hub or spokes (includes truing wheel) front Replace rim, hub or spokes (includes truing wheel) rear Replace wheel bearings Replace wheel bearings Replace tire includes balancing Replace tire includes balancing Replace wheel assembly - includes disc and sprocket exchange and balancing Replace wheel assembly - includes disc and sprocket exchange and balancing HANDLEBARS rear 2114 0.9 0.9 0.9 0.9 front rear front rear front 2116 2121 2136 2141 2106 2111 2113 2.2 2.3 0.5 0.6 0.5 0.6 0.8 2.2 --0.5 0.6 0.5 0.6 0.8 2.2 2.3 0.5 0.6 0.5 0.6 0.8 ----0.5 0.6 0.5 0.6 0.8 at predelivery only 2010 2008 2009 2011 2021 2044 0.2 ----0.7 0.8 0.6 0.2 ----0.7 0.8 0.6 0.2 ----0.7 0.8 0.6 0.2 0.8 0.3 0.7 0.8 0.6 1102 1104 1106 1108 1110 0.2 0.4 0.6 0.8 1.0 0.2 0.4 0.6 0.8 1.0 0.2 0.4 0.6 0.8 1.0 0.2 0.4 0.6 0.8 1.0
3-2
CP2 = XL883C CX3 = XL1200L
CR2 = XL883L CZ3 = XL1200N
CS2 = XL883R LA6 = XR1200
LE2 = XL883N LD6 = XR1200X
CT3 = XL1200C
Table 3-2. Chassis

2206 2221 2226 2231 one or both 2241 2251 one or both 2253 2254 rear 2258
MODELS CR2 CS2 LE2 CX3 CZ3

0.5 0.1 0.2 0.4 0.7 0.2 0.4 0.2 ---
CP2
0.5 0.1 0.2 0.4 0.7 0.2 0.6 0.2 0.2
CT3
0.5 0.1 0.2 0.4 0.7 0.2 0.6 0.2 0.2
LA6 LD6
0.5 0.1 0.2 0.4 0.7 0.2 --0.2 ---
Replace handlebars Replace clutch hand lever Replace clutch hand lever bracket Replace throttle control Replace and adjust throttle control cables Replace rubber handlebar grip Replace handlebar riser Replace handlebar clamp or bracket Replace handlebar riser cover FRAME/SWING ARM/FRONT FORK Replace frame includes removal and installation of all accessories and motorcycle components Replace foot pegs Replace right side foot peg mount Replace left side foot peg mount Replace tail section Replace passenger foot peg bracket Replace lower fork bracket and stem Replace upper fork bracket Replace steering head cups and bearings, including bearing adjustment Replace fork lock Adjust steering head bearings Change front fork oil at predelivery only one
2306
12.2
12.2
12.2
12.2
2307 2310 2312 2328 2390 2316 2318 2321
0.1 0.4 0.2 ----2.1 0.6 1.9
0.1 0.2 0.2 --0.2 2.1 0.6 1.9
0.1 0.2 0.2 --0.2 2.1 0.6 1.9
0.1 0.2 0.2 0.2 0.2 2.1 0.6 1.9
2330 2290 ---
0.6 0.3 0.5
0.6 0.3 0.5
0.6 0.3 0.5
0.6 0.3 0.7
3-3
CP2 = XL883C CX3 = XL1200L
CR2 = XL883L CZ3 = XL1200N
CS2 = XL883R LA6 = XR1200
LE2 = XL883N LD6 = XR1200X
CT3 = XL1200C
Table 3-2. Chassis

2341

0.7
CP2
0.7
CT3
0.7
LA6 LD6
0.9
Service or replace fork slider and/or seal includes one side removal, disassembly, cleaning, inspection, replacing parts, servicing damper tube, replacing bushings, assembly and installation Service or replace fork slider and/or seal includes both sides removal, disassembly, cleaning, inspection, replacing parts, servicing damper tube, replacing bushings, assembly and installation Replace fork side Replace fork side Replace fork tube Replace fork tube Replace fork boot (CZ3 and LE2 models only) Replace fork boot (CZ3 and LE2 models only) Replace rear swing arm and/or bearings Replace rear shock absorber assembly Replace rear shock absorber assembly Replace rear shock absorber component(s) Replace rear shock absorber component(s) Replace jiffy stand Replace jiffy stand BRAKES Replace hydraulic brake line includes filling/bleeding brakes Replace hydraulic brake line includes filling/bleeding brakes Replace brake pads Replace brake pads front - each caliper rear rear front one side both sides one side both sides spring and/or stand rubber bumper one side both sides one side both sides one both
2342
1.1
1.1
1.1
1.3
2346 2351 2356 2361 2495 2499 2366 2371 2376 2381 2386 2396 2399
0.5 0.8 0.7 1.1 0.7 0.9 2.0 0.2 0.4 0.3 0.6 0.2 0.1
0.5 0.8 0.7 1.1 ----2.0 0.2 0.4 0.3 0.6 0.2 0.1
0.5 0.8 0.7 1.1 ----2.0 0.2 0.4 0.3 0.6 0.2 0.1
0.5 0.8 0.9 1.3 ----2.0 0.2 0.4 0.3 0.6 0.2 0.1
2404
0.6
0.6
0.6
0.7
2411
0.6
0.6
0.6
0.6
2416 2421
0.1 0.3
0.1 0.3
0.1 0.3
0.1 0.3
3-4
CP2 = XL883C CX3 = XL1200L
CR2 = XL883L CZ3 = XL1200N
CS2 = XL883R LA6 = XR1200
LE2 = XL883N LD6 = XR1200X
CT3 = XL1200C
Table 3-2. Chassis

2426

0.4
CP2
0.4
CT3
0.4
LA6 LD6
0.4
Replace brake caliper includes filling/bleeding brakes Replace brake caliper includes filling/bleeding brakes Replace brake disc Replace brake disc Replace brake disc Bleed brake caliper front or rear caliper Overhaul brake caliper includes filling/bleeding brakes Overhaul brake caliper includes filling/bleeding brakes Replace master cylinder assembly includes filling/bleeding brakes Replace master cylinder assembly includes filling/bleeding brakes Rebuild master cylinder assembly includes filling/bleeding brakes Rebuild master cylinder assembly includes filling/bleeding brakes Replace master cylinder cover or gasket Replace rear brake pedal Replace front brake lever SEATS/FENDERS/TANKS Replace seat Replace passenger seat Replace passenger seat strap- all except CR2, LE2, and CZ3 models
front - each caliper
rear
2431
0.6
0.6
0.6
0.6
front both - CS2, LA6 LD6 only rear
2436 2437 2441 2446
0.3 0.4 0.8 0.2 0.6
0.3 --0.8 0.2 0.6
0.3 --0.8 0.2 0.6
0.3 0.4 0.8 0.2 0.6
front - each caliper
2451
rear
2456
0.8
0.8
0.8
0.8
front
2461
0.4
0.4
0.4
0.4
rear
2466
0.5
0.5
0.5
0.5
front
2471
0.6
0.6
0.6
0.6
rear
2476
0.7
0.7
0.7
0.7
front or rear
2479 2492 2494
0.1 0.5 0.1
0.1 0.5 0.1
0.1 0.5 0.1
0.1 0.2 0.1
2506 2502 2588
0.1 --0.1
0.1 --0.1
0.1 --0.1
0.1 0.1 0.1
3-5
CP2 = XL883C CX3 = XL1200L
CR2 = XL883L CZ3 = XL1200N
CS2 = XL883R LA6 = XR1200
LE2 = XL883N LD6 = XR1200X
CT3 = XL1200C
Table 3-2. Chassis

2526 2531 2536 2539 2541 CT3 and CX3 models only 6507 2553 2543 2561 2566 3479 3480 feed line-oil tank to pump feed line-oil pump to filter return line-oil pump to tank vent line inlet line to cylinder head both return line- front cylinder head 2571 2577 2578 2581 2673 2674 2675 2676

0.3 1.3 0.3 0.6 0.3 0.3 ----0.2 1.2 0.4 0.1 0.7 0.2 0.7 0.9 ---------
CP2
0.3 1.3 0.3 0.6 0.3 ------0.2 1.2 0.4 0.1 0.7 0.2 0.7 0.9 ---------
CT3
0.3 1.3 0.3 0.6 0.8 0.3 0.5 --0.2 1.2 0.4 0.1 0.7 0.2 0.7 0.9 ---------
LA6 LD6
0.3 0.4 0.5 0.6 0.4 ----0.2 0.2 1.2 0.4 0.1 0.8 ----0.9 0.3 0.4 1.1 1.0
Replace fender Replace fender Replace rear fender support Replace rear fender support Replace fuel tank assembly Replace fuel tank trim or medallion Replace fuel tank console Replace fuel tank cover Replace fuel tank valve assembly Replace oil tank Replace oil tank mounting bracket Replace dipstick Replace oil tank lines Replace oil tank lines Replace oil tank lines Replace oil tank lines Replace precision inlet line - one or both Replace precision inlet line - one or both Replace front precision return line
front rear one both
Replace return manifold/ rear precision return line return manifold to tank assy. Replace return manifold/ rear precision return line return line crankcase to manifold assy. Replace oil filter (other than normal maintenance) Replace oil pump to cooler line Replace oil cooler one or both
2677
---
---
---
1.5
2582 2583 2591
0.1 -----
0.1 -----
0.1 -----
0.1 0.2 0.4
3-6
CP2 = XL883C CX3 = XL1200L
CR2 = XL883L CZ3 = XL1200N
CS2 = XL883R LA6 = XR1200
LE2 = XL883N LD6 = XR1200X
CT3 = XL1200C
Table 3-2. Chassis

2590

1.3
CP2
---
CT3
---
LA6 LD6
---
Replace license plate holder (Applicable CZ3 and LE2 models only) BELT GUARDS Replace rear belt guard Replace debris deflector EXHAUST SYSTEM Replace complete exhaust system Replace exhaust interconnect Replace any exhaust pipe cover Replace one muffler/inlet gasket Replace rear muffler mount Replace header assembly
2616 2617
0.1 0.1
0.1 0.1
0.1 0.1
0.1 0.1
2621 2625 2661 2665 2618 2615
0.7 0.6 0.1 0.2 -----
0.7 0.6 0.1 0.2 -----
0.7 0.6 0.1 0.2 -----
0.7 --0.1 0.2 0.2 0.6
3-7
CP2 = XL883C CX3 = XL1200L
CR2 = XL883L CZ3 = XL1200N
CS2 = XL883R LA6 = XR1200
LE2 = XL883N LD6 = XR1200X
CT3 = XL1200C
Table 3-3. Engine

GENERAL Remove and install engine Remove and install engine Replace stabilizer and/or bracket Replace engine mount Replace mount CYLINDER HEAD Recondition cylinder head includes removal of head and gasket, remove carbon, service valve guides, grind valves and seats, test springs and install head and gaskets. Recondition cylinder head includes removal of head and gasket, remove carbon, service valve guides, grind valves and seats, test springs and install head and gaskets. Recondition cylinder head includes removal of head and gasket, remove carbon, service valve guides, grind valves and seats, test springs and install head and gaskets. Replace cylinder head Replace cylinder head Replace valve seal or spring after head removal Replace valve seal or spring after head removal Replace cylinder head gasket Replace cylinder head gasket Replace cylinder head gasket Replace rocker arm covers and/or gaskets Replace rocker arm covers and/or gaskets one cylinder head both cylinder heads one seal or spring (intake or exhaust ) both seals or springs (intake or exhaust) front cylinder rear cylinder both cylinders front cylinder rear cylinder 3106 3108 3131 3132 3140 3142 3143 3144 3145 2.8 4.1 0.1 0.2 2.2 2.0 2.7 1.1 0.9 2.8 4.1 0.1 0.2 2.2 2.0 2.7 1.1 0.9 2.8 4.1 0.1 0.2 2.2 2.0 2.7 1.1 0.9 3.8 4.9 0.1 0.2 3.0 3.0 3.5 1.1 0.9 both cylinder heads 3104 5.9 5.9 5.9 6.7 rear cylinder head 3103 3.8 3.8 3.8 4.8 front cylinder head 3101 4.0 4.0 4.0 4.8 California vehicles only one one each additional 3006 3004 3013 3014 3015 4.1 4.2 0.2 4.1 0.1 4.1 4.2 0.2 4.1 0.1 4.1 4.2 0.2 4.1 0.1 4.1 4.2 0.2 4.1 0.1
3-8
CP2 = XL883C CX3 = XL1200L
CR2 = XL883L CZ3 = XL1200N
CS2 = XL883R LA6 = XR1200
LE2 = XL883N LD6 = XR1200X
CT3 = XL1200C
Table 3-3. Engine

3148 3147

1.3 1.2
CP2
1.3 1.2
CT3
1.3 1.2
LA6 LD6
1.3 1.2
Replace rocker arm covers and/or gaskets
both cylinders
Replace lower rocker cover/gasket, or rocker arms front cylinder and/or shafts Replace lower rocker cover/gasket, or rocker arms rear cylinder and/or shafts Replace lower rocker cover/gasket, or rocker arms both cylinders and/or shafts Replace rear rocker wire form Replace induction module cover rear cylinder between cylinders
3152
1.0
1.0
1.0
1.0
3153
1.8
1.8
1.8
1.8
3126 3127 3149 3150 3161 3163 3168 3172 3174
----0.5 1.0 2.8 2.6 3.1 1.0 1.2
----0.5 1.0 2.8 2.6 3.1 1.0 1.2
----0.5 1.0 2.8 2.6 3.1 1.0 1.2
0.2 0.3 0.5 1.0 3.6 3.6 4.1 1.0 1.2
Recondition rocker arms after heads are removed one head Recondition rocker arms after heads are removed both heads Replace cylinder base gasket Replace cylinder base gasket Replace cylinder base gasket Replace crankcase umbrella valve Replace crankcase umbrella valve CYLINDER AND PISTON Replace piston and resize cylinder includes dis- one piston and cylinder assembly, replacing piston, and sizing cylinder, all items listed under recondition cylinder head and assembly Replace piston and resize cylinder includes dis- both pistons and cylinders assembly, replacing piston, and sizing cylinder, all items listed under recondition cylinder head and assembly Recondition cylinder and piston includes disassembly, deglazing cylinder and replacing rings, or replacing cylinder and piston, all items listed under recondition cylinder head and assembly one piston and cylinder front cylinder rear cylinder both cylinders one both
3202
5.2
5.2
5.2
---
3203
7.9
7.9
7.9
---
3207
4.5
4.5
4.5
5.5
3-9
CP2 = XL883C CX3 = XL1200L
CR2 = XL883L CZ3 = XL1200N
CS2 = XL883R LA6 = XR1200
LE2 = XL883N LD6 = XR1200X
CT3 = XL1200C
Table 3-3. Engine

3208

7.1
CP2
7.1
CT3
7.1
LA6 LD6
8.1
Recondition cylinder and piston includes disassembly, deglazing cylinder and replacing rings, or replacing cylinder and piston, all items listed under recondition cylinder head and assembly
Replace piston rings includes deglazing cylinder one cylinder Replace piston rings includes deglazing cylinder both cylinders Replace piston and piston rings includes removal one cylinder of cylinder head and cylinder, fitting new piston with rings, resizing cylinder and assembly Replace piston and piston rings includes removal both cylinders of cylinder head and cylinder, fitting new piston with rings, resizing cylinder and assembly Replace cylinder and piston assembly Replace cylinder and piston assembly Replace upper connecting rod bushing during upper end repair Replace one cylinder stud GEARCASE Replace tappet Replace tappet Replace tappet Replace push rod, push rod cover and/or o-ring Replace push rod, push rod cover and/or o-ring Replace push rod, push rod cover and/or o-ring Replace gearcase cover and/or gasket Replace all cam gears Replace oil pump Replace oil pump cover one two same cylinder two one each cylinder one two same cylinder two one each cylinder cylinder removed one cylinder both cylinders
3206 3216 3221
3.2 4.1 3.4
3.2 4.1 3.4
3.2 4.1 3.4
4.2 5.1 4.4
3231
5.3
5.3
5.3
6.3
3236 3246 3251
2.4 3.5 0.4
2.4 3.5 0.4
2.4 3.5 0.4
3.4 4.5 0.4
3253
0.1
0.1
0.1
0.1
3306 3311 3313 3316 3317 3318 3326 3336 3341 3351
2.7 2.8 3.7 2.1 2.2 2.7 2.3 2.5 0.7 ---
2.7 2.8 3.7 2.1 2.2 2.7 2.3 2.5 0.7 ---
2.7 2.8 3.7 2.1 2.2 2.7 2.3 2.5 0.7 ---
2.7 2.8 3.7 2.1 2.2 2.7 1.1 2.5 2.3 0.5
3-10
CP2 = XL883C CX3 = XL1200L
CR2 = XL883L CZ3 = XL1200N
CS2 = XL883R LA6 = XR1200
LE2 = XL883N LD6 = XR1200X
CT3 = XL1200C
Table 3-3. Engine

3352 3353 3366

----0.1
CP2
----0.1
CT3
----0.1
LA6 LD6
0.5 0.5 0.1
Replace precision cooling check valve Replace oil cooler thermostat Replace oil pump check valve CRANKCASE Replace crank position sensor o-ring Replace crankcases Seal crankcase only Replace left main bearing Replace flywheels Check flywheel trueness after removal Check flywheels after removal includes checking trueness piston removal and reinstallation, if required Recondition cylinder heads head removed (for non-related repairs ) Recondition cylinder heads head removed (for non-related repairs ) Replace piston rings Replace piston and rings includes oversizing FUEL SYSTEM Replace air cleaner assembly Replace air cleaner to induction module boot Replace air cleaner backing plate Replace air cleaner cover Replace induction module Replace manifold, inserts or clamps Replace external fuel hose both cylinders removed (for non-related repairs) both cylinders removed (for non-related repairs) both heads one head includes remove and install engine
3403 3406 3407 3410 3411 3420 3421
0.1 13.7 9.4 9.7 12.7 0.1 0.5
0.1 13.7 9.4 9.7 12.7 0.1 0.5
0.1 13.7 9.4 9.7 12.7 0.1 0.5
0.1 13.7 9.4 9.7 12.7 0.1 0.5
3425
1.8
1.8
1.8
1.8
3426
3.3
3.3
3.3
3.3
3428 3430
0.7 1.4
0.7 1.4
0.7 1.4
0.7 1.4
3538 3539 3501 3502 3510 3511 3514
----0.2 0.1 0.7 0.4 0.3
----0.2 0.1 0.7 0.4 0.3
----0.2 0.1 0.7 0.4 0.3
0.4 0.5 ----0.7 0.4 0.3
3-11
CP2 = XL883C CX3 = XL1200L
CR2 = XL883L CZ3 = XL1200N
CS2 = XL883R LA6 = XR1200
LE2 = XL883N LD6 = XR1200X
CT3 = XL1200C
Table 3-3. Engine

3536

0.6
CP2
0.6
CT3
0.6
LA6 LD6
---
Replace induction module o-ring EVAPORATIVE EMISSIONS SYSTEM Replace canister Replace vapor valve Replace any one hose California vehicles only
3527 3528 3529
0.1 0.1 0.7
0.1 0.1 0.7
0.1 0.1 0.7
0.1 0.1 0.7
3-12
CP2 = XL883C CX3 = XL1200L
CR2 = XL883L CZ3 = XL1200N
CS2 = XL883R LA6 = XR1200
LE2 = XL883N LD6 = XR1200X
CT3 = XL1200C

DRIVE Adjust primary chain Replace primary inspection cover/o-ring/ or gasket Replace primary chain Replace engine sprocket Replace engine sprocket oil seal Replace primary cover Replace primary gasket CLUTCH Adjust clutch Replace clutch release mechanism Service the clutch includes disassembly, cleaning, inspection, repair, assembly and adjustment Replace shift lever Replace clutch cable Replace shifter seal 4012 4013 4015 0.1 0.2 0.1 0.1 0.2 0.1 0.14 0.2 0.1 0.1 0.2 0.1 --4006 4011 0.1 0.1 1.5 0.1 0.1 1.5 0.1 0.1 1.5 0.1 0.1 1.5 --4001 4002 4003 4005 4007 4009 0.1 0.1 0.8 0.8 0.9 0.7 0.5 0.1 0.1 0.8 0.8 0.9 0.7 0.5 0.1 0.1 0.8 0.8 0.9 0.7 0.5 0.1 0.1 0.8 0.8 0.9 0.7 0.5
3-13
CP2 = XL883C CX3 = XL1200L
CR2 = XL883L CZ3 = XL1200N
CS2 = XL883R LA6 = XR1200
LE2 = XL883N LD6 = XR1200X
CT3 = XL1200C

TRANSMISSION CASE Overhaul transmission includes disassembly, removal, cleaning, inspection, replacing parts, assembly and installation Replace shifter drum Replace shift linkage and/or spring Replace shifter fork Replace shifter fork Replace transmission case countershaft bearing Replace main drive gear and/or bearing and/or oring Replace detent arm and/or spring Replace main drive gear belt sprocket Replace main drive gear seal Replace vehicle speed sensor o-ring in crankcase 4368 4309 4311 4380 11.3 0.8 0.9 0.5 11.3 0.8 0.9 0.5 11.3 0.8 0.9 0.5 11.3 0.8 0.9 0.5 one each additional 4329 4332 4343 4345 4361 4366 11.3 1.3 11.3 0.1 11.4 11.8 11.3 1.3 11.3 0.1 11.4 11.8 11.3 1.3 11.3 0.1 11.4 11.8 11.3 1.3 11.3 0.1 11.4 11.8 4306 13.5 13.5 13.5 13.5
3-14
CP2 = XL883C CX3 = XL1200L
CR2 = XL883L CZ3 = XL1200N
CS2 = XL883R LA6 = XR1200
LE2 = XL883N LD6 = XR1200X
CT3 = XL1200C

ACCESSORIES Replace mirror Replace one frame side cover/side cover clips or grommets 6513 6263 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1
3-15
CP2 = XL883C CX3 = XL1200L
CR2 = XL883L CZ3 = XL1200N
CS2 = XL883R LA6 = XR1200
LE2 = XL883N LD6 = XR1200X
CT3 = XL1200C

INSTRUMENTS Replace speedometer Replace tachometer Replace odometer reset boot WIRING Replace connector housing Replace connector anchor Replace battery cable Replace main wiring harness Replace rear fender wiring harness Replace speedometer wiring harness Replace engine sub-harness Replace electrical caddie (under fuel tank) Replace electrical caddie (behind voltage reg.) Replace fuse Replace fuse block (H bracket/ECM caddie) Replace ECM cover SWITCHES Replace ignition switch Replace left upper handlebar switch housing Replace left lower handlebar switch housing Replace right upper handlebar switch housing Replace right lower handlebar switch housing LIGHTS Replace headlight bracket Replace headlight housing Includes adjustment Includes adjustment 5181 5189 0.2 0.4 0.2 0.7 0.2 0.7 0.2 0.4 5129 5177 5178 5179 5180 0.5 0.2 0.2 0.2 0.4 0.5 0.2 0.2 0.2 0.4 0.5 0.2 0.2 0.2 0.4 0.5 0.2 0.2 0.2 0.4 One (negative or positive) 5022 5023 5024 5026 5036 5046 5066 5081 5082 5145 5196 5091 0.1 0.1 0.3 2.6 0.5 0.7 0.7 1.0 0.6 0.1 1.2 0.1 0.1 0.1 0.3 2.6 0.5 0.7 0.7 1.0 0.6 0.1 1.2 0.1 0.1 0.1 0.3 2.6 0.5 0.7 0.7 1.0 0.6 0.1 1.2 0.1 0.1 0.1 0.3 2.6 0.5 0.7 0.7 1.0 --0.1 1.2 --Cosmetic issue Cosmetic issue 6003 6009 6043 0.3 --0.1 0.3 --0.1 0.3 --0.1 0.3 0.3 0.1
3-16
CP2 = XL883C CX3 = XL1200L
CR2 = XL883L CZ3 = XL1200N
CS2 = XL883R LA6 = XR1200
LE2 = XL883N LD6 = XR1200X
CT3 = XL1200C

5190 Front Rear 5201 5205

0.2 0.2 0.3
CP2
0.2 0.4 0.3
CT3
0.2 0.4 0.3
LA6 LD6
0.2 0.2 0.3
Replace indicator lens/trim plate/bezel Replace turn signal light assembly Replace turn signal light assembly BATTERY Replace the battery Replace battery tray
5705 5767
0.3 0.6
0.3 0.6
0.3 0.6
0.3 0.6
3-17
CP2 = XL883C CX3 = XL1200L
CR2 = XL883L CZ3 = XL1200N
CS2 = XL883R LA6 = XR1200
LE2 = XL883N LD6 = XR1200X
CT3 = XL1200C
Table 3-8. Sportster Diagnostics

NOTE: Unless otherwise noted, all codes include diagnostic time and replacement time if required. The codes must be used in conjunction with the diagnostic/repair procedures listed in the current Sportster Service Manual and Electrical Diagnostic Manual GENERAL Repair any single wire Repair any single wire Repair any single wire Replace position lamp Replace headlight bulb Replace indicator lamp assembly Light circuit Accessory circuit All wires except lighting and accessory circuits Position lamp inoperative Headlamp inoperative High beam indicator inoperative, neutral lamp inoperative, oil pressure lamp inoperative, turn signal indicator inoperative Replace tail lamp bulb/lens Replace tail lamp assembly or circuit board Replace horn and/or bracket Running lamps inoperative Headlamp inoperative, stop lamp inoperative Horn inoperative 5197 5215 5765 7210 0.1 0.2 0.1 0.7 0.1 0.2 0.1 0.7 0.1 0.2 0.1 0.7 0.1 0.2 0.1 0.7 5039 5043 5041 5143 5185 5191 0.5 0.5 0.5 0.1 0.1 1.1 0.5 0.5 0.5 0.1 0.1 1.0 0.5 0.5 0.5 0.1 0.1 1.0 0.5 0.5 0.5 0.1 0.1 1.1
Repair engine compression, use in conjunction with Engine cranks but will not start, starts hard additional code(s) Code not present B1006, B1007, B0563, P0562, P0563, P0603, P0605 SWITCHES Replace rear stoplight switch - includes bleeding brakes Replace neutral switch Nothing clicks, neutral lamp always on, neutral lamp inoperative, B1155 Replace oil pressure switch Oil pressure lamp always on, oil pressure lamp inoperative Replace clutch switch Replace left upper handlebar switch Nothing clicks, B1154 Horn always on, horn inoperative, headlamp inoperative Stop lamp inoperative
7770
0.2
0.2
0.2
0.2
5141
0.3
0.3
0.3
0.3
5157
1.3
1.3
1.3
1.3
5161
0.1
0.1
0.1
0.1
5168 5171
0.9 0.5
0.9 0.5
0.9 0.5
0.9 0.5
3-18
CP2 = XL883C CX3 = XL1200L
CR2 = XL883L CZ3 = XL1200N
CS2 = XL883R LA6 = XR1200
LE2 = XL883N LD6 = XR1200X
CT3 = XL1200C

5176 5818 6001 6002 6811 6730 7295 6782 7287

0.6 0.9 0.3 0.1 0.7 0.7 1.3 0.9 1.0
CP2
0.6 0.9 0.4 0.1 0.7 0.7 1.3 0.9 1.0
CT3
0.6 0.9 0.4 0.1 0.7 0.7 1.3 0.9 1.0
LA6 LD6
0.6 0.9 0.3 0.1 0.7 0.7 1.3 0.9 1.0
Replace front brake light switch Replace start button Replace odometer reset switch Replace odometer reset switch boot Replace turn signal switch Replace engine stop switch Replace engine stop switch Replace ignition switch Replace ignition switch FUSES AND RELAYS Replace battery fuse Inspect/access main wire harness/wiggle test/replace ignition fuse Inspect/wiggle test/replace main fuse
Stop lamp inoperative Starter inoperative B1008 B1008 Both lamps on one side inoperative Serial data missing No check engine lamp U1097, U1255 Serial data missing
U1064 Serial data missing
6713 6729
0.5 0.3
0.5 0.3
0.5 0.3
0.5 0.3
Serial data missing
6733 6781
0.4 0.7
0.4 0.7
0.4 0.7
0.4 0.7
Access instruments\wiggle test\replace accessory U1097, U1255 fuse Replace battery fuse Replace battery fuse Replace starter relay Replace starter relay Inspect/main wiring harness/replace battery fuse Replace 15 amp fuse Replace system relay Replace system relay Replace system relay U1255 Turn signal error 2C Starter inoperative B1134 No check engine lamp, U1255 Engine cranks but will not start, starts hard Serial data missing, P1001, P1003 P1002 P1004
6754 6807 5832 6841 7159 7181 7904 7909 7911 7918
--0.3 0.3 0.4 0.2 0.3 0.4 0.2 0.2 0.3
--0.3 0.3 0.4 0.2 0.3 0.4 0.2 0.2 0.3
--0.3 0.3 0.4 0.2 0.3 0.4 0.2 0.2 0.3
0.7 0.3 0.3 0.4 0.2 0.3 0.4 0.2 0.2 0.3
Harness inspection/wiggle test/replace system relay P1004
3-19
CP2 = XL883C CX3 = XL1200L
CR2 = XL883L CZ3 = XL1200N
CS2 = XL883R LA6 = XR1200
LE2 = XL883N LD6 = XR1200X
CT3 = XL1200C

7937

0.5
CP2
0.5
CT3
0.5
LA6 LD6
0.5
Harness inspection/wiggle test/Replace ECM fuse P1003, P1351, P1354 CHARGING CIRCUIT Milliamp draw Replace stator Total current draw Replace voltage regulator Replace voltage regulator Replace rotor Replace battery Low battery after extended ignition off Low or no charging Diagnose charging system No or low charging, overcharging Serial data missing No or low charging Engine cranks but will not start, starts hard
5308 5309 5310 5316 6724 5319 7185 7771
0.2 1.5 0.2 0.4 0.4 1.4 0.3 0.2
0.2 1.5 0.2 0.4 0.4 1.4 0.3 0.2
0.2 1.5 0.2 0.4 0.4 1.4 0.3 0.2
0.2 1.5 0.2 0.4 0.4 1.4 0.3 0.2
Repair charging system/accompanies other codes B1006, B1007, B0563, P0562, P0563 STARTER CIRCUIT Replace starter Replace starter Replace starter Replace starter clutch Replace starter solenoid IGNITION CIRCUIT Replace spark plugs Misfire at idle or under load, rough or rolling idle, engine cranks but will not start, starts hard Replace spark plug wire Misfire at idle or under load, rough or rolling idle, engine cranks but will not start, starts hard Replace ignition coil Replace ignition coil Replace ignition coil AIR INTAKE Repair intake leak P0131, P0151 Misfire at idle or under load, rough or rolling idle Engine cranks but will not start, starts hard P1351, P1352, P1354, P1355 Starter inoperative Starter inoperative - damaged motor Slow starter crank or starter stalls Starter spins but does not engage Starter testing, starter relay clicks
5817 5825 5836 5837 5845
1.0 0.9 0.3 1.0 1.1
1.0 0.9 0.3 1.0 1.1
1.0 0.9 0.3 1.0 1.1
1.0 0.9 0.3 1.0 1.1
7134
0.3
0.3
0.3
0.3
7138
0.3
0.3
0.3
0.3
7139 7226 7856
0.7 0.7 0.9
0.7 0.7 0.9
0.7 0.7 0.9
0.6 0.6 0.8
7486
1.5
1.5
1.5
1.6
3-20
CP2 = XL883C CX3 = XL1200L
CR2 = XL883L CZ3 = XL1200N
CS2 = XL883R LA6 = XR1200
LE2 = XL883N LD6 = XR1200X
CT3 = XL1200C

FUEL SYSTEM Replace fuel level switch Replace fuel level resistor assembly Replace fuel filter or clean fuel pump screen Replace fuel filter screen B1004, B1005 B1004, B1005 starts - then stalls Misfire at idle or under load, rough or rolling idle, Engine cranks but will not start, starts hard, P0131, P0151 Repair/Replace fuel pump/pressure regulator/fuel Misfire at idle or under load, rough or rolling idle, line/fuel filter Engine cranks but will not start, starts hard, P0131, P0132, P0151, P0152 Repair/Replace fuel pump/pressure regulator/fuel Starts - then stalls line/fuel filter Replace fuel injector Misfire at idle or under load, rough or rolling idle, P0131, P0132, P0151, P0152 Replace fuel injector Replace fuel injector Replace fuel injector Replace fuel pump Replace fuel pump Replace fuel pressure regulator SENSORS AND ECM Replace jiffy stand sensor IAC system OK, may use with other codes Replace idle air control (IAC) Replace throttle position sensor Replace throttle position sensor P1501, P1502 P0505 P0505 P0122 Engine cranks but will not start, starts hard, P0122, P0123 5085 7028 7490 7590 7595 0.3 0.3 0.6 0.8 0.5 0.3 0.3 0.6 0.8 0.5 0.3 0.3 0.6 0.8 0.5 0.3 0.3 0.7 1.2 0.9 Emits black smoke P0261P0264 Engine cranks but will not start, starts hard Engine cranks but will not start, starts hard P1003 Emits black smoke 7596 7795 7992 7415 7924 7480 0.8 0.5 0.7 0.6 0.8 0.6 0.8 0.5 0.7 0.6 0.8 0.6 0.8 0.5 0.7 0.6 0.8 0.6 1.0 0.7 0.7 0.7 0.9 0.7 7144 0.6 0.6 0.6 0.8 7014 0.8 0.8 0.8 0.9 7164 1.0 1.0 1.0 1.1 6035 6083 7013 7163 0.6 0.3 0.8 1.0 0.6 0.3 0.8 1.0 0.6 0.3 0.8 1.0 0.7 0.3 0.9 1.1
3-21
CP2 = XL883C CX3 = XL1200L
CR2 = XL883L CZ3 = XL1200N
CS2 = XL883R LA6 = XR1200
LE2 = XL883N LD6 = XR1200X
CT3 = XL1200C

7598 7710 7667 7725 7981 7982 7152 7597 7630 7650 7939 7967 7149 7555 7601 7641

0.9 0.6 0.5 0.9 0.5 0.3 1.0 1.4 0.8 1.0 0.4 0.4 1.2 0.5 1.4 0.8
CP2
0.9 0.6 0.5 0.9 0.5 0.3 1.0 1.4 0.8 1.0 0.4 0.4 1.2 0.5 1.4 0.8
CT3
0.9 0.6 0.5 0.9 0.5 0.3 1.0 1.4 0.8 1.0 0.4 0.4 1.2 0.5 1.4 0.8
LA6 LD6
0.9 0.6 0.5 0.7 0.5 0.3 0.8 1.2 0.6 0.8 0.4 0.4 1.4 0.7 1.6 0.8
Replace engine temperature (ET) sensor Replace engine temperature (ET) sensor Replace oxygen sensor Replace intake air temperature (IAT) sensor Replace crankshaft position (CKP) sensor Clean or repair crankshaft position (CKP) sensor Replace MAP sensor Replace MAP sensor Replace MAP sensor Replace MAP sensor Clean or repair vehicle speed sensor (VSS) Replace vehicle speed sensor (VSS) Replace ECM Replace ECM Replace ECM Replace ECM
Emits black smoke P0117, P0118 P0131, P0132, P0134, P0151, P0152, P0154 P0112, P0113 P0373, P0374 P0373, P0374 Misfire at idle or under load, rough or rolling idle Emits black smoke P0107 P0107, P0108, P0122 P0501 P0122, P0501, P0502 Misfire at idle or under load, rough or rolling idle P0123 Emits black smoke Engine cranks but will not start, starts - then stalls , starts hard, P0107, P0108, P0118, P0122, P0373, P0501, P1502, P0505, P1010
Replace ECM
Serial data missing, P0112, P0113, P0117, P0131, P0132, P0134, P0151, P0152, P0154, P0262, P0264, P0603, P0605, P1351, P1352, P1354, P1355
7735
0.7
0.7
0.7
0.7
Replace ECM
Serial data missing, P0261, P0263, P1009, P1501, P1502, U1300, U1301
7850
0.9
0.9
0.9
1.1
Replace ECM TURN SIGNALS/INSTRUMENTS/SECURITY
No check engine lamp, P1001, P1002
7906
0.6
0.6
0.6
0.8
Perform ECM/TSM/TSSM/HFSM module replace- P1009 ment procedure
6701
0.4
0.4
0.4
0.4
3-22
CP2 = XL883C CX3 = XL1200L
CR2 = XL883L CZ3 = XL1200N
CS2 = XL883R LA6 = XR1200
LE2 = XL883N LD6 = XR1200X
CT3 = XL1200C

6702 6707 6755 6756 6796

0.5 0.4 0.1 0.1 0.2
CP2
0.5 0.4 0.1 0.1 0.2
CT3
0.5 0.4 0.1 0.1 0.2
LA6 LD6
0.5 0.4 0.1 0.1 0.2
Replaced TSM/TSSM/HFSM , system now ok Replaced TSM/TSSM/HFSM , system now ok Replace FOB battery Replace FOB Replace bulb
P1009 P1010 Fails to disarm Fails to disarm Both lamps on one side inoperative, flash at double normal rate, B1121, B1122
Replace turn signal converter module Remove corrosion/Replace bulb Replace lamp assembly
Flash at double normal rate, B1123-B1126 Bulbs flash at double normal rate Flash at double normal rate, one lamp inoperative, B1121, B1122
6809 6822 6823
0.9 0.2 0.3
--0.2 0.4
--0.2 0.4
--0.2 0.3
Replace speedometer Replace speedometer Replace speedometer Replace speedometer
B1008 No security lamp during bulb check Security lamp on continuously after bulb check Serial data missing, no check engine lamp, U1016, U1097, U1255, U1300, U1301
6020 6738 6752 6765
0.3 0.4 0.4 0.8
0.4 0.4 0.4 0.9
0.4 0.4 0.4 0.9
------0.8
Replace speedometer Replace tachometer
No check engine lamp No security lamp during bulb check, security lamp on continuously after bulb check, B1008
7311 6095
0.5 ---
0.6 ---
0.6 ---
0.5 0.4
Replace tachometer
Serial data missing, no check engine lamp, U1016, U1097, U1255
6772
---
---
---
0.5
Replace tachometer Replace TSM/TSSM/HFSM Replace TSM/TSSM/HFSM Replace TSM/TSSM/HFSM
U1097, U1255, U1300, U1301 B1154, B1155 U1016, U1064, U1255 Fails to disarm, will not cancel upon turn completion, both lamps on one side inoperative, flash at double normal rate, starter inoperative, B1121B1126, B1131, B1132, B1134B1141
6803 5863 6717 6757
0.8 1.5 1.0 0.7
0.8 1.5 1.0 0.7
0.8 1.5 1.0 0.7
0.8 1.5 1.0 0.7
Replace TSM/TSSM/HFSM
B1135, B1136, B1142, B1143, B1144, B1145
6845
0.6
0.6
0.6
0.6
3-23
CP2 = XL883C CX3 = XL1200L
CR2 = XL883L CZ3 = XL1200N
CS2 = XL883R LA6 = XR1200
LE2 = XL883N LD6 = XR1200X
CT3 = XL1200C

7306 7998 6832 7161 6878 6881

1.2 1.1 0.6 0.6 0.2 0.6
CP2
1.2 1.3 0.6 0.6 0.2 0.6
CT3
1.2 1.3 0.6 0.6 0.2 0.6
LA6 LD6
1.2 1.1 0.6 0.6 0.2 0.6
Replace TSM/TSSM/HFSM Replace TSM/TSSM/HFSM Replace siren Replace siren Replace security antenna Replace security antenna harness
No check engine lamp Serial data missing, U1300, U1301 B1131, B1132 No check engine lamp B1143, B1144, B1145 B1145
3-24
SUBJECT..............................................................................................................PAGE NO. 4.1 Service........................................................................................................................4-1 4.2 Chassis.......................................................................................................................4-2 4.3 Engine.........................................................................................................................4-8 4.4 Clutch........................................................................................................................4-12 4.5 Transmission.............................................................................................................4-13 4.6 OEM Accessories......................................................................................................4-14 4.7 Cooling......................................................................................................................4-15 4.8 Electrical - General....................................................................................................4-16 4.9 VRSC Diagnostics.....................................................................................................4-17
VRSC MODELS
HFH = VRSCAW
HFJ = VRSCAW 105
HHH = VRSCDX
HHJ = VRSCDX 105
HPH = VRSCF
HPJ = VRSCF 105
Table 4-1. Service

ITEM DESCRIPTION LABOR CODE MODELS HFH HFJ HHH HHJ HPH HPJ
NEW Set-up and predelivery 1,000 mile (1,600 km) service REGULAR 5,000 mile (8,000 km) maintenance 10,000 mile (16,000 km) maintenance 15,000 mile (24,000 km) maintenance 20,000 mile (24,000 km) maintenance 25,000 mile (24,000 km) maintenance 30,000 mile (24,000 km) maintenance Addition to any maintenance- required every 2 years Addition to 1,000, 5,000 and 20,000 mile (1,600, 8,000, and 32,000 km) maintenance and every 15,000 mile (24,000 km) interval there after Includes Valve lash adjustment flush/fill D.O.T 4 brake fluid- front and rear brake, and clutch Tighten spoke wheels if equipped, time per wheel --0.5 0.5 --------Includes Valve lash adjustment --------------1.5 1.5 3.0 2.0 1.5 3.0 0.8 1.5 1.5 3.0 2.0 1.5 3.0 0.8 1.5 1.5 3.0 2.0 1.5 3.0 0.8 1.5 1.5 3.0 2.0 1.5 3.0 0.8 1.6 1.6 3.2 2.1 1.6 3.2 0.8 1.6 1.6 3.2 2.1 1.6 3.2 0.8 ----1.5 2.0 1.5 2.0 1.5 2.0 1.5 2.0 1.6 2.1 1.6 2.1
2010 VRSC Models
4-1
HFH = VRSCAW
HFJ = VRSCAW 105
HHH = VRSCDX
HHJ = VRSCDX 105
HPH = VRSCF
HPJ = VRSCF 105
Table 4-2. Chassis

PAINT REPAIR NOTE: Use these codes when repairing any painted part on vehicle with the Kent Moore finesse kit or other paint repair methods Light scuff/scratch - buff Light sanding/buff/blend Buff entire part Repair build up in clear/paint Color blend/paint/buff DRIVE Adjust secondary belt Replace sprocket cover Replace secondary belt Replace rear wheel sprocket Replace rear wheel sprocket bearing Replace rear compensator cushion Replace rear compensator bowl Replace front sprocket WHEELS Replace tire - includes balancing Replace tire - includes balancing Replace wheel assembly - includes disc and sprocket exchange and balancing Replace wheel assembly - includes disc and sprocket exchange and balancing Replace wheel bearings Replace wheel bearings Check or true spoke wheel front rear front 2136 2141 2155 0.3 0.6 0.5 0.3 0.6 0.5 0.3 0.6 --0.3 0.6 --0.3 0.6 --0.3 0.6 --rear 2114 1.0 1.0 1.0 1.0 1.0 1.0 front rear front 2106 2111 2113 0.4 0.9 0.6 0.4 0.9 0.6 0.4 0.9 0.6 0.4 0.9 0.6 0.4 0.9 0.6 0.4 0.9 0.6 PDI Only 2010 2044 2011 2021 2012 2013 2014 2015 0.3 0.1 0.5 0.4 0.6 0.5 0.6 0.5 0.3 0.1 0.5 0.4 0.6 0.5 0.6 0.5 0.3 0.1 0.5 0.4 0.6 0.5 0.6 0.5 0.3 0.1 0.5 0.4 0.6 0.5 0.6 0.5 0.3 0.2 0.6 0.4 0.6 0.5 0.6 0.6 0.3 0.2 0.6 0.4 0.6 0.5 0.6 0.6 1102 1104 1106 1108 1110 0.2 0.4 0.6 0.8 1.0 0.2 0.4 0.6 0.8 1.0 0.2 0.4 0.6 0.8 1.0 0.2 0.4 0.6 0.8 1.0 0.2 0.4 0.6 0.8 1.0 0.2 0.4 0.6 0.8 1.0
2010 VRSC Models
4-2
HFH = VRSCAW
HFJ = VRSCAW 105
HHH = VRSCDX
HHJ = VRSCDX 105
HPH = VRSCF
HPJ = VRSCF 105
Table 4-2. Chassis

HANDLEBARS Replace handlebar riser Replace handlebar clamp Replace handlebars Replace clutch hand lever Replace brake hand lever Replace throttle control (grip and sleeve)and adjust right side cables Replace and adjust throttle control cables Replace rubber handlebar grip FRAME/SWING ARM/FRONT FORK Replace frame includes removal and installation of all accessories and motorcycle components Replace lower fork bracket and stem Replace steering head cups and bearings, including bearing adjustment Replace headlamp mount bracket Replace upper fork bracket Replace fork lock Adjust steering head bearing Change front fork oil Service fork slider and/or seal includes removal, one side disassembly, cleaning, inspection, replacing parts, servicing damper tube, replacing bushings, assembly and installation 2244 2326 2330 2290 --2341 0.2 1.0 0.3 0.4 0.5 0.7 0.2 1.0 0.3 0.4 0.5 0.7 0.2 1.0 0.3 0.4 0.5 0.7 0.2 1.0 0.3 0.4 0.5 0.7 0.2 1.0 0.3 0.4 0.7 0.9 0.2 1.0 0.3 0.4 0.7 0.9 2316 2321 1.1 1.8 1.1 1.8 1.1 1.8 1.1 1.8 1.1 1.8 1.1 1.8 2306 12.0 12.0 12.0 12.0 12.0 12.0 one or both left side 2241 2251 0.6 0.1 0.6 0.1 0.6 0.1 0.6 0.1 0.7 0.1 0.7 0.1 one 2253 2254 2206 2221 2494 2231 ----0.5 0.1 0.1 0.4 ----0.5 0.1 0.1 0.4 0.3 0.3 0.5 0.1 0.1 0.4 0.3 0.3 0.5 0.1 0.1 0.4 ----0.8 0.1 0.1 0.4 ----0.8 0.1 0.1 0.4
2010 VRSC Models
4-3
HFH = VRSCAW
HFJ = VRSCAW 105
HHH = VRSCDX
HHJ = VRSCDX 105
HPH = VRSCF
HPJ = VRSCF 105
Table 4-2. Chassis

2342
MODELS HFH
1.5
HFJ
1.5
HHH
1.5
HHJ
1.5
HPH
1.7
HPJ
1.7
Service fork slider and/or seal includes removal, both sides disassembly, cleaning, inspection, replacing parts, servicing damper tube, replacing bushings, assembly and installation Replace fork slider Replace fork slider one side both sides
2346 2351 2356
0.6 0.8 0.7
0.6 0.8 0.7
0.6 0.8 0.7
0.6 0.8 0.7
0.8 1.0 0.9
0.8 1.0 0.9
Replace fork tube includes removal, disassembly, one side cleaning, inspection, replacing parts, servicing damper tube, replacing bushings, assembly and installation Replace fork tube includes removal, disassembly, both sides cleaning, inspection, replacing parts, servicing damper tube, replacing bushings, assembly and installation Replace rear swing arm-complete Replace rear swing arm bearings Replace passenger foot peg mount Replace passenger foot peg mount Replace rear shock absorber assembly Replace rear shock absorber assembly both sides left side right side left side right side
2361
1.1
1.1
1.1
1.1
1.5
1.5
2359 2366 2393 2310 2371 2376 2382 2383 2396 front left side right side 2398 2345 2347
1.5 2.2 0.1 0.1 0.1 0.2 0.2 0.3 0.2 1.2 1.0 0.7
1.5 2.2 0.1 0.1 0.1 0.2 0.2 0.3 0.2 1.2 1.0 0.7
1.5 2.2 0.1 0.1 0.1 0.2 0.2 0.3 0.2 1.2 1.0 0.7
1.5 2.2 0.1 0.1 0.1 0.2 0.2 0.3 0.2 1.2 1.0 0.7
1.5 2.2 0.1 0.1 0.1 0.2 0.2 0.3 0.2 1.2 1.0 0.7
1.5 2.2 0.1 0.1 0.1 0.2 0.2 0.3 0.2 1.2 1.0 0.7
Replace shock bushing includes removing shock left side Replace shock bushing includes removing shock right side Replace jiffy stand/spring Replace engine mount Replace lower frame rail Replace lower frame rail BRAKES Replace hydraulic brake line Non-ABS Note:Does front not include brake bleeding.
2406
0.4
0.4
0.4
0.4
0.4
0.4
2010 VRSC Models
4-4
HFH = VRSCAW
HFJ = VRSCAW 105
HHH = VRSCDX
HHJ = VRSCDX 105
HPH = VRSCF
HPJ = VRSCF 105
Table 4-2. Chassis

2411
MODELS HFH
0.5
HFJ
0.5
HHH
0.5
HHJ
0.5
HPH
0.5
HPJ
0.5
Replace hydraulic brake line Non-ABS Note:Does rear not include brake bleeding. Replace brake pads Replace brake pads Replace caliper Note:Does not include brake bleeding. Replace caliper Note:Does not include brake bleeding. Replace brake disc Replace brake disc Replace master cylinder cover/gasket. Bleed brake system Non-ABS Bleed brake system Non-ABS Bleed brake system ABS-only front rear front or rear front rear (front or rear, ABS models only includes system verification with Digital Technician II) Replace hydraulic brake line (ABS vehicles only) Note:Does not include brake bleeding. Replace hydraulic brake line (ABS vehicles only) Note:Does not include brake bleeding. Replace hydraulic brake line (ABS vehicles only) Note:Does not include brake bleeding. Replace hydraulic brake line (ABS vehicles only) Note:Does not include brake bleeding. Replace front brake line manifold or seal washers includes replacing all seal washers (ABS vehicles (ABS vehicles only) Note:Does not include brake bleeding. Replace ABS HCU (hydraulic control unit) Note:Does not include brake bleeding. only) rear, ABS unit to rear caliper, (ABS vehicles only) front, mastercylinder to ABS unit, (ABS vehicles only) rear, master cylinder to ABS unit, (ABS vehicles only) front, ABS unit to calipers, (ABS vehicles only) rear front both sides rear front
2416 2421 2426
0.3 0.2 0.4
0.3 0.2 0.4
0.3 0.2 0.4
0.3 0.2 0.4
0.3 0.2 0.4
0.3 0.2 0.4
2431
0.5
0.5
0.5
0.5
0.5
0.5
2436 2441 2479 2442 2443 2446
0.4 0.6 0.2 0.3 0.2 0.6
0.4 0.6 0.2 0.3 0.2 0.6
0.4 0.6 0.2 0.3 0.2 0.6
0.4 0.6 0.2 0.3 0.2 0.6
0.4 0.6 0.2 0.3 0.2 0.6
0.4 0.6 0.2 0.3 0.2 0.6
2463
1.2
1.2
1.2
1.2
1.2
1.2
2464
0.7
0.7
0.7
0.7
0.7
0.7
2465
1.2
1.2
1.2
1.2
1.2
1.2
2467
1.3
1.3
1.3
1.3
1.3
1.3
2468
0.5
0.5
0.5
0.5
0.5
0.5
2473
1.3
1.3
1.3
1.3
1.3
1.3
2010 VRSC Models
4-5
HFH = VRSCAW
HFJ = VRSCAW 105
HHH = VRSCDX
HHJ = VRSCDX 105
HPH = VRSCF
HPJ = VRSCF 105
Table 4-2. Chassis

2461
MODELS HFH
0.4
HFJ
0.4
HHH
0.4
HHJ
0.4
HPH
0.4
HPJ
0.4
Replace master cylinder assembly Note:Does not front include brake bleeding. Replace master cylinder assembly Note:Does not rear include brake bleeding. Rebuild master cylinder assembly Note:Does not include brake bleeding. Rebuild master cylinder assembly Note:Does not include brake bleeding. Replace rear brake pedal Replace rear brake reservoir hose Replace rear reservoir tank only Replace brake caliper screen SEATS/COSMETIC COVERS/FUEL TANK/VISOR KIT Replace seat/lanyard Replace passenger seat Replace seat strap Replace rear fender, outer Replace rear fender support Replace side covers, left or right/rubber mount Replace air box cover/rubber mount Replace front fender/chrome bracket/painted bracket Replace radiator trim cover Replace radiator cover Replace fuel tank assembly Replace fuel tank gasket Replace fuel gauge sending unit one side rear front
2466
0.5
0.5
0.5
0.5
0.5
0.5
2471
0.6
0.6
0.6
0.6
0.6
0.6
2476
0.6
0.6
0.6
0.6
0.6
0.6
2492 2414 2418 2428
0.2 0.2 0.2 0.1
0.2 0.2 0.2 0.1
0.2 0.2 0.2 0.1
0.2 0.2 0.2 0.1
0.2 0.2 0.2 0.1
0.2 0.2 0.2 0.1
2506 2586 2588 2537 2536 2520 2521 2522
0.1 0.1 0.1 0.2 0.5 0.1 0.1 0.2
0.1 0.1 0.1 0.2 0.5 0.1 0.1 0.2
0.1 0.1 0.1 0.2 0.5 0.1 0.1 0.2
0.1 0.1 0.1 0.2 0.5 0.1 0.1 0.2
0.1 0.1 0.1 0.2 0.5 0.1 0.2 0.1
0.1 0.1 0.1 0.2 0.5 0.1 0.2 0.1
2523 2524 2541 2548 2564
0.1 0.2 1.7 0.4 0.5
0.1 0.2 1.7 0.4 0.5
0.1 0.2 1.7 0.4 0.5
0.1 0.2 1.7 0.4 0.5
0.1 0.2 1.7 0.4 0.5
0.1 0.2 1.7 0.4 0.5
2010 VRSC Models
4-6
HFH = VRSCAW
HFJ = VRSCAW 105
HHH = VRSCDX
HHJ = VRSCDX 105
HPH = VRSCF
HPJ = VRSCF 105
Table 4-2. Chassis

2590 2598
MODELS HFH
0.3 ---
HFJ
0.3 ---
HHH
0.3 0.2
HHJ
0.3 0.2
HPH
0.4 ---
HPJ
0.4 ---
Replace license plate bracket replacing visor kit BELTS GUARDS Replace sprocket cover Replace debris deflector Replace belt guard EXHAUST SYSTEM Replace complete exhaust system and/or gaskets Replace exhaust pipe dual exhaust system Replace exhaust pipe dual exhaust system Replace auxiliary volume/front clamp Replace any muffler/clamp Replace any exhaust shield Replace muffler support Replace muffler end caps (both) Replace heat shield screws front rear
2613 2617 2616
0.1 0.1 0.1
0.1 0.1 0.1
0.1 0.1 0.1
0.1 0.1 0.1
0.2 0.1 0.1
0.2 0.1 0.1
2626 2631 2636 2638 2646 2661 2666 2601 2664
0.6 0.6 0.6 0.5 0.2 0.1 0.6 0.2 0.1
0.6 0.6 0.6 0.5 0.2 0.1 0.6 0.2 0.1
0.6 0.6 0.6 0.5 0.2 0.2 0.6 0.2 0.1
0.6 0.6 0.6 0.5 0.2 0.2 0.6 0.2 0.1
0.6 0.4 0.4 0.5 0.2 0.1 0.5 0.2 0.1
0.6 0.4 0.4 0.5 0.2 0.1 0.5 0.2 0.1
2010 VRSC Models
4-7
HFH = VRSCAW
HFJ = VRSCAW 105
HHH = VRSCDX
HHJ = VRSCDX 105
HPH = VRSCF
HPJ = VRSCF 105
Table 4-3. Engine

GENERAL Remove and install engine Check compression/leak down Check compression/leak down Check compression/leak down Remove oil pan/inspection Replace pan gasket Replace alternator cover/gasket Replace derby cover/o-ring Change shim/check clearence CYLINDER HEAD Recondition cylinder head-includes removal of head front head and gasket (Non Warranty Procedures) Recondition cylinder head-includes removal of head rear head and gasket (Non Warranty Procedures) Recondition cylinder head-includes removal of head both heads and gasket (Non Warranty Procedures) Replace cylinder head/engine removal not required one head for frt cylinder head Replace cylinder head/engine removal not required both heads for frt cylinder head Replace valve seal or spring after cylinder head removal Replace valve seal or spring after cylinder head removal Replace cylinder head gasket Replace cylinder head gasket Replace secondary cam chain tensioner front cylinder engine not removed rear or both cylinders including engine removal both 3140 3142 3155 3.0 4.2 0.3 3.0 4.2 0.3 3.0 4.2 0.3 3.0 4.2 0.3 3.0 4.2 0.3 3.0 4.2 0.3 all seals and springs, one head 3132 0.4 0.4 0.4 0.4 0.4 0.4 one seal or spring (intake or exhaust) 3131 0.1 0.1 0.1 0.1 0.1 0.1 3108 4.7 4.7 4.7 4.7 4.7 4.7 3106 3.5 3.5 3.5 3.5 3.5 3.5 3104 6.7 6.7 6.7 6.7 6.7 6.7 3103 6.5 6.5 6.5 6.5 6.5 6.5 3101 5.7 5.7 5.7 5.7 5.7 5.7 one shim front only rear only both includes gasket replacement 3006 3020 3021 3022 3009 3030 3040 3042 3044 3.5 0.4 0.2 0.5 0.4 0.4 0.3 0.1 0.2 3.5 0.4 0.2 0.5 0.4 0.4 0.3 0.1 0.2 3.5 0.4 0.2 0.5 0.4 0.4 0.3 0.1 0.2 3.5 0.4 0.2 0.5 0.4 0.4 0.3 0.1 0.2 3.5 0.4 0.2 0.5 0.4 0.4 0.5 0.1 0.2 3.5 0.4 0.2 0.5 0.4 0.4 0.5 0.1 0.2
2010 VRSC Models
4-8
HFH = VRSCAW
HFJ = VRSCAW 105
HHH = VRSCDX
HHJ = VRSCDX 105
HPH = VRSCF
HPJ = VRSCF 105
Table 4-3. Engine

3156 3157 3158 could be done in chassis; remove engine if heads are damaged CYLINDER AND PISTON Replace piston rings includes deglazing cylinder one cylinder Replace piston rings includes deglazing cylinder both cylinders Replace piston and piston rings includes removal one cylinder of cylinder head and fitting new piston with rings Replace piston and piston rings includes removal both cylinders of cylinder head and fitting new piston with rings Replace cylinder liner and piston Deglaze/measure one cylinder CAM COVER Replace cam cover/gasket, lower Replace cam cover/gasket, lower Replace cam cover/gasket, lower Replace cam cover/gasket, upper Replace cam cover/gasket, upper Replace cam cover/gasket, upper Replace cam cover gasket, inner Replace cam cover gasket, inner Replace cam cover gasket, inner Replace secondary top guide front rear both front rear both front rear both 3319 3320 3321 3322 3324 3329 3330 3332 3334 3350 1.2 1.2 1.4 1.1 1.1 1.2 1.2 1.2 1.4 1.2 1.2 1.2 1.4 1.1 1.1 1.2 1.2 1.2 1.4 1.2 1.2 1.2 1.4 1.1 1.1 1.2 1.2 1.2 1.4 1.2 1.2 1.2 1.4 1.1 1.1 1.2 1.2 1.2 1.4 1.2 1.3 1.3 1.5 1.2 1.2 1.3 1.3 1.3 1.5 1.3 1.3 1.3 1.5 1.2 1.2 1.3 1.3 1.3 1.5 1.3 one cylinder 3237 3238 0.1 0.2 0.1 0.2 0.1 0.2 0.1 0.2 0.1 0.2 0.1 0.2 3231 10.0 10.0 10.0 10.0 10.0 10.0 3206 3216 3221 9.8 10.0 9.8 9.8 10.0 9.8 9.8 10.0 9.8 9.8 10.0 9.8 9.8 10.0 9.8 9.8 10.0 9.8 3159
MODELS HFH
4.0 4.3 1.5 1.7
HFJ
4.0 4.3 1.5 1.7
HHH
4.0 4.3 1.5 1.7
HHJ
4.0 4.3 1.5 1.7
HPH
4.2 4.5 1.5 1.7
HPJ
4.2 4.5 1.5 1.7
Replace secondary guide Replace secondary guide Replace camshaft/sprocket Replace secondary cam chain
front rear
2010 VRSC Models
4-9
HFH = VRSCAW
HFJ = VRSCAW 105
HHH = VRSCDX
HHJ = VRSCDX 105
HPH = VRSCF
HPJ = VRSCF 105
Table 4-3. Engine

CRANKCASE Replace crankcases Seal crankcase only Replace crankshaft Remove primary crank gear from crank Replace primary cam chain tensioner Replace primary cam chain guide Replace primary cam chain can be done in chassis, depends on damage includes remove and install engine add to crankshaft replacement includes remove and install engine 3406 3407 3470 3471 3472 3473 3474 3425 11.0 4.9 6.1 0.2 0.4 0.4 1.9 1.7 11.0 4.9 6.1 0.2 0.4 0.4 1.9 1.7 11.0 4.9 6.1 0.2 0.4 0.4 1.9 1.7 11.0 4.9 6.1 0.2 0.4 0.4 1.9 1.7 11.0 4.9 6.1 0.2 0.6 0.6 2.1 1.7 11.0 4.9 6.1 0.2 0.6 0.6 2.1 1.7
Recondition cylinder head-head removed (for non- one head related repairs) Replace oil pump and/or O-rings Replace main bearing shell Replace connecting rod Replace limiter assembly Replace gear, ball clutch Replace o-ring, VSS Replace o-ring, CPS Replace dipstick BALANCER SYSTEM Replace balancer shaft/crankcase bearing Replace primary crank gear Replace balancer shaft gear/bolt FUEL SYSTEM Replace air cleaner bottom Replace air cleaner cover/snorkel Filter element cap includes bearings, outer and inner engine can stay in frame engine can stay in frame
3341 3475 3476 3477 3478 3481 3482 3480
0.8 4.9 10.0 0.5 0.6 0.1 0.2 0.1
0.8 4.9 10.0 0.5 0.6 0.1 0.2 0.1
0.8 4.9 10.0 0.5 0.6 0.1 0.2 0.1
0.8 4.9 10.0 0.5 0.6 0.1 0.2 0.1
0.8 4.9 10.0 0.7 0.8 0.1 0.2 0.1
0.8 4.9 10.0 0.7 0.8 0.1 0.2 0.1
3450 3451 3453
7.2 1.3 1.1
7.2 1.3 1.1
7.2 1.3 1.1
7.2 1.3 1.1
7.2 1.3 1.1
7.2 1.3 1.1
3545 3547 3549
0.2 0.1 0.1
0.2 0.1 0.1
0.2 0.1 0.1
0.2 0.1 0.1
0.3 0.2 0.2
0.3 0.2 0.2
2010 VRSC Models
4-10
HFH = VRSCAW
HFJ = VRSCAW 105
HHH = VRSCDX
HHJ = VRSCDX 105
HPH = VRSCF
HPJ = VRSCF 105
Table 4-3. Engine

3551 3553 3555 3557 3559 3561 one or both lines 3563 3565 inside air box front rear 3567 3569 3571
MODELS HFH
0.1 0.1 0.2 0.2 0.6 0.5 0.3 0.4 0.1 0.2 0.1
HFJ
0.1 0.1 0.2 0.2 0.6 0.5 0.3 0.4 0.1 0.2 0.1
HHH
0.1 0.1 0.2 0.2 0.6 0.5 0.3 0.4 0.1 0.2 0.1
HHJ
0.1 0.1 0.2 0.2 0.6 0.5 0.3 0.4 0.1 0.2 0.1
HPH
0.2 0.2 0.3 0.3 0.7 0.6 0.5 0.6 0.2 0.2 0.2
HPJ
0.2 0.2 0.3 0.3 0.7 0.6 0.5 0.6 0.2 0.2 0.2
Replace filter element Replace bottom to upper seal Replace air cleaner bottom gasket to throttle body Replace velocity stack Replace fuel rail Throttle body boot/clamp Replace fuel line Replace throttle body Replace breather hose Replace breather hose Replace breather hose EVAPORATIVE EMISSIONS SYSTEM Replace canister Replace any one hose Replace evaporative purge solenoid California vehicles only California vehicles only California vehicles only
3527 3529 3522
0.2 0.1 0.4
-------
0.2 0.1 0.4
-------
0.2 0.1 0.4
-------
2010 VRSC Models
4-11
HFH = VRSCAW
HFJ = VRSCAW 105
HHH = VRSCDX
HHJ = VRSCDX 105
HPH = VRSCF
HPJ = VRSCF 105
Table 4-4. Clutch

CLUTCH Replace clutch master cylinder Replace clutch secondary actuator cylinder Clutch service includes disassembly, cleaning, inspection, repair, assembly, replacement of friction plates Replace clutch release bearing Bleed clutch system for air Replace clutch cover/gasket Replace clutch line Replace clutch complete Replace secondary actuator cylinder cover new clutch assembly, exhaust removal 4016 4024 4026 4028 4030 4032 0.5 0.2 0.8 0.5 1.2 0.1 0.5 0.2 0.8 0.5 1.2 0.1 0.5 0.2 0.8 0.5 1.2 0.1 0.5 0.2 0.8 0.5 1.2 0.1 0.5 0.2 0.8 0.5 1.2 0.1 0.5 0.2 0.8 0.5 1.2 0.1 4020 4022 4011 0.4 0.3 1.5 0.4 0.3 1.5 0.4 0.3 1.5 0.4 0.3 1.5 0.4 0.3 1.5 0.4 0.3 1.5
2010 VRSC Models
4-12
HFH = VRSCAW
HFJ = VRSCAW 105
HHH = VRSCDX
HHJ = VRSCDX 105
HPH = VRSCF
HPJ = VRSCF 105

TRANSMISSION Overhaul transmission includes disassembly, cleaning, inspection, replacing all parts. includes engine removal Replace transmission complete Replace input shaft Replace output shaft Replace shift actuator assembly Replace output shaft flange/seal Replace shaft end bearing Replace shifter drum/shaft Replace shifter forks and/or shaft Replace plastic cap Replace shift pedal and/or lever Replace transmission shifter shaft seal Replace shift shaft Replace shift linkage engine removal is not necessary engine removal is not necessary add to job, per bearing includes removal and installation includes checking gear engagement 4305 4322 4323 4324 4325 4326 4331 4343 4371 4372 4390 4386 4388 6.3 6.3 6.4 7.4 0.6 0.2 7.2 7.2 0.2 0.2 0.3 0.3 0.1 6.3 6.3 6.4 7.4 0.6 0.2 7.2 7.2 0.2 0.2 0.3 0.3 0.1 6.3 6.3 6.4 7.4 0.6 0.2 7.2 7.2 0.2 0.2 0.3 0.3 0.1 6.3 6.3 6.4 7.4 0.6 0.2 7.2 7.2 0.2 0.2 0.3 0.3 0.1 6.3 6.3 6.4 7.4 0.6 0.2 7.2 7.2 0.2 0.2 0.3 0.3 0.1 6.3 6.3 6.4 7.4 0.6 0.2 7.2 7.2 0.2 0.2 0.3 0.3 0.1 4306 7.8 7.8 7.8 7.8 7.8 7.8
2010 VRSC Models
4-13
HFH = VRSCAW
HFJ = VRSCAW 105
HHH = VRSCDX
HHJ = VRSCDX 105
HPH = VRSCF
HPJ = VRSCF 105

ACCESSORIES Replace windshield Replace mirror Air box cover emblems/medallion Air box cover emblems/medallion one letter three letters or more 6203 6513 6548 6549 --0.1 0.1 0.3 --0.1 0.1 0.3 --0.1 0.1 0.3 --0.1 0.1 0.3 --0.1 0.1 0.3 --0.1 0.1 0.3
2010 VRSC Models
4-14
HFH = VRSCAW
HFJ = VRSCAW 105
HHH = VRSCDX
HHJ = VRSCDX 105
HPH = VRSCF
HPJ = VRSCF 105
Table 4-7. Cooling

COOLING Replace radiator assembly Replace radiator Replace coolant hose/engine in Replace coolant pipe/engine in Replace coolant hose/engine out Replace coolant pipe/engine out Replace any clamp Replace shrink clamp Replace water pump/gasket/cover o-ring Replace thermostat/housing/gasket/o-rings Replace radiator cover Replace radiator trim cover Replace oil cooler Replace oil pipe/outlet Replace oil pipe/inlet Replace oil pipe connector/inlet Replace oil pipe connector outlet Replace oil filter mount Replace radiator cap Replace hose from cap to over flow bottle Replace coolant overflow bottle Replace overflow hose Replace hose trim cover on any one coolant pipe oil lines and oil cooler removed 4501 4503 4505 4507 4509 4511 4513 4515 4517 4519 4521 4523 4525 4527 4529 4531 4532 4533 4535 4537 4539 4541 4543 1.0 1.3 0.8 1.1 0.8 1.1 0.1 1.1 2.3 1.2 0.2 0.1 0.8 0.8 0.8 0.2 0.5 0.6 0.1 0.1 0.2 0.3 0.1 1.0 1.3 0.8 1.1 0.8 1.1 0.1 1.1 2.3 1.2 0.2 0.1 0.8 0.8 0.8 0.2 0.5 0.6 0.1 0.1 0.2 0.3 0.1 1.0 1.3 0.8 1.1 0.8 1.1 0.1 1.1 2.3 1.2 0.2 0.1 0.8 0.8 0.8 0.2 0.5 0.6 0.1 0.1 0.2 0.3 0.1 1.0 1.3 0.8 1.1 0.8 1.1 0.1 1.1 2.3 1.2 0.2 0.1 0.8 0.8 0.8 0.2 0.5 0.6 0.1 0.1 0.2 0.3 0.1 1.0 1.3 0.8 1.1 0.8 1.1 0.1 1.1 2.3 1.2 0.2 0.1 0.8 0.8 0.8 0.2 0.5 0.6 0.2 0.2 0.3 0.4 0.1 1.0 1.3 0.8 1.1 0.8 1.1 0.1 1.1 2.3 1.2 0.2 0.1 0.8 0.8 0.8 0.2 0.5 0.6 0.2 0.2 0.3 0.4 0.1
2010 VRSC Models
4-15
HFH = VRSCAW
HFJ = VRSCAW 105
HHH = VRSCDX
HHJ = VRSCDX 105
HPH = VRSCF
HPJ = VRSCF 105

INSTRUMENTS Replace speedometer Replace bezel/housing WIRING Replace connector housing Replace connector anchor Replace main wiring harness Replace fuse ( front or rear) Replace fuse block SWITCHES Replace ignition switch Replace right upper handlebar switch Replace left upper handlebar switch housing Replace left lower handlebar switch housing Replace right upper handlebar switch housing Replace right lower handlebar switch housing LIGHTS Replace headlight bracket Replace headlight housing Replace turn signal light assembly Replace turn signal light assembly License plate bracket BATTERY Replace the battery( including caddy) 5705 0.4 0.4 0.4 0.4 0.5 0.5 Includes adjustment Includes adjustment Front Rear 5181 5189 5201 5205 5237 0.2 0.2 0.5 0.3 0.3 0.2 0.2 0.5 0.3 0.3 0.3 0.1 0.5 0.3 0.3 0.3 0.1 0.5 0.3 0.3 0.2 0.1 0.7 0.2 0.3 0.2 0.1 0.7 0.2 0.3 5129 5173 5177 5178 5179 5180 0.1 0.7 0.2 0.2 0.2 0.4 0.1 0.7 0.2 0.2 0.2 0.4 0.1 0.7 0.2 0.2 0.2 0.4 0.1 0.7 0.2 0.2 0.2 0.4 0.1 0.7 0.2 0.7 0.2 0.7 0.1 0.7 0.2 0.7 0.2 0.7 5022 5023 5026 5145 5196 0.1 0.1 2.1 0.1 0.4 0.1 0.1 2.1 0.1 0.4 0.1 0.1 2.1 0.1 0.4 0.1 0.1 2.1 0.1 0.4 0.1 0.1 2.1 0.1 0.4 0.1 0.1 2.1 0.1 0.4 Cosmetic issue 6003 6044 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1
2010 VRSC Models
4-16
HFH = VRSCAW
HFJ = VRSCAW 105
HHH = VRSCDX
HHJ = VRSCDX 105
HPH = VRSCF
HPJ = VRSCF 105
Table 4-9. VRSC Diagnostics

NOTE: The diagnostic/replacement operations and times listed on the following pages have been created for your use. The codes must be used in conjunction with the repair procedures listed in the current VRSCA Service Manual, and diagnostics performed through the use of Digital Technician and Electrical Diagnostics Manual. DIAGNOSTICS GENERAL Repair any single wire Repair any single wire Repair any single wire Replace position lamp Replace headlight Replace taillight light bulb or lens Replace tail lamp assembly License plate bracket light Replace horn and/or bracket Replace fan Light circuit Accessory circuit All wires except lighting and accessory circuits Position lamp inoperative Headlamp inoperative Running lamps inoperative Headlamp inoperative, stop lamp inoperative Running lamps inoperative Horn inoperative IM inoperative, P1481 5039 5043 5041 5143 5185 5197 5215 5239 5765 6054 7210 0.5 0.5 0.5 0.1 0.1 0.1 0.3 0.2 0.2 0.8 0.6 0.5 0.5 0.5 0.1 0.1 0.1 0.3 0.2 0.2 0.8 0.6 0.5 0.5 0.5 0.1 0.1 0.1 0.3 0.2 0.2 0.8 0.6 0.5 0.5 0.5 0.1 0.1 0.1 0.3 0.2 0.2 0.8 0.6 0.5 0.5 0.6 0.1 0.1 --0.4 0.3 0.2 0.9 0.8 0.5 0.5 0.6 0.1 0.1 --0.4 0.3 0.2 0.9 0.8
Repair engine compression; use in conjunction with Engine cranks but will not start additional code(s) Code not present System OK Code not present SWITCHES Replace rear stoplight switch Note:Does not include Stop lamp inoperative brake bleeding. Replace neutral switch Nothing clicks, neutral lamp always on, neutral lamp inoperative, B1155 Replace oil pressure switch Oil pressure lamp always on, oil pressure lamp inoperative Replace clutch switch Nothing clicks, B1154 B1006, B0563, P0562, P0563, C0563 P0605 P0603
7770 7916 7931
0.3 0.3 0.2
0.3 0.3 0.2
0.3 0.3 0.2
0.3 0.3 0.2
0.4 0.4 0.3
0.4 0.4 0.3
5141
0.4
0.4
0.8
0.8
0.8
0.8
5157
0.5
0.5
0.5
0.5
0.6
0.6
5161
0.4
0.4
0.4
0.4
0.6
0.6
5168
0.7
0.7
0.7
0.7
0.8
0.8
2010 VRSC Models
4-17
HFH = VRSCAW
HFJ = VRSCAW 105
HHH = VRSCDX
HHJ = VRSCDX 105
HPH = VRSCF
HPJ = VRSCF 105

5171
MODELS HFH
0.5
HFJ
0.5
HHH
0.5
HHJ
0.5
HPH
0.5
HPJ
0.5
Replace front brake light switch Replace start button Replace trip switch Replace trip switch boot Replace turn signal switch Replace engine stop switch Replace engine stop switch Replace ignition switch
Stop lamp inoperative Starter testing, nothing clicks B1008 B1008 Both lamps on one side inoperative Serial data missing No check engine lamp Starter testing, serial data missing, no check engine lamp, stop lamp inoperative, IM inoperative
5176 5818 6001 6002 6811 6730 7295 7287
0.6 0.9 0.4 0.1 0.7 0.9 0.8 0.5
0.6 0.9 0.4 0.1 0.7 0.9 0.8 0.5
0.6 0.9 0.4 0.1 0.7 0.9 0.8 0.5
0.6 0.9 0.4 0.1 0.7 0.9 0.8 0.5
0.6 1.0 0.4 0.1 0.8 1.0 0.9 0.6
0.6 1.0 0.4 0.1 0.8 1.0 0.9 0.6
FUSES AND RELAYS Replace fan relay P1481, P1482 6051 6053 6713 7159 6729 0.2 0.3 0.4 0.5 0.3 0.2 0.3 0.4 0.5 0.3 0.2 0.3 0.4 0.5 0.3 0.2 0.3 0.4 0.5 0.3 0.3 0.4 0.5 0.6 0.4 0.3 0.4 0.5 0.6 0.4
Harness inspection/wiggle test/Replace battery fuse P1481 Replace battery fuse Replace battery fuse U1064 U1096, U1255
Inspect main wire harness/wiggle test/replace igni- Serial data missing tion fuse Inspect harness/wiggle test/replace main fuse Replace fuse Replace accessory fuse Serial data missing Engine cranks but will not start No check engine lamp
6733 7181 7313 7937 5832 6841 6734 7904 7909
0.3 0.2 0.3 0.4 0.3 0.4 0.3 0.4 0.2
0.3 0.2 0.3 0.4 0.3 0.4 0.3 0.4 0.2
0.3 0.2 0.3 0.4 0.3 0.4 0.3 0.4 0.2
0.3 0.2 0.3 0.4 0.3 0.4 0.3 0.4 0.2
0.4 0.3 0.4 0.5 0.4 0.5 0.4 0.5 0.3
0.4 0.3 0.4 0.5 0.4 0.5 0.4 0.5 0.3
Harness inspection/wiggle test/replace ECM fuse P1003, P1351, P1354 Replace starter relay Replace starter relay Replace system relay Replace system relay Replace system relay Starter testing, nothing clicks B1134 Serial data missing P1001, P1003 P1002, P1004
2010 VRSC Models
4-18
HFH = VRSCAW
HFJ = VRSCAW 105
HHH = VRSCDX
HHJ = VRSCDX 105
HPH = VRSCF
HPJ = VRSCF 105

CHARGING CIRCUIT Milliamp draw Replace stator Total current draw AC output Replace voltage regulator Replace voltage regulator Replace rotor Replace battery Low battery after extended ignition off Low or no charging Diagnose charging system Diagnose charging system No or low charging, overcharging Serial data missing No or low charging Engine cranks but will not start 5308 5309 5310 5314 5316 6724 5319 7185 7771 0.3 0.8 0.4 0.8 0.8 0.5 0.9 0.3 0.2 0.3 0.8 0.4 0.8 0.8 0.5 0.9 0.3 0.2 0.3 0.8 0.4 0.8 0.8 0.5 0.9 0.3 0.2 0.3 0.8 0.4 0.8 0.8 0.5 0.9 0.3 0.2 0.4 1.0 0.4 0.8 0.8 0.6 1.1 0.5 0.3 0.4 1.0 0.4 0.8 0.8 0.6 1.1 0.5 0.3
Repair charging system/accompanies other codes B1007, B0563, P0562, P0563, C0562, C0563 STARTER CIRCUIT Replace starter motor Replace starter motor Replace limiter assembly Replace ball clutch assembly Replace starter solenoid Repair starting system, use in conjunction with additional code(s) IGNITION CIRCUIT Replace spark plugs Replace spark plugs Replace spark plug Replace spark plug Replace ignition coil Replace front ignition coil Replace ignition coil Misfire at idle or under load, rough or rolling idle Engine cranks but will not start P1353, P1357 P1356, P1358 Misfire at idle or under load, rough or rolling idle P1353, P1357 P1356, P1358 Solenoid clicks Starter spins, but does not engage Starter spins Starter runs on Starter testing, starter relay clicks Engine cranks but will not start
5817 5825 5837 5839 5845 7166
0.8 0.9 0.3 0.6 0.6 0.2
0.8 0.9 0.3 0.6 0.6 0.2
0.8 0.9 0.3 0.6 0.6 0.2
0.8 0.9 0.3 0.6 0.6 0.2
0.8 0.9 0.5 0.8 0.8 0.3
0.8 0.9 0.5 0.8 0.8 0.3
7134 7520 7536 7548 7139 7531 7532
0.7 0.6 0.5 0.3 0.7 0.6 0.3
0.7 0.6 0.5 0.3 0.7 0.6 0.3
0.7 0.6 0.5 0.3 0.7 0.6 0.3
0.7 0.6 0.5 0.3 0.7 0.6 0.3
0.9 0.8 0.7 0.5 0.9 0.8 0.5
0.9 0.8 0.7 0.5 0.9 0.8 0.5
2010 VRSC Models
4-19
HFH = VRSCAW
HFJ = VRSCAW 105
HHH = VRSCDX
HHJ = VRSCDX 105
HPH = VRSCF
HPJ = VRSCF 105

7856 7858
MODELS HFH
0.5 0.6
HFJ
0.5 0.6
HHH
0.5 0.6
HHJ
0.5 0.6
HPH
0.7 0.8
HPJ
0.7 0.8
Replace ignition coil Replace ignition coil AIR INTAKE Repair intake leak FUEL SYSTEM Replace fuel level sensor Replace purge solenoid Replace fuel filter or clean fuel pump screen
P1354, P1355 Engine cranks but will not start, P1351, P1352
P0131, P0151
7486
1.0
1.0
1.0
1.0
1.2
1.2
B1004, B1005, stop lamp inoperative P0444, P0445 Misfire at idle or under load, rough or rolling idle, starts - then stalls, engine cranks but will not start, P1353, P1356-P1358
6035 6861 7013
0.5 0.4 1.1
0.5 0.4 1.1
0.5 0.4 1.1
0.5 0.4 1.1
0.5 0.5 1.1
0.5 0.5 1.1
Repair or replace fuel pump, hoses, or filter - fuel delivery failure
Misfire at idle or under load, rough or rolling idle, starts - then stalls, engine cranks but will not start, P1353, P1356-P1358
7014
1.1
1.1
1.1
1.1
1.3
1.3
Replace fuel filter screen
P0131, P0151
7163 7164
1.0 1.0
1.0 1.0
1.0 1.0
1.0 1.0
1.0 1.0
1.0 1.0
Repair/Replace fuel pump/pressure regulator/fuel P0131, P0132, P0151, P0152 line/fuel filter Replace fuel injector Misfire at idle or under load, Rough or rolling idle, P0131, P0132, P0151, P0152 Replace fuel injector Replace fuel injector Replace fuel pump Replace fuel pressure regulator SENSORS AND ECM Replace jiffy stand sensor IAC system OK, may use with other codes Replace idle air control (IAC) Replace engine temperature (ET) sensor Replace engine temperature (ET) sensor P1501, P1502 P0505 P0505 Emits black smoke P0117, P0118 Emits black smoke, P0261-P0264 Engine cranks but will not start Engine cranks but will not start Emits black smoke
7144
1.1
1.1
1.1
1.1
1.3
1.3
7596 7992 7415 7480
0.6 0.8 0.4 0.6
0.6 0.8 0.4 0.6
0.6 0.8 0.4 0.6
0.6 0.8 0.4 0.6
0.8 1.0 0.4 0.6
0.8 1.0 0.4 0.6
5085 7028 7490 7598 7710
0.4 0.5 0.5 0.7 0.6
0.4 0.5 0.5 0.7 0.6
0.4 0.5 0.5 0.7 0.6
0.4 0.5 0.5 0.7 0.6
0.4 0.7 0.7 0.9 0.8
0.4 0.7 0.7 0.9 0.8
2010 VRSC Models
4-20
HFH = VRSCAW
HFJ = VRSCAW 105
HHH = VRSCDX
HHJ = VRSCDX 105
HPH = VRSCF
HPJ = VRSCF 105

7667 7725 7760 7981 7982 7152 7597 7630 7590 7595 7939 7967 7149 7534 7555 7565
MODELS HFH
0.6 0.3 0.4 0.4 0.3 1.1 0.6 0.5 0.8 0.5 0.4 0.4 2.0 1.0 0.6 0.8
HFJ
0.6 0.3 0.4 0.4 0.3 1.1 0.6 0.5 0.8 0.5 0.4 0.4 2.0 1.0 0.6 0.8
HHH
0.6 0.3 0.4 0.4 0.3 1.1 0.6 0.5 0.8 0.5 0.4 0.4 2.0 1.0 0.6 0.8
HHJ
0.6 0.3 0.4 0.4 0.3 1.1 0.6 0.5 0.8 0.5 0.4 0.4 2.0 1.0 0.6 0.8
HPH
0.7 0.5 0.6 0.5 0.4 1.3 0.8 0.7 1.0 0.7 0.5 0.5 2.2 1.2 0.8 1.0
HPJ
0.7 0.5 0.6 0.5 0.4 1.3 0.8 0.7 1.0 0.7 0.5 0.5 2.2 1.2 0.8 1.0
Replace oxygen sensor Replace intake air temp (IAT) sensor Replace intake air temp (IAT) sensor Replace crankshaft position (CKP) sensor Clean or repair crankshaft position (CKP) sensor Replace MAP Sensor Replace MAP Sensor Replace MAP Sensor Replace throttle position sensor Replace throttle position sensor Clean or Repair vehicle speed sensor (VSS) Replace vehicle speed sensor (VSS) Replace ECM Replace ECM Replace ECM Replace ECM
P0131, P0132, P0134, P0151, P0152, P0154 P0112, P0113 P0112, P0113 P0373, P0374 P0373, P0374 Misfire at idle or under load, rough or rolling idle Emits black smoke, P0107, P0108, P0122 P0107 P0122 Engine cranks but will not start, P0122, P0123 P0501 P0501, P0502 Misfire at idle or under load, rough or rolling idle P1353, P1357 P0112, P0117, P0123 P0107, P0108, P0122, P0262, P0264, P1351, P1352, P1354, P1355
Replace ECM Replace ECM Replace ECM Replace ECM
Emits black smoke P0261, P0263, P1501, P1502 P1002 Starts - then stalls, engine cranks but will not start, serial data missing, no check engine lamp, P0113, P0118, P0373, P0374, P0501, P0502, P0505, P0603, P0605, P1001, P1010, P1356, P1358, U1016, U1064
7601 7850 7902 7913
0.9 0.6 0.5 0.7
0.9 0.6 0.5 0.7
0.9 0.6 0.5 0.7
0.9 0.6 0.5 0.7
1.1 0.7 0.6 0.9
1.1 0.7 0.6 0.9
Replace ECM
P0131, P0132, P0134, P0151, P0152, P0154, P0444, P0445, U1300, U1301, P1481, P1482
7993
0.8
0.8
0.8
0.8
0.9
0.9
2010 VRSC Models
4-21
HFH = VRSCAW
HFJ = VRSCAW 105
HHH = VRSCDX
HHJ = VRSCDX 105
HPH = VRSCF
HPJ = VRSCF 105

TURN SIGNALS/INSTRUMENTS/SECURITY SYSTEM Perform ECM/ TSM/TSSM/HFSM module replace- P1009 ment procedure Replaced TSM/TSSM/HFSM, system now ok Replace ECM, remove TSM/TSSM/HFSM Replaced TSM/TSSM/HFSM, system now ok Replace FOB battery Replace FOB Replace Bulb Replace bulb Remove corrosion Remove corrosion/Replace bulb Replace lamp assembly P1009 P1009 P1010 Fails to disarm Fails to disarm B1121, B1122 Flash at double normal rate, one lamp inoperative Flash at double normal rate Flash at double normal rate Flash at double normal rate, one lamp inoperative, B1121, B1122 Replace siren Replace security antenna Replace security antenna harness Replace tail lamp assembly - VRSCF only Replace front turn signal module - VRSCF only B1131, B1132 Fails to disarm, B1143-B1145 B1145 B1123-B1126 Flash at double normal rate, one lamp inoperative, B1123-B1126 Replace front turn signal lamp - VRSCF only Flash at double normal rate, headlamp inoperative, B1121, B1122 Replace front turn signal module and tail lamp assembly - VRSCF only Replace rear lamp assembly - VRSCF only Replace instrument module Flash at double normal rate, one lamp inoperative High beam indictor inoperative, turn signal indicator inoperative, B1003 Replace instrument module B1008 6020 0.1 0.1 0.1 0.1 0.1 0.1 6894 6006 --0.2 --0.2 --0.2 --0.2 0.5 0.3 0.5 0.3 B1121, B1122 6893 --------0.9 0.9 6892 --------1.5 1.5 6832 6878 6881 6890 6891 0.5 0.3 0.4 ----0.5 0.3 0.4 ----0.5 0.3 0.4 ----0.5 0.3 0.4 ----0.6 0.4 0.5 0.8 0.7 0.6 0.4 0.5 0.8 0.7 6702 6703 6707 6755 6756 6796 6820 6821 6822 6823 0.4 0.8 0.3 0.1 0.1 0.3 0.2 0.3 0.5 0.6 0.4 0.8 0.3 0.1 0.1 0.3 0.2 0.3 0.5 0.6 0.4 0.8 0.3 0.1 0.1 0.3 0.2 0.3 0.5 0.6 0.4 0.8 0.3 0.1 0.1 0.3 0.2 0.3 0.5 0.6 0.5 0.9 0.4 0.1 0.1 ----0.4 ----0.5 0.9 0.4 0.1 0.1 ----0.4 ----6701 0.4 0.4 0.4 0.4 0.5 0.5
2010 VRSC Models
4-22
HFH = VRSCAW
HFJ = VRSCAW 105
HHH = VRSCDX
HHJ = VRSCDX 105
HPH = VRSCF
HPJ = VRSCF 105

6033 6039 6826
MODELS HFH
0.2 0.6 0.5
HFJ
0.2 0.6 0.5
HHH
0.2 0.6 0.5
HHJ
0.2 0.6 0.5
HPH
0.2 0.7 0.6
HPJ
0.2 0.7 0.6
Replace instrument module Replace instrument module Replace instrument module
B1004 U1300, U1301 Headlamp inoperative, stop lamp inoperative, serial data missing, B1121, B1122, U1096, U1255
Replace instrument module
No check engine lamp, IM inoperative, oil pressure lamp always on, oil pressure lamp inoperative, neutral lamp always on, neutral lamp inoperative
7311
0.3
0.3
0.3
0.3
0.4
0.4
Replace TSM/TSSM/HFSM Replace TSM/TSSM/HFSM Replace TSM/TSSM/HFSM Replace TSM/TSSM/HFSM
Nothing clicks Fails to disarm Will not cancel upon turn completion Starter inoperative, flash at double normal rate, B1121-B1126, B1134, B1141
5838 6757 6773 6791
0.9 0.3 0.9 0.6
0.9 0.3 0.9 0.6
0.9 0.3 0.9 0.6
0.9 0.3 0.9 0.6
0.9 0.3 1.0 0.7
0.9 0.3 1.0 0.7
Replace TSM/TSSM/HFSM Replace TSM/TSSM/HFSM
B1131, B1132 Neutral lamp always on, serial data missing, B1135, B1136, B1142, B1154, B1155, U1064, U1255
6833 6845
0.7 0.5
0.7 0.5
0.7 0.5
0.7 0.5
0.7 0.6
0.7 0.6
Replace TSM/TSSM/HFSM Replace TSM/TSSM/HFSM ABS BRAKES Replace ABS diode pack Replace rear brake lamp switch Note: Includes brake bleeding and verifying system function with Digital Technician II. Faulty wheel speed sensor routing or wiring damage Worn or damaged wheel bearings or suspension components, may be used in conjunction with other codes Repair or replace front brake light switch
B1143-B1145 U1300, U1301
6880 7998
0.4 0.8
0.4 0.8
0.4 0.8
0.4 0.8
0.5 0.9
0.5 0.9
Stop lamp inoperative, C1095, C1216 C1212, C1214
1404 1409
0.3 0.9
0.3 0.9
0.3 0.9
0.3 0.9
0.5 0.9
0.5 0.9
C1021, C1023, C1025, C1027, C1206, C1208
1411
1.0
1.0
1.0
1.0
1.0
1.0
C1021, C1023, C1025, C1027, C1206, C1208
1412
0.2
0.2
0.2
0.2
0.2
0.2
C1094, C1212
1413
1.1
1.1
1.1
1.1
1.1
1.1
2010 VRSC Models
4-23
HFH = VRSCAW
HFJ = VRSCAW 105
HHH = VRSCDX
HHJ = VRSCDX 105
HPH = VRSCF
HPJ = VRSCF 105

1418 1427
MODELS HFH
0.7 2.1
HFJ
0.7 2.1
HHH
0.7 2.1
HHJ
0.7 2.1
HPH
0.7 2.1
HPJ
0.7 2.1
Reroute brake lines Replace ABS HCU (Hydraulic control unit) Note: Includes brake bleeding and verifying system function with Digital Technician II.
C1151, C1153 C1014, C1017, C1018, C0562, C1021, C1023, C1025, C1027, C1032, C1034, C1042, C1043, C1055, C1056, C1057, C1061, C1062, C1065, C1066, C1094, C1095, C1118, C1121, C1151, C1153, C1158, C1206, C1208, C1214, C1216, U1300, U1301
Replace ABS ECU (Electronic control unit) Note: Includes brake bleeding and verifying system function with Digital Technician II.
C1014, C1017, C1018, C0562, C1021, C1023, C1025, C1027, C1032, C1034, C1042, C1043, C1055, C1056, C1057, C1061, C1062, C1065, C1066, C1094, C1095, C1118, C1121, C1151, C1153, C1158, C1206, C1208, C1214, C1216, U1300, U1301
2430
2.1
2.1
2.1
2.1
2.1
2.1
Replace ABS front wheel sensor Replace rear wheel speed sensor
C1021, C1025, C1032, C1206 C1023, C1027, C1034, C1208
2439 2440
0.8 1.3
0.8 1.3
0.8 1.3
0.8 1.3
0.8 1.3
0.8 1.3
2010 VRSC Models
4-24
SUBJECT..............................................................................................................PAGE NO. 5.1 Service........................................................................................................................5-1 5.2 Chassis.......................................................................................................................5-2 5.3 Engine.........................................................................................................................5-9 5.4 Drive and Clutch........................................................................................................5-15 5.5 Transmission.............................................................................................................5-16 5.6 OEM Accessories......................................................................................................5-17 5.7 Electrical - General....................................................................................................5-19 5.8 FLHT/FLTR Diagnostics............................................................................................5-23 Unless otherwise specified, Job Times shown include all operations necessary to complete the listed job.
FLHT/FLTR MODELS
FV4 = FLHT KB4 = FLHX
FF4 = FLHTC FL4 = FLHTCU Shrine
FC4 = FLHTCU FMM = FLHTP
FG4 = FLHTCU w/Sidecar KEM = FLHTK
KH4 = FLTRX
Table 5-1. Service

ITEM DESCRIPTION LABOR CODE MODELS FV4 KB4 FF4 FC4 FL4 FG4 KEM FMM KH4
NEW Set-up and predelivery 1,000 (1,600 km) mile service REGULAR 5,000 (8,000 km) mile maintenance 10,000 (16,000 km) mile maintenance 15,000 (24,000 km) mile maintenance 20,000 (32,000 km) mile maintenance 25,000 (40,000 km) mile maintenance 30,000 (48,000 km) mile maintenance 35,000 (56,000 km) mile maintenance 40,000 (64,000 km) mile maintenance 45,000 (72,000 km) mile maintenance 50,000 (80,000 km) mile maintenance Addition to any maintenance- required every 2 years Addition to any maintenance- required every 2 years Addition to 1,000, 5,000 and 20,000 mile (1,600, 8,000, and 32,000 km) maintenance and every 15,000 mile (24,000 km) interval there after flush/fill D.O.T 4 brake fluid- front and rear NONABS models flush/fill D.O.T 4 brake fluid- front and rear ABS models Tighten spoke wheels if equipped, time per wheel --0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 --1.2 1.2 1.2 1.2 1.2 1.2 1.2 1.2 ----------------------1.8 2.3 1.6 2.6 2.9 2.5 1.8 2.4 1.4 7.0 0.6 1.8 2.3 1.6 2.6 2.9 2.5 1.8 2.4 1.4 7.0 0.6 1.8 2.3 1.6 2.6 2.9 2.5 1.8 2.4 1.4 7.0 0.6 1.8 2.3 1.6 2.6 2.9 2.5 1.8 2.4 1.4 7.0 0.6 2.3 2.8 2.1 3.2 3.4 3.0 2.3 2.9 1.9 7.5 0.6 1.8 2.3 1.6 2.6 2.9 2.5 1.8 2.4 1.4 7.0 0.6 1.8 2.3 1.6 2.6 2.9 2.5 1.8 2.4 1.4 7.0 0.6 1.8 2.3 1.6 2.6 2.9 2.5 1.8 2.4 1.4 7.0 0.6 ----2.0 2.5 2.0 2.5 2.2 2.5 2.5 2.5 2.5 3.0 2.5 2.5 2.0 2.5 2.0 2.5
2010 FLHT/FLTR Models
5-1
KH4 = FLTRX
Table 5-2. Chassis

PAINT REPAIR NOTE: use these codes when repairing any painted part on vehicle with the Kent Moore finesse kit or other paint repair methods Light scuff/scratch - buff Light sanding/buff/blend Buff entire part Repair build up in clear/paint Color blend/paint/buff DRIVE Adjust secondary belt Replace secondary belt Replace rear wheel sprocket Replace rear wheel sprocket bearing Replace rear wheel compensator cushion WHEELS Replace tire or inner tube - includes balancing Replace tire or inner tube - includes balancing Replace wheel assembly - includes disc and sprocket exchange, bearing install and balancing Replace wheel assembly - includes disc and sprocket exchange, bearing install and balancing Replace rim, hub or spokes- includes truing and balancing Replace rim, hub or spokes- includes truing and balancing Replace wheel bearings Replace wheel bearings Check or true spoked wheel front rear each wheel 2136 2141 2155 0.7 0.9 0.5 0.7 0.9 0.5 0.7 0.9 0.5 0.7 0.9 0.5 0.7 0.9 0.5 0.7 0.9 0.5 0.7 0.9 --0.7 0.9 0.5 rear 2121 2.4 2.4 2.4 2.4 2.4 2.4 --2.4 front 2116 2.2 2.2 2.2 2.2 2.2 2.2 --2.2 rear 2114 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 front rear front 2106 2111 2113 0.6 0.8 1.0 0.6 0.8 1.0 0.6 0.8 1.0 0.6 0.8 1.0 0.6 0.8 1.0 0.6 0.8 1.0 0.6 0.8 1.0 0.6 0.8 1.0 both at PDI only 2010 2011 2021 2012 2013 0.3 3.4 0.8 1.0 0.9 0.3 3.4 0.8 1.0 0.9 0.3 3.4 0.8 1.0 0.9 0.3 3.4 0.8 1.0 0.9 0.3 3.4 0.8 1.0 0.9 0.3 3.4 0.8 1.0 0.9 0.3 3.4 0.8 1.0 0.9 0.3 3.4 0.8 1.0 0.9 1102 1104 1106 1108 1110 0.2 0.4 0.6 0.8 1.0 0.2 0.4 0.6 0.8 1.0 0.2 0.4 0.6 0.8 1.0 0.2 0.4 0.6 0.8 1.0 0.2 0.4 0.6 0.8 1.0 0.2 0.4 0.6 0.8 1.0 0.2 0.4 0.6 0.8 1.0 0.2 0.4 0.6 0.8 1.0
5-2
KH4 = FLTRX
Table 5-2. Chassis

HANDLEBARS Replace handlebars Replace handlebars Replace clutch hand lever Replace clutch hand lever bracket Replace both rubber handlebar mounts Replace rubber handlebar grip Replace handlebar riser Replace handlebar clamp FRAME/SWING ARM/FRONT FORK Adjust steering head bearings Change front fork oil Replace frame both sides includes removal and installation of all accessories and motorcycle components Replace tail section sub frame Replace rear frame section and tag bracket Replace front fork assembly includes removal and installation of upper and lower fork brackets Replace lower fork bracket and stem Replace steering head cups and bearings Replace upper fork bracket Service or replace fork slider and/or seal includes one side removal, disassembly, cleaning, inspection, replacing parts, servicing damper tube, replacing bushings, assembly and installation including bearing adjustment 2316 2321 2326 2341 3.2 3.2 2.7 2.4 3.2 3.2 2.7 2.4 3.2 3.2 2.7 2.4 3.2 3.2 2.7 2.4 3.2 3.2 2.7 2.4 3.2 3.2 2.7 2.4 3.2 3.2 2.7 2.4 3.2 3.2 2.7 2.1 2339 2308 2311 1.6 --3.0 1.6 --3.0 2.4 --3.0 2.4 --3.0 2.4 --3.0 2.4 --3.0 1.8 1.0 3.0 1.6 --3.0 2290 --2306 0.7 2.2 17.0 0.7 2.2 17.0 0.7 2.2 17.2 0.7 2.2 17.5 0.7 2.2 17.5 0.7 2.2 17.5 0.7 2.2 17.0 0.7 1.8 17.0 includes removing radio, if applicable NOTE: for heated grips see diagnostic section one or both - includes loosening radio, if applicable includes removing radio, if applicable includes removing radio 2176 2206 2221 2226 2246 2251 2253 2254 1.4 --0.2 0.2 1.0 0.2 1.0 0.8 --1.5 0.2 0.2 1.0 0.2 1.0 0.8 --1.5 0.2 0.2 1.0 0.2 1.0 0.8 --1.5 0.2 0.2 1.0 0.2 1.0 0.8 --1.5 0.2 0.2 1.0 0.2 1.0 0.8 --1.8 0.2 0.2 1.0 --1.0 0.8 1.4 --0.2 0.2 1.0 0.2 1.0 0.8 --1.3 0.2 0.2 1.0 0.2 1.0 0.8
5-3
KH4 = FLTRX
Table 5-2. Chassis

2342
MODELS FV4
2.9
KB4
2.9
FF4
2.9
FC4 FL4
2.9
FG4
2.9
KEM
2.9
FMM
2.9
KH4
2.5
Service or replace fork slider and/or seal includes both sides removal, disassembly, cleaning, inspection, replacing parts, servicing damper tube, replacing bushings, assembly and installation Replace fork side Replace fork side Replace fork tube Replace fork tube Replace fork slider cover Replace rear swing arm and/or bearings Replace rear fork pivot shaft Replace rear shock air line Replace rear shock absorber assembly Replace rear shock absorber assembly Replace jiffy stand Replace jiffy stand Replace jiffy stand Replace footboard or foot peg Replace footboard insert Replace motor mount Replace motor mount Replace motor mount BRAKES Replace hydraulic brake line does not include bleeding brakes, use with appropriate bleed code (non ABS vehicles only) front (non ABS vehicles) rear right rear left both front rubber mounts and/or front mount bracket one side both sides complete spring and/or stand rubber bumper one side both sides one side both sides one side
2346 2351 2356 2361 2499 2366 2368 2369 2371 2376 2391 2396 2399 2394 2299 2395 2397 2398
1.2 1.5 2.0 2.5 1.3 1.9 0.8 0.2 0.2 0.4 0.3 0.2 0.1 0.2 0.1 1.2 0.3 1.4
1.2 1.5 2.0 2.5 1.3 1.9 0.8 0.2 0.2 0.4 0.3 0.2 0.1 0.2 0.1 1.2 0.3 1.4
1.2 1.5 2.0 2.5 1.3 1.9 0.8 0.2 0.2 0.4 0.3 0.2 0.1 0.2 0.1 1.2 0.3 1.4
1.2 1.5 2.0 2.5 1.3 1.9 0.8 0.2 0.2 0.4 0.3 0.2 0.1 0.2 0.1 1.2 0.3 1.4
1.2 1.5 2.0 2.5 1.3 1.9 0.8 0.2 0.2 0.4 0.3 0.2 0.1 0.2 0.1 1.2 0.3 1.4
1.2 1.5 2.0 2.5 1.3 1.9 0.8 0.2 0.2 0.4 0.3 0.2 0.1 0.2 0.1 1.2 0.3 1.4
1.2 1.5 2.0 2.5 1.3 1.9 0.8 0.2 0.2 0.4 0.3 0.2 0.1 0.2 0.1 1.2 0.3 1.4
1.2 1.5 1.6 2.1 1.3 1.9 0.8 0.2 0.2 0.4 0.3 0.2 0.1 0.2 0.1 1.2 0.3 1.4
2406
0.8
0.8
0.8
0.8
0.8
---
0.8
0.8
5-4
KH4 = FLTRX
Table 5-2. Chassis

2411
MODELS FV4
0.4
KB4
0.4
FF4
0.4
FC4 FL4
0.4
FG4
0.4
KEM
---
FMM
0.4
KH4
0.4
Replace hydraulic brake line does not include bleeding brakes, use with appropriate bleed code (non ABS vehicles only) Replace hydraulic brake line does not include code (ABS vehicles only) Replace hydraulic brake line does not include code (ABS vehicles only) Replace hydraulic brake line does not include filling/bleeding brakes, use with appropriate bleed code (ABS vehicles only) Replace hydraulic brake line does not include filling/bleeding brakes, use with appropriate bleed code (ABS vehicles only) Replace brake pads Replace brake pads
rear (non ABS vehicles)
front, mastercylinder to ABS unit (ABS vehicles
2463
1.1
1.1
1.1
1.1
1.1
1.1
1.1
1.1
filling/bleeding brakes, use with appropriate bleed only)
rear, master cylinder to ABS unit (ABS vehicles
2464
0.3
0.3
0.3
0.3
0.3
0.3
0.3
0.3
front, ABS unit to calipers (ABS vehicles only)
2465
1.1
1.1
1.1
1.1
1.1
1.1
1.1
1.1
rear, ABS unit to rear caliper (ABS vehicles only)
2467
0.3
0.3
0.3
0.3
0.3
0.3
0.3
0.3
front each caliper rear
2416 2421 2426
0.1 0.3 0.3
0.1 0.3 0.3
0.1 0.3 0.3
0.1 0.3 0.3
0.1 0.3 0.3
0.1 0.3 0.3
0.1 0.3 0.3
0.1 0.3 0.3
Replace brake caliper does not include bleeding front each caliper brakes, use with appropriate bleed code Replace brake caliper does not include bleeding rear brakes, use with appropriate bleed code Replace rear brake caliper mount Replace brake caliper screen Replace brake rotor Replace brake rotor Replace brake rotor Bleed brake caliper Bleed brake caliper front each caliper front one side front both sides rear front (both) - non ABS rear - non ABS
2431
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
2408 2428 2436 2437 2441 2442 2443
0.5 0.1 0.3 0.4 1.0 0.3 0.2
0.5 0.1 0.3 0.4 1.0 0.3 0.2
0.5 0.1 0.3 0.4 1.0 0.3 0.2
0.5 0.1 0.3 0.4 1.0 0.3 0.2
0.5 0.1 0.3 0.4 1.0 0.3 0.2
0.5 0.1 0.3 0.4 1.0 -----
0.5 0.1 0.3 0.4 1.0 0.3 0.2
0.5 0.1 0.3 0.4 1.0 0.3 0.2
5-5
KH4 = FLTRX
Table 5-2. Chassis

2446
MODELS FV4
0.6
KB4
0.6
FF4
0.6
FC4 FL4
0.6
FG4
0.6
KEM
0.6
FMM
0.6
KH4
0.6
Bleed brake caliper front (one or two calipers) or ABS vehicles only - includes bleeding and verifying rear caliper Replace master cylinder assembly - does not include bleeding brakes, use with appropriate bleed code Replace master cylinder assembly - does not include bleeding brakes, use with appropriate bleed code Replace master cylinder cover Rebuild master cylinder assembly does not include bleeding brakes, use with appropriate bleed code Rebuild master cylinder assembly does not include bleeding brakes, use with appropriate bleed code Replace ABS hydrallic control unit (HCU) or gasket, used if module leaking, includes bleeding both brakes and verifying system function with Digital Technician II (ABS vehicles only) Replace rear brake pedal Replace front brake lever SEATS/FENDERS/TANKS Replace seat and/or strap or spring(s) and / or hinge bracket Replace top frame cover (solo seat) Replace seat air spring Replace air tank Replace air line Replace fender Replace fender front rear (includes installing new wire conduit and facia if applicable) rear front or rear front rear system function with Digital Technician II front
2461
0.3
0.3
0.3
0.3
0.3
0.3
0.3
0.3
2466
0.4
0.4
0.4
0.4
0.4
0.4
0.4
0.4
2479 2471
0.1 0.4
0.1 0.4
0.1 0.4
0.1 0.4
0.1 0.4
0.1 0.4
0.1 0.4
0.1 0.4
2476
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
2473
1.7
1.7
1.7
1.7
1.7
1.7
1.7
1.7
2492 2494
0.3 0.2
0.3 0.2
0.3 0.2
0.3 0.2
0.3 0.2
0.3 0.2
0.3 0.2
0.3 0.2
2506
0.1
0.1
0.1
0.1
0.1
0.1
0.2
0.1
2510 2514 2516 2518 2526 2531
--------1.0 1.0
--------1.0 1.0
--------1.0 1.0
--------1.0 1.0
--------1.0 1.0
--------1.0 1.0
0.3 0.4 0.8 0.5 1.0 1.0
--------1.0 1.0
5-6
KH4 = FLTRX
Table 5-2. Chassis

2525 2528 2529 2533 left or right 2536 2541 2553 2558 2559
MODELS FV4
0.4 ----0.7 0.2 1.2 0.3 0.2 0.1
KB4
0.4 0.5 0.8 --0.2 1.2 0.3 0.2 0.1
FF4
0.4 ----0.7 0.2 1.2 0.3 0.2 0.1
FC4 FL4
0.4 ----0.7 0.2 1.2 0.3 0.2 0.1
FG4
0.4 ----0.7 0.2 1.2 0.3 0.2 0.1
KEM
0.4 ----0.7 0.2 1.2 0.3 0.2 0.1
FMM
0.4 ----0.7 0.2 1.2 0.3 0.2 0.1
KH4
0.4 0.5 0.8 --0.2 1.2 0.3 0.2 0.1
Replace license plate mount Replace rear fender facia/ground effects Replace rear fender facia/ground effects stud plate one or both Replace rear fender wire conduit Replace rear fender support cover Replace fuel tank assembly Replace fuel tank console/instrument panel Replace fuel tank console insert Replace fuel tank console fuel door or fuel door lock Replace fuel tank console rubber mounting strip Replace fuel level sending unit Replace fuel tank check valve assembly Replace canopy gasket Replace fuel filter Replace fuel transfer hose inside tank Replace fuel tank trim or medallion Replace oil filter BELT GUARDS Replace rear belt guard debris deflector EXHAUST SYSTEM Replace complete exhaust system and/or gaskets Replace exhaust pipe Replace exhaust pipe right side header assembly and/or port gaskets left side cross under pipe, support clamp and/or gasket (where applicable) Replace one muffler includes fuel line attached to check valve
2557 2564 2567 2570 2575 2579 6507 2582
0.2 0.5 0.6 0.4 0.5 0.5 --0.1
0.2 0.5 0.6 0.4 0.5 0.5 0.3 0.1
0.2 0.5 0.6 0.4 0.5 0.5 --0.1
0.2 0.5 0.6 0.4 0.5 0.5 0.3 0.1
0.2 0.5 0.6 0.4 0.5 0.5 0.3 0.1
0.2 0.5 0.6 0.4 0.5 0.5 0.3 0.1
0.2 0.5 0.6 0.4 0.5 0.5 --0.1
0.2 0.5 0.6 0.4 0.5 0.5 0.3 0.1
2616
0.2
0.2
0.2
0.2
0.2
0.2
0.2
0.2
2626 2631 2636
1.1 1.0 0.3
1.1 1.0 0.3
1.1 1.0 0.3
1.1 1.0 0.3
1.1 1.0 0.3
1.1 1.0 0.3
1.1 1.0 0.3
1.1 1.0 0.3
2646
0.2
0.2
0.2
0.2
0.2
0.2
0.2
0.2
5-7
KH4 = FLTRX
Table 5-2. Chassis

2651 2661 2666
MODELS FV4
0.4 0.1 0.2
KB4
0.4 0.1 0.2
FF4
0.4 0.1 0.2
FC4 FL4
0.4 0.1 0.2
FG4
0.4 0.1 0.2
KEM
0.4 0.1 0.2
FMM
0.4 0.1 0.2
KH4
0.4 0.1 0.2
Replace rear exhaust support bracket Replace any one exhaust shield Replace one muffler support
at transmission side cover
5-8
KH4 = FLTRX
Table 5-3. Engine

GENERAL Remove and install engine includes remove, replace, install oil passage gasket Remove and install engine includes remove, replace, install oil passage gasket Replace stabilizer link or stabilizer bracket top front 3005 3009 0.2 0.3 0.2 0.3 0.2 0.3 0.2 0.3 0.2 0.3 0.2 0.3 0.2 0.3 0.2 0.3 3006 4.5 4.5 4.5 4.8 4.8 4.8 4.5 4.5 California vehicles only 3006 4.6 4.6 4.6 4.9 --4.9 --4.6
Remove and replace oil pan for inspection/decon- with engine removed tamination Replace dipstick CYLINDER HEAD Recondition cylinder head includes removal of head and gasket, remove carbon, service valve guides, grind valves and seats, test springs and install head and gaskets. Recondition cylinder head includes removal of head and gasket, remove carbon, service valve guides, grind valves and seats, test springs and install head and gaskets. Recondition cylinder head includes removal of head and gasket, remove carbon, service valve guides, grind valves and seats, test springs and install head and gaskets. Replace cylinder head Replace cylinder head Replace valve seal or spring after cylinder head removal Replace valve seal or spring after cylinder head removal Replace cylinder head gasket/o-ring front cylinder both seals or springs (intake or exhaust) one head both heads one seal or spring (intake or exhaust ) both heads rear head front head
3480
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
3101
4.5
4.5
4.5
4.9
4.9
4.9
4.5
4.5
3103
4.5
4.5
4.5
4.9
4.9
4.9
4.5
4.5
3104
5.1
5.1
5.1
5.5
5.5
5.5
5.1
5.1
3106 3108 3131
3.5 4.4 0.1
3.5 4.4 0.1
3.5 4.4 0.1
3.9 4.8 0.1
3.9 4.8 0.1
3.9 4.8 0.1
3.5 4.4 0.1
3.5 4.4 0.1
3132
0.2
0.2
0.2
0.2
0.2
0.2
0.2
0.2
3140
2.6
2.6
2.6
3.0
3.0
3.0
2.6
2.6
5-9
KH4 = FLTRX
Table 5-3. Engine

3142 3143 3144 3145 3148 3149 3150 3147
MODELS FV4
2.6 3.0 0.8 0.8 0.9 0.7 1.4 1.2
KB4
2.6 3.0 0.8 0.8 0.9 0.7 1.4 1.2
FF4
2.6 3.0 0.8 0.8 0.9 0.7 1.4 1.2
FC4 FL4
3.0 3.4 0.8 0.8 0.9 0.7 1.4 1.6
FG4
3.0 3.4 0.8 0.8 0.9 0.7 1.4 1.6
KEM
3.0 3.4 0.8 0.8 0.9 0.7 1.4 1.6
FMM
2.6 3.0 0.8 0.8 0.9 0.7 1.4 1.2
KH4
2.6 3.0 0.8 0.8 0.9 0.7 1.4 1.2
Replace cylinder head gasket/o-ring Replace cylinder head gasket/o-ring Replace rocker arm covers and/or gaskets Replace rocker arm covers and/or gaskets Replace rocker arm covers and/or gaskets
rear cylinder both cylinders front cylinder rear cylinder both cylinders
Recondition rocker arms after heads are removed one head Recondition rocker arms after heads are removed both heads Replace lower rocker arm cover/gasket, or rocker front cylinder arms and /or shafts/rocker arm support Replace lower rocker arm cover/gasket, or rocker rear cylinder arms and /or shafts/rocker arm support Replace lower rocker arm cover/gasket, or rocker both cylinders arms and /or shafts/rocker arm support Replace cylinder o-ring/drain o-ring Replace cylinder o-ring/drain o-ring Replace cylinder o-ring/drain o-ring Replace crankcase umbrella valve Replace crankcase umbrella valve CYLINDER AND PISTON Recondition top end - includes disassembly, replacement of piston and sizing cylinder (.005 pistons), replacing piston rings and all items listed under recondition cylinder head and assembly. Recondition top end - includes disassembly, replacement of piston and sizing cylinder (.005 pistons), replacing piston rings and all items listed under recondition cylinder head and assembly. Replace piston rings includes deglazing cylinder one cylinder both pistons and cylinders one piston and cylinder front cylinder rear cylinder both cylinders one both
3152
1.2
1.2
1.2
1.6
1.6
1.6
1.2
1.2
3153
1.4
1.4
1.4
1.8
1.8
1.8
1.4
1.9
3161 3163 3168 3172 3174
2.8 2.8 3.2 1.1 1.2
2.8 2.8 3.2 1.1 1.2
2.8 2.8 3.2 1.1 1.2
3.2 3.2 3.6 1.1 1.2
3.2 3.2 3.6 1.1 1.2
3.2 3.2 3.6 1.1 1.2
2.8 2.8 3.2 1.1 1.2
2.8 2.8 3.2 1.1 1.2
3202
5.5
5.5
5.5
5.9
5.9
5.9
5.5
5.5
3203
6.1
6.1
6.1
6.5
6.5
6.5
6.1
6.1
3206
3.1
3.1
3.1
3.5
3.5
3.5
3.1
3.1
5-10
KH4 = FLTRX
Table 5-3. Engine

3216 3207
MODELS FV4
3.7 5.3
KB4
3.7 5.3
FF4
3.7 5.3
FC4 FL4
4.1 5.7
FG4
4.1 5.7
KEM
4.1 5.7
FMM
3.7 5.3
KH4
3.7 5.3
Replace piston rings includes deglazing cylinder both cylinders Recondition top end includes disassembly, deglazing cylinder and replacing rings, or replacing cylinder and piston, all items listed under recondition cylinder head and assembly. Recondition top end includes disassembly, deglazing cylinder and replacing rings, or replacing cylinder and piston, all items listed under recondition cylinder head and assembly. Recondition top end - includes disassembly, replacement of piston and bore and hone, resizing cylinder (.010 oversize or above), replacing piston rings and all items listed under recondition cylinder head and assembly. Recondition top end - includes disassembly, replacement of piston and bore and hone, resizing cylinder (.010 oversize or above), replacing piston rings and all items listed under recondition cylinder head and assembly. Replace piston and piston rings includes removal one cylinder of cylinder head and cylinder, fitting new piston with rings, resizing cylinder and assembly Replace piston and piston rings includes removal both cylinders of cylinder head and cylinder, fitting new piston with rings, resizing cylinder and assembly Replace cylinder and piston Replace cylinder and piston Replace one cylinder stud Replace all eight cylinder studs one cylinder both cylinders cylinder removed cylinders removed both pistons and cylinders one piston and cylinder both pistons and cylinders one piston and cylinder
3208
5.9
5.9
5.9
6.3
6.3
6.3
5.9
5.9
3211
5.9
5.9
5.9
6.3
6.3
6.3
5.9
5.9
3212
6.5
6.5
6.5
6.9
6.9
6.9
6.5
6.5
3221
3.7
3.7
3.7
4.1
4.1
4.1
3.7
3.7
3231
4.9
4.9
4.9
5.3
5.3
5.3
4.9
4.9
3236 3246 3253 3254
3.0 3.5 0.1 0.5
3.0 3.5 0.1 0.5
3.0 3.5 0.1 0.5
3.4 3.9 0.1 0.5
3.4 3.9 0.1 0.5
3.4 3.9 0.1 0.5
3.0 3.5 0.1 0.5
3.0 3.5 0.1 0.5
5-11
KH4 = FLTRX
Table 5-3. Engine

CAM COVER Replace lifter cover/gasket or lifter/and, or antirotation pin Replace lifter cover/gasket or lifter/and, or antirotation pin Replace push rod, push rod cover and/or o-ring or one or two same cylinder quad seal Replace push rod, push rod cover and/or o-ring or one each cylinder quad seal Replace cam cover and/or gasket Replace primary cam chain, sprockets and/or fastener Replace primary cam chain tensioner Replace cam support plate/o-rings Replace cam support plate Replace cam support bearing/cams/secondary cam chain/tensioner Replace oil pump and/or o-rings Replace cam bearing crankcase Replace cam bearing crankcase By pass valve inspection CRANKCASE Replace crankcases California vehicles only includes remove and install engine Replace crankcases Seal crankcase only Replace flywheels Replace right side main bearing includes remove and install engine California vehicles only includes remove and install engine 3406 3407 3411 3412 7.9 6.8 7.5 7.5 7.9 6.8 7.5 7.5 7.9 6.8 7.5 7.5 8.3 7.1 7.9 7.9 8.3 7.1 7.9 --8.3 7.1 7.9 7.9 7.8 6.7 7.4 --7.9 6.8 7.5 7.5 3406 8.0 8.0 8.0 8.4 --8.4 --8.0 one bearing two bearings 3341 3342 3343 3354 2.7 3.4 3.6 2.7 2.7 3.4 3.6 2.7 2.7 3.4 3.6 2.7 3.1 3.8 4.0 3.1 3.1 3.8 4.0 3.1 3.1 3.8 4.0 3.1 2.7 3.4 3.6 2.7 2.7 3.4 3.6 2.7 3328 3335 3337 3338 1.7 2.8 3.7 3.9 1.7 2.8 3.7 3.9 1.7 2.8 3.7 3.9 2.1 3.2 4.1 4.3 2.1 3.2 4.1 4.3 2.1 3.2 4.1 4.3 1.7 2.8 3.7 3.9 1.7 2.8 3.7 3.9 3325 3327 1.6 1.7 1.6 1.7 1.6 1.7 2.0 2.1 2.0 2.1 2.0 2.1 1.6 1.7 1.6 1.7 3318 1.6 1.6 1.6 2.0 2.0 2.0 1.6 1.6 3317 1.4 1.4 1.4 1.8 1.8 1.8 1.4 1.4 on both cylinders 3310 1.7 1.7 1.7 2.1 2.1 2.1 1.7 1.7 one or two same cylinder 3307 1.4 1.4 1.4 1.8 1.8 1.8 1.4 1.4
5-12
KH4 = FLTRX
Table 5-3. Engine

3412 California vehicles only 3410 3410 one both 3413 3414 3403 3420
MODELS FV4
7.4 7.0 6.9 3.0 3.4 0.1 0.1
KB4
7.4 7.0 6.9 3.0 3.4 0.1 0.1
FF4
7.4 6.9 6.8 3.0 3.4 0.1 0.1
FC4 FL4
7.8 7.1 7.0 3.4 3.8 0.1 0.1
FG4
7.8 --7.0 3.4 3.8 0.1 0.1
KEM
7.8 7.1 7.0 3.4 3.8 0.1 0.1
FMM
7.3 --6.8 2.9 3.3 0.1 0.1
KH4
7.4 7.0 6.9 3.0 3.4 0.1 0.1
Replace right side main bearing Replace left side main bearing Replace left side main bearing Piston jet/o-ring Piston jet/o-ring Replace crank position sensor o-ring Check flywheel trueness before assembly or after removal Recondition cylinder heads - head removed (for non-related repairs ) Recondition cylinder heads - head removed (for non-related repairs ) Replace piston rings cylinders removed (for non-related repairs deglaze only) Replace piston rings cylinders removed (for non-related repairs) includes resizing cylinders Replace oil filter mount end cap and/or gasket Replace oil cooler Replace oil cooler mounting bracket Replace oil cooler hose and/or clamp Replace oil filter mount/fittings FUEL SYSTEM Replace air cleaner backing plate Replace air cleaner cover Replace induction module Replace induction module seal Replace external fuel supply hose one or both both heads one head
3425
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
3426
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
3428
0.3
0.3
0.3
0.3
0.3
0.3
0.3
0.3
3430
1.4
1.4
1.4
1.4
1.4
1.4
1.4
1.4
4519 4525 4526 4528 4533
-----------
-----------
-----------
-----------
-----------
0.2 0.4 0.4 0.6 0.4
0.2 0.4 0.4 0.6 0.4
-----------
3501 3502 3508 3510 3514
0.2 0.1 1.1 1.2 0.2
0.2 0.1 1.1 1.2 0.2
0.2 0.1 1.1 1.2 0.2
0.2 0.1 1.1 1.2 0.2
0.2 0.1 1.1 1.2 0.2
0.2 0.1 1.1 1.2 0.2
0.2 0.1 1.1 1.2 0.2
0.2 0.1 1.1 1.2 0.2
5-13
KH4 = FLTRX
Table 5-3. Engine

EVAPORATIVE EMISSIONS SYSTEM Replace evaporative purge solenoid Replace canister Replace any one hose 3522 3527 3529 0.3 0.5 0.4 0.3 0.5 0.4 0.3 0.5 0.4 0.3 0.5 0.4 0.3 0.5 0.4 0.3 0.5 0.4 0.3 0.5 0.4 0.3 0.5 0.4
5-14
KH4 = FLTRX

DRIVE Replace derby cover and/or gasket/o-ring Replace primary chain Replace primary chain tensioner Replace engine sprocket Replace engine sprocket seal Replace primary cover Replace inner primary case and/or seals or mainshaft bearing Replace primary cover gasket Replace shift lever Replace shift lever shaft and/or inner lever Replace starter-primary o-ring CLUTCH Adjust clutch Replace release cable assembly Service the clutch includes disassembly, cleaning, inspection repair, assembly ,and adjustment Replace clutch release bearing and/or push rod Replace clutch release (ball ramp) and/or side cover 4016 4018 1.2 1.6 1.2 1.6 1.2 1.6 1.2 1.7 1.2 1.7 1.2 1.7 1.2 1.6 1.2 1.6 --4006 4011 0.2 1.2 1.3 0.2 1.2 1.3 0.2 1.2 1.3 0.2 1.4 1.3 0.2 1.4 1.3 0.2 1.4 1.3 0.2 1.2 1.3 0.2 1.2 1.3 heel or toe shifter includes removal of heel and toe shift levers 4009 4012 4017 4034 0.6 0.1 0.2 0.6 0.6 0.1 0.2 0.6 0.6 0.1 0.2 0.6 0.6 0.1 0.2 0.6 0.6 0.1 0.2 0.6 0.6 0.1 0.2 0.6 0.6 0.1 0.2 0.6 0.6 0.1 0.2 0.6 4001 4002 4033 4003 4005 4007 4008 0.1 0.9 0.8 0.9 2.4 0.6 2.1 0.1 0.9 0.8 0.9 2.4 0.6 2.1 0.1 0.9 0.8 0.9 2.4 0.6 2.1 0.1 0.9 0.8 0.9 2.4 0.6 2.1 0.1 0.9 0.8 0.9 2.4 0.6 2.1 0.1 0.9 0.8 0.9 2.4 0.6 2.1 0.1 0.9 0.8 0.9 2.4 0.6 2.1 0.1 0.9 0.8 0.9 2.4 0.6 2.1
5-15
KH4 = FLTRX

TRANSMISSION CASE Replace transmission case Replace transmission complete- Includes remove, replace, install oil passage gasket Overhaul transmission includes disassembly, cleaning, inspection, replacing parts (transmission case in frame) Replace transmission sprocket Replace main drive gear oil seal Replace mainshaft oil seal Replace side door gasket Replace shifter drum Replace shifter arm assembly or springs Replace transmission top cover and/or gasket Replace shifter forks and/or shaft Replace side door bearing Replace side door bearing Replace transmission case countershaft bearing Replace main drive gear and/or bearing Replace transmission side cover gasket Replace oil pan and/or gasket Replace transmission shift shaft seal Replace vehicle speed sensor o-ring one both in transmission case in main drive gear 4309 4311 4316 4321 4331 4336 4341 4343 4348 4351 4361 4366 4368 4378 4390 4380 2.6 2.7 2.2 2.8 2.9 3.0 0.6 2.9 3.1 3.2 3.1 3.4 1.1 0.9 2.2 0.7 2.6 2.7 2.2 2.8 2.9 3.0 0.6 2.9 3.1 3.2 3.1 3.4 1.1 0.9 2.2 0.7 2.6 2.7 2.2 2.8 2.9 3.0 0.6 2.9 3.1 3.2 3.1 3.4 1.1 0.9 2.2 0.7 2.6 2.7 2.2 2.8 2.9 3.0 0.6 2.9 3.1 3.2 3.1 3.4 1.1 0.9 2.2 0.7 2.6 2.7 2.2 2.8 2.9 3.0 0.6 2.9 3.1 3.2 3.1 3.4 1.1 0.9 2.2 0.7 2.6 2.7 2.2 2.8 2.9 3.0 0.6 2.9 3.1 3.2 3.1 3.4 1.1 0.9 2.2 0.7 2.6 2.7 2.2 2.8 2.9 3.0 0.6 2.9 3.1 3.2 3.1 3.4 1.1 0.9 2.2 0.7 2.6 2.7 2.2 2.8 2.9 3.0 0.6 2.9 3.1 3.2 3.1 3.4 1.1 0.9 2.2 0.7 4306 4.6 4.6 4.6 4.6 4.6 4.6 4.6 4.6 4304 4305 5.3 4.9 5.3 4.9 5.3 4.9 5.6 5.2 5.6 5.2 5.6 5.2 5.3 4.9 5.3 4.9
5-16
KH4 = FLTRX

ACCESSORIES Replace windshield Replace one fairing wind deflector Replace one mid frame air deflector Replace instrument panel support housing or inner fairing Remove outer fairing/diagnosis Replace saddlebag mounting bracket or bail head stud/retainer Replace saddlebag guard Replace outer fairing or support brace Replace a single saddlebag guard rail Replace a saddlebag Replace saddlebag lock Replace saddlebag cover Replace saddlebag bottom Replace tour-pak lock or latch Replace one saddlebag tether strap Replace one frame sidecover or mounting grommet Replace tour-pak hinge Replace inner fairing bracket Replace nameplate tour-pak Replace instrument nacelle Replace plastic sticker/instrument nacelle Replace outer headlight lens Replace tour-pak cover one cover only one bottom only complete 6254 6255 6256 6257 6259 6260 6244 6261 6262 6263 6264 6265 6266 6267 6268 6269 6270 0.3 0.3 --0.2 0.2 0.2 0.3 --0.1 0.1 --0.7 ------------0.3 --0.2 0.2 0.2 0.3 --0.1 0.1 --0.7 ----------0.3 0.3 0.2 0.2 0.2 0.2 0.3 0.2 0.1 0.1 0.3 0.8 0.2 ------0.7 0.3 0.3 0.2 0.2 0.2 0.2 0.3 0.2 0.1 0.1 0.3 0.9 0.2 ------0.7 0.3 0.3 0.2 0.2 0.2 0.2 0.3 0.2 0.1 0.1 0.3 0.9 0.2 ------0.7 0.3 0.3 --0.2 0.2 0.2 0.3 0.2 0.1 0.1 0.3 0.9 0.2 ------0.8 0.3 0.3 0.2 0.2 0.3 0.3 0.4 ----0.1 --0.7 ------------0.4 --0.2 0.2 0.2 0.3 --0.1 0.1 --1.0 --0.4 0.1 0.1 --6252 6253 --0.2 --0.2 --0.2 --0.2 --0.2 --0.2 --0.2 0.2 0.2 6203 6205 6201 6209 0.1 ----1.7 0.1 ----1.7 0.1 ----1.8 0.1 0.1 0.2 1.9 0.1 0.1 0.2 1.9 0.1 0.1 0.2 1.9 0.1 --0.2 1.7 0.1 ----1.8
5-17
KH4 = FLTRX

6243 6453 6271 left or right 6272 6242
MODELS FV4
----0.3 -----
KB4
----0.3 -----
FF4
0.9 --0.3 -----
FC4 FL4
1.4 --0.3 0.2 0.3
FG4
1.4 --0.3 0.2 0.3
KEM
1.4 0.2 0.3 0.2 0.3
FMM
----0.3 -----
KH4
-----------
Replace tour-pak bottom Replace tour-pak top rack Replace fairing cap Replace one fairing lower Replace one fairing lower glove compartment assembly or vent door Replace fairing lower vent door serrated washers left or right side, one or both washers Replace chrome fairing skirt Replace lock-set Replace bumper Replace bumper Replace highway bar Replace tour-pak mount/luggage rack Replace tour-pak includes lights and brackets, antenna assembly, backrest, and rear speakers Replace rear view mirror Replace backrest Replace amplifier Replace speaker Replace strobe lamp Repair or replace rear mount one or both front rear front
6241 6273 6276 6303 6305 6353 6453 6509
--0.2 0.5 --0.2 0.3 0.6 ---
--0.2 0.5 ----0.3 -----
--0.2 0.6 0.3 0.2 0.3 0.7 0.9
0.1 0.2 0.6 0.3 0.2 0.6 0.8 1.4
0.1 0.2 0.6 0.3 0.2 0.7 0.8 1.4
0.1 0.2 0.6 0.3 0.2 0.6 0.8 1.4
--0.2 0.5 0.3 0.2 0.4 0.7 ---
----0.5 ----0.6 -----
6513 6515 6521 6523 6526 6529
0.1 -----------
0.3 -----------
0.1 0.2 ---------
0.1 0.2 ---------
0.1 0.2 ---------
0.1 0.2 ---------
0.1 --0.2 0.1 0.6 0.3
0.1 -----------
5-18
KH4 = FLTRX

INSTRUMENTS Replace speedometer Replace tachometer Replace indicator panel lens Replace voltmeter or fuel gauge Replace oil pressure or air temperature gauge Replace ambient temperature sensor Replace odometer reset switch boot WIRING Replace connector housing Replace connector anchor Replace main wiring harness Replace audio harness Replace rear fender wiring harness Replace front fender wiring harness Replace interconnect harness Replace main harness trough/tray Replace main harness trough cover Replace auxiliary power outlet Replace front headset harness SWITCHES Replace ignition switch Replace fuse Replace main fuse or cover Replace main fuse block 5129 5145 5147 5151 0.8 0.2 0.2 0.5 0.8 0.2 0.2 0.5 0.8 0.2 0.2 0.5 0.8 0.2 0.2 0.5 0.8 0.2 0.2 0.5 0.8 0.2 0.2 0.5 0.8 0.2 0.2 0.5 0.8 0.2 0.2 0.5 Lower trough, or both lower trough and cover Trough cover only In tour pak Includes installing new conduit 5022 5023 5026 5027 5036 5049 5052 5078 5079 5116 6616 0.1 0.1 3.6 --1.0 0.9 0.5 0.9 0.4 ----0.1 0.1 3.6 --1.0 --0.5 0.9 0.4 ----0.1 0.1 3.6 --1.0 0.9 0.5 0.9 0.4 ----0.1 0.1 3.6 1.8 1.0 0.9 0.5 0.9 0.4 --0.7 0.1 0.1 3.6 1.8 1.0 0.9 0.5 0.9 0.4 --0.7 0.1 0.1 3.6 1.8 1.0 0.9 0.5 0.9 0.4 0.2 0.7 0.1 0.1 3.6 --1.0 0.9 0.5 0.9 0.4 ----0.1 0.1 3.6 --1.0 --0.5 0.9 0.4 ----Cosmetic issue Cosmetic issue 6003 6009 6018 6021 6026 6028 6043 0.3 0.3 0.3 0.3 0.3 --0.1 0.3 0.3 0.3 0.3 0.3 0.1 0.1 0.3 0.3 0.3 0.3 0.3 0.1 0.1 0.3 0.3 0.3 0.3 0.3 0.1 0.1 0.3 0.3 0.3 0.3 0.3 0.1 0.1 0.3 0.3 0.3 0.3 0.3 0.1 0.1 0.3 0.3 0.3 0.3 ----0.1 0.3 0.3 0.3 0.3 0.3 0.1 0.1
5-19
KH4 = FLTRX

5169 5173 5177 5178 5179 5180 5182 5183 5184 5186 5187 5188 5192 6143 Volume/PTT switch Any handlebar switch 6627 6953
MODELS FV4
0.2 0.7 0.2 0.3 0.2 0.7 1.2 1.0 --1.0 ----0.4 ----0.4
KB4
0.2 0.7 0.2 0.3 0.2 0.7 1.2 1.5 --1.4 ----0.4 ----0.4
FF4
0.2 0.7 0.2 0.2 0.2 0.7 1.2 1.5 --1.4 ----0.4 ----0.4
FC4 FL4
0.2 0.7 0.2 0.2 0.2 0.7 1.2 1.5 1.2 1.4 ----0.4 0.6 0.7 0.4
FG4
0.2 0.7 0.2 0.2 0.2 0.7 1.2 1.5 1.2 1.4 ----0.4 0.6 0.7 0.4
KEM
0.2 0.7 0.2 0.2 0.2 0.7 1.2 1.5 1.2 1.4 ----0.4 0.6 0.7 0.4
FMM
0.2 0.7 0.2 0.4 0.2 0.7 1.2 ------0.8 0.8 0.4 ----0.4
KH4
0.2 0.7 0.2 0.3 0.2 0.7 1.2 1.6 1.2 1.4 ----0.4 0.6 --0.4
Replace rear stoplight relay Replace right handlebar switch Replace left upper handlebar switch housing Replace left lower handlebar switch housing Replace right upper handlebar switch housing Replace right lower handlebar switch housing Replace handlebar (cruise set) switch Replace handlebar mode switch Replace handlebar (PTT) switch Replace handlebar audio switch Replace pursuit/aux. switch Replace horn/yelp siren switch Replace any fairing switch (except speaker) Replace speaker switch (includes diagnostics) Replace passenger switch Replace switch knob LIGHTS Replace headlight housing Replace instrument panel bulb Replace turn signal light assembly Replace turn signal light assembly Replace rear turn signal bar Replace fender tip light bulb or lens Replace fender tip light bulb or lens Replace fender tip lamp assembly/or rear facia fender lamp Front Rear Front Includes adjustment Includes diagnosis Front Rear
5189 5193 5201 5205 5207 5217 5221 5225
0.2 0.2 0.4 0.4 0.4 0.1 0.1 0.2
0.2 0.2 0.4 0.4 0.6 -------
0.2 0.2 0.4 0.4 0.4 0.1 0.1 0.2
0.2 0.2 0.4 0.4 0.4 0.1 0.1 0.2
0.2 0.2 0.4 0.4 0.4 0.1 0.1 0.2
0.2 0.2 0.4 0.4 0.4 0.1 0.1 0.2
0.2 0.2 0.4 0.4 0.4 0.1 0.1 0.2
0.3 0.2 0.4 0.4 0.4 -------
5-20
KH4 = FLTRX

5229
MODELS FV4
0.3
KB4
0.5
FF4
0.3
FC4 FL4
0.3
FG4
0.3
KEM
0.3
FMM
0.3
KH4
---
Replace fender tip lamp assembly/or rear facia fender lamp Replace auxiliary lamp assembly Replace front auxiliary/directional lamp bracket Replace king tour-pak light bulb or lens Replace king tour-pak lower light assembly Replace king tour-pak wrap-around light assembly Replace license plate light bulb Replace license plate light assembly BATTERY Replace the battery Replace battery tray Replace battery cable SOUND SYSTEM REPAIR Replace radio Replace one speaker grill Replace one speaker grill Replace rear speaker housing Replace rear speaker housing Replace front antenna lead Replace antenna mast mount Replace CB antenna mast Complete stereo antenna inspection Replace stereo antenna mast Replace front headset DIN cover Replace console housing
Rear
Includes adjustment Includes auxiliary lamp adjustment where applicable Includes diagnosis
5230 5232 5233 5234 5235
0.5 0.8 --------0.4
--0.7 ------0.2 0.4
0.5 0.8 0.2 0.5 ----0.4
0.5 0.8 0.2 0.5 0.8 --0.4
0.5 0.8 0.2 0.5 0.8 -----
0.5 0.8 0.2 0.5 0.8 --0.4
0.5 0.8 --------0.4
----------0.2 0.4
Not used for LED equipped models
5246 5247
Includes diagnosis
5705 5767 5769
0.3 0.8 0.4
0.3 0.8 0.4
0.3 0.8 0.4
0.3 0.8 0.4
0.3 0.8 0.4
0.3 0.8 0.4
0.3 0.8 0.4
0.3 0.8 0.4
Cosmetic issue Front Rear Right side Left side Radio or CB
6101 6607 6612 6608 6610 6609 6611 6613 6615 6617 6619 6623
-------------------------
0.6 0.2 ------0.8 0.3 --0.2 0.1 -----
0.6 0.2 ------0.8 0.2 --0.2 0.1 -----
0.6 0.2 0.1 0.3 0.3 0.9 0.2 0.4 0.2 0.1 0.3 0.3
0.6 0.2 0.1 0.3 0.3 0.9 0.2 0.4 0.2 0.1 0.3 0.3
0.6 0.2 0.1 0.3 0.3 0.9 0.2 0.4 0.2 0.1 0.3 0.3
-------------------------
0.7 0.2 ------0.9 0.2 --0.2 0.1 -----
5-21
KH4 = FLTRX

6628 6940
MODELS FV4
-----
KB4
-----
FF4
-----
FC4 FL4
0.1 1.0
FG4
0.1 1.0
KEM
0.1 1.0
FMM
-----
KH4
-----
Replace rear headset DIN cover Repair/replace audio harness
5-22
KH4 = FLTRX
Table 5-8. FLHT/FLTR Diagnostics

NOTE: Unless otherwise noted, all codes include diagnostic time and replacement time if required. The codes must be used in conjunction with the diagnostic/repair procedures listed in the current Service Manual and Electrical Diagnostic Manual. DIAGNOSTICS GENERAL Repair any single wire Repair any single wire Repair any single wire Replace position lamp Replace headlight Replace indicator lamp assembly Light circuit Accessory circuit All wires except lighting and accessory circuits Position lamp inoperative Headlamp inoperative High beam indicator inoperative, neutral lamp inoperative, oil pressure lamp inoperative, turn signal indicator inoperative Replace taillight bulb or single light bulb or lens Replace taillight assembly or circuit board Replace auxiliary lamp bulb Replace horn and/or bracket Running lamps inoperative Headlamp inoperative, stop lamp inoperative Auxiliary lamp inoperative Horn inoperative 5197 5215 5227 5765 7210 0.1 0.2 0.1 0.1 0.5 0.1 0.2 --0.1 0.5 0.1 0.2 0.1 0.1 0.5 0.1 0.2 0.1 0.1 0.5 0.1 0.2 0.1 0.1 0.5 0.1 0.2 0.1 0.1 0.5 0.1 0.2 0.1 0.1 0.5 0.1 0.2 --0.1 0.5 5039 5043 5041 5143 5185 5191 0.5 0.5 0.5 0.1 0.1 0.2 0.5 0.5 0.5 0.1 0.1 0.2 0.5 0.5 0.5 0.1 0.1 0.2 0.5 0.5 0.5 0.1 0.1 0.2 0.5 0.5 0.5 0.1 0.1 0.2 0.5 0.5 0.5 0.1 0.1 0.2 0.5 0.5 0.5 0.1 0.1 0.2 0.5 0.5 0.5 0.1 0.2 ---
Repair engine compression, use in conjunction with Engine cranks but will not start, starts hard, starts additional code(s) Code not present - then stalls B0563, B1006, B1007, P0562, P0563, P0603, P0605, C0563 SWITCHES Replace rear stoplight switch - does not include bleeding brakes, use with appropriate bleed code Replace rear stoplight switch - does not include bleeding brakes, use with appropriate bleed code Replace rear stoplight switch - does not include bleeding brakes, use with appropriate bleed code Replace neutral switch Nothing clicks, neutral lamp always on, neutral lamp inoperative, B1155 U1097, U1255 Stop lamp inoperative, cruise control malfunction P0572, C1212, C1214
7770
0.2
0.2
0.2
0.2
0.2
0.2
0.2
0.2
1409
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
5141
0.3
0.3
0.3
0.3
0.3
0.3
0.3
0.3
6787
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
5157
0.3
0.3
0.3
0.3
0.3
0.3
0.3
0.3
5-23
KH4 = FLTRX

5161
MODELS FV4
0.3
KB4
0.3
FF4
0.3
FC4 FL4
0.3
FG4
0.3
KEM
0.3
FMM
0.3
KH4
0.3
Replace oil pressure switch
Oil pressure lamp always on, oil pressure lamp inoperative
Replace clutch switch Replace left handlebar switch
Nothing clicks, B1154 Horn always on, horn inoperative, headlamp inoperative
5168 5171
0.8 0.5
0.8 0.5
0.8 0.5
0.8 0.5
0.8 0.5
0.8 0.5
0.8 0.5
0.8 0.5
Replace front brake light switch Replace front brake light switch Replace handlebar (cruise set) switch Replace any fairing switch Replace start button Replace odometer reset switch Replace odometer reset switch boot Replace engine stop switch Replace engine stop switch Replace turn signal switch Replace turn signal switch Replace ignition switch Replace ignition switch FUSES AND RELAYS Replace brake relay Replace accessory fuse Replace fuse Replace brake relay
P0572, C1094, C1212 Stop lamp inoperative, cruise control malfunction P0577 Cruise control malfunction Starter inoperative B1008 B1008 Serial data missing No check engine lamp Both lamps on one side inoperative Both lamps on one side inoperative U1097, U1255 Serial data missing
1413 5176 5182 5192 5818 6001 6002 6730 7295 6811 6815 6782 7287
1.2 0.7 1.2 0.4 1.0 0.4 0.1 0.8 0.7 0.8 0.8 0.9 0.8
1.2 0.7 1.2 0.4 1.0 0.4 0.1 0.8 0.7 0.8 0.8 0.9 0.8
1.2 0.7 1.2 0.4 0.2 0.4 0.1 0.8 0.7 0.8 0.8 0.9 0.8
1.2 0.7 1.2 0.4 1.0 0.4 0.1 0.8 0.7 0.8 0.8 0.9 0.8
1.2 0.7 1.2 0.4 1.0 0.4 0.1 0.8 0.7 0.8 0.8 0.9 0.8
1.2 0.7 1.2 0.4 1.0 0.4 0.1 0.8 0.7 0.8 0.8 0.9 0.8
1.2 0.7 1.2 0.4 1.0 0.4 0.1 0.8 0.7 0.8 0.8 0.9 0.8
1.3 0.7 1.2 0.4 1.0 0.4 0.1 0.9 0.7 0.8 0.9 0.9 0.8
P0572, C1095, C1216 P0572 Cruise control malfunction Cruise control malfunction
1407 1804 5145 5169 6713 6729
0.4 0.4 0.2 0.2 0.5 0.3
0.4 0.4 0.2 0.2 0.5 0.3
0.4 0.4 0.2 0.2 0.5 0.3
0.4 0.4 0.2 0.2 0.5 0.3
0.4 0.4 0.2 0.2 0.5 0.3
0.4 0.4 0.2 0.2 0.5 0.3
0.4 0.4 0.2 0.2 0.5 0.3
0.4 0.4 0.2 0.2 0.5 0.4
Harness inspection/wiggle test/replace battery fuse U1064 Inspect/access main wire harness/wiggle test/replace ignition fuse Inspect harness/wiggle test/replace main fuse Serial data missing Serial data missing
6733
0.3
0.3
0.3
0.3
0.3
0.3
0.3
0.3
5-24
KH4 = FLTRX

6766
MODELS FV4
0.4
KB4
0.4
FF4
0.4
FC4 FL4
0.4
FG4
0.4
KEM
0.4
FMM
0.4
KH4
0.4
Access instruments\wiggle test\replace instrument U1097, U1255 fuse Access instruments\wiggle test\replace accessory U1097, U1255 fuse Replace starter relay Replace starter relay Replace key switch relay Inspect/main wiring harness/replace battery fuse Replace 15 amp fuse Replace engine control fuse Replace system relay Replace system relay Replace system relay Starter inoperative B1134 U1097 No check engine lamp, U1255 Engine cranks but will not start, starts hard P1475 Serial data missing, P1001, P1003 P1002 P1004
6781
0.4
0.4
0.4
0.4
0.4
0.4
0.4
0.4
5832 6841 7098 7159 7181 7826 7904 7909 7911 7937
0.4 0.2 0.5 0.4 0.6 0.3 0.4 0.2 0.2 0.7
0.4 0.2 0.5 0.4 0.6 0.3 0.4 0.2 0.2 0.7
0.4 0.2 0.5 0.4 0.6 0.3 0.4 0.2 0.2 0.7
0.4 0.2 0.5 0.4 0.6 0.3 0.4 0.2 0.2 0.7
0.4 0.2 0.5 0.4 0.6 0.3 0.4 0.2 0.2 0.7
0.4 0.2 0.5 0.4 0.6 0.3 0.4 0.2 0.2 0.7
0.4 0.2 0.5 0.4 0.6 0.3 0.4 0.2 0.2 0.7
0.4 0.2 0.5 0.4 0.6 0.3 0.4 0.2 0.2 0.7
Harness inspection/wiggle test/replace ECM fuse P1003, P1351, P1354 CHARGING CIRCUIT Milliamp draw Replace stator Total current draw Replace voltage regulator Replace voltage regulator Replace rotor Replace battery Low battery after extended ignition off Low or no charging Diagnose charging system No or low charging, overcharging Serial data missing Replace rotor Engine cranks but will not start, starts hard, starts - then stalls Repair charging system/accompanies other codes B0563, B1006, B1007, P0562, P0563, C0562, C0563 STARTER CIRCUIT Replace starter Solenoid clicks
5308 5309 5310 5316 6724 5319 7185
0.2 2.8 0.2 0.8 0.4 2.5 0.5
0.2 2.8 0.2 0.8 0.4 2.5 0.5
0.2 2.8 0.2 0.8 0.4 2.5 0.5
0.2 2.8 0.2 0.8 0.4 2.5 0.5
0.2 2.8 0.2 0.8 0.4 2.5 0.5
0.2 2.8 0.2 0.8 0.4 2.5 0.5
0.2 2.8 0.2 0.8 0.4 2.5 0.5
0.2 2.8 0.2 0.8 0.4 2.5 0.5
7771
0.2
0.2
0.2
0.2
0.2
0.2
0.2
0.2
5817
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
5-25
KH4 = FLTRX

5825 5837 5845 7166
MODELS FV4
1.0 1.1 1.2 0.2
KB4
1.0 1.1 1.2 0.2
FF4
1.0 1.1 1.2 0.2
FC4 FL4
1.0 1.1 1.2 0.2
FG4
1.0 1.1 1.2 0.2
KEM
1.0 1.1 1.2 0.2
FMM
1.0 1.1 1.2 0.2
KH4
1.0 1.1 1.2 0.2
Replace starter Replace starter clutch Replace starter solenoid Repair starting system, use in conjunction with additional code(s) IGNITION CIRCUIT Replace spark plugs
Starter spins but does not engage Starter spins but does not engage Starter testing, starter relay clicks Engine cranks but will not start, starts hard, starts - then stalls
Engine cranks but will not start, starts hard, starts - then stalls, misfire at idle or under load, rough or rolling idle
7134
0.4
0.4
0.4
0.4
0.4
0.4
0.4
0.4
Replace spark plug Replace spark plug wire
P1353, P1356, P1357, P1358 Engine cranks but will not start, starts hard, starts - then stalls, misfire at idle or under load, rough or rolling idle
7548 7138
0.2 0.7
0.2 0.7
0.2 0.7
0.2 0.7
0.2 0.7
0.2 0.7
0.2 0.7
0.2 0.7
Replace spark plug wire Replace ignition coil Replace ignition coil
P1353, P1356, P1357, P1358 Misfire at idle or under load, rough or rolling idle Engine cranks but will not start, starts hard, starts - then stalls
7549 7139 7226
0.2 0.8 1.0
0.2 0.8 1.0
0.2 0.8 1.0
0.2 0.8 1.0
0.2 0.8 1.0
0.2 0.8 1.0
0.2 0.8 1.0
0.2 0.8 1.0
Replace ignition coil Replace ignition coil AIR INTAKE Repair intake leak FUEL SYSTEM Replace fuel level sender Replace fuel gauge Replace fuel gauge Replace purge solenoid Replace fuel filter or clean fuel pump screen
P1353, P1356, P1357, P1358 P1351, P1352, P1354, P1355
7547 7856
0.6 0.6
0.6 0.6
0.6 0.6
0.6 0.6
0.6 0.6
0.6 0.6
0.6 0.6
0.6 0.6
Misfire at idle or under load, P0131, P0151
7486
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
B1004, B1005 B1005 U1097, U1255 P0444, P0445 Starts - then stalls, P1353, P1356, P1357, P1358
6035 6047 6775 6861 7013
0.9 0.4 0.5 0.5 0.8
0.9 0.4 0.5 0.5 0.8
0.9 0.4 0.5 0.5 0.8
0.9 0.4 0.5 0.5 0.8
0.9 0.4 0.5 0.5 0.8
0.9 0.4 0.5 0.5 0.8
0.9 0.4 0.5 0.5 0.8
1.0 0.5 0.6 0.5 0.8
5-26
KH4 = FLTRX

7014
MODELS FV4
1.0
KB4
1.0
FF4
1.0
FC4 FL4
1.0
FG4
1.0
KEM
1.0
FMM
1.0
KH4
1.0
Repair/replace fuel pump/pressure regulator/fuel line/fuel filter Replace fuel filter screen
Starts - then stalls, P1353, P1356, P1357, P1358
Engine cranks but will not start, starts hard, misfire at idle or under load, rough or rolling idle, P0131, P0151
7163
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
Engine cranks but will not start, starts hard, misfire at idle or under load, rough or rolling idle, P0131, P0132, P0151, P0152
7164
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
Misfire at idle or under load, rough or rolling idle, P0131, P0132, P0151, P0152,
7144
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
Replace fuel injector Replace fuel injector Replace fuel injector Replace fuel pump Replace fuel pump Replace fuel pressure regulator SENSORS AND ECM Replace jiffy stand sensor Replace sidecar bank angle sensor Replace sidecar bank angle sensor Replace induction module Remove and clean or replace induction module Replace twist grip sensor or repair connections
Emits black smoke P0261, P0262, P0263, P0264 Engine cranks but will not start, starts hard Engine cranks but will not start, starts hard P1003 Emits black smoke
7596 7795 7992 7415 7924 7480
2.0 0.7 0.7 0.9 1.3 1.0
2.0 0.7 0.7 0.9 1.3 1.0
2.0 0.7 0.7 0.9 1.3 1.0
2.0 0.7 0.7 0.9 1.3 1.0
2.0 0.7 0.7 0.9 1.3 1.0
2.0 0.7 0.7 0.9 1.3 1.0
2.0 0.7 0.7 0.9 1.3 1.0
2.0 0.7 0.7 0.9 1.3 1.0
P0641, P1501, P1502 B1152, B1153 B1151 P0641, P2100, P2102 P2101, P2119, P2176 P0641, P0651, P2122, P2123, P2127, P2128, P2138
5085 6967 6968 7085 7091 7564
0.5 ----1.4 1.6 1.4
0.5 ----1.4 1.6 1.4
0.5 ----1.4 1.6 1.4
0.5 ----1.4 1.6 1.4
0.5 0.4 0.2 1.4 1.6 1.4
0.5 ----1.4 1.6 1.4
0.5 ----1.4 1.6 1.4
0.5 ----1.4 1.6 1.5
Replace induction module
P0120, P0122, P0123, P0220, P0222, P0223, P0505, P2135
7590
1.6
1.6
1.6
1.6
1.6
1.6
1.6
1.6
Replace engine temperature (ET) sensor Replace engine temperature (ET) sensor
Emits black smoke P0117, P0118
7598 7710
2.0 0.4
2.0 0.4
2.0 0.4
2.0 0.4
2.0 0.4
2.0 0.4
2.0 0.4
2.0 0.4
5-27
KH4 = FLTRX

7667
MODELS FV4
0.5
KB4
0.5
FF4
0.5
FC4 FL4
0.5
FG4
0.5
KEM
0.5
FMM
0.5
KH4
0.5
Replace oxygen sensor
P0031, P0032, P0131, P0132, P0134, P0151, P0152, P0154
Replace crankshaft position (CKP) sensor Clean or repair crankshaft position (CKP) sensor Replace TMAP sensor Replace TMAP sensor Replace TMAP sensor Replace TMAP sensor Replace TMAP sensor Replace TMAP sensor Clean or repair vehicle speed sensor (VSS) Replace vehicle speed sensor (VSS) Replace ECM
P0373, P0374 P0373, P0374 Misfire at idle or under load, rough or rolling idle Emits black smoke P0107 P0107, P0108, P0651 P0112, P0113 P0112, P0113 P0501, P0502 P0501, P0502 P0031, P0032, P0131, P0132, P0134, P0151, P0152, P0154, P0262, P0264, U1016
7981 7982 7152 7597 7630 7650 7725 7760 7939 7967 6123
0.4 0.3 0.6 2.0 0.7 0.8 0.8 0.8 0.9 1.2 0.8
0.4 0.3 0.6 2.0 0.7 0.8 0.8 0.8 0.9 1.2 0.8
0.4 0.3 0.6 2.0 0.7 0.8 0.8 0.8 0.9 1.2 0.8
0.4 0.3 0.6 2.0 0.7 0.8 0.8 0.8 0.9 1.2 0.8
0.4 0.3 0.6 2.0 0.7 0.8 0.8 0.8 0.9 1.2 0.8
0.4 0.3 0.6 2.0 0.7 0.8 0.8 0.8 0.9 1.2 0.8
0.4 0.3 0.6 2.0 0.7 0.8 0.8 0.8 0.9 1.2 0.8
0.4 0.3 0.6 2.0 0.7 0.8 0.8 0.8 0.9 1.2 0.9
Replace ECM Replace ECM Replace ECM Replace ECM Replace ECM Replace ECM Replace ECM
P1009 U1016 Automatic compression release diagnosis P2100, P2103 Misfire at idle or under load, rough or rolling idle Emits black smoke Serial data missing, P0107, P0112, P0120, P0122, P0123, P0220, P0222, P0223, P0505, P1655, P1656, U1300, U1301
6703 6125 7080 7093 7149 7601 7641
0.7 ----1.4 0.9 2.2 1.1
0.7 1.2 --1.4 0.9 2.2 1.1
0.7 1.2 --1.4 0.9 2.2 1.1
0.7 1.2 --1.4 0.9 2.2 1.1
0.7 1.2 --1.4 0.9 2.2 1.1
0.7 1.2 --1.4 0.9 2.2 1.1
0.7 --0.9 1.4 0.9 2.2 1.1
0.7 1.3 --1.4 0.9 2.2 1.1
Replace ECM
Engine cranks but will not start, starts hard, starts - then stalls, P0117, P0118, P0373, P0374, P1002, P1351, P1352, P1354, P1355, P1353, P1356, P1357, P1358
7680
0.6
0.6
0.6
0.6
0.6
0.6
0.6
0.6
5-28
KH4 = FLTRX

7740
MODELS FV4
1.0
KB4
1.0
FF4
1.0
FC4 FL4
1.0
FG4
1.0
KEM
1.0
FMM
1.0
KH4
1.0
Replace ECM
P0113, P0572, P0641, P0651, P2122, P2123, P2127, P2128
Replace ECM
Serial data missing, no check engine lamp, P0261, P0263, P0444, P0445, P0603, P0605, P1001, P1010, P1270, P1475, P1477, P1478, P1501, P1502, P1600, P2107, U1064
7850
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
Replace ECM HDI ACTIVE EXHAUST Replace exhaust actuator Replace exhaust actuator valve Replace exhaust actuator cable
P0501, P0502
7968
1.2
1.2
1.2
1.2
1.2
1.2
1.2
1.2
P1475, P1477, P1478 P1475 P1475
7811 7812 7814
1.1 1.1 1.2
1.1 1.1 1.2
1.1 1.1 1.2
1.1 1.1 1.2
-------
1.1 1.1 1.2
1.1 1.1 1.2
1.1 1.1 1.2
TURN SIGNALS/INSTRUMENTS/SECURITY/CRUISE Replace volt meter Replace air temp gauge Replace oil pressure gauge Replace cigarette lighter Perform ECM TSM/TSSM/HFSM module replace procedure Replaced TSM/TSSM/HFSM, system now ok Replaced TSM/TSSM/HFSM, system now ok Replace FOB battery Replace FOB Replace bulb P1009 P1010 Fails to disarm Fails to disarm Both lamps on one side inoperative, flash at double normal rate, B1121, B1122 Replace bulb Remove corrosion Remove corrosion/replace bulb Flash at double normal rate Flash at double normal rate Flash at double normal rate 6820 6821 6822 0.2 0.2 0.4 0.2 0.2 0.4 0.2 0.2 0.4 0.2 0.2 0.4 0.2 0.2 0.4 0.2 0.2 0.4 0.2 0.2 0.4 0.2 0.2 0.4 6702 6707 6755 6756 6796 0.4 1.1 0.1 0.1 0.2 0.4 1.1 0.1 0.1 0.2 0.4 1.1 0.1 0.1 0.2 0.4 1.1 0.1 0.1 0.2 0.4 1.1 0.1 0.1 0.2 0.4 1.1 0.1 0.1 0.2 0.4 1.1 0.1 0.1 0.2 0.4 1.1 0.1 0.1 0.2 U1097, U1255 U1097, U1255 U1097, U1255 U1097, U1255 P1009 6074 6075 6076 6077 6701 0.5 0.5 0.5 0.4 0.4 0.5 0.5 0.5 0.4 0.4 0.5 0.5 0.5 0.4 0.4 0.5 0.5 0.5 0.4 0.4 0.5 0.5 0.5 0.4 0.4 0.5 0.5 0.5 0.4 0.4 0.5 0.5 0.5 0.4 0.4 0.6 0.6 0.6 0.5 0.4
5-29
KH4 = FLTRX

6823 6072
MODELS FV4
0.4 0.5
KB4
0.4 0.5
FF4
0.4 0.5
FC4 FL4
0.4 0.5
FG4
0.4 0.5
KEM
0.4 0.5
FMM
0.4 0.5
KH4
0.5 0.5
Replace lamp assembly Replace speedometer
Flash at double normal rate, B1121, B1122 Serial data missing, no check engine lamp, U1016, U1097, U1255,
Replace speedometer Replace speedometer Replace speedometer Replace speedometer
No security lamp during bulb check U1300, U1301 Cruise control malfunction No check engine lamp, Security lamp on continuously after bulb check, B1008
6738 6765 6769 7311
0.3 0.7 0.4 0.3
0.3 0.7 0.4 0.3
0.3 0.7 0.4 0.3
0.3 0.7 0.4 0.3
0.3 0.7 0.4 0.3
0.3 0.7 0.4 0.3
0.3 0.7 0.4 0.3
0.3 0.7 0.4 0.3
Replace TSM/TSSM\HFSM Replace TSM/TSSM\HFSM Replace TSM/TSSM\HFSM Replace TSM/TSSM\HFSM
Starter inoperative - nothing clicks U1016, U1064, U1255 Will not cancel upon turn completion Starter inoperative, nothing clicks, fails to disarm, both lamps on one side inoperative, flash at double normal rate, no check engine lamp, B1121, B1122, B1123, B1124, B1125, B1126, B1134, B1141, B1143, B1144, B1145, B1154, B1155
5838 6717 6773 6791
0.6 0.8 0.9 0.5
0.6 0.8 0.9 0.5
0.6 0.8 0.9 0.5
0.6 0.8 0.9 0.5
0.6 0.8 0.9 0.5
0.6 0.8 0.9 0.5
0.6 0.8 0.9 0.5
0.6 0.8 0.9 0.5
Replace TSM/TSSM\HFSM Replace TSM/TSSM\HFSM Replace TSM/TSSM\HFSM Replace TSM/TSSM\HFSM Replace tachometer Replace tachometer
B1131 B1135 B1152, B1153 Serial data missing, U1300, U1301 Cruise control malfunction Serial data missing, no check engine lamp, U1016, U1097, U1255
6833 6845 6963 7998 6009 6772
0.7 0.4 --1.0 0.3 0.5
0.7 0.4 --1.0 0.3 0.5
0.7 0.4 --1.0 0.3 0.5
0.7 0.4 --1.0 0.3 0.5
0.7 0.4 0.6 1.0 0.3 0.5
0.7 0.4 --1.0 0.3 0.5
0.7 0.4 --1.0 0.3 0.5
0.7 0.4 --1.0 0.3 0.5
Replace tachometer Replace security siren Replace security siren Replace security siren Replace security antenna
U1300, U1301 B1131, B1132 B1151 No check engine lamp B1143, B1144, B1145
6803 6832 6969 7161 6878
0.7 0.5 --0.3 0.3
0.7 0.5 --0.3 0.3
0.7 0.5 --0.3 0.3
0.7 0.5 --0.3 0.3
0.7 0.5 0.3 0.3 0.3
0.7 0.5 --0.3 0.3
0.7 0.5 --0.3 0.3
0.7 0.5 --0.3 0.3
5-30
KH4 = FLTRX

6881
MODELS FV4
0.5
KB4
0.5
FF4
0.5
FC4 FL4
0.5
FG4
0.5
KEM
0.5
FMM
0.5
KH4
0.5
Replace security antenna harness AUTOMATIC COMPRESSION RELEASE Replace ACR solenoid ABS BRAKES Replace ABS diode pack Worn or damaged wheel bearings or suspension components, may be used in conjunction with other codes Reroute brake lines Replace ABS hydraulic control unit (HCU)
B1145
P1655, P1656
7077
---
---
---
---
---
2.3
2.3
---
P0572, C1095, C1216 C1021, C1023, C1025, C1027, C1206, C1208
1404 1412
0.5 0.2
0.5 0.2
0.5 0.2
0.5 0.2
0.5 0.2
0.5 0.2
0.5 0.2
0.5 0.2
C1151, C1153 P0572, C0562, C1014, C1017, C1018, C1021, C1023, C1025, C1027, C1032, C1034, C1042, C1043, C1055, C1056, C1057, C1061, C1062, C1065, C1066, C1094, C1095, C1118, C1121, C1151, C1153, C1158, C1206, C1208, C1214, C1216
1418 1427
0.9 2.0
0.9 2.0
0.9 2.0
0.9 2.0
0.9 2.0
0.9 2.0
0.9 2.0
0.9 2.0
Replace ABS electronic control unit (ECU)
P0572, C0562, C1014, C1017, C1018, C1021, C1023, C1025, C1027, C1032, C1034, C1042, C1043, C1055, C1056, C1057, C1061, C1062, C1065, C1066, C1094, C1095, C1118, C1121, C1151, C1153, C1158, C1206, C1208, C1214, C1216
2430
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
Replace ABS front wheel sensor Replace rear wheel speed sensor HEATED GRIPS Replace heated handlebar grip Replace heated handlebar grip Replace fuse SOUND SYSTEM Replace mode switch
C1021, C1025, C1032, C1206 C1023, C1027, C1034, C1208
2439 2440
0.8 1.0
0.8 1.0
0.8 1.0
0.8 1.0
0.8 1.0
0.8 1.0
0.8 1.0
0.8 1.0
Left Right Heated grips inoperative
6553 6554 6556
-------
-------
-------
-------
-------
1.2 0.3 0.1
-------
-------
B2009
5183
---
1.5
1.5
1.5
1.5
1.5
---
1.6
5-31
KH4 = FLTRX

5184 5186 6101 6102 6103
MODELS FV4
-----------
KB4
1.2 1.4 0.6 --0.7
FF4
1.2 1.4 0.6 --0.7
FC4 FL4
1.2 1.4 0.6 0.7 0.7
FG4
1.2 1.4 0.6 0.7 0.7
KEM
1.2 1.4 0.6 0.7 0.7
FMM
-----------
KH4
1.3 1.5 0.7 --0.8
Replace PTT/squelch switch Replace audio switch Replace radio Replace radio Replace radio
B2009 B2009 Switches inoperative, B2006 - B2027 U1302, U1307, U1317 Poor/no reception AM (HDI LW/MW), FM, WB, radio inoperative, intercom inoperative, handheld microphone PTT inoperative, speaker switch malfunction, CD wont eject on base radio, auxiliary input inoperative, headset speakers inoperative
Replace radio
No or low audio with high output amplifier (no DTCs)
6104
---
---
---
---
0.8
---
---
---
Replace radio Replace radio Replace radio Replace radio Replace high output amplifier Replace high output amplifier Replace high output amplifier Replace high output amplifier
CB receiver inoperative No or low audio from microphones Serial data missing, U1300, U1301 CD skipping B2016 - B2023 U1302 U1317 No or low audio with high output amplifier (no DTCs)
6105 6106 6120 6174 6107 6108 6109 6110
-----------------
----1.0 0.9 ---------
----1.0 0.9 ---------
1.0 1.0 1.0 0.9 ---------
1.0 1.0 1.0 0.9 0.6 0.7 0.4 0.8
1.0 1.0 1.0 0.9 ---------
-----------------
----1.1 1.0 ---------
Replace sidecar console switch assembly Replace fuse
Switches inoperative, B2015 No or low audio with high output amplifier (no DTCs), U1317
6111 6130
-----
-----
-----
-----
0.8 0.2
-----
-----
-----
Replace fuse Replace spark plugs Replace spark plug wires Replace voltage regulator Replace starter relay
Radio inoperative Static present in audio Static present in audio Static present in audio Radio inoperative
6136 6132 6133 6134 6138
-----------
0.2 0.4 0.4 0.3 0.5
0.2 0.4 0.4 0.3 0.5
0.2 0.4 0.4 0.3 0.5
0.2 0.4 0.4 0.3 0.5
0.2 0.4 0.4 0.3 0.5
-----------
0.2 0.4 0.4 0.3 0.6
5-32
KH4 = FLTRX

6143 6171 6173 6605 6606 6943 6609
MODELS FV4
---------------
KB4
--0.4 0.9 0.3 ----0.8
FF4
--0.4 0.9 0.3 ----0.8
FC4 FL4
0.6 0.4 0.9 0.3 0.5 --0.9
FG4
0.6 0.4 0.9 0.4 0.5 0.8 0.9
KEM
0.6 0.4 0.9 0.3 0.5 --0.9
FMM
---------------
KH4
--0.5 1.0 0.4 ----0.9
Replace speaker switch Align radio chassis Align or replace front motor mount Replace speaker Replace speaker Replace speaker Replace antenna cable or mast connector
Speaker switch malfunction CD skipping CD skipping B2016, B2017 B2020, B2021 B2024, B2025 Poor/no reception AM (HDI LW/MW), FM, WB, CB transmitter inoperative, CB receiver inoperative
Replace CB antenna mast Replace headset harness
CB receiver inoperative, CB transmitter inoperative Handheld microphone PTT inoperative, headset speakers inoperative
6613 6616
-----
-----
-----
0.4 0.7
0.4 0.7
0.4 0.7
-----
-----
Replace CB module includes SWR check
CB receiver inoperative, CB transmitter inoperative, no or low audio from microphones, U1302, U1307
6625
---
---
---
0.7
0.7
0.7
---
---
Replace passenger rear control switch
B2012
6627
---
---
---
0.7
0.7
0.7
---
---
5-33
NOTES
SUBJECT..............................................................................................................PAGE NO. 6.1 Service........................................................................................................................6-1 6.2 Chassis.......................................................................................................................6-2 6.3 Engine.........................................................................................................................6-8 6.4 Drive and Clutch........................................................................................................6-14 6.5 Transmission.............................................................................................................6-15 6.6 OEM Accessories......................................................................................................6-16 6.7 Electrical - General....................................................................................................6-18 6.8 FLHR Diagnostics.....................................................................................................6-20 Unless otherwise specified, Job Times shown include all operations necessary to complete the listed job.
FLHR MODELS
FB4 = FLHR
FR4 = FLHRC
FW4 = FLHR Shrine
FHM = FLHP Police
FTM = FLHPE
Table 6-1. Service

ITEM DESCRIPTION LABOR CODE MODELS FR4 FB4 FW4 FHM FTM
NEW Set-up and predelivery 1,000 mile service REGULAR 5,000 mile maintenance 10,000 mile maintenance 15,000 mile maintenance 20,000 mile maintenance 25,000 mile maintenance 30,000 mile maintenance 35,000 mile maintenance 40,000 mile maintenance 45,000 mile maintenance 50,000 mile maintenance Addition to any maintenance- required every 2 years Addition to any maintenance- required every 2 years Addition to 1,000, 5,000 and 20,000 mile (1,600, 8,000, and 32,000 km) maintenance and every 15,000 mile (24,000 km) interval there after flush/fill D.O.T 4 brake fluid- front and rear NON ABS models flush/fill D.O.T 4 brake fluid- front and rear ABS models Tighten spoke wheels if equipped, time per wheel --0.5 0.5 0.5 --1.2 1.2 1.2 ----------------------1.8 2.3 1.6 2.6 2.9 2.5 1.8 2.4 1.4 7.0 0.6 1.8 2.3 1.6 2.6 2.9 2.5 1.8 2.4 1.4 7.0 0.6 1.8 2.3 1.6 2.6 2.9 2.5 1.8 2.4 1.4 7.0 0.6 ----2.0 2.5 2.0 2.5 2.0 2.5
2010 FLHR Models
6-1
FB4 = FLHR
FR4 = FLHRC
FW4 = FLHR Shrine
FHM = FLHP Police
FTM = FLHPE
Table 6-2. Chassis

PAINT REPAIR NOTE: Use these codes when repairing any painted part on vehicle with the kent moore finesse kit or other paint repair methods Light scuff/scratch - buff Light sanding/buff/blend Buff entire part Repair build up in clear/paint Color blend/paint/buff DRIVE Adjust secondary belt Replace secondary belt Replace rear wheel sprocket Replace rear wheel sprocket bearing Replace rear wheel compensator cushion WHEELS Replace tire/or inner tube - includes balancing Replace tire/or inner tube - includes balancing Replace wheel assembly - includes disc and sprocket exchange, bearing install and balancing Replace wheel assembly - includes disc and sprocket exchange, bearing install and balancing Replace rim, hub or spokes- includes truing and balancing Replace rim, hub or spokes- includes truing and balancing Replace wheel bearings Replace wheel bearings Check or true spoke wheel front rear each wheel 2136 2141 2155 0.7 0.9 0.5 0.7 0.9 0.5 0.7 0.9 --rear 2121 2.4 2.4 --front 2116 2.2 2.2 --rear 2114 1.5 1.5 1.5 front rear front 2106 2111 2113 0.6 0.8 1.0 0.6 0.8 1.0 0.6 0.8 1.0 both at PDI only 2010 2011 2021 2012 2013 0.3 3.4 0.8 1.0 0.9 0.3 3.4 0.8 1.0 0.9 0.3 3.4 0.8 1.0 0.9 1102 1104 1106 1108 1110 0.2 0.4 0.6 0.8 1.0 0.2 0.4 0.6 0.8 1.0 0.2 0.4 0.6 0.8 1.0
2010 FLHR Models
6-2
FB4 = FLHR
FR4 = FLHRC
FW4 = FLHR Shrine
FHM = FLHP Police
FTM = FLHPE
Table 6-2. Chassis

HANDLEBARS Replace handlebars Replace handlebar cover Replace clutch hand lever Replace clutch hand lever bracket Replace both rubber handlebar mounts Replace rubber handlebar grip Replace handlebar riser Replace handlebar clamp FRAME/SWING ARM/FRONT FORK Adjust steering head bearings Change front fork oil Replace frame both sides includes removal and installation of all accessories and motorcycle components Replace tail section sub frame Replace rear frame section and tag bracket Replace lower fork bracket and stem Replace steering head cups and bearings, including bearing adjustment Replace upper fork bracket Replace fork lock Replace headlamp nacelle Service or replace fork slider and/or seal includes one side removal, disassembly, cleaning, inspection, replacing parts, servicing damper tube, replacing bushings, assembly and installation 2326 2329 2331 2341 2.7 0.3 0.6 1.9 2.7 0.3 0.6 1.9 2.7 0.3 0.6 1.9 2339 2308 2316 2321 1.6 --3.2 3.2 1.6 --3.2 3.2 1.8 1.0 3.2 3.2 2290 --2306 0.7 1.6 16.0 0.7 1.6 16.0 0.7 1.6 16.0 one or both 2206 2209 2221 2226 2246 2251 2253 2254 1.5 0.2 0.2 0.2 1.0 0.2 1.0 0.8 1.4 0.2 0.2 0.2 1.0 0.2 1.0 0.8 1.5 0.3 0.2 0.2 1.0 0.2 1.0 0.8
2010 FLHR Models
6-3
FB4 = FLHR
FR4 = FLHRC
FW4 = FLHR Shrine
FHM = FLHP Police
FTM = FLHPE
Table 6-2. Chassis

2342
MODELS FR4
2.3
FB4 FW4
2.3
FHM FTM
2.3
Service or replace fork slider and/or seal includes both sides removal, disassembly, cleaning, inspection, replacing parts, servicing damper tube, replacing bushings, assembly and installation Replace fork side Replace fork side Replace fork tube Replace fork tube Replace fork slider cover Replace rear swing arm and/or bearings Replace rear fork pivot shaft Replace rear shock air line Replace rear shock absorber assembly Replace rear shock absorber assembly Replace jiffy stand Replace jiffy stand Replace jiffy stand Replace footboard / foot peg Replace footboard insert Replace motor mount Replace motor mount Replace motor mount BRAKES Replace hydraulic brake line does not include bleeding brakes use with appropriate bleed code (non ABS vehicles only) front (non ABS vehicles) rear right rear left both front rubber mounts and/or front mount bracket one side both sides complete spring and/or stand rubber bumper one side both sides one side both sides one side
2346 2351 2356 2361 2499 2366 2368 2369 2371 2376 2391 2396 2399 2394 2299 2395 2397 2398
1.2 1.5 1.4 1.7 1.3 1.9 0.8 0.2 0.2 0.4 0.3 0.2 0.1 0.2 0.1 1.2 0.3 1.4
1.2 1.5 1.4 1.7 1.3 1.9 0.8 0.2 0.2 0.4 0.3 0.2 0.1 0.2 0.1 1.2 0.3 1.4
1.2 1.5 1.4 1.7 1.3 1.9 0.8 0.2 0.2 0.4 0.3 0.2 0.1 0.2 0.1 1.2 0.3 1.4
2406
0.8
0.8
0.8
2010 FLHR Models
6-4
FB4 = FLHR
FR4 = FLHRC
FW4 = FLHR Shrine
FHM = FLHP Police
FTM = FLHPE
Table 6-2. Chassis

2411
MODELS FR4
0.4
FB4 FW4
0.4
FHM FTM
0.4
Replace hydraulic brake line does not include bleeding brakes use with appropriate bleed code (non ABS vehicles only) Replace hydraulic brake line does not include code (ABS vehicles only) Replace hydraulic brake line does not include code (ABS vehicles only) Replace hydraulic brake line does not include filling/bleeding brakes, use with appropriate bleed code (ABS vehicles only) Replace hydraulic brake line does not include filling/bleeding brakes, use with appropriate bleed code (ABS vehicles only) Replace brake pads Replace brake pads
rear (non ABS vehicles)
front, mastercylinder to ABS unit (ABS vehicles
2463
1.1
1.1
1.1
rear, master cylinder to ABS unit (ABS vehicles
2464
0.3
0.3
0.3
front, ABS unit to calipers (ABS vehicles only)
2465
1.1
1.1
1.1
rear, ABS unit to rear caliper (ABS vehicles only)
2467
0.3
0.3
0.3
front each caliper rear
2416 2421 2426
0.1 0.3 0.3
0.1 0.3 0.3
0.1 0.3 0.3
Replace brake caliper does not include bleeding front each caliper brakes, use with appropriate bleed code Replace brake caliper does not include bleeding rear brakes, use with appropriate bleed code Replace rear brake caliper mount Replace brake caliper screen Replace brake rotor Replace brake rotor Replace brake rotor Bleed brake caliper Bleed brake caliper front each caliper front one side front both sides rear front (both calipers) - non ABS rear - non ABS
2431
0.5
0.5
0.5
2408 2428 2436 2437 2441 2442 2443
0.5 0.1 0.3 0.4 1.0 0.3 0.2
0.5 0.1 0.3 0.4 1.0 0.3 0.2
0.5 0.1 0.3 0.4 1.0 0.3 0.2
2010 FLHR Models
6-5
FB4 = FLHR
FR4 = FLHRC
FW4 = FLHR Shrine
FHM = FLHP Police
FTM = FLHPE
Table 6-2. Chassis

2446
MODELS FR4
0.6
FB4 FW4
0.6
FHM FTM
0.6
Bleed brake caliper front (one or two calipers) or ABS vehicles only - includes bleeding and verifying rear caliper Replace master cylinder assembly - does not include bleeding brakes, use with appropriate bleed code Replace master cylinder assembly - does not include bleeding brakes, use with appropriate bleed code Replace master cylinder cover Rebuild master cylinder assembly does not include bleeding brakes, use with appropriate bleed code Rebuild master cylinder assembly does not include bleeding brakes, use with appropriate bleed code Replace ABS hydrallic control unit (HCU) or gasket, used if module leaking, includes bleeding both brakes and verifying system function with Digital Technician II (ABS vehicles only) Replace rear brake pedal Replace front brake lever SEATS/FENDERS/TANKS Replace seat and/or strap or spring(s) and / or hinge bracket Replace top frame cover (solo seat) Replace seat air spring Replace air tank Replace air line Replace fender Replace fender front rear (includes installing new wire conduit where applicable) rear front or rear front rear system function with Digital Technician II front
2461
0.3
0.3
0.3
2466
0.4
0.4
0.4
2479 2471
0.1 0.4
0.1 0.4
0.1 0.4
2476
0.5
0.5
0.5
2473
1.7
1.7
1.7
2492 2494
0.3 0.2
0.3 0.2
0.3 0.2
2506
0.1
0.1
0.2
2510 2514 2516 2518 2526 2531
--------1.0 1.0
--------1.0 1.0
0.3 0.4 0.8 0.5 1.0 1.0
2010 FLHR Models
6-6
FB4 = FLHR
FR4 = FLHRC
FW4 = FLHR Shrine
FHM = FLHP Police
FTM = FLHPE
Table 6-2. Chassis

2525 rear fender left or right 2533 2536 2541 2553 2557 fuel tank console 2558 2563 2564 includes fuel line attached to check valve 2567 2570 2575 2579 6507 2582
MODELS FR4
0.4 0.7 0.2 1.2 0.3 0.2 0.2 0.3 0.5 0.6 0.4 0.5 0.5 0.3 0.1
FB4 FW4
0.4 0.7 0.2 1.2 0.3 0.2 0.2 0.3 0.5 0.6 0.4 0.5 0.5 0.3 0.1
FHM FTM
0.4 0.7 0.2 1.2 0.3 0.2 0.2 0.3 0.5 0.6 0.4 0.5 0.5 --0.1
Replace license plate mount Replace wire conduit Replace rear fender support cover Replace fuel tank assembly Replace fuel tank console / instrument panel Replace fuel tank console rubber molding strip Replace dash insert Replace fuel tank gauge Replace fuel level sending unit Replace fuel tank check valve assembly Replace canopy gasket Replace fuel filter Replace fuel transfer hose inside tank Replace fuel tank trim or medallion Replace oil filter BELT GUARDS Replace rear belt guard debris deflector EXHAUST SYSTEM Replace complete exhaust system and/or gaskets Replace exhaust pipe Replace exhaust pipe right side header assembly and/or port gaskets left side cross under pipe, support clamp and/or gasket Replace one muffler Replace rear exhaust support bracket Replace any one exhaust shield Replace one muffler support at transmission side cover
2616
0.2
0.2
0.2
2626 2631 2636
1.1 1.0 0.3
1.1 1.0 0.3
1.1 1.0 0.3
2646 2651 2661 2666
0.2 0.4 0.1 0.2
0.2 0.4 0.1 0.2
0.2 0.4 0.1 0.2
2010 FLHR Models
6-7
FB4 = FLHR
FR4 = FLHRC
FW4 = FLHR Shrine
FHM = FLHP Police
FTM = FLHPE
Table 6-3. Engine

GENERAL Remove and install engine includes oil passage gasket Remove and install engine includes oil passage gasket Replace stabilizer link or stabilizer bracket Remove and replace oil pan for inspection / decontamination Replace dipstick CYLINDER HEAD Recondition cylinder head includes removal of head and gasket, remove carbon, service valve guides, grind valves and seats, test springs and install head and gaskets Recondition cylinder head includes removal of head and gasket, remove carbon, service valve guides, grind valves and seats, test springs and install head and gaskets Recondition cylinder head includes removal of head and gasket, remove carbon, service valve guides, grind valves and seats, test springs and install head and gaskets Replace cylinder head Replace cylinder head Replace valve seal or spring after cylinder head removal Replace valve seal or spring after cylinder head removal Replace cylinder head gasket/O-ring Replace cylinder head gasket/O-ring front cylinder rear cylinder 3140 3142 2.6 2.6 2.6 2.6 2.6 2.6 both seals or springs (intake or exhaust) 3132 0.2 0.2 0.2 one head both heads one seal or spring (intake or exhaust ) 3106 3108 3131 3.5 4.4 0.1 3.5 4.4 0.1 3.5 4.4 0.1 both heads 3104 5.1 5.1 5.1 rear head 3103 4.5 4.5 4.5 front head 3101 4.5 4.5 4.5 3480 0.1 0.1 0.1 top front with engine removed 3005 3009 0.2 0.3 0.2 0.3 0.2 0.3 3006 4.5 4.5 4.5 California vehicles only 3006 4.6 4.6 4.6
2010 FLHR Models
6-8
FB4 = FLHR
FR4 = FLHRC
FW4 = FLHR Shrine
FHM = FLHP Police
FTM = FLHPE
Table 6-3. Engine

3143 3144 3145 3148 3149 3150 3147
MODELS FR4
3.0 0.8 0.8 0.9 0.7 1.4 1.2
FB4 FW4
3.0 0.8 0.8 0.9 0.7 1.4 1.2
FHM FTM
3.0 0.8 0.8 0.9 0.7 1.4 1.2
Replace cylinder head gasket/O-ring Replace rocker arm covers and/or gaskets Replace rocker arm covers and/or gaskets Replace rocker arm covers and/or gaskets
both cylinders front cylinder rear cylinder both cylinders
Recondition rocker arms after heads are removed one head Recondition rocker arms after heads are removed both heads Replace lower rocker arm cover/gasket, or rocker front cylinder arms and /or shafts/rocker arm support Replace lower rocker arm cover/gasket, or rocker rear cylinder arms and /or shafts/rocker arm support Replace lower rocker arm cover/gasket, or rocker both cylinders arms and /or shafts/rocker arm support Replace cylinder o-ring/drain o-ring Replace cylinder o-ring/drain o-ring Replace cylinder o-ring/drain o-ring Replace crankcase umbrella valve Replace crankcase umbrella valve CYLINDER AND PISTON Recondition top end - includes disassembly, replacement of piston and sizing cylinder (.005 oversize pistons), replacing piston rings and all items listed under recondition cylinder head and assembly Recondition top end - includes disassembly, replacement of piston and sizing cylinder (.005 oversize pistons), replacing piston rings and all items listed under recondition cylinder head and assembly Replace piston rings includes deglazing cylinder one cylinder both pistons and cylinders one piston and cylinder front cylinder rear cylinder both cylinders one both
3152
1.2
1.2
1.2
3153
1.9
1.9
1.9
3161 3163 3168 3172 3174
2.8 2.8 3.2 1.1 1.2
2.8 2.8 3.2 1.1 1.2
2.8 2.8 3.2 1.1 1.2
3202
5.5
5.5
5.5
3203
6.1
6.1
6.1
3206
3.1
3.1
3.1
2010 FLHR Models
6-9
FB4 = FLHR
FR4 = FLHRC
FW4 = FLHR Shrine
FHM = FLHP Police
FTM = FLHPE
Table 6-3. Engine

3216 3207
MODELS FR4
3.7 5.3
FB4 FW4
3.7 5.3
FHM FTM
3.7 5.3
Replace piston rings includes deglazing cylinder both cylinders Recondition top end includes disassembly, deglazing cylinder and replacing rings, or replacing cylinder and piston, all items listed under recondition cylinder head and assembly Recondition top end includes disassembly, deglazing cylinder and replacing rings, or replacing cylinder and piston, all items listed under recondition cylinder head and assembly Recondition top end - includes disassembly, replacement of piston and bore and hone, resizing cylinder (.010 oversize or above), replacing piston rings and all items listed under recondition cylinder head and assembly Recondition top end - includes disassembly, replacement of piston and bore and hone, resizing cylinder (.010 oversize or above), replacing piston rings and all items listed under recondition cylinder head and assembly Replace piston and piston rings includes removal one cylinder of cylinder head and cylinder, fitting new piston with rings, resizing cylinder and assembly Replace piston and piston rings includes removal both cylinders of cylinder head and cylinder, fitting new piston with rings, resizing cylinder and assembly Replace cylinder and piston Replace cylinder and piston Replace one cylinder stud Replace all eight cylinder studs one cylinder both cylinders cylinder removed cylinders removed both pistons and cylinders one piston and cylinder both pistons and cylinders one piston and cylinder
3208
5.9
5.9
5.9
3211
5.9
5.9
5.9
3212
6.5
6.5
6.5
3221
3.7
3.7
3.7
3231
4.9
4.9
4.9
3236 3246 3253 3254
3.0 3.5 0.1 0.5
3.0 3.5 0.1 0.5
3.0 3.5 0.1 0.5
2010 FLHR Models
6-10
FB4 = FLHR
FR4 = FLHRC
FW4 = FLHR Shrine
FHM = FLHP Police
FTM = FLHPE
Table 6-3. Engine

CAM COVER Replace lifter cover/gasket or lifter/and, or antirotation pin Replace lifter cover/gasket or lifter/and, or antirotation pin Replace push rod, push rod cover and/or o-ring or one or two same cylinder quad seal Replace push rod, push rod cover and/or o-ring or one each cylinder quad seal Replace cam cover and/or gasket Replace primary cam chain, sprockets and/or fastener Replace primary cam chain tensioner Replace cam support plate/o-rings Replace cam support plate Replace cam support bearing/cams/secondary cam chain/tensioner Replace oil pump and/or o-rings Replace cam bearing crankcase Replace cam bearing crankcase By pass valve inspection CRANKCASE Replace crankcases California vehicles only includes remove and install engine Replace crankcases Seal crankcase only Replace flywheels includes remove and install engine includes remove and install engine 3406 3407 3411 7.9 6.8 7.5 7.9 6.8 7.5 7.9 6.7 7.5 3406 8.0 8.0 8.0 one bearing two bearings 3341 3342 3343 3354 2.6 3.4 3.7 2.7 2.6 3.4 3.7 2.7 2.6 3.4 3.7 2.7 3328 3335 3337 3338 1.7 2.8 3.5 3.7 1.7 2.8 3.5 3.7 1.7 2.8 3.5 3.7 3325 3327 1.6 1.7 1.6 1.7 1.6 1.7 3318 1.6 1.6 1.6 3317 1.4 1.4 1.4 on both cylinders 3310 1.7 1.7 1.7 one or two same cylinder 3307 1.4 1.4 1.4
2010 FLHR Models
6-11
FB4 = FLHR
FR4 = FLHRC
FW4 = FLHR Shrine
FHM = FLHP Police
FTM = FLHPE
Table 6-3. Engine

3412 3412 California vehicles only 3410 3410 one both 3413 3414 3403 3420
MODELS FR4
7.5 7.4 7.0 6.9 3.0 3.4 0.1 0.1
FB4 FW4
7.5 7.4 7.0 6.9 3.0 3.4 0.1 0.1
FHM FTM
7.4 6.9 7.0 6.9 3.0 3.4 0.1 0.1
Replace right side main bearing Replace right side main bearing Replace left side main bearing Replace left side main bearing Piston jet/o-ring Piston jet/o-ring Replace crank position sensor o-ring Check flywheel trueness before assembly or after removal Recondition cylinder heads head removed for non-related repairs Recondition cylinder heads head removed for non-related repairs Replace piston rings
California vehicles only
one head
3425
1.0
1.0
1.0
both heads
3426
2.0
2.0
2.0
3428
0.3
0.3
0.3
Replace pistons
3430
1.4
1.4
1.4
Replace oil filter mount end cap and/or gasket Replace oil cooler Replace oil cooler mounting bracket Replace oil cooler hose and/or clamp Replace oil filter mount/fittings FUEL SYSTEM Replace air cleaner backing plate Replace air cleaner cover Replace induction module Replace induction module seal one or both
4519 4525 4526 4528 4533
-----------
-----------
0.2 0.4 0.4 0.6 0.4
3501 3502 3508 3510
0.2 0.1 1.1 1.2
0.2 0.1 1.1 1.2
0.2 0.1 1.1 1.2
2010 FLHR Models
6-12
FB4 = FLHR
FR4 = FLHRC
FW4 = FLHR Shrine
FHM = FLHP Police
FTM = FLHPE
Table 6-3. Engine

3514
MODELS FR4
0.2
FB4 FW4
0.2
FHM FTM
0.2
Replace external fuel supply hose EVAPORATIVE EMISSIONS SYSTEM Replace evaporative purge solenoid Replace canister Replace any one hose
3522 3527 3529
0.3 0.5 0.4
0.3 0.5 0.4
0.3 0.5 0.4
2010 FLHR Models
6-13
FB4 = FLHR
FR4 = FLHRC
FW4 = FLHR Shrine
FHM = FLHP Police
FTM = FLHPE

DRIVE Replace primary derby cover and/or gasket/o-ring Replace primary chain Replace Primary chain tensioner Replace engine sprocket Replace engine sprocket seal Replace primary cover Replace inner primary case &/or seals or bearing Replace primary cover gasket Replace shift lever Replace shift lever shaft and/or inner lever Replace starter-primary o-ring CLUTCH Adjust clutch Replace release cable assembly Service the clutch includes disassembly, cleaning, inspection repair, assembly ,and adjustment Replace clutch release bearing and/or push rod Replace clutch release (ball ramp) and/or side cover 4016 4018 1.2 1.6 1.2 1.6 1.2 1.6 --4006 4011 0.2 1.2 1.3 0.2 1.2 1.3 0.2 1.2 1.3 heel or toe includes removal of heel and toe shift levers 4001 4002 4033 4003 4005 4007 4008 4009 4012 4017 4034 0.1 0.9 0.8 0.9 2.4 0.6 2.1 0.6 0.1 0.2 0.6 0.1 0.9 0.8 0.9 2.4 0.6 2.1 0.6 0.1 0.2 0.6 0.1 0.9 0.8 0.9 2.4 0.6 2.1 0.6 0.1 0.2 0.6
2010 FLHR Models
6-14
FB4 = FLHR
FR4 = FLHRC
FW4 = FLHR Shrine
FHM = FLHP Police
FTM = FLHPE

TRANSMISSION CASE Replace transmission case Replace transmission complete- Includes RRI oil passage gasket Overhaul transmission includes disassembly, cleaning, inspection, replacing parts (transmission case in frame) Replace transmission sprocket Replace main drive gear oil seal Replace mainshaft oil seal Replace side door gasket Replace shifter drum Replace shifter arm assembly or springs Replace transmission top cover and/or gasket Replace shifter forks and/or shaft Replace side door bearing Replace side door bearing Replace transmission case countershaft bearing Replace main drive gear and/or bearing Replace transmission side cover gasket Replace oil pan and/or gasket Replace transmission shifter shaft seal Replace vehicle speed sensor o-ring one both in transmission case in main drive gear 4309 4311 4316 4321 4331 4336 4341 4343 4348 4351 4361 4366 4368 4378 4390 4380 2.6 2.7 2.2 2.8 2.9 3.0 0.6 2.9 3.1 3.2 3.1 3.4 1.1 0.9 2.2 0.7 2.6 2.7 2.2 2.8 2.9 3.0 0.6 2.9 3.1 3.2 3.1 3.4 1.1 0.9 2.2 0.7 2.6 2.7 2.2 2.8 2.9 3.0 0.6 2.9 3.1 3.2 3.1 3.4 1.1 0.9 2.2 0.7 4306 4.6 4.6 4.6 4304 4305 5.3 4.9 5.3 4.9 5.3 4.9
2010 FLHR Models
6-15
FB4 = FLHR
FR4 = FLHRC
FW4 = FLHR Shrine
FHM = FLHP Police
FTM = FLHPE

ACCESSORIES Replace windshield Replace windshield Replace windshield bushing Replace spring clip on windshield Replace saddlebag mounting bracket or bail head stud/retainer Replace saddlebag guard Replace a single saddlebag guard rail Replace saddlebag Replace saddlebag lock Replace saddlebag cover Replace saddlebag bottom Replace saddlebag latch Replace one saddlebag tether strap Replace one frame sidecover or mounting grommet Replace lock-set Replace fender tip Replace fender tip Replace bumper Replace bumper Replace highway bar Replace rear view mirror Replace amplifier Replace speaker Replace strobe lamp front rear front rear front one or both one one bottom only 6254 6256 6257 6259 6260 6244 6261 6262 6263 6276 6302 6304 6303 6305 6353 6513 6521 6523 6526 0.3 --0.2 ------0.2 --0.1 0.5 0.1 0.1 ----0.3 0.1 ------0.3 --0.2 0.2 0.2 0.3 0.2 0.1 0.1 0.7 0.1 ----0.2 0.3 0.1 ------0.3 0.2 0.2 0.3 0.3 0.4 0.2 --0.1 0.7 ----0.3 0.2 0.4 0.1 0.2 0.1 0.6 entire assembly window only all or one 6203 6204 6208 6210 6253 0.1 0.3 0.2 0.2 0.2 0.1 0.3 0.2 0.2 0.2 0.1 0.3 0.2 0.2 0.2
2010 FLHR Models
6-16
FB4 = FLHR
FR4 = FLHRC
FW4 = FLHR Shrine
FHM = FLHP Police
FTM = FLHPE

6529
MODELS FR4
---
FB4 FW4
---
FHM FTM
0.3
Repair or replace rear mount
2010 FLHR Models
6-17
FB4 = FLHR
FR4 = FLHRC
FW4 = FLHR Shrine
FHM = FLHP Police
FTM = FLHPE

INSTRUMENTS Fuel gauge, see fuel tank Replace speedometer Replace tachometer Replace indicator panel lens Replace odometer reset switch boot WIRING Replace connector housing Replace connector anchor Replace main wiring harness Replace rear fender wiring harness Replace front fender wiring harness Replace main harness trough/tray Replace main harness trough cover SWITCHES Replace handlebar cruise on/off switch Replace ignition switch Replace fuse Replace main fuse or cover Replace main fuse block Replace rear stoplight relay Replace right handlebar switch Replace left upper handlebar switch housing Replace left lower handlebar switch housing Replace right upper handlebar switch housing Replace right lower handlebar switch housing 5128 5129 5145 5147 5151 5169 5173 5177 5178 5179 5180 0.5 0.3 0.2 0.2 0.5 0.2 0.7 0.2 0.3 0.2 0.7 0.5 0.3 0.2 0.2 0.5 0.2 0.7 0.2 0.2 0.2 0.7 0.5 0.3 0.2 0.2 0.5 0.2 0.7 0.2 0.4 0.2 0.7 Lower trough, or both lower trough and cover Trough cover only Includes installing new conduit 5022 5023 5026 5036 5049 5078 5079 0.1 0.1 3.1 1.0 --0.9 0.4 0.1 0.1 3.1 1.0 0.9 0.9 0.4 0.1 0.1 3.1 1.0 0.9 0.9 0.4 Cosmetic issue Cosmetic issue ---6003 6009 6018 6043 --0.3 --0.1 0.1 --0.3 --0.1 0.1 --0.3 0.3 0.1 0.1
2010 FLHR Models
6-18
FB4 = FLHR
FR4 = FLHRC
FW4 = FLHR Shrine
FHM = FLHP Police
FTM = FLHPE

5182 5192 Any handlebar switch 6953
MODELS FR4
1.0 0.5 0.4
FB4 FW4
1.0 0.5 0.4
FHM FTM
1.0 0.5 0.4
Replace handlebar cruise set/res. Switch Replace any nacelle switch Replace switch knob LIGHTS Replace headlight housing Replace turn signal light assembly Replace turn signal light assembly Replace rear turn signal bar Replace fender tip light bulb or lens, includes dia- Front gnosis Replace fender tip light bulb or lens, includes dia- Rear gnosis Replace fender tip lamp assembly Replace fender tip lamp assembly Replace auxiliary lamp assembly Replace auxiliary lamp bracket Replace license plate light assembly BATTERY Replace the battery Replace battery tray Replace battery cable Includes diagnosis Front Rear Includes adjustment Includes adjustment Includes adjustment Front Rear
5189 5201 5205 5207 5217
0.2 0.4 0.4 0.4 ---
0.2 0.4 0.4 0.4 0.1
0.2 0.4 0.4 0.4 0.1
5221
0.1
0.1
0.1
5225 5229 5230 5232 5247
--0.3 0.5 0.8 ---
0.2 0.3 0.5 0.8 0.4
0.2 0.3 0.5 0.8 0.4
5705 5767 5769
0.3 0.8 0.4
0.3 0.8 0.4
0.3 0.8 0.4
2010 FLHR Models
6-19
FB4 = FLHR
FR4 = FLHRC
FW4 = FLHR Shrine
FHM = FLHP Police
FTM = FLHPE
Table 6-8. FLHR Diagnostics

NOTE: Unless otherwise noted, all codes include diagnostic time and replacement time if required. The codes must be used in conjunction with the diagnostic/repair procedures listed in the current Service Manual and Electrical Diagnostic Manual. DIAGNOSTICS GENERAL Repair any single wire Repair any single wire Repair any single wire Replace position lamp Replace headlight Replace indicator lamp assembly Light circuit Accessory circuit All wires except lighting and accessory circuits Position lamp inoperative Headlamp inoperative High beam indicator inoperative, neutral lamp inoperative, oil pressure lamp inoperative, turn signal indicator inoperative Replace tail lamp bulb or single light bulb or lens Replace tail lamp assembly or circuit board Replace auxiliary lamp bulb Replace horn and/or bracket Running lamps inoperative Headlamp inoperative, stop lamp inoperative Auxiliary lamp inoperative Horn inoperative 5197 5215 5227 5765 7210 0.1 0.2 0.1 0.1 0.5 0.1 0.2 0.1 0.1 0.5 0.1 0.2 0.1 0.1 0.5 5039 5043 5041 5143 5185 5191 0.5 0.5 0.5 0.1 0.1 0.2 0.5 0.5 0.5 0.1 0.1 0.2 0.5 0.5 0.5 0.1 0.1 0.2
Repair engine compression, use in conjunction with Engine cranks but will not start, starts hard, starts additional code(s) Code not present - then stalls B1006, B1007, B0563, P0562, P0563, P0603, P0605, C0563 SWITCHES Replace rear stoplight switch - does not include bleeding brakes, use with appropriate bleed code Replace rear stoplight switch - does not include bleeding brakes, use with appropriate bleed code Replace rear stoplight switch - does not include bleeding brakes, use with appropriate bleed code Replace neutral switch Nothing clicks, neutral lamp always on, neutral lamp inoperative, B1155 U1097, U1255 Stop lamp inoperative, cruise control malfunction P0572, C1212, C1214
7770
0.2
0.2
0.2
1409
0.9
0.9
0.9
5141
0.3
0.3
0.3
6787
0.5
0.5
0.5
5157
0.3
0.3
0.3
2010 FLHR Models
6-20
FB4 = FLHR
FR4 = FLHRC
FW4 = FLHR Shrine
FHM = FLHP Police
FTM = FLHPE

5161
MODELS FR4
0.3
FB4 FW4
0.3
FHM FTM
0.3
Replace oil pressure switch
Oil pressure lamp always on, oil pressure lamp inoperative
Replace auxiliary lamp switch Replace clutch switch Replace left handlebar switch
Auxiliary lamp inoperative Nothing clicks, B1154 Horn always on, horn inoperative, headlamp inoperative
5167 5168 5171
0.2 0.8 0.5
0.2 0.8 0.5
0.2 0.8 0.5
Replace front brake light switch Replace front brake light switch Replace handlebar (cruise set) switch Replace cruise enable switch Replace start button Replace odometer reset switch Replace odometer reset switch boot Replace engine stop switch Replace engine stop switch Replace turn signal switch Replace turn signal switch Replace ignition switch Replace ignition switch FUSES AND RELAYS Replace brake relay Replace accessory fuse Replace fuse Replace brake relay
P0572, C1094, C1212 Stop lamp inoperative, cruise control malfunction P0577 Cruise control malfunction Starter inoperative B1008 B1008 Serial data missing No check engine lamp Both lamps on one side inoperative Both lamps on one side inoperative U1097, U1255 Serial data missing
1413 5176 5182 5192 5818 6001 6002 6730 7295 6811 6815 6782 7287
1.2 0.7 1.0 0.5 1.0 0.4 0.1 0.8 0.7 0.8 0.8 0.4 0.4
1.2 0.7 1.0 0.5 1.0 0.4 0.1 0.8 0.7 0.8 0.8 0.4 0.4
1.3 0.7 1.0 0.5 1.0 0.4 0.1 0.8 0.7 0.8 0.8 0.4 0.4
P0572, C1095, C1216 P0572 Cruise control malfunction Cruise control malfunction
1407 1804 5145 5169 6713
0.4 0.4 0.2 0.2 0.5
0.4 0.4 0.2 0.2 0.5
0.4 0.4 0.2 0.2 0.5
Harness inspection/wiggle test/replace battery fuse U1064
2010 FLHR Models
6-21
FB4 = FLHR
FR4 = FLHRC
FW4 = FLHR Shrine
FHM = FLHP Police
FTM = FLHPE

6729
MODELS FR4
0.3
FB4 FW4
0.3
FHM FTM
0.3
Inspect/access main wire harness/wiggle test/replace ignition fuse Inspect harness/wiggle test/replace main fuse
Serial data missing
Serial data missing
6733 6766
0.3 0.4
0.3 0.4
0.3 0.4
Access instruments\wiggle test\replace instrument U1097, U1255 fuse Access instruments\wiggle test\replace accessory U1097, U1255 fuse Replace starter relay Replace starter relay Replace key switch relay Inspect/main wiring harness/replace battery fuse Replace 15 amp fuse Replace engine control fuse Replace system relay Replace system relay Replace system relay Starter inoperative B1134 U1097 No check engine lamp, U1255 Engine cranks but will not start, starts hard P1475 Serial data missing, P1001, P1003 P1002 P1004
6781
0.4
0.4
0.4
5832 6841 7098 7159 7181 7826 7904 7909 7911 7937
0.4 0.2 0.5 0.4 0.6 0.3 0.4 0.2 0.2 0.7
0.4 0.2 0.5 0.4 0.6 0.3 0.4 0.2 0.2 0.7
0.4 0.2 0.5 0.4 0.6 0.3 0.4 0.2 0.2 0.7
Harness inspection/wiggle test/replace ECM fuse P1003, P1351, P1354 CHARGING CIRCUIT Milliamp draw Replace stator Total current draw Replace voltage regulator Replace voltage regulator Replace rotor Replace battery Low battery after extended ignition off Low or no charging Diagnose charging system No or low charging, overcharging Serial data missing Replace rotor Engine cranks but will not start, starts hard, starts - then stalls
5308 5309 5310 5316 6724 5319 7185
0.2 2.8 0.2 0.8 0.4 2.5 0.5
0.2 2.8 0.2 0.8 0.4 2.5 0.5
0.2 2.8 0.2 0.8 0.4 2.5 0.5
2010 FLHR Models
6-22
FB4 = FLHR
FR4 = FLHRC
FW4 = FLHR Shrine
FHM = FLHP Police
FTM = FLHPE

7771
MODELS FR4
0.2
FB4 FW4
0.2
FHM FTM
0.2
Repair charging system/accompanies other codes B0563, B1006, B1007, P0562, P0563, C0562, C0563 STARTER CIRCUIT Replace starter Replace starter Replace starter clutch Replace starter solenoid Repair starting system, use in conjunction with additional code(s) IGNITION CIRCUIT Replace spark plugs Engine cranks but will not start, starts hard, starts - then stalls, misfire at idle or under load, rough or rolling idle Replace spark plug Replace spark plug wire P1353, P1356, P1357, P1358 Engine cranks but will not start, starts hard, starts - then stalls, misfire at idle or under load, rough or rolling idle Replace spark plug wire Replace ignition coil Replace ignition coil P1353, P1356, P1357, P1358 Misfire at idle or under load, rough or rolling idle Engine cranks but will not start, starts hard, starts - then stalls Replace ignition coil Replace ignition coil AIR INTAKE Repair intake leak FUEL SYSTEM Replace fuel level sender B1004, B1005 Misfire at idle or under load, P0131, P0151 P1353, P1356, P1357, P1358 P1351, P1352, P1354, P1355 Solenoid clicks Starter spins but does not engage Starter spins but does not engage Starter testing, starter relay clicks Engine cranks but will not start, starts hard, starts - then stalls
5817 5825 5837 5845 7166
1.0 1.0 1.1 1.2 0.2
1.0 1.0 1.1 1.2 0.2
1.0 1.0 1.1 1.2 0.2
7134
0.4
0.4
0.4
7548 7138
0.2 0.7
0.2 0.7
0.2 0.7
7549 7139 7226
0.2 0.8 1.0
0.2 0.8 1.0
0.2 0.8 1.0
7547 7856
0.6 0.6
0.6 0.6
0.6 0.6
7486
1.0
1.0
1.0
6035
0.7
0.7
0.7
2010 FLHR Models
6-23
FB4 = FLHR
FR4 = FLHRC
FW4 = FLHR Shrine
FHM = FLHP Police
FTM = FLHPE

6047 6775 6861 7013 7014
MODELS FR4
0.4 0.4 0.5 0.8 0.8
FB4 FW4
0.4 0.4 0.5 0.8 0.8
FHM FTM
0.4 0.4 0.5 0.8 0.8
Replace fuel gauge Replace fuel gauge Replace purge solenoid Replace fuel filter or clean fuel pump screen Repair/replace fuel pump/pressure regulator/fuel line/fuel filter Replace fuel filter screen
B1005 U1097, U1255 P0444, P0445 Starts - then stalls, P1353, P1356, P1357, P1358 Starts - then stalls, P1353, P1356, P1357, P1358
7163
1.0
1.0
1.0
7164
1.0
1.0
1.0
Misfire at idle or under load, rough or rolling idle, P0131, P0132, P0151, P0152
7144
0.9
0.9
0.9
Replace fuel injector Replace fuel injector Replace fuel injector Replace fuel pump Replace fuel pump Replace fuel pressure regulator SENSORS AND ECM Replace jiffy stand sensor Replace induction module Remove and clean or replace induction module Replace twist grip sensor or repair connections
Emits black smoke P0261, P0262, P0263, P0264 Engine cranks but will not start, starts hard Engine cranks but will not start, starts hard P1003 Emits black smoke
7596 7795 7992 7415 7924 7480
2.0 0.7 0.7 0.9 1.3 1.0
2.0 0.7 0.7 0.9 1.3 1.0
2.0 0.7 0.7 0.9 1.3 1.0
P0641, P1501, P1502 P0641, P2100, P2102 P2101, P2119, P2176 P0641, P0651, P2122, P2123, P2127, P2128, P2138
5085 7085 7091 7564
0.5 1.4 1.6 1.4
0.5 1.4 1.6 1.4
0.5 1.4 1.6 1.4
P0120, P0122, P0123, P0220, P0222, P0223, P0505, P2135
7590
1.6
1.6
1.6
2010 FLHR Models
6-24
FB4 = FLHR
FR4 = FLHRC
FW4 = FLHR Shrine
FHM = FLHP Police
FTM = FLHPE

7598 7710 7667
MODELS FR4
2.0 0.4 0.5
FB4 FW4
2.0 0.4 0.5
FHM FTM
2.0 0.4 0.5
Replace engine temperature (ET) sensor Replace engine temperature (ET) sensor Replace oxygen sensor
Emits black smoke P0117, P0118 P0031, P0032, P0131, P0132, P0134, P0151, P0152, P0154
Replace crankshaft position (CKP) sensor Clean or repair crankshaft position (CKP) sensor Replace TMAP sensor Replace TMAP sensor Replace TMAP sensor Replace TMAP sensor Replace TMAP sensor Replace TMAP sensor clean or repair vehicle speed sensor (VSS) Replace vehicle speed sensor (VSS) Replace ECM
7981 7982 7152 7597 7630 7650 7725 7760 7939 7967 6123
0.4 0.3 0.6 2.0 0.7 0.8 0.8 0.8 0.9 1.2 0.8
0.4 0.3 0.6 2.0 0.7 0.8 0.8 0.8 0.9 1.2 0.8
0.4 0.3 0.6 2.0 0.7 0.8 0.8 0.8 0.9 1.2 0.8
Replace ECM Replace ECM Replace ECM Replace ECM Replace ECM Replace ECM
P1009 P1655, P1656 P2100, P2103 P1353, P1356, p1357, P1358 Emits black smoke Serial data missing, P0107, P0112, P0120, P0122, P0123, P0220, P0222, P0223, P0505, P1655, P1656, U1300, U1301
6703 7080 7093 7544 7601 7641
0.7 --1.4 0.5 2.2 1.1
0.7 --1.4 0.5 2.2 1.1
0.7 0.9 1.4 0.5 2.2 1.1
Replace ECM
Engine cranks but will not start, starts - then stalls, P0117, P0118, P0120, P0373, P0374, P1002, P1351, P1352, P1354, P1355
7680
0.6
0.6
0.6
2010 FLHR Models
6-25
FB4 = FLHR
FR4 = FLHRC
FW4 = FLHR Shrine
FHM = FLHP Police
FTM = FLHPE

7740
MODELS FR4
1.0
FB4 FW4
1.0
FHM FTM
1.0
Replace ECM
P0113, P0572, P0641, P0651, P2122, P2123, P2128, P2127, P2138
Replace ECM
P0131, P0132, P0134, P0151, P0152, P0154, P0262, P0264
7815
0.8
0.8
0.8
Replace ECM
Serial data missing, no check engine lamp, P0261, P0263, P0444, P0603, P0605, P1001, P1010, P1270, P1475, P1477, P1478, P1501, P1502, P1600, P2107, U1064
7850
0.7
0.7
0.7
P0501, P0502 Misfire at idle or under load, rough or rolling idle, serial data missing, U1300, U1301
7968 7993
1.2 0.9
1.2 0.9
1.2 0.9
HDI ACTIVE EXHAUST Replace exhaust actuator Replace exhaust actuator valve Replace exhaust actuator cable TURN SIGNALS/INSTRUMENTS/SECURITY Perform ECM/TSM/TSSM/HFSM module replace P1009 procedure Replaced TSM/TSSM/HFSM, system now ok Replaced TSM/TSSM/HFSM, System now ok Replace FOB battery Replace FOB Replace Bulb P1009 P1010 Fails to disarm Fails to disarm Both lamps on one side inoperative, flash at double normal rate, B1121, B1122 Replace Bulb Remove corrosion Remove corrosion/replace bulb Replace lamp assembly Flash at double normal rate Flash at double normal rate Flash at double normal rate Flash at double normal rate, B1121, B1122 6820 6821 6822 6823 0.2 0.2 0.4 0.4 0.2 0.2 0.4 0.4 0.2 0.2 0.4 0.4 6702 6707 6755 6756 6796 0.4 1.1 0.1 0.1 0.2 0.4 1.1 0.1 0.1 0.2 0.4 1.1 0.1 0.1 0.2 6701 0.4 0.4 0.4 P1475, P1477, P1478 P1475 P1475 7811 7812 7814 1.1 1.1 1.2 1.1 1.1 1.2 1.1 1.1 1.2
2010 FLHR Models
6-26
FB4 = FLHR
FR4 = FLHRC
FW4 = FLHR Shrine
FHM = FLHP Police
FTM = FLHPE

6003 6072
MODELS FR4
0.3 0.5
FB4 FW4
0.3 0.5
FHM FTM
0.3 0.5
Replace speedometer Replace speedometer
B1008 Serial data missing, no check engine lamp, U1016, U1097, U1255
Replace speedometer Replace speedometer Replace speedometer Replace speedometer Replace speedometer Replace tachometer Replace tachometer Replace TSM/TSSM/HFSM Replace TSM/TSSM/HFSM Replace TSM/TSSM/HFSM Replace TSM/TSSM/HFSM
No security lamp during bulb check Security lamp on continuously after bulb check U1300, U1301 Cruise control malfunction No check engine lamp Serial data missing, no check engine lamp U1301 Starter inoperative - nothing clicks U1016, U1064, U1255 Will not cancel upon turn completion Starter inoperative, nothing clicks, fails to disarm, both lamps on one side inoperative, flash at double normal rate, no check engine lamp, B1121, B1122, B1123, B1124, B1125, B1126, B1134, B1141, B1143, B1144, B1145, B1154, B1155
6738 6752 6765 6769 7311 6772 6803 5838 6717 6773 6791
0.3 0.3 0.6 0.4 0.3 ----0.6 0.8 0.9 0.5
0.3 0.3 0.6 0.4 0.3 ----0.6 0.8 0.9 0.5
0.3 0.3 0.6 0.4 0.3 0.4 0.6 0.6 0.8 0.9 0.5
Replace TSM/TSSM/HFSM Replace TSM/TSSM/HFSM Replace TSM/TSSM/HFSM Replace security siren Replace security siren Replace security antenna Replace security antenna harness AUTOMATIC COMPRESSION RELEASE Replace ACR solenoid
B1131, B1132 B1135, B1136, B1142 Serial data missing, U1300, U1301 B1131, B1132 No check engine lamp B1143, B1144, B1145 B1145
6833 6845 7998 6832 7161 6878 6881
0.7 0.4 0.9 0.5 0.3 0.3 0.5
0.7 0.4 0.9 0.5 0.3 0.3 0.5
0.7 0.4 0.9 0.5 0.3 0.3 0.5
P1655, P1656
7077
---
---
2.3
2010 FLHR Models
6-27
FB4 = FLHR
FR4 = FLHRC
FW4 = FLHR Shrine
FHM = FLHP Police
FTM = FLHPE

ABS BRAKES Replace ABS diode pack Worn or damaged wheel bearings or suspension components, may be used in conjunction with other codes Reroute brake lines Replace ABS hydraulic control unit (HCU) C1151, C1153 P0572, C0562, C1014, C1017, C1018, C1021, C1023, C1025, C1027, C1032, C1034, C1042, C1043, C1055, C1056, C1057, C1061, C1062, C1065, C1066, C1094, C1095, C1118, C1121, C1151, C1153, C1158, C1206, C1208, C1214, C1216 Replace ABS electronic control unit (ECU) P0572, C0562, C1014, C1017, C1018, C1021, C1023, C1025, C1027, C1032, C1034, C1042, C1043, C1055, C1056, C1057, C1061, C1062, C1065, C1066, C1094, C1095, C1118, C1121, C1151, C1153, C1158, C1206, C1208, C1214, C1216 Replace ABS front wheel sensor Replace rear wheel speed sensor C1021, C1025, C1032, C1206 C1023, C1027, C1034, C1208 2439 2440 0.8 1.0 0.8 1.0 0.8 1.0 2430 2.0 2.0 2.0 1418 1427 0.9 2.0 0.9 2.0 0.9 2.0 P0572, C1095, C1216 C1021, C1023, C1025, C1027, C1206, C1208 1404 1412 0.5 0.2 0.5 0.2 0.5 0.2
2010 FLHR Models
6-28
SUBJECT..............................................................................................................PAGE NO. 7.1 Service........................................................................................................................7-1 7.2 Chassis.......................................................................................................................7-2 7.3 Engine.........................................................................................................................7-8 7.4 Drive and Clutch........................................................................................................7-14 7.5 Transmission.............................................................................................................7-16 7.6 OEM Accessories......................................................................................................7-17 7.7 Electrical - General....................................................................................................7-19 7.8 Tri Glide Diagnostics..................................................................................................7-22 Unless otherwise specified, Job Times shown include all operations necessary to complete the listed job.
TRIKE MODELS
MAM = FLHTCUTG
MBM = FLHXXX
Table 7-1. Service

ITEM DESCRIPTION LABOR CODE MODELS MAM MBM
NEW Set-up and pre-delivery 1,000 (1,600 km) mile service REGULAR 5,000 (8,000 km) mile maintenance 10,000 (16,000 km) mile maintenance 15,000 (24,000 km) mile maintenance 20,000 (32,000 km) mile maintenance 25,000 (40,000 km) mile maintenance 30,000 (48,000 km) mile maintenance 35,000 (56,000 km) mile maintenance 40,000 (64,000 km) mile maintenance 45,000 (72,000 km) mile maintenance 50,000 (80,000 km) mile maintenance Addition to any maintenance- required every 2 years flush/fill D.O.T 4 brake fluid- front and rear ----------------------2.6 3.1 2.4 3.5 3.7 3.3 2.6 3.3 2.2 8.1 0.7 2.6 3.1 2.4 3.5 3.7 3.3 2.6 3.3 2.2 8.1 0.7 ----2.1 3.3 2.1 3.3
2010 Trike Models
7-1
MAM = FLHTCUTG
MBM = FLHXXX
Table 7-2. Chassis

PAINT REPAIR NOTE: Use these codes when repairing any painted part on vehicle with the Kent Moore finesse kit or other paint repair methods Light scuff/scratch - buff Light sanding/buff/blend Buff entire part Repair build up in clear/paint Color blend/paint/buff DRIVE Adjust secondary belt Replace secondary belt Replace rear wheel sprocket Replace rear wheel compensator cushion Replace rear wheel compensator bowl WHEELS Replace tire - includes mounting and balancing Replace tire - includes mounting and balancing front rear 2106 2111 2113 0.6 0.5 0.8 0.6 0.5 0.8 with bearing at PDI only 2010 2011 2021 2013 2014 0.7 5.2 2.7 2.3 2.7 0.7 5.2 2.7 2.3 2.7 1102 1104 1106 1108 1110 0.2 0.4 0.6 0.8 1.0 0.2 0.4 0.6 0.8 1.0
Replace wheel assembly - includes disc exchange, front mounting and balancing Replace wheel assembly - includes disc exchange, rear mounting and balancing Replace wheel bearings Replace rear wheel center cap HANDLEBARS Replace handlebars Replace clutch hand lever Replace clutch hand lever bracket includes removing radio front left or right
2114
0.5
0.5
2136 2159
0.7 0.1
0.7 0.1
2206 2221 2226
1.5 0.2 0.3
1.5 0.2 0.3
2010 Trike Models
7-2
MAM = FLHTCUTG
MBM = FLHXXX
Table 7-2. Chassis

2246 2251 one or both - includes loosening radio, if applicable includes removing radio, if applicable 2253 2254
MODELS MAM
1.0 0.2 1.0 0.8
MBM
1.0 0.2 1.0 0.8
Replace both rubber handlebar mounts Replace rubber handlebar grip Replace handlebar riser Replace handlebar clamp FRAME/REAR FORK/FRONT FORK Replace steer damper Adjust steering head bearings Change front fork oil Replace frame
includes removing radio, if applicable
1896 2290 both sides includes removal and installation of all accessories and motorcycle components --2306
0.1 0.7 2.2 17.5
0.1 0.7 2.2 17.5
Replace frame assembly, rear Replace intermediate frame Replace frame connection brackets Replace panhard rod Replace front fork assembly includes removal and installation of upper and lower fork brackets Replace lower fork bracket and stem Replace steering head cups and bearings Replace upper fork bracket Service or replace fork slider and/or seal includes one side removal, disassembly, cleaning, inspection, replacing parts, servicing damper tube, replacing bushings, assembly and installation Service or replace fork slider and/or seal includes both sides removal, disassembly, cleaning, inspection, replacing parts, servicing damper tube, replacing bushings, assembly and installation Replace fork side one side including bearing adjustment
2339 1897 1898 1899 2311
1.7 1.0 0.6 0.7 3.0
1.7 1.0 0.6 0.7 3.0
2316 2321 2326 2341
3.2 3.2 2.7 2.4
3.2 3.2 2.7 2.4
2342
2.9
2.9
2346
1.2
1.2
2010 Trike Models
7-3
MAM = FLHTCUTG
MBM = FLHXXX
Table 7-2. Chassis

2351 2356 2361 2366 2368 2369 one side both sides 2371 2376 2394 2299 rear right rear left both front rubber mounts and/or front mount bracket 2395 2397 2398
MODELS MAM
1.5 2.4 2.9 3.0 0.8 0.2 0.8 1.0 0.2 0.1 2.3 0.3 1.4
MBM
1.5 2.4 2.9 3.0 0.8 0.2 0.8 1.0 0.2 0.1 2.3 0.3 1.4
Replace fork side Replace fork tube Replace fork tube Replace rear fork and/or bearings or adaptor plate Replace rear fork pivot shaft Replace rear shock air line Replace rear shock absorber assembly Replace rear shock absorber assembly Replace footboard or foot peg Replace footboard insert Replace motor mount Replace motor mount Replace motor mount BRAKES Replace hydraulic brake line includes filling/bleeding brakes Replace hydraulic brake line includes filling/bleeding brakes Replace brake pads Replace brake pads Replace brake caliper includes filling/bleeding brakes Replace brake caliper includes filling/bleeding brakes Replace rear brake caliper mount Replace brake caliper screen Replace brake rotor
both sides one side both sides
front
2406
1.1
1.1
rear
2411
0.8
0.8
front each caliper rear-includes p. brake adj. front each caliper
2416 2421 2426
0.1 0.6 0.4
0.1 0.6 0.4
rear
2431
0.7
0.7
caliper bracket to axle bracket, each side front each caliper front one side
2408 2428 2436
0.3 0.1 0.3
0.3 0.1 0.3
2010 Trike Models
7-4
MAM = FLHTCUTG
MBM = FLHXXX
Table 7-2. Chassis

2437 2441 2442 2443 2461
MODELS MAM
0.4 0.2 0.3 0.4 0.6
MBM
0.4 0.2 0.3 0.4 0.6
Replace brake rotor Replace brake rotor Bleed brake caliper Bleed brake caliper Replace master cylinder assembly includes filling/bleeding brakes Replace master cylinder assembly includes filling/bleeding brakes Replace master cylinder cover Rebuild master cylinder assembly includes filling/bleeding brakes PARKING BRAKE Adjust parking brake Adjust parking brake Replace parking brake knob Replace parking brake cable Replace parking brake cable Replace parking brake lever Replace hardware kit Replace parking brake lever pivot pin Replace parking brake lever assembly Replace parking brake boot Replace rear brake pedal Replace front brake lever SEATS/FENDERS/TANKS Replace seat and/or strap or spring(s) and / or hinge bracket
front both sides rear - one side front (both) rear (both) front
rear
2466
0.8
0.8
front or rear front
2479 2471
0.1 0.7
0.1 0.7
PDI only at the knob full adjustment
1838 1839 1841
0.1 0.3 0.1 0.7 0.7 0.6 0.6 0.1 0.4 0.1 0.3 0.2
0.1 0.3 0.1 0.7 0.7 0.6 0.6 0.1 0.4 0.1 0.3 0.2
right- includes adjustment left-includes adjustment Includes side plates and adjustment includes adjustment
1842 1843 1844 1845 1846
with cables/adjustment
1847 1848 2492 2494
2506
0.1
0.1
2010 Trike Models
7-5
MAM = FLHTCUTG
MBM = FLHXXX
Table 7-2. Chassis

2526 --2525 2541 2553 2558 2559
MODELS MAM
1.0 --0.1 1.2 0.3 0.2 0.1
MBM
1.0 --0.1 1.2 0.3 0.2 0.1
Replace fender Replace fender Replace license plate mount Replace fuel tank assembly Replace fuel tank console/instrument panel Replace fuel tank console insert Replace fuel tank console fuel door or fuel door lock Replace fuel tank console rubber mounting strip Replace fuel level sending unit Replace fuel tank check valve assembly Replace canopy gasket Replace fuel filter Replace fuel transfer hose inside tank Replace fuel tank trim or medallion Replace oil filter EXHAUST SYSTEM Replace complete exhaust system and/or gaskets Replace exhaust pipe Replace exhaust pipe
front rear - see body section
2557 2564 includes fuel line attached to check valve 2567 2570 2575 2579 6507 2582
0.2 0.5 0.6 0.4 0.5 0.5 0.3 0.1
0.2 0.5 0.6 0.4 0.5 0.5 0.3 0.1
2626 right side header assembly and/or port gaskets left side cross under pipe, support clamp and/or gasket 2631 2636
1.1 1.0 0.3
1.1 1.0 0.3
Replace one muffler Replace rear exhaust support bracket Replace any one exhaust shield Replace one muffler support at transmission side cover
2646 2651 2661 2666
0.2 0.4 0.1 0.2
0.2 0.4 0.1 0.2
2010 Trike Models
7-6
MAM = FLHTCUTG
MBM = FLHXXX
Table 7-2. Chassis

BODY Replace trunk door cover Replace trunk door Replace trunk door seal Replace trunk door hinge Replace trunk door hinge Replace trunk door lanyard Replace trunk door lanyard Replace trunk door lock/lock bezel and/or o-ring Replace trunk door striker Replace body Replace body trim Replace trunk door latch assembly Replace trunk door latch/cable Replace fender rear left or right both includes bracket one or both left right left right backside of door 1851 1852 1853 1854 1855 1856 1857 1858 1859 1861 1864 1862 1863 2531 0.1 0.4 0.3 0.1 0.1 0.1 0.1 0.1 0.1 1.3 --0.2 0.5 0.5 0.1 0.4 0.3 0.1 0.1 0.1 0.1 0.1 0.1 1.1 0.1 0.2 0.5 0.5
2010 Trike Models
7-7
MAM = FLHTCUTG
MBM = FLHXXX
Table 7-3. Engine

GENERAL Remove and install engine includes remove, replace, install oil passage gasket Remove and install engine includes remove, replace, install oil passage gasket Replace stabilizer/stabilizer bracket top front 3005 3009 0.2 0.3 0.2 0.3 3006 4.8 4.8 California vehicles only 3006 4.9 4.9
Remove and replace oil pan for inspection/decon- with engine removed tamination Replace dipstick CYLINDER HEAD Recondition cylinder head includes removal of head and gasket, remove carbon, service valve guides, grind valves and seats, test springs and install head and gaskets. Recondition cylinder head includes removal of head and gasket, remove carbon, service valve guides, grind valves and seats, test springs and install head and gaskets. Recondition cylinder head includes removal of head and gasket, remove carbon, service valve guides, grind valves and seats, test springs and install head and gaskets. Replace cylinder head Replace cylinder head Replace valve seal or spring after cylinder head removal Replace valve seal or spring after cylinder head removal Replace cylinder head gasket/o-ring Replace cylinder head gasket/o-ring front cylinder rear cylinder both seals or springs (intake or exhaust) one head both heads one seal or spring (intake or exhaust ) both heads rear head front head
3480
0.1
0.1
3101
4.9
4.9
3103
4.9
4.9
3104
5.5
5.5
3106 3108 3131
3.9 4.8 0.1
3.9 4.8 0.1
3132
0.2
0.2
3140 3142
3.0 3.0
3.0 3.0
2010 Trike Models
7-8
MAM = FLHTCUTG
MBM = FLHXXX
Table 7-3. Engine

3143 3144 3145 3148 3149 3150 3147
MODELS MAM
3.4 0.8 0.8 0.9 0.7 1.4 1.6
MBM
3.4 0.8 0.8 0.9 0.7 1.4 1.6
Replace cylinder head gasket/o-ring Replace rocker arm covers and/or gaskets Replace rocker arm covers and/or gaskets Replace rocker arm covers and/or gaskets
both cylinders front cylinder rear cylinder both cylinders
Recondition rocker arms after heads are removed one head Recondition rocker arms after heads are removed both heads Replace lower rocker arm cover/gasket, or rocker front cylinder arms and /or shafts/rocker arm support Replace lower rocker arm cover/gasket, or rocker rear cylinder arms and /or shafts/rocker arm support Replace lower rocker arm cover/gasket, or rocker both cylinders arms and /or shafts/rocker arm support Replace cylinder o-ring/drain o-ring Replace cylinder o-ring/drain o-ring Replace cylinder o-ring/drain o-ring Replace crankcase umbrella valve Replace crankcase umbrella valve CYLINDER AND PISTON Recondition top end - includes disassembly, replacement of piston and sizing cylinder (.005 pistons), replacing piston rings and all items listed under recondition cylinder head and assembly. Recondition top end - includes disassembly, replacement of piston and sizing cylinder (.005 pistons), replacing piston rings and all items listed under recondition cylinder head and assembly. Replace piston rings includes deglazing cylinder one cylinder Replace piston rings includes deglazing cylinder both cylinders both pistons and cylinders one piston and cylinder front cylinder rear cylinder both cylinders one both
3152
1.6
1.6
3153
1.8
1.8
3161 3163 3168 3172 3174
3.2 3.2 3.6 1.1 1.2
3.2 3.2 3.6 1.1 1.2
3202
5.9
5.9
3203
6.5
6.5
3206 3216
3.5 4.1
3.5 4.1
2010 Trike Models
7-9
MAM = FLHTCUTG
MBM = FLHXXX
Table 7-3. Engine

3207
MODELS MAM
5.7
MBM
5.7
Recondition top end includes disassembly, deglazing cylinder and replacing rings, or replacing cylinder and piston, all items listed under recondition cylinder head and assembly. Recondition top end includes disassembly, deglazing cylinder and replacing rings, or replacing cylinder and piston, all items listed under recondition cylinder head and assembly. Recondition top end - includes disassembly, replacement of piston and bore and hone, resizing cylinder (.010 oversize or above), replacing piston rings and all items listed under recondition cylinder head and assembly. Recondition top end - includes disassembly, replacement of piston and bore and hone, resizing cylinder (.010 oversize or above), replacing piston rings and all items listed under recondition cylinder head and assembly.
3208
6.3
6.3
3211
6.3
6.3
3212
6.9
6.9
Replace piston and piston rings includes removal one cylinder of cylinder head and cylinder, fitting new piston with rings, resizing cylinder and assembly Replace piston and piston rings includes removal both cylinders of cylinder head and cylinder, fitting new piston with rings, resizing cylinder and assembly Replace cylinder and piston Replace cylinder and piston Replace one cylinder stud Replace all eight cylinder studs CAM COVER Replace lifter cover/gasket or lifter/and, or antirotation pin one or two same cylinder one cylinder both cylinders cylinder removed cylinders removed
3221
4.1
4.1
3231
5.3
5.3
3236 3246 3253 3254
3.4 3.9 0.1 0.5
3.4 3.9 0.1 0.5
3307
1.8
1.8
2010 Trike Models
7-10
MAM = FLHTCUTG
MBM = FLHXXX
Table 7-3. Engine

3310
MODELS MAM
2.1
MBM
2.1
on both cylinders
Replace push rod, push rod cover and/or o-ring or one or two same cylinder quad seal Replace push rod, push rod cover and/or o-ring or one each cylinder quad seal Replace cam cover and/or gasket Replace primary cam chain, sprockets and/or fastener Replace primary cam chain tensioner Replace cam support plate/o-rings Replace cam support plate Replace cam support bearing/cams/secondary cam chain/tensioner Replace oil pump and/or o-rings Replace cam bearing crankcase Replace cam bearing crankcase By pass valve inspection CRANKCASE Replace crankcases California vehicles only includes remove and install engine Replace crankcases Seal crankcase only Replace flywheels Replace right side main bearing Replace right side main bearing Replace left side main bearing California vehicles only includes remove and install engine California vehicles only includes remove and install engine one bearing two bearings
3317
1.8
1.8
3318
2.0
2.0
3325 3327
2.0 2.1
2.0 2.1
3328 3335 3337 3338
2.1 3.2 4.1 4.3
2.1 3.2 4.1 4.3
3341 3342 3343 3354
3.1 3.8 4.0 3.1
3.1 3.8 4.0 3.1
3406
8.4
8.4
3406 3407 3411 3412 3412 3410
8.3 7.1 7.9 7.9 7.8 7.1
8.3 7.1 7.9 7.9 7.8 7.1
2010 Trike Models
7-11
MAM = FLHTCUTG
MBM = FLHXXX
Table 7-3. Engine

3410 one both 3413 3414 3403 3420
MODELS MAM
7.0 3.4 3.8 0.1 0.1
MBM
7.0 3.4 3.8 0.1 0.1
Replace left side main bearing Piston jet/o-ring Piston jet/o-ring Replace crank position sensor o-ring Check flywheel trueness before assembly or after removal Recondition cylinder heads - head removed (for non-related repairs ) Recondition cylinder heads - head removed (for non-related repairs ) Replace piston rings cylinders removed (for non-related repairs deglaze only) Replace pistons cylinders removed (for non-related repairs) includes resizing cylinders Replace oil filter mount end cap and/or gasket Replace oil cooler Replace oil cooler mounting bracket Replace oil cooler hose and/or clamp Replace oil filter mount/fittings FUEL SYSTEM Replace air cleaner backing plate Replace air cleaner cover Replace induction module Replace induction module seal Replace external fuel supply hose EVAPORATIVE EMISSIONS SYSTEM Replace evaporative purge solenoid California vehicles only one or both both heads one head
3425
1.0
1.0
3426
2.0
2.0
3428
0.3
0.3
3430
1.4
1.4
4519 4525 4526 4528 4533
0.2 0.4 0.4 0.6 0.4
0.2 0.4 0.4 0.6 0.4
3501 3502 3508 3510 3514
0.2 0.1 1.1 1.2 0.2
0.2 0.1 1.1 1.2 0.2
3522
0.3
0.3
2010 Trike Models
7-12
MAM = FLHTCUTG
MBM = FLHXXX
Table 7-3. Engine

3527 3529
MODELS MAM
0.5 0.4
MBM
0.5 0.4
Replace canister Replace any one hose
California vehicles only
2010 Trike Models
7-13
MAM = FLHTCUTG
MBM = FLHXXX

DRIVE Replace derby cover and/or gasket/o-ring Replace primary chain Replace primary chain tensioner Replace engine sprocket Replace engine sprocket seal Replace primary cover Replace inner primary case and/or seals or mainshaft bearing Replace primary cover gasket Replace shift lever Replace shift lever shaft and/or inner lever Replace starter-primary o-ring CLUTCH Adjust clutch Replace release cable assembly Service the clutch includes disassembly, cleaning, inspection repair, assembly ,and adjustment Replace clutch release bearing and/or push rod Replace clutch release (ball ramp) and/or side cover DIFFERENTIAL Replace axle assembly Replace axle Replace axle bearing Replace axle stud Replace axle housing left or right left or right one 4037 4038 4039 4041 4042 3.3 0.3 0.5 0.4 3.3 3.3 0.3 0.5 0.4 3.3 4016 4018 1.2 1.7 1.2 1.7 --4006 4011 0.2 1.4 1.3 0.2 1.4 1.3 heel or toe shifter includes removal of heel and toe shift levers 4009 4012 4017 4034 0.6 0.1 0.2 0.6 0.6 0.1 0.2 0.6 4001 4002 4033 4003 4005 4007 4008 0.1 0.9 0.8 0.9 2.4 0.6 2.1 0.1 0.9 0.8 0.9 2.4 0.6 2.1
2010 Trike Models
7-14
MAM = FLHTCUTG
MBM = FLHXXX

4043 4044 4045 4046 4047
MODELS MAM
2.5 2.3 2.3 0.5 2.3
MBM
2.5 2.3 2.3 0.5 2.3
Replace differential assembly Replace differential carrier bearings Replace reverse ring gear Replace reverse bracket Replace differential seal
2010 Trike Models
7-15
MAM = FLHTCUTG
MBM = FLHXXX

TRANSMISSION CASE Replace transmission case Replace transmission complete- Includes remove, replace, install oil passage gasket Overhaul transmission includes disassembly, cleaning, inspection, replacing parts (transmission case in frame) Replace transmission sprocket Replace main drive gear oil seal Replace mainshaft oil seal Replace side door gasket Replace shifter drum Replace shifter arm assembly or springs Replace transmission top cover and/or gasket Replace shifter forks and/or shaft Replace side door bearing Replace side door bearing Replace transmission case countershaft bearing Replace main drive gear and/or bearing Replace transmission side cover gasket Replace oil pan and/or gasket Replace transmission shift shaft seal Replace vehicle speed sensor o-ring one both in transmission case in main drive gear 4309 4311 4316 4321 4331 4336 4341 4343 4348 4351 4361 4366 4368 4378 4390 4380 2.6 2.7 2.2 2.8 2.9 3.0 0.6 2.9 3.1 3.2 3.1 3.4 1.1 0.6 2.2 0.7 2.6 2.7 2.2 2.8 2.9 3.0 0.6 2.9 3.1 3.2 3.1 3.4 1.1 0.6 2.2 0.7 4306 4.6 4.6 4304 4305 6.2 5.8 6.2 5.8
2010 Trike Models
7-16
MAM = FLHTCUTG
MBM = FLHXXX

ACCESSORIES Replace windshield Replace one fairing wind deflector Replace one mid frame air deflector Replace instrument panel support housing or inner fairing Replace outer fairing or support brace Replace Tour-Pak lock or latch Replace one frame sidecover or mounting grommet or post Replace Tour-Pak hinge Replace inner fairing bracket Replace Nameplate Tour-Pak Replace Tour-Pak cover Replace Tour-Pak bottom Replace fairing cap Replace one fairing lower Replace one fairing lower glove compartment assembly or vent door Replace fairing lower vent door serrated washers left or right side, one or both washers Replace chrome fairing skirt Replace lock set Replace highway bar Replace tour-pak mount/luggage rack Replace tour-pak includes lights and brackets, antenna assembly, backrest, and rear speakers Replace rear view mirror one or both 6513 0.1 0.3 front 6241 6273 6276 6353 6453 6509 0.1 0.2 0.5 0.6 0.2 1.4 --0.2 0.3 ------left or right 6264 6265 6266 6270 6243 6271 6272 6242 0.3 0.9 0.2 0.7 1.4 0.3 0.2 0.3 --0.9 ------0.3 ----6255 6261 6263 0.3 0.2 0.1 0.3 --0.1 6203 6205 6201 6209 0.1 0.1 0.2 1.9 0.1 --0.2 1.9
2010 Trike Models
7-17
MAM = FLHTCUTG
MBM = FLHXXX

6515
MODELS MAM
0.2
MBM
---
Replace backrest
2010 Trike Models
7-18
MAM = FLHTCUTG
MBM = FLHXXX

INSTRUMENTS Replace speedometer Replace tachometer Replace indicator panel lens Replace voltmeter or fuel gauge Replace oil pressure or air temperature gauge Replace ambient temperature sensor Replace odometer reset switch boot WIRING Replace connector housing Replace connector anchor Replace main wiring harness Replace audio harness Replace rear fender/body wiring harness Replace front fender wiring harness Replace interconnect harness Replace main harness trough/tray Replace main harness trough cover Replace front headset harness SWITCHES Replace ignition switch Replace fuse Replace main fuse or cover Replace main fuse block Replace left upper handlebar switch housing 5129 5145 5147 5151 5177 0.8 0.2 0.2 0.5 0.2 0.8 0.2 0.2 0.5 0.2 Lower trough, or both lower trough and cover Trough cover only 5022 5023 5026 5027 5036 5049 5052 5078 5079 6616 0.1 0.1 3.6 1.8 0.8 0.9 0.5 0.9 0.4 0.7 0.1 0.1 3.6 --0.8 --0.5 0.9 0.4 --Cosmetic issue Cosmetic issue Cosmetic issue Cosmetic issue Cosmetic issue 6003 6009 6018 6021 6026 6028 6043 0.3 0.3 0.3 0.3 0.3 0.1 0.1 0.3 0.3 0.3 0.3 0.3 0.1 0.1
2010 Trike Models
7-19
MAM = FLHTCUTG
MBM = FLHXXX

5178 5179 5180 5192 Any handlebar switch 6953
MODELS MAM
0.2 0.2 0.7 0.4 0.4
MBM
0.2 0.2 0.7 0.4 0.4
Replace left lower handlebar switch housing Replace right upper handlebar switch housing Replace right lower handlebar switch housing Replace any fairing switch (except speaker) Replace switch knob LIGHTS Replace headlight housing Replace instrument panel bulb Replace turn signal light assembly Replace fender tip light bulb or lens Replace fender tip lamp assembly Replace auxiliary lamp assembly Replace front auxiliary/directional lamp bracket Replace king tour-pak light bulb or lens Replace king tour-pak lower light assembly Replace king tour-pak wrap-around light assembly Replace license plate light bulb Replace license plate light assembly BATTERY Replace the battery Replace battery tray Replace battery cable SOUND SYSTEM Replace radio Replace one speaker grill Replace one speaker grill Cosmetic issue Front Rear Includes diagnosis Not used for LED equipped models Includes adjustment Includes diagnosis Front Front Front Includes adjustment Includes auxiliary lamp adjustment where applicable Includes diagnosis
5189 5193 5201 5217 5225 5230 5232 5233 5234 5235 5246 5247
0.2 0.2 0.4 0.1 0.2 0.5 0.8 0.2 0.5 0.8 0.2 0.2
0.2 0.2 0.4 ------0.7 ------0.2 0.2
5705 5767 5769
0.3 0.8 0.4
0.3 0.8 0.4
6101 6607 6612
0.6 0.2 0.1
0.6 0.2 ---
2010 Trike Models
7-20
MAM = FLHTCUTG
MBM = FLHXXX

6608 6610 6609 6611 Includes checking SWR 6613 6615 6617 6619 6623 6628
MODELS MAM
0.3 0.3 0.9 0.2 0.4 0.2 0.1 0.3 0.3 0.1
MBM
----1.0 0.2 --0.2 0.1 -------
Replace rear speaker housing Replace rear speaker housing Replace front antenna lead Replace antenna mast mount Replace CB antenna mast Complete stereo antenna inspection Replace stereo antenna mast Replace front headset DIN cover Replace console housing Replace rear headset DIN cover
Right side Left side Radio or CB, includes checking SWR
2010 Trike Models
7-21
MAM = FLHTCUTG
MBM = FLHXXX
Table 7-8. Tri Glide Diagnostics

NOTE: Unless otherwise noted, all codes include diagnostic time and replacement time if required. The codes must be used in conjunction with the diagnostic/repair procedures listed in the current Touring Service Manual, Tri Glide Service Manual Supplement and Touring Electrical Diagnostic Manual. GENERAL Repair any single wire Repair any single wire Repair any single wire Replace position lamp Replace headlight Replace indicator lamp assembly Light circuit Accessory circuit All wires except lighting and accessory circuits Position lamp inoperative Headlamp inoperative High beam indicator inoperative, neutral lamp inoperative, oil pressure lamp inoperative, turn signal indicator inoperative Replace taillight bulb or single light bulb or lens Replace taillight assembly or circuit board Replace auxiliary lamp bulb Replace horn and/or bracket Running lamps inoperative Headlamp inoperative, stop lamp inoperative Auxiliary lamp inoperative Horn inoperative 5197 5215 5227 5765 7210 0.1 0.2 0.1 0.1 0.5 0.1 0.2 --0.1 0.5 5039 5043 5041 5143 5185 5191 0.5 0.5 0.5 0.1 0.1 0.2 0.5 0.5 0.5 0.1 0.1 0.2
Repair engine compression, use in conjunction with Engine cranks but will not start, starts hard, starts additional code(s) Code not present - then stalls B0563, B1006, B1007, P0562, P0563, P0603, P0605 SWITCHES Replace rear stoplight switch - includes filling/bleeding brakes Replace rear stoplight switch - includes filling/bleeding brakes Replace neutral switch Nothing clicks, neutral lamp always on, neutral lamp inoperative, B1155 Replace oil pressure switch Oil pressure lamp always on, oil pressure lamp inoperative Stop lamp inoperative, cruise control malfunction P0572, U1097, U1255
7770
0.2
0.2
1409
0.9
0.9
5141
0.5
0.5
5157
0.3
0.3
5161
0.3
0.3
2010 Trike Models
7-22
MAM = FLHTCUTG
MBM = FLHXXX

5168 5171
MODELS MAM
0.8 0.5
MBM
0.8 0.5
Replace clutch switch Replace left handlebar switch
Starter inoperative, B1154 Horn always on, horn inoperative, headlamp inoperative
Replace front stoplight switch Replace front stoplight switch Replace handlebar (cruise set) switch Replace any fairing switch Replace start button Replace odometer reset switch Replace odometer reset switch boot Replace engine stop switch Replace engine stop switch Replace turn signal switch Replace ignition switch Replace ignition switch FUSES AND RELAYS Replace brake relay Replace brake relay Replace accessory fuse Replace battery fuse Replace fuse Replace fuse
P0572 Stop lamp inoperative, cruise control malfunction Cruise control malfunction, P0577 Cruise control malfunction Starter inoperative B1008 B1008 Serial data missing No check engine lamp Both lamps on one side inoperative U1097, U1255 Serial data missing
1413 5176 5182 5192 5818 6001 6002 6730 7295 6811 6782 7287
1.2 0.7 1.2 0.4 1.0 0.4 0.1 0.8 0.7 0.8 0.9 0.8
1.2 0.7 1.2 0.4 1.0 0.4 0.1 0.8 0.7 0.8 0.9 0.8
P0572 Cruise control malfunction P0572 Turn signal error 2C Cruise control malfunction Symptom - radio inoperative
1407 5169 1804 6807 5145 6136 6713 6729
0.4. 0.2 0.4 0.2 0.2 0.2 0.5 0.3
0.4. 0.2 0.4 0.2 0.2 0.2 0.5 0.3
Harness inspection/wiggle test/replace battery fuse U1064 Inspect/access main wire harness/wiggle test/replace ignition fuse Inspect harness/wiggle test/replace main fuse Serial data missing Serial data missing
6733
0.3
0.3
2010 Trike Models
7-23
MAM = FLHTCUTG
MBM = FLHXXX

6766
MODELS MAM
0.4
MBM
0.4
Access instruments\wiggle test\replace instrument U1097, U1255 fuse Access instruments\wiggle test\replace accessory U1097, U1255 fuse Replace starter relay Replace starter relay Replace key switch relay Starter inoperative B1134 U1097
6781
0.4
0.4
5832 6841 7098 7159
0.4 0.2 0.5 0.4
0.4 0.2 0.5 0.4
Inspect/main wiring harness/Replace 15 AMP bat- No check engine lamp, U1255 tery fuse Replace 15 amp fuse Replace system relay Replace system relay Replace system relay Engine cranks but will not start, starts hard Serial data missing, P1001, P1003 P1002 P1004
7181 7904 7909 7911 7937
0.6 0.4 0.2 0.2 0.7
0.6 0.4 0.2 0.2 0.7
Harness inspection/wiggle test/replace ECM fuse P1003, P1351, P1354 CHARGING CIRCUIT Milliamp draw Replace stator Total current draw Replace voltage regulator Replace voltage regulator Replace rotor Replace battery Low battery after extended ignition off Low or no charging Diagnose charging system No or low charging, overcharging Serial data missing Low or no charging Engine cranks but will not start, starts hard, starts - then stalls Repair charging system/accompanies other codes B0563, B1006, B1007, P0562, P0563 STARTER CIRCUIT Replace starter Replace starter Solenoid clicks Starter spins but does not engage
5308 5309 5310 5316 6724 5319 7185
0.2 2.8 0.2 1.0 0.4 2.5 0.5
0.2 2.8 0.2 1.0 0.4 2.5 0.5
7771
0.2
0.2
5817 5825
1.0 1.0
1.0 1.0
2010 Trike Models
7-24
MAM = FLHTCUTG
MBM = FLHXXX

5837 5845 7166
MODELS MAM
1.1 1.2 0.2
MBM
1.1 1.2 0.2
Replace starter clutch Replace starter solenoid Repair starting system, use in conjunction with additional code(s) IGNITION CIRCUIT Replace spark plugs
Starter spins but does not engage Starter testing, starter relay clicks Engine cranks but will not start, starts hard, starts - then stalls
Engine cranks but will not start, starts hard, starts - then stalls, misfire at idle or under load, rough or rolling idle
7134
0.4
0.4
Replace spark plug Replace spark plug wire
P1353, P1356-P1358 Engine cranks but will not start, starts hard, starts - then stalls, misfire at idle or under load, rough or rolling idle
7548 7138
0.2 0.7
0.2 0.7
Replace spark plug wire Replace ignition coil Replace ignition coil
P1353, P1356-P1358 Misfire at idle or under load, rough or rolling idle Engine cranks but will not start, starts hard, starts - then stalls
7549 7139 7226
0.2 0.8 1.0
0.2 0.8 1.0
Replace ignition coil
P1351, P1352, P1354, P1353, P1355, , P1356P1358
7856
0.6
0.6
AIR INTAKE Repair intake leak FUEL SYSTEM Replace fuel gauge sender Replace fuel gauge Replace fuel gauge Replace purge solenoid Replace fuel filter or clean fuel pump screen B1004, B1005 B1005 U1097, U1255 P0444, P0445 Starts - then stalls, P1353, P1356-P1358 6035 6047 6775 6861 7013 0.9 0.4 0.5 0.5 0.8 0.9 0.4 0.5 0.5 0.8 Misfire at idle or under load, P0131, P0151 7486 1.0 1.0
2010 Trike Models
7-25
MAM = FLHTCUTG
MBM = FLHXXX

7163
MODELS MAM
1.0
MBM
1.0
Replace fuel filter screen
Repair/replace fuel pump/pressure regulator/fuel line/fuel filter Repair/replace fuel pump/pressure regulator/fuel line/fuel filter
Starts - then stalls, P1353, P1356-P1358
7014
1.0
1.0
7164
1.0
1.0
Misfire at idle or under load, rough or rolling idle, P0131, P0132, P0151, P0152,
7144
0.9
0.9
Replace fuel injector Replace fuel injector Replace fuel injector Replace fuel pump
Emits black smoke P0261-P0264 Engine cranks but will not start, starts hard Engine cranks but will not start, starts hard, starts - then stalls
7596 7795 7992 7415
2.0 0.7 0.7 0.9
2.0 0.7 0.7 0.9
Replace fuel pump Replace fuel pressure regulator SENSORS AND ECM Replace bank angle sensor Replace bank angle sensor Replace induction module Remove and clean or replace induction module Replace twist grip sensor or repair connections
P1003 Emits black smoke
7924 7480
1.3 1.0
1.3 1.0
B1152, B1153 B1151 P0641, P2100, P2102 P2101, P2119, P2176 P0641, P0651, P2122, P2123, P2127, P2128, P2138
6967 6968 7085 7091 7564
0.4 0.2 1.4 1.6 1.4
0.4 0.2 1.4 1.6 1.4
P0120, P0122, P0123, P0220, P0222, P0223, P0505, P2135
7590
1.6
1.6
Replace engine temperature (ET) sensor Replace engine temperature (ET) sensor
Emits black smoke P0117, P0118
7598 7710
2.0 0.4
2.0 0.4
2010 Trike Models
7-26
MAM = FLHTCUTG
MBM = FLHXXX

7667
MODELS MAM
0.5
MBM
0.5
Replace oxygen sensor
P0031, P0032, P0131, P0132, P0134, P0151, P0152, P0154
Replace crankshaft position (CKP) sensor Clean or repair crankshaft position (CKP) sensor Replace TMAP sensor Replace TMAP sensor Replace TMAP sensor Replace TMAP sensor Replace TMAP sensor Replace TMAP sensor Clean or repair vehicle speed sensor (VSS) Replace vehicle speed sensor (VSS) Replace ECM
7981 7982 7152 7597 7630 7650 7725 7760 7939 7967 6123
0.4 0.3 0.6 2.0 0.7 0.8 0.8 0.8 0.9 1.2 0.8
0.4 0.3 0.6 2.0 0.7 0.8 0.8 0.8 0.9 1.2 0.8
Replace ECM Replace ECM Replace ECM Replace ECM Replace ECM
U1016 P1009 Automatic compression release diagnosis P2100, P2103 Misfire at idle or under load, rough or rolling idle, automatic compression release diagnosis
6125 6703 7080 7093 7149
1.2 0.7 0.9 1.4 0.9
1.2 0.7 0.9 1.4 0.9
Replace ECM
No check engine lamp, serial data missing, P0261, P0263, P0444, P0445, P0603, P0605, P1001, P1010, P1270, P1600, P2107, U1064
7130
0.7
0.7
Replace ECM
P0113, P0572, P0641, P0651, P2122, P2123, P2127, P2128
7568
1.0
1.0
Replace ECM
Emits black smoke
7601
2.2
2.2
2010 Trike Models
7-27
MAM = FLHTCUTG
MBM = FLHXXX

7641
MODELS MAM
1.1
MBM
1.1
Replace ECM
Serial data missing, P0107, P0112, P0120, P0122, P0123, P0220, P0222, P0223, P0505, P1655, P1656, U1300, U1301
Replace ECM
Engine cranks but will not start, starts hard, starts - then stalls, P0117, P0118, P0373, P0374, P1002, P1351-P1358
7680
0.6
0.6
Replace ECM TURN SIGNALS/INSTRUMENTS/SECURITY Replace volt meter Replace air temp gauge Replace oil pressure gauge Replace cigarette lighter Perform ECM TSM/TSSM/HFSM module replace procedure Replaced TSM/TSSM/HFSM, system now ok Replaced TSM/TSSM/HFSM, system now ok Replace FOB battery Replace FOB
P0501, P0502
7968
1.2
1.2
U1097, U1255 U1097, U1255 U1097, U1255 U1097, U1255 P1009
6074 6075 6076 6077 6701
0.5 0.5 0.5 0.4 0.4
0.5 0.5 0.5 0.4 0.4
P1009 P1010 Fails to disarm Fails to disarm
6702 6707 6755 6756 6809 6820
0.4 1.1 0.1 0.1 0.4 0.2
0.4 1.1 0.1 0.1 0.4 0.2
Replace tail lamp and turn signal converter module Both lamps on one side inoperative, B1123-B1126 Replace bulb Both lamps on one side inoperative, flash at double normal rate, B1121, B1122 Remove corrosion Remove corrosion/Replace bulb Replace lamp assembly Replace speedometer Flash at double normal rate Flash at double normal rate Flash at double normal rate, B1121, B1122 Serial data missing, no check engine lamp, U1016, U1097, U1255 Replace speedometer Replace speedometer No security lamp during bulb check U1300, U1301
6821 6822 6823 6072
0.2 0.4 0.4 0.5
0.2 0.4 0.4 0.5
6738 6765
0.3 0.7
0.3 0.7
2010 Trike Models
7-28
MAM = FLHTCUTG
MBM = FLHXXX

6769 7311
MODELS MAM
0.4 0.3
MBM
0.4 0.3
Replace speedometer Replace speedometer
Cruise control malfunction No check engine lamp, cosmetics only, B1008, security lamp on continuously after bulb check
Replace tachometer
Serial data missing, no check engine lamp, U1016, U1097, U1255
6772
0.5
0.5
Replace tachometer Replace TSM/TSSM/HFSM Replace TSM/TSSM/HFSM Replace TSM/TSSM/HFSM Replace TSM/TSSM/HFSM Replace TSM/TSSM/HFSM
U1300, U1301 U1016, U1064, U1255 Turn signal error 1A - won't cancel upon completion B1131 B1135 Starter inoperative, nothing clicks, fails to disarm, both lamps on one side inoperative, flash at double normal rate, no check engine lamp, B1121, B1122, B1123, B1124, B1125, B1126, B1134, B1141, B1143, B1144, B1145, B1154, B1155
6803 6717 6773 6833 6845 6880
0.7 0.8 0.9 0.7 0.4 0.5
0.7 0.8 0.9 0.7 0.4 0.5
Replace TSM/TSSM/HFSM Replace TSM/TSSM/HFSM Replace security siren Replace security siren Replace security antenna Replace security antenna harness AUTOMATIC COMPRESSION RELEASE Replace ACR solenoid. SOUND SYSTEM Replace mode switch Replace PTT/Squelch switch Replace audio switch
Starter inoperative - nothing clicks, B1152, B1153 Serial data missing, U1300, U1301 B1131, B1132 No check engine lamp, B 1151 B1143-B1145 B1145
6963 7998 6832 7161 6878 6881
0.6 1.0 0.5 0.3 0.3 0.5
0.6 1.0 0.5 0.3 0.3 0.5
P1655, P1656
7077
2.3
2.3
B2009 B2009 B2009
5183 5184 5186
1.5 1.2 1.4
1.5 --1.4
2010 Trike Models
7-29
MAM = FLHTCUTG
MBM = FLHXXX

6101
MODELS MAM
0.6
MBM
0.6
Replace radio
Symptom - switches inoperative, B2006-B2012, B2016-B2023
Replace radio
Symptom - poor/no reception AM (HDI LW/MW), FM, WB, symptom - radio inoperative, symptom intercom inoperative, handheld microphone PTT inoperative, symptom - speaker switch malfunction, symptom - CD wont eject on base radio, symptom - aux input inoperative, symptom - headset speakers inoperative, U1302, U1307
6103
0.7
0.7
Replace radio
Symptom - no or low audio from microphones, symptom - CB receiver inoperative, serial data missing, U1300, U1301
6120
1.0
---
Replace radio Replace spark plugs Replace spark plug wires Replace voltage regulator Replace starter relay Replace speaker switch Loosen and align radio chassis Align or replace front motor mount Replace speaker Replace speaker Replace antenna cable or mast connector
Symptom - CD skipping Symptom - static present in audio Symptom - static present in audio Symptom - static present in audio Symptom - radio inoperative Symptom - speaker switch malfunction Symptom - CD skipping Symptom - CD skipping B2016, B2017 B2020, B2021 Symptom - poor/no reception AM (HDI LW/MW), FM, WB, symptom - CB receiver inoperative, symptom - CB transmitter inoperative
6174 6132 6133 6134 6138 6143 6171 6173 6605 6606 6609
0.9 0.4 0.4 0.3 0.5 0.6 0.4 0.9 0.3 0.5 0.9
0.9 0.4 0.4 0.3 0.5 --0.4 0.9 0.3 0.5 0.9
Replace CB antenna mast
Symptom - CB receiver inoperative, symptom - CB transmitter inoperative
6613
0.4
---
Replace pod headset harness
Handheld microphone PTT inoperative, symptom - headset speakers inoperative
6616
0.7
---
2010 Trike Models
7-30
MAM = FLHTCUTG
MBM = FLHXXX

6625
MODELS MAM
0.7
MBM
---
Replace CB module includes SWR check
Symptom - CB receiver inoperative, symptom - CB transmitter inoperative, symptom - no or low audio from microphones, U1302, U1307
Replace passenger rear control switch REVERSE CIRCUIT Replace reverse motor
B2012
6627
0.7
---
Reverse motor runs continuously, reverse motor spins but does not engage
1817
0.5
0.5
Replace reverse motor
Reverse motor stalls or spins too slowly, Reverse inoperative
1828
0.7
0.7
Replace RCM solenoid Replace RCM solenoid Replace RCM Replace RCM Replace ring gear/clean bolts/adjust belt Mechanical bind present in reverse system, use with additional appropriate code Replace reverse switch assembly - includes diagnostics Replace circuit breaker
Reverse motor runs continuously Reverse inoperative Reverse motor runs continuously Reverse inoperative Reverse motor spins but does not engage Reverse motor stalls or spins too slowly
1818 1832 1822 1831 1824 1827
0.3 0.5 0.6 0.5 2.2 0.6
0.3 0.5 0.6 0.5 2.2 0.6
Reverse inoperative
1833
0.7
0.7
Reverse inoperative
1834
0.3
0.3
2010 Trike Models
7-31
NOTES
SUBJECT..............................................................................................................PAGE NO. 8.1 All Times......................................................................................................................8-1 Unless otherwise specified, Job Times shown include all operations necessary to complete the listed job.
SIDECAR MODELS
SZX = TLE
SKX = TLEU
Table 8-1. All Times

ITEM DESCRIPTION LABOR CODE MODELS SZX TLE SKX TLE-U
PAINT REPAIR NOTE: Use these codes when Repairing any painted part on vehicle with the Kent Moore finesse kit or other paint Repair methods Light scuff/scratch - buff Light sanding/buff/blend Buff entire part Repair build up in clear/paint Color blend/paint/buff ACCESSORY SIDECAR Replace sidecar windshield Replace sidecar fender Replace seat Replace liner (carpeting) Replace armrest storage pouch Replace armrest Replace handles Replace brake pads Replace brake caliper Replace brake disc Replace wheel Check or true spoke wheel Replace axle Replace console Replace switch chrome trim plate Removal of sidecar for service and reattachment Sidecar alignment Includes installation of new trim insert Includes brake bleed and verifying alignment if equipped 6901 6904 6907 6913 6916 6919 6922 6926 6927 6929 6931 2155 6934 6946 6955 6954 6956 0.2 0.8 0.2 0.4 --0.2 --0.2 0.3 0.3 0.7 0.5 0.3 ----1.1 0.8 0.2 0.8 0.2 0.4 0.2 0.2 0.1 0.2 0.3 0.3 0.7 0.5 0.3 0.6 0.3 1.3 0.8 1102 1104 1106 1108 1110 0.2 0.4 0.6 0.8 1.0 0.2 0.4 0.6 0.8 1.0
2010 Sidecar Models
8-1
SZX = TLE
SKX = TLEU
Table 8-1. All Times

6958
MODELS SZX TLE

0.3
SKX TLE-U
0.5
Sidecar tub removal ELECTRICAL Repair any single wire Repair any single wire Repair any single wire Repair/Replace audio harness Replace speaker Replace amplifier Replace console switch assembly Replace console switch knobs Sidecar bank angle sensor switch kit installation Replace TSM/TSSM/HFSM Replace sidecar bank angle sensor Replace sidecar bank angle sensor Replace security siren B1152, B 1153 B 1152, B 1153 B 1151 B 1151 Light circuit Accessory circuit All wires except lighting and accessory circuits
5039 5043 5041 6940 6943 6949 6952 6953 --6963 6967 6968 6969
0.5 0.5 0.5 ----------0.4 0.6 0.4 0.2 0.3
0.5 0.5 0.5 1.4 0.8 0.6 0.8 0.1 0.4 0.6 0.4 0.2 0.3
2010 Sidecar Models
8-2
SUBJECT..............................................................................................................PAGE NO. 9.1 Service........................................................................................................................9-1 9.2 Chassis.......................................................................................................................9-2 9.3 Engine.........................................................................................................................9-4 9.4 Drive and Clutch..........................................................................................................9-5 9.5 Transmission...............................................................................................................9-6 9.6 OEM Accessories........................................................................................................9-7 9.7 Electrical - General......................................................................................................9-8 9.8 FLHTCUSE5 Diagnostics............................................................................................9-9 Unless otherwise specified, Job Times shown include all operations necessary to complete the listed job.
CVO: FLHTCUSE5
PR8 = FLHTCUSE5
Table 9-1. Service

ITEM DESCRIPTION LABOR CODE MODELS PR8
NEW Set-up and predelivery 1,000 mile (1,600 km) service REGULAR 5,000 mile (8,000 km) maintenance 10,000 mile (16,000 km) maintenance 15,000 mile (24,000 km) maintenance 20,000 mile (32,000 km) maintenance 25,000 mile (40,000 km) maintenance 30,000 mile (48,000 km) maintenance 35,000 mile (56,000 km) maintenance 40,000 mile (64,000 km) maintenance 45,000 mile (72,000 km) maintenance 50,000 mile (80,000 km) maintenance Addition to any maintenance- required every 2 years flush/fill D.O.T 4 brake fluid- front and rear ABS models, clutch ----------------------1.7 2.2 1.5 2.5 2.8 2.4 1.7 2.3 1.3 6.9 1.4 ----2.5 2.4
2010 CVO: FLHTCUSE5
9-1
PR8 = FLHTCUSE5
Table 9-2. Chassis

PAINT REPAIR NOTE: Use these codes when repairing any painted part on vehicle with the Kent Moore finesse kit or other paint repair methods Light scuff/scratch - buff Light sanding/buff/blend Buff entire part Repair build up in clear/paint Color blend/paint/buff WHEELS Replace axle covers HANDLEBARS Replace handlebars FRAME/SWING ARM/FRONT FORK Replace lower triple tree chrome cover Replace shift lever peg/insert BRAKES Replace caliper decorative insert Replace rear brake pedal cover SEATS/FENDERS/TANKS Replace seat/seat strap Replace rider backrest pad Replace rider backrest bracket Replace passenger backrest Replace passenger backrest lumbar adjustment knob EXHAUST SYSTEM Replace one muffler end 2647 0.1 on rear fender either or both; includes diagnosis for heated seat 2506 2509 2511 6515 6536 0.3 0.1 0.3 0.2 0.2 one 2429 2496 0.1 0.1 2314 2392 0.1 0.1 includes removing radio 2206 2.6 front 2112 0.1 1102 1104 1106 1108 1110 0.2 0.4 0.6 0.8 1.0
2010 CVO: FLHTCUSE5
9-2
PR8 = FLHTCUSE5
Table 9-2. Chassis

2649
MODELS PR8
0.1
Replace one muffler heat shield
2010 CVO: FLHTCUSE5
9-3
PR8 = FLHTCUSE5
Table 9-3. Engine

CRANKCASE Replace oil cooler guard Replace oil cooler Replace oil cooler mounting bracket Replace oil cooler hose and/or clamp Replace oil filter mount/fittings Replace oil filter mount bypass cover and/or gasket one or both 4521 4525 4526 4528 4533 4534 0.3 0.4 0.4 0.6 0.4 0.4
2010 CVO: FLHTCUSE5
9-4
PR8 = FLHTCUSE5

CLUTCH Replace clutch release plate and/or bearing Replace clutch actuator cover and/or gasket Replace clutch push rod Replace clutch master cylinder Rebuild clutch master cylinder assembly includes fluid refill and system bleed includes gasket replacement, fluid refill, and system bleed Rebuild clutch actuator assembly includes gasket replacement, fluid refill, and system bleed Bleed clutch system of air Replace clutch master cylinder cover and/or gasket Replace clutch line Replace clutch line gaskets and/or o-ring includes fluid refill and system bleed leak repair, fluid refill, and system bleed includes fluid refill 4024 4026 4028 4029 0.1 0.1 0.8 0.2 4022 1.7 includes fluid refill and system bleed 4016 4018 4019 4020 4021 0.4 1.5 0.3 0.4 0.6
2010 CVO: FLHTCUSE5
9-5
PR8 = FLHTCUSE5

TRANSMISSION NOTE: See the FLHTK (KEM) model information for all Transmission times.
2010 CVO: FLHTCUSE5
9-6
PR8 = FLHTCUSE5

ACCESSORIES Replace inner fairing dash pad Replace one saddlebag filler strip Replace garage door opener transmitter/harness includes outer fairing removal 6214 6278 6415 0.4 0.2 0.4
2010 CVO: FLHTCUSE5
9-7
PR8 = FLHTCUSE5

WIRING Handlebar harness Handlebar harness Replace amplifier harness LIGHTS Replace turn signal light assembly Replace turn signal light assembly Replace turn signal light assembly Replace auxiliary lamp assembly Replace auxiliary lamp assembly Replace auxiliary lamp/directional mount Replace auxiliary lamp/directional mount front - one side front - both sides rear front - one side includes aiming front - both sides includes aiming one side, includes lamp remove, replace and aiming both sides, includes lamp remove, replace and aiming Replace king tour-pak wrap-around light bezel Replace king tour-pak wrap around light LED assembly Replace tour pak or one saddlebag interior light 5253 0.2 any or all of the 3 LED assemblies 5235 5249 0.4 0.4 5201 5202 5205 5242 5243 5244 5245 0.5 0.7 0.6 0.6 0.9 0.9 1.3 repair short repair open 6551 6552 6559 2.3 2.3 1.1
2010 CVO: FLHTCUSE5
9-8
PR8 = FLHTCUSE5
Table 9-8. FLHTCUSE5 Diagnostics

NOTE: All codes include diagnostic time and replacement time if required. The codes must be used in conjunction with the diagnostic/repair procedures listed in the current Touring Service Manual, FLHTCUSE5 Service Supplement and the Touring Electrical Diagnostic Manual. AUTOMATIC COMPRESSION RELEASE Replace grounded/defective ACR solenoid. Replace both ACR solenoids. Replace ECM POWER LOCK SYSTEM Replace lock cam or cable in saddlebag or tour pak Power locks inoperative Replace lock cylinder in saddlebag or tour pak Replace power lock module Replace power lock fuse Replace power lock switch Power locks inoperative Power locks inoperative Power locks inoperative Power locks inoperative 6220 6221 6223 6226 6228 6231 0.5 0.4 0.4 0.4 0.5 0.5 Automatic compression release diagnosis Automatic compression release diagnosis Automatic compression release diagnosis 7077 7078 7080 2.3 2.5 0.9
Replace power lock actuator in saddlebag or tour Power locks inoperative pak Replace power lock fob Replace power lock fob battery HEATED SEAT Replace fuse Replace seat assembly - includes diagnosis HEATED GRIPS Replace heated handlebar grip Replace heated handlebar grip Replace fuse SOUND SYSTEM DIAGNOSIS, REPAIR Replace amplifier Replace high output amplifier B2016 Left Right Heated grips inoperative Heated seat inoperative Heated seat inoperative Power locks inoperative Power locks inoperative
6232 6233
0.2 0.1
6546 2506
0.1 0.3
6553 6554 6556
1.8 0.3 0.1
6949 6107
0.6 0.6
2010 CVO: FLHTCUSE5
9-9
PR8 = FLHTCUSE5
Table 9-8. FLHTCUSE5 Diagnostics

6605 6606 6108 6126 6102 6130 6109 6102 6132 6133 6134 6130
MODELS PR8
0.4 0.5 0.7 0.5 0.7 0.2 0.4 0.7 0.5 0.5 0.4 0.2
Replace speaker Replace speaker Replace high output amplifier Replace XM module Replace radio Replace fuse Replace high output amplifier Replace radio Replace spark plugs Replace spark plug wires Replace voltage regulator Replace fuse
B2016 B2020 U1302 U1302 U1313 U1317 U1317 U1317 Static present in audio Static present in audio Static present in audio No or low audio with high output amplifier (No DTCs)
Replace radio
No or low audio with high output amplifier (No DTCs)
6104
0.8
Replace high output amplifier
No or low audio with high output amplifier (No DTCs)
6110
0.8
Replace radio Replace XM module Replace XM antenna NAVIGATION MODULE Replace navigation antenna or bracket Replace navigation module Replace navigation module
No or partial audio from XM module No or partial audio from XM module XM, no reception, intermittent reception
6101 6126 6146
0.6 0.5 0.4
6180 U1302 Navigation inop 6181 6182
0.4 0.5 0.4
2010 CVO: FLHTCUSE5
9-10
SUBJECT..............................................................................................................PAGE NO. 10.1 Service....................................................................................................................10-1 10.2 Chassis...................................................................................................................10-2 10.3 Engine.....................................................................................................................10-3 10.4 Drive and Clutch......................................................................................................10-4 10.5 Transmission...........................................................................................................10-5 10.6 OEM Accessories....................................................................................................10-6 10.7 Electrical - General..................................................................................................10-7 10.8 FLHXSE Diagnostics...............................................................................................10-8 Unless otherwise specified, Job Times shown include all operations necessary to complete the listed job.
CVO: FLHXSE
PZ8 = FLHXSE
Table 10-1. Service

ITEM DESCRIPTION LABOR CODE MODELS PZ8
NEW Set-up and predelivery 1,000 mile (1,600 km) service REGULAR 5,000 mile (8,000 km) maintenance 10,000 mile (16,000 km) maintenance 15,000 mile (24,000 km) maintenance 20,000 mile (32,000 km) maintenance 25,000 mile (40,000 km) maintenance 30,000 mile (48,000 km) maintenance 35,000 mile (56,000 km) maintenance 40,000 mile (64,000 km) maintenance 45,000 mile (72,000 km) maintenance 50,000 mile (80,000 km) maintenance Addition to any maintenance- required every 2 years flush/fill D.O.T 4 brake fluid- front and rear ABS models, clutch ----------------------1.7 2.2 1.5 2.5 2.8 2.4 1.7 2.3 1.3 6.9 1.4 ----2.5 2.4
2010 CVO: FLHXSE
10-1
PZ8 = FLHXSE
Table 10-2. Chassis

PAINT REPAIR NOTE: Use these codes when repairing any painted part on vehicle with the Kent Moore finesse kit or other paint repair methods Light scuff/scratch - buff Light sanding/buff/blend Buff entire part Repair build up in clear/paint Color blend/paint/buff WHEELS Replace axle covers HANDLEBARS Replace handlebars FRAME/SWING ARM/FRONT FORK Replace lower triple tree chrome cover Replace shift lever peg/insert BRAKES Replace caliper decorative insert Replace rear brake pedal cover SEATS/FENDERS/TANKS Replace passenger backrest mounts / bushings Replace passenger backrest pad/trim/insert EXHAUST SYSTEM Replace one muffler end Replace one muffler heat shield 2647 2649 0.1 0.1 all or one 2513 6515 0.3 0.1 one 2429 2496 0.1 0.1 2314 2392 0.1 0.1 includes removing radio 2206 2.3 front 2112 0.1 1102 1104 1106 1108 1110 0.2 0.4 0.6 0.8 1.0
2010 CVO: FLHXSE
10-2
PZ8 = FLHXSE
Table 10-3. Engine

CRANKCASE Replace oil cooler guard Replace oil cooler Replace oil cooler mounting bracket Replace oil cooler hose and/or clamp Replace oil filter mount/fittings Replace oil filter mount bypass cover and/or gasket one or both 4521 4525 4526 4528 4533 4534 0.3 0.4 0.4 0.6 0.4 0.4
2010 CVO: FLHXSE
10-3
PZ8 = FLHXSE

CLUTCH Replace clutch release plate and/or bearing Replace clutch actuator cover and/or gasket Replace clutch push rod Replace clutch master cylinder Rebuild clutch master cylinder assembly includes fluid refill and system bleed includes gasket replacement, fluid refill, and system bleed Rebuild clutch actuator assembly includes gasket replacement, fluid refill, and system bleed Bleed clutch system of air Replace clutch master cylinder cover and/or gasket Replace clutch line Replace clutch line gaskets and/or o-ring includes fluid refill and system bleed leak repair, fluid refill, and system bleed includes fluid refill 4024 4026 4028 4029 0.1 0.1 0.8 0.2 4022 1.7 includes fluid refill and system bleed 4016 4018 4019 4020 4021 0.4 1.5 0.3 0.4 0.6
2010 CVO: FLHXSE
10-4
PZ8 = FLHXSE

TRANSMISSION NOTE: See the FLHX (KB4) model information for all Transmission times.
2010 CVO: FLHXSE
10-5
PZ8 = FLHXSE

ACCESSORIES NOTE: See the FLHX (KB4) model information for all OEM Accessory times.
2010 CVO: FLHXSE
10-6
PZ8 = FLHXSE

WIRING Handlebar harness Handlebar harness Repair short Repair open 6551 6552 2.3 2.3
2010 CVO: FLHXSE
10-7
PZ8 = FLHXSE
Table 10-8. FLHXSE Diagnostics

NOTE: All codes include diagnostic time and replacement time if required. The codes must be used in conjunction with the diagnostic/repair procedures listed in the current Touring Service Manual, FLHXSE Service Supplement and the Touring Electrical Diagnostic Manual. AUTOMATIC COMPRESSION RELEASE Replace grounded/defective ACR solenoid. Replace both ACR solenoids. Replace ECM Automatic compression release diagnosis Automatic compression release diagnosis Automatic compression release diagnosis 7077 7078 7080 2.3 2.5 0.9
2010 CVO: FLHXSE
10-8
SUBJECT..............................................................................................................PAGE NO. 11.1 Service....................................................................................................................11-1 11.2 Chassis...................................................................................................................11-2 11.3 Engine.....................................................................................................................11-4 11.4 Drive and Clutch......................................................................................................11-5 11.5 Transmission...........................................................................................................11-6 11.6 Electrical - General..................................................................................................11-7 11.7 FLSTSE Diagnostics...............................................................................................11-8 Unless otherwise specified, Job Times shown include all operations necessary to complete the listed job.
CVO: FLSTSE
PY9 = FLSTSE
Table 11-1. Service

ITEM DESCRIPTION LABOR CODE MODELS LABOR CODE
NEW Set-up and predelivery 1000 (800 km)mile service REGULAR 5,000 (8,000 km) mile maintenance 10,000 (16,000 km) mile maintenance 15,000 (24,000 km) mile maintenance 20,000 (32,000 km) mile maintenance 25,000 (40,000 km) mile maintenance 30,000 (48,000 km) mile maintenance Addition to any maintenance- required every 2 years flush/fill D.O.T 4 brake fluid- front and rear brake, and clutch --------------1.0 1.5 1.0 1.5 1.5 1.5 ------2.1 1.5
2010 CVO: FLSTSE
11-1
PY9 = FLSTSE
Table 11-2. Chassis

ITEM DESCRIPTION LABOR CODE MODELS PY9
PAINT REPAIR NOTE: Use these codes when repairing any painted part on vehicle with the Kent Moore finesse kit or other paint repair methods Light scuff/scratch - buff Light sanding/buff/blend Buff entire part Repair build up in clear/paint Color blend/paint/buff HANDLEBARS Replace handlebars FRAME/SWING ARM/FRONT FORK Replace front axle covers Replace rear axle covers Replace rear axle covers SEATS/FENDERS/TANKS Replace fender support cover - one only Rear fender accents (each) ACCESSORIES Sissybar upright Replace backrest Sissybar side plate Replace one saddlebag Replace one saddlebag bracket Replace windshield Replace fairing lower Replace inner fairing Replace fairing supports 6511 6515 6564 6518 6519 6517 6272 6237 6238 0.8 0.2 0.2 0.1 0.2 0.5 0.5 0.5 0.5 2536 6558 0.1 0.1 either one left side right side 6502 6503 6504 0.1 0.1 0.2 2206 2.2 1102 1104 1106 1108 1110 0.2 0.4 0.6 0.8 1.0
2010 CVO: FLSTSE
11-2
PY9 = FLSTSE
Table 11-2. Chassis

6239
MODELS PY9
0.5
Replace windshield bracket
2010 CVO: FLSTSE
11-3
PY9 = FLSTSE
Table 11-3. Engine

FUEL SYSTEM Replace air cleaner backing plate Replace air cleaner insert Replace air cleaner Replace air cleaner cover 3501 3541 3543 3502 0.3 0.1 0.1 0.1
2010 CVO: FLSTSE
11-4
PY9 = FLSTSE

CLUTCH Replace and/or service clutch control lever Replace clutch release plate and/or bearing Replace clutch actuator cover and/or gasket Replace clutch push rod Replace clutch master cylinder Rebuild clutch master cylinder assembly includes fluid refill and system bleed includes gasket replacement, fluid refill, and system bleed Rebuild clutch actuator assembly includes gasket replacement, fluid refill, and system bleed Bleed clutch system of air Replace clutch master cylinder cover and/or gasket Replace clutch line Replace clutch line gaskets and/or o-ring includes fluid refill and system bleed leak repair, fluid refill, and system bleed includes fluid refill 4024 4026 4028 4029 0.1 0.1 0.5 0.2 4022 1.6 includes fluid refill and system bleed 2221 4016 4018 4019 4020 4021 0.1 0.3 1.5 0.3 0.4 0.6
2010 CVO: FLSTSE
11-5
PY9 = FLSTSE

TRANSMISSION NOTE: See the FLST model information for all Transmission times.
2010 CVO: FLSTSE
11-6
PY9 = FLSTSE

HANDLEBARS Replace left upper handlebar switch Replace right upper handlebar switch Replace front brake light switch Replace headlight shroud INSTRUMENTS Replace speedometer Replace console Replace lower console cosmetics only 6003 6012 6085 0.5 0.5 0.5 5171 5173 5176 5241 0.6 0.8 1.0 0.4
2010 CVO: FLSTSE
11-7
PY9 = FLSTSE
Table 11-7. FLSTSE Diagnostics

AUTOMATIC COMPRESSION RELEASE Replace grounded/defective ACR solenoid. Replace both ACR solenoids Replace ECM Automatic compression release diagnosis Automatic compression release diagnosis Automatic compression release diagnosis 7077 7078 7080 2.1 2.3 0.9
2010 CVO: FLSTSE
11-8
SUBJECT..............................................................................................................PAGE NO. 12.1 Service....................................................................................................................12-1 12.2 Chassis...................................................................................................................12-2 12.3 Engine.....................................................................................................................12-3 12.4 Drive and Clutch......................................................................................................12-4 12.5 Transmission...........................................................................................................12-5 12.6 Electrical - General..................................................................................................12-6 12.7 FXDFSE2 Diagnostics............................................................................................12-7 Unless otherwise specified, Job Times shown include all operations necessary to complete the listed job.
CVO: FXDFSE2
PX8 = FXDFSE2
PX4 = FXDFSE2
Table 12-1. Service

ITEM DESCRIPTION LABOR CODE MODELS PX8 PX4
NEW Set-up and predelivery 1,000 (1,600 km) mile service REGULAR 5,000 (8,000km) mile maintenance 10,000 (16,000 km) mile maintenance 15,000 (24,000 km) mile maintenance 20,000 (32,000 km) mile maintenance 25,000 (40,000 km) mile maintenance 30,000 (48,000 km) mile maintenance Addition to any maintenance- required every 2 years flush/fill D.O.T 4 brake fluid- front and rear brake, and clutch --------------2.1 3.1 2.1 2.2 2.1 2.7 0.4 2.1 3.1 2.1 2.2 2.1 2.7 0.4 ----2.1 2.0 2.1 2.0
2010 CVO: FXDFSE2
12-1
PX8 = FXDFSE2
PX4 = FXDFSE2
Table 12-2. Chassis

PAINT REPAIR NOTE: Use these codes when repairing any painted part on vehicle with the Kent Moore finesse kit or other paint repair methods Light scuff/scratch - buff Light sanding/buff/blend Buff entire part Repair build up in clear/paint Color blend/paint/buff HANDLEBARS Replace handlebars Replace master cylinder cover FRAME/SWING ARM/FRONT FORK Replace chin fairing Replace chin fairing mounting bracket Replace motor rubber mount Replace rear axle covers Replace rear axle covers front left side right side 6213 6215 2398 6503 6504 0.2 0.5 0.4 0.1 0.1 0.2 0.5 0.4 0.1 0.1 2206 2479 2.0 0.1 2.0 0.1 1102 1104 1106 1108 1110 0.2 0.4 0.6 0.8 1.0 0.2 0.4 0.6 0.8 1.0
2010 CVO: FXDFSE2
12-2
PX8 = FXDFSE2
PX4 = FXDFSE2
Table 12-3. Engine

EVAPORATIVE EMISSIONS SYSTEM Replace canister California vehicles only 3527 0.3 0.3
2010 CVO: FXDFSE2
12-3
PX8 = FXDFSE2
PX4 = FXDFSE2

CLUTCH Replace and/or service clutch control lever Replace clutch release plate and/or bearing Replace clutch actuator cover and/or gasket Replace clutch push rod Replace clutch master cylinder Rebuild clutch master cylinder assembly includes fluid refill and system bleed includes gasket replacement, fluid refill, and system bleed Rebuild clutch actuator assembly includes gasket replacement, fluid refill, and system bleed Bleed clutch system of air Replace clutch master cylinder cover and/or gasket Replace clutch line Replace clutch line gaskets and/or o-ring includes fluid refill and system bleed leak repair, fluid refill, and system bleed includes fluid refill 4024 4026 4028 4029 0.1 0.1 0.5 0.2 0.1 0.1 0.5 0.2 4022 1.6 1.6 includes fluid refill and system bleed 2221 4016 4018 4019 4020 4021 0.1 0.3 1.5 0.3 0.4 0.6 0.1 0.3 1.5 0.3 0.4 0.6
2010 CVO: FXDFSE2
12-4
PX8 = FXDFSE2
PX4 = FXDFSE2

TRANSMISSION NOTE: See the FXDF model information for all Transmission times.
2010 CVO: FXDFSE2
12-5
PX8 = FXDFSE2
PX4 = FXDFSE2

ELECTRICAL Replace tachometer Cosmetic issue 6009 0.3 0.3
2010 CVO: FXDFSE2
12-6
PX8 = FXDFSE2
PX4 = FXDFSE2
Table 12-7. FXDFSE2 Diagnostics

NOTE: All codes include diagnostic time and replacement time if required.The codes must be used in conjunction with the diagnostic/repair procedures listed in the Dyna Service Manual, the FXDFSE2 Service Supplement and the Dyna Electrical Diagnostic Manual DIAGNOSTIC TROUBLE CODES Replace TSM/TSSM/HFSM U1064 Loss of TSM/TSSM/HFSM serial data at tachometer Replace ECM and reprogram AUTOMATIC COMPRESSION RELEASE Replace grounded/defective ACR solenoid. Replace both ACR solenoids. Replace ECM Automatic compression release diagnosis Automatic compression release diagnosis Automatic compression release diagnosis 7077 7078 7080 2.1 2.3 0.9 ------U1300 Tachometer serial data low/high 7993 0.9 0.9 6717 0.5 0.5
2010 CVO: FXDFSE2
12-7
NOTES
SUBJECT..............................................................................................................PAGE NO. 13.1 Chassis...................................................................................................................13-1 13.2 Functional................................................................................................................13-2 13.3 Decorative...............................................................................................................13-3 13.4 Performance............................................................................................................13-4 13.5 Electrical..................................................................................................................13-5 13.6 Advanced Audio System.........................................................................................13-6
HARLEY ACCESSORIES
If necessary, see GENERAL INFORMATION pages for model-to-name mapping.
Table 13-1. Chassis

8112 each 8114 8116 8111 8113 8115 8117 8118 8119 Non-Fairing models Fairing models Softail FLT FL models FX and XL models V-Rod models all models except VRSC V-Rod models FL models Softail and Dyna models XL models 8121 8123 8125 8126 8127 8128 8102 8129 8103 8131 8133 8135 8145 V-Rod models 8101 8154
MODELS JOB TIME

0.5 1.3 0.5 0.3 0.3 0.4 0.2 0.1 2.0 1.0 2.0 0.7 1.0 1.1 0.3 0.2 1.4 0.2 1.2 0.9 0.3 0.4 0.1 0.8
Handlebars Wheels Suspension Foot pegs Floorboards Grips Hand levers Mirrors Chrome swingarm Chrome front fork slider (Both) Chrome front fork slider (Both) Chrome fork covers Chrome fork covers Front fender Front fender Front fender Rear fender Rear fender Fuel tank Fuel tank Fuel tank Chrome caliper Airbox cover Composite fenders, spoilers, lowers
2010 Harley Accessories
13-1
Table 13-2. Functional

8142 8143 8144 8146
MODELS JOB TIME

1.0 0.8 0.6 0.6
Sissy bars/sideplates Chrome rear sprockets Saddlebag support kit Chrome engine guards with adjustable highway pegs Oil cooler/thermostats Tour Pak/Detachable Tour Pak Windshields Soft saddlebags Hard saddlebags Miscellaneous soft bags Customer seats Backrest pads Forward Controls Rider Backrest Tour Pak Spoiler Saddle Bag Guard Rail Kit Clock or Thermometer Detachable Backrest/Luggage Rack Handlebar Mount Includes Turn Signal Relocation if necessary Inlcudes Mounting Hardware
8147 8158 8152 8160 8156 8162 8164 8166 8110 8214 8215 8216 8217 8218
1.0 1.8 0.5 0.4 1.8 0.1 0.2 0.2 1.8 1.0 1.5 1.8 0.2 1.2
13-2
Table 13-3. Decorative

8132 8134 8136 8138 8201 8141 8148 8168 8145
MODELS JOB TIME

0.2 0.1 0.1 0.5 0.2 0.2 0.5 0.1 1.0
Decorative covers O.E. Style Items with logos Visors Dashinators Muffler end caps Chrome fender skirts/rails Rotor covers Tank panels Brake Caliper/Rotor Covers
13-3
Table 13-4. Performance

8172 8174 8175 8176 8177 8178 8179 pushrods, springs, etc. 8180 8190 8195
MODELS JOB TIME

0.2 3.5 3.2 2.5 7.0 0.7 3.5 3.5 1.0 5.5
Air cleaners P&A Head, valves Cylinders/pistons Cams Flywheel/connecting rod assembly Ignition Cylinder heads/gaskets Valve train Clutch Transmission/SE 6 Speed
13-4
Table 13-5. Electrical

8137 8219 8220 8221 8205
MODELS JOB TIME

0.7 0.5 1.7 0.5 1.8
Turn signal relocation kit Security System/Pager/Siren Electra Glow Lights Tour Pak Light Heated Grips
13-5
Table 13-6. Advanced Audio System

ITEM DESCRIPTION LABOR CODE MODELS JOB TIME
HANDS FREE MODULE Hands free module won't pair Infotainment bus lost communications with Hands free module, DTC U1306 U1302 Infotainment Bus Off Error Symptom - No or Partial Audio to Hands free module (HFM) Symptom - No or Partial Audio to Hands free module (HFM) Symptom - No or Partial Audio to Hands free module (HFM) Symptom - No or Partial Audio from Hands free module (HFM) Symptom - No or Partial Audio from Hands free module (HFM) Symptom - No or Partial Audio from Hands free module (HFM) Symptom - No or low audio from microphones Symptom - No or low audio from microphones Replace Hands free module Locate and repair short in harness between R and BK wires XM MODULE U1302 Infotainment Bus Off Error No or intermittent reception on XM No or intermittent reception on XM NAVIGATION MODULE U1302 Infotainment Bus Off Error Symptom - Navigation inop Symptom - Navigation inop Replace Navigation module Replace Navigation module Replace GPS (Navigation) antenna 8197 8198 8199 0.5 0.4 0.4 Replace XM module Replace XM module Replace XM antenna 8193 8194 8196 0.5 0.5 0.4 8191 8192 0.8 0.9 Replace radio 8189 0.7 Repair wiring 8188 0.6 Replace Hands free module 8187 0.5 Replace radio 8186 0.7 Repair wiring 8185 0.6 Replace Hands free module Replace Hands free module 8183 8184 0.5 0.2 8181 8182 0.2 0.5
13-6
Table 13-6. Advanced Audio System

8222 8223
MODELS JOB TIME

0.5 1.5
Advanced Audio Navigation/XM Amplifier For Advanced Audio System
Install Install
13-7
NOTES

H-D Job Codes 2010

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H-D Job Codes 2010

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All Harley-Davidson Models

JOB TIME/CODE MANUAL 2010

2009 H-D. ALL RIGHTS RESERVED

CMI - X.xM - MM/YY

Printed in the U.S.A.

JOB TIME/CODE UPDATE FORM

MODEL AND YEAR

JOB TIME JOB/CODE NUMBER (IF ANY)

Name: Street: City: Email:

Date: Dealership Number: State and Zip: Phone Number:

Chapter 4. VRSC Models

HFH HFJ HHH HHJ HPH HPJ

VRSCAW VRSCAW 105 VRSCDX VRSCDX 105 VRSCF VRSCF 105

Chapter 1. Softail Models

Chapter 5. FLHT/FLTR Models

FC4 FF4 FG4 FL4 FMM FV4 KB4 KEM KH4

Chapter 2. Dyna Models

GM4 GN4 GP4 GV4 GX4 GY4

FXD FXDL FXDWG FXDC FXDB FXDF

Chapter 6. FLHR Models

FB4 FHM FR4 FTM FW4

FLHR FLHP Police FLHRC FLHPE FLHR Shrine

Chapter 3. Sportster Models

Chapter 7. Trike Models

CP2 CR2 CS2 CT3 CX3 CZ3 LA6 LD6 LE2

XL883C XL883L XL883R XL1200C XL1200L XL1200N XR1200 XR1200X XL883N

Chapter 8. Sidecar Models

Chapter 9. CVO: FLHTCUSE5

Chapter 10. CVO: FLHXSE

Chapter 12. CVO: FXDFSE2

Chapter 11. CVO: FLSTSE

Chapter 13. Harley Accessories

See previous tables for model-to-name matching.

TABLE OF CONTENTS SPORTSTER MODELS

TABLE OF CONTENTS III

BV5 = FXST JM5 = FLSTSB

BW5 = FLSTC JG5 = FLSTF Shrine

BX5 = FLSTF JH5 = FLSTC Shrine

JD5 = FLSTN JE5 = FLST

JL5 = FXSTC JN5 = FLSTFB

Table 1-1. Service

2010 Softail Models

BV5 = FXST JM5 = FLSTSB

BW5 = FLSTC JG5 = FLSTF Shrine

BX5 = FLSTF JH5 = FLSTC Shrine

JD5 = FLSTN JE5 = FLST

JL5 = FXSTC JN5 = FLSTFB

Table 1-2. Chassis

2010 Softail Models

BV5 = FXST JM5 = FLSTSB

BW5 = FLSTC JG5 = FLSTF Shrine

BX5 = FLSTF JH5 = FLSTC Shrine

JD5 = FLSTN JE5 = FLST

JL5 = FXSTC JN5 = FLSTFB

Table 1-2. Chassis

BX5 JG5 JN5

left side right side

2211 2212 2221 2226 2231

2241 2246 2251

one or both one or both

includes removal and installation of all accessories and motorcycle components

2309 2311 2316 2321

--2.3 2.4 1.9

--2.3 2.4 1.9