• QUICK REFERENCE DATA
• CHAPTER ONE - GENERAL INFORMATION
  • Manual organization
  • Warnings, cautions and notes
  • Safety
  • Serial numbers
  • Fasteners
  • Shop supplies
  • Basic tools
  • Special tools
  • Precision measuring tools
  • Electrical system fundamentals
  • Basic service methods
  • Storage

• CHAPTER EIGHT - ELECTRICAL SYSTEM
  • Basic information
  • Battery
  • Charging system
  • Alternator
  • Voltage regulator
  • Ignition system
  • Starting system
  • Lighting system
  • Switches/Horn
  • Turn signal module (1999-2000 models)
  • Turn signal module and turn signal
  • Security module (2001-on models)
  • Speedometer speed sensor
  • Starter relay switch replacement
  • Instruments
  • Premium sound, CD and intercom systems

  • Fuses

  • Circuit breaker

  • Electrical connector service

  • Wiring diagrams

• CHAPTER TWO - TROUBLESHOOTING
  • Operating requirements
  • Engine starting
  • Engine performance
  • Starting system
  • Charging system
  • Ignition system
  • Engine management system
  • Diagnostic Codes
  • Cruise control system diagnostic codes
  • Fuel system (carbureted models)
  • Fuel system
  • Engine noises
  • Engine lubrication
  • Clutch
  • Transmission
  • Lighting system
  • Excessive vibration
  • Front lubrication suspension and steering
  • Brake system

• CHAPTER NINE - WHEELS, HUBS AND TIRES
  • Motorcycle stands
  • Front wheel
  • Rear wheel
  • Front and rear hubs (1999)
  • Front and rear wheel bearing end play check (1999 models)
  • Front and rear hubs (2000-on)
  • Driven sprocket assembly
  • Drive sprocket/Drive belt
  • Wheel runout
  • Rim and laced wheel service
  • Cast wheels/Wheel balance/Tires/Tubeless tire changing
  • Tire repairs/Motorcycle alignment

• CHAPTER THREE - LUBRICATION, MAINTENANCE AND TUNE-UP
  • Routine safety checks
  • Tires and wheels
  • Periodic lubrication
  • Periodic maintenance
  • Tune-up
  • Idle speed adjustment

• CHAPTER TEN - FRONT SUSPENSION AND STEERING
  • Handlebar/Front fork-non cartridge type (all 1999-2001 models and 2002 FLHR,FLHRI and FLHRCI right side only)
  • Front fork air pressure adjustment(1999-2001 models)
  • Front fork-cartridge type (2002 models except 2002 FLHR,FLHRI and FLHRCI right side)
  • Steering head and stem
  • Steering head bearingrace replacement/Steering play adjustment

• CHAPTER FOUR - ENGINE
  • Service precautions
  • Special tools
  • Servicing engine in frame
  • Engine
  • Rocker arms and pushrods
  • Cylinder head
  • Valves and valve components
  • Cylinder
  • Piston and piston rings
  • Pushrods
  • Valve lifters
  • Oil pump
  • Oil filter mount
  • Camshaft support plate
  • Crankcase and crankshaft
  • Engine break-in

• CHAPTER ELEVEN -REAR SUSPENSION
  • Shock absorbers/Shock air pressure adjustment/Rear swing arm

• CHAPTER FIVE - CLUTCH AND PRIMARY DRIVE
  • Primary chaincase cover
  • Clutch assembly
  • Clutch shell, compensating sprocket and primary drive chain
  • Clutch shell, clutch hub and sprocket
  • Primary chain and guide inspection
  • Primary chain alignment
  • Compensating sprocket inspection
  • Primary chaincase housing
  • Starter jackshaft
  • Clutch cable inspection
  • Clutch cable replacement

• CHAPTER TWELVE - BRAKES
  • Brake service
  • Front brake pad replacement
  • Front brake caliper/Front master cylinder
  • Rear brake pad replacement/Rear brake caliper/Rear master cylinder and rear brake pedal
  • Brake hose and line replacement/Brake disc/Bleeding the system/Rear brake pedal

• CHAPTER SIX - TRANSMISSION
  • Shifter assembly
  • External shift mechanism
  • Transmission top cover
  • Shift cam
  • Shift arm assembly
  • Shift forks
  • Transmission side door and transmission shaft assemblies
  • Transmission shafts
  • Main drive gear
  • Transmission clutch release cover assembly
  • Transmission drive sprocket
  • Transmission case
  • Oil pan

• CHAPTER THIRTEEN - CRUISE CONTROL
  • System components and operation
  • Control cables/Cruise control module/Cruise control switches

• CHAPTER SEVEN -FUEL, EXHAUST AND EMISSION CONTROL SYSTEMS
  • Air filter backplate
  • Carburetor operation
  • Carburetor/Intake manifold (carbureted models)
  • Electronic fuel injection (EFI)
  • Depressurizing the fuel system (fuel injected models)
  • Induction module (fuel injected models)
  • Throttle and idle cables (carbureted models)
  • Starting enrichment valve (choke) cable replacement (carbureted models)
  • Throttle and idle cables (fuel injected models)
  • Fuel tank console/Fuel tank (carbureted models)
  • Fuel tank (fuel injected models)
  • Fuel pump and fuel filter (fuel injected models)
  • Fuel tank gauge (FLHR)
  • Exhaust system
  • Evaporative emission control system (California models)

• CHAPTER FOURTEEN - ½ BODY
  • Seat/Front fender/Rear fender
  • Windshield and headlight nacelle (FLHR models)
  • Windshield and front fairing (FLTR models)
  • Front fairing (FLHT models)
  • Saddlebags and guards
  • Tour-pak (FLHT models)
  • Footboards

Specifications