Harley Davidson Softail Models (2003) - Service Manual / Repair Manual - Wiring Diagrams

HARLEY DAVIDSON SOFTAIL MODELS (2003) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS

- English Service Manual and Wiring Diagrams, to motorcycles Harley Davidson Softail Models (2003).


MODELS COVERED:

- Harley Davidson Softail FXST Model
- Harley Davidson Softail FLSTC Model
- Harley Davidson Softail FXSTS Model
- Harley Davidson Softail FLSTF Model
- Harley Davidson Softail FLSTS Model
- Harley Davidson Softail FXSTD Model
- Harley Davidson Softail FXSTB Model
- Harley Davidson Softail FXSTI Model
- Harley Davidson Softail FLSTCI Model
- Harley Davidson Softail FXSTSI Model
- Harley Davidson Softail FLSTFI Model
- Harley Davidson Softail FLSTSI Model
- Harley Davidson Softail FXSTDI Model
- Harley Davidson Softail FXSTBI Model
- Harley Davidson Softail FXSTDSE Model



CONTENTS:

MAIN SERVICE MANUAL

1 - Maintenance
- general 1.1
- fuel and oil 1.2
- maintenance schedule 1.3
- engine oil and filter 1.4
- battery maintenance 1.5
- brakes 1.6
- bleeding brakes 1.7
- brake pads and discs 1.8
- tires and wheels 1.9
- primary chain 1.10
- primary chaincase lubricant 1.11
- clutch 1.12
- transmission lubricant 1.13
- rear belt deflection 1.14
- rear belt and sprockets 1.15
- suspension adjustments 1.16
- steering head bearings: all but flsts/fxsts 1.17
- steering head bearings: flsts/fxsts 1.18
- rocker bearings: flsts/fxsts 1.19
- front fork oil 1.20
- spark plugs 1.21
- air cleaner filter 1.22
- cable and chassis lubrication 1.23
- throttle cables 1.24
- enrichener: carbureted 1.25
- idle speed and ignition timing: carbureted 1.26
- fuel supply valve filter: carbureted 1.27
- engine mounts 1.28
- headlamp alignment 1.29
- critical fasteners 1.30
- storage 1.31
- troubleshooting 1.32
2 - Chassis
- specifications 2.1
- torque values 2.2
- vehicle identification number 2.3
- front wheel: fxst/flstc/flstf/fxstb 2.4
- front wheel: fxstd 2.5
- front wheel: flsts 2.6
- front wheel: fxsts 2.7
- rear wheel 2.8
- sealed wheel bearings 2.9
- wheel lacing: 16 in. rim 2.10
- wheel lacing: 21 in. rim 2.11
- truing laced wheel 2.12
- disc rim runout 2.13
- tires 2.14
- vehicle alignment 2.15
- front brake master cylinder 2.16
- rear brake master cylinder/reservoir 2.17
- front brake caliper: all but flsts/fxsts 2.18
- front brake caliper: flsts 2.19
- front brake caliper: fxsts 2.20
- rear brake caliper 2.21
- front forks: all but flsts/fxsts 2.22
- springer fork: flsts/fxsts 2.23
- steering head 2.24
- rear fork 2.25
- rear shock absorbers 2.26
- throttle control 2.27
- clutch hand control 2.28
- front fender: all but flsts/fxsts 2.29
- front fender: flsts 2.30
- front fender: fxsts 2.31
- rear fender: all but fxstd/flsts 2.32
- rear fender: fxstd 2.33
- rear fender: flsts 2.34
- belt guard/debris deflector 2.35
- jiffy stand 2.36
- fork lock 2.37
- seat/strap retention nut 2.38
- seat: fxst/fxstb/fxsts 2.39
- seat: flstf/flstc 2.40
- seat: flsts 2.41
- seat: fxstd 2.42
- saddlebags: flstc 2.43
- saddlebags: flsts 2.44
- windshield: flstc 2.45
3 - Engine
- specifications 3.1
- engine torque values 3.2
- service wear limits 3.3
- engine oil flow 3.4
- oil pump operation 3.5
- breather operation 3.6
- oil pressure 3.7
- how to use this section 3.8
- top end service 3.9
- bottom end service 3.10
- troubleshooting 3.11
- stripping motorcycle for service 3.12
- assembling motorcycle after service 3.13
- removing engine from chassis 3.14
- installing engine in chassis 3.15
- top end overhaul: disassembly 3.16
- top end overhaul: assembly 3.17
- bottom end overhaul: disassembly 3.18
- bottom end overhaul: assembly 3.19
- breather assembly 3.20
- rocker arm support plate 3.21
- pushrods, lifters and covers 3.22
- cylinder head 3.23
- cylinder 3.24
- piston 3.25
- upper connecting rod 3.26
- cover and cam support plate 3.27
- oil pump 3.28
- crankcase 3.29
- counterbalancer assembly 3.30
- flywheel/connecting rod 3.31
- oil tank 3.32
4 - Fuel System
- specifications 4.1
- fuel system troubleshooting 4.2
- enrichener: carbureted 4.3
- carburetor 4.4
- carburetor adjustments 4.5
- fuel supply valve: carbureted 4.6
- fuel tank: carbureted 4.7
- air cleaner: carbureted 4.8
- exhaust system: all but fxstd/flstf/flsts 4.9
- exhaust system: fxstd/flstf 4.10
- exhaust system: flsts 4.11
- evaporative emissions control: ca models 4.12
5 - Electric Starter
- specifications 5.1
- electric starter system 5.2
- starter relay 5.3
- starter 5.4
- starter solenoid 5.5
- starter jackshaft 5.6
6 - Drive
- specifications 6.1
- primary chaincase 6.2
- drive components 6.3
- clutch 6.4
- transmission sprocket 6.5
- drive belt 6.6
7 - Transmission
- specifications 7.1
- transmission 7.2
- shifter cam assembly 7.3
- shifter forks 7.4
- transmission clutch release cover 7.5
- mainshaft and countershaft 7.6
- transmission case 7.7
8 - Electrical
- specifications 8.1
- bulb requirements 8.2
- ignition system: carbureted models 8.3
- electrical panel 8.4
- ignition module 8.5
- bank angle sensor (bas) 8.6
- manifold absolute pressure sensor (map): carbureted models 8.7
- crank position sensor (ckp) 8.8
- spark plug cables 8.9
- ignition coil 8.10
- fuses 8.11
- relays 8.12
- main circuit breaker 8.13
- ignition/light switch 8.14
- alternator 8.15
- voltage regulator 8.16
- battery 8.17
- battery cables 8.18
- headlamp 8.19
- tail lamp: all but fxstd/flsts 8.20
- tail lamp: fxstd 8.21
- tail lamp: flsts 8.22
- passing lamps: flsts 8.23
- passing lamps: flstc 8.24
- front fender lamp: flsts 8.25
- turn signals/running lights 8.26
- turn signal/turn signal security module 8.27
- tsm/tssm key fob and code assignment 8.28
- fuel gauge: carbureted 8.29
- fuel gauge: efi 8.30
- instrument console: fxstd 8.31
- speedometer: all but fxstd 8.32
- speedometer: fxstd 8.33
- vehicle speed sensor: vss 8.34
- indicator lamps: all but fxstd 8.35
- indicator lamps: fxstd 8.36
- neutral switch 8.37
- oil pressure switch 8.38
- rear stop light switch 8.39
- horn: all but flsts 8.40
- horn: flsts 8.41
- main wiring harness 8.42
- handlebar switch assemblies 8.43
- right handlebar switch 8.44
- left handlebar switch 8.45
9 - Fuel Injection
- specifications 9.1
- electronic fuel injection (efi) system 9.2
- idle speed: efi 9.3
- air cleaner: efi 9.4
- fuel tank: efi 9.5
- electronic control module (ecm) 9.6
- throttle position sensor (tp) 9.7
- intake air temperature sensor (iat) 9.8
- engine temperature sensor (et) 9.9
- induction module 9.10
- idle air control (iac) 9.11
- manifold absolute pressure sensor (map): efi models 9.12
- fuel injectors 9.13
- fuel pump/fuel gauge sending unit 9.14
- fuel pressure test 9.15
Appendices
- appendix a - tools
- appendix b - wiring
- appendix c - metric conversions


ELECTRICAL DIAGNOSTICS MANUAL

1 - Starting And Charging
- starter troubleshooting 1.1
- starting system diagnosis 1.2
- starter activation circuits 1.3
- diagnostics/troubleshooting 1.4
- starter system testing 1.5
- testing assembled starter 1.6
- charging system 1.7
- ignition coil 1.8
- battery load test 1.9
2 - Instruments
- fuel gauge operation 2.1
- speedometer 2.2
- speedometer performance check 2.3
- indicator lamps 2.4
3 - Tsm & Tssm
- tsm/tssm overview 3.1
- tsm/tssm features 3.2
- tsm/tssm vehicle delivery 3.3
- tsm/tssm turn signal functions 3.4
- tsm/tssm bank angle function 3.5
- security system (tssm) functions 3.6
- arming/disarming security system (tssm) 3.7
- checking for trouble codes: tsm/tssm 3.8
- checking for trouble codes: tssm only 3.9
- breakout box: tsm/tssm 3.10
- scanalyzer: efi models only 3.11
- initial diagnostic check: tsm/tssm 3.12
- no security lamp at key on 3.13
- security lamp on continuously 3.14
- key fob signal to tssm weak or fails 3.15
- turn signal errors 3.16
- dtc b0563 3.17
- dtc b1125 3.18
- dtc b1131, b1132 3.19
- dtc b1134 3.20
- dtc b1135 3.21
- dtc u1016, u1255 3.22
- tsm/tssm 3.23
- tssm maintenance 3.24
4 - Engine Management (Carbureted)
- specifications 4.1
- diagnostic introduction 4.2
- checking for trouble codes 4.3
- scanalyzer 4.4
- check engine lamp diagnostics 4.5
- breakout box 4.6
- wiggle test 4.7
- initial diagnostic check 4.8
- no check engine lamp at key on 4.9
- check engine lamp on continuously 4.10
- engine cranks, but will not start 4.11
- no spark/no check engine lamp at key on 4.12
- misfire 4.13
- dtc 12 4.14
- dtc 16 4.15
- dtc 24, 25 4.16
- dtc 41 4.17
- dtc 44 4.18
- dtc 52, 53, 54 and 55 4.19
5 - Engine Management (Efi)
- specifications 5.1
- efi system 5.2
- efi diagnostic introduction 5.3
- checking for trouble codes: efi 5.4
- scanalyzer: efi 5.5
- check engine lamp diagnostics: efi 5.6
- breakout box: efi 5.7
- wiggle test 5.8
- initial diagnostic check: efi 5.9
- no check engine lamp at key on 5.10
- check engine lamp on continuously 5.11
- engine cranks, but will not start 5.12
- no ecm power 5.13
- starts, then stalls 5.14
- fuel system electrical test 5.15
- system relay check 5.16
- fuel pressure test 5.17
- idle air control 5.18
- misfire at idle or under load 5.19
- combustion absent/intermittent 5.20
- dtc p0107, p0108 5.21
- dtc p0112, p0113 5.22
- dtc p0117, p0118 5.23
- dtc p0122, p0123 5.24
- dtc p0261, p0262, p0263, p0264 5.25
- dtc p0373, p0374 5.26
- dtc p0501, p0502 5.27
- dtc p0562, p0563 5.28
- dtc p0603, p0605 5.29
- dtc p1009, p1010 5.30
- dtc p1351, p1352, p1354, p1355 5.31
- dtc p1653, p1654 5.32
- dtc u1064, u1255 5.33
6 - Wiring
- connector locations 6.1
- amp multilock electrical connectors 6.2
- deutsch electrical connectors 6.3
- mini-deutsch connectors 6.4
- sealed butt splice connectors 6.5
- packard electrical connectors 6.6
- packard ecm connector 6.7
- index to wiring diagrams 6.8
- 2003 all carbureted softail dom. and int. models, main harness
- 2003 all carbureted softail dom. and int. models, ignition circuit
- 2003 all efi softail dom. and int. models, main harness: sheet 1 of 3
- 2003 all carbureted softail dom. and int. models, lighting circuit: sheet 1 of 2
- 2003 all carbureted softail dom. and int. models, horn & instruments
- 2003 all carbureted softail dom. and int. models, security circuit: sheet 1 of 2
- 2003 all carbureted softail dom. and int. models, security circuit: sheet 2 of 2
- 2003 all carbureted softail dom. and int. models, charging & starting circuits
- 2003 all efi softail dom. and int. models, main harness: sheet 2 of 3
- 2003 all efi softail dom. and int. models, main harness: sheet 3 of 3
- 2003 all carbureted softail dom. and int. models, lights, speedo. & indicators
- 2003 all efi softail dom. and int. models, ignition circuit
- 2003 all efi softail dom. and int. models, ignition & charging circuits
- 2003 all efi softail dom. and int. models, lighting circuit: sheet 1 of 2
- 2003 all efi softail dom. and int. models, lighting circuit: sheet 2 of 2
- 2003 all efi softail dom. and int. models, horn & instruments circuit: sheet 1 of 2
- 2003 all carbureted softail dom. and int. models, lighting circuit: sheet 2 of 2
- 2003 all efi softail dom. and int. models, horn & instruments circuit: sheet 2 of 2
- 2003 all efi softail dom. and int. models, starting circuit
- 2003 all efi softail dom. and int. models, security circuit: sheet 1 of 2
- 2003 all efi softail dom. and int. models, security circuit: sheet 2 of 2