Harley Davidson XLH Models (2005) - Workshop Manual / Repair Manual - Wiring Schematics

HARLEY DAVIDSON XLH MODELS (2005) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING SCHEMATICS

- English Workshop Manual and Wiring Schematics, to motorcycles Harley Davidson XLH Models (2005).


MODELS COVERED:

- Harley-Davidson Sportster XL883 Model
- Harley-Davidson Sportster XL883L Model
- Harley-Davidson Sportster XL883C Custom Model
- Harley-Davidson Sportster XL1200C Custom Model
- Harley-Davidson Sportster XL1200R Roadster Model


INDEX:

General 1.1
- Servicing A New Motorcycle
- Shop Practices
- Repair And Replacement Procedures
- Cleaning
- Tool Safety
Fuel And Oil 1.2
- Fuel
- Gasoline Blends
- Engine Oil
- Winter Lubrication
Maintenance Schedule 1.3
Critical Fasteners 1.4
- Inspection
Engine Oil And Filter 1.5
- Checking And Adding Oil
- Changing Oil And Filter
Battery Maintenance 1.6
- General
- Left Side Cover
- Battery Disconnection And Removal
- Battery Inspection
- Battery Storage
- Battery Installation And Connection
Brakes 1.7
- General
- Inspection
- Troubleshooting
Bleeding Hydraulic Brake System 1.8
- General
- Bleeding Front Brake
- Bleeding Rear Brake
Brake Pads And Discs 1.9
- Inspection
- Brake Pad Replacement
Tires And Wheels 1.10
- Tires
- Tire Wear Indicators
- Wheel Bearings
- Wheel Spokes
Primary Chain 1.11
- Inspection
- Adjustment
Clutch 1.12
- Adjustment
Transmission Lubricant 1.13
- General
- Draining Lubricant
- Refilling Lubricant
Rear Belt Deflection 1.14
- Inspection
- Belt Deflection Adjustment
- Wheel Alignment
Rear Belt And Sprockets 1.15
- General
- Cleaning
- Inspection
Shock Absorber Adjustment 1.16
- General
- Procedure
Steering Head Bearings 1.17
- General
- Adjustment
- Lubrication
Rear Fork Bearings 1.18
- General
- Procedure
Front Fork Oil 1.19
- General
- Changing Fork Oil
Spark Plugs 1.20
- General
- Adjustment
- Cleaning And Inspection
- Installation
Cable And Chassis Lubrication 1.21
- General
- Cables And Hand Levers
- Foot Shift Lever And Rear Brake Pedal
- Jiffy Stand
- Steering Head Bearings
Air Filter Element 1.22
- General
- Removal
- Cleaning, Inspection And Repair
- Installation
Throttle Cables And Enrichener 1.23
- Cable Inspection, Lubrication And Adjustment
- Enrichener Adjustment
Idle Speed And Ignition Timing 1.24
- Idle Speed Adjustment
- Ignition Timing
Fuel Supply Valve Filter 1.25
- Inspection
- Fuel System Lines And Fittings
Engine Mounts And Stabilizer Links 1.26
- Inspection
Headlamp Alignment 1.27
- Inspection
- Adjustment
Fluid/Lubricant Requirements 1.28
- Brake Fluid
- Brake Component Grease
- Front Fork Oil
- Engine Oil
- Primary Drive/Transmission Lubricant
Storage 1.29
- General
- Removal From Storage
Troubleshooting 1.30
- General
- Engine
- Engine Lubrication System
- Electrical System
- Fuel
- Transmission
- Clutch
- Chassis
Specifications 2.1
- Tires
Torque Values 2.2
Vehicle Identification Number (Vin) 2.3
- General
Wheels 2.4
- General
- Troubleshooting
- Front Wheel
- Rear Wheel
- Sealed Wheel Bearings
Wheel Lacing: 16 Inch Rim 2.5
- General
- Procedure
Wheel Lacing: 19 Inch Rim 2.6
- General
- Procedure
Wheel Lacing: 21 Inch Rim 2.7
- General
- Procedure
Truing Laced Wheels 2.8
- Procedure
Checking Cast Rim Runout 2.9
- Checking Lateral And Radial Runout
Tires 2.10
- General
- Removal
- Cleaning, Inspection And Repair
- Installation
- Checking Tire Runout
- Wheel Balancing
Front Brake Master Cylinder 2.11
- General
- Removal
- Disassembly
- Cleaning, Inspection And Repair
- Assembly
- Installation
Rear Brake Master Cylinder 2.12
- General
- Removal
- Disassembly
- Cleaning, Inspection And Repair
- Assembly
- Installation
Rear Brake Master Cylinder Reservoir 2.13
- General
- Removal
- Installation
Front Brake Caliper 2.14
- Removal
- Disassembly
- Cleaning, Inspection And Repair
- Assembly
- Lubricating Front Caliper Bolt Pins And Boots
- Installation
Rear Brake Caliper 2.15
- Removal
- Disassembly
- Cleaning, Inspection And Repair
- Assembly
- Lubricating Rear Caliper Bolt Pins And Boots
- Installation
Brake Lines 2.16
- Front Brake Line
- Rear Brake Line
Front Fork 2.17
- General
- Removal
- Disassembly
- Cleaning, Inspection And Repair
- Assembly
- Installation
Fork Stem And Bracket Assembly 2.18
- Removal/Disassembly
- Cleaning, Inspection And Repair
- Assembly/Installation
Rear Fork 2.19
- Removal
- Disassembly
- Cleaning And Inspection
- Assembly
- Installation
Rear Shock Absorber 2.20
- General
- Removal
- Cleaning And Inspection
- Installation
Stabilizer Links 2.21
- General
- Upper Front Stabilizer Link
- Lower Front Stabilizer Link
- Rear Stabilizer Link
Front Engine Mount/Isolator 2.22
- Removal
- Installation
Rear Engine Mount/Isolator 2.23
- Removal
- Installation
Throttle Control 2.24
- Removal/Disassembly
- Cleaning, Inspection And Repair
- Assembly/Installation
Handlebars 2.25
- Removal
- Installation
Clutch Control 2.26
- General
- Removal/Disassembly
- Assembly/Installation
Exhaust System 2.27
- Removal
- Installation
Front Fender 2.28
- Removal
- Installation
Rear Fender 2.29
- Removal
- Installation
Belt Guard/Debris Deflector 2.30
- Removal
- Installation
Jiffy Stand 2.31
- General
- Removal
- Cleaning And Lubrication
- Installation
Seat 2.32
- General
- Removal
- Installation
Rider Foot Controls: Xl 883/Xl 883l/Xl 1200r 2.33
- Right Footrest And Rear Brake Pedal Assembly
- Left Footrest And Shift Lever Assembly
Rider Foot Controls: Xl 883c/Xl 1200c 2.34
- Right Footrest And Rear Brake Pedal Assembly
- Left Footrest And Shift Lever Assembly
- Adjusting Shift Pedal
Passenger Footrests 2.35
- General
- Removal
- Installation
Fork Lock 2.36
- Removal
- Installation
Specifications 3.1
Service Wear Limits 3.2
- General
Torque Values 3.3
Engine 3.4
- General
Troubleshooting 3.5
- Diagnosing Valve Train Noise
- Compression Test
- Cylinder Leakage Test
- Diagnosing Smoking Engine Or High Oil Consumption
- Adjustment/Testing
Engine Lubrication System 3.6
- General
- Oil Pump
Oil Pressure 3.7
- General
- Checking Oil Pressure
Crankcase Breathing System 3.8
- General
How To Use This Section 3.9
- Typical Symptoms
- Top End Repair
- Bottom End Repair
Top End Service 3.10
- Engine In Chassis
- Engine Removed From Chassis
Bottom End Service 3.11
- Engine In Chassis: Cam Compartment Service
- Engine Removed: Flywheel Compartment Service Or Complete Engine Overhaul
Removing Engine From Chassis 3.12
- General
- Procedure
Installing Engine In Chassis 3.13
- General
- Procedure
Top End Overhaul: Disassembly 3.14
- General
- Stripping Motorcycle For Top End Repair
- Cylinder Head
- Cylinder And Piston
Cylinder Head 3.15
- Removal
- Disassembly
- Cleaning And Inspection
- Replacing Rocker Arm Bushings
- Replacing Valve Guides
- Refacing Valve Seats
- Assembly
- Installation
Cylinder And Piston 3.16
- Removal/Disassembly
- Cleaning, Inspection, And Repair
- Connecting Rod Bushings
- Assembly/Installation
Top End Overhaul: Assembly 3.17
- General
- Piston And Cylinder
- Push Rods, Covers And Retainers
- Cylinder Head
- Rocker Covers
- Assembling Motorcycle After Top End Repair
Bottom End Overhaul: Disassembly 3.18
- General
- Tappets
- Oil Pump
- Gearcase Cover And Cam Gears
- Crankcase
Valve Tappets 3.19
- General
- Removal
- Cleaning And Inspection
- Installation
Gearcase Cover And Cam Gears 3.20
- General
- Removal/Disassembly
- Cleaning, Inspection And Repair
- Bushing Installation
- Bushing Reaming
- Assembly/Installation
Oil Pump 3.21
- General
- Removal
- Disassembly
- Cleaning, Inspection And Repair
- Assembly
- Installation
Oil Filter Mount 3.22
- General
- Disassembly
- Cleaning And Inspection
- Assembly
Crankcase 3.23
- General
- Removal
- Disassembly
- Fitting Pinion Bearings
- Lapping Engine Main Bearing Races
- Assembling Crankcase Halves
Bottom End Overhaul: Assembly 3.24
- General
- Crankcase
- Cam Gears And Gearcase Cover
- Tappets
- Assembling Top End Of Engine
Oil Tank 3.25
- Oil Hose Routing
- Removal
- Installation
Specifications 4.1
Torque Values 4.2
Troubleshooting 4.3
Enrichener 4.4
- General
- Operation
Carburetor 4.5
- General
- Adjustment
- Operation Check: Vacuum Piston
- Removal
- Disassembly
- Cleaning, Inspection And Repair
- Assembly
- Installation
Air Cleaner 4.6
- Removal
- Cleaning, Inspection And Repair
- Installation
Fuel Supply Valve 4.7
- General
- Operation
- Removal, Inspection And Installation
- Troubleshooting
Fuel Tank 4.8
- General
- Removal
- Cleaning, Inspection And Repair
- Installation
- Console Replacement
Evaporative Emissions Control–Ca Models 4.9
- General
- Removal
- Installation
- Hose Routing
Intake Leak Test 4.10
- General
- Leak Tester
- Procedure
Specifications 5.1
Torque Values 5.2
Electric Starter System 5.3
- General
- Operation
Starter Motor 5.4
- Removal
- Disassembly, Inspection And Repair
- Assembly
- Installation
Starter Solenoid 5.5
- General
- Disassembly
- Assembly
Specifications 6.1
Torque Values 6.2
Primary Chain Adjuster 6.3
- General
- Removal
- Installation
Clutch Release Mechanism 6.4
- Removal/Disassembly
- Cleaning, Inspection And Repair
- Assembly/Installation
Primary Drive/Clutch 6.5
- General
- Removal
- Disassembly
- Inspection And Repair
- Assembly
- Installation
Secondary Drive Belt 6.6
- Removal
- Installation
Transmission 6.7
- Operation
Case Disassembly For Transmission Removal 6.8
- General
- Right Crankcase Removal
Transmission Removal And Disassembly 6.9
- Transmission Removal From Left Crankcase
- Mainshaft/Countershaft
- Mainshaft Disassembly
- Countershaft Disassembly
Transmission Assembly 6.10
- Mainshaft Assembly
- Countershaft Assembly
Main Drive Gear 6.11
- Removal
- Disassembly
- Assembly
- Installation
Transmission Right Case Bearings 6.12
- Removal
- Installation
Transmission Left Case Bearings 6.13
- Removal
- Installation
Transmission Installation 6.14
- Installation
- Shifter Forks And Drum Assembly
- Assembling Crankcases
- Shifter Shaft Installation
Transmission Sprocket 6.15
- Removal
- Installation
Specifications 7.1
- Ignition
- Charging System
- Battery
- Fuses
Torque Values 7.2
Bulb Requirements 7.3
- Bulb Chart
Electrical Bracket 7.4
- General
- Removal
- Installation
Ignition System 7.5
- General
- Troubleshooting
Manifold Absolute Pressure Sensor: Map 7.6
- Removal
- Installation
Ignition/Light Switch 7.7
- General
- Removal
- Installation
Ignition Control Module: Icm 7.8
- General
- Removal
- Installation
Spark Plug Cables 7.9
- General
- Removal
- Inspection
- Installation
Ignition Coil 7.10
- General
- Troubleshooting
- Removal
- Installation
Charging System 7.11
- General
- Alternator
- Voltage Regulator
Alternator 7.12
- Removal And Disassembly
- Cleaning, Inspection And Repair
- Assembly And Installation
Voltage Regulator 7.13
- General
- Removal
- Installation
Battery 7.14
- Testing
- Battery Charging
Battery Cables 7.15
- Removal
- Installation
Headlamp 7.16
- Replacement: Xl 883c/Xl 1200c
- Replacement: Xl 883/Xl 883l/ Xl 1200r
Indicator Lamps 7.17
- Replacement: Xl 883c/Xl 1200c
- Replacement: Xl 883/Xl 883l
- Replacement: Xl 1200r
Tail Lamp 7.18
- Bulb Replacement
- Base Replacement
Turn Signals 7.19
- Bulb Replacement
- Front Housing Replacement
- Rear Housing Replacement
Rear Stop Light Switch 7.20
- General
- Replacement
Handlebar Switches 7.21
- General
- Repair Procedures
- Connectors
Right Handlebar Switch 7.22
- Removal
- Installation
- Disassembly
- Switch Repair/Replacement
- Assembly
Left Handlebar Switch 7.23
- Removal
- Installation
- Disassembly
- Switch Repair/Replacement
- Assembly
Horn 7.24
- Troubleshooting
- Voltage Test
- Replacement: All Models Except Xl 1200c
- Replacement: Xl 1200c
Fuses And Starter Relay 7.25
- General
- Replacing Maxi-Fuse
- Replacing 15-Amp Fuses
- Replacing Starter Relay
Maxi-Fuse Holder 7.26
- Replacement
Relay/Fuse Block 7.27
- Removal
- Installation
Speedometer: Xl 883/Xl 883l 7.28
- Removal
- Installation
Speedometer: Xl 883c/Xl 1200c 7.29
- Removal
- Installation
Speedometer And Tachometer: Xl 1200r 7.30
- Trip Odometer Reset Switch Replacement
- Speedometer Removal
- Tachometer Removal
- Speedometer Installation
- Tachometer Installation
Turn Signal/Security Module: Tsm/Tssm 7.31
- General
- Removal
- Testing
- Installation
Oil Pressure Switch 7.32
- General
- Removal
- Installation
Crank Position Sensor: Ckp 7.33
- General
- Removal
- Installation
Vehicle Speed Sensor: Vss 7.34
- General
- Removal
- Installation
Neutral Indicator Switch 7.35
- General
- Test
- Replacement
Bank Angle Sensor: Bas 7.36
- General
- Operation
- Testing
- Replacement
Appendix A–Tools A.1
Appendix B–Wiring Amp Multilock Electrical Connectors B.1
- Removing Socket/Pin Terminals
- Installing Socket/Pin Terminals
- Crimping Instructions
Deutsch Electrical Connectors B.2
- General
- Removing/Disassembling
- Removing/Installing Sockets
- Removing/Installing Pins
- Assembling/Installing
- Crimping Instructions
Mini-Deutsch Connectors B.3
- General
- Crimping Instructions
Packard Electrical Connectors B.4
- General
- Removing Pull-To-Seat Terminals/External Latch Type
- Installing Pull-To-Seat Terminals/External Latch Type
Sealed Butt Splice Connectors B.5
- Installing Sealed Butt Splice Connectors
Connector Locations B.6
Index To Wiring Schematics B.7
Appendix C–Metric Conversions C.1
Fluid Conversions C.2
- United States System
- Metric System
- British Imperial System
Appendix D: Compensating Sprocket D.1
- General
- Removal/Disassembly
- Cleaning, Inspection And Repair
- Assembly/Installation
Starter Troubleshooting 1.1
Starting System Diagnosis 1.2
- Diagnostics
Starter Activation Circuits 1.3
Diagnostics/Troubleshooting 1.4
- General
- Voltage Drops
Testing Starter On Motorcycle 1.5
- Starter Relay Test
- Starter Current Draw Test
Testing Starter On Bench 1.6
- Free Running Current Draw Test
- Starter Solenoid
- Solenoid Pull-In Test
- Solenoid Hold-In Test
- Solenoid Return Test
Charging System 1.7
- General
- Troubleshooting
- Testing
Ignition Coil 1.8
- Troubleshooting
Battery Load Test 1.9
- General
Checking For Diagnostic Trouble Codes 2.1
- Check Engine Lamp
- Security Lamp
- Code Types
- Retrieving Diagnostic Trouble Codes
- Multiple Diagnostic Trouble Codes
Initial Diagnostic Check: Speedometer 2.2
- General
- Initial Diagnostics
Speedometer Self Diagnostics 2.3
- General
- Diagnostics
Speedometer/Tachometer 2.4
- General
- Speedometer Theory Of Operation
- Tachometer Theory Of Operation
- Diagnostics
Breakout Box: Speedometer/Tachometer 2.5
- General
- Speedometer
- Tachometer
Indicator Lamps 2.6
- General
- Diagnostics
Dtc B1006, B1007 2.7
- General
Dtc B1008 2.8
- General
Dtc U1016, U1255 2.9
- General
- Diagnostics
Dtc U1064, U1255 2.10
- General
- Diagnostics
Dtc U1300, U1301 Or Bus Er 2.11
- General
- Diagnostics
Tsm/Tssm Overview 3.1
- General
- Troubleshooting
Tsm/Tssm Features 3.2
- General
- Turn Signal Functions
- Bank Angle Functions
- Security Alarm And Immobilization Functions
Tsm/Tssm Vehicle Delivery 3.3
- General
- Sidecar Configuration
- Power Disruption And Configuring
- Key Fob Assignment
- Personal Code Entry
Tsm/Tssm Turn Signal Functions 3.4
- General
- Automatic Cancellation
- Manual Cancellation
- Four-Way Flashing
- Diagnostics Mode
Tsm/Tssm Bank Angle Function 3.5
- General
- Operation
Security System (Tssm) Functions 3.6
- General
- Alarm Sensitivity
- Auto-Arming Function
- Storage Mode
Arming/Disarming Security System (Tssm) 3.7
- General
- Security Lamp
- Using Key Fob
- Using The Personal Code
Checking For Diagnostic Trouble Codes 3.8
- Tsm
- Tssm
- Code Types
- Retrieving Diagnostic Trouble Codes
- Multiple Diagnostic Trouble Codes
Initial Diagnostic Check: Tsm/Tssm 3.9
- General
- Initial Diagnostics
Speedometer Self Diagnostics 3.10
- General
- Diagnostics
Breakout Box: Tsm/Tssm 3.11
- General
- Installation
- Removal
No Security Lamp At Key On 3.12
- General
- Diagnostics
Security Lamp On Continuously 3.13
- General
- Diagnostics
Key Fob Signal To Tssm Weak Or Fails 3.14
- General
- Diagnostics
Turn Signal Errors 3.15
- General
- Diagnostics
Dtc B0563 3.16
- General
- Diagnostics
Dtc B1131, B1132 3.17
- General
- Diagnostics
Dtc B1134 3.18
- General
- Diagnostics
Dtc B1135 3.19
- General
Dtc U1016, U1255 3.20
- General
- Diagnostics
Dtc U1097, U1255 3.21
- General
- Diagnostics
Dtc U1300, U1301 Or Bus Er 3.22
- General
- Diagnostics
Password Learn 3.23
- General
- Password Learning
Tssm Maintenance 3.24
- General
- Key Fob
- Siren (If Installed)
Specifications 4.1
Diagnostic Introduction 4.2
- System Problems
- Resolving Problems
Checking For Diagnostic Trouble Codes 4.3
- Check Engine Lamp
- Security Lamp
- Code Types
- Retrieving Diagnostic Trouble Codes
- Multiple Diagnostic Trouble Codes
Initial Diagnostic Check: Icm 4.4
- General
- Initial Diagnostics
Speedometer Self Diagnostics 4.5
- General
- Diagnostics
Breakout Box: Icm 4.6
- General
- Installation
- Removal
Wiggle Test 4.7
- General
- Procedure
Intake Leak Test 4.8
- General
- Leak Tester
- Procedure
Engine Cranks But Will Not Start 4.9
- General
- Diagnostics
Starts Then Stalls 4.10
- General
- Diagnostics
No Spark/No Icm Power 4.11
- General
- Diagnostics
Misfire 4.12
- General
- Diagnostics
Dtc P0106, P0107, P0108 4.13
- General
- Diagnostics
Dtc P0371, P0372, P0374 4.14
- General
- Diagnostics
Dtc P0501, P0502 4.15
- General
- Diagnostics
Dtc P0562, P0563 4.16
- General
- Diagnostics
Dtc P0602, P0603, P0604, P0605, P0607 4.17
- General
- Diagnostics
Dtc P1009, P1010 4.18
- General
- Diagnostics
Dtc P1351, P1352, P1354, P1355 4.19
- General
- Diagnostics
Dtc U1064 4.20
- General
- Diagnostics
Dtc U1097 4.21
- General
- Diagnostics
Connector Locations 5.1
Amp Multilock Electrical Connectors 5.2
- Removing Socket/Pin Terminals
- Installing Socket/Pin Terminals
- Crimping Instructions
Deutsch Electrical Connectors 5.3
- General
- Removing/Disassembling
- Removing/Installing Sockets
- Removing/Installing Pins
- Assembling/Installing
- Crimping Instructions
Mini-Deutsch Electrical Connectors 5.4
- General
- Crimping Instructions
Sealed Butt Splice Connectors 5.5
- Installation
Packard Electrical Connectors 5.6
- General
- Pull-To-Seat Terminals
- Push-To-Seat Terminals
- Crimping Instructions
- Micro 64 Terminals
Index To Wiring Schematics 5.7
Appendix A–Tools A.1
Appendix B–Wiring Amp Multilock Electrical Connectors B.1
- Removing Socket/Pin Terminals
- Installing Socket/Pin Terminals
- Crimping Instructions
Deutsch Electrical Connectors B.2
- General
- Removing/Disassembling
- Removing/Installing Sockets
- Removing/Installing Pins
- Assembling/Installing
- Crimping Instructions
Mini-Deutsch Connectors B.3
- General
- Crimping Instructions
Packard Electrical Connectors B.4
- General
- Removing Pull-To-Seat Terminals/External Latch Type
- Installing Pull-To-Seat Terminals/External Latch Type
Sealed Butt Splice Connectors B.5
- Installing Sealed Butt Splice Connectors
Connector Locations B.6
Index To Wiring Schematics B.7
Appendix C–Metric Conversions C.1
Fluid Conversions C.2
- United States System
- Metric System
- British Imperial System
Appendix D: Compensating Sprocket D.1
- General
- Removal/Disassembly
- Cleaning, Inspection And Repair
- Assembly/Installation