2005 harley softail wiring diagram

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2004-2005 Harley Davidson Dyna EFI Tuner Installation Manual

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Filed Under (Harley Davidson) by admin on 14-04-2012

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1 Remove the seat 2 Remove the left hand side cover (Fig. A). 3 Unplug the stock wiring harness connector from the ECM (Fig. B). 4 Move the data plug (Fig. B) out of the way to access bolt. 5 Remove the 3 bolts that hold the electrical box in place (Fig. B). 6 Slide the plastic box out from the frame. 7 Route the stock connector through the box and into the small opening in the frame (Fig. C). Fig. A Fig. B Fig. C Remove side cover Stock connector Stock connector Data plug Remove bolt Remove bolts FM810 www. fuelmotousa.com 2004-2005 Harley Davidson Dyna – FM EFI Tuner – 2 8 Plug the black connector of the Power Commander into the stock wiring harness connector (Fig. D). 9 Route the grey connector of the Power Commander through the box and plug it into the ECM. 10 Install the Power Commander against the rear part of the electrical box. Make sure to clean both surfaces with the alcohol swab first. Use the supplied velcro to attach the Power Commander. 11 Bolt the box back into place. 12 Reinstall the seat. Fig. D Fig.

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SUZUKI SV 1000 RADIATOR (COOLING SYSTEM) SERVICE MANUAL

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Filed Under (Suzuki) by admin on 26-02-2011

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FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION MALFUNCTION CODE DETECTED ITEM DETECTED FAILURE CONDITION CHECK FOR COO NO FAULT C11 Camshaft position sen- sor The signal does not reach ECM for more than 3 sec . after receiving the starter signal . The camshaft position sensor wiring and mechanical parts (Camshaft position sensor, intake cam pin, wiring/coupler con- nection) C12 Crankshaft position sensor The signal does not reach ECM for more than 2 sec . after receiving the starter signal . The crankshaft position sensor wiring and mechanical parts (Crankshaft position sensor, wiring/coupler connection) C13 Intake air pressure sensor The sensor should produce following voltage . (0.50 V < sensor voltage < 4 .85 V) Without the above range, C13 is indicated. Intake air pressure sensor, wiring/coupler connection C14 Throttle position sen- sor The sensor should produce following voltage . (0.20 V < sensor voltage < 4 .80 V) Without the above range, C14 is indicated. Throttle position sensor, wiring/coupler connection C15 Engine coolant temperature sensor The sensor voltage should be the following. (0.15 V <_ sensor voltage < 4 .5 V) Without the above range, C15 is indicated. Engine coolant temperature sensor, wiring/coupler connection C21 Intake air temperature sensor The sensor voltage should be the following. (0.15 V < sensor voltage < 4 .5 V) Without the above range, C21 is indicated. Intake air temperature sensor, wiring/coupler connection C22 Atmospheric pressure sensor The sensor voltage should be the following. (0.50 V < sensor voltage < 4 .5 V) Without the above range, C22 is indicated. Atm. pressure sensor, wiring/coupler connection C23 Tip over sensor The sensor voltage should be the following for more than 2 sec . after ignition switch turns ON . (0 .20 V < sensor voltage < 4 .80 V) Without the above value, C23 is indicated. Tip over sensor, wiring/coupler connection C24 or C25 Ignition signalCrankshaft position sensor signal is produced and ECM determines the ignition signal but signal from ignition coil is interrupted continuous by 4 times or more. In this case, the code C24 or C25 is indicated. Ignition coil, wiring/coupler connection, power supply from the battery SERVICING INFORMATION 8 .3 C28 Secondary throttle valve actuator No operating voltage is supplied from the ECM, C28 is indicated. STVA can not operate. STVA lead wire/coupler, STVA C29 Secondary throttle valve position sensor The sensor should produce following voltage . (0.10 V < sensor voltage < 4 .90 V) Without the above range, C29 is indicated . Secondary throttle position sensor, wiring/coupler connection C31 Gear position signalGear position signal voltage should be higher than the following for more than 2 seconds. (Gear position switch voltage >_ 0 .6 V) Without the above value, C31 is indicated. Gear position sensor, wiring/coupler connection, gearshift cam, etc. C32 or C33 Fuel injector Crankshaft position sensor signal is produced and ECM determines the injection signal but fuel injection signal is interrupted continuous by 4 times or more. In this case, the code C32 or C33 is indicated. Injector, wiring/coupler connection, power supply to the injector C41 Fuel pump relay No voltage is applied to fuel pump although fuel pump relay is turned ON, or voltage is applied to fuel pump although fuel pump relay is turned OFF . Fuel pump relay, connecting lead, power source to fuel pump relay C42 Ignition switchIgnition switch signal is not input in the ECM . Ignition switch, lead wire/coupler C44 Heated oxygen sensor (HO2S) [For E-02, 19] During 02 feedback control, 02 sensor voltage is higher or lower than the specification . No signal is detected during engine operation or no electrical power is supplied from the battery . HO2S lead wire/coupler connection Battery voltage supply to the HO2S C49 PAIR control solenoid valve (PAIR valve) When no operating voltage is supplied from the ECM, C49 is indicated. PAIR valve can not operate. PAIR valve lead wire/coupler

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Harley Davidson Softail Motorcycles EZ-Steer Installation Manual

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Filed Under (Harley Davidson) by admin on 16-02-2011

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Softail EZ-Steer Instruction Supplement Installation of the Champion EZ-Steer system is similar to the installation of the OEM triple clamps of your Harley Davidson Softail Motorcycle. We strongly recommend that you use your OEM service manual and follow the prescribed disassembly, installation and torque specifications (except where noted below) for the upper and lower clamp assembly. Installation Notes • Note the torque specifications for the items listed below. Item # Description (Qty) Torque Spec. (Lb.Ft.) N/A OEM Steering Stem Bolt (1) 35 7 7/16-20 x 1.5 Socket Head Cap Screw (2) 45 • The supplied fork tube extensions (Item #2) must be used with the Champion EZ-Steer system. • Do not torque the steering stem bolt until fork tubes have been installed to the assembly. • Remove O-rings from OEM fork tube ends and install to Champion fork tube extensions (Item #2) prior to installation onto fork tubes. • The supplied fork tube covers (Item #9) must be installed to lower triple clamp prior to installation of fork tubes. WARNING: If the Champion EZ-Steer system is installed on a motorcycle / sidecar combination and the sidecar is removed, the motorcycle is not safe to ride, and OEM triple clamps should be replaced.

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2007 Softail HARLEY DAVIDSON FUEL PUMP/ FUEL GAUGE SENDING UNIT REMOVAL AND INSTALLATION

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Filed Under (Harley Davidson) by admin on 30-03-2012

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1. Remove seat. 1 WARNING 1 WARNING To prevent spray of fuel, purge system of high-pressure fuel before supply line is disconnected. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00275a) 2. Purge the fuel supply line of high pressure gasoline. a. See Figure 4-36. Disconnect the fuel pump fuse from the main wiring harness. b. Start the engine and allow the vehicle to run. c. When the engine stalls, operate the starter for 3 seconds to remove any remaining fuel from the fuel lines. 1 WARNING 1 WARNING To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 3. Disconnect negative battery cable. 4. Remove instrument console. a. All but FXSTD, see Figure 4-37. Remove acorn nut and washer on instrument console to separate console from fuel tank. b. For FXSTD, see 8.26 INSTRUMENT CONSOLE: FXSTD. 5. Disconnect console wiring. Figure 4-36. Fuel Pump Fuse: View From Top Figure 4-37. Acorn Nut And Washer: All But FXSTD s0660x8xx 7526
4-28 2007 Softail: Fuel System HOME 1 WARNING 1 WARNING Gasoline can drain from the crossover line when disconnected from fuel tank. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. Wipe up spilled fuel immediately and dispose of rags in a suitable manner. (00259a) 6. Drain fuel tank. a. Obtain a short section of hose (5/16 inch I.D.). Insert bolt in one end of hose and install hose clamp to ensure that end is securely plugged. b. See Figure 4-38. Cut clamp (1) from one end of crossover hose (2). Quickly replace crossover hose on fuel tank fitting with open end of short hose while directing flow of gasoline from free end of crossover hose into suitable container. 7. See Figure 4-39. Unplug fuel pump module connector (3) [86]. 8. Remove top plate screws (2) and discard. 9. See Figure 4-40. Pull top plate (2) out of fuel tank enough to expose fuel hose and clamp (1). CAUTION Carefully inspect end of hose for cuts, tears, holes or other damage. Replace hose if any damage is found. Even the smallest hole can cause a reduction in fuel pressure. 10. Cut clamp and remove hose from regulator housing fit- ting.

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HARLEY DAVIDSON BILLET HEADLAMP WITH SHORT/ TALL MOUNTS REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 06-03-2011

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Kit 68593-06 is a 5-3/4 inch headlamp and kit 69851-06 is a 4-1/2 inch headlamp. Both kits will fit the models listed in Table 1. Table 1. Short and Tall Mount Kits Models Kits 1984-1999 FXSTC, 1998- Later FXST/B, and 2000-Later FXSTD; 1994-2005 FXDWG Short Mount Kit 68595-06 1996-Later XL 1200C and 1998-Later XL 883C; All 2006 Dyna Models; 1999-2000 FXR2/3/4 Tall Mount Kit 69611-06 Additional Parts Required This kit also requires the separate purchase of a Short or Tall Mounting Kit 68595-06 or 69611-06 for your model motorcycle, and can be purchased from a Harley-Davidson dealer. The rider’s safety depends upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333a) NOTE This instruction sheet references Service Manual information. A Service Manual for your model motorcycle is required for this installation and is available from a Harley-Davidson dealer. Kit Contents See Figure 21, Table 2 and Figure 22, Table 3. REMOVAL Remove Headlamp and Mounting Bracket for Softail Models To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Disconnect negative (-) battery cable. 2. Remove fuel tank. Refer to FUEL TANK in Service Manual. 3. Disconnect 4-place headlamp connector [38] from main wire harness. Headlamp connector is located under fuel tank on left side. 8 5 7 5 6 2 1 3 4 is01835 1. Screw 2. Washer 3. Nut 4. Lockwasher 5. Washer (2) 6. Screw 7. Mounting block 8. Headlamp assembly Figure 1. Softail and Dyna Headlamp Assembly with Mount (except FXSTD) NOTE All Softails (except FXSTD) complete steps 4 through 6. For FXSTD models complete steps 7 through 9 4. All Softails (except FXSTD): See Figure 1. Remove screw (1) and washer (2) from stem and bracket. Discard screw but save washer for later use. 5. Remove and discard mounting block (7) and headlamp assembly (8). 6. FXSTD models: See Figure 2. Remove screw (1) and washer (2) from stem and bracket. Save screw and washer for later use. 7. Remove and discard nut (3), washers (4), and screw (5). 8. Remove and discard mounting block (6) and headlamp assembly (7). 7 3 4 2 1 4 6 5 is01838 1. Screw 2. Washer 3. Acorn nut 4. Washer (2) 5. Screw 6. Mounting block 7. Headlamp assembly Figure 2. FXSTD Headlamp Assembly with Mount Remove Headlamp and Mounting Bracket for Dyna Models 1. Remove seat following the instructions in the Service Manual. 2. Disconnect negative (-) battery cable. 3. Remove fuel tank. Refer to FUEL TANK in Service Manual. 2 1 is01750 1. Cable strap 2. Wire harness Figure 3. Dyna Service Loop (2005-Earlier) 4. 2005-Earlier FXDWG: See Figures 3 and 4. Remove plug on right side of top frame tube. At service loop, remove cable clip and push wire harness into top frame tube. Pull connector out from hole on right side of tube. 2006-Later FXD: See Figure 5. Remove cover under top frame tube, then pull connector out from opening under tube. 5. Disconnect 4-place headlamp connector [38] from main wire harness

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HARLEY DAVIDSON SOFTAIL SPROCKET KIT INSTALLATION NOTES

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Filed Under (Harley Davidson) by admin on 29-01-2011

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NORMAL TOOTH WARRANTY This extended warranty applies only to the normal wear that will occur to the tooth profile geometry on the rear belt sprocket. Normal wear is considered wear that occurs when the protective hard coating has worn away exposing the underlying aluminum, changing the profile of the sprocket tooth significantly. Warranty is for five years from date of purchase with unlimited mileage. Warranty claims will require a dated receipt showing proof of purchase from an authorized Harley-Davidson Dealer. Warranty only applies to original purchaser of the sprocket. Original owners name must appear on the receipt. All applications of the sprocket require installation of upper and lower original equipment belt guard, or Harley-Davidson accessory belt guards where applicable. Warranty is voided if these items are not installed. Excessive chips found in the tooth profile due to abnormal riding conditions will void warranty. Occasional chips in the tooth are to be considered normal and should not be considered a warranty issue. Decorative external chrome carries the standard parts and accessories 90 day warranty. Staking the flange on the backside of the sprocket will pierce through the chrome, this is to be considered a normal process and should not be considered an issue. All warranty claims must be pursued through your authorized Harley-Davidson Dealer

Harley Davidson 1990 and later HSR Choke Cable Installation Manual

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Filed Under (Harley Davidson) by admin on 28-02-2012

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The majority of HSR42/45 installations use the Harley cable. Installation is simple when the installation instructions are followed, step by step. Those steps are: • Remove the stock Harley choke cable assembly. • Remove the spring and plunger from the stock cable. • Remove the Mikuni “Starter Nut” from the HSR. • Remove the Mikuni spring and plunger from the HSR. • Install the Mikuni spring and plunger on the Harley choke cable. • Install the Harley choke cable with the fitted Mikuni spring and plunger into the HSR carburetor. • DO NOT use the Mikuni Starter Nut; discard it. • DO NOT use the Harley spring or plunger; discard them. Note: If you do not have installation instructions, you may download them from the www.mikuni.com website in the “manuals” section. If the Mikuni Starter Nut is fitted to the Harley cable, the choke plunger is held off its seat and the choke is open all the time. If the Harley spring and plunger are used, the plunger does not seal and the choke is open all the time. The result, in both cases, is very poor fuel mileage (30 mpg or less). Another possible cause of poor mileage, rough idle and fouled spark plugs is incorrect cable routing. The stock Harley choke cable is very stiff and may not be fully seated in the metal elbow at the carburetor end of its run. This condition is easily corrected. On occasion, one of these errors may have been made by someone else at another location. The unfortunate mechanic who inherits the task of correcting the rich condition, poor idle and poor fuel mileage may have no clue as to the mismatch of parts. For this reason, we include the photos and text to help you discover if your installation is correct.

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2004 – 2005 Camry, Highlander, And Solara, 2005 Matrix & Corolla PASSENGER AIRBAG INDICATOR LAMP

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Filed Under (Toyota Manuals) by admin on 10-10-2011

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passengers weighing approximately less than 100 pounds, depending on their seating position. It is important for the front seat passengers to know that proper operation of the advanced frontal airbag system is highly dependent on the pressure placed on the seat bottom. Situations that add or subtract sensed weight can result in occupant misclassification. To minimize this situation: Check seating posture. Passengers should be seated upright with their back against the seat back and feet on the floor. Check loading conditions. Extra weight from items, such as bags or groceries or toys, hanging on the seat back can add to the sensed weight of the front seat passenger. A rear seat passenger lifting the front seat with their legs, objects placed under the front seat, or the front seatback in contact with the rear seat can subtract from the sensed weight of the front seat passenger. If the passenger airbag indicator lamp continues to switch ON to OFF after checking the above conditions, perform the following repair procedure. NOTE: The safest place for children is in the rear seat. Please note that Toyota recommends that you never install a rear-facing child restraint in the front passenger seat, even if the passenger “Airbag OFF” lamp is illuminated. Please refer to you Owner’s Manual for additional details. 2004 – 2005 model year Camry, Highlander, and Solara vehicles produced BEFORE the Production Change Effective VINs shown on the following page. 2005 model year Matrix and Corolla vehicles produced BEFORE the Production Change Effective VINs shown on the following page

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2003 – 2005 Sequoia, 2004 – 2005 Highlander, Sienna, And Tundra DIAGNOSTIC GUIDE FOR REAR SEAT ENTERTAINMENT SYSTEMS

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Filed Under (Toyota Manuals) by admin on 08-10-2011

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Check the power, ground, and TX+, TX- wiring between the RSE ECU and the display. Perform the following check without disconnecting any connectors. A. Using the EWD, check the resistance of the wires between the DVD player ground terminal or integrated DVD player/RSE display and chassis ground. The resistance of the wires should be below 1 Ω. Refer to the Technical Information System (TIS): applicable model year Wiring Diagrams. B. Check the resistance of the wires between the RSE ECU ground terminal and chassis ground. The resistance of the wires should be below 1 Ω. C. Check the voltage on the power terminals on the DVD player and the RSE ECU. Voltage should be greater than 12 V. D. Check the voltage between terminals TX+ and chassis ground and TX- and chassis ground at both the RSE ECU and the DVD player. Voltage should be between 2.0 V and 3.0 V Check the resistance of the wires between the RSE ECU and the radio/player. The resistance of the wires should be below 1Ω. C. Check the resistance of the wires between the RSE ECU and the radio/player to ground. The resistance of the wires should be 10 kΩ or higher

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HARLEY DAVIDSON SOFTAIL DETACHABLE SADDLEBAG KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 22-03-2011

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Detachable Saddlebag Configurations Table 1 provides a short description of the detachable saddlebag configurations. Table 1. Softail Detachable Saddlebag Configurations Accessory Configuration (Long Description) Short Descrip- tion Kit 2003-Later FLST/C and 2003-2005 FX Softail Models (Except FXSTD) With Other Detachable Accessories FL Outer 88237-07 2003-Later FLST/C and 2003-2005 FX Softail Models (Except FXSTD) Without Other Detachable Accessories FL Inner 2003-Later FLST/C and 2003-2005 FX Softail Models (Except FXSTD) With Rigid-Mounted Accessories FL Rigid 2006-Later FX Models (Except FXSTD) With Other Detachable Accessories FX Outer 88238-07 2006-Later FX Models (Except FXSTD) Without Other Detachable Accessories FX Inner 2006-Later FX Models (Except FXSTD) With Rigid-Mounted Accessories FX Rigid 2007-Later FXSTC Models With Stock Passenger Upright FXSTC Stock NOTE Proper installation of these kits requires that tasks be completed for one side of the motorcycle first before continuing to the opposite side. Install Turn Signal Relocation Kit Refer to instructions included with Turn Signal Relocation Kit 69857-07. Install Docking Hardware Kit(s) Without Other Detachable Accessories: Refer to instructions included with Docking Hardware Kit 53932-03. With Other Detachable Accessories: Refer to instructions included with Docking Hardware Kits 53932-03 and 88256-07. Install Rear Docking Adapter NOTE This procedure only applies to models without detachable accessories. 1. See Figure 1. Insert rear docking adapter (1) into holes in saddlebag bracket and hold in place. 2. Install rear docking adapter using screw (2) and nut (3). Tighten snugly.

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