2022 Harley-Davidson Pan America Models 94000974 (Preview)
2022 PAN AMERICA MODELS SERVICE MANUAL #94000974
FOREWORD
GENERAL
MANUAL LAYOUT
HOW TO USE THIS SERVICE MANUAL
PREPARATION FOR SERVICE
USE GENUINE REPLACEMENT PARTS
SHOP PRACTICES
CLEANING
DISPOSAL AND RECYCLING
TOOLS AND MATERIALS
PRODUCT REGISTERED MARKS
H-D U.S.A., LLC TRADEMARK INFORMATION
CONTENTS
TABLE OF CONTENTS
1. SAFETY
1.1 SAFETY
2. MAINTENANCE
2.1 FASTENER TORQUE VALUES
2.2 GENERAL
2.3 MAINTENANCE SCHEDULE
2.4 FUEL AND OIL
2.5 REPLACE ENGINE OIL AND FILTER
2.6 INSPECT TIRES AND WHEELS
2.7 LUBRICATE CABLES AND CHASSIS
2.8 INSPECT BRAKES
2.9 CHECK AND REPLACE BRAKE FLUID
2.10 CHECK AND ADJUST CLUTCH
2.11 REBUILD FRONT FORK AND REPLACE OIL
2.12 ADJUST AND LUBRICATE STEERING HEAD BEARINGS
2.13 INSPECT RADIATOR AND COOLANT
2.14 INSPECT FUEL LINES AND FITTINGS
2.15 INSPECT AND LUBRICATE JIFFY STAND
2.16 INSPECT AND ADJUST DRIVE CHAIN AND SPROCKETS
2.17 INSPECT REAR SPROCKET ISOLATOR
2.18 ADJUST SUSPENSION
2.19 INSPECT EXHAUST SYSTEM
2.20 INSPECT AIR FILTER
2.21 INSPECT BATTERY
2.22 INSPECT AND REPLACE SPARK PLUGS
2.23 STORAGE
2.24 TROUBLESHOOTING
3. CHASSIS
3.1 FASTENER TORQUE VALUES
3.2 SPECIFICATIONS
3.3 VEHICLE IDENTIFICATION NUMBER (VIN)
3.4 FRONT WHEEL
3.5 REAR WHEEL
3.6 WHEEL LACING
3.7 CHECKING AND TRUING WHEELS
3.8 REAR WHEEL COMPENSATOR
3.9 SEALED WHEEL BEARINGS
3.10 TIRE PRESSURE MONITORING SYSTEM (TPMS)
3.11 TIRES
3.12 WHEEL ALIGNMENT
3.13 ELECTRONIC CHASSIS CONTROL
3.14 FRONT BRAKE MASTER CYLINDER
3.15 FRONT BRAKE CALIPER
3.16 REAR BRAKE MASTER CYLINDER
3.17 REAR BRAKE CALIPER
3.18 BRAKE LINES
3.19 ABS MODULE
3.20 BLEED BRAKES
3.21 SIDE COVERS
3.22 FRONT FORK
3.23 STEERING HEAD/FORK STEM AND BRACKET ASSEMBLY
3.24 STEERING DAMPER ASSEMBLY
3.25 FORK LOCK
3.26 REAR FORK
3.27 CHAIN GUARDS
3.28 REAR SHOCK ABSORBER
3.29 CLUTCH CONTROL
3.30 COWL
3.31 FAIRING
3.32 FAIRING LOWERS
3.33 SKID PLATE
3.34 ENGINE GUARDS
3.35 HEADLAMP GUARD
3.36 HANDLEBAR WIND DEFLECTORS
3.37 HAND GRIPS
3.38 HANDLEBAR
3.39 MIRRORS
3.40 FRONT FENDER
3.41 REAR LICENSE PLATE BRACKET
3.42 RIDER FOOTRESTS
3.43 PASSENGER FOOTRESTS
3.44 JIFFY STAND
3.45 CENTER STAND
3.46 SEAT
3.47 TAIL SECTION
3.48 FRAME
3.49 FRAME CROSSMEMBER
3.50 MEDALLIONS, BADGES, TANK EMBLEMS AND ADHESIVE STRIPS
4. ENGINE
4.1 FASTENER TORQUE VALUES
4.2 SPECIFICATIONS
4.3 ENGINE OIL FLOW
4.4 OIL PUMP OPERATION
4.5 BREATHER OPERATION
4.6 CAMSHAFT AND PHASER OPERATION
4.7 OIL PRESSURE
4.8 TROUBLESHOOTING
4.9 CRIMP CLAMPS
4.10 OIL COOLER
4.11 CRANKSHAFT LOCKOUT
4.12 CYLINDER HEAD COVERS
4.13 CAMSHAFT COVERS
4.14 PHASER SOLENOIDS
4.15 CAMSHAFT SPROCKET AND TIMING CHAIN
4.16 SECONDARY BALANCER
4.17 CYLINDER HEADS
4.18 CAMSHAFTS AND PHASERS
4.19 VALVES
4.20 CYLINDERS
4.21 PISTONS
4.22 PRIMARY COVER
4.23 COOLANT MANIFOLD
4.24 STARTER GEAR
4.25 OIL PUMP DRIVE
4.26 OIL PUMP
4.27 REPLACE ENGINE
4.28 CRANKCASE
4.29 BALANCER
4.30 CRANKSHAFT AND CONNECTING RODS
4.31 SCAVENGE OIL PUMP
4.32 PISTON COOLING JETS
5. DRIVE AND TRANSMISSION
5.1 FASTENER TORQUE VALUES
5.2 SPECIFICATIONS
5.3 TRANSMISSION OPERATION
5.4 DRIVE CHAIN
5.5 OUTPUT SPROCKET
5.6 SHIFTER SHAFT
5.7 CLUTCH
5.8 DRUM AND FORKS
5.9 TRANSMISSION
5.10 TRANSMISSION RIGHT CRANKCASE BEARINGS
5.11 TRANSMISSION LEFT CRANKCASE BEARINGS
6. FUEL AND EXHAUST
6.1 FASTENER TORQUE VALUES
6.2 SPECIFICATIONS
6.3 AIR BOX
6.4 BREATHER BOLT
6.5 BREATHER HOSES
6.6 CONSOLE
6.7 FUEL PRESSURE TEST
6.8 PURGE FUEL LINE
6.9 FUEL LINE
6.10 FUEL INLET
6.11 FUEL TANK
6.12 FUEL LEVEL SENDER
6.13 FUEL PUMP
6.14 DRAIN LINE
6.15 THROTTLE POSITION SENSOR (TPS)
6.16 INTAKE AIR TEMPERATURE (IAT) SENSOR
6.17 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
6.18 TWIST GRIP SENSOR (TGS)
6.19 THROTTLE CONTROL ACTUATOR (TCA)
6.20 FUEL INJECTORS
6.21 INDUCTION MODULE
6.22 INTAKE MANIFOLD
6.23 INTAKE LEAK TEST
6.24 HEATED OXYGEN SENSORS (HO2S)
6.25 MUFFLERS
6.26 EXHAUST SYSTEM
6.27 PURGE SOLENOID: EVAPORATIVE EMISSIONS
6.28 CHARCOAL CANISTER: EVAPORATIVE EMISSIONS
6.29 PURGE LINES: EVAPORATIVE EMISSIONS
7. COOLING SYSTEM
7.1 FASTENER TORQUE VALUES
7.2 SPECIFICATIONS
7.3 COOLANT FLOW
7.4 DIAGNOSE AND TEST
7.5 COOLANT
7.6 THERMOSTAT HOUSING
7.7 COOLANT PUMP
7.8 COOLANT OVERFLOW TANK
7.9 COOLANT HOSES
7.10 ENGINE COOLANT TEMPERATURE (ECT) SENSOR
7.11 RADIATOR
8. ELECTRICAL
8.1 FASTENER TORQUE VALUES
8.2 SPECIFICATIONS
8.3 POWER DISCONNECT
8.4 STARTER
8.5 STARTER SOLENOID
8.6 ALTERNATOR
8.7 VOLTAGE REGULATOR
8.8 SPARK PLUG CABLES
8.9 IGNITION COIL
8.10 LEFT HAND CONTROL MODULE (LHCM)
8.11 CLUTCH SWITCH
8.12 RIGHT HAND CONTROL MODULE (RHCM)
8.13 FRONT STOPLAMP SWITCH
8.14 INSTRUMENT MODULE (IM)
8.15 OIL PRESSURE SWITCH
8.16 HORN
8.17 HEADLAMP
8.18 CORNERING LAMP
8.19 FRONT TURN SIGNAL LAMPS
8.20 REAR TURN SIGNAL LAMPS
8.21 TAIL LAMP
8.22 REAR STOPLAMP SWITCH
8.23 LICENSE PLATE LAMP
8.24 ELECTRONIC CONTROL MODULE (ECM)
8.25 BODY CONTROL MODULE (BCM)
8.26 SECURITY SYSTEM ACTIVATION
8.27 PERSONAL IDENTIFICATION NUMBER (PIN)
8.28 SECURITY SYSTEM MAINTENANCE
8.29 SECURITY SYSTEM ANTENNA
8.30 COOLING FAN
8.31 CRANKSHAFT POSITION SENSOR (CKP)
8.32 CAMSHAFT TIMING SENSORS
8.33 KNOCK SENSOR (KS)
8.34 GEAR POSITION SENSOR
8.35 FRONT WHEEL SPEED SENSOR (WSS)
8.36 REAR WHEEL SPEED SENSOR (WSS)
8.37 TWIST GRIP SENSOR (TGS)
8.38 INERTIAL MEASUREMENT UNIT (IMU)
8.39 JIFFY STAND SENSOR (JSS)
8.40 FRONT ELECTRICAL CADDY
8.41 CYLINDER HEAD COVER CADDY
8.42 UNDER SEAT CADDY
8.43 BATTERY TRAY
8.44 VARIABLE VALVE TIMING (VVT) HARNESS
8.45 ENGINE WIRE HARNESS
8.46 MAIN WIRE HARNESS
A. WIRING
A.1 WIRING DIAGRAMS
WIRING DIAGRAM LIST
Power Distribution: 2022 Pan America
Sensor Grounds: 2022 Pan America
Ground Circuit: 2022 Pan America
Front Lighting and Hand C ontrols: 2022 Pan America
Main Harness 1 of 2: 2022 Pan America
Main Harness 2 of 2: 2022 Pan America
Engine Harness 1 of 2: 2022 Pan America
Engine Harness 2 of 2: 2022 Pan America
Rear Lighting: 2022 Pan America
A.2 WIRE HARNESS CONNECTORS
B. REFERENCE
B.1 GLOSSARY
B.2 METRIC CONVERSION
B.3 FLUID CONVERSION
B.4 TORQUE CONVERSION
TOOLS
TORQUE VALUES
INDEX
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