2025 Harley-Davidson Pan America Models 94001295 (Preview)
2025 PAN AMERICA MODELS SERVICE MANUAL #94001295
FOREWORD
TABLE OF CONTENTS
1 SAFETY
1.1 SAFETY
SAFETY
SAFETY MESSAGES
CUSTOMER SAFETY
PERSONAL PROTECTION
TOOL SAFETY
PRODUCT SAFETY
HAZARDOUS MATERIALS
ELECTRICAL SYSTEMS
2 MAINTENANCE
2.1 FASTENER TORQUE VALUES
FASTENER TORQUE VALUES IN THIS CHAPTER
2.2 GENERAL
SERVICING A MOTORCYCLE
SERVICING A NEW MOTORCYCLE
SECURE THE MOTORCYCLE FOR SERVICE
SET MOTORCYCLE UPRIGHT
LIFTING MOTORCYCLE
2.3 MAINTENANCE SCHEDULE
GENERAL
REGULAR SERVICE INTERVALS
2.4 FUEL AND OIL
FUEL
GASOLINE BLENDS
ENGINE LUBRICATION
ENGINE LUBRICATION
LOW TEMPERATURE LUBRICATION
2.5 REPLACE ENGINE OIL AND FILTER
CHECK ENGINE OIL LEVEL
CHANGE OIL AND OIL FILTER
2.6 INSPECT TIRES AND WHEELS
GENERAL
TIRES
TIRE PRESSURE
INSPECTING TIRES
TIRE REPLACEMENT
WHEEL BEARINGS
WHEEL SPOKES
INSPECT
ADJUST WHEEL SPOKE
2.7 LUBRICATE CABLES AND CHASSIS
GENERAL
LUBRICATION POINTS
2.8 INSPECT BRAKES
INSPECT
BRAKE PADS
BRAKE DISC
REPLACE FRONT BRAKE PADS
REMOVE
INSTALL
REPLACE REAR BRAKE PADS
REMOVE
INSTALL
2.9 CHECK AND REPLACE BRAKE FLUID
CHECK BRAKE FLUID LEVEL
DRAIN AND REPLACE FLUID
INSPECT BRAKE LINES
2.10 CHECK AND ADJUST CLUTCH
CHECK AND ADJUST
2.11 REBUILD FRONT FORK AND REPLACE OIL
REBUILD AND REPLACE FORK OIL
2.12 ADJUST AND LUBRICATE STEERING HEAD BEARINGS
PREPARE
CHECK AND ADJUST
MEASURE
ADJUST
LUBRICATE
COMPLETE
2.13 INSPECT RADIATOR AND COOLANT
GENERAL
GENERAL
CHECKING COOLANT LEVEL
CLEAN RADIATOR
INSPECT
CHECK FREEZE POINT
CHECK FOR LEAKS
DRAIN AND FILL COOLING SYSTEM
2.14 INSPECT FUEL LINES AND FITTINGS
INSPECT
2.15 INSPECT AND LUBRICATE JIFFY STAND
INSPECT AND LUBRICATE
2.16 INSPECT AND ADJUST DRIVE CHAIN AND SPROCKETS
INSPECT
GENERAL
CLEANING AND LUBRICATION
SPROCKETS
DRIVE CHAIN
CHAIN GUIDE
MEASURE DRIVE CHAIN DEFLECTION
ADJUST CHAIN
2.17 INSPECT REAR SPROCKET ISOLATOR
INSPECT
2.18 ADJUST SUSPENSION
SUSPENSION ADJUSTMENTS
SUSPENSION IDENTIFICATION
SUSPENSION DEFINITIONS
SUSPENSION TUNING
CHANGES IN LOAD
ELECTRONIC SUSPENSION
ARH
SEMI-ACTIVE SUSPENSION
ADJUSTING ELECTRONIC SUSPENSION
ARH (W/PASSIVE SUSPENSION)
2.19 INSPECT EXHAUST SYSTEM
LEAK CHECK
2.20 INSPECT AIR FILTER
PREPARE
REMOVE AND INSTALL
COMPLETE
2.21 INSPECT BATTERY
PREPARE
REMOVE
INSTALL
CLEAN AND INSPECT
VOLTAGE TEST
STORAGE
COMPLETE
2.22 INSPECT AND REPLACE SPARK PLUGS
PREPARE
REMOVE
INSPECT
INSTALL
COMPLETE
2.23 STORAGE
PLACE IN STORAGE
REMOVE FROM STORAGE
2.24 TROUBLESHOOTING
GENERAL
ENGINE
STARTER MOTOR DOES NOT OPERATE OR DOES NOT TURN ENGINE OVER
ENGINE TURNS OVER BUT DOES NOT START
STARTS HARD
STARTS BUT RUNS IRREGULARLY OR MISSES
A SPARK PLUG FOULS REPEATEDLY
PRE-IGNITION OR DETONATION (KNOCKS OR PINGS)
OVERHEATING
VALVE TRAIN NOISE
EXCESSIVE VIBRATION
CHECK ENGINE LIGHT ILLUMINATES DURING OPERATION
LUBRICATION SYSTEM
ENGINE OIL NOT CIRCULATING (OIL PRESSURE INDICATOR LIT)
OIL DOES NOT RETURN TO CRANKCASE OIL RESERVOIR
ENGINE USES TOO MUCH OIL OR SMOKES EXCESSIVELY
ENGINE LEAKS OIL FROM CASES, ETC.
LOW OIL PRESSURE
HIGH OIL PRESSURE
ELECTRICAL SYSTEM
ALTERNATOR DOES NOT CHARGE
ALTERNATOR CHARGE RATE IS BELOW NORMAL
TRANSMISSION
TRANSMISSION SHIFTS HARD
TRANSMISSION JUMPS OUT OF GEAR
CLUTCH SLIPS
CLUTCH DRAGS OR DOES NOT RELEASE
CLUTCH CHATTERS
HANDLING
IRREGULARITIES
BRAKES
BRAKES DO NOT HOLD NORMALLY
3 CHASSIS
3.1 FASTENER TORQUE VALUES
FASTENER TORQUE VALUES IN THIS CHAPTER
3.2 SPECIFICATIONS
CHASSIS
CHASSIS SPECIFICATIONS
3.3 VEHICLE IDENTIFICATION NUMBER (VIN)
VEHICLE IDENTIFICATION NUMBER (VIN)
GENERAL
LOCATION
ABBREVIATED VIN
3.4 FRONT WHEEL
PREPARE
REMOVE
INSTALL
DISASSEMBLE
LACED WHEEL
CAST WHEEL
CLEAN AND INSPECT
ASSEMBLE
LACED WHEEL
CAST WHEEL
COMPLETE
3.5 REAR WHEEL
PREPARE
REMOVE
INSTALL
DISASSEMBLE
CLEAN AND INSPECT
ASSEMBLE
COMPLETE
3.6 WHEEL LACING
WHEEL LACING
3.7 CHECKING AND TRUING WHEELS
GENERAL
CHECKING WHEEL RUNOUT
CHECKING RADIAL RUNOUT
CHECKING LATERAL RUNOUT
3.8 REAR WHEEL COMPENSATOR
PREPARE
REMOVE
INSTALL
DISASSEMBLE
CLEAN AND INSPECT
ASSEMBLE
COMPLETE
3.9 SEALED WHEEL BEARINGS
PREPARE
INSPECT
REMOVE
INSTALL
COMPLETE
3.10 TIRE PRESSURE MONITORING SYSTEM (TPMS)
GENERAL
PREPARE
REMOVE
INSTALL
INSTALL SENSOR
COMPLETE
3.11 TIRES
GENERAL
PREPARE
REMOVE
CLEAN, INSPECT AND REPAIR
INSTALL
CHECK TIRE RUNOUT
LATERAL RUNOUT
RADIAL RUNOUT
BALANCE
STATIC VERSUS DYNAMIC
WEIGHTS
COMPLETE
3.12 WHEEL ALIGNMENT
INSPECT
CHECKING WHEEL ALIGNMENT
ADJUST
3.13 ELECTRONIC CHASSIS CONTROL
RIDER ENHANCEMENTS
LINKED BRAKING WITH ANTI-LOCK BRAKE SYSTEM (ABS)
SYSTEM COMPONENTS
TRACTION CONTROL SYSTEM (TCS)
DRAG-TORQUE SLIP CONTROL SYSTEM (DSCS)
VEHICLE HOLD CONTROL (VHC)
3.14 FRONT BRAKE MASTER CYLINDER
PREPARE
REMOVE
INSTALL
DISASSEMBLE
MASTER CYLINDER RESERVOIR
BRAKE LEVER
CLEAN AND INSPECT
ASSEMBLE
BRAKE LEVER
MASTER CYLINDER RESERVOIR
COMPLETE
3.15 FRONT BRAKE CALIPER
PREPARE
REMOVE
INSTALL
COMPLETE
3.16 REAR BRAKE MASTER CYLINDER
PREPARE
REMOVE
INSTALL
DISASSEMBLE
CLEAN AND INSPECT
ASSEMBLE
COMPLETE
3.17 REAR BRAKE CALIPER
PREPARE
REMOVE
INSTALL
COMPLETE
3.18 BRAKE LINES
FRONT CROSSOVER BRAKE LINE
PREPARE
REMOVE
INSTALL
COMPLETE
BRAKE LINE: FRONT MASTER CYLINDER TO ABS MODULE
PREPARE
REMOVE
INSTALL
COMPLETE
BRAKE LINE: FRONT CALIPER TO ABS MODULE
PREPARE
REMOVE
INSTALL
COMPLETE
BRAKE LINE: REAR MASTER CYLINDER TO ABS MODULE
PREPARE
REMOVE
INSTALL
COMPLETE
BRAKE LINE: REAR CALIPER TO ABS MODULE
PREPARE
REMOVE
INSTALL
COMPLETE
3.19 ABS MODULE
GENERAL
PREPARE
REMOVE
INSTALL
COMPLETE
3.20 BLEED BRAKES
DRAIN
FILL AND BLEED
3.21 SIDE COVERS
PREPARE
STEERING HEAD COVER
MIDDLE SIDE COVER
REAR SIDE COVER
REMOVE
STEERING HEAD COVER
MIDDLE SIDE COVER
REAR SIDE COVER
RADIATOR COVERS
INSTALL
STEERING HEAD COVER
MIDDLE SIDE COVER
REAR SIDE COVER
RADIATOR COVERS
COMPLETE
STEERING HEAD COVER
MIDDLE SIDE COVER
REAR SIDE COVER
3.22 FRONT FORK
CHECK FOR OIL LEAK
FORK OIL SEALS
CHECK OIL LEAK
PREPARE
REMOVE
INSTALL
DISASSEMBLE AND ASSEMBLE: STANDARD
DISASSEMBLE
DRAIN FORK OIL
COMPLETE DISASSEMBLY
CLEAN AND INSPECT
INITIAL ASSEMBLY
FORK FILL
COMPLETE ASSEMBLY
DISASSEMBLE AND ASSEMBLE: LEFT SIDE, S AND ST MODELS, ALL
DISASSEMBLE
DRAIN FORK OIL
COMPLETE DISASSEMBLY
CLEAN AND INSPECT
INITIAL ASSEMBLY
FORK FILL
DISASSEMBLE AND ASSEMBLE: RIGHT SIDE, S MODELS, WITHOUT ARH
DISASSEMBLE
DRAIN FORK OIL
COMPLETE DISASSEMBLY
CLEAN AND INSPECT
INITIAL ASSEMBLY
ASSEMBLE FOR FORK FILL
FORK FILL
COMPLETE ASSEMBLY
DISASSEMBLE AND ASSEMBLE: RIGHT SIDE, S AND ST MODELS, WITH ARH
DISASSEMBLE
DRAIN FORK OIL
COMPLETE DISASSEMBLY
CLEAN AND INSPECT
INITIAL ASSEMBLY
FORK FILL
COMPLETE ASSEMBLY
COMPLETE
3.23 STEERING HEAD/FORK STEM AND BRACKET ASSEMBLY
PREPARE
REMOVE
UPPER FORK BRACKET
LOWER FORK BRACKET
STEERING HEAD BEARINGS
INSTALL
STEERING HEAD BEARINGS
LOWER FORK BRACKET
UPPER FORK BRACKET
COMPLETE
3.24 STEERING DAMPER ASSEMBLY
REMOVE
INSTALL
3.25 FORK LOCK
PREPARE
REMOVE
INSTALL
COMPLETE
3.26 REAR FORK
PREPARE
REMOVE
INSTALL
DISASSEMBLE
CLEAN AND INSPECT
ASSEMBLE
COMPLETE
3.27 CHAIN GUARDS
REMOVE
BOTTOM CHAIN GUARD
TOP CHAIN GUARD
SPROCKET COVER
INSTALL
SPROCKET COVER
TOP CHAIN GUARD
BOTTOM CHAIN GUARD
3.28 REAR SHOCK ABSORBER
PREPARE
REMOVE
REAR SHOCK ABSORBER
SWING ARM MOUNT BLOCK ASSEMBLY
CLEAN AND INSPECT
INSTALL
SWING ARM MOUNT BLOCK ASSEMBLY
REAR SHOCK ABSORBER
DISASSEMBLE
STANDARD REAR SHOCK KNOB
REAR SUSPENSION LINK
SWING ARM ASSEMBLY MOUNT BLOCK
ASSEMBLE
STANDARD REAR SHOCK KNOB
REAR SUSPENSION LINK
SWING ARM ASSEMBLY MOUNT BLOCK
ADJUST PRELOAD
RA1250
RA1250S AND RA1250S WITH ARH
COMPLETE
3.29 CLUTCH CONTROL
PREPARE
REMOVE
CLUTCH CABLE: LOWER END
CLUTCH CABLE: UPPER END
CLUTCH HAND CONTROL
CLUTCH SWITCH
COMPLETE CABLE
CLEAN AND INSPECT
INSTALL
CLUTCH SWITCH
CLUTCH HAND CONTROL
CLUTCH CABLE: LOWER END
CLUTCH CABLE: UPPER END
DISASSEMBLE
ASSEMBLE
COMPLETE
3.30 COWL
REMOVE AND INSTALL: COWL
PREPARE
REMOVE
INSTALL
COMPLETE
DISASSEMBLE AND ASSEMBLE: COWL
DISASSEMBLY
ASSEMBLY
REMOVE AND INSTALL: DEFLECTORS
REMOVE
INSTALL
REMOVE AND INSTALL: WINDSHIELD
REMOVE
INSTALL
3.31 FAIRING
REMOVE AND INSTALL
REMOVE
INSTALL
3.32 FAIRING LOWERS
PREPARE
REMOVE
INSTALL
DISASSEMBLE
ASSEMBLE
COMPLETE
3.33 SKID PLATE
REMOVE AND INSTALL
ONE PIECE SKID PLATE
TWO PIECE SKID PLATE
3.34 ENGINE GUARDS
PREPARE
REMOVE
INSTALL
COMPLETE
3.35 HEADLAMP GUARD
GENERAL
3.36 AIR DEFLECTORS
REMOVE AND INSTALL: MID FRAME DEFLECTORS
REMOVE
INSTALL
3.37 HANDLEBAR WIND DEFLECTORS
REMOVE
INSTALL
3.38 HAND GRIPS
PREPARE
REMOVE
LEFT
RIGHT
INSTALL
LEFT
RIGHT
COMPLETE
3.39 HANDLEBAR
PREPARE
REPLACE HANDLEBAR
REMOVE HANDLEBAR FOR SERVICE
REMOVE
REMOVE HANDLEBAR FOR SERVICE
REMOVE HANDLEBAR
INSTALL
INSTALL HANDLEBAR AFTER SERVICE
INSTALL NEW HANDLEBAR
COMPLETE
INSTALL HANDLEBAR AFTER SERVICE
REPLACE HANDLEBAR
3.40 MIRRORS
REMOVE
REMOVE
INSTALL
3.41 FRONT FENDER
REMOVE
REMOVE
INSTALL
3.42 REAR LICENSE PLATE BRACKET
PREPARE
REMOVE
IF REPLACING REAR LICENSE PLATE BRACKET
INSTALL
IF REAR LICENSE PLATE BRACKET WAS REPLACED
INSTALL REAR LICENSE PLATE BRACKET
COMPLETE
3.43 RIDER FOOTRESTS
PREPARE
IF REMOVING RIGHT SIDE FOOTREST BRACKET OR BRAKE PEDAL.
IF REMOVING LEFT SIDE FOOTREST BRACKET OR SHIFT LEVER.
REMOVE AND INSTALL: FOOTPEGS
REMOVE
INSTALL
DISASSEMBLE AND ASSEMBLE
REMOVE AND INSTALL: BRACKET
RIGHT SIDE FOOTREST BRACKET
LEFT SIDE FOOTREST BRACKET
REMOVE AND INSTALL: BRAKE PEDAL
REMOVE
INSTALL
COMPLETE
IF RIGHT SIDE FOOTREST BRACKET OR BRAKE PEDAL WAS REMOVED.
IF LEFT SIDE FOOTREST BRACKET OR PEDAL WAS REMOVED.
3.44 PASSENGER FOOTRESTS
PREPARE
REMOVE AND INSTALL: FOOTPEGS
REMOVE
INSTALL
DISASSEMBLE AND ASSEMBLE
REMOVE AND INSTALL: BRACKET
REMOVE
INSTALL
COMPLETE
3.45 JIFFY STAND
PREPARE
REMOVE
INSTALL
DISASSEMBLE
ASSEMBLE
COMPLETE
3.46 CENTER STAND
REMOVE
INSTALL
3.47 SEAT
REMOVE
REMOVAL
INSTALL
INSTALLATION
3.48 TAIL SECTION
PREPARE
REMOVE
INSTALL
DISASSEMBLE
PASSENGER HANDHOLD ASSEMBLY
REAR LICENSE PLATE BRACKET
REAR SIDE COVERS
ASSEMBLE
REAR SIDE COVERS
REAR LICENSE PLATE BRACKET
PASSENGER HANDHOLD ASSEMBLY
COMPLETE
3.49 FRAME
PREPARE
FRONT FRAME
MIDFRAME
REMOVE
FRONT FRAME
MIDFRAME
INSTALL
FRONT FRAME
MIDFRAME
COMPLETE
FRONT FRAME
MIDFRAME
3.50 FRAME CROSSMEMBER
PREPARE
REMOVE
INSTALL
COMPLETE
3.51 MEDALLIONS, BADGES, TANK EMBLEMS AND ADHESIVE STRIPS
REMOVE
INSTALL
4 ENGINE
4.1 FASTENER TORQUE VALUES
FASTENER TORQUE VALUES IN THIS CHAPTER
4.2 SPECIFICATIONS
ENGINE
SERVICE WEAR LIMITS
4.3 ENGINE OIL FLOW
OPERATION
OIL DISTRIBUTION
OIL SCAVENGE
4.4 OIL PUMP OPERATION
GENERAL
OPERATION
4.5 BREATHER OPERATION
GENERAL
4.6 CAMSHAFT AND PHASER OPERATION
OPERATION
4.7 OIL PRESSURE
OPERATION
OIL PRESSURE CHECK
4.8 TROUBLESHOOTING
TYPICAL SYMPTOMS
COMPRESSION TEST
CYLINDER LEAKDOWN TEST
DIAGNOSE VALVE TRAIN NOISE
DIAGNOSE SMOKING ENGINE OR HIGH OIL CONSUMPTION
CHECK BEFORE CYLINDER HEAD REMOVAL:
CHECK AFTER CYLINDER HEAD REMOVAL:
TROUBLESHOOTING TABLES
4.9 CRIMP CLAMPS
REMOVE
REMOVAL
INSTALL
INSTALLATION
4.10 OIL COOLER
PREPARE
REMOVE
HOSE
OIL COOLER
INSTALL
OIL COOLER
HOSE
COMPLETE
4.11 CRANKSHAFT LOCKOUT
CRANKSHAFT LOCKOUT
PREPARE
LOCK
UNLOCK
COMPLETE
4.12 CYLINDER HEAD COVERS
PREPARE
REMOVE
INSTALL
COMPLETE
4.13 CAMSHAFT COVERS
PREPARE
REMOVE
INSTALL
COMPLETE
4.14 PHASER SOLENOIDS
PREPARE
REMOVE
PLATE ASSEMBLY
SOLENOID
INSTALL
PLATE ASSEMBLY
SOLENOID
COMPLETE
4.15 CAMSHAFT SPROCKET AND TIMING CHAIN
PREPARE
REMOVE
CAM TIMING
CRANKSHAFT
CAMSHAFT TIMING
FRONT CYLINDER HEAD
REAR CYLINDER HEAD
CLEAN AND INSPECT
SPROCKETS AND TIMING CHAIN
TIMING CHAIN TENSIONER
INSTALL
COMPLETE
4.16 SECONDARY BALANCER
PREPARE
REMOVE
TENSIONER
BALANCE GEAR
INSTALL
BALANCE GEAR
TENSIONER
COMPLETE
4.17 CYLINDER HEADS
PREPARE
REMOVE
CLEAN
INSTALL
DISASSEMBLE
CLEAN AND INSPECT
CYLINDER HEAD
VALVE
ASSEMBLE
COMPLETE
4.18 CAMSHAFTS AND PHASERS
PREPARE
REMOVE
CLEAN AND INSPECT
CAMSHAFT
ROLLER FINGER FOLLOWERS
GEARS
INSTALL
COMPLETE
4.19 CYLINDERS
PREPARE
REMOVE
INSTALL
CLEAN AND INSPECT
COMPLETE
4.20 PISTONS
PREPARE
REMOVE
INSTALL
DISASSEMBLE
CLEAN AND INSPECT
CHECK PISTON RING GAP
ASSEMBLE
COMPLETE
4.21 PRIMARY COVER
PREPARE
REMOVE
PRIMARY COVER
OIL BAFFLE
INSTALL
OIL BAFFLE
PRIMARY COVER
DISASSEMBLE
ASSEMBLE
COMPLETE
4.22 COOLANT MANIFOLD
PREPARE
REMOVE
COOLANT FITTINGS
ALTERNATOR COVER
COOLANT MANIFOLD
COOLANT TUBES
COOLANT PUMP
STATOR
INSTALL
STATOR
COOLANT PUMP
COOLANT TUBES
COOLANT MANIFOLD
ALTERNATOR COVER
COOLANT FITTINGS
COMPLETE
4.23 STARTER GEAR
PREPARE
REMOVE
INSTALL
COMPLETE
4.24 OIL PUMP DRIVE
PREPARE
REMOVE
INSTALL
COMPLETE
4.25 OIL PUMP
PREPARE
REMOVE
INSTALL
COMPLETE
4.26 REPLACE ENGINE
REMOVE
INSTALL
4.27 CRANKCASE
PREPARE
DISASSEMBLE
CLEAN AND INSPECT
ASSEMBLE
REPAIR RIGHT CRANKCASE HALF
MAIN BEARING
BALANCER BEARING
TRANSMISSION MAINSHAFT BEARING
TRANSMISSION COUNTERSHAFT BEARING
TRANSMISSION SHIFT DRUM BEARING
REPAIR LEFT CRANKCASE HALF
MAIN BEARING
BALANCER BEARING
TRANSMISSION MAINSHAFT BEARING
TRANSMISSION COUNTERSHAFT BEARING
TRANSMISSION SHIFT DRUM BEARING
PLUGS AND OIL FITTINGS
ENGINE BODY PLUG
OIL FILTER ADAPTER FITTING
COMPLETE
4.28 BALANCER
PREPARE
REMOVE
INSTALL
COMPLETE
4.29 CRANKSHAFT AND CONNECTING RODS
PREPARE
REMOVE
INSTALL
DISASSEMBLE
CLEAN AND INSPECT
ASSEMBLE
COMPLETE
4.30 SCAVENGE OIL PUMP
PREPARE
REMOVE
INSTALL
COMPLETE
4.31 PISTON COOLING JETS
PREPARE
REMOVE
INSTALL
COMPLETE
5 DRIVE AND TRANSMISSION
5.1 FASTENER TORQUE VALUES
FASTENER TORQUE VALUES IN THIS CHAPTER
5.2 SPECIFICATIONS
DRIVE SPECIFICATIONS
TRANSMISSION SPECIFICATIONS
TRANSMISSION AND CLUTCH
5.3 TRANSMISSION OPERATION
POWER FLOW
NEUTRAL
FIRST GEAR
SECOND GEAR
THIRD GEAR
FOURTH GEAR
FIFTH GEAR
SIXTH GEAR
5.4 DRIVE CHAIN
PREPARE
REMOVE
INSTALL
COMPLETE
5.5 OUTPUT SPROCKET
PREPARE
REMOVE
INSTALL
COMPLETE
5.6 SHIFTER SHAFT
PREPARE
REMOVE
SHIFTER LINKAGE
SHIFTER SHAFT ASSEMBLY
DETENT ASSEMBLY
INSTALL
DETENT ASSEMBLY
SHIFTER SHAFT ASSEMBLY
SHIFTER LINKAGE
DISASSEMBLE
DISASSEMBLE
ASSEMBLE
ASSEMBLE
COMPLETE
5.7 CLUTCH
PREPARE
REMOVE
INSTALL
DISASSEMBLE
CLEAN AND INSPECT
ASSEMBLE
COMPLETE
5.8 DRUM AND FORKS
PREPARE
REMOVE
INSTALL
COMPLETE
5.9 TRANSMISSION
PREPARE
REMOVE
INSTALL
DISASSEMBLE
INPUT SHAFT
OUTPUT SHAFT
ASSEMBLE
INPUT SHAFT
OUTPUT SHAFT
COMPLETE
5.10 TRANSMISSION RIGHT CRANKCASE BEARINGS
GENERAL
5.11 TRANSMISSION LEFT CRANKCASE BEARINGS
GENERAL
6 FUEL AND EXHAUST
6.1 FASTENER TORQUE VALUES
FASTENER TORQUE VALUES IN THIS CHAPTER
6.2 SPECIFICATIONS
SPECIFICATIONS
6.3 AIR BOX
PREPARE
REMOVE
INSTALL
COMPLETE
6.4 BREATHER BOLT
REMOVE
INSTALL
6.5 BREATHER HOSES
PREPARE
REMOVE
INSTALL
COMPLETE
6.6 CONSOLE
REMOVE
INSTALL
6.7 FUEL PRESSURE TEST
PREPARE
TEST
COMPLETE
6.8 PURGE FUEL LINE
PREPARE
PURGE
COMPLETE
6.9 FUEL LINE
PREPARE
REMOVE
INSTALL
COMPLETE
6.10 FUEL INLET
PREPARE
REMOVE
INSTALL
COMPLETE
6.11 FUEL TANK
PREPARE
REMOVE
INSTALL
COMPLETE
6.12 FUEL LEVEL SENDER
PREPARE
REMOVE
INSTALL
COMPLETE
6.13 FUEL PUMP
PREPARE
REMOVE
INSTALL
COMPLETE
6.14 DRAIN LINE
PREPARE
REMOVE
INSTALL
COMPLETE
6.15 THROTTLE POSITION SENSOR (TPS)
GENERAL
6.16 INTAKE AIR TEMPERATURE (IAT) SENSOR
PREPARE
REMOVE
INSTALL
COMPLETE
6.17 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
PREPARE
REMOVE
REAR MAP SENSOR
FRONT MAP SENSOR
INSTALL
REAR MAP SENSOR
FRONT MAP SENSOR
COMPLETE
6.18 TWIST GRIP SENSOR (TGS)
PREPARE
REMOVE
INSTALL
COMPLETE
6.19 THROTTLE CONTROL ACTUATOR (TCA)
GENERAL
6.20 FUEL INJECTORS
PREPARE
REMOVE
INSTALL
COMPLETE
6.21 INDUCTION MODULE
PREPARE
REMOVE
INSTALL
COMPLETE
6.22 INTAKE MANIFOLD
PREPARE
REMOVE
INSTALL
COMPLETE
6.23 INTAKE LEAK TEST
LEAK TESTER
PARTS LIST
TESTER ASSEMBLY
TESTER ADJUSTMENT
PROCEDURE
6.24 HEATED OXYGEN SENSORS (HO2S)
PREPARE
REMOVE
INSTALL
COMPLETE
6.25 MUFFLERS
PREPARE
REMOVE
EXHAUST WITH UNDER SLUNG MUFFLERS
EXHAUST WITHOUT UNDER SLUNG MUFFLERS
INSTALL
EXHAUST WITH UNDER SLUNG MUFFLERS
COMPLETE
6.26 EXHAUST SYSTEM
GENERAL
PREPARE
REMOVE
INSTALL
COMPLETE
6.27 PURGE SOLENOID: EVAPORATIVE EMISSIONS
PREPARE
REMOVE
INSTALL
COMPLETE
6.28 CHARCOAL CANISTER: EVAPORATIVE EMISSIONS
PREPARE
REMOVE
INSTALL
COMPLETE
6.29 PURGE LINES: EVAPORATIVE EMISSIONS
PREPARE
REMOVE AND INSTALL: VAPOR VENT LINE
REMOVE
INSTALL
REMOVE AND INSTALL: TIP OVER HOSE
REMOVE
INSTALL
REMOVE AND INSTALL: PURGE PORT HOSE
REMOVE
INSTALL
REMOVE AND INSTALL: FRESH AIR PORT HOSE
REMOVE
INSTALL
REMOVE AND INSTALL: CARBON CANISTER-TO-PURGE SOLENOID HOSE
REMOVE
INSTALL
COMPLETE
7 COOLING SYSTEM
7.1 FASTENER TORQUE VALUES
FASTENER TORQUE VALUES IN THIS CHAPTER
7.2 SPECIFICATIONS
GENERAL
7.3 COOLANT FLOW
OPERATION
ENGINE BELOW OPERATING TEMPERATURE
COOLANT FLOW WITH ENGINE AT OPERATING TEMPERATURE
COOLANT OVERFLOW TANK
7.4 DIAGNOSE AND TEST
TROUBLESHOOTING
TROUBLESHOOTING
PRESSURE CAP TEST
PRESSURE CAP TEST
SYSTEM PRESSURE TEST
SYSTEM PRESSURE TEST
FREEZE POINT TEST
FREEZE POINT TEST
LEAK DETECTION DYE TEST
LEAK DETECTION DYE TEST
GASKET LEAK TEST
GASKET LEAK TEST
7.5 COOLANT
PREPARE
CHECK COOLANT LEVEL
DRAIN AND FILL COOLING SYSTEM
DRAIN
FILL
COMPLETE
7.6 THERMOSTAT HOUSING
PREPARE
REMOVE
INSTALL
COMPLETE
7.7 COOLANT PUMP
GENERAL
7.8 COOLANT OVERFLOW TANK
PREPARE
REMOVE
INSTALL
COMPLETE
7.9 COOLANT HOSES
PREPARE
REMOVE AND INSTALL: COOLANT HOSES
REMOVE
INSTALL
REMOVE AND INSTALL: OVERFLOW HOSE
COMPLETE
7.10 ENGINE COOLANT TEMPERATURE (ECT) SENSOR
PREPARE
REMOVE
INSTALL
COMPLETE
7.11 RADIATOR
RELOCATE RADIATOR FOR SERVICE
PREPARE
REMOVE
INSTALL
COMPLETE
REMOVE AND INSTALL: RADIATOR
PREPARE
REMOVE
INSTALL
COMPLETE
8 ELECTRICAL
8.1 FASTENER TORQUE VALUES
FASTENER TORQUE VALUES IN THIS CHAPTER
8.2 SPECIFICATIONS
SPECIFICATIONS
8.3 POWER DISCONNECT
MAIN FUSE
REMOVE MAIN FUSE.
INSTALL MAIN FUSE.
NEGATIVE BATTERY CABLE
DISCONNECT NEGATIVE BATTERY CABLE
CONNECT NEGATIVE BATTERY CABLE
8.4 STARTER
PREPARE
REMOVE
INSTALL
COMPLETE
8.5 STARTER SOLENOID
PREPARE
REMOVE
INSTALL
COMPLETE
8.6 ALTERNATOR
PREPARE
REMOVE
ROTOR
STARTER RING GEAR AND NEEDLE BEARINGS
STATOR
INSTALL
STATOR
STARTER RING GEAR AND NEEDLE BEARINGS
ROTOR
COMPLETE
8.7 VOLTAGE REGULATOR
PREPARE
REMOVE
REMOVE VOLTAGE REGULATOR
REMOVE VOLTAGE REGULATOR BRACKET.
INSTALL
INSTALL VOLTAGE REGULATOR BRACKET
INSTALL VOLTAGE REGULATOR
COMPLETE
8.8 SPARK PLUG CABLES
PREPARE
REMOVE
INSTALL
COMPLETE
8.9 IGNITION COIL
PREPARE
REMOVE
SIDE MOUNT IGNITION COIL.
IGNITION COIL BRACKET.
HEAD MOUNTED IGNITION COILS.
INSTALL
IGNITION COIL BRACKET.
SIDE MOUNT IGNITION COIL.
HEAD MOUNTED IGNITION COILS.
COMPLETE
8.10 LEFT HAND CONTROL MODULE (LHCM)
PREPARE
REMOVE
INSTALL
COMPLETE
8.11 CLUTCH SWITCH
REMOVE
INSTALL
8.12 RIGHT HAND CONTROL MODULE (RHCM)
PREPARE
REMOVE
INSTALL
COMPLETE
8.13 FRONT STOPLAMP SWITCH
REMOVE
INSTALL
8.14 INSTRUMENT MODULE (IM)
PREPARE
REMOVE
INSTALL
COMPLETE
8.15 OIL PRESSURE SWITCH
PREPARE
REMOVE
INSTALL
COMPLETE
8.16 HORN
PREPARE
REMOVE
INSTALL
COMPLETE
8.17 HEADLAMP
PREPARE
REMOVE
INSTALL
ALIGN
PREPARE
CHECK ALIGNMENT
ADJUST
COMPLETE
8.18 CORNERING LAMP
PREPARE
REMOVE
INSTALL
COMPLETE
ALIGN AND ADJUST
CHECK BANK ANGLE LIGHT ALIGNMENT (IF EQUIPPED)
ADJUSTMENT
8.19 FRONT TURN SIGNAL LAMPS
PREPARE
REMOVE
INSTALL
COMPLETE
8.20 REAR TURN SIGNAL LAMPS
PREPARE
REMOVE
INSTALL
COMPLETE
8.21 TAIL LAMP
PREPARE
REMOVE
INSTALL
COMPLETE
8.22 REAR STOPLAMP SWITCH
PREPARE
REMOVE
INSTALL
COMPLETE
8.23 LICENSE PLATE LAMP
PREPARE
REMOVE
INSTALL
COMPLETE
8.24 ELECTRONIC CONTROL MODULE (ECM)
PREPARE
REMOVE
INSTALL
COMPLETE
8.25 BODY CONTROL MODULE (BCM)
PREPARE
REMOVE
INSTALL
COMPLETE
8.26 SECURITY SYSTEM ACTIVATION
ACTIVATION
FOB ASSIGNMENT
8.27 PERSONAL IDENTIFICATION NUMBER (PIN)
CHANGING THE PIN
CHANGING THE PIN
8.28 SECURITY SYSTEM MAINTENANCE
SERVICE MODE
TRANSPORT MODE
TO ENTER TRANSPORT MODE
TO EXIT TRANSPORT MODE
FOB BATTERY
8.29 SECURITY SYSTEM ANTENNA
PREPARE
REMOVE
INSTALL
COMPLETE
8.30 COOLING FAN
PREPARE
REMOVE
INSTALL
COMPLETE
8.31 CRANKSHAFT POSITION SENSOR (CKP)
PREPARE
REMOVE
INSTALL
COMPLETE
8.32 CAMSHAFT TIMING SENSORS
PREPARE
REMOVE
INSTALL
COMPLETE
8.33 KNOCK SENSOR (KS)
PREPARE
REMOVE
INSTALL
COMPLETE
8.34 GEAR POSITION SENSOR
PREPARE
REMOVE
INSTALL
COMPLETE
8.35 FRONT WHEEL SPEED SENSOR (WSS)
PREPARE
REMOVE
INSTALL
COMPLETE
8.36 REAR WHEEL SPEED SENSOR (WSS)
PREPARE
REMOVE
INSTALL
COMPLETE
8.37 TWIST GRIP SENSOR (TGS)
PREPARE
REMOVE
INSTALL
COMPLETE
8.38 INERTIAL MEASUREMENT UNIT (IMU)
PREPARE
REMOVE
INSTALL
COMPLETE
8.39 JIFFY STAND SENSOR (JSS)
PREPARE
REMOVE
INSTALL
COMPLETE
8.40 FRONT ELECTRICAL CADDY
PREPARE
REMOVE
INSTALL
COMPLETE
8.41 CYLINDER HEAD COVER CADDY
PREPARE
REMOVE
INSTALL
COMPLETE
8.42 UNDER SEAT CADDY
PREPARE
REMOVE
INSTALL
COMPLETE
8.43 BATTERY TRAY
PREPARE
REMOVE
INSTALL
COMPLETE
8.44 VARIABLE VALVE TIMING (VVT) HARNESS
PREPARE
REMOVE
INSTALL
COMPLETE
8.45 ENGINE WIRE HARNESS
PREPARE
REMOVE
INSTALL
COMPLETE
8.46 MAIN WIRE HARNESS
PREPARE
REMOVE
INSTALL
COMPLETE
A REFERENCE
A.1 GLOSSARY
ACRONYMS AND ABBREVIATIONS
A.2 METRIC CONVERSION
CONVERSION TABLE
A.3 FLUID CONVERSION
UNITED STATES SYSTEM
METRIC SYSTEM
BRITISH IMPERIAL SYSTEM
A.4 TORQUE CONVERSION
UNITED STATES SYSTEM
METRIC SYSTEM
TOOLS
TORQUE VALUES
INDEX
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