Victory Tour ABS 2010 Manuals

Manuals and User Guides for Victory Tour ABS 2010. We have 1 Victory Tour ABS 2010 manual available for free PDF download: Service Manual

Victory Tour ABS 2010 Service Manual (578 pages)

Brand: Victory | Category: Automobile | Size: 33 MB

Table of Contents

1
- General Information
  3
- Service Rules
  3
- Trademarks
  3
- Safety Information
  4
- General Specifications
  5
- Vehicle Loading
  9
  - Gross Vehicle Weight Rating (Gvwr)
    9
- Model Number
  10
- Vehicle Identification Number (Vin)
  10
- Vehicle Information
  10
- Engine Number Location
  11
- Key Identification Number
  11
- Veci / Neci / Tire Information Labels
  11
- Vin Number / Manufacturer Label
  11
- Material Safety Data Sheet (Msds)
  12
- Publication Part Numbers
  12
- Publications & Technical Literature
  12
- Painting Terms
  13
- Refinishing
  13
- Victory Detail & Finish Restorer Kits and Products
  13
- Victory Touch-Up & Refinishing Paint
  13
- Paint Colors by Model
  14
  - Model Year
    15
- Paint Color Codes
  16
- Break in Period
  17
  - Break-In Procedure
    17
  - Break-In Guidelines
    17
- Emissions
  18
- Special Service Tools
  19
  - Electrical Tools
    19
- Transporting, Elevating, and Securing the Motorcycle
  22
  - General Guidelines
    22
- Instrumentation / Controls
  23
  - Ignition Key
    23
  - Ignition Switch
    23
- Changing Information Display Units
  26
- Console Mounted Switches
  26
- Driving Lamp Switch
  26
- Hand Grip Heater Switch
  26
- Hazard Switch (Emergency Flashers)
  26
- Indicator Lamps
  27
- Headlamp High / Low Beam Switch
  28
- Left Handlebar Switch, Mode Button
  28
- Seat Heater
  28
- Windshield Adjustment Switch (Motorized)
  28
- Manual Windshield Adjustment
  29
- Turn Signal Switch
  29
  - Right Handlebar Controls
    30
- Audio / Com / Cruise Control Buttons
  30
- Linked Brake System / Abs Brake System
  30
- Mirrors
  30
- Foot Control Adjustment
  31
  - Glove Compartment
    32
  - Trunk Operation
    33
- Front Brake Lever Reach Adjustment
  31
- Main User Interface
  34
- Radio / Audio System
  34
- Radio / Audio Systems Operation
  34
- Radio Frequencies
  34
- Audio System Power
  35
- Left Hand Controls / Rear Passenger Control
  35
- Volume Control / Audio Mute / Audio Volume / Passenger Volume
  36
  - Audio Mute
    36
  - Audio Volume
    36
- Audio Source Selection
  37
- Audio Mode Menus
  38
- Audio Tuning
  38
- Memory Presets
  38
- Cb Headset Volume Controls / Cb Headset Ent Mode
  40
- Icom Volume
  40
- Tuning (Seek / Scan Modes)
  40
  - Radio Data System (Rds)
    41
  - Aux Mode
    41
- XM Display / XM Tune Mode
  41
- Noaa Weather Band (Wb or Wx)
  42
- XM Category
  42
- Cb Radio / Icom System
  43
- Cb Radio Fcc Rules
  43
- Getting Started / Cb Channels
  43
- Headset Use
  43
- Push-To-Talk (Ptt) / Squelch
  44
- Cb Lo/DX
  45
- Cb Radio Volume Setting (Driver / Passenger)
  45
- Cb Frequencies
  46
- Icom System
  46
- Vox Break Setting
  46
- Headset Receptacles
  47
- Icom Volume Setting (Driver / Passenger)
  47
- Aux / Ipod
  48
- Getting Started / aux Input Cable / Input Cable Setup
  48
- Ipod Use
  48
- Aux Mode (2010)
  49
- Ipod Play Lists / Ipod Tuning
  49
- About XM Radio
  50
- Getting Started - XM Radio
  50
- XM Radio
  50
- XM Ready Legal
  50
- XM Ready Subscription
  50
- XM Radio Reception / XM Radio Specific Menu Options
  51
- XM Radio Settings / XM Category Selection
  51
- Before You Begin
  52
- Nav Mp3
  52
- Tips for Operation
  52
- XM Channel Selection
  52
- CD Changer (2008-2009)
  54
- Getting Started / Changing aux Mode to Nav Mp3
  54
- Metric Tap Drill Sizes
  55
  - Decimal Equivalents
    55
- Sae Tap Drill Sizes
  55
- Fahrenheit to Celsius
  56
- Measurement Conversion Chart
  56
Maintenance Chapter 2 Maintenance 2

57
- Maintenance
  58
- Oil Change
  58
- Service Specifications
  58
- Tune up
  58
- Fastener Torque Specifications
  59
  - Maintenance Items
    59
- Special Tools
  59
  - Maintenance Tools
    59
- Maintenance Products
  60
- Periodic Maintenance
  61
- Periodic Maintenance Interval Table
  61
- Air Filter / Air Box Drain Hose
  62
- Engine Oil Level
  62
- Engine Oil and Filter Change
  63
- Reverse Idler Shaft
  63
- Idle Speed / Fast Idle Speed
  64
- Tire Pressure
  64
- Throttle Cable Inspection / Lubrication / Free Play
  65
  - Throttle Cable Free Play
    65
- Cruise Control Cable
  66
- Front Brake Lever
  66
- Clutch Lever Lubrication (Hydraulic)
  67
- Front Brake Lever Reach / Lever Reserve
  67
- Clutch Lever Lubrication (Cable)
  68
- Clutch Pull Rod Bushing Lubrication (Hydraulic)
  68
- Clutch Fluid
  69
- Clutch Lever Free Play (Cable)
  69
- Brake Fluid Level
  70
- Brake Pad Inspection
  71
  - Rear Brake Pad Inspection
    71
- Crankcase Ventilation / Evaporative Emission Control
  72
- Fuel Tank Vent Inspection (49 State)
  72
- Shift Pedal / Brake Pedal
  72
  - Rear Brake Pedal
    72
  - Crankcase Ventilation System
    72
- Fuel Filter / Fuel System Inspection
  73
  - Fuel System Inspection
    73
  - Spark Plug Removal & Inspection
    74
- Spark Plug
  74
- Battery
  75
- Battery Removal / Installation
  76
- Drive Belt Cleaning
  77
- Engine Compression Test / Cylinder Leakage
  77
- Sprocket Inspection
  77
- Drive Belt Wear Analysis / Condition
  78
  - Drive Belt Condition
    78
- Drive Belt Tension Inspection
  79
  - Belt Deflection
    80
- Drive Belt Adjustment / Alignment
  80
- Headlamp Aim Inspection / Adjustment
  82
  - Headlamp Aim Adjustment
    82
- Sidestand & Spring Removal
  83
- Sidestand Inspection / Sidestand Pad Inspection
  83
- Sidestand Pad Replacement
  84
- Rear Suspension / Swingarm Inspection
  85
- Rear Suspension Adjustment
  86
- Front Suspension Inspection
  87
- Steering Head / Front Wheel Inspection
  87
- Fasteners
  88
- Fuse Replacement
  88
- Storage
  90
Chapter 3 Frame-Body-Exhaust

91
- Safety
  92
  - General Precautions
    92
- Body Fastener Types / Special Tools / How to Use this Chapter
  93
- General Information
  93
- Front Fender
  94
- Removal / Installation Procedures - Front Body
  94
- Console Cover / Air Deflectors
  95
- Iac Cover / Left Engine Cover
  96
- Windshield Access Panel / Windshield
  96
- Instrument Bezel
  97
- Mirrors
  98
- Visor
  99
- Belly Pan
  101
- Fuel Tank Covers
  101
- Turn Signal Lens, Front
  103
- Fairings (Front Outer)
  104
  - Instrument Display
    104
- Assembly Views - Front Body
  105
- Windshield / Windshield Motor
  105
- Belly Pan
  106
- Console / Console Attachments
  107
- Console / Radio
  108
- Front Support / Speaker / Speaker Volume
  109
- Visor / Front Speaker Grill
  110
- Fuel Tank Cover
  111
- Leg Fairing / Leg Fairing Support
  112
- Front Turn Signal Headlamp / Fairing
  114
- Lower Front Frame
  115
- Battery Box
  116
- Removal / Installation Procedures - Rear Body
  117
  - Side Cover
    117
- Lower Access Panels (Saddlebag Lower Panel)
  118
- Street Trim Panel Removal / Installation
  119
- Trunk Removal / Installation
  120
- Tail Light Trim ("M" Panel) / Rear Bumper Cover
  121
- Tail Light / Tail Light Housing
  122
- Saddlebag Door / Saddlebag (Inner Bag)
  123
- Saddlebag Support Plate (Passenger Hand Grip and Trim)
  124
- Assembly Views - Rear Body
  125
- Tail Trim "M" Panel
  125
- Trunk Mount and Attachments
  126
- Trunk Base / Trunk Lid
  128
- Saddlebag Inner
  130
- Tail Light / Tail Light Housing
  131
- Floorboard / Foot Control Mounting
  132
- Passenger Floorboard Mounting
  133
  - Left Side
    133
  - Right Side
    133
- Lower Access Panel / Passenger Hand Grip / Side Cover
  134
- Exhaust System
  135
- Assembly View - Muffler & Head Pipe Shields
  136
- Exhaust Muffler
  137
- Head Pipe Removal
  138
Chapter 4 Lubrication & Cooling

139
- Oiling System
  140
- Operation
  140
- Special Tools
  140
- Troubleshooting
  140
- Oiling System Data
  141
- Specifications - Lubrication
  141
- Diagram
  142
- Oil Flow
  142
- Assembly View - Oil Cooler and Lines
  143
- Oil Cooler
  143
- Oil Cooler Inspection / Cleaning
  144
- Oil Cooler Removal
  144
- Oil Cooler / Line Installation
  145
- Cooling Oil Flow Inspection
  146
- Lubrication Oil Pressure
  146
- Oil Pressure Inspection
  146
- Oil Pump
  147
- Oil Pump Removal
  147
- Oil Pressure Relief Valves
  148
- Oil Pump Inspection
  149
- Oil Pump Disassembly
  150
- Oil Pump Assembly
  151
- Oil Pump Installation
  153
Chapter 5 Fuel System / Fuel Injection

155
- Fuel Safety
  157
- Safety Precautions
  157
- Basics Troubleshooting
  158
- Idle Stop Screw
  158
  - Service Precautions
    159
- Special Tools
  158
- Specifications
  158
- Throttle Body Flow Screw and
  158
- Fuel System Assembly Views
  160
- Fuel Tank Hose Connection - 49 State Models
  160
- Fuel Tank Hose Connection - California Models
  161
- Fuel Level Sensor / Fuel Pump
  162
- Air Intake / Box Frame Assembly View
  163
- Fuel Pump and Fuel Tank Assembly View
  163
- Idle Air Control Assembly View
  164
- Fuel Pump Removal
  165
- Fuel System Depressurization
  165
- Fuel System Service
  165
- Fuel Tank Vent Inspection
  165
- Priming the Fuel System
  165
- Fuel Pump Installation
  166
- Fuel Tank Assembly View
  168
- Fuel Tank Installation
  169
- Fuel Tank Removal
  169
- Fuel Pump Circuit Diagram
  170
  - Fuel Pump Relay
    170
- Fuel Level Guage
  171
- Fuel Level Sensor Resistance Test
  171
- Battery Voltage Not Reaching Fuel Pump
  172
- Fuel Pump Electrical Diagnostics
  172
- Fuel Pump Supply Voltage Test
  172
- Fuel Pump Current Draw Test
  173
- Fuel Pump Pressure Inspection
  174
- Idle Air Control Removal
  175
- Efi System Components
  176
- Fuel Injection Component Locations
  176
- Fuel Rail / Fuel Injector Removal
  177
- Fuel Rail Installation
  177
- Fuel Injection System - Overview of Operation
  178
- Fuel Injection System Testing and Diagnostics
  178
- Idle Air Control (Iac) - Overview of Operation
  178
- Self-Diagnostic Feature
  178
- Ecm Connector Map
  179
- Sensor Diagnostics
  180
- Viewing and Clearing Trouble Codes
  180
- Trouble Codes
  181
- Ecm Connector Removal
  183
- Ecm Harness Connector Test Precautions
  183
- Ecm Removal
  183
- Efi Sensor Circuit Wiring Diagrams
  184
- Sensor Tests
  186
- Throttle Position Sensor (Tps) Diagnostics
  186
- Temperature & Manifold Absolute Pressure Sensor (Tmap)
  187
- Air Temperature Sensor (Ats) Diagnostics
  188
- Cylinder Head Temperature Sensor (Cht) Diagnostics
  189
- Idle Air Control (Iac)
  190
- Gear Position Switch Test
  191
- Memory Check Sum Error
  191
- Tipover Sensor
  191
- Vehicle Speed Sensor Test
  191
- Battery Voltage at Ecm Diagnostics
  192
- Crankshaft Position Sensor Diagnostics
  192
- Diagnostic Software Version
  193
- Digital Wrench
  193
- Ecm Replacement
  193
- Tps Calibration Not Required
  193
- Using Digital Wrench Diagnostic Software
  193
- Digital Wrench Communication Errors
  194
- Digital Wrench Features
  194
- Guided Diagnostics Available
  194
- Digital Wrench Feature Map
  195
- Digital Wrench Screen Examples
  196
- Digital Wrench Screen Examples
  198
  - Process Overview
    199
- Reprogramming Tips
  199
- Reprogramming Process
  201
- Troubleshooting
  203
  - Fuel System Troubleshooting
    203
Chapter 6 Engine Removal & Installation

207
- Engine Removal and Installation
  207
- General
  208
- Overview - Engine Removal
  208
- Specifications
  208
- Special Tools
  209
- Engine Mounting - Airbox / Main Frame Assembly
  210
- Torque Values
  210
- Engine Mounting - Rear Sub Frame Assembly
  211
- Engine Removal
  212
- Precautions
  212
- Preparation for Removal
  212
- Removal Procedure
  212
- Injector Removal
  216
- Engine Installation
  217
- Installation Procedure
  217
- Preparation for Installation
  217
Chapter 7 Cylinder Head & Valve Train

219
- Cylinder Head & Valve Train
  219
- General Information
  220
- Important Notes
  220
- Special Tools
  220
- Data - Cylinder Head
  221
- Specifications
  221
- Cam Drive & Valve Cover
  222
- Torque Values and Assembly Views
  222
- Camshaft Carrier / Rocker Arm - 2008
  223
- Cylinder Head
  225
- Camshaft Timing Quick Reference
  226
- Cam Chain Tensioner Removal
  227
- Camshaft Drive Cover
  227
- Cylinder Head Service
  227
- Valve Cover Installation
  227
- Valve Cover Removal
  227
- Cam Chain Tensioner Inspection
  228
- Cam Chain Tensioner Installation
  228
- Camshaft Chain & Sprocket Removal
  229
- Rocker Arm & Shaft Inspection - 2008
  230
  - Camshaft Inspection
    231
  - Camshaft Carrier Removal
    232
- Rocker Arm Removal - 2008
  230
- Cylinder Head Removal - 2008
  234
- Cylinder Head Disassembly
  235
- Cylinder Head Inspection
  236
- Valve Inspection
  236
- Valve Spring Free Length Inspection
  236
- Valve Guide Removal / Installation
  239
- Valve Seat Inspection
  240
- Valve Seat Reconditioning
  240
- Cylinder Head Assembly
  241
- Cylinder Head Installation - 2008
  243
- Camshaft / Rocker Installation - 2008
  244
- Camshaft Chain Guide Installation
  248
- Camshaft Timing - Rear Cylinder
  248
- Camshaft Timing - Front Cylinder
  249
- Troubleshooting, Cylinder Head and Valve Train
  252
Chapter 8 Cylinder & Piston

255
- Cylinder and Piston
  255
- Base Gasket Sealing & Cylinder Stud Torque
  256
- General
  256
- Piston Ring Profile and Orientation
  256
- Special Tools
  257
- Specifications
  257
- Cylinder Bore Measurement
  258
- Cylinder Inspection
  258
- Cylinder Removal
  258
- Piston to Cylinder Clearance Worksheet
  259
- Cylinder Warpage Measurement
  260
- Piston & Piston Ring Inspection
  260
- Piston & Piston Ring Removal
  260
- Piston Pin / Pin Bore Inspection
  261
- Cylinder Stud Replacement
  262
- Piston Ring Installation
  262
- Piston Installation
  263
- Cylinder Installation
  264
- Troubleshooting, Cylinder & Piston
  265
- Troubleshooting (Cont.)
  266
Chapter 9 Clutch, Primary, & Shift Linkage

267
- General
  268
- Service / Maintenance
  268
- Special Tools
  268
- Specifications
  268
- Assembly Views & Torque Values
  269
- Hydraulic Clutch Hose Routing
  269
- Hydraulic Clutch System Components
  270
- Clutch (Cable) Routing
  271
- Shift Linkage / Footrest - Fastener Torque
  272
- Primary Cover
  273
- Shift Mechanism
  274
- Service Procedures
  275
- Clutch Pinion Shaft Installation
  276
- Clutch Pinion Shaft Seal Removal & Installation
  276
- Primary Cover Removal
  277
- Shift Ratchet Removal & Inspection
  278
- Shift Ratchet Installation
  279
- Shift Shaft Bearing & Seal Replacement
  279
- Locking the Crankshaft
  280
- Primary Cover Installation
  280
- Clutch Assembly View & Torque
  281
- Clutch Service
  281
- Clutch Removal
  282
- Clutch Disassembly
  283
- Clutch Inspection
  284
- Clutch Assembly
  286
- Clutch Installation
  288
- Primary Drive Assembly View & Torque
  289
- Torque Compensator Inspection
  290
- Torque Compensator Removal
  290
- Torque Compensator Installation
  291
- Rotor (Flywheel) Removal
  292
- Rotor (Flywheel) Installation
  293
- Split Gear Inspection
  293
- Split Gear Removal
  293
- Split Gear Installation
  294
- Starter Clutch Removal / Inspection
  295
- Starter Drive
  295
- Primary Drive Gear
  296
- Primary Drive Gear Removal / Inspection
  296
- Starter Torque Limit Clutch Inspection
  296
- Primary Drive Gear Installation
  297
- Starter Gear / Starter Clutch Installation
  298
- Troubleshooting
  299
Chapter 10 Transmission & Crankshaft

301
- Crankcase / Crankshaft / Connecting Rod Special Tools
  302
- Drive Train
  302
- General
  302
- Service Information
  302
- Special Tools
  302
- Specifications
  302
- Transmission & Crankshaft
  302
- Connecting Rod and Crankshaft Specifications
  303
- Assembly Views & Torque Values
  304
- Crankcase Components
  304
- Crankcase Bolt Length and Torque Pattern
  305
- Crankshaft / Connecting Rod / Crankcase Torque Pattern
  305
- Crankcase Separation
  306
- Service Procedures
  306
- Transmission Assembly View
  308
- Mainshaft / Clutch Shaft Assembly View
  309
- Countershaft Assembly View
  310
- Shift Drum and Shift Fork Assembly View
  311
- Power Delivery
  312
- Clutch Shaft Inspection / Removal
  313
- Transmission Removal
  313
- Transmission Inspection
  314
- Crankshaft Removal
  315
- Connecting Rod Removal / Identification
  316
- Connecting Rod Side Clearance Inspection
  316
- Connecting Rod Bearing Inspection
  317
- Connecting Rod Inspection (Big End)
  317
- Connecting Rod Bearing Clearance Inspection (Typical)
  318
- Connecting Rod Bearing Selection
  318
- Connecting Rod Installation
  319
- Crankshaft Inspection
  319
- Crankshaft Cleaning
  320
- Main Bearing Inspection
  320
- Main Bearing Oil Clearance Inspection
  320
- Left Crankcase Assembly
  321
- Crankcase Reed Valve Assembly Removal & Inspection
  322
- Crankshaft Installation
  322
- Right Crankcase Assembly
  322
- Transmission Installation
  323
- Balance Shaft
  324
- Balance Shaft Installation
  324
- Balance Shaft Removal & Inspection
  324
- Crankcase
  325
- Crankcase Assembly & Sealing
  325
- Troubleshooting
  328
Drive Line / Reverse System Chapter 11 Drive Line / Reverse System

331
- Assembly Views & Torque Values
  332
- Drive Line Special Tools
  332
- Rear Wheel Fastener Torques
  332
- Special Tools
  332
- Drive Sprocket Fastener Torques
  333
- Belt Guard / Fastener Torque
  334
- Belt Inspection
  335
- Belt Installation
  335
- Belt Removal
  335
- Drive Belt
  335
- Drive Sprocket
  335
- Drive Sprocket and Seal Removal
  335
- Drive Sprocket and Seal Installation
  336
- Drive Sprocket Inspection
  336
- Rear Sprocket
  338
- Rear Sprocket Inspection
  339
- Reverse Drive Mechanism
  340
- Reverse System (2009 - 2010 if Equipped)
  340
- Reverse Gear Case Assembly View
  341
- Reverse Linkage Adjustment
  342
- Reverse Coupler Shaft Key Replacement
  343
- Reverse System Test
  343
- Troubleshooting
  344
Chapter 12 Front Wheel / Suspension

345
- Fastener Torque Specifications
  346
- Front Wheel / Suspension
  346
- General
  346
- Important Information
  346
- Maintenance Products
  346
- Special Tools
  346
- Torque Specifications
  346
- Front Fork Service Specifications
  347
- Specifications
  347
- Assembly Views & Torque Values
  348
- Front Fork Type Identification
  349
- Assembly View, Triple Clamp & Front Axle
  350
- Assembly View, Front Fork -Type 1 (Marz / 45Mm Tube Diameter)
  351
- Assembly View, Front Fork -Type 2 (Kyb) (46Mm Tube Diameter)
  352
- Assembly View, Front Wheel
  353
- Assembly View, Front Wheel / Hub Cut-Away
  354
- Assembly View, Handlebar
  355
- Handlebar Installation
  356
- Handlebar Removal
  356
- Front Wheel Removal
  357
- Front Axle Inspection
  358
- Front Wheel Inspection
  358
- Brake Disc Installation
  359
- Brake Disc Removal
  359
- Front Wheel Bearing Inspection
  359
- Front Wheel Bearing Installation
  360
- Front Wheel Bearing Removal
  360
- Front Wheel Installation
  361
- Front Fork Removal
  362
- Front Fork Disassembly
  363
- Front Fork Inspection
  368
- Front Fork Assembly
  369
- Fork Guard Replacement
  373
- Assembly View, Steering Stem / Triple Clamps
  375
- Triple Clamp Removal
  376
- Triple Clamp Installation / Steering Head Bearing Adjustment
  377
- Steering Stem Bearing Removal (Typical Example)
  378
- Steering Stem Bearing Installation (Typical Example)
  379
- Lower Bearing Race Installation
  380
- Lower Bearing Race Removal
  380
- Troubleshooting
  381
- Troubleshooting (Cont.)
  382
Chapter 13 Rear Wheel & Suspension

383
- General Information
  384
- Rear Wheel & Suspension
  384
- Special Tools
  384
- Warnings and Precautions
  384
- Specifications
  385
- Specifications - Rear Wheel and Suspension
  385
- Assembly View - Rear Axle & Adjusters
  386
- Assembly Views & Torque
  386
- Assembly View - Swingarm & Suspension
  387
- Rear Wheel - Cast
  388
- Rear Wheel - Billet
  389
- Rear Wheel Removal
  390
- Rear Wheel Service
  390
- Rear Axle Inspection
  391
- Rear Wheel Bearing Inspection
  392
- Rear Wheel Inspection
  392
- Wheel Bearing Removal (Typical)
  392
- Wheel Bearing Installation
  394
- Brake Disc Installation
  396
- Brake Disc Removal
  396
- Rear Sprocket Installation
  396
- Rear Sprocket Removal
  396
- Rear Wheel Installation
  397
- Rear Shock
  399
- Rear Shock Service Data
  399
- Rear Shock Removal
  400
- Rear Shock and Pivot Inspection
  401
- Shock Absorber Installation
  402
- Swing Arm Removal
  403
- Swingarm Service
  403
- Swing Arm Bushings / Bearing Replacement
  404
- Swing Arm Installation
  405
- Troubleshooting
  406
Chapter 14 Tires / Wheels

407
- General / Safety
  408
- Tires / Wheels
  408
- Warnings / Precautions
  408
  - Warnings & Precautions
    408
- Special Tools
  409
- Tire Data
  409
- Tire Pressure / Loading
  409
- Wheel Data
  409
- Wheel Specifications
  409
- Front Tire Cupping
  410
- Ozone Cracking
  410
- Tire Inspection
  410
- Tire Wear Patterns & General Causes
  410
- General
  411
- Tire Changing
  411
- Tire Removal
  412
- Tire Removal (Typical)
  412
- Visual Inspection & Runout
  413
- Wheel Inspection
  413
- Tire Repair Precautions
  414
- Tire Valve and Stem Inspection
  414
- Valve Stem
  414
- Valve Stem Installation - Metal
  414
- Valve Stem Installation - Rubber
  414
- Tire Installation
  415
- Tire Mounting
  415
- Tire Balancing
  417
- Troubleshooting
  419
Chapter 15 Brakes

421
- Brake System Safety
  422
- Special Tools
  423
- Specifications
  423
- Torque Specifications
  423
- Assembly Views & Routing
  424
- Front Brake / Clutch Master Cylinder
  428
- Master Cylinders
  428
- Rear Brake Master Cylinder
  429
- Calipers
  430
- Front Brake Caliper
  430
- Rear Brake Caliper
  431
- Brake System Operation
  432
- Master Cylinders / Brake Calipers / Delay Valve / Proportion Valve15.12
  432
- Brake Fluid Replacement & Bleeding Precautions
  433
- Brake System Service
  433
- Brake Bleeding / Fluid Change
  434
- Front Brake Pad Replacement
  437
- Rear Brake Pad Replacement
  438
- Brake Disc Inspection
  440
- Front Brake Master Cylinder / Clutch Master Cylinder Service
  440
- Front Caliper Removal
  443
- Front Master Cylinder Installation
  443
- Front Caliper Service
  444
- Front Caliper Installation
  447
- Rear Master Cylinder Installation
  448
- Rear Master Cylinder Removal
  448
- Rear Caliper Service
  449
- Rear Caliper Installation
  451
- Abs General Information
  452
- Abs System Safety Precautions
  452
- Anti-Lock Brake System (Abs)
  452
- Abs Overview of Operation
  453
- Abs System Components
  453
- Abs System Components
  454
- Abs System Circuit Diagrams
  455
- Abs System - Front Brake
  456
- Abs System - Rear Brake (Linked)
  457
- Abs System - Wiring Harness / Tie Strap Location
  458
- Abs System - Module Connections
  459
- Abs Brake Vacuum Bleeder
  460
- Abs Fluid Change
  460
- Abs Rear (Linked) Brake Bleeding
  460
- Abs Front Brake System Bleeding
  462
- Abs Front Brake Supplementary Bleeding Procedure
  463
- Abs Trouble Codes
  465
- Troubleshooting
  466
- Troubleshooting - Brake System
  466
Chapter 16 Battery Charging System

469
- Battery Charging System
  470
- Battery Safety
  470
- General
  470
- Important Information
  470
- Special Tools
  471
- Charging System & Alternator
  472
- Fastener Torque
  472
- General
  472
- Specifications
  472
- Battery
  473
- Battery Charging - General
  473
- Battery Charging - New Battery
  473
- Battery Removal
  473
- Diagnostics
  474
- Troubleshooting
  474
- Battery Load Test
  475
- Current Draw Inspection (Key Off)
  475
- Regulated Voltage / Amperage Output Inspection
  476
- Stator No-Load Ac Voltage Output Inspection
  477
- Stator Resistance Inspection
  478
- Stator Windings to Ground Inspection
  478
- Rectifier / Regulator Connector Inspection
  479
- Voltage Drop: Rectifier / Regulator to Battery(+)
  479
- Diode Leakage Test
  480
- Regulator / Rectifier Test
  481
- Rectifier / Regulator Replacement
  482
- Flywheel Removal
  483
Chapter 17 Ignition

485
- Stator Installation
  483
- Stator Removal
  483
- General Information
  486
- Ignition System Specifications
  486
- Safety Information
  486
- Basics
  487
- Special Tools
  487
- Torque Specifications
  487
- Troubleshooting
  487
- Ignition Circuit Diagram
  488
- Ecm Connector Map
  489
- Test Lead Adapter Kit
  489
- Ignition System Test Flowchart
  490
- Battery Voltage Inspection - Test 1
  491
- Spark Inspection - Test 2
  491
- Coil High Tension Leads - Test 3
  492
- Ignition Coil Signal - Test 4
  492
  - Top View
    492
- Ignition Coil Resistance - Test 5
  493
- Crankshaft Position Sensor (Cps) Resistance Inspection - Test
  494
- Crank Position Sensor Circuit and Signal Test 6A
  495
- Crank Position Sensor Circuit Continuity Test 6B
  495
- Ground Circuit Inspection - Test 7
  495
- Ignition Coil
  496
- Ignition Coil Installation
  496
- Ignition Coil Removal
  496
- Ignition Switch Removal / Clearance Adjustment
  497
Chapter 18 Electric Starter

499
- Electric Starter
  500
- Fastener Torque Specifications
  500
- General
  500
- Safety Information
  500
- Specifications
  500
- Starter Specifications
  500
- Diagnostics
  501
- Special Tools
  501
- Starter System Special Tools
  501
- Troubleshooting Flow Chart Menu
  501
- Starter Circuit Diagram
  502
  - Troubleshooting Flowchart
    503
- Troubleshooting Chart 3
  504
- Battery Inspection & Charging Procedures
  505
- Battery Load Test
  505
- Circuit & Switch Testing
  505
- Starter Relay Ground Bypass Circuit Test
  505
- Neutral Switch Bypass Test
  506
- Clutch Switch / Circuit Test
  507
- Clutch Switch Installation
  508
- Clutch Switch Removal
  508
- Starter Relay to Starter Motor Positive Cable Bypass Test
  508
- Starter Relay Bypass Test
  509
- Starter Relay Positive Circuit Test
  509
- Starter Relay to Starter Motor Positive Cable Bypass Test
  510
- Positive Side Voltage Drop Test
  511
- Negative Cable Bypass Test
  513
- Negative Side Voltage Drop Test
  514
- Starter Current Draw Test
  516
- Starter Clutch Removal
  517
- Starter Motor Installation
  517
- Starter Motor Removal
  517
Chapter 19 Wiring / Lighting Systems

519
- Abs Fuse
  520
- Fuses
  520
  - Fuse Box Location
    520
- Wiring / Lighting Systems
  520
- Assembly View
  521
- Turn Signal System (2008)
  525
- Turn Signal System (2009-2010)
  529
- Speedometer
  531
  - Speed Sensor Test
    531
- Switch Testing
  532
  - Gear Position Switch Removal
    534
- Cruise Control
  535
- Operation Overview - Resume / Accelerate
  535
- Operation Overview - Setting Speed
  535
- Operational Overview - Decelerate / Cancel
  535
- Cruise Control Diagnostic Blink Codes (Overview)
  536
- Cruise Control Disengage Codes
  536
- Cruise Module Input / Output
  536
- Cruise Control Switch Diagnostics
  537
- Cruise Control Cable Replacement
  538
- Cruise Control Cable "Lash Learn" Procedure
  539
  - Press and Hold
    539
- Horn Relay Circuits
  541
  - System Diagram
    541
- Windshield / Trunk Lamp Circuits
  542
- Instrument Cluster
  543
- Heaters (Seat / Handgrip)
  546
  - Switch Contact
    546
- Console Switch Wire Connections
  547
- Audio Systems
  549
- Audio Systems Control Switch On-Board Diagnostics
  551
  - Button Function
    552
  - Reprogramming Procedure
    554
  - Audio Troubleshooting Tips
    557
- Gps Navigation & Nav Mp3 Player
  557
- Navigation System
  557
- Reverse System
  558
- Wiring Diagram / Reverse Harness
  558
- Reverse System Diagnostics
  559
- Reverse Module / Fuse Access
  561
- Tachometer Signal Test
  562
- Ground Locations
  563
  - Chassis Wiring Diagram
    574
  - Engine Wiring Diagram
    575

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Table of Contents

Table of Contents

Maintenance Chapter 2 Maintenance 2

Chapter 3 Frame-Body-Exhaust

Chapter 4 Lubrication & Cooling

Chapter 5 Fuel System / Fuel Injection

Chapter 6 Engine Removal & Installation

Chapter 7 Cylinder Head & Valve Train

Chapter 8 Cylinder & Piston

Chapter 9 Clutch, Primary, & Shift Linkage

Chapter 10 Transmission & Crankshaft

Drive Line / Reverse System Chapter 11 Drive Line / Reverse System

Chapter 12 Front Wheel / Suspension

Chapter 13 Rear Wheel & Suspension

Chapter 14 Tires / Wheels

Chapter 15 Brakes

Chapter 16 Battery Charging System

Chapter 17 Ignition

Chapter 18 Electric Starter

Chapter 19 Wiring / Lighting Systems

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