2001-2009 Harley Davidson Touring Troubleshooting/Trouble Shooting Guide


Troubleshooting the Harley Touring Motorcycle
Need to fix your bike? Visit the download center page to get the complete factory service manual for your bike, and get it delivered to your computer in just seconds!
 
 
2001 Harley Davidson Touring H-D Service Manual & 2001 H-D Electrical Diagnostics Manual for Harley Models: FLHTCUI Ultra Classic Electra Glide (2001), FLHTC/I Electra Glide Classic (2001), FLHT  Electra Glide Standard (2001), FLTR/I Road Glide (2001), FLHRCI Road King Classic (2001), FLHR/I Road King (2001) and also contains the 2001 H-D FLT Police Model Service Manual Supplement and 2001 H-D FLTRSEI2 Service Manual Supplement.
 
2002 Harley Davidson Touring Service Manual & 2002 H-D Touring Electrical Diagnostic Manual for models: FLHTCUI Ultra Classic Electra Glide (2002), FLHTC/FLHTCI Electra Glide Classic (2002), FLHT Electra Glide Standard (2002), FLHTCUI Ultra Classic Electra Glide (2002), FLTR/I Road Glide (2002), FLHRCI Road King Classic (2002), FLHR Road King (2002), 2002 FLT Police Models Service Manual Supplement and 2002 FLTRSEI2 Model Service Manual Supplement.
 
2003 Harley Davidson Touring 2003 H-D Touring Service Manual, 2003 H-D Electrical Diagnostics Manual, 2003 H-D Police Model Service Manual Supplement and 2003 H-D FLHRSEI2 Service Manual Supplement for: 2003 Harley-Davidson FLHTCUI Ultra Classic- Electra Glide, 2003 Harley-Davidson FLHR/FLHRI Road King, 2003 Harley-Davidson FLHT Electra Glide -Standard, 2003 Harley-Davidson FLHRCI Road King -Classic, 2003 Harley-Davidson FLTR/FLTRI Road Glide, 2003 Harley-Davidson FLHTC/FLHTCI Electra Glide- Classic, 2003 FLHP, FLHTP and FLHRSEI2.
 
2004 Harley Touring Service Repair Manual & Electrical Diagnostics Manual For: 2004 H-D FLT Police Model, 2004 H-D FLHTCSE, FLHRS/I Road King Custom (2004), FLHTCUI Ultra Classic Electra Glide (2004), FLHTC/I Electra Glide Classic (2004), FLHT/I  Electra Glide Standard (2004), FLTRI Road Glide (2004), FLHRCI Road King Classic (2004), FLHR/I Road King (2004).
 
2005 Harley Davidson Touring  Service Repair Manual & Electrical Diagnostics Manual For: FLHRS/FLHRSI Road King Custom (2005) FLHTCUI Ultra Classic Electra Glide (2005), FLHTC/FLHTCI Electra Glide Classic (2005), FLHT/FLHTI  Electra Glide Standard (2005), FLHTCUI Ultra Classic Electra Glide (2005), FLTRI Road Glide (2005), FLHRCI Road King Classic (2005), FLHR/FLHRI Road King (2005), 2005 H-D Touring Electrical Diagnostic Manual (800+ pages), 2005 FLT Police Models Service Manual Supplement and 2005 FLHTCSE 2 Model Service Manual Supplement.
 
2006 Harley Davidson Touring Motorcycle Service Manual for:  2006 FLHX Street Glide,  2006 FLHT Electra Glide Standard, 2006 FLHTC Electra Glide Classic, 2006 FLHTCU Electra Glide Ultra Classic, 2006 FLTR Road 2006 Glide, FLTRI Road Glide.
 
2007 Harley Davidson Touring Service Repair Manual & Electrical Diagnostics Manual For: (2007) FLHT Electra Glide Standard (2007), FLHR Road King (2007), FLHTC Electra Glide Classic (2007), FLHRS Road King Custom (2007), FLHTCU  Ultra Classic Electra Glide (2007), FLHRC  Road King Classic (2007), FLTR Road Glide (2007), FLHX Street Glide (2007).
 
2008 Harley Davidson Touring Motorcycle Factory Service Manual for: FLHT Electra Glide Standard, FLHR Road King, FLHTC Electra Glide Classic, FLHRC Road King Classic, FLHTCU Ultra Classic Electra Glide, FLHTCU ANV 105th Anniversary Ultra Classic Electra Glide, FLHRC ANV 105th Anniversary Road King Classic, FLTR Road Glide, FLHX Street Glide, 2008 FLT Police Models Service Manual Supplement, 2008 FLHTCUSE 3 Model Service Manual Supplement.
 
2009 Harley Davidson Touring Motorcycle Factory Service Manual for: 2009 FLHT Electra Glide, 2009 FLHTC/U Ultra Classic*Electra Glide with Side Car, 09 FLTR Road Glide, 09 FLHX Street Glide, 09 FLHR Road King Shrine, FLHRC Road King classic, FLHTC Electra Glide Classic.
MAINTENANCE
 
TROUBLESHOOTING
 
2001-2009 HARLEY DAVIDSON TOURING TROUBLESHOOTIN GENERAL
 
The following is a check list of problems possible with the Harley touring motorcycle when trying to operate, refer to the service manual for possible causes and their probable causes which will be helpful in keeping your Harley Touring motorcycle in good operating condition. Many conditions may be causing the trouble and all should be carefully checked. Learn how to identify the root of your problem and step-by-step procedures to fix, repair & service your motorcycle. The service manual includes high resolution pictures & exploded diagrams to help you along the way.
 
2001-2009 HARLEY DAVIDSON TOURING TROUBLESHOOTING ENGINE
 
Tire of asking your local Harley Davidson service repair Technician questions with no answers. Want answers now and get your bike on the road? This manual will answer all your what, where, how and why questions and is the complete factory service manual covering everything you need to fix or service your Touring Motorcycle.
 
 
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
Check Engine Lamp/Check Engine Light Illuminates During Operation
Pre-Ignition or Detonation (Knocks or Pings)
Oil Does Not Return To Oil Pan
Overheating
Engine Uses Too Much Oil Or Smokes Excessively
Valve Train Noise
Engine Leaks Oil From Case, Push Rods, Hoses, Etc.
Excessive Vibration
Low Oil Pressure
High Oil Pressure
 
 2001-2009 HARLEY DAVIDSON TOURING TROUBLESHOOTING ELECTRICAL SYSTEM
 
 
Alternator Does Not Charge
Alternator Charge Rate Is Below Normal
Speedometer Operates Erratically
 
2001-2009 HARLEY DAVIDSON TOURING TROUBLESHOOTING CARBURETOR/EFI
 
Carburetor Floods
 
2001-2009 HARLEY DAVIDSON TOURING TROUBLESHOOTING TRANSMISSION
 
Transmission Shifts Hard
Jumps Out Of Gear
Clutch Slips
Clutch Drags Or Does Not Release
Clutch Chatters
 
2001-2009 HARLEY DAVIDSON TOURING TROUBLESHOOTING BRAKES
 
Brake Does Not Hold Normally
 
 
2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008 & 2009 Halrey Davidson Touring H-D FLHTCUI Ultra Classic Electra Glide, FLHTC FLHTCI Electra Glide Classic, FLHT  Electra Glide Standard, FLTR Road Glide, FLTRI Road Glide, FLHRCI Road King Classic, FLHR Road King, FLHRI, H-D FLT Police Model, H-D FLTRSEI2, FLHRS, FLHRSI Road King Custom, FLHTI  Electra Glide Standard, FLHX Street Glide, FLHTCU 105th Anniversary Ultra Classic Electra Glide, FLHRC ANV 105th Anniversary Road King Classic, FLT Police Models, FLHTCUSE, FLHTC/U Ultra Classic*Electra Glide with Side Car FLHR Road King Shrine, FLHRC Road King classic search phrases.
 
Harley Searches:
 
Ignition/Light Key Switch.
Engine Stop switch in the OFF position.
Discharged battery, loose or corroded connections (solenoid chatters).
Bank Angle Sensor tripped and Ignition/Light Key Switch not cycled to OFF and then back to IGNITION.
Starter control circuit, relay or solenoid.
Electric starter shaft pinion gear not engaging or overrunning clutch slipping.
Fuel tank empty.
Fuel supply valve turned to OFF.
Fouled spark plugs.
Engine flooded with gasoline.
Fuel valve or filter.
Vacuum hose to automatic fuel supply valve disconnected, leaking or pinched.
Discharged battery, loose or broken battery terminal connections.
Wire connection at coil, battery or plug between ignition sensor and module.
Spark plug cables and shorting, cable connections, cables connected to cylinders.
Spark plug gap.
Ignition coil, module sensor.
Battery nearly discharged.
Intermittent short circuit.
Fuel tank vent system or carburetor vent line.
Carburetor controls.
What fuel octane rating.
What is causing faulty spark plugs.
What plug for the kind of service.
Why excessive carbon deposit on piston head or in combustion chamber.
Why is oil pan overfilled.
Where is restricted oil return line to pan.
How do you fix restricted breather operation.
How do you fix restricted oil filter.
Why is piston rings badly worn or broken.
Valve guides or seals worn.
O-ring damaged or missing from oil pump/crankcase junction (also results in poor engine performance).
Wheels and/or tires worn or damaged.
Engine/transmission/vehicle not aligned properly.
Primary chain badly worn or links tight as a result of insufficient lubrication or misalignment.
Engine to transmission mounting bolts.
Which upper engine mounting bracket do I need.
Ignition timing incorrect/poorly tuned engine.
Internal engine problem.
Broken frame
Oil pan underfilled.
Faulty low oil pressure switch.
Oil pump O-ring(s) damaged or missing.
Oil pressure relief valve stuck in open position.
Ball missing from cam support plate.
Module not grounded.
Engine ground wire loose or broken.
Faulty regulator-rectifier module.
Loose or broken wires in charging circuit.
Faulty stator and/or rotor.
Alternator Charge Rate Is Below Normal
Weak or damaged battery.
Faulty regulator-rectifier module.
Faulty stator and/or rotor.
Speedometer Operates Erratically
Contaminated speedometer sensor.
Loose connections.
Dirt or other foreign matter between valve and its seat.
Inlet valve sticking.
Inlet valve and/or valve seat worn or damaged.
Float misadjusted.
Leaky or damaged float.
Excessive “pumping” of hand throttle grip.
Transmission Shifts Hard
Clutch dragging slightly.
Primary chaincase overfilled with lubricant.
Corners worn off shifter clutch dogs.
Shifter return spring bent or broken.
Bent shifter rod.
Shifter forks sprung.
Transmission lubrication too heavy (winter operation).
Jumps Out Of Gear
Shifter rod improperly adjusted.
Shifter drum improperly adjusted or damaged.
Shifter engaging parts (inside transmission) badly worn and rounded.
Shifter forks bent.
Damaged gears.
Clutch Slips
Clutch controls improperly adjusted.
Worn friction discs.
Clutch Drags Or Does Not Release
Clutch controls improperly adjusted.
Lubricant level too high in primary chaincase.
Primary chain badly misaligned.
Clutch discs warped.
Insufficient clutch spring tension.
Friction discs or steel discs worn or warped.
Master cylinder reservoir low on fluid.
Brake system contains air bubbles.
Master or wheel cylinder piston worn or parts damaged.
Brake pads contaminated with grease or oil.
Brake pads badly worn- friction material 0.04 inch (1.02mm) thick or less.
Brake disc badly worn or warped.
Brake fades due to heat build up – brake pads dragging or excessive braking.
Brake drags – insufficient brake pedal free play.