2000-2005 Harley-Davidson Softail service manual

Table of Contents

Chapter One: General Information

• Manual Organization
• Maintenance and Repair Information
• Safety Precautions
• General Specifications
• Torque Specifications

Chapter Two: Maintenance

• Routine Maintenance Schedule
• Lubrication Points
• Oil and Filter Change
• Air Filter Replacement
• Primary Chain Adjustment
• Drive Belt Inspection and Adjustment
• Brake System Inspection
• Tire Inspection and Maintenance

Chapter Three: Engine

• Engine Overview
• Engine Removal and Installation
• Cylinder Head and Valves
• Piston and Cylinder
• Crankshaft and Bearings
• Camshaft and Timing
• Engine Assembly
• Engine Troubleshooting

Chapter Four: Fuel System

• Fuel System Overview
• Fuel Tank Removal and Installation
• Fuel Pump and Filter
• Carburetor Adjustment and Overhaul
• Fuel Injection System
• Throttle and Choke Cables
• Fuel System Troubleshooting

Chapter Five: Electrical System

• Electrical System Overview
• Battery Maintenance
• Charging System
  • Alternator
  • Voltage Regulator
• Starting System
  • Starter Motor
  • Solenoid
• Ignition System
  • Spark Plugs
  • Ignition Coils
• Lighting System
  • Headlights
  • Taillights
  • Turn Signals
• Instrumentation and Gauges
• Wiring Diagrams
• Electrical System Troubleshooting

Chapter Six: Cooling System

• Cooling System Overview
• Radiator Removal and Installation
• Coolant Replacement
• Water Pump
• Cooling Fan
• Cooling System Troubleshooting

Chapter Seven: Transmission

• Transmission Overview
• Clutch System
  • Clutch Removal and Installation
  • Clutch Adjustment
• Gearshift Mechanism
• Transmission Removal and Installation
• Transmission Overhaul
• Transmission Troubleshooting

Chapter Eight: Suspension and Steering

• Front Suspension
  • Forks
  • Steering Head Bearings
• Rear Suspension
  • Swingarm
  • Shock Absorbers
• Suspension Adjustment
• Steering Components
• Suspension and Steering Troubleshooting

Chapter Nine: Brakes

• Brake System Overview
• Front Brakes
  • Brake Pads
  • Brake Discs
• Rear Brakes
  • Brake Pads
  • Brake Discs
• Brake Fluid Replacement
• Brake Bleeding Procedures
• Brake System Troubleshooting

Chapter Ten: Wheels and Tires

• Wheel Removal and Installation
• Tire Removal and Installation
• Tire Balancing
• Wheel Bearing Inspection and Replacement
• Wheels and Tires Troubleshooting

Chapter Eleven: Body and Frame

• Body Panels
  • Removal and Installation
• Seat Removal and Installation
• Frame Inspection and Maintenance
• Side Stand and Center Stand
• Body and Frame Troubleshooting

Chapter Twelve: Final Drive

• Final Drive Overview
• Drive Belt Replacement
• Sprocket Inspection and Replacement
• Final Drive Troubleshooting

Chapter Thirteen: Exhaust System

• Exhaust System Overview
• Exhaust Pipe Removal and Installation
• Muffler Removal and Installation
• Exhaust System Troubleshooting

Chapter Fourteen: Troubleshooting

• General Troubleshooting Procedures
• Engine Troubleshooting
• Electrical System Troubleshooting
• Fuel System Troubleshooting
• Transmission Troubleshooting
• Suspension and Steering Troubleshooting
• Brake System Troubleshooting
• Final Drive Troubleshooting
• Exhaust System Troubleshooting

Appendices

• Special Tools
• Conversion Tables
• Service Specifications
• Torque Specifications
• Wiring Diagrams Index

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