Harley-Davidson VRSCA V-Rod 2002-2009 - Comprehensive Service & Repair Manual

Harley-Davidson VRSCA V-Rod Service Manual (2002-2009) - Professional Workshop Guide

Maintain the performance and soul of your liquid-cooled V-Twin with this definitive service manual. Specifically engineered for the Harley-Davidson VRSCA V-Rod models produced between 2002 and 2009, this guide is the ultimate resource for owners who demand factory-level precision. Whether you are a dedicated DIY enthusiast or a professional technician, this manual provides the technical depth required to keep the 1131cc Revolution engine running at its peak.

This manual isn't just a collection of instructions—it is a comprehensive technical breakdown of the motorcycle that redefined the Harley-Davidson brand. From routine oil changes to complex fuel injection diagnostics, every procedure is explained with clarity and supported by professional-grade diagrams.

Model Coverage

• VRSCA V-Rod (2002-2009)

Deep-Dive Technical Content

• 1131cc Revolution Engine: Complete coverage of the 60-degree V-Twin, including cam timing, valve lash adjustments (using specific 6mm pilots and reamers), and full top-to-bottom rebuild procedures.
• Cooling System Management: In-depth service for the pressurized ethylene-glycol system, radiator maintenance, and water pump diagnostics to prevent overheating.
• Precision Chassis & Suspension: Full data on the hydroformed frame, front forks, and rear suspension setup to ensure the signature V-Rod handling remains sharp.
• Advanced Electrical & EFI: Detailed troubleshooting for the Electronic Fuel Injection (EFI) system, including ECM diagnostics, sensor testing, and full-color-coded wiring diagrams.
• Drive & Transmission: Step-by-step guides for the 5-speed transmission, high-performance clutch service, and final drive belt tensioning.

Professional Features for Real-World Use

• Identification & Serial Numbers: Includes a dedicated guide to the 17-digit Vehicle Identification Number (V.I.N.) located on the steering head, and the abbreviated V.I.N. on the left-side crankcase for precise parts matching.
• Torque & Fluid Specs: Precise torque tables for every critical bolt and specialized fluid requirements (including D.O.T. 5 Silicone brake fluid specifications).
• Specialty Tooling: References for official Harley-Davidson tools (such as HD-45319 Valve Guide Reamer and HD-34751 Cleaning Brush) to ensure professional results.
• Mobile-Optimized Layout: Structured with clear headings and concise bullet points, making it easy to read on a smartphone or tablet while working in the garage.

Comprehensive Manual Sections:

• Maintenance: Scheduled service intervals and lubrication charts.
• Chassis: Wheel, tire, and brake system overhauls.
• Engine: Detailed wear limits and crankshaft tolerances.
• Fuel System: Fuel pump replacement and vapor valve service.
• Electric Starter: Starter motor and solenoid troubleshooting.
• Cooling System: Thermostat testing and pressure checks.
• Transmission: Input and output shaft disassembly.
• Electrical: TSSM (Turn Signal Security Module) and lighting.
• Fuel Injection: Diagnostic Trouble Codes (DTC) and sensor mapping.

Equip yourself with the same knowledge used by factory-trained technicians. This manual is an essential investment for protecting the longevity and resale value of your Harley-Davidson VRSCA V-Rod.