Harley-Davidson Softail 2001 Service & Electrical Diagnostics Manual Set (P/N 99482-01A)

The service volume covers component removal and repair; the diagnostics volume supplies the fault-isolation charts referenced by those procedures. Replacement-parts selection, the owner’s handbook, and subsequent service bulletins are separate references.

Engine repair limit: Connecting-rod service is limited to upper-bushing replacement. Flywheels and connecting rods are handled as a complete assembly, with factory service or replacement specified for work on that assembly.

Text Search, Bookmarks, and Wiring Detail

Navigation and small labels: Searchable text and embedded bookmarks cover both publications. Dense wiring sheets require zooming to read small connector numbers, pin labels, and wire-color codes.

One printable English PDF contains 917 pages, including one combined contents page, two foreword pages, 15 blank or divider pages, and 12 notes pages. Section contents and appendices are also included in that total.

Twin Cam Repair, Chassis Service, and Fault Diagnosis

The following selected coverage outlines the main workshop areas. Other included topics range from storage preparation to handlebar-switch service.

• Engine repair: Step-by-step engine removal and installation, top-end and bottom-end overhaul, valve service, cam-support-plate work, oil-pump service, and counterbalancer timing.

• Drive and transmission: Primary chaincase, compensating sprocket, clutch inspection and assembly, starter jackshaft, final-drive belt and sprockets, shifter mechanisms, and transmission internals.

• Chassis and brakes: Sealed wheel bearings, wheel lacing and truing, vehicle alignment, master cylinders, calipers, hydraulic forks, Springer assemblies, steering-head bearings, and rear suspension.

• Carbureted fuel system: C.V. carburetor disassembly, float adjustment, accelerator-pump inspection, enrichener adjustment, vacuum fuel valve and filter, and California evaporative-emissions controls.

• EFI service: Induction module, ECM, sensors, idle-air control, injectors, fuel pump/sender, fuel-pressure testing, and diagnostic-tool-based idle adjustment.

• Electrical troubleshooting: Starter and charging tests, battery load testing, instruments, TSM/TSSM security, fault-code flowcharts, connector information, and carbureted/EFI wiring diagrams.

The major-repair material is written for professional Harley-Davidson technicians and calls for the specified service tools and diagnostic equipment.

Engine Overhaul and Counterbalancer Work

Detailed procedures reach the rocker-arm support plate, pushrods and lifters, cylinder heads, pistons, connecting-rod bushings, cam bearings, crankcase bearings, and balance-shaft assembly.

Illustrations include Engine Oil Flow: Cam Support Plate/Right Crankcase Half, Balance Chain, and Flywheel Alignment Mark. Tool references include the HD-42313 cam chain tensioner unloader and HD-44064 balance-shaft sprocket alignment tool.

Incorrect balance-chain indexing, improper housing preparation, or a loose retention-pin tip can cause engine damage.

Primary Drive and Transmission Internals

Transmission coverage distinguishes shifter-cam and fork service, clutch-release-cover work, mainshaft/countershaft disassembly, and transmission-case service. Mainshaft/Countershaft Assembly provides an illustrated reference for the internal components.

The main drive gear and bearing can be serviced with the transmission case in the frame. The procedure specifies the HD-35316A main drive gear remover/installer.

Hydraulic Forks, Springer Assemblies, and Brakes

Separate front-wheel procedures cover FXSTD, FLSTS, and FXSTS. Front-caliper procedures distinguish FLSTS, FXSTS, and the remaining models.

Wheel-lacing instructions distinguish 16- and 21-inch rims, followed by radial and lateral truing and disc-wheel runout checks. Front Fork: FLSTS (FXSTS Similar) supports the Springer procedures; the maintenance schedule also distinguishes Springer from hydraulic-fork requirements.

The FLSTS/FXSTS sections explain the sidecar restriction and front-end geometry cautions. Operating a brake control with a wheel removed can force a caliper piston out and require caliper disassembly.

Secure the motorcycle on a stable lift or stand before major repair work, and follow the fuel, battery, spring-pressure, brake, and lifting warnings.

Carburetor and EFI Service Differences

Carburetor procedures extend to the vacuum piston, float inlet valve, and accelerator pump. Related sections cover the fuel tank, air cleaner, vacuum-operated supply valve, model-specific exhaust systems, and California evaporative controls.

EFI procedures distinguish throttle-position, intake-air-temperature, engine-temperature, and MAP sensors, together with the idle-air-control system and pump/sender assembly. EFI idle adjustment requires the HD-41325 Scanalyzer or HD-44750 Digital Technician; the Scanalyzer procedure is included.

Electrical Tests, Security Setup, and Wiring

Diagnostic charts address no-start conditions, check-engine and security lamps, misfire, sensor and injector faults, serial-data loss, and intermittent harness problems. Initial Diagnostic Check: EFI connects symptom assessment with the relevant fault-isolation procedures.

Tests cover starter current draw and solenoid operation, stator and regulator output, fuel gauges, speedometers, and indicator lamps. TSM/TSSM material includes security setup, key-fob assignment, and password learning.

Factory methods reference the HD-39978 DVOM, HD-42682 ignition-module/TSM/TSSM breakout box, and HD-43876 EFI breakout box. Connector views and pin assignments support circuit testing without piercing wires.

The diagnostics wiring section contains nine carbureted and twelve EFI sheets for domestic and international models, covering main harnesses, ignition, charging, starting, lighting, instruments, and security.

Torque tables, fluid capacities, approved lubricants, component dimensions, wear limits, alignment data, and electrical voltage/resistance/current specifications accompany the procedures.

Examples of Chain-Clearance and Pressure Specifications

Primary-chain inspection specifies upward free play in the upper strand of 5/8–7/8 in. with the engine cold and 3/8–5/8 in. with it hot.

EFI fuel-pressure testing specifies a steady 55–62 psi as engine speed changes. Engine oil-pressure testing specifies 30–38 psi at 2,000 RPM with the oil at normal operating temperature, 230°F (110°C).