2003 Harley-Davidson VRSCA Service Manual Pn99501-03 - PDF DOWNLOAD

2003 Harley-Davidson VRSCA Service Manual Pn99501-03 - PDF DOWNLOAD

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2003 Harley-Davidson VRSCA Service Manual Pn99501-03 - PDF DOWNLOAD

Language :English
Pages :447
Downloadable : Yes
File Type : PDF

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2003 Harley-Davidson VRSCA Service Manual Pn99501-03 - PDF DOWNLOAD

FOREWORD
GENERAL

This Service Manual has been prepared with two purposes in mind. First, it will acquaint the user with the construction of the Harley-Davidson product and assist in the performance of basic maintenance and repair. Secondly, it will introduce to the professional Harley-Davidson Technician the latest fieldtested and factory-approved major repair methods. We sincerely believe that this Service Manual will make your association with Harley-Davidson products more pleasant and profitable.

HOW TO USE
YOUR SERVICE MANUAL
Information is arranged as follows:
• Section 1-Maintenance
• Section 2-Chassis
• Section 3-Engine
• Section 4-Fuel System
• Section 5- Electric Starter
• Section 6-Cooling System
• Section ?- Transmission
• Section 8- Electrical
• Section 9-Fuel Injection
• Appendix A- Tools
• Appendix B- Wiring
• Appendix C-Metric Conversions
• Appendix D- Service Templates

TABLE OF CONTENTS:

2003 Harley-Davidson VRSCA Service Manual Pn99501-03 - PDF DOWNLOAD

Front Cover 1
Index 3
Table of Contents 6
1 Maintenance 14
Fuel and Oil 19
Airbox and Air Filter 23
Cooling System 26
Engine Oil and Filter 27
Battery Maintenance 29
Brakes 32
Bleeding Brakes 34
Brake Pads and Discs 35
Tires and Wheels 38
Clutch 39
Bleeding Clutch 40
Rear Belt Deflection 42
Rear Belt and Sprockets 44
Suspension Adjustments 46
Steering Head Bearings 47
Front Fork Oil 48
Spark Plug/Coil 50
Cable and Chassis Lubrication 52
Throttle Cables 53
Valve Lash 54
Verify Cam Tiiming 58
Lash Adjustment 59
Secondary Cam Chain 64
Headlamp Alignment 67
Critical Fasteners 68
Storage 69
Troubleshooting 71
2 Chassis 75
Specifications 76
Torque Values 77
V I N 80
Frame/Lower Frame Rails 81
Front Engine Mount 83
Exhaust System 86
Rear Engine Mounts 88
Engine Replacement 89
Jiffy Stand 98
Footrests/Foot Controls 100
Throttle Cables 102
Clutch Master Cylinder/Reservoir 104
Clutch Hand Lever 107
Clutch Fluid Line 108
Secondary Clutch Actuator 109
Front Brake Master Cylinder/Reservoir 111
Front Brake Calipers 115
Rear Brake Master Cylinder/Reservoir 120
Rear Brake Caliper 126
Handlebars 131
Front Wheel 133
Rear Wheel 137
Sealed Wheel Bearings 142
Disc Rim Runout 145
Tires 146
Front Fender 151
Front Fork 152
Steering Head 157
Fork Lock 160
Belt Guard/Debris Deflector 161
Rear Shock Absorbers 162
Rear Fork 164
Seat Latch 167
Seat 168
Rear Fender/Supports 170
3 Engine 172
Specifications 173
Service Wear Limits 178
Engine Torque Values 179
Oil Flow 180
Oil Pressure 184
Troubleshooting 186
Stripping Motorcycle For Service 188
Throttle Body 190
Top End Disassembly 192
Cylinder Head Service 198
Oil Pump 208
Clutch 210
Upper and Lower Crankcase Service 222
Counterbalancer Bearing Replacement 237
Crankshaft Bearing Replacement 243
Shift Shaft and Seal 245
Crankshaft, Piston and Cylinder Liner 247
Oil Filter Mount 261
Cam Drive 262
Cylinder Heads 265
Installing and Timing the Cams 267
4 Fuel System 273
Specifications 274
Fuel Pump/Filters/Fuel Level Sender Assembly 275
Suction Side Fuel Filter 278
Fuel Pump 279
Fuel Tank 280
Vapor Valve 282
Evaporative Emissions Control - CA Models 283
Purge Solenoid/Vapor Valve 284
Charcoal Canister 285
Hose Routing/Replacement 286
5 Electric Starter 287
Specifications 288
Electric Starter System 289
Starter Relay 291
Starter 293
Starter Solenoid 294
6 Cooling System 296
Specifications 297
Coolant Flow 298
Troubleshooting 300
Pressure Cap Test 301
System Pressure Test 302
Leak Detection Dye Test?Blown Gasket 303
Engine Coolant 304
Thermostat 306
Water Pump 308
Coolant Pipes and Hoses 310
Oil Line Fittings 313
Radiator/Oil Cooler 314
Oil Cooler 317
7 Transmission 319
Specifications 320
Output Shaft 321
Input Shaft 330
8 Electrical 336
Specifications 337
Torque Values 338
Bulb Requirements 339
Relay/Fuse Block 340
Crank Position Sensor: CKP 342
Maxi-Fuse 343
Ignition/Light Switch 344
Alternator 345
Voltage Regulator 347
Battery 349
Battery Cables 354
Headlamp 355
Tail Lamp 357
Turn Signal/Running Lights 359
Turn Signal Security Module:TSSM 361
Instrument Cluster 362
Vehicle Speed Sensor:VSS 364
Neutral Switch 365
Oil Pressure Switch 366
Stop Light Switch 368
Horn 369
Cooling Fans 370
9 Fuel Injection 372
Specifications 373
Torque Values 374
Electronic Fuel Injection:EFI 375
Electronic Control Module:ECM 377
Throttle Position Sensor:TP 378
Intake Air Temperature Sensor:IAT 379
Engine Coolant Temperature Sensor:ECT 380
Idle Air Control:IAC 381
Manifold Absolute Pressure Sensor:MAP 383
Fuel Rail/Fuel Injectors 384
Fuel Pressure Test 386
Intake Leak Test 388
Appendix 390
Appendix A - Tools 391
Appendix B - Wiring 403
Appendix C - Conversions 424
Index 439

S.M 22/3/2025