Harley Davidson Service Manual VRSC 2008.pdf

2008 VRSC Models Service

Manual

99501-08

Printed in the U.S.A.

VISIT THE HARLEY-DAVIDSON WEB SITE

http://www.harley-davidson.com

ABOUT THIS MANUAL

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 pro-

fessional Harley-Davidson Technician the latest field-tested

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

Refer to the table below for the content layout of this manual.

Cleaning will occasionally uncover sources of trouble. Tools,

instruments and any parts needed for the job should be

gathered before work is started. Interrupting a job to locate

tools or parts is a distraction and causes needless delay.

NOTES

• To avoid unnecessary disassembly, carefully read all rel-

ative service information before repair work is started.

• In figure legends, the number which follows the name of

a part indicates the quantity necessary for one complete

assembly.

• When servicing a vehicle equipped with the Harley-

Davidson Smart Security System (H-DSSS), you must

first disarm the security system. Either keep the fob in

close proximity to the vehicle, or use Digital Technician to

disable the security system while the vehicle is being ser-

viced and re-enable the system after service is completed.

SERVICE BULLETINS

In addition to the information presented in this Service Manual,

Harley-Davidson Motor Company will periodically issue Service

Bulletins to Harley-Davidson dealers. Service Bulletins cover

interim engineering changes and supplementary information.

Consult the Service Bulletins to keep your product knowledge

current and complete.

USE GENUINE REPLACEMENT PARTS

NO.

CHAPTER

Maintenance

Chassis

Engine

Fuel System

Starter

Cooling System

Transmission

Electrical

Appendix A Connector Repair

Appendix B Wiring

Appendix C ABS

Appendix D Valve Lash

Do not use aftermarket parts and custom made front forks

which can adversely affect performance and handling.

Removing or altering factory installed parts can adversely

affect performance and could result in death or serious

injury. (00001a)

To ensure satisfactory and lasting repairs, carefully follow the

Service Manual instructions and use only genuine Harley-

Davidson replacement parts. Behind the emblem bearing the

words GENUINE HARLEY-DAVIDSON stand more than 100

years of design, research, manufacturing, testing and inspecting

experience. This is your assurance that the parts you are using

will fit right, operate properly and last longer.

WARNINGS AND CAUTIONS

Statements in this service manual preceded by the following

words are of special significance.

Appendix E Conversions

Appendix F Glossary

Use the TABLE OF CONTENTS (which follows this FORE-

WORD) and the INDEX (at the back of this manual) to quickly

locate subjects. Sections and topics in this manual are

sequentially numbered for easy navigation.

For example, a cross-reference shown as 2.1 SPECIFICA-

TIONS refers to chapter 2 CHASSIS, heading 2.1 SPECIFIC-

ATIONS.

For quick and easy reference, all pages contain a section

number followed by a page number. For example, page 3-5

refers to page 5 in section 3.

A number of acronyms and abbreviations are used in this

document. See the F.1 GLOSSARY for a list of acronyms,

abbreviations and definitions.

PREPARATION FOR SERVICE

WARNING indicates a potentially hazardous situation

which, if not avoided, could result in death or serious

injury. (00119a)

Stop the engine when refueling or servicing the fuel

system. Do not smoke or allow open flame or sparks near

gasoline. Gasoline is extremely flammable and highly

explosive, which could result in death or serious injury.

(00002a)

Good preparation is very important for efficient service work.

A clean work area at the start of each job will allow you to

perform the repair as easily and quickly as possible, and will

reduce the incidence of misplaced tools and parts. A motorcycle

that is excessively dirty should be cleaned before work starts.

CAUTION indicates a potentially hazardous situation

which, if not avoided, may result in minor or moderate

injury. (00139a)

Kent-Moore Products

All tools mentioned in this manual with an "HD", "J" or "B"

preface must be ordered through SPX Kent-Moore. For ordering

information or product returns, warranty or otherwise, visit

www.spx.com.

Loctite Sealing and Threadlocking Products

Some procedures in this manual call for the use of Loctite

products. If you have any questions regarding Loctite product

usage or retailer/wholesaler locations, please contact Loctite

Corp. at www.loctite.com.

PRODUCT REGISTERED MARKS

Allen, Amp Multilock, Bluetooth, Brembo, Delphi, Deutsch,

Dunlop, Dynojet, Fluke, G.E. Versilube, Gunk, Hydroseal,

Hylomar, Kevlar, Lexan, Loctite, Lubriplate, Keps, K&N, Mag-

naflux, Marson Thread-Setter Tool Kit, MAXI fuse, Molex, MPZ,

Mulitilock, Novus, Packard, Pirelli, Permatex, Philips, PJ1,

Pozidriv, Robinair, S100, Sems, Snap-on, Teflon, Threadlocker,

Torca, Torco, TORX, Tufoil, Tyco, Ultratorch, Velcro, X-Acto,

and XM Satellite Radio are among the trademarks of their

respective owners.

H-D MICHIGAN, INC. TRADEMARK

INFORMATION

Harley, Harley-Davidson, H-D, Bar & Shield, Digital Tech,

Digital Technician, Destroyer, Deuce, Dyna, Electra Glide,

Evolution, Fat Boy, Glaze, Gloss, H-D, H-Dnet.com, HD, Harley,

Heritage Softail, Heritage Springer, Low Rider, Night Rod, Night

Train, Profile, Revolution, Road Glide, Road King, Rocker,

Softail, Sportster, Sun Ray, Sunwash, Tech Link, Twin Cam

88, Twin Cam 88B, Twin Cam 96, Twin Cam 96B, Twin Cam

103, Twin Cam 103B, Twin Cam 110, Twin Cam 110B, Tour-

Pak, Screamin' Eagle, Softail, Super Guide, Super Premium,

SYN3, Ultra Glide, V-Rod, VRSC, Wide Glide, and Harley-

Davidson Genuine Motor Parts and Genuine Motor Accessories

are among the trademarks of H-D Michigan, Inc.

CONTENTS

All photographs, illustrations and procedures may not neces-

sarily depict the most current model or component, but are

based on the latest production information available at the time

of publication.

Since product improvement is our continual goal, Harley-

Davidson reserves the right to change specifications, equipment

or designs at any time without notice and without incurring

obligation.

CAUTION used without the safety alert symbol indicates

a potentially hazardous situation which, if not avoided,

may result in property damage. (00140a)

NOTE

Refers to important information, and is placed in italic type. It

is recommended that you take special notice of these items.

Proper service and repair is important for the safe, reliable

operation of all mechanical products. The service procedures

recommended and described in this service manual are

effective methods for performing service operations.

Always wear proper eye protection when using hammers,

arbor or hydraulic presses, gear pullers, spring com-

pressors, slide hammers and similar tools. Flying parts

could result in death or serious injury. (00496b)

Some of these service operations require the use of tools

specially designed for the purpose. These special tools should

be used when and as recommended. It is important to note

that some warnings against the use of specific service methods,

which could damage the motorcycle or render it unsafe, are

stated in this service manual. However, please remember that

these warnings are not all-inclusive. Inadequate safety precau-

tions could result in death or serious injury.

Since Harley-Davidson could not possibly know, evaluate or

advise the service trade of all possible ways in which service

might be performed, or of the possible hazardous con-

sequences of each method, we have not undertaken any such

broad evaluation. Accordingly, anyone who uses a service

procedure or tool which is not recommended by Harley-

Davidson must first thoroughly satisfy himself that neither his

nor the operator's safety will be jeopardized as a result. Failure

to do so could result in death or serious injury.

PRODUCT REFERENCES

Read and follow warnings and directions on all products.

Failure to follow warnings and directions can result in

death or serious injury. (00470b)

When reference is made in this manual to a specific brand

name product, tool or instrument, an equivalent product, tool

or instrument may be substituted.

II FOREWORD

MAINTENANCE

1.7 COOLING SYSTEM

Checking Coolant Level in Overflow Bottle.......................1-16

Check for Coolant in System............................................1-16

1.1 GENERAL

Servicing a New Motorcycle...............................................1-1

Safe Operating Maintenance..............................................1-1

Shop Practices...................................................................1-1

Repair Notes...............................................................1-1

Safety..........................................................................1-1

Removing Parts...........................................................1-1

Cleaning......................................................................1-1

Disassembly and Assembly........................................1-2

Checking Torques on Fasteners with Lock Patches.....1-2

Magnetic Parts Trays...................................................1-2

Repair and Replacement Procedures................................1-2

Hardware and Threaded Parts....................................1-2

Threadlocking Agents..................................................1-2

Wiring, Hoses and Lines.............................................1-2

Instruments and Gauges.............................................1-2

Bearings......................................................................1-2

Bushings.....................................................................1-2

Gaskets.......................................................................1-2

Lip Type Seals.............................................................1-2

O-Rings (Preformed Packings)....................................1-3

Gears..........................................................................1-3

Shafts..........................................................................1-3

Part Replacement........................................................1-3

Exhaust System Leakage............................................1-3

Cleaning.............................................................................1-3

Part Protection............................................................1-3

Cleaning Process........................................................1-3

Rust or Corrosion Removal.........................................1-3

Bearings......................................................................1-3

Tool Safety..........................................................................1-3

Air Tools.......................................................................1-3

Wrenches....................................................................1-3

Pliers/Cutters/Pry bars................................................1-3

Hammers.....................................................................1-4

Punches/Chisels..........................................................1-4

Screwdrivers................................................................1-4

Ratchets and Handles.................................................1-4

Sockets........................................................................1-4

Storage Units...............................................................1-4

1.8 ENGINE OIL AND FILTER

Checking and Adding Oil..................................................1-17

Cold Engine Oil Level Check.....................................1-17

Hot Engine Oil Level Check.......................................1-17

Changing Oil and Filter.....................................................1-18

1.9 BATTERY MAINTENANCE

General.............................................................................1-20

Disconnection/Removal....................................................1-21

Cleaning and Inspection...................................................1-21

Charging Battery..............................................................1-21

Safety Precautions....................................................1-21

Using a Battery Charger............................................1-22

Installation/Connection.....................................................1-23

Storage.............................................................................1-24

1.10 BRAKES

Fluid Inspection................................................................1-25

Rear Brake Pedal.............................................................1-26

Pedal Adjustment......................................................1-26

1.11 BRAKE PADS AND DISCS

Inspection.........................................................................1-27

Brake Pads................................................................1-27

Brake Disc Thickness................................................1-27

Brake Disc Lateral Runout and Warpage..................1-27

Brake Pad Replacement...................................................1-27

Rear Brake Caliper....................................................1-27

Front Brake Caliper...................................................1-28

E F S

1.12 BLEEDING BRAKES

General.............................................................................1-31

Procedure.........................................................................1-31

1.13 TIRES AND WHEELS

Tires.................................................................................1-33

Wheel Bearings................................................................1-33

1.14 CLUTCH

General.............................................................................1-34

Checking Clutch Fluid Level.............................................1-34

1.2 MAINTENANCE SCHEDULE

General...............................................................................1-5

1.3 FUEL AND OIL

Fuel....................................................................................1-8

Gasoline Blends.................................................................1-8

Engine Lubrication..............................................................1-8

Winter Lubrication..............................................................1-8

1.15 BLEEDING CLUTCH FLUID LINE

Procedure.........................................................................1-35

1.16 REAR BELT DEFLECTION

Inspection.........................................................................1-37

1.4 BULB REQUIREMENTS

General.............................................................................1-10

1.17 REAR BELT AND SPROCKETS

General.............................................................................1-39

Cleaning...........................................................................1-39

Inspection.........................................................................1-39

Sprockets..................................................................1-39

Rear Belt...................................................................1-39

1.5 AIR CLEANER AND EXHAUST SYSTEM

Removal...........................................................................1-11

Installation........................................................................1-12

Exhaust System Leak Check............................................1-13

1.18 DRIVE BELT REPLACEMENT

Replacement....................................................................1-41

1.6 RADIATOR SIDE COVERS

Removal...........................................................................1-14

Installation........................................................................1-15

1.19 DRIVE SPROCKET FLANGE

Replacement....................................................................1-43

III

TABLE OF CONTENTS

1.20 SUSPENSION ADJUSTMENTS

Rear Shock Absorbers: VRSC Models.............................1-45

General......................................................................1-45

Adjustment................................................................1-45

Valve Train Noise.......................................................1-71

Excessive Vibration...................................................1-71

Check Engine Light Illuminates During Operation.....1-71

Lubrication System...........................................................1-71

Engine Uses Too Much Oil Or Smokes Excessively...1-71

Engine Leaks Oil From Cases, Hoses, Etc...............1-71

Low Oil Pressure.......................................................1-71

High Oil Pressure......................................................1-71

Electrical System..............................................................1-71

Alternator Does Not Charge......................................1-71

Alternator Charge Rate Is Below Normal..................1-71

Speedometer Operates Erratically............................1-71

Transmission.....................................................................1-71

Shifts Hard................................................................1-71

Jumps Out Of Gear...................................................1-72

Clutch Slips...............................................................1-72

Clutch Drags Or Does Not Release..........................1-72

Clutch Chatters..........................................................1-72

Handling...........................................................................1-72

Irregularities..............................................................1-72

Brakes..............................................................................1-72

Brake Does Not Hold Normally.................................1-72

1.21 STEERING HEAD BEARINGS

Adjustment (Fall-Away).....................................................1-46

1.22 SPARK PLUGS AND COIL

General.............................................................................1-47

Removal/Inspection..........................................................1-47

Installation........................................................................1-48

1.23 CABLE, LINE AND FRAME INSPECTION

General.............................................................................1-49

Cables and Hand Levers..................................................1-49

Jiffy Stand.........................................................................1-49

Fuel System Lines and Fittings........................................1-49

Hydraulic Lines.................................................................1-49

1.24 THROTTLE CABLES

Inspection.........................................................................1-50

Lubrication........................................................................1-50

Adjustment.......................................................................1-50

CHASSIS

2.1 SPECIFICATIONS: CHASSIS

General...............................................................................2-1

1.25 VALVE LASH

Lash Measurement...........................................................1-51

Camshaft Inspection.........................................................1-54

Lobe Surface Finish..................................................1-54

Camshaft Spalling (typical)........................................1-54

Verify Cam Timing............................................................1-55

Lash Adjustment...............................................................1-56

2.2 VEHICLE IDENTIFICATION NUMBER

(V.I.N.)

Vehicle Identification Number: VRSC Models.....................2-3

2.3 FRAME AND LOWER FRAME RAILS

General...............................................................................2-5

Removal.............................................................................2-5

Installation..........................................................................2-5

1.26 SECONDARY CAM CHAIN

General.............................................................................1-62

Adjustment.......................................................................1-62

2.4 FRONT ENGINE MOUNT

Replacement......................................................................2-7

1.27 HEADLAMP ALIGNMENT

Inspection.........................................................................1-65

Adjustment.......................................................................1-65

2.5 FRONT ENGINE MOUNT ASSEMBLY

Removal.............................................................................2-8

Disassembly And Assembly...............................................2-8

Installation..........................................................................2-8

1.28 CRITICAL FASTENERS

Inspection.........................................................................1-67

1.29 STORAGE

General.............................................................................1-68

Placing in Storage............................................................1-68

Removal from Storage......................................................1-68

2.6 REAR ENGINE MOUNTS

Removal...........................................................................2-10

Installation........................................................................2-10

2.7 ENGINE REPLACEMENT

General.............................................................................2-11

Removal...........................................................................2-11

Installation........................................................................2-16

1.30 TROUBLESHOOTING

General.............................................................................1-70

Engine..............................................................................1-70

Starter Motor Does Not Operate or Does Not Turn Engine

Over...........................................................................1-70

Engine Turns Over But Does Not Start......................1-70

Starts Hard................................................................1-70

Starts But Runs Irregularly or Misses........................1-70

Spark Plug Fouls Repeatedly....................................1-70

Pre-Ignition or Detonation (Knocks or Pings)............1-70

Overheating...............................................................1-71

2.8 FOOTRESTS AND FOOT CONTROLS:

FORWARD MOUNT

Rider Footrests.................................................................2-19

Removal....................................................................2-19

Installation.................................................................2-19

IV TABLE OF CONTENTS

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