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XV1600A Road Star (1999-2007)
XV1700A Road Star (1999-2007)
XV1600AS Road Star MM Limited (2000)
XV1600ALE Road Star Limited Edition (2003)
XV1700AM Road Star Midnight (2004-2007)
XV1600AT Road Star Silverado (1999-2007)
XV1700AT Road Star Silverado (1999-2007)
XV1600AS Road Star Midnight Star (2001-2003)
XV1600ATLE Road Star Silverado Limited Edition (2003)
XV1700ATM Road Star Midnight Silverado (2004-2007)
This manual does not cover XV1700P Warrior models.
QUICK REFERENCE DATA
CHAPTER ONE / GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Safety / Serial numbers / Fasteners / Shop supplies / Basic tools / Precision measuring tools / Electrical system fundamentals / Basic service methods / Storage Specifications
CHAPTER TWO / TROUBLESHOOTING
Engine operating requirements / Starting the engine / Engine will not start / Engine performance / Engine noises / Engine lubrication / Engine leakdown test / Clutch / Gearshift linkage / Transmission / Carburetor / Carburetor heater / Fuel pump / Electrical testing / Electrical troubleshooting / Suspension and steering / Brake system
CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Fuel type / Maintenance intervals / Cylinder numbering / Engine rotation / Tune-up / Spark plugs / Engine oil and filter change / Transfer gearcase / Fuel and exhaust systems / Control cable lubrication / Clutch cable adjustment / Transmission / Sidestand / General lubrication / Battery / Tires / Front suspension / Steering head / Rear suspension / Drive belt / Brakes / Specifications
CHAPTER FOUR / ENGINE TOP END
Servicing engine in the frame / Cylinder head covers / Rocker arms and pushrods / Valve lifters / Cylinder head / Valves and valve components / Cylinder / Pistons and piston rings / Specifications
CHAPTER FIVE / ENGINE LOWER END
Engine removal installation / Oil filter mount / Camshafts / Oil pump / Crankcase / Crankcase seal and bearing replacement / Crankshaft / Connecting rods / Alternator drive shaft / Engine break-in / Specifications
CHAPTER SIX / TRANSFER GEARCASE
Drive sprocket / Transfer gearcase / Oil pump / Case and cover / Specifications
CHAPTER SEVEN / CLUTCH AND PRIMARY DRIVE GEAR
Clutch cover / Clutch / Primary drive gear / Oil pump driven gear / Specifications
CHAPTER EIGHT / TRANSMISSION AND SHIFT MECHANISM
Shift pedal/footrest assembly / External shift mechanism / Internal shift mechanism / Transmission / Specifications
CHAPTER NINE / FUEL, EXHAUST, AND EMISSION CONTROL SYSTEMS
Fuel system safety / Fuel hose identification / Fuel tank / Air filter housing / Surge tank solenoid valve / Carburetor / Carburetor overhaul / Pilot screw / Fuel level / Idle speed / Throttle cable / Throttle position sensor / Carburetor heater / Throttle cable / Starter (choke) cable / Fuel filters / Fuel pump / Fuel pump/fuel filter module / Air induction system / Evaporative emission control / Exhaust system / Specifications
CHAPTER TEN / ELECTRICAL SYSTEM
Electrical component replacement / Electrical connectors / Charging system / Alternator stator / Flywheel, starter clutch and starter reduction gears / Voltage regulator/rectifier / Ignition system / Spark plug cap / Ignition coil / Pickup coil and timing rotor / Diode (1999-2003) / Ignitor unit / Starting system / Starter / Starting circuit cutoff relay (Relay unit) / Starter relay / Lighting system / Headlight / Meter assembly / Taillight/brake light / License plate light / Signal system / Horn / Turn signals / Neutral indicator light / Speed sensor / Fuel level sender / Decompression solenoid / Switches / Self-diagnostic system / Fuses / Specifications
CHAPTER ELEVEN / WHEELS AND TIRES
Motorcycle stand / Brake rotor protection / Wheel inspection / Wheel bearings / Front wheel / Front hub / Rear wheel / Rear hub / Driven sprocket clutch hub / Drive belt / Laced wheel service / Wheel balance / Tire changing / Specifications
CHAPTER TWELVE / FRONT SUSPENSION AND STEERING
Front fork / Handlebar / Steering head / Steering head bearing races / Lower bearing replacement / Specifications
CHAPTER THIRTEEN / REAR SUSPENSION
Shock absorber and suspension linkage / Swing arm / Specifications
CHAPTER FOURTEEN / BRAKES
Brake service / Brake bleeding / Brake fluid draining / Brake pads / Front caliper / Front master cylinder / Rear brake caliper / Rear brake master cylinder / Brake pedal/footrest / Brake disc / Brake hose / Specifications
CHAPTER FIFTEEN / BODY AND FRAME
Seats / Side covers / Rider footrest / Passenger footpegs / Front fender / Rear fender / Saddlebags and mounting brackets / Backrest / Sidestand / Windshield / Battery box / Specifications
COLOR WIRING DIAGRAMS
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