Positioning:
The Harley-Davidson V-Rod (VRSC) series, particularly the initial VRSC A, represented a significant departure for Harley-Davidson, blending American cruiser aesthetics with a modern, liquid-cooled, high-performance engine developed in collaboration with Porsche. This manual serves owners and technicians looking to maintain and repair this performance-oriented cruiser.
Competitors:
Competed with other performance-oriented cruisers and power cruisers from Japanese manufacturers (e.g., Yamaha VMAX, Suzuki M109R) and other American brands seeking to inject modern performance into their lineups.
Features:
Liquid-cooled, fuel-injected V-twin engine, aluminum frame, sporty handling, distinctive styling.
Covered Years:
2002, 2003, 2004, 2005, 2006, 2007, 2008
Estimated Pages:
Approximately 600-800 pages (typical for comprehensive service manuals of this era)
Type:
Service Repair Workshop Manual
Engine:
Revolution V-Twin, cooling system, lubrication system, fuel injection, ignition system, exhaust system
Transmission:
Clutch, gearbox, primary drive, final drive (belt)
Chassis:
Frame, suspension (front fork, rear shock absorber), steering, wheels, tires
Brakes:
Front and rear brake system, hydraulic circuits, caliper overhaul, master cylinder
Electrical:
Wiring diagrams, lighting, instrumentation, battery, charging system, starter system, ignition switch, security system
Bodywork:
Fenders, fuel tank, seat, handlebars, controls, fairings (if applicable)
Maintenance:
Scheduled maintenance intervals, fluid changes (oil, brake fluid, coolant), filter replacements, lubrication points, spark plug service
Repair:
Engine disassembly and reassembly, transmission overhaul, suspension adjustments and replacement, brake system repair, electrical component diagnosis and replacement
Troubleshooting:
Diagnostic charts, fault finding procedures, common issue identification and resolution
Special Tools:
Identification and usage of specialized Harley-Davidson tools required for various procedures
Depth:
Comprehensive, covering basic to advanced repair and diagnostic procedures, suitable for professional mechanics and advanced DIY enthusiasts
Quality:
High-resolution, ensuring clear diagrams, images, and text for printing
Binding:
N/A (Digital format - PDF)
Paper:
N/A (Digital format - PDF)
Engine Type:
Revolution V-Twin, 4-stroke, 60-degree V-twin
Displacement:
1131 cc (69 cubic inches)
Bore X Stroke:
100 mm x 72 mm
Cooling System:
Liquid-cooled
Valve Train:
DOHC, 4 valves per cylinder
Compression Ratio:
11.3:1
Horsepower:
Approximately 115-120 hp @ 8,250 rpm (model dependent)
Torque:
Approximately 93-98 ft-lbs @ 6,000 rpm (model dependent)
Fuel Delivery:
Sequential Port Fuel Injection (H-D Electronic Sequential Port Fuel Injection - ESPFI)
Fuel Type:
Unleaded premium gasoline
Fuel Capacity:
5.0 US gallons (18.9 L)
Oil Capacity W Filter:
3.4 US quarts (3.2 L)
Oil Type Spec:
Harley-Davidson V-Twin Synthetic (or equivalent SAE 20W50 motorcycle oil meeting Harley-Davidson specifications)
Type:
5-speed constant mesh
Final Drive:
Belt drive, 140-tooth, 14mm pitch
Clutch:
Wet, multi-plate, hydraulic actuation
Fluid Type:
Harley-Davidson Formula+ (or equivalent SAE 50 transmission lubricant)
Fluid Capacity:
2.5 US quarts (2.4 L)
Crash Test Ratings:
N/A (Motorcycle safety ratings are not standardized in the same way as automobiles)
Braking System:
Hydraulic disc brakes front and rear, often with dual front discs for enhanced stopping power.
Lighting:
Halogen headlight, LED taillight and brake light.
Security:
Factory-installed alarm system (optional on some early models, standard on later ones).
Audio System:
N/A for the VRSC A model as standard. Some aftermarket integrations or later VRSCDX models may have had audio systems.
ABS:
Anti-lock Braking System (ABS) was optional on many models during this period and may be present on some VRSC A units.
Diagnostics:
On-board diagnostics (OBD) are integrated, allowing for electronic fault code retrieval via a diagnostic port using Harley-Davidson diagnostic tools (e.g., Digital Technician).
Initial Service:
First service typically at 1,000 miles (1,600 km) or 6 months, whichever comes first.
Subsequent Service:
Every 5,000 miles (8,000 km) or 12 months thereafter.
Major Service Points:
Spark plugs, drive belt inspection, brake fluid flush, coolant flush, transmission fluid change (as specified in the manual).
Engine Oil:
Harley-Davidson V-Twin Synthetic SAE 20W50 or equivalent meeting HD-360 specification.
Transmission Oil:
Harley-Davidson Formula+ (SAE 50) or equivalent.
Primary Chain Case Oil:
Harley-Davidson Formula+ (SAE 50) or equivalent (same as transmission).
Coolant:
Ethylene glycol-based coolant with corrosion inhibitors, suitable for aluminum engines (e.g., Harley-Davidson Performance Coolant).
Common Problems:
Potential for stator failure (especially on early models), regulator issues, fuel pump inconsistencies, and occasional coolant leaks at seals. Some owners report rear suspension not being plush enough for longer rides. Drive belt requires regular tension checks and adjustments.
Maintenance Focus:
Proper fuel injection system maintenance, regular cooling system checks, and ensuring the correct drive belt tension are critical for longevity and performance.
Heritage Summary:
Harley-Davidson, founded in 1903, is renowned for its iconic cruiser motorcycles. The V-Rod line represented a strategic move to embrace modern technology and performance while maintaining the brand's core identity.
Vrod Development:
The V-Rod concept originated from the 'Nova' project, aiming to create a 'different' kind of Harley. The partnership with Porsche for engine development was crucial, resulting in the high-revving, liquid-cooled Revolution engine, a significant departure from Harley's traditional air-cooled V-twins.
Vrod Variants:
The VRSC 'A' (V-Rod) was the foundational model. Subsequent variations included the VRSCB (different styling), VRSCAW (longer wheelbase, larger rear tire), VRSCX (limited edition), VRSCX 'Night Rod', and VRSCDX 'Night Rod Special'.
Production Period:
2002-2017 (The manual covers the early key years)
Manufacturing Location:
Kansas City, Missouri, USA
