Harley Davidson Touring 2009 Service Manual

2009 Touring Models Service Manual

99483-09

©2008 H-D.

Harley-Davidson motorcycles conform to all applicable U.S.A. Federal Motor Vehicle Safety Standards
and U.S.A. Environmental Protection Agency regulations effective on the date of manufacture.

To maintain the safety, dependability, and emission and noise control performance, it is essential that
the procedures, specifications and service instructions in this manual are followed.

Any substitution, alteration or adjustment of emission system and noise control components outside of
factory specifications may be prohibited by law.

IMPORTANT NOTICE

Harley-Davidson Motor Company

2009 Touring Models Service

Manual

©2008 H-D.

ALL RIGHTS RESERVED

99483-09

Printed in the U.S.A.

VISIT THE HARLEY-DAVIDSON WEB SITE

http://www.harley-davidson.com

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READER COMMENTS

Please comment on the completeness, accuracy, organization, usability, and readability of this manual.

Please list the page, item, and part number(s) of any errors you find in this manual.

Please tell us how we can improve this manual.

Occupation:

Name: Dealership:

Street: Department:

City: State: Zip:

Please clip out and mail to:
Service Communications Department
Harley-Davidson Motor Company
P.O. Box 653
Milwaukee, WI USA 53201

The Harley-Davidson Service Communications Department maintains a continuous effort to improve the quality
and usefulness of its publications. To do this effectively, we need user feedback - your critical evaluation of
this manual.

2009 Touring Models Service Manual (99483-09)

NOTES

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 pro­fessional 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.

CHAPTERNO.

Maintenance1
Chassis2
Engine3
Fuel System4
Drive5
Transmission6
Electrical7
Appendix A Connector RepairA
Appendix B WiringB
Appendix C ABSC
Appendix D ConversionsD
Appendix E GlossaryE

Use the TABLE OF CONTENTS (which follows this FORE­WORD) 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 SPECIFIC­ATIONS.

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 E.1 GLOSSARY for a list of acronyms,
abbreviations and definitions.

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 rel­ative 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 II to
disable the security system while the vehicle is being ser­viced 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. Ser vice Bulletins cover
interim engineering changes and supplementary information.
Consult the Service Bulletins to keep your product knowledge
current and complete.

USE GENUINE REPLACEMENT PARTS

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 Harley­Davidson 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.

FOREWORD

PREPARATION FOR SERVICE

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.
Cleaning will occasionally uncover sources of trouble. Tools,
instruments and any parts needed for the job should be

WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury. (00119a)

CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury. (00139a)

CAUTION used without the safety alert symbol indicates
a potentially hazardous situation which, if not avoided,
may result in property damage. (00140a)

I

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.

information or product returns, warranty or otherwise, visit
www.spx.com.

Loctite Sealing and Threadlocking Pr oducts

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

Always wear proper ey e protection when using hammer s,
arbor or hydraulic presses, gear pullers, spring com­pressors, 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. Howe v er, please remember that
these warnings are not all-inclusive. Inadequate safety precau­tions 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 con­sequences 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.

Kent-Moore Products

All tools mentioned in this manual with an "HD", "J" or "B"
preface must be ordered through SPX K ent-Moore. For ordering

Alcantara S.p.A., Allen, Amp Multilock, Bluetooth, Brembo,
Delphi, Deutsch, Dunlop, Dynojet, Fluke, G.E.Versilube, Gunk,
Hydroseal, Hylomar, Kevlar, Lexan, Loctite, Lubriplate, Keps,
K&N, Magnaflux, 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, Cross Bones,
Digital Tech, Digital Technician, Digital Technician II, Dyna,
Electra Glide, Evolution, Fat Bob, Fat Boy, Glaze, Gloss, H-D,
H-Dnet.com, HD, Harley, Harley-Davidson, Heritage Softail,
Low Rider, Night Rod, Nightster, Night Train, Profile, Revolu­tion, Road Glide, Road King, Road Tech, Rocker, Softail,
Sportster, Street Glide, Street Rod, 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 Glide,
SYN3, Ultra Classic, V-Rod, VRSC 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 neces­sarily 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-Da v­idson reserves the right to change specifications, equipment
or designs at any time without notice and without incurring
obligation.

II FOREWORD

MAINTENANCE

1.1 FASTENER TORQUE VALUES

Fastener Torque Values in this Chapter..............................1-1

1.2 GENERAL

Servicing a New Motorcycle...............................................1-3

Safe Operating Maintenance..............................................1-3

Shop Practices...................................................................1-3

Repair Notes...............................................................1-3

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

Removing Parts...........................................................1-3

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

Disassembly and Assembly........................................1-4

Checking Torques on Fasteners..................................1-4

Magnetic Parts Trays...................................................1-4

Repair and Replacement Procedures................................1-4

Hardware and Threaded Par ts....................................1-4

Threadlocking Agents..................................................1-4

Wiring, Hoses and Lines.............................................1-4

Instruments and Gauges.............................................1-4

Bearings......................................................................1-4

Bushings.....................................................................1-4

Gaskets.......................................................................1-4

Lip Type Seals.............................................................1-4

O-Rings (Preformed Packings)....................................1-5

Gears..........................................................................1-5

Shafts..........................................................................1-5

Part Replacement........................................................1-5

Exhaust System Leakage............................................1-5

Cleaning.............................................................................1-5

Part Protection............................................................1-5

Cleaning Process........................................................1-5

Rust or Corrosion Removal.........................................1-5

Bearings......................................................................1-5

Tool Safety..........................................................................1-5

Air Tools.......................................................................1-5

Wrenches....................................................................1-5

Pliers/Cutters/Pry bars................................................1-5

Hammers.....................................................................1-6

Punches/Chisels..........................................................1-6

Screwdrivers................................................................1-6

Ratchets and Handles.................................................1-6

Sockets........................................................................1-6

Storage Units...............................................................1-6

1.7 PRIMARY CHAIN

General.............................................................................1-17

Chaincase Lubricant.........................................................1-17

General......................................................................1-17

Check Lubricant Level...............................................1-17

Changing Chaincase Lubricant.................................1-17

1.8 TRANSMISSION LUBRICANT

Transmission Lubrication..................................................1-18

General......................................................................1-18

Check Lubricant Level...............................................1-18

Changing Transmission Fluid....................................1-18

1.9 AIR CLEANER AND EXHAUST SYSTEM

Removal...........................................................................1-20

Installation........................................................................1-21

Exhaust System Leak Check............................................1-21

1.10 TIRES AND WHEELS

Tires.................................................................................1-22

Tire Replacement.............................................................1-22

Inspection..................................................................1-22

When To Replace Tires.............................................1-22

Wheel Bearings................................................................1-23

Wheel Spokes..................................................................1-23

1.11 CLUTCH

Adjustment.......................................................................1-25

1.12 REAR BELT AND SPROCKETS

General.............................................................................1-27

Cleaning...........................................................................1-27

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

Sprockets..................................................................1-27

Rear Belt...................................................................1-27

1.13 REAR BELT DEFLECTION

Checking Belt Deflection..................................................1-29

Setting Belt Deflection......................................................1-29

Adjustment................................................................1-29

Assembly...................................................................1-31

1.14 BRAKES

Fluid Inspection................................................................1-32

TABLE OF CONTENTS

1.3 MAINTENANCE SCHEDULE

General...............................................................................1-7

1.4 FUEL AND OIL

Fuel..................................................................................1-10

Gasoline Blends...............................................................1-10

Engine Lubrication............................................................1-10

Winter Lubrication............................................................1-11

1.5 BULB REQUIREMENTS

General.............................................................................1-12

1.6 ENGINE OIL AND FILTER

Checking Oil Level............................................................1-14

Oil Level Cold Check.................................................1-14

Oil Level Hot Check...................................................1-14

Changing Oil and Oil Filter...............................................1-15

1.15 BRAKE PADS AND DISCS

Inspection.........................................................................1-33

Brake Pads................................................................1-33

Brake Disc Thickness................................................1-33

Brake Disc Lateral Runout........................................1-33

Brake Pad Replacement...................................................1-33

Rear Brake Caliper....................................................1-33

Front Brake Calipers..................................................1-35

1.16 BLEEDING BRAKES

General.............................................................................1-37

Procedure.........................................................................1-37

1.17 BATTERY MAINTENANCE

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

Cleaning and Inspection...................................................1-40

Battery..............................................................................1-40

Disconnection and Removal......................................1-40

Installation and Connection.......................................1-40

Voltmeter Test...................................................................1-41

III

TABLE OF CONTENTS

Voltmeter Test............................................................1-41

Charging Battery..............................................................1-41

Safety Precautions....................................................1-41

Using a Battery Charger............................................1-41

Storage.............................................................................1-42

1.18 SUSPENSION ADJUSTMENTS

General.............................................................................1-44

1.19 FRONT FORK OIL

Replacing Fork Oil............................................................1-46

1.20 SPARK PLUGS

Inspection.........................................................................1-47

Spark Plug Cable Inspection............................................1-47

1.21 STEERING HEAD BEARINGS

Lubrication........................................................................1-49

Checking...........................................................................1-49

Adjustment.......................................................................1-49

1.22 CABLE AND CHASSIS LUBRICATION

General.............................................................................1-51

Steering Head Bearings...................................................1-51

Jiffy Stand.........................................................................1-51

1.23 HEADLAMP ALIGNMENT

Headlamp Alignment........................................................1-52

Main Headlamp Adjustment.............................................1-52

Adjust FLHR/FLHT Headlamp...................................1-52

Adjust FLTR Headlamps............................................1-53

Auxiliary Lamp Alignment.................................................1-54

1.24 ENGINE MOUNTS

Inspection.........................................................................1-55

General......................................................................1-55

Top Link.....................................................................1-55

Front Engine Mount...................................................1-55

Rear Frame Fasteners..............................................1-55

1.25 STORAGE

General.............................................................................1-56

Placing in Storage............................................................1-56

Removal from Storage......................................................1-56

1.26 TROUBLESHOOTING

General.............................................................................1-58

Engine..............................................................................1-58

Starter Motor Does Not Operate or Does Not Turn Engine

Over ..........................................................................1-58

Engine Turns Over But Does Not Start .....................1-58

Starts Hard................................................................1-58

Starts But Runs Irregularly or Misses .......................1-58

A Spark Plug Fouls Repeatedly................................1-59

Pre-Ignition or Detonation (Knocks or Pings)............1-59

Overheating...............................................................1-59

Valve Train Noise.......................................................1-59

Excessive Vibration...................................................1-59

Check Engine Light Illuminates During Operation.....1-59

Lubrication System...........................................................1-59

Oil Does Not Return To Oil Reservoir........................1-59

Engine Uses Too Much Oil Or Smokes Excessively...1-59
Engine Leaks Oil From Cases, Push Rods, Hoses,

Etc.............................................................................1-59

Low Oil Pressure.......................................................1-60

High Oil Pressure......................................................1-60

Electrical System..............................................................1-60

Alternator Does Not Charge......................................1-60

Alternator Charge Rate Is Below Normal..................1-60

Speedometer Operates Erratically............................1-60

Transmission.....................................................................1-60

Shifts Hard................................................................1-60

Jumps Out Of Gear...................................................1-60

Clutch Slips...............................................................1-60

Clutch Drags Or Does Not Release..........................1-60

Clutch Chatters..........................................................1-60

Handling...........................................................................1-60

Irregularities..............................................................1-60

Brakes..............................................................................1-61

Brake Does Not Hold Normally.................................1-61

1.27 CRITICAL FASTENERS

Inspection.........................................................................1-62

Checking Torques on Fasteners................................1-62

CHASSIS

2.1 FASTENER TORQUE VALUES

Fastener Torque Values in this Chapter..............................2-1

2.2 SPECIFICATIONS

Specifications.....................................................................2-7

Chassis Specifications................................................2-7

Tire Specifications.......................................................2-8

2.3 VEHICLE IDENTIFICATION NUMBER
(V.I.N.)

Vehicle Identification Number: Touring Models.................2-10

2.4 FRONT WHEEL

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

Cleaning and Inspection...................................................2-12

Installation........................................................................2-12

2.5 REAR WHEEL

Removal...........................................................................2-14

Cleaning and Inspection...................................................2-15

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

2.6 REAR WHEEL COMPENSATOR

Isolator Replacement.......................................................2-18

Removal....................................................................2-18

Installation.................................................................2-18

Sprocket Bearing Replacement........................................2-18

Removal....................................................................2-18

Installation.................................................................2-18

2.7 CHECKING RIM RUNOUT

Inspection.........................................................................2-21

IV TABLE OF CONTENTS

TABLE OF CONTENTS

2.8 WHEEL LACING: 16 INCH FRONT RIM

General.............................................................................2-22

Procedure.........................................................................2-22

Spoke Tightness...............................................................2-24

2.9 WHEEL LACING: 16 INCH REAR RIM

Procedure.........................................................................2-25

2.10 WHEEL LACING: 17 INCH RIM

General.............................................................................2-28

Procedure.........................................................................2-28

2.11 SEALED WHEEL BEARINGS

Inspection.........................................................................2-31

Removal...........................................................................2-31

Installation........................................................................2-33

2.12 TRUING LACED WHEELS

General.............................................................................2-35

Lateral Truing....................................................................2-35

Radial Truing.....................................................................2-36

2.13 CHECKING CAST WHEEL RUNOUT

General.............................................................................2-38

Lateral Runout..................................................................2-38

Radial Runout...................................................................2-38

2.14 FRONT BRAKE MASTER CYLINDER

General.............................................................................2-39

Removal and Disassembly...............................................2-39

Removal....................................................................2-39

Disassembly..............................................................2-39

Cleaning and Inspection...................................................2-41

Assembly and Installation.................................................2-41

Assembly...................................................................2-41

Installation.................................................................2-41

Front Brake Line - Non-ABS Equipped.............................2-41

Removal....................................................................2-41

Installation.................................................................2-42

2.18 TIRES

General.............................................................................2-52

Removal...........................................................................2-52

Cleaning, Inspection and Repair......................................2-53

Installation........................................................................2-53

Tube Type Tires.........................................................2-53

Tubeless Tires...........................................................2-54

2.19 FRONT FORK

Changing Fork Oil.............................................................2-55

Draining.....................................................................2-55

Filling.........................................................................2-55

Removal...........................................................................2-56

Disassembly.....................................................................2-56

Cleaning and Inspection...................................................2-58

Assembly..........................................................................2-59

Installation........................................................................2-60

2.20 AIR BAFFLE: FLTR

Air Baffle (FLTR)...............................................................2-61

Removal....................................................................2-61

Installation.................................................................2-61

2.21 STEERING HEAD BEARINGS

Removal...........................................................................2-62

Inspection.........................................................................2-63

Installation........................................................................2-63

2.22 REAR AIR SUSPENSION

Check for Air Leaks..........................................................2-65

Compression Fitting..................................................2-65

Air Valve Assembly....................................................2-65

Air Tubes....................................................................2-66

2.23 REAR SHOCK ABSORBERS

Removal...........................................................................2-68

Cleaning and Inspection...................................................2-68

Disassembly and Assembly..............................................2-68

Installation........................................................................2-68

2.15 FRONT BRAKE CALIPER

Removal...........................................................................2-44

Installation........................................................................2-44

2.16 REAR BRAKE MASTER CYLINDER

General.............................................................................2-45

Removal and Disassembly...............................................2-45

Removal....................................................................2-45

Disassembly..............................................................2-46

Cleaning and Inspection...................................................2-48

Assembly and Installation.................................................2-48

Assembly...................................................................2-48

Installation.................................................................2-48

Rear Brake Line: Non-ABS Equipped...............................2-48

Removal....................................................................2-48

Installation.................................................................2-50

2.17 REAR BRAKE CALIPER

Removal...........................................................................2-51

Installation........................................................................2-51

2.24 REAR FORK

Removal...........................................................................2-69

Disassembly and Assembly..............................................2-70

Bearing Removal.......................................................2-70

Bearing Installation....................................................2-70

Pivot Shaft Disassembly............................................2-71

Installation........................................................................2-71

2.25 CLUTCH CABLE

Removal...........................................................................2-72

Installation........................................................................2-72

2.26 HANDLEBARS

Adjustment.......................................................................2-75

Removal...........................................................................2-75

Installation........................................................................2-76

Left Hand Grip..................................................................2-76

Removal....................................................................2-76

Installation.................................................................2-77

Rubber Mounts.................................................................2-77

TABLE OF CONTENTS V

TABLE OF CONTENTS

General......................................................................2-77

Removal....................................................................2-77

Installation.................................................................2-77

Installation: General...................................................2-78

2.27 MIRRORS

All Models Except FLHX...................................................2-79

Removal....................................................................2-79

Installation.................................................................2-79

FLHX................................................................................2-79

Removal....................................................................2-79

Installation.................................................................2-79

2.28 SEAT

Seat: FLHT, FLTR, FLHX..................................................2-81

Removal....................................................................2-81

Installation.................................................................2-81

Seat: FLHTC/U.................................................................2-82

Removal....................................................................2-82

Installation.................................................................2-82

Seat: FLHR/C...................................................................2-82

Removal....................................................................2-82

Installation.................................................................2-82

Seat Retention Nut Replacement.....................................2-83

2.29 SADDLEBAGS

Removal...........................................................................2-84

Installation........................................................................2-84

2.30 SADDLEBAG SERVICE

Saddlebag Hardware........................................................2-85

Removal....................................................................2-85

Installation.................................................................2-86

Saddlebag Guard/Support Rail........................................2-86

Removal....................................................................2-86

Installation.................................................................2-86

Removal....................................................................2-92

Installation.................................................................2-93

Tether Brackets.................................................................2-93

Removing Tether Bracket from Tour-Pak...................2-93

Removing Tether Bracket from Tour-Pak Lid.............2-93

Installing Tether Bracket on Tour-Pak Lid..................2-93

Installing Tether Bracket on Tour-Pak........................2-93

2.33 TOUR-PAK LIGHTS

General.............................................................................2-94

Side Marker Lights (FLHTCU)..........................................2-94

Removal....................................................................2-94

Installation.................................................................2-94

Tour-Pak Lights Harness..................................................2-94

Removal....................................................................2-94

Installation.................................................................2-94

Wrap-Around Lights (FLHTCU)........................................2-95

Bulb Replacement.....................................................2-95

Removal....................................................................2-95

Installation.................................................................2-96

2.34 TOUR-PAK BACKREST

Passenger Backrest..........................................................2-97

Removal....................................................................2-97

Installation.................................................................2-97

Rubber Isolators...............................................................2-97

Removal....................................................................2-97

Installation.................................................................2-97

Passenger Backrest Flap (FLHTCU)................................2-98

Removal....................................................................2-98

Installation.................................................................2-98

2.35 TOUR-PAK SPEAKER BOX: FLHTCU

Speaker Box (FLHTCU)...................................................2-99

Removal....................................................................2-99

Installation.................................................................2-99

2.31 TOUR-PAK

Removal/Installation.........................................................2-88

Removal....................................................................2-88

Installation.................................................................2-88

Adjustment.......................................................................2-89

..................................................................................2-89

Luggage Rack/Tour-Pak Support.....................................2-89

Removal....................................................................2-89

Assembly and Installation..........................................2-89

2.32 TOUR-PAK SERVICE

Lockset.............................................................................2-91

Removal....................................................................2-91

Installation.................................................................2-91

Hinges..............................................................................2-91

Removal....................................................................2-91

Installation.................................................................2-91

Latches/Lockset Catch.....................................................2-92

Removal....................................................................2-92

Installation.................................................................2-92

Catches............................................................................2-92

Removal....................................................................2-92

Installation.................................................................2-92

Tether................................................................................2-92

2.36 LOWER F AIRING AND ENGINE GU ARD

Lower Fairing (FLHTCU)................................................2-100

Removal..................................................................2-100

Disassembly............................................................2-101

Assembly.................................................................2-101

Installation...............................................................2-101

Serrated Washer Replacement......................................2-101

Removal..................................................................2-101

Installation...............................................................2-101

Engine Guard.................................................................2-101

Removal..................................................................2-101

Installation...............................................................2-101

2.37 UPPER FAIRING AND WINDSHIELD:
FLHX, FLHT/C/U

Outer Fairing and Windshield.........................................2-103

Removal..................................................................2-103

Installation...............................................................2-103

2.38 FAIRING CAP: FLHX, FLHT/C/U

Fairing Cap.....................................................................2-104

Removal..................................................................2-104

Installation...............................................................2-104

VI TABLE OF CONTENTS

TABLE OF CONTENTS

2.39 INNER FAIRING: FLHX, FLHT/C/U

Removal.........................................................................2-105

Installation......................................................................2-107

2.40 AIR DEFLECTORS

Air Deflectors (FLHTCU)................................................2-109

Removal..................................................................2-109

Installation...............................................................2-109

Mid-Frame Air Deflectors................................................2-109

Removal..................................................................2-109

Installation...............................................................2-109

2.41 UPPER FAIRING AND WINDSHIELD:
FLTR

Windshield......................................................................2-110

Removal..................................................................2-110

Installation...............................................................2-110

Outer Fairing...................................................................2-110

Removal..................................................................2-110

Installation...............................................................2-111

2.42 INSTRUMENT BEZEL: FLTR

Bezel...............................................................................2-113

Removal..................................................................2-113

Installation...............................................................2-114

2.43 INSTRUMENT NACELLE: FLTR

Instrument Nacelle.........................................................2-115

Removal..................................................................2-115

Installation...............................................................2-116

2.44 INNER FAIRING: FLTR

Removal.........................................................................2-118

Installation......................................................................2-120

Outer Fairing...........................................................2-120

Inner Fairing............................................................2-120

2.45 GLOVE BOX DOOR AND HINGE: FLTR

Glove Box Door and Hinge.............................................2-122

Removal..................................................................2-122

Installation...............................................................2-122

2.46 WINDSHIELD: FLHR/C

Windshield......................................................................2-123

Removal..................................................................2-123

Installation...............................................................2-123

Windshield Window........................................................2-123

Removal..................................................................2-123

Installation...............................................................2-124

2.47 HEADLAMP NACELLE: FLHR/C

Removal.........................................................................2-126

Installation......................................................................2-127

Installation......................................................................2-129

Rear Fender Lights Conduit...........................................2-130

Removal..................................................................2-130

Installation...............................................................2-130

2.50 REAR FASCIA: FLHX

Removal.........................................................................2-131

Installation......................................................................2-131

Stud Plate.......................................................................2-131

Removal..................................................................2-131

Installation...............................................................2-131

Rear Fascia Lamp..........................................................2-131

Removal..................................................................2-131

Installation...............................................................2-131

2.51 REAR FRAME

Rear Frame....................................................................2-132

Removal..................................................................2-132

Installation...............................................................2-133

Thread Repair.........................................................2-133

2.52 FOOTBOARDS AND FOOTRESTS

Rider Footboards............................................................2-134

Removal..................................................................2-134

Installation...............................................................2-134

Disassembly............................................................2-134

Assembly.................................................................2-134

Passenger Footboard.....................................................2-135

Removal..................................................................2-135

Installation...............................................................2-135

Disassembly............................................................2-135

Assembly.................................................................2-135

Passenger Footrest: FLHX.............................................2-135

Removal..................................................................2-135

Installation...............................................................2-135

Disassembly............................................................2-135

Assembly.................................................................2-136

2.53 JIFFY STAND

General...........................................................................2-137

Removal.........................................................................2-137

Installation......................................................................2-137

Jiffy Stand Bracket..........................................................2-138

Removal..................................................................2-138

Installation...............................................................2-138

Jiffy Stand Interlock Sensor............................................2-138

Removal..................................................................2-138

Installation...............................................................2-138

2.54 FRONT ENGINE MOUNT

Removal.........................................................................2-139

Installation......................................................................2-139

ENGINE

2.48 FRONT FENDER

Removal.........................................................................2-128

Installation......................................................................2-128

2.49 REAR FENDER

Removal.........................................................................2-129

3.1 FASTENER TORQUE VALUES

Fastener Torque Values in this Chapter..............................3-1

3.2 SPECIFICATIONS

Specifications.....................................................................3-3

TABLE OF CONTENTS VII

TABLE OF CONTENTS

3.3 SERVICE WEAR LIMITS

General...............................................................................3-5

3.4 ENGINE OIL FLOW

Oil Feed..............................................................................3-7

Top End..............................................................................3-7

Bottom End.........................................................................3-9

Oil Return.........................................................................3-11

3.5 OIL PUMP OPERATION

General.............................................................................3-13

Operation..........................................................................3-13

3.6 BREATHER OPERATION

General.............................................................................3-15

3.7 OIL PRESSURE

Oil Pressure Indicator Lamp.............................................3-16

Checking Oil Pressure......................................................3-16

3.8 TROUBLESHOOTING

Diagnosing Valve Train Noise...........................................3-17

Compression Test.............................................................3-17

Cylinder Leakdown Test....................................................3-17

Diagnosing Smoking Engine or High Oil Consumption.....3-18

Check Prior To Cylinder Head Removal....................3-18

Check After Cylinder Head Removal.........................3-18

3.9 HOW TO USE THIS SECTION

General.............................................................................3-19

Top End Overhaul.............................................................3-19

Bottom End Overhaul.......................................................3-19

Subassembly Service and Repair....................................3-20

3.10 TOP END SERVICE

Engine in Chassis.............................................................3-21

Engine Removed from Chassis........................................3-22

3.11 BOTTOM END SERVICE

Engine in Chassis.............................................................3-23

Engine Removed From Chassis.......................................3-24

3.12 STRIPPING MOTORCYCLE FOR
SERVICE

Procedure.........................................................................3-25

Cam Compartment Service Only..............................3-25

Top End Service........................................................3-25

3.13 ASSEMBLING MOTORCYCLE AFTER
SERVICE

Procedure.........................................................................3-26

After Top End Service................................................3-26

After Cam Compartment Service..............................3-26

3.14 REMOVING ENGINE FROM CHASSIS

Procedure.........................................................................3-27

3.15 INSTALLING ENGINE IN CHASSIS

Procedure.........................................................................3-28

3.16 TOP END OVERHAUL: DISASSEMBLY

General.............................................................................3-29

Rocker Covers..................................................................3-29

Rocker Arm Support Plate................................................3-29

Push Rods, Lifters and Covers.........................................3-31

Cylinder Head...................................................................3-32

Cylinder............................................................................3-33

Piston...............................................................................3-33

3.17 TOP END OVERHAUL: ASSEMBLY

General.............................................................................3-35

Piston...............................................................................3-35

Cylinder............................................................................3-36

Cylinder Head...................................................................3-38

Push Rods, Lifters and Covers.........................................3-42

Rocker Arm Support Plate................................................3-43

Breather Assembly...........................................................3-44

3.18 BOTTOM END OVERHAUL:
DISASSEMBLY

General.............................................................................3-46

Cam Support Plate and Cover..........................................3-46

Prepare Engine.........................................................3-46

Cam Chain and Sprockets........................................3-46

Cam Support Plate....................................................3-47

Crankcase........................................................................3-48

3.19 BOTT OM END OVERHA UL: ASSEMBL Y

General.............................................................................3-50

Crankcase........................................................................3-50

Cam Support Plate and Cover..........................................3-52

3.20 BREATHER ASSEMBLY

Removal Overview............................................................3-57

Disassembly.....................................................................3-57

Cleaning and Inspection...................................................3-57

Assembly..........................................................................3-57

Installation Overview........................................................3-57

3.21 ROCKER ARM SUPPORT PLATE

Removal Overview............................................................3-58

Disassembly.....................................................................3-58

Cleaning and Inspection...................................................3-58

Inspection..................................................................3-58

Rocker Shaft Fit.........................................................3-58

Rocker Arm Shaft to Bushing....................................3-59

Replace Rocker Arm Bushings.................................3-59

Assembly..........................................................................3-60

Installation Overview........................................................3-60

3.22 PUSH RODS, LIFTERS AND COVERS

Removal Overview............................................................3-61

Disassembly.....................................................................3-61

Cleaning and Inspection...................................................3-61

Lifter Inspection................................................................3-62

Assembly..........................................................................3-62

Installation Overview........................................................3-63

3.23 CYLINDER HEAD

Removal Overview............................................................3-64

VIII TABLE OF CONTENTS

TABLE OF CONTENTS

Disassembly.....................................................................3-64

Cleaning...........................................................................3-65

Inspection.........................................................................3-66

Cylinder Head............................................................3-66

Valve Guides.............................................................3-66

Valves........................................................................3-66

Valve Springs............................................................3-66

Tapered Keepers.......................................................3-67

Valve Seats...............................................................3-67

Valve Guide Replacement................................................3-67

Removal....................................................................3-67

Installation.................................................................3-68

Valve and Seat Refacing..................................................3-71

Assembly..........................................................................3-73

Installation Overview........................................................3-74

3.24 CYLINDER

Removal Overview............................................................3-75

Cleaning...........................................................................3-75

Inspection.........................................................................3-76

Deglazing Cylinder...........................................................3-77

Boring and Honing Cylinder.............................................3-78

Installation Overview........................................................3-78

3.25 PISTON

Removal Overview............................................................3-79

Disassembly.....................................................................3-79

Piston Rings..............................................................3-79

Cleaning...........................................................................3-79

Inspection.........................................................................3-80

Assembly..........................................................................3-81

Checking Piston Ring Gap........................................3-81

Installing Piston Rings...............................................3-82

Installation Overview........................................................3-83

Piston Jets Removal..................................................3-92

Piston Jets Installation...............................................3-92

Left Crankcase Half..........................................................3-92

Main Bearing Removal..............................................3-92

Main Bearing Installation...........................................3-94

Sprocket Shaft Bearing Inner Race..................................3-95

Removal....................................................................3-95

Installation.................................................................3-96

Cylinder Studs..................................................................3-97

Removal....................................................................3-97

Installation.................................................................3-97

Pipe Plug and Oil Fittings.................................................3-98

Removal....................................................................3-98

Installation.................................................................3-98

Cleaning and Inspection...................................................3-98

Installation Overview........................................................3-98

3.29 FLYWHEEL AND CONNECTING RODS

Removal Overview............................................................3-99

Inspection.........................................................................3-99

Installation Overview........................................................3-99

3.30 OIL PAN

Removal.........................................................................3-100

Installation......................................................................3-100

FUEL SYSTEM

4.1 FASTENER TORQUE VALUES

Fastener Torque Values in this Chapter..............................4-1

4.2 SPECIFICATIONS: FUEL SYSTEM

Specifications.....................................................................4-3

3.26 CAM SUPPORT PLATE AND COVER

Removal Overview............................................................3-84

Camshafts........................................................................3-84

Removal....................................................................3-84

Assembly...................................................................3-84

Oil Pressure Relief Valve..................................................3-86

Removal....................................................................3-86

Installation.................................................................3-86

Inspection..................................................................3-86

Cam Needle Bearings......................................................3-86

Removal....................................................................3-86

Installation.................................................................3-88

Cleaning and Inspection...................................................3-89

Oil Pressure Valve.....................................................3-89

Cam Support Plate....................................................3-89

Installation Overview........................................................3-89

3.27 OIL PUMP

Removal Overview............................................................3-90

Cleaning and Inspection...................................................3-90

Installation Overview........................................................3-90

3.28 CRANKCASE

Removal Overview............................................................3-91

Right Crankcase Half........................................................3-91

Main Bearing Removal..............................................3-91

Main Bearing Installation...........................................3-91

4.3 ELECTRONIC FUEL INJECTION (EFI)

Troubleshooting..................................................................4-4

4.4 AIR CLEANER ASSEMBLY

Removal.............................................................................4-5

Installation..........................................................................4-5

4.5 FUEL TANK

Removal.............................................................................4-7

Purge and Disconnect Fuel Line.................................4-7

Remove Tank...............................................................4-7

Installation..........................................................................4-8

Evaporative Emissions Tube: Non-CA Models....................4-8

Removal......................................................................4-8

Installation...................................................................4-8

Fuel Supply Check Valve/Tube...........................................4-9

Removal......................................................................4-9

Installation...................................................................4-9

4.6 FUEL TANK TOP PLATE

Removal...........................................................................4-10

Installation........................................................................4-11

4.7 FUEL FILTER

Removal...........................................................................4-13

Installation........................................................................4-13

TABLE OF CONTENTS IX

TABLE OF CONTENTS

4.8 FUEL PRESSURE REGULATOR

Removal...........................................................................4-14

Installation........................................................................4-14

4.9 FUEL LEVEL SENDER

Removal...........................................................................4-15

Installation........................................................................4-15

4.10 TWIST GRIP SENSOR

Removal...........................................................................4-16

Installation........................................................................4-17

Twist Grip Sensor Jumper Harness..................................4-18

Removal....................................................................4-18

Installation.................................................................4-18

4.11 THROTTLE CONTROL ACTUATOR
(TCA)

General.............................................................................4-20

4.12 ENGINE TEMPERATURE SENSOR (ET)

Removal...........................................................................4-21

Installation........................................................................4-21

4.13 INDUCTION MODULE

Removal...........................................................................4-22

Installation........................................................................4-23

4.14 TEMPERA TURE MANIFOLD ABSOLUTE
PRESSURE SENSOR (TMAP)

General.............................................................................4-25

Removal...........................................................................4-25

Installation........................................................................4-25

4.15 OXYGEN SENSORS (O2)

General.............................................................................4-26

Removal...........................................................................4-26

Installation........................................................................4-26

4.16 FUEL INJECTORS

General.............................................................................4-27

Removal...........................................................................4-27

Installation........................................................................4-27

4.17 FUEL PUMP

General.............................................................................4-29

Removal...........................................................................4-29

Installation........................................................................4-29

Fuel Pump and Fuel Level Sender Wire Har ness............4-30

Removal....................................................................4-30

Installation.................................................................4-30

4.18 FUEL PRESSURE TEST

General.............................................................................4-31

Testing..............................................................................4-31

4.19 EXHAUST SYSTEM

Mufflers.............................................................................4-33

Removal....................................................................4-33

Installation.................................................................4-33

System Removal..............................................................4-33

System Installation...........................................................4-34

4.20 ACTIVE EXHAUST (HDI)

Exhaust Valve Actuator.....................................................4-36

Removal....................................................................4-36

Installation.................................................................4-36

Exhaust Valve Actuator Cable..........................................4-36

Removal....................................................................4-36

Installation.................................................................4-36

Active Exhaust Valve........................................................4-36

General......................................................................4-36

4.21 INTAKE LEAK TEST

General.............................................................................4-37

Leak Tester.......................................................................4-37

Parts List...................................................................4-37

Tester Assembly........................................................4-37

Tester Adjustment......................................................4-37

Procedure.........................................................................4-37

4.22 EVAPORATIVE EMISSIONS CONTROL
(CA MODELS)

General.............................................................................4-39

Vapor Valve.......................................................................4-40

Fuel Vapor Vent Tube........................................................4-40

Removal....................................................................4-40

Installation.................................................................4-40

Canister-to-Solenoid Tube................................................4-40

Removal....................................................................4-40

Installation.................................................................4-40

Solenoid-to-Induction Module Tube..................................4-40

Removal....................................................................4-40

Installation.................................................................4-40

Purge Solenoid.................................................................4-41

Removal....................................................................4-41

Installation.................................................................4-41

Charcoal Canister.............................................................4-41

Removal....................................................................4-41

Installation.................................................................4-41

DRIVE

5.1 FASTENER TORQUE VALUES

Fastener Torque Values in this Chapter..............................5-1

5.2 SPECIFICATIONS: DRIVE

Specifications.....................................................................5-2

5.3 PRIMARY CHAINCASE COVER

General...............................................................................5-3

Removal.............................................................................5-3

Installation..........................................................................5-3

5.4 DRIVE COMPONENTS

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

Installation..........................................................................5-6

5.5 PRIMARY CHAINCASE HOUSING

Removal...........................................................................5-10

X TABLE OF CONTENTS

TABLE OF CONTENTS

Inspection.........................................................................5-10

Mainshaft Bearing and Lip Seal.......................................5-10

Removal....................................................................5-10

Installation.................................................................5-10

Mainshaft Bearing Inner Race..........................................5-11

Removal....................................................................5-11

Installation.................................................................5-12

Shifter Shaft Bushings......................................................5-12

Installation........................................................................5-13

5.6 CLUTCH

Removal and Installation..................................................5-15

Clutch Pack Only..............................................................5-15

Partial Disassembly...................................................5-15

Cleaning And Inspection...........................................5-15

Assembly...................................................................5-17

Clutch Pack and Bearing..................................................5-17

Complete Disassembly..............................................5-17

Assembly...................................................................5-18

5.7 TRANSMISSION SPROCKET

Removal...........................................................................5-20

Cleaning and Inspection...................................................5-20

Installation........................................................................5-20

5.8 DRIVE BELT

Removal and Adjustment.................................................5-22

Adjustment................................................................5-22

Removal....................................................................5-22

Installation........................................................................5-22

TRANSMISSION

Disassembly.......................................................................6-9

Shifter Cam/Shifter Forks............................................6-9

Mainshaft...................................................................6-11

Countershaft..............................................................6-13

Replacing Side Door Bearings..................................6-14

Cleaning and Inspection...................................................6-15

Assembly..........................................................................6-15

Installing Side Door Bearings....................................6-15

Countershaft..............................................................6-15

Mainshaft...................................................................6-16

Shifter Cam/Shifter Forks..........................................6-16

Installation........................................................................6-19

6.7 MAIN DRIVE GEAR AND BEARING

Removal...........................................................................6-21

Cleaning and Inspection...................................................6-22

Needle Bearing Replacement...................................6-23

Mainshaft Seal Replacement............................................6-24

Installation........................................................................6-25

Installing Main Drive Gear Bearing...........................6-25

Installing Main Drive Gear.........................................6-25

Installing Main Drive Gear Large Seal.......................6-26

6.8 TRANSMISSION CASE

Removal...........................................................................6-28

Installation........................................................................6-28

Disassembly.....................................................................6-29

Shifter Arm Assembly................................................6-29

Cleaning and Inspection...................................................6-29

Assembly..........................................................................6-30

Countershaft Needle Bearing Replacement..............6-30

Shifter Pawl Lever Assembly.....................................6-30

6.1 FASTENER TORQUE VALUES

Fastener Torque Values in this Chapter..............................6-1

6.2 SPECIFICATIONS:TRANSMISSION

Specifications.....................................................................6-2

Service Wear Limits............................................................6-2

6.3 TRANSMISSION

Power Flow.........................................................................6-3

Neutral.........................................................................6-3

1st Gear......................................................................6-3

2nd Gear.....................................................................6-3

3rd Gear......................................................................6-3

4th Gear......................................................................6-3

5th Gear......................................................................6-3

6th Gear......................................................................6-3

6.4 SHIFTER LINKAGE

Shifter Rod.........................................................................6-5

6.5 CLUTCH RELEASE COVER

Removal and Disassembly.................................................6-6

Cleaning and Inspection.....................................................6-7

Assembly and Installation...................................................6-7

6.6 TRANSMISSION ASSEMBLY

Removal.............................................................................6-8

ELECTRICAL

7.1 FASTENER TORQUE VALUES

Fastener Torque Values in this Chapter..............................7-1

7.2 SPECIFICATIONS: ELECTRICAL

Specifications.....................................................................7-4

7.3 VOLTAGE REGULATOR

Removal.............................................................................7-5

Installation..........................................................................7-5

7.4 ELECTRONIC CONTROL MODULE (ECM)

ECM...................................................................................7-6

Removal......................................................................7-6

Installation...................................................................7-6

7.5 IGNITION COIL

Removal.............................................................................7-7

Installation..........................................................................7-7

7.6 SYSTEM FUSES AND RELAYS

Main Fuse...........................................................................7-8

Removal......................................................................7-8

Installation...................................................................7-8

Main Fuse Holder...............................................................7-8

Removal......................................................................7-8

TABLE OF CONTENTS XI

TABLE OF CONTENTS

Installation...................................................................7-8

System Fuses and Relays..................................................7-8

Removal......................................................................7-8

Installation...................................................................7-8

Fuse Blocks........................................................................7-9

Removal......................................................................7-9

Installation...................................................................7-9

7.7 ELECTRICAL CADDIES

Top Caddy........................................................................7-10

Removal....................................................................7-10

Installation.................................................................7-10

Left Side Caddy................................................................7-10

Removal....................................................................7-10

Installation.................................................................7-11

Battery Tray.......................................................................7-12

Removal....................................................................7-12

Installation.................................................................7-13

7.8 SECURITY SIREN

Removal...........................................................................7-14

Installation........................................................................7-14

7.9 STARTER

General.............................................................................7-15

Wiring Diagrams........................................................7-15

Paint Touch-Up..........................................................7-15

Removal...........................................................................7-15

Field Coil Assembly..........................................................7-15

Disassembly..............................................................7-15

Inspection..................................................................7-15

Assembly...................................................................7-16

Drive Assembly.................................................................7-17

Disassembly..............................................................7-17

Inspection..................................................................7-17

Assembly...................................................................7-17

Installation........................................................................7-18

7.10 STARTER SOLENOID

Solenoid Assembly...........................................................7-19

Disassembly..............................................................7-19

Assembly...................................................................7-19

Solenoid Plunger..............................................................7-19

Disassembly..............................................................7-19

Assembly...................................................................7-19

Solenoid Contacts............................................................7-19

Disassembly..............................................................7-19

Assembly...................................................................7-20

7.11 HEADLAMP: ALL EXCEPT FLTR

Headlamp Assembly.........................................................7-22

Removal....................................................................7-22

Installation.................................................................7-22

Headlamp Bulb Replacement...........................................7-22

7.12 HEADLAMP: FLTR

Headlamp Assembly.........................................................7-24

Removal....................................................................7-24

Installation.................................................................7-24

Headlamp Bulb Replacement...........................................7-24

Removal....................................................................7-24

Installation.................................................................7-24

7.13 AUXILIARY LAMPS AND BRACKETS

Auxiliary Lamp Bulb..........................................................7-26

Removal....................................................................7-26

Installation.................................................................7-26

Auxiliary Lamp Housing....................................................7-27

Removal....................................................................7-27

Installation.................................................................7-28

Auxiliary Lamp Bracket.....................................................7-29

Removal....................................................................7-29

Installation.................................................................7-29

Adjustment.......................................................................7-29

7.14 TAIL LAMP

Tail Lamp/Tail Lamp Bulb..................................................7-30

Removal....................................................................7-30

Installation.................................................................7-30

Circuit Board/Chrome Base..............................................7-30

Removal....................................................................7-30

Installation.................................................................7-31

Rear Fender Lights Harness............................................7-32

Removal....................................................................7-32

Installation.................................................................7-32

7.15 FENDER TIP LAMPS

Front Fender Tip Lamp.....................................................7-34

Removal....................................................................7-34

Installation.................................................................7-34

Front Fender Tip Lamp Jumper Harness..........................7-34

Removal....................................................................7-34

Installation.................................................................7-35

Rear Fender Tip Lamp......................................................7-36

Removal....................................................................7-36

Installation.................................................................7-37

7.16 TURN SIGNAL LAMPS

Bulb Replacement............................................................7-38

Removal....................................................................7-38

Installation.................................................................7-38

Front Turn Signal Lamp....................................................7-38

Removal: FLHR/C, FLHT/C/U...................................7-38

Installation: FLHR/C, FLHT/C/U................................7-39

Removal: FLXH.........................................................7-40

Installation: FLHX......................................................7-40

Removal: FLTR..........................................................7-41

Installation: FLTR.......................................................7-41

Rear Turn Signal Lamp.....................................................7-42

Removal: FLHR/C, FLHT/C/U...................................7-42

Installation: FLHR/C, FLHT/C/U................................7-42

Removal: FLHX, FLTR...............................................7-43

Installation: FLHX, FLTR...........................................7-43

Rear Turn Signal Lamps Bracket......................................7-43

Removal: FLHR/C, FLHT/C/U...................................7-43

Installation: FLHR/C, FLHT/C/U................................7-44

Removal: FLHX, FLTR...............................................7-44

Installation: FLHX, FLTR...........................................7-44

7.17 TSM/HFSM

Removal...........................................................................7-45

Installation........................................................................7-45

HFSM Antenna.................................................................7-45

XII TABLE OF CONTENTS

TABLE OF CONTENTS

Removal....................................................................7-45

Installation.................................................................7-45

7.18 IGNITION/LIGHT KEY SWITCH AND
FORK LOCK

FLHX, FLHT/C/U, FLTR....................................................7-46

Removal....................................................................7-46

Installation.................................................................7-48

FLHR/C............................................................................7-49

Ignition/Light Key Switch: Removal...........................7-49

Ignition/Light Key Switch: Installation........................7-49

Fork Lock: Removal...................................................7-49

Fork Lock: Installation................................................7-49

7.19 FAIRING CAP SWITCHES: FLHTC/U

Removal...........................................................................7-51

Installation........................................................................7-51

7.20 INSTRUMENT NACELLE SWITCHES:
FLTR

Removal...........................................................................7-53

Left Side Switch........................................................7-53

Right Side Switches..................................................7-54

Installation........................................................................7-54

Left Side Switch........................................................7-54

Right Side Switches..................................................7-54

7.21 CRANKSHAFT POSITION SENSOR
(CKP)

General.............................................................................7-57

Removal...........................................................................7-57

Installation........................................................................7-57

7.22 ALTERNATOR

Removal...........................................................................7-58

Cleaning and Inspection...................................................7-58

Installation........................................................................7-59

7.23 VEHICLE SPEED SENSOR (VSS)

VSS..................................................................................7-60

Removal....................................................................7-60

Installation.................................................................7-60

7.24 NEUTRAL SWITCH

Removal...........................................................................7-61

Installation........................................................................7-61

7.25 OIL PRESSURE SWITCH AND SENDER

Removal...........................................................................7-62

Installation........................................................................7-62

7.26 STOPLIGHT SWITCHES

Front Stoplight Switch.......................................................7-63

Removal/Installation..................................................7-63

Rear Stoplight Switch.......................................................7-63

Removal....................................................................7-63

Installation.................................................................7-63

7.27 HORN

Inspection.........................................................................7-64

Removal...........................................................................7-64

Installation........................................................................7-64

7.28 CIGARETTE LIGHTER: FLHX,
FLHT/C/U, FLTR

Troubleshooting................................................................7-65

Removal...........................................................................7-65

Installation........................................................................7-65

7.29 GAUGES AND INSTRUMENTS: FLHX,
FLHT/C/U, FLTR

2 Inch Diameter Gauges: Fuel Le vel, Ambient Air Temperature,

Voltmeter, Oil Pressure.....................................................7-66

Removal....................................................................7-66

Installation.................................................................7-66

Tachometer.......................................................................7-66

Removal....................................................................7-66

Installation.................................................................7-66

Speedometer....................................................................7-67

Removal....................................................................7-67

Installation.................................................................7-67

7.30 INDICATOR LAMPS: FLHX, FLHT/C/U,
FLTR

Indicator Lamps................................................................7-68

Removal....................................................................7-68

Installation.................................................................7-68

7.31 GAUGES AND INSTR UMENTS: FLHR/C

Fuel Gauge.......................................................................7-69

Removal....................................................................7-69

Installation.................................................................7-69

Speedometer....................................................................7-69

Removal....................................................................7-69

Installation.................................................................7-70

7.32 INDICATOR LAMPS: FLHR/C

Indicator Lamps................................................................7-71

Removal....................................................................7-71

Installation.................................................................7-71

7.33 ADVANCED AUDIO SYSTEM

Radio (Storage Box).........................................................7-72

Removal....................................................................7-72

Installation.................................................................7-73

Front Fair ing Speakers.....................................................7-73

Removal....................................................................7-73

Installation.................................................................7-73

Front Headset Receptacle................................................7-73

Removal....................................................................7-73

Installation.................................................................7-73

Rear Headset Receptacle................................................7-74

Rear Passenger Switches................................................7-74

Removal....................................................................7-74

Installation.................................................................7-74

Rear Speakers..................................................................7-76

Removal....................................................................7-76

Installation.................................................................7-76

CB Module........................................................................7-76

Removal....................................................................7-76

TABLE OF CONTENTS XIII

TABLE OF CONTENTS

Installation.................................................................7-76

7.34 WIRE TROUGH

Removal...........................................................................7-77

Installation........................................................................7-78

7.35 MAIN WIRING HARNESS

Removal: All Models (Part 1)............................................7-79

Removal: FLHR/C (Part 2)................................................7-79

Removal: FLHX, FLHT/C/U (Part 2).................................7-80

Removal: FLTR (Part 2)....................................................7-82

Removal: All Models (Part 3)............................................7-82

Installation: All Models (Part 1).........................................7-84

Installation: FLHR/C (Par t 2)............................................7-87

Installation: FLHX, FLHT/C/U (Par t 2)..............................7-88

Installation: FLTR (Part 2).................................................7-88

Installation: All Models (Part 3).........................................7-88

7.36 INTERCONNECT HARNESS

FLHX, FLHT/C/U..............................................................7-89

Removal....................................................................7-89

Installation.................................................................7-92

FLTR.................................................................................7-94

Removal....................................................................7-94

Installation.................................................................7-96

7.37 RADIO ANTENNA CABLE

FLHTC/U..........................................................................7-98

Removal....................................................................7-98

Installation.................................................................7-98

FLHX, FLTR......................................................................7-99

Removal....................................................................7-99

Installation...............................................................7-100

7.38 AUDIO HARNESS: FLHTCU

Removal.........................................................................7-101

Installation......................................................................7-101

7.39 CB ANTENNA CABLE: FLHTCU

Removal.........................................................................7-103

Installation......................................................................7-103

7.40 HANDLEBAR SWITCH ASSEMBLIES

Removal.........................................................................7-105

Right Handlebar Controls........................................7-105

Left Handlebar Controls..........................................7-105

Disassembly...................................................................7-105

Right Side Handlebar Switches...............................7-105

Left Side Handlebar Switches.................................7-106

Specific Repair Procedures: Upper Switch Housings.....7-106

Right Side Handlebar (All Models)..........................7-106

Left Side Handlebar (All Models).............................7-107

Specific Repair Procedures: Right Side Lower Switch

Housings........................................................................7-108

Preliminary Instructions...........................................7-108

Turn-Right Signal Switch (All Models).....................7-108

Front Stoplight Switch (All Models).........................7-108

Mode Select Switch (Classic and Ultra Models)......7-108

Cruise Set/Resume Switch (Road King Classic and Ultra

Models)...................................................................7-109

Final Instructions.....................................................7-110

Specific Repair Procedures: Left Side Lower Switch

Housings........................................................................7-111

Preliminary Instructions...........................................7-111

Turn-Left Signal Switch (All Models).......................7-111

Clutch Interlock Switch............................................7-111

Audio Control Switch (Classic and Ultra Models).....7-113

CB Push-To-Transmit Switch (Ultra Models)...........7-113

Cruise On/Off Switch (Road King Classic Models)..7-113

Final Instructions.....................................................7-114

General Repair Procedures............................................7-114

Assembly: Right Side Handlebar Switches.....................7-115

Assembly: Left Side Handlebar Switches.......................7-116

Installation......................................................................7-116

Right Handlebar Controls........................................7-116

Left Handlebar Controls..........................................7-117

APPENDIX A CONNECTOR REPAIR

A.1 AMP MULTILOCK CONNECTORS

AMP Multilock Connector Repair.......................................A-1

General.......................................................................A-1

Separating Pin and Socket Housings.........................A-1

Mating Pin and Socket Housings................................A-1

Removing Terminals from Housing.............................A-1

Inserting Terminals into Housing.................................A-2

Preparing Wire Leads for Crimping.............................A-2

Crimping Terminals to Leads......................................A-3

Inspecting Crimped Terminals.....................................A-4

A.2 AUTOFUSE ELECTRICAL
CONNECTORS

Autofuse Connector Repair................................................A-5

General.......................................................................A-5

Disassembly................................................................A-5

Assembly....................................................................A-5

A.3 DELPHI CONNECTORS

Delphi Connector Repair....................................................A-6

General.......................................................................A-6

Separating Pin and Socket Housings.........................A-6

Mating Pin and Socket Housings................................A-6

Removing Socket Terminals........................................A-6

Installing Socket Terminals..........................................A-6

A.4 DELPHI MAIN FUSE HOUSING

Delphi Main Fuse Housing Repair.....................................A-8

Removing Socket Terminals........................................A-8

Installing Socket Terminals..........................................A-8

A.5 DEUTSCH ELECTRICAL CONNECTORS

Deutsch Connector Repair.................................................A-9

General.......................................................................A-9

Separating Pin and Socket Housings.........................A-9

Mating Pin and Socket Housings................................A-9

Removing Socket Terminals........................................A-9

Installing Socket Terminals..........................................A-9

Removing Pin Terminals...........................................A-11

Installing Pin Terminals.............................................A-11

Crimping Terminals...................................................A-12

XIV TABLE OF CONTENTS

TABLE OF CONTENTS

A.6 DEUTSCH STANDARD TERMINAL
REPAIR

Deutsch Standard Terminal Crimps.................................A-13

Preparing Wire Leads for Crimping...........................A-13

Crimping Terminal to Lead........................................A-13

Inspecting Crimps.....................................................A-13

A.7 DEUTSCH SOLID BARREL MINI
TERMINAL REPAIR

Deutsch Solid Barrel Terminal Crimps.............................A-14

Preparing Wire Leads For Crimping.........................A-14

Adjusting Crimper Tool..............................................A-14

Crimping a Barrel Contact To Wire Lead...................A-14

Inspecting Crimps.....................................................A-14

A.8 DEUTSCH MINI TERMINAL REPAIR

Deutsch Mini Terminal Crimps.........................................A-16

Preparing Wire Leads for Crimping...........................A-16

Crimping a Mini Terminal to Wire Lead.....................A-16

Inspecting Crimps.....................................................A-16

A.9 MOLEX CONNECTORS

Molex Connector Repair..................................................A-17

Separating Pin and Socket Housings.......................A-17

Mating Pin and Socket Housings..............................A-17

Removing Terminals.................................................A-17

Installing Terminals...................................................A-17

Crimp Terminal to Lead....................................................A-18

Prepare Lead............................................................A-18

Prepare Tool..............................................................A-18

Position Terminal in the Punch/Die...........................A-19

Insert Stripped Lead.................................................A-19

Crimp Terminal to Lead.............................................A-20

Inspect Crimp............................................................A-20

A.13 PACKARD 630 METRI-PACK
CONNECTORS

630 Metri-Pack Connector Repair....................................A-25

General.....................................................................A-25

Separating Pin and Socket Housings.......................A-25

Mating Pin and Socket Housings..............................A-25

Removing Socket Terminal.......................................A-25

Installing Socket Terminal.........................................A-25

A.14 PACKARD METRI-PACK TERMINALS

Metri-Pack Terminal Crimps.............................................A-26

Matching Terminal To Crimper..................................A-26

Preparing Wire Lead.................................................A-26

Crimping Wire Core..................................................A-26

Crimping Insulation/Seal...........................................A-26

Inspecting Crimps.....................................................A-27

A.15 ECM CONNECTOR

Delphi 73-Terminal ECM Connector................................A-28

Separating Socket Housing From ECM....................A-28

Mating Socket Housing To ECM...............................A-28

Socket Terminal.........................................................A-28

ECM Ground Terminal..............................................A-28

A.16 PACKARD MICRO-64 CONNECTORS

Packard Micro-64 Connector Repair................................A-30

General.....................................................................A-30

Separating Pin and Socket Housings.......................A-30

Mating Pin and Socket Housings..............................A-30

Removing Terminal...................................................A-30

Installing Terminal.....................................................A-31

Preparing Wire Leads for Crimping...........................A-31

Crimping Terminals...................................................A-31

Inspecting Crimps.....................................................A-31

A.10 PACKARD 150 METRI-PACK
CONNECTORS

150 Metri-Pack Connector Repair....................................A-21

General.....................................................................A-21

Separating Pin and Socket Housings.......................A-21

Mating Pin and Socket Housings..............................A-21

Removing Socket Terminal.......................................A-21

Inserting Socket Terminal..........................................A-21

A.11 PACKARD 280 METRI-PACK RELAY
AND FUSE BLOCK CONNECTORS

Fuse Block Repair............................................................A-23

Removing Socket Terminals......................................A-23

Installing Socket Terminals........................................A-23

Crimping Terminals...................................................A-23

A.12 PACKARD 480 METRI-PACK
CONNECTORS

480 Metri-Pack Connector Repair....................................A-24

General.....................................................................A-24

Separating Pin and Socket Housings.......................A-24

Mating Pin and Socket Housings..............................A-24

Removing Socket Terminals......................................A-24

Installing Socket Terminals........................................A-24

A.17 SEALED SPLICE CONNECTORS

Sealed Splice Connector Repair......................................A-33

General.....................................................................A-33

Preparing Wire Leads...............................................A-33

Splicing Wire Leads..................................................A-33

Inspecting Seals.......................................................A-33

APPENDIX B WIRING

B.1 CONNECTORS

Connector Locations..........................................................B-1

Function/Location.......................................................B-1

Place and Color..........................................................B-1

Connector Number......................................................B-1

Repair Instructions......................................................B-1

B.2 WIRING DIAGRAMS

Wiring Diagram Information.............................................B-19

Wire Color Codes......................................................B-19

Wiring Diagram Symbols..........................................B-19

2009 Touring Wiring Diagrams.........................................B-20

TABLE OF CONTENTS XV

TABLE OF CONTENTS
APPENDIX C ABS

C.1 ABS MODULE

Removal.............................................................................C-1

Hydraulic Control Unit (HCU)......................................C-1

Electrical Control Unit (ECU)......................................C-1

Installation..........................................................................C-2

ABS Module................................................................C-2

Electrical Control Unit (ECU)......................................C-3

C.2 WHEEL SPEED SENSORS

Front Wheel Speed Sensor................................................C-4

Removal......................................................................C-4

Installation..................................................................C-4

Rear Wheel Speed Sensor................................................C-5

Removal......................................................................C-5

Installation..................................................................C-5

C.3 ABS BRAKE LINES

Front Master Cylinder to ABS Module...............................C-6

Removal......................................................................C-6

Installation..................................................................C-7

ABS Module to Front Brake Calipers.................................C-7

Removal......................................................................C-7

Installation..................................................................C-8

Rear Master Cylinder to ABS Module................................C-9

Removal......................................................................C-9

Installation................................................................C-10

ABS Module to Rear Brake Caliper.................................C-11

Removal....................................................................C-11

Installation................................................................C-11

APPENDIX D CONVERSIONS

D.1 METRIC CONVERSION

Conversion Table................................................................D-1

D.2 FLUID CONVERSIONS

United States System........................................................D-2

Metric System....................................................................D-2

British Imperial System......................................................D-2

D.3 TORQUE CONVERSIONS

United States System........................................................D-3

Metric System....................................................................D-3

APPENDIX E GLOSSARY

E.1 GLOSSARY

Acronyms and Abbreviations..............................................E-1

REFERENCE MATERIAL

TOOLS...........................................................I

TORQUE VALUES......................................VII

INDEX......................................................XXIII

XVI TABLE OF CONTENTS

TABLE OF CONTENTS

SUBJECT............................................................................................................................PAGE NO.

1.1 FASTENER TORQUE VALUES.................................................................................................1-1

1.2 GENERAL.................................................................................................................................1-3

1.3 MAINTENANCE SCHEDULE....................................................................................................1-7

1.4 FUEL AND OIL........................................................................................................................1-10

1.5 BULB REQUIREMENTS.........................................................................................................1-12

1.6 ENGINE OIL AND FILTER......................................................................................................1-14

1.7 PRIMARY CHAIN....................................................................................................................1-17

1.8 TRANSMISSION LUBRICANT................................................................................................1-18

1.9 AIR CLEANER AND EXHAUST SYSTEM..............................................................................1-20

1.10 TIRES AND WHEELS............................................................................................................1-22

1.11 CLUTCH................................................................................................................................1-25

1.12 REAR BELT AND SPROCKETS...........................................................................................1-27

1.13 REAR BELT DEFLECTION...................................................................................................1-29

1.14 BRAKES................................................................................................................................1-32

1.15 BRAKE PADS AND DISCS...................................................................................................1-33

1.16 BLEEDING BRAKES.............................................................................................................1-37

1.17 BATTERY MAINTENANCE...................................................................................................1-39

1.18 SUSPENSION ADJUSTMENTS...........................................................................................1-44

1.19 FRONT FORK OIL................................................................................................................1-46

1.20 SPARK PLUGS......................................................................................................................1-47

1.21 STEERING HEAD BEARINGS..............................................................................................1-49

1.22 CABLE AND CHASSIS LUBRICATION.................................................................................1-51

1.23 HEADLAMP ALIGNMENT.....................................................................................................1-52

1.24 ENGINE MOUNTS................................................................................................................1-55

1.25 STORAGE.............................................................................................................................1-56

1.26 TROUBLESHOOTING...........................................................................................................1-58

1.27 CRITICAL FASTENERS........................................................................................................1-62

MAINTENANCE

NOTES

HOME

FASTENER TORQUE VALUES IN THIS CHAPTER

The table below lists torque values for all fasteners presented
in this chapter.

screws

screws

screws

1.1FASTENER TORQUE VALUES

NOTESTORQUE VALUEFASTENER

1.11 CLUTCH, Adjustment8.1-13.6 Nm72-120 in-lbsAdjuster screw jam nut

1.3 MAINTENANCE SCHEDULE, General4.5-6.8 Nm40-60 in-lbsAir cleaner cover bracket screw

4.5-6.8 Nm40-60 in-lbsAir cleaner cover bracket screws

4.1-6.8 Nm36-60 in-lbsAir cleaner cover screw

20.3-24.4 Nm15-18 ft-lbsAuxiliary lamp flange nut

37.9-51.5 Nm28-38 ft-lbsBrake caliper (front) mounting screws

58.3-65.1 Nm43-48 ft-lbsBrake caliper (rear) to caliper bracket

8.5-11.5 Nm75-102 in-lbsBrake caliper pad pin

8.5-11.5 Nm75-102 in-lbsBrake caliper pad pin

19.0-28.5 Nm14-21 ft-lbsEngine oil drain plug

94.9-108.4 Nm70-80 ft-lbsFork stem nut

94.9-108.4 Nm70-80 ft-lbsFork stem nut

0.8-1.1 Nm7-10 in-lbsFront master cylinder reservoir cover

1.9 AIR CLEANER AND EXHAUST
SYSTEM, Installation/metric

1.3 MAINTENANCE SCHEDULE, General4.1-6.8 Nm36-60 in-lbsAir cleaner cover screw

1.9 AIR CLEANER AND EXHAUST
SYSTEM, Installation/Use Loctite Medium Strength
Threadlocker 243 (Blue)

1.23 HEADLAMP ALIGNMENT, Auxiliary Lamp
Alignment

1.3 MAINTENANCE SCHEDULE, General6.8-7.9 Nm60-70 in-lbsBattery terminal bolt

1.17 BATTERY MAINTENANCE, Battery6.8-7.9 Nm60-70 in-lbsBattery terminal bolt

1.17 BATTERY MAINTENANCE, Battery6.8-7.9 Nm60-70 in-lbsBattery terminal bolt

1.15 BRAKE PADS AND DISCS, Brake Pad
Replacement/metric

1.15 BRAKE PADS AND DISCS, Brake Pad
Replacement/metric

1.16 BLEEDING BRAKES, Procedure9.0-11.3 Nm80-100 in-lbsBrake caliper bleeder valve

1.3 MAINTENANCE SCHEDULE, General8.5.-11.5 Nm75-102 in-lbsBrake caliper pad pin

1.15 BRAKE PADS AND DISCS, Brake Pad
Replacement/Always use new pin

1.15 BRAKE PADS AND DISCS, Brake Pad
Replacement/Always use new pin

1.3 MAINTENANCE SCHEDULE, General8.1-13.6 Nm72-120 in-lbsClutch adjuster screw locknut

1.3 MAINTENANCE SCHEDULE, General9.5-12.2 Nm84-108 in-lbsClutch inspection cover screws

1.7 PRIMARY CHAIN, Chaincase Lubricant9.5-12.2 Nm84-108 in-lbsClutch inspection cover screws

1.11 CLUTCH, Adjustment9.5-12.2 Nm84-108 in-lbsClutch inspection cover screws

1.3 MAINTENANCE SCHEDULE, General19.0-28.5 Nm14-21 ft-lbsEngine oil drain plug

1.6 ENGINE OIL AND FILTER, Changing Oil and
Oil Filter

1.24 ENGINE MOUNTS, Inspection49-54 Nm36-40 ft-lbsEngine to front engine mounting bracket

1.21 STEERING HEAD BEARINGS, Adjustment71.9-77.3 Nm53-57 ft-lbsFork bracket pinch bolt

1.21 STEERING HEAD BEARINGS, Adjust­ment/Anti-seize

1.21 STEERING HEAD BEARINGS, Adjust­ment/Anti-seize

1.24 ENGINE MOUNTS, Inspection56.9-65.0 Nm42-48 ft-lbsFront engine mount end cap fastener

1.14 BRAKES, Fluid Inspection0.8-1.1 Nm7-10 in-lbsFront master cylinder reservoir cover

1.15 BRAKE PADS AND DISCS, Brake Pad
Replacement

2009 Touring Service: Maintenance 1-1

HOME

screws

screws

screws

screws

screws

NOTESTORQUE VALUEFASTENER

1.16 BLEEDING BRAKES, Procedure0.8-1.1 Nm7-10 in-lbsFront master cylinder reservoir cover

1.24 ENGINE MOUNTS, Inspection24.4-29.9 Nm18-22 ft-lbsFront stabilizer link eyelet

1.24 ENGINE MOUNTS, Inspection24.4-29.9 Nm18-22 ft-lbsFront stabilizer link eyelet

1.3 MAINTENANCE SCHEDULE, General4.0-5.1 Nm35-45 in-lbsHandlebar switch housing screw

1.3 MAINTENANCE SCHEDULE, General0.8-1.1 Nm7-10 in-lbsMaster cylinder reservoir cover

1.3 MAINTENANCE SCHEDULE, General1.4-1.7 Nm12-15 in-lbsMaster cylinder reservoir cover

1.3 MAINTENANCE SCHEDULE, General19.0-28.5 Nm14-21 ft-lbsPrimary chaincase drain plug

1.7 PRIMARY CHAIN, Chaincase Lubricant19.0-28.5 Nm14-21 ft-lbsPrimary chaincase drain plug

20-27 Nm15-20 ft-lbsRear axle cone nut

128.8-142.4 Nm95-105 ft-lbsRear axle cone nut

1.4-1.7 Nm12-15 in-lbsRear master cylinder reservoir cover

10.9-16.3 Nm96-144 in-lbsRear muffler fastener

19.0-28.5 Nm14-21 ft-lbsTransmission drain plug

2.8-8.5 Nm25-75 in-lbsTransmission filler/check plug

2.8-8.5 Nm25-75 in-lbsTransmission filler/check plug

4.1-6.8 Nm36-60 in-lbsTurn signal lamp to mounting bracket

1.13 REAR BELT DEFLECTION, Setting Belt
Deflection/For belt adjustment only

1.13 REAR BELT DEFLECTION, Setting Belt
Deflection

1.24 ENGINE MOUNTS, Inspection54.2-67.8 Nm40-50 ft-lbsRear frame-to-main frame fastener

1.14 BRAKES, Fluid Inspection1.4-1.7 Nm12-15 in-lbsRear master cylinder reservoir cover

1.15 BRAKE PADS AND DISCS, Brake Pad
Replacement

1.16 BLEEDING BRAKES, Procedure1.4-1.7 Nm12-15 in-lbsRear master cylinder reservoir cover

1.13 REAR BELT DEFLECTION, Setting Belt
Deflection

1.3 MAINTENANCE SCHEDULE, General16.3-24.4 Nm12-18 ft-lbsSpark plug

1.20 SPARK PLUGS, Inspection16.3-24.4 Nm12-18 ft-lbsSpark plug

1.3 MAINTENANCE SCHEDULE, General6.2 Nm55 in-lbsSpoke nipple

1.10 TIRES AND WHEELS, Wheel Spokes6.2 Nm55 in-lbsSpoke nipple

1.3 MAINTENANCE SCHEDULE, General8.1-10.9 Nm72-96 in-lbsTop caddy mounting screw

1.17 BATTERY MAINTENANCE, Battery8.1-10.9 Nm72-96 in-lbsTop caddy mounting screw

1.3 MAINTENANCE SCHEDULE, General19.0-28.5 Nm14-21 ft-lbsTransmission drain plug

1.8 TRANSMISSION LUBRICANT, Transmission
Lubrication

1.3 MAINTENANCE SCHEDULE, General2.8-8.5 Nm25-75 in-lbsTransmission filler/check plug

1.8 TRANSMISSION LUBRICANT, Transmission
Lubrication

1.8 TRANSMISSION LUBRICANT, Transmission
Lubrication

1.23 HEADLAMP ALIGNMENT, Auxiliary Lamp
Alignment

1-2 2009 Touring Service: Maintenance

HOME

1.2GENERAL

SERVICING A NEW MOTORCYCLE

Perform the service and maintenance operations as
indicated in the regular service interval table. Lack of
regular maintenance at the recommended intervals can
affect the safe operation of your motorc ycle, which could
result in death or serious injury. (00010a)

Service operations to be performed before customer delivery
are specified in the applicable model year predelivery and set­up instructions.

The performance of new motorcycle initial service is required
to keep warranty in force and to verify proper emissions sys­tems operation. See 1.3 MAINTENANCE SCHEDULE.

SAFE OPERATING MAINTENANCE

NOTES

• Do not attempt to retighten engine head bolts. Retightening
can cause engine damage.

• During the initial break-in period, use only Harley-Davidson
20W50 engine oil. F ailure to use the recommended oil will
result in improper break-in of the engine cylinders and
piston rings.

A careful check of certain equipment is necessary after periods
of storage, and frequently between regular service intervals,
to determine if additional maintenance is required.

Check:

1. Tires for abrasions, cuts and correct pressure.

2. Secondary drive belt for proper tension and condition.

3. Brakes, steering and throttle for responsiveness.

4. Brake fluid lev el and condition. Hydraulic lines and fittings
for leaks. Also, check brake pads and rotors for wear.

5. Cables for fraying, crimping and free operation.

6. Engine oil and transmission fluid levels.

7. Headlamp, auxiliary lamp, tail lamp , brake lamp , horn and
turn signal operation.

SHOP PRACTICES
Repair Notes

General maintenance practices are given in this section.

NOTES

• Repair = Disassembly/Assembly.

• Replacement = Substitute a new part for existing com-

ponent.

All special tools and torque values are noted at the point of
use.

All required parts or materials can be found in the appropriate
PARTS CATALOG.

Safety

Safety is always the most important consideration when per­forming any job. Be sure you have a complete understanding
of the task to be performed. Use common sense. Use the
proper tools. Protect yourself and bystanders with approved
eye protection. Don't just do the job - do the job safely.

Removing Parts

Always consider the weight of a part when lifting. Use a hoist
whenever necessary. Do not lift heavy parts by hand. A hoist
and adjustable lifting beam or sling are needed to remove some
parts.The lengths of chains or cables from the hoist to the part
should be equal and parallel and should be positioned directly
over the center of the part. Be sure that no obstructions will
interfere with the lifting operation. Nev er leav e a part suspended
in mid-air.

Be sure to check capacity rating and condition of hoists,
slings, chains and cables bef ore use. Exceeding capacity
ratings or using lifting devices that are in poor condition
can lead to an accident, which could result in death or
serious injury. (00466c)

Always use blocking or proper stands to support the par t that
has been hoisted. If a part cannot be removed, verify that all
bolts and attaching hardware have been removed. Check to
see if any parts are in the way of the part being removed.

When removing hoses, wiring or tubes, always tag each part
to verify proper installation.

Cleaning

If you intend to reuse parts, follow good shop practice and
thoroughly clean the parts before assembly. Keep all dirt out
of parts; the unit will perform better and last longer. Seals , filters
and covers are used in this vehicle to keep out environmental
dirt and dust. These items must be kept in good condition to
guarantee satisfactory operation.

When you are instructed in a step to clean fastener threads or
threaded holes, proceed as follows: Clean all LOCTITE material
from fastener threads and threaded holes. Use a wire brush
to clean fastener threads. Use a thread chaser or other suitable
tool to clean threaded holes. Use PJ-1 cleaner or equivalent
to remove all traces of oil and contaminants from threads. Blo w
out all threaded holes with low pressure compressed air.

Clean and inspect all parts as they are removed. Be sure all
holes and passages are clean and open. After cleaning, co ver
all parts with clean lint-free cloth, paper or other material. Be
sure the part is clean when it is installed.

Always clean around lines or cov ers bef ore the y are remo v ed.
Plug, tape or cap holes and openings to keep out dirt, dust and
debris.

Always verify cleanliness of blind holes before assembly.
Tightening a screw with dirt, water or oil in the hole can cause
castings to crack or break.

2009 Touring Service: Maintenance 1-3

HOME

Disassembly and Assembly

Always assemble or disassemble one part at a time. Do not
work on two assemblies simultaneously. Be sure to make all
necessary adjustments. Recheck y our work when finished. Be
sure that everything is done.

Operate the vehicle to perform any final chec k or adjustments.
If all is correct, the vehicle is ready to go back to the customer .

Checking Torques on Fasteners

Attempt to turn the fastener using a torque wrench set to the
minimum torque specification for that fastener. If the fastener
does not rotate, the fastener torque has been maintained. If
the fastener rotates, remov e it to determine if it is a lock-patch
type.

If it has a locking agent, clean all locking material from the
threaded hole. Replace the fastener with a new one or clean
the original fastener threads and apply the appropriate Loctite
product (see appropriate procedure). Install and tighten the
fastener to specification.

If the fastener is not lock-patch type, install and tighten to
specification.

Magnetic Parts Trays

Magnetic parts trays are becoming common in the service
facility because they are convenient and can keep par ts from
becoming lost during a repair procedure.

Howev er , hardened steel parts can become magnetized when
held in magnetic parts trays. Metal fragments that would
ordinarily be washed away in the oil and tr apped in the oil filter
or magnetic drain plug during vehicle operation could be cap­tured by magnetized parts in the engine, potentially causing
accelerated engine wear and damage.

Parts that will be returned to service inside the vehicle's
powertrain such as gears, thrust washers and especially
bearings should never be kept in magnetic parts trays.

REPAIR AND REPLACEMENT PROCEDURES

Hardware and Threaded Parts

Install helical thread inserts when inside threads in castings
are stripped, damaged or not capable of withstanding specified
torque.

Replace bolts, nuts, studs, washers, spacers and small
common hardware if missing or in any way damaged. Clean
up or repair minor thread damage with a suitable tap or die.

Replace all damaged or missing lubrication fittings.
Use Teflon pipe sealant or LOCTITE 565 THREAD SEALANT

on pipe fitting threads.

Threadlocking Agents

Always f ollow specific service manual procedures when working
with fasteners containing preapplied threadlocking agents when
fastener replacement is recommended. When re-using
fasteners containing threadlocking agents, be sure to com­pletely remove all existing threadlocking agent from fastener
threads with a wire brush or wire wheel. Also, be sure to
remove residual threadlocking agent from fastener hole using
an appropriate thread chasing device and compressed air when

using new or existing f asteners. Alwa ys use the recommended
threadlocking agent for your specific procedure.

Wiring, Hoses and Lines

Hoses, clamps, electrical wiring, electrical switches or fuel lines
if they do not meet specifications.

Instruments and Gauges

Replace broken or defectiv e instruments and gauges. Replace
dials and glass that are so scratched or discolored that reading
is difficult.

Bearings

Anti-friction bearings must be handled in a special way. To
keep out dirt and abrasives, cover the bearings as soon as
they are removed from the package.

Wash bearings in a non-flammable cleaning solution. Knock
out packed lubricant inside by tapping the bearing against a
wooden block.Wash bearings again. Cover bearings with clean
material after setting them down to dry. Ne ver use compressed
air to dry bearings.

Coat bearings with clean oil.Wrap bearings in clean paper.
When bearings are installed against shoulders, be sure that

the chamfered side of the bearing always faces the shoulder.
Lubricate bearings and all metal contact surfaces before
pressing into place. Only apply pressure on the part of the
bearing that makes direct contact with the mating part. Install
bearings with numbered side facing out.

Always use the proper tools and fixtures for removing and
installing bearings.

Bearings do not usually need to be removed. Only remove
bearings if necessary.

Bushings

Do not remove a bushing unless damaged, excessively worn
or loose in its bore. Press out bushings that m ust be replaced.

When pressing or driving bushings, be sure to apply pressure
in line with the bushing bore. Use a bear ing/bushing driver or
a bar with a smooth, flat end. Never use a hammer to drive
bushings.

Inspect the bushing and the mated part for oil holes. Be sure
all oil holes are properly aligned.

Gaskets

Always discard gaskets after removal. Replace with new gas­kets. Never use the same gasket twice. Be sure that gasket
holes match up with holes in the mating part. But be aware
that sections of a gasket may be used to seal passages.

If a gasket must be made, be sure to cut holes that match up
with the mating part. Serious damage can occur if any flange
holes are blocked by the gasket. Use material that is the right
type and thickness.

Lip Type Seals

Lip seals are used to seal oil or grease and are usually installed
with the sealing lip facing the contained lubricant. Seal orient­ation, however, may vary under different applications.

1-4 2009 Touring Service: Maintenance

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Seals should not be removed unless necessary. Only remove
seals if required to gain access to other parts or if seal damage
or wear dictates replacement.

Leaking oil or grease usually means that a seal is damaged.
Replace leaking seals to prevent overheated bearings.

Always discard seals after remov al. Do not use the same seal
twice.

O-Rings (Preformed Packings)

Always discard o-rings after removal. Replace with ne w o-rings.
T o pre vent leaks , lubricate the o-rings before installation. Apply
the same type of lubricant as that being sealed. Be sure that
all gasket, o-ring and seal mating surfaces are thoroughly clean
before installation.

Gears

Always check gears for damaged or worn teeth.
Remove burrs and rough spots with a honing stone or crocus

cloth before installation.
Lubricate mating surfaces before pressing gears on shafts.

Shafts

If a shaft does not come out easily, check that all nuts, bolts
or retaining rings have been removed. Check to see if other
parts are in the way before using force.

Shafts fitted to tapered splines should be very tight. If shafts
are not tight, disassemble and inspect tapered splines. Discard
parts that are worn. Be sure tapered splines are clean, dry and
free of burrs before putting them in place. Press mating par ts
together tightly.

Clean all rust from the machined surfaces of new parts.

Part Replacement

Always replace worn or damaged parts with new parts.

Exhaust System Leakage

In the event of an exhaust system leak at a muffler or header
pipe connection location, disassemble and clean all mating
surfaces. Replace any damaged components. If leak still e xists,
disassemble and repair the leak by applying a bead of Harley­Davidson High-Perfor mance Sealant (Part No. 99650-02) (or
an equivalent 02 Sensor/Catalyst-safe alternative). Reassemble
components, wipe off any excess sealant and allo w adequate
curing time following sealant product instructions before oper­ating vehicle.

CLEANING

Rust or Corrosion Removal

Remove rust and corrosion with a wire brush, abrasive cloth,
sand blasting, vapor blasting or rust remover. Use buffing
crocus cloth on highly polished parts that are rusted.

Bearings

Remove shields and seals from bearings before cleaning.
Clean bearings with permanent shields and seals in solution.

Using compressed air to "spin dry" bearings can cause
bearing to fly apart, which could result in death or serious
injury. (00505b)

Clean open bearings by soaking them in a petroleum cleaning
solution. Never use a solution that contains chlorine.

Let bearings stand and dry. Do not dr y with compressed air.
Do not spin bearings while they are drying.

TOOL SAFETY
Air Tools

• Always use approved eye protection equipment when
performing any task using air-operated tools.

• On all power tools, use only recommended accessories
with proper capacity ratings.

• Do not exceed air pressure ratings of any power tools.

• Bits should be placed against work surface before air

hammers are operated.

• Disconnect the air supply line to an air hammer before
attaching a bit.

• Never point an air tool at yourself or another person.

• Protect bystanders with approved eye protection.

Wrenches

• Never use an extension on a wrench handle.

• If possible, always pull on a wrench handle and adjust

your stance to prevent a fall if something lets go.

• Never cock a wrench.

• Never use a hammer on any wrench other than a

STRIKING FACE wrench.

• Discard any wrench with broken or battered points.

• Never use a pipe wrench to bend, raise or lift a pipe.

Part Protection

Before cleaning, protect rubber parts (such as hoses, boots
and electrical insulation) from cleaning solutions. Use a grease­proof barrier material. Remove the rubber part if it cannot be
properly protected.

Cleaning Process

Any cleaning method may be used as long as it does not result
in parts damage. Thorough cleaning is necessary for proper
parts inspection. Strip rusted paint areas to bare metal before
priming and repainting.

Pliers/Cutters/Pry bars

• Plastic- or vinyl-covered pliers handles are not intended
to act as insulation. Do not use on live electrical circuits.

• Do not use pliers or cutters for cutting hardened wire
unless they were designed for that purpose.

• Always cut at right angles.

• Do not use any pry bar as a chisel, punch or hammer.

2009 Touring Service: Maintenance 1-5

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Hammers

• Never strike a hammer against a hardened object, such
as another hammer.

• Always grasp a hammer handle firmly, close to the end.

• Strike the object with the full face of the hammer.

• Never work with a hammer which has a loose head.

• Discard hammer if face is chipped or mushroomed.

• Wear approved eye protection when using striking tools.

• Protect bystanders with approved eye protection.

Punches/Chisels

• Never use a punch or chisel with a chipped or mush­roomed end; dress mushroomed chisels and punches with
a file.

• Hold a chisel or a punch with a tool holder if possible.

• When using a chisel on a small piece, clamp the piece

firmly in a vise and chip toward the stationary jaw.

• Wear approved eye protection when using these tools.

• Protect bystanders with approved eye protection.

Screwdrivers

• Do not use a screwdriver for prying, punching, chiseling,
scoring or scraping.

• Use the right type of screwdriver for the job; match the tip
to the fastener.

• Do not interchange POZIDRIV, PHILLIPS or REED AND
PRINCE screwdrivers.

• Screwdriver handles are not intended to act as insulation.
Do not use on live electrical circuits.

• Do not use a screwdriver with rounded edges because it
will slip. Redress with a file.

Ratchets and Handles

• Periodically clean and lubricate ratchet mechanisms with
a light grade oil. Do not replace parts individually; ratchets
should be rebuilt with the entire contents of service kit.

• Never hammer or put a pipe extension on a ratchet or
handle for added leverage.

• Always support the ratchet head when using socket
extensions, but do not put your hand on the head or you
may interfere with the action of its reversing mechanism.

• When breaking loose a fastener , apply a small amount of
pressure as a test to be sure the ratchet's gear wheel is
engaged with the pawl.

Sockets

• Never use hand sockets on power or impact wrenches.

• Select the right size socket for the job.

• Never cock any wrench or socket.

• Select only impact sockets for use with air or electric

impact wrenches.

• Replace sockets showing cracks or wear.

• Keep sockets clean.

• Always use approved eye protection when using power

or impact sockets.

Storage Units

• Do not open more than one loaded drawer at a time. Close
each drawer before opening up another.

• Close lids and lock drawers and doors before moving
storage units.

• Do not pull on a tool cabinet; push it in front of you.

• Set the brakes on the locking casters after the cabinet has

been rolled to your workspace.

1-6 2009 Touring Service: Maintenance

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1.3MAINTENANCE SCHEDULE

GENERAL

The table below lists the periodic maintenance requirements
for Touring model motorcycles. If you are familiar with the
procedures, just refer to the table f or the recommended service
interval. If necessary , see the quic k reference tab le (Table 1-2.)
for the required specifications.

Table 1-1. Regular Service Intervals: 2009 Touring Models

1000 MI.
1600 KM

Tires

sprocket

ators

switches

Air suspension

applicable)

bags

Battery

Exhaust system

Road test

NOTES:

PROCEDUREITEM SERVICED

tread

and leakage

connections

loose or missing fasteners or
heat shields

system functions

1. Should be performed by an authorized Harley-Da vidson dealer , unless you hav e the proper tools, service data and are mechanically
qualified.

2. Disassemble, lubricate and inspect every 50,000 miles (80,000 kilometers).

3. Perform annually.

4. Change D.O.T. 4 and flush brake system every two years.

5. Perform at each rear tire change.

6. Not all vehicles are equipped with spoke wheels. Consult appropriate topic in service manual.

If more detailed information is needed, turn to the sections
which follow for step-by-step instructions.

Also, throughout this manual, you will be instructed to use
various lubricants, greases and sealants. Refer to Table 1-3.
for the correct part numbers of these items.

5000 MI.
8000 KM

10,000 MI.
16,000 KM

15,000 MI.
24,000 KM

20,000 MI.
32,000 KM

XXXCheck pressure, inspect

XXXReplacePrimary chaincase lubricant
XXReplaceTransmission lubricant

XReplace

40,000 KM

XXXXXXReplaceEngine oil and filter

XXXXXXInspect, service as requiredAir cleaner

XXXXXXInspect for wearBrake pads and discs
XXXXXInspectSpark plugs

XXXXXXCheck operationElectrical equipment and

XXXXXXLubricate hinges and latchesFuel door, Tour-Pak, saddle-

XXXXXXVerify component and

NOTES25,000 MI.

1XXXXXXInspect for leaksOil lines and brake system

1, 6XXXCheck tightnessWheel spokes

1XXXXXXCheck adjustmentClutch
1XXXXXXInspect, adjust beltDrive belt and compensator

5Inspect for wearCompensator sprocket isol-

1XXXXXXCheck, adjust and lubricateBrake and clutch controls
1XXXXXXInspect and lubricateJiffy stand
1XXXXXXInspect for leaksFuel lines and fittings
1XReplaceFuel tank filter
4XXXXXXCheck levels and conditionBrake fluid

1, 2ReplaceFront fork oil

2XXXLubricateSteering head bearings
1XAdjust
1XXXXXXCheck pressure, operation

1XXInspectWindshield bushings (if

1XXXCheck tightnessCritical fasteners
3Check battery and clean

3XXXXXXInspect for leaks, crac ks, and

2009 Touring Service: Maintenance 1-7

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Drive belt deflection

Table 1-2. Quick Reference Maintenance Chart: 2009 Touring Models

DATASPECIFICATIONITEM SERVICED

14-21 ft-lbs (19.0-28.5 Nm)Drain plug torqueEngine oil and filter
4 qt. (3.8 L)Oil capacity
Hand tighten 1/2-3/4 turn after gasket contactFilter
63798-99AChrome filter part number
63731-99ABlack filter part number

Lubricant type and capacityPrimary chain lubricant

Lubricant levelTransmission lubricant

Lubricant type and capacity

Wear

strand

Air cleaner cover screw Threadlocker

Lubricant part numberClutch cable

FORMULA+ TRANSMISSION AND PRIMARY
CHAIN LUBRICATION (Part No. 99851-05)
Wet:38 oz. (1124 ml)
Dry: 45 oz. (1331 ml)

14-21 ft-lbs (19.0-28.5 Nm)Primary chaincase drain plug torque
1/2-1 turnAdjuster screw free playClutch adjustment
72-120 in-lbs (8.1-13.6 Nm)Adjuster screw locknut torque
1/16-1/8 in. (1.6-3.2 mm)Free play at hand lever
84-108 in-lbs (9.5-12.2 Nm)Clutch inspection cover torque
Dipstick at FULL with motorcycle on jiffy stand and

filler plug resting on threads.
FORMULA+ TRANSMISSION AND PRIMARY

CHAIN LUBRICATION (Part No. 99851-05)
32 oz (0.95 liters)

14-21 ft-lbs (19.0-28.5 Nm)Transmission drain plug torque
25-75 in-lbs (2.8-8.5 Nm)Transmission filler plug/dipstick torque
Front:36 psi (248 kPA)Pressure: solo rider or with passengerTire pressure and wear

Rear: 40 psi (276 kPA)
Replace if less than1/32 in. (0.8 mm) of tread pat-

tern
55 in-lbs (6.2 Nm) minimumSpoke nipple torqueWheel spokes
99953-99A (12 oz.)D.O.T. 4 hydraulic brake fluid part numberBrake fluid level
Front:0.20 in. (5.0 mm)Fluid level (from top of master cylinder reservoir)

Rear: 0.26 in. (6.5 mm)
Front:7-10 in-lbs (0.8-1.1 Nm)Master cylinder reservoir cover screw torque

Rear: 12-15 in-lbs (1.4-1.7 Nm)

0.016 in. (0.4 mm)Minimum brake pad thicknessBrake pads and discs
75-102 in-lbs (8.5.-11.5 Nm)Brake caliper pad pin torque
Front: 0.18 in. (4.5 mm)Minimum brake disc thickness

Rear: 0.25 in. (6.3 mm)

0.008 in. (0.2 mm)Maximum brake disc lateral runout (warpage)
10 lb. (4.5 kg)Upward force applied at midpoint of bottom belt

3/8-7/16 in. (9.5-11.1 mm)FLHR/C, FLHT/C/U, FLTR
1/4-5/16 in. (6.4-7.9 mm)FLHX
40-60 in-lbs (4.5-6.8 Nm)Air cleaner cover bracket screw torqueAir cleaner
36-60 in-lbs (4.1-6.8 Nm)Air cleaner cover screw torque
LOCTITE MEDIUM STRENGTH THREADLOCKER

243 (BLUE)
Part No. 99642-97 (6 ml)

LUBIT-8 SUPER OIL, Part No. 94968-85TV (1/4
fl. oz.)

35-45 in-lbs (4.0-5.1 Nm)Handlebar switch housing screw torque

1-8 2009 Touring Service: Maintenance

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Table 1-2. Quick Reference Maintenance Chart: 2009 Touring Models

CCI #20 Brake Grease

Transmission and Primary Chaincase
Lubricant

Loctite Prism Primer (770)
Loctite Prism Superbonder (411)
Loctite Superbonder 420 Adhesive

DATASPECIFICATIONITEM SERVICED

HD-6R12TypeSpark plugs

0.038-0.043 in. (0.97-1.09 mm)Gap
12-18 ft-lbs (16.3-24.4 Nm)Torque
See 2.19 FRONT FORK.AmountFront fork oil
HYDRAULIC FORK OIL (TYPE E)Type and part number

Part No. 99884-80 (16 oz.)
60-70 in-lbs (6.8-7.9 Nm)Terminal bolt torqueBattery
72-96 in-lbs (8.1-10.9 Nm)Top caddy screw torque

Table 1-3. Lubricants, Greases, Sealants

PACKAGEPART NUMBERITEM

1 oz squeeze tube98960-97Anti-Seize Lubricant
squeeze packet42830-05 (included in master cylinder

rebuild kit)

12 oz. bottle99953-99AD.O.T. 4 Brake Fluid
1 oz squeeze tube99861-02Electrical Contact Lubricant
1 qt bottle99851-05Genuine Harley-Davidson Formula+

squeeze packet42820-04G40M Brake Grease

1.9 oz squeeze tube99650-02Gray High Performance Sealant

3.5 oz tube99653-85HYLOMAR Gasket and Thread Sealant
6 ml squeeze tube99818-97Loctite Pipe Sealant With Teflon 565

6 ml squeeze tube99642-97Loctite Threadlocker 243 (blue)
6 ml squeeze tube94759-99Loctite Threadlocker 262 (red)
10 ml bottle98618-03Loctite Threadlocker 272
14 oz. cartridge99857-97Special Purpose Grease
1/4 fl. oz94968-85TVSuper Oil
16 oz bottle99884-80Type "E" Hydraulic Fork Oil

2009 Touring Service: Maintenance 1-9

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1.4FUEL AND OIL

FUEL

Refer to Table 1-4. Always use a good quality unleaded gas-
oline. Octane ratings are usually found on the pump.

Avoid spills. Slowly remove filler cap. Do not fill above
bottom of filler neck insert, leaving air space for fuel
expansion. Secure filler cap after refueling. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00028a)

Use care when refueling. Pressurized air in fuel tank can
force gasoline to escape through filler tube. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00029a)

Modern service station pumps dispense a high flow of gasoline
into a motorcycle fuel tank making air entrapment and pressur­ization a possibility.

Table 1-4. Octane Ratings

RATINGSPECIFICATION

91 (95 RON)Pump Octane (R+M)/2

and as much as 15% MTBE. Gasoline/MTBE blends can
be used in your motorcycle.

• ETHANOL is a mixture of 10% ethanol (Grain alcohol) and
90% unleaded gasoline. Gasoline/ethanol blends can be
used in your motorcycle if the ethanol content does not
exceed 10%.

• REFORMULATED OR OXYGENATED GASOLINES
(RFG): Reformulated gasoline is a term used to describe
gasoline blends that are specifically designed to burn
cleaner than other types of gasoline, leaving fe wer tailpipe
emissions. They are also formulated to evaporate less
when you are filling your tank. Reformulated gasolines
use additives to oxygenate the gas. Your motorcycle will
run normally using this type of gas and Harley-Davidson
recommends you use it when possible, as an aid to cleaner
air in our environment.

• Do not use race gas or octane boosters. Use of these fuels
will damage the fuel system.

Some gasoline blends might adversely affect the starting,
driveability or fuel efficiency of the motorcycle. If any of these
problems are experienced, try a different brand of gasoline or
gasoline with a higher octane blend.

ENGINE LUBRICATION

GASOLINE BLENDS

Your motorcycle was designed to get the best performance
and efficiency using unleaded gasoline. Most gasoline is
blended with alcohol and/or ether to create oxygenated blends .
The type and amount of alcohol or ether added to the fuel is
important.

Do not use gasoline that contains methanol. Doing so can
result in fuel system component failure, engine damage
and/or equipment malfunction. (00148a)

• Gasoline containing METHYL TER TIARY BUTYL ETHER
(MTBE): Gasoline/MTBE blends are a mixture of gasoline

Table 1-5. Recommended Engine Oils

H-D RATINGVISCOSITYH-D TYPE

Do not switch lubricant brands indiscriminately because
some lubricants interact chemically when mixed. Use of
inferior lubricants can damage the engine. (00184a)

Engine oil is a major factor in the performance and service life
of the engine. Alwa ys use the proper grade of oil f or the low est
temperature expected before the next scheduled oil change.
Refer to Table 1-5.Your authorized dealer has the proper oil
to suit your requirements.

If it is necessary to add oil and Harley-Davidson oil is not
available, use an oil certified for diesel engines. Acceptable
diesel engine oil designations include: CF-4, CG-4, CH-4 and
CI-4.

The preferred viscosities for the diesel engine oils in des­cending order are: 20W50, 15W40 and 10W40.

At the first opportunity, see an authorized dealer to change
back to 100 percent Harley-Davidson oil.

LOWEST AMBIENT

TEMPERATURE

COLD WEATHER

STARTS BELOW 50° F

(10° C)

ExcellentBelow 40° F (4° C)HD 360SAE 10W40H-D Multi-grade

GoodAbove 40° F (4° C)HD 360SAE 20W50H-D Multi-grade

PoorAbove 60° F (16° C)HD 360SAE 50H-D Regular Heavy
PoorAbove 80° F (27° C)HD 360SAE 60H-D Extra Heavy

1-10 2009 Touring Service: Maintenance

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WINTER LUBRICATION

In colder climates, the engine oil should be changed often. If
motorcycle is used frequently for short trips, less than 15 miles
(24 kilometers), in ambient temperatures below 60° F (16° C),
oil change intervals should be reduced to 1500 miles (2400
kilometers). Motorcycles used only for short runs must have a
thorough tank flush-out before new oil is put in.The tank flush­out should be performed by an authorized dealer or qualified
technician.

NOTE

The further below freezing the temperature drops, the shorter
the oil change interval should be.

Water vapor is a normal by-product of combustion in any
engine. During cold weather operation, some of the water vapor
condenses to liquid form on the cool metal surfaces inside the
engine. In freezing weather this water will become slush or ice
and, if allowed to accumulate too long, may block the oil lines
and cause damage to the engine.

If the engine is run frequently and allowed to thoroughly warm
up, most of this water will become vapor again and will be
blown out through the crankcase breather.

If the engine is not run frequently and allowed to thoroughly
warm up, this water will accumulate, mix with the engine oil
and form a sludge that is harmful to the engine.

2009 Touring Service: Maintenance 1-11

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1.5BULB REQUIREMENTS

GENERAL

Use the table to identify the bulb location and part number.
Refer to Table 1-6.

Table 1-6. Bulb Chart: 2009 Touring Models

LAMP

lamp

lamps
FLHT/C/U
FLHR/C
FLTR
FLHX

FLHR/C

DESCRIPTION
(ALL LAMPS 12 VOLT)

domestic

High beam indicatorInstrument panel
Oil pressure indicator
Neutral indicator
Turn signal indicator

REQUIRED

Instrument panel is illuminated with LEDs. Replace entire assemb ly upon
failure.

NOTE

The speedometer, tachometer, odometer and indicator lamps
are illuminated with LEDs. LEDs are non-repairable.The entire
assembly must be replaced if an LED fails.

BULBS

Illuminated with LEDs. Replace assembly upon failure.Fuel gauge*

CURRENT

DRAW

AMPERAGE

HARLEY-DAVIDSON

PART NUMBER

68329-034.58/5.01FLHT/C/U, FLHR/C, FLHXHeadlamp
68329-034.58/5.02FLTR
53438-920.321Position lamp, international
53436-970.321Position lamp, FLTR Japan
68167-040.59/2.101Tail/stop lampTail and stop

68168-89A2.25/0.592Front/runningTurn signal lamp
68572-64B1.752Front international

68163-841.752Front, FLHX (HDI), FLTR (Japan)

68572-64B2.252Rear

68163-841.752Rear, FLTR/FLHX international
68163-841.752Rear, other international

53788-06 (right side)0.14N/ATour-Pak side lampsAdditional lighting

53789-06 (left side)0.14FLHTCU*

68165-640.59/2.102Tour-Pak tail/stop lamps
68193-950.301Fender tip lamps, front

69375-06 (FLHX)N/AN/AFender tip lamps, rear*

59672-09 (all but FLHX)

53436-970.371License plate lamp international
52441-950.352License plate lamp FLTR/FLHX

68453-052.12Auxiliary lamps
68851-982.72Auxiliary lamps international

N/AN/AN/ASpeedometerGauge lamps
N/AN/AN/AOdometer

N/AN/AN/AEngine

1-12 2009 Touring Service: Maintenance

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Table 1-6. Bulb Chart: 2009 Touring Models

LAMP

FLHT/C/U
FLTR
FLHX

DESCRIPTION
(ALL LAMPS 12 VOLT)

FLHT/C/U

FLHT/C/U

Illuminated with LEDs. Replace entire assembly upon failure.Items with *

BULBS

REQUIRED

CURRENT

DRAW

AMPERAGE

HARLEY-DAVIDSON

PART NUMBER

N/AN/AN/ASpeedometerGauge lamps

N/AN/AN/ATachometer
67445-000.241Voltmeter
67445-000.241Oil pressure indicator

67445-000.241Air temperature gauge

67445-000.241Fuel gauge

2009 Touring Service: Maintenance 1-13

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1.6ENGINE OIL AND FILTER

CHECKING OIL LEVEL

Oil level cannot be accurately measured on a cold engine.
For pre-ride inspection, with motorcycle leaning on jiffy
stand on level ground, oil should register on dipstick
between arrows when engine is cold. Do not add oil to
bring the level to the FULL mark on a COLD engine.
(00185a)

For dipstick location, see Figure 1-1.

Figure 1-1. Engine Oil Filler Cap

NOTES

See Figure 1-2.The oil level marks for checking oil level with
motorcycle upright or on jiffy stand are on the same side of the
dipstick. Be sure to use the correct portion of dipstick when
checking oil level. Oil level must not exceed the midpoint (2)
when performing cold oil level check.

Oil Level Cold Check

Perform engine oil level COLD CHECK as follows:

1. For pre-ride inspection, place vehicle on lev el ground and
rest the vehicle on its jiffy stand (unless sidecar is
attached).

2. Remove filler plug/dipstick and wipe off the dipstic k. Insert
the dipstick and tighten into the fill spout.

NOTE
The oil level marks for checking with motorcycle upright or on
jiffy stand are on the same side of the dipstick. Be sure to use
the correct portion of dipstick when checking oil level.

3. See Figure 1-2. Remove the dipstick and verify the level

of the oil.The correct oil level should register midway (2)
between the FULL and ADD marks on the dipstick.

Oil Level Hot Check

NOTES

• The engine will require a longer warm up period in colder
weather.

• Engine oil level hot chec k should be performed only when
engine is at normal operating temperature.

Perform engine oil level HOT CHECK as follows:

1. Ride motorcycle until engine is at normal operating tem­perature.

2. Place vehicle on level ground and rest the vehicle on its
jiffy stand (unless sidecar is attached). Allow engine to
idle for 1-2 minutes.Turn engine off.

3. Remove filler plug/dipstick and wipe off the dipstic k. Insert
the dipstick and tighten into the fill spout.

NOTE
The oil level marks for checking with motorcycle upright or on
jiffy stand are on the same side of the dipstick. Be sure to use
the correct portion of dipstick when checking oil level.

4. See Figure 1-2. Remove the dipstick and note the level

of the oil. The level should be between the ADD (1) and
FULL (3) marks. Add oil as necessary to bring the level
to the FULL mark on the dipstick. Do not overfill.

NOTE
Refer to Table 1-5. Use only recommended oil specified in

1.4 FUEL AND OIL, Engine Lubrication.

5. Start engine and carefully check for oil leaks around drain

plug and oil filter.

Do not allow hot oil level to fall below Add/Fill mark on
dipstick. Doing so can result in equipment damage and/or
equipment malfunction. (00189a)

Do not overfill oil tank. Doing so can result in oil carry over
to the air cleaner leading to equipment damage and/or
equipment malfunction. (00190a)

• Check engine oil level at each complete fuel refill.

• Refer to Table 1-1. Oil should be changed at specified

intervals in normal service at warm or moderate temperat­ures.

• Oil change intervals should be more frequent in cold

weather or severe operating conditions. See 1.4 FUEL

AND OIL, Winter Lubrication.

NOTE

If oil level is at or below the ADD mark, add only enough oil to
bring the level to the middle of the two marks on the dipstick.

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1. ADD QT (lower) mark

2. Cold check level

3. FULL (hot check) mark
Figure 1-2. Engine Oil Dipstick

CHANGING OIL AND OIL FILTER

TOOL NAMEPART NUMBER

OIL FILTER WRENCHHD-42311
OIL FILTER WRENCHHD-44067A

Do not switch lubricant brands indiscriminately because
some lubricants interact chemically when mixed. Use of
inferior lubricants can damage the engine. (00184a)

Be sure that no lubricants or fluids get on tires, wheels or
brakes when changing fluid. Traction can be adversely
affected, which could result in loss of control of the
motorcycle and death or serious injury. (00047d)

T win Cam equipped v ehicles require the premium oil filter (Part
No. 63798-99A Chrome or Part No. 63731-99A Black).

Refer to Table 1-1. Oil should be changed after the first 1000
miles (1600 kilometers) for a new engine and at regular inter­vals in normal service at warm or moderate temperatures.

1. Ride motorcycle until oil is at normal operating temper­ature.Turn engine off.

2. Remove filler plug/dipstick.

3. See Figure 1-3. Remove the oil drain plug (2). Do not
remove hex plug (3) or transmission drain plug (1). Allow
oil to drain completely.

1. Transmission drain plug (right side)

2. Engine oil drain plug and O-ring

3. Hex plug (do not remove)
Figure 1-3. Oil Pan

4. Inspect the oil drain plug o-ring for cuts, tears or signs of
deterioration. Replace as necessary.

Use Harley-Davidson oil filter wrench for filter removal.
This tool can prevent damage to crankshaft position
sensor and/or sensor cable. (00192b)

5. See Figure 1-4. Remove the oil filter using OIL FILTER
WRENCH (Part No. HD-42311) or OIL FILTER
WRENCH (Part No. HD-44067A) and hand tools. Do not
use with air tools.

6. Clean the oil filter mount flange of any old gasket material.

NOTE

Dispose of oil and oil filter in accordance with local regulations.

7. See Figure 1-5. Lubricate gasket with clean engine oil and
install new oil filter on filter mount. Hand tighten oil filter
1/2-3/4 turn after gasket first contacts filter mounting sur­face. Do not use OIL FILTER WRENCH (Part No. HD-

42311) for oil filter installation.

8. Install engine oil drain plug and tighten to 14-21 ft-lbs
(19.0-28.5 Nm).

NOTE
Use the proper grade of oil for the low est temperature expected
before the next oil change . Refer to Table 1-5 for recommended
oil.

9. Initially add 3.5 quarts (3.3 liters) of engine oil.

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10. V erify proper oil level. See 1.6 ENGINE OIL AND FIL TER,

Checking Oil Level.

a. Check engine oil level using COLD CHECK pro-

cedure.

b. Start engine and carefully check for oil leaks around

drain plug and oil filter.

c. Check engine oil level using HOT CHECK procedure.

1. Thin oil film ONLY

2. Oil filter

3. Mounting plate
Figure 1-5. Applying Thin Oil Film

Figure 1-4. Oil Filter Wrench (Part No. HD-42311)

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1.7PRIMARY CHAIN

GENERAL

All models have an automatic chain tensioner. For primary
chain service procedures, see 5.4 DRIVE COMPONENTS.

CHAINCASE LUBRICANT
General

Refer to Table 1-1.The primary chaincase lubricant should be
drained and refilled with fresh lubricant at specified intervals.

Check Lubricant Level

1. Ride motorcycle until engine is warmed up to normal
operating temperature.

2. Stand vehicle upright on a level surface, so that primar y
chaincase is level.

3. See Figure 1-6. Remove five screws to free clutch
inspection cover from primary chaincase cover.

4. Remove seal ring from clutch inspection cover and discard.

5. If the fluid level can be seen, it is adequate. Otherwise,
pour enough GENUINE Harley-Davidson FORMULA+
TRANSMISSION AND PRIMARY CHAINCASE LUB­RICANT (Part No. 99851-05, U.S. quart) in through the
clutch inspection cover opening until it is visible along the
bottom portion of the clutch assembly.

6. Refer to CHANGING CHAINCASE LUBRICANT to install
seal ring and clutch inspection cover.

Do not overfill the primary chaincase with lubricant.
Overfilling can cause rough clutch engagement, incom­plete disengagement, clutch drag and/or difficulty in
finding neutral at engine idle. (00199b)

Changing Chaincase Lubricant

When draining or adding lubricant, do not allow dirt, debris
or other contaminants to enter the engine. (00198a)

1. Ride motorcycle until engine is warmed up to normal
operating temperature.

2. Remove five screws to free clutch inspection cover from
primary chaincase cover.

3. Remove drain plug at bottom of primary chaincase. Drain
lubricant into suitable container.

NOTE
Dispose of chaincase lubricant in accordance with local regu­lations.

4. Clean drain plug magnet. If plug has accum ulated a lot of

debris, inspect the condition of chaincase components.

5. Inspect drain plug O-ring for cuts, tears or signs of deteri-

oration. Replace as necessary.

6. Install drain plug into primary chaincase and tighten to 14-

21 ft-lbs (19.0-28.5 Nm).

7. Pour 38 fl. oz. (1124 ml) of GENUINE Harley-Davidson

FORMULA+ TRANSMISSION AND PRIMARY CHAIN­CASE LUBRICANT (Part No. 99851-05 quart) through the
clutch inspection cover opening.

NOTE
Only add 45 fl. oz. (1331 ml) after service that inv olves remov al
of the primary chaincase or primary chaincase cover.

Do not overfill the primary chaincase with lubricant.
Overfilling can cause rough clutch engagement, incom­plete disengagement, clutch drag and/or difficulty in
finding neutral at engine idle. (00199b)

1. Primary chaincase cover

2. Drain plug

3. Clutch inspection cover

4. Torque sequence
Figure 1-6. Primary Chaincase

Be sure that no lubricants or fluids get on tires, wheels or
brakes when changing fluid. Traction can be adversely
affected, which could result in loss of control of the
motorcycle and death or serious injury. (00047d)

8. Swab all lubricant from seal ring groove in clutch inspection
cover . Install ne w seal ring in groove with n ubs contacting
ring groove walls.

9. See Figure 1-6. Install clutch inspection cover to primary
chaincase cover. Tighten screws in the sequence shown
to 84-108 in-lbs (9.5-12.2 Nm).

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TRANSMISSION LUBRICATION
General

The transmission lubricant level should be checked monthly.
Refer to Table 1-1. The transmission should be drained and

refilled with fresh lubricant at specified intervals.

NOTE

When checking the transmission lubricant level, the motorcycle
should be leaning on the jiffy stand. Allow a short period of
time to equalize lubricant level in the transmission compart­ments.

Check Lubricant Level

1. Park motorcycle on its jiffy stand.

2. See Figure 1-7. Remove the threaded filler plug/dipstick.

3. See Figure 1-8.Wipe off filler plug/dipstick. Place in filler
hole and remove. (Dipstick should rest on lip of filler. Do
not screw in.) Lubricant level should be between the full
and low marks on the plug/dipstick when removed.

1.8TRANSMISSION LUBRICANT

Figure 1-7.Transmission Filler Plug/Dipstick Location

Be sure that no lubricants or fluids get on tires, wheels or
brakes when changing fluid. Traction can be adversely
affected, which could result in loss of control of the
motorcycle and death or serious injury. (00047d)

When draining or adding lubricant, do not allow dirt, debris
or other contaminants to enter the engine. (00198a)

4. Add lubricant, if necessary. Do not overfill or leakage may
occur.When filling the transmission, use GENUINE Harley­Davidson FORMULA+ TRANSMISSION AND PRIMARY
CHAINCASE LUBRICANT (Part No. 99851-05 quart).The
transmission fluid capacity is approximately 32 fluid ounces
(0.95 liters).

5. Inspect o-ring for tears or damage. Replace if required.
Wipe any foreign material from plug.

6. Install threaded filler/check plug and tighten clockwise to
25-75 in-lbs (2.8-8.5 Nm).

1. FULL

2. ADD

Figure 1-8.Transmission Filler Plug/Dipstick Lubricant

Level

Changing Transmission Fluid

1. See Figure 1-7. Remove the threaded filler plug/dipstick.

When draining or adding lubricant, do not allow dirt, debris
or other contaminants to enter the engine. (00198a)

Be sure that no lubricants or fluids get on tires, wheels or
brakes when changing fluid. Traction can be adversely
affected, which could result in loss of control of the
motorcycle and death or serious injury. (00047d)

2. See Figure 1-3. Remove transmission drain plug (1) and
drain lubricant into a suitable container.

NOTE
Dispose of transmission lubricant in accordance with local
regulations.

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3. Inspect the drain plug o-ring for tears or damage. Replace
if required.Wipe any foreign material from plug.

4. Install drain plug and tighten to 14-21 ft-lbs (19.0-28.5
Nm). Fill the transmission with 32 fl. oz. (0.95 liters) of
GENUINE Harley-Davidson FORMULA+ TRANSMISSION
AND PRIMARY CHAINCASE LUBRICANT (Part No.
99851-05 quart).

NOTE
Do not overfill or leakage may occur. The transmission fluid
capacity is approximately 32 fl. oz. (0.95 liters).

5. Install threaded filler plug/dipstick and tighten clockwise

to 25-75 in-lbs (2.8-8.5 Nm).

6. Start engine and carefully check for oil leaks around drain

plug.

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REMOVAL

1.9AIR CLEANER AND EXHAUST SYSTEM

1. See Figure 1-9. Remove screw (1) and air cleaner cover
with rubber seal (3).

2. Remove three screws (4) to release co ver brack et (5) from
filter element.

3. Remove filter element (6) pulling two breather tubes (8)
from holes on inboard side.

4. Remove and discard gasket (7).

5. Remove breather tubes from breather bolts.

6. Inspect the breather tubes and rubber seal for cuts, tears,
holes or signs of deterioration. Replace as necessary.

Do not use gasoline or solvents to clean filter element.
Flammable cleaning agents can cause an intake system
fire, which could result in death or serious injury . (00101a)

Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)

7. Clean filter element.
a. Wash the paper/wire mesh filter element (and

breather tubes) in lukewarm water with a mild deter­gent. Do not strike filter element on a hard surface to
dislodge dirt.

b. Allow filter element to either air dry or blow it dry , from

the inside, with low pressure air. Do NOT use air
cleaner filter oil on the Harley-Davidson paper/wire
mesh air filter element.

c. Hold the filter element up to a strong light source.The

element is sufficiently clean if light is uniformly visible
through the media.

d. Replace the filter element if damaged or if filter media

cannot be adequately cleaned.

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5.1. Cover bracketCover screw

2. 6.Air cleaner cover Filter element

7.3. GasketRubber seal

4. 8.Cover bracket screw (3) Breather tube (2)
Figure 1-9. Air Cleaner Assembly

INSTALLATION

1. Install new gasket (7) on air filter element.

2. Insert breather tubes approximately 0.25 inch (6.4 mm)
into holes on inboard side of filter element.

NOTE
Air cleaner mounting without installation of the breather tubes
allows crankcase vapors to be vented into the atmosphere in
violation of legal emissions standards.

3. Install breather tubes onto breather bolts.

4. Place filter element onto backplate with the flat side down.

5. Install cover bracket and start screws (4).Tighten screws

to 40-60 in-lbs (4.5-6.8 Nm).

6. V erify that rubber seal is properly seated around perimeter

of air cleaner cover.

7. Fit air cleaner cover into backplate. Apply a small dab of
LOCTITE MEDIUM STRENGTH THREADLOCKER 243
(BLUE) to threads of cover screw . Install scre w and tighten
to 36-60 in-lbs (4.1-6.8 Nm).

EXHAUST SYSTEM LEAK CHECK

Check the exhaust system f or leaks at every scheduled service
interval as follows:

1. Check entire exhaust system for loose or missing
fasteners, broken pipe clamps or brackets, and obvious
signs of leakage (carbon tracks at pipe joints, etc.).

2. Check for loose or broken heat shields . Repair or replace
as necessary.

3. Start engine, cover muffler ends with clean, dry shop
towels and listen for audible signs of exhaust leakage.

4. Correct any leaks detected. See 4.19 EXHAUST SYSTEM
for exhaust system removal and installation procedures.

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1.10TIRES AND WHEELS

TIRES

Match tires, tubes, air valves and caps to the correct wheel
rim. Contact a Harley-Davidson dealer. Mismatching can
result in damage to the tire bead, allow tire slippage on
the rim or cause tire failure, which could result in death
or serious injury. (00023a)

Use only Harley-Davidson approved tires. See a Harley­Davidson dealer . Using non-approved tires can adversely
affect stability, which could result in death or serious
injury. (00024a)

Use inner tubes on laced (wire spoked) wheels. Using
tubeless tires on laced wheels can cause air leaks, which
could result in death or serious injury. (00025a)

NOTES

• Tubeless tires fitted with the correct size inner tubes may
be used on all Harley-Davidson laced (wire spoked)
wheels. Protective rubber rim strips must be used with

tubeless tires (fitted with correct size inner tubes) when
mounted on laced (wire spoked) wheels.

• Inner tubes must not be used in radial tires and radial tires
must not be used on laced (wire spoked) wheels.

• Tubeless tires are used on all Harley-Davidson cast and
disc wheels.

• Tire sizes are molded on the tire sidewall. Inner tube sizes
are printed on the tube.

• New tires should be stored on a horizontal tire rack. Avoid
stacking new tires in a vertical stack. The weight of the
stack compresses the tires and closes down the beads.

Check tire pressure and tread:

• As part of the pre-ride inspection.

• At every scheduled service interval.

1. Inspect each tire for punctures, cuts and breaks.

2. Inspect each tire for wear . Replace tires bef ore they reach
the tread wear indicator bars.

NOTE

Missing indicator wear bars represent less than 1/32 in. (0.8
mm) tread pattern depth remaining.

3. Check for proper front and rear tire pressures when tires
are cold. Compare results against Table 1-7.

Table 1-7.Tire Pressures: 2009 Touring Models

TIRE REPLACEMENT
Inspection

Harley-Davidson tires are equipped with wear bars that
run horizontally across the tread.When wear bars become
visible and only 1/32 in. (0.8 mm) tread depth remains,
replace tire immediately. Using a worn tire can adversely
affect stability and handling, which could result in death
or serious injury. Use only Harley-Davidson approved
replacement tires. (00090b)

See Figure 1-10. Arrows on tire sidewalls pinpoint location of
wear bar indicators.

Tread wear indicator bars will appear on tire tread surfaces
when 1/32 in. (0.8 mm) or less of tire tread remains. See

Figure 1-11. Always replace tires before the tread wear indic-

ator bars appear.

TIRE PRESSURE (COLD)MODEL

REARFRONT

kPaPSIkPaPSI

2764024836All

When To Replace Tires

New tires are needed if any of the following conditions exist:

1. Tread wear indicator bars become visible on the tread
surfaces.

2. Tire cords or fabric become visible through cracked side­walls, snags or deep cuts.

3. A bump, bulge or split in the tire.

4. Puncture, cut or other damage to the tire that cannot be
repaired.

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Figure 1-10.Tire Sidewall Wear Bar Locator

2. If wheel is already removed, check wheel bearings as f ol­lows:

a. See Figure 1-12. Insert finger into wheel bearing and

rotate the inner race in both directions. Repeat step
on opposite side of wheel.

b. Replace the wheel bearings if there is drag, rough

rotation, abnormal noise or anything unusual.

3. Check axle spacers for wear and corrosion. Replace as
necessary.

Figure 1-11.Wear Bar Appearance (Typical)

WHEEL BEARINGS

Service wheel bearings:

1. Check wheel bearings as outlined in 2.11 SEALED

WHEEL BEARINGS. Replace wheel bearings if end play

exceeds 0.002 in. (0.051 mm).

Figure 1-12. Inspect Wheel Bearings

WHEEL SPOKES

Spokes that are too tight can draw nipples through the rim
or distort hub flanges. Spokes that are too loose can
continue to loosen when put in service. Either condition
can adversely affect stability and handling, which could
result in death or serious injury. (00286a)

If nipples require more than one full turn to tighten spoke,
remove tire to check that spoke protrusion has not dam­aged tube. (00526b)

1. Raise motorcycle wheel off the ground.

NOTE

Perform the entire procedure for each spoke, one at a time.

2. Mark one of the spokes with a reference mark to the rim.

3. Loosen spoke 1/4 turn.

NOTES

• Use a spoke torque wrench to tighten spokes.

• Do not tighten spoke more than 1/4 turn past reference

mark. If more tension is needed, label spoke and check
after completing rest of wheel.

4. Tighten spoke to reference mark. If torque is less then the
value listed in Table 1-8, continue to tighten spoke until it
reaches the listed torque.

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5. Once the entire wheel has been checked, repeat pro­cedure for each labeled spoke.

6. If more than a few spokes w ere loose, true the entire wheel
following procedure under 2.12 TRUING LA CED WHEELS.

Table 1-8. Spoke Nipple Torque Specification

MINIMUM TORQUERIM TYPE

55 in-lbs (6.2 Nm)All

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ADJUSTMENT

NOTE

Perform the clutch adjustment with the motorcycle at room
temperature.The clearance at the adjuster screw will increase
as the powertrain temperature increases. If adjuster screw is
adjusted with powertrain hot, clearance at push rod bearing
could be insufficient with powertrain cold and clutch slippage
could occur.

1. Stand motorcycle upright and level.

2. Remove clutch inspection cover from primary chaincase
cover.

3. Remove seal ring from clutch inspection cover and discard.

4. See Figure 1-13. Add freeplay to cable.
a. Slide rubber boot (1) off cable adjuster.

b. Loosen jam nut (3) and back away from cable

adjuster.

c. Move adjuster (2) toward jam nut to introduce a large

amount of free play at hand lever.

1.11CLUTCH

1. Rubber boot

2. Cable adjuster

3. Jam nut

4. Cable end
Figure 1-13. Clutch Cable Adjuster

5. See Figure 1-14. Loosen jam nut (1) on clutch adjuster
screw. Turn adjuster screw (2) inward (clockwise) until
lightly seated.

6. Back out adjuster screw 1/2 to 1 full turn. While holding
adjuster screw , tighten jam nut to 72-120 in-lbs (8.1-13.6
Nm).

7. Squeeze clutch lever to maximum limit three times to set
ball and ramp release mechanism.

8. See Figure 1-13. Check freeplay.
a. Turn cable adjuster (2) away from jam nut (3) until

slack is eliminated at hand lever.

b. See Figure 1-15. Pull clutch cable ferrule (2) away

from clutch lever bracket to check free play. Turn
cable adjuster as necessary to obtain 1/16-1/8 in.
(1.6-3.2 mm) free play between end of cable ferr ule
and clutch lever bracket.

9. Hold adjuster and tighten jam nut against cable adjuster.
Cover cable adjuster mechanism with rubber boot.

10. Swab all lubricant from seal ring groove in clutch inspection
cover . Install ne w seal ring in groove with n ubs contacting
ring groove walls.

11. Fasten clutch inspection cov er to primary chaincase cover.
Alternately tighten screws to 84-108 in-lbs (9.5-12.2 Nm)
in the sequence shown in Figure 1-6.

1. Jam nut

2. Clutch adjuster screw
Figure 1-14. Clutch Adjuster Screw

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1. Clutch cable

2. Cable ferrule

3. Clutch lever bracket

4. 1/16-1/8 in. (1.6-3.2 mm)
Figure 1-15. Clutch Hand Lever

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GENERAL

When a drive belt is replaced for any reason other than stone
damage, it is recommended that the transmission and rear
sprockets also be replaced to increase the longevity of the ne w
drive belt. In the case of stone damage, inspect sprockets for
damage and replace as required.

Never bend belt forward into a loop smaller than the drive
sprocket diameter. Never bend belt into a reverse loop.
Over bending can damage belt resulting in premature
failure, which could cause loss of control and death or
serious injury. (00339a)

CLEANING

1.12REAR BELT AND SPROCKETS

Keep dirt, grease, oil, and debris off the belt and sprockets.
Clean the belt with a rag slightly dampened with a light cleaning
agent.

INSPECTION
Sprockets

NOTE

If chrome chips or gouges to rear sprocket are large enough
to be harmful, they will leave a pattern on the belt face.

1. See Figure 1-16. Inspect each tooth (1) of rear sprocket
for:

a. Major tooth damage.
b. Large chrome chips with sharp edges.
c. Gouges caused by hard objects.
d. Excessive loss of chrome plating (see next step).

2. To check if chrome plating has worn off, drag a scribe or
sharp knife point across the bottom of a groove (2)
(between two teeth) with medium pressure.

a. If scribe or knife point slides across groove without

digging in or leaving a visible mark, chrome plating
is still good.

b. If scribe or knife points digs in and leaves a visible

mark, it is cutting the bare aluminum. A knife point
will not penetrate the chrome plating.

3. Replace rear sprocket if major tooth damage or loss of
chrome exists.

1. Tooth

2. Groove
Figure 1-16. Rear Sprocket

Rear Belt

See Figure 1-17. Inspect drive belt for:

• Cuts or unusual wear patterns.

• Outside edge bevelling (8). Some bevelling is common,

but it indicates that sprockets are misaligned.

• Outside ribbed surface for signs of stone puncture (7). If
cracks/damage exists near edge of belt, replace belt
immediately. Damage to center of belt will require belt
replacement eventually, but when cracks extend to edge
of belt, belt failure is imminent.

• Inside (toothed portion) of belt for exposed tensile cords
(normally covered by nylon la yer and polyethylene layer).
This condition will result in belt failure and indicates worn
transmission sprocket teeth. Replace belt and transmission
sprocket.

• Signs of puncture or cracking at the base of the belt teeth.
Replace belt if either condition exists.

• Replace belt if conditions 2, 3, 6 or 7 (on edge of belt)
exist.

NOTE

Condition 1 may develop into 2 or 3 over time. Condition 1 is
not grounds for replacing the belt, but it should be watched
closely before condition 2 develops which will require belt
replacement.

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Figure 1-17. Drive Belt Wear Patterns

Table 1-9. Drive Belt Wear Analysis

REQUIRED ACTIONCONDITIONPATTERN

OK to run, but monitor condition.Internal tooth cracks (hairline)1
Replace belt.External tooth cracks2
Replace belt.Missing teeth3
OK to run, but monitor condition.Chipping (not serious)4
OK to run, but monitor condition.Fuzzy edge cord5
Replace belt and sprocket.Hook wear6
Replace belt if damage is on the edge.Stone damage7
OK to run, but monitor condition.Bevel wear (outboard edge only)8

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CHECKING BELT DEFLECTION

TOOL NAMEPART NUMBER

BELT TENSION GAUGEHD-35381A

NOTE

Always use BELT TENSION GAUGE (Part No. HD-35381A)
to measure belt deflection. Do not rely on "feel" as this can
result in belts that are under tensioned. Loose belts will f ail due
to "ratcheting" (jumping a tooth) with resultant tensile cord
crimping and breakage.

Check rear belt deflection:

• As part of pre-ride inspection.

• At every scheduled service interval.

• With transmission in neutral.

• At loosest spot in belt.

• With motorcycle at ambient temperature.

• With motorcycle upright and rear wheel off the ground or

on jiffy stand without rider or luggage.

1. Remove left side saddlebag.

2. See Figure 1-18. Obtain BELT TENSION GAUGE (Part
No. HD-35381A).

3. Slide O-ring toward 0 lbs (0 kg) mark.

4. See Figure 1-19. Fit cradle against bottom of belt half w ay
between transmission and rear wheel compensator
sprockets.

5. While observing belt deflection through the window on the
debris deflector, push upward on knob until O-ring slides
down to the 10 lbs (4.5 kg) mark.

NOTE
Each graduation on scale represents 1/8 in. (3.2 mm) of belt
deflection.

6. Rotate rear wheel and measure deflection at different

spots on the belt. Compare results with specifications in

Table 1-10.

a. If deflection is within specification, install left side

saddlebag.

b. If deflection is not within specification, see 1.13 REAR

BELT DEFLECTION, Setting Belt Deflection.

1.13REAR BELT DEFLECTION

1. Cradle

2. 0 lbs (0 kg) mark

3. O-ring

4. Knob
Figure 1-18. Belt Tension Gauge

1. Transmission sprocket

2. Rear wheel sprocket

3. 10 lbs (4.5 kg) of force

4. Amount of deflection

Figure 1-19. Checking Belt Deflection

SETTING BELT DEFLECTION

Table 1-10. Belt Deflection

MILLIMETERSINCHESMODEL

6.4-7.91/4-5/16FLHX

9.5-11.13/8-7/16Other models

Adjustment

1. Remove both saddlebags.

2. Remove and discard E-clip from groove at end of axle.

The AXLE NUT TORQUE ADAPTER simplifies the belt
adjustment procedure by allowing the cone nut to be loosened

BELT TENSION GAUGEHD-35381A
AXLE NUT TORQUE ADAPTERHD-47925

TOOL NAMEPART NUMBER

NOTE

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and tightened without having to remove the right side muffler.
The tool also can be used to rotate the weld nut on the left
side.

3. See Figure 1-20. Install AXLE NUT TORQUE
ADAPTER (Part No. HD-47925) on 1/2 inch breaker bar,
perpendicular to breaker bar. For best clearance with
muffler, install torque adapter on the outboard side.

NOTE
In order to provide adequate room to install tools on the cone
nut and weld nut, it may be necessary to remove bolts f astening
each muffler to the rear of the saddlebag frame and pulling
each muffler away from the end of the axle.

4. Insert tool up between rear wheel and muffler and onto

cone nut. Loosen cone nut.

NOTE
Since any added length can act as a torque multiplier, the
torque wrench must be perpendicular to the torque adapter.

5. Install AXLE NUT TORQUE ADAPTER (Part No. HD-

47925) on torque wrench, perpendicular to torque wrench.

6. Insert tool up between rear wheel and muffler to capture

cone nut.

7. See Figure 1-21. Push wheel forward and verify that cam

(5) contacts boss (4) on both sides of rear fork.

8. For purposes of adjustment only , sn ug the cone nut (6) to

15-20 ft-lbs (20-27 Nm).

9. Use BELT TENSION GAUGE (Par t No. HD-35381A) to

check belt deflection as adjustment is made. See

1.13 REAR BEL T DEFLECTION, Checking Belt Deflection.

1. Torque wrench

2. Axle nut torque adapter (HD-47925)

Figure 1-20. Install Tool Perpendicular to Torque Wrench

NOTE

It may be beneficial to use a second AXLE NUT TORQUE
ADAPTER (Part No. HD-47925) and breaker bar or ratchet to
rotate and hold the weld nut.The position of the breaker bar
or ratchet in relation to the tool is not important and can be
mated in any position that will make use easy.

10. See Figure 1-21. Adjust belt tension by rotating weld nut
(3) on left side of axle; clockwise to tighten the belt or
counterclockwise to loosen the belt. If loosening the belt
tension, push the wheel forward and verify both cams (5)
touch the bosses (4) on both sides after the weld nut is
rotated.

11. When correct tension is obtained, verify the cams touch
the bosses on both sides of the rear fork.

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5.1. Adjuster camIncrease belt deflection

2. 6.Reduce belt deflection Cone nut

7.3. E-clipWeld nut

4. Weld nub
Figure 1-21. Rear Wheel Adjuster Cams

Assembly

NOTE

It is important that the weld nut does not rotate once belt ten­sion is correct. If the axle mo ves during tightening of the cone
nut, the belt deflection procedure must be restarted.

1. Hold weld nut and tighten cone nut to 95-105 ft-lbs (128.8-

142.4 Nm).

2. Again, verify the cams touch the bosses on both sides of
the rear fork. Check belt deflection to verify that it is still
within specification.

3. With the flat side out, install new E-clip in groove on right
side of axle.

4. If removed, install fasteners that attach mufflers to the
saddlebag frames and tighten to 96-144 in-lbs (10.9-16.3
Nm).

5. Install saddlebags.

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1.14BRAKES

FLUID INSPECTION

Direct contact of D.O.T. 4 brake fluid with eyes can cause
irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention.
Swallowing large amounts of D.O .T . 4 brake fluid can cause
digestive discomfort. If swallowed, obtain medical atten­tion. Use in well ventilated area. KEEP OUT OF REACH OF
CHILDREN. (00240a)

D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Alwa ys use caution and
protect surfaces from spills whenever brake work is per­formed. F ailure to comply can result in cosmetic damage.
(00239b)

Do not allow dirt or debris to enter the master cylinder
reservoir . Dirt or debris in the reservoir can cause improper
operation and equipment damage. (00205c)

1. Check level in rear master cylinder reservoir.
a. Stand motorcycle upright, so that master cylinder

reservoir is level.

b. Remove two screws to release cover from master

cylinder reservoir.

c. See Figure 1-22. Check brake fluid le vel. If necessary ,

add D.O.T. 4 BRAKE FLUID until level is flush with
top of ledge cast at front of reservoir.

d. Install master cylinder reservoir cover and tighten

screws to 12-15 in-lbs (1.4-1.7 Nm).

2. Check level in front master cylinder reservoir.
a. T urn front wheel toward left f ork stop until front master

cylinder reservoir is level.
b. Remove cover from master cylinder reservoir.
c. See Figure 1-22. Check brake fluid le vel. If necessary ,

add D.O.T. 4 BRAKE FLUID until level is flush with

step (marked MAX) cast at rear of reservoir.
d. Install master cylinder reservoir cover. Install cover

screws and tighten to 7-10 in-lbs (0.8-1.1 Nm).

After repairing the brake system, test brakes at low speed.
If brakes are not operating properly , testing at high speeds
can cause loss of control, which could result in death or
serious injury. (00289a)

3. Verify that front brake lever and rear brake pedal have a
firm feel when applied. Bleed appropriate system if brak e
feels spongy. See 1.16 BLEEDING BRAKES.

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1. Front master cylinder reservoir

2. Rear master cylinder reservoir
Figure 1-22. Brake Fluid Level

HOME

1.15BRAKE PADS AND DISCS

INSPECTION

Check brake pads and discs:

• At every scheduled service interval.

• Whenever the components are removed dur ing service

procedures.

Brake Pads

Direct contact of D.O.T. 4 brake fluid with eyes can cause
irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention.
Swallowing large amounts of D.O .T . 4 brake fluid can cause
digestive discomfort. If swallowed, obtain medical atten­tion. Use in well ventilated area. KEEP OUT OF REACH OF
CHILDREN. (00240a)

D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Alwa ys use caution and
protect surfaces from spills whenever brake work is per­formed. F ailure to comply can result in cosmetic damage.
(00239b)

Always replace brake pads in complete sets for correct
and safe brake operation. Improper brake operation could
result in death or serious injury. (00111a)

Replace both rear brake pads (inner and outer) if the friction
material of either pad is worn to 0.016 in. (0.4 mm) or less
above the backing plate.

Replace all front brake pads (inner and outer pads of both the
left and right side calipers) if the friction material of any single
pad is worn to 0.016 in. (0.4 mm) or less above the backing
plate.

NOTE

Refer to the wear indicator lines for a gener al indication of pad
wear. See Figure 1-24.

Always install a new pad pin (provided in brake pad service
kit) whenever the brake pads are replaced.

Inspect the brake lines and hoses for damage or wear.

Brake Disc Thickness

The minimum front brake disc thickness is 0.18 in. (4.5 mm)
and is stamped on the side of the disc.

The minimum rear brake disc thickness is 0.25 in. (6.3 mm)
and is stamped on the side of the disc.

Replace any disc that is excessively worn or badly scored.

BRAKE PAD REPLACEMENT
Rear Brake Caliper

1. Remove right side saddlebag. See 2.29 SADDLEBAGS,

Removal.

2. If ABS equipped, carefully cut cable strap to release rear
wheel speed sensor cable from brake hose to brake cal­iper.

3. Remove two screws to release brake caliper from caliper
bracket.

4. Remove brake caliper from brake disc.

NOTE
Do not operate the brake pedal with the rear brake caliper
removed or the caliper pistons may be forced out. Reseating
pistons requires caliper disassembly.

5. Stand motorcycle upright, so that rear master cylinder

reservoir is level. Wrap a clean shop cloth around the
outside of the reservoir to protect paint from brake fluid
spills.

6. Remove two screws to release co ver from master cylinder

reservoir.

NOTE
Fluid level will rise as pistons are pushed back into the caliper ,
possibly overflowing the master cylinder reservoir. Remove
some fluid from the reservoir if necessary.

7. Alternately push each pad back until pistons are fully

seated in the bores.

8. See Figure 1-26. Pull retaining clip from groo ve in pad pin.

9. See Figure 1-23. Remove pad pin (metric).

10. Pull on pad pin side of brake pads to release from caliper .

11. Remove pad spring if damaged or worn.

12. If removed, seat new pad spring on flat in caliper, so that

clips on spring engage indentations in caliper. Be sure
that forked end of pad spring is on the pad pin side of the
caliper.

Always replace brake pads in complete sets for correct
and safe brake operation. Improper brake operation could
result in death or serious injury. (00111a)

Brake Disc Lateral Runout

Maximum brake disc lateral runout or warpage is 0.008 in. (0.2
mm) when measured near the outside diameter of the disc.

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18. If ABS equipped, install new cable strap 1.25 in. (31.8
mm) in front of the brake hose crimp capturing rear wheel
speed sensor cable and brake hose.

After servicing brakes and before moving motorcycle,
pump brakes to build brake system pressure. Insufficient
pressure can adversely affect brake performance, which
could result in death or serious injury. (00279a)

19. Depress brake pedal several times to set brake pads to
proper operating position within caliper.

20. See Figure 1-27. Chec k brake fluid le vel in master cylinder
reservoir. If necessar y, add D.O.T. 4 BRAKE FLUID until
level is flush with ledge cast at front of reservoir.

21. Install master cylinder reservoir cover . Install cover scre ws
and tighten to 12-15 in-lbs (1.4-1.7 Nm).

22. Install right side saddlebag. See 2.29 SADDLEBAGS,

Installation.

1. Rear caliper

2. Front left caliper (screen removed)
Figure 1-23. Brake Caliper Pad Pin

13. Install new brake pads as follows:
a. See Figure 1-24. Hold inner brake pad, so that pad

pin tab is on the same side as pad pin hole in caliper.

b. See Figure 1-25. Insert opposite side of brake pad

into caliper engaging square shaped corner of pad in
slot of caliper.

c. Push pad pin tab side of brake pad into caliper until

seated.

d. V erify that brake pad friction material faces brake disc

gap in caliper.

e. Repeat step to install outer brake pad.

After repairing the brake system, test brakes at low speed.
If brakes are not operating properly , testing at high speeds
can cause loss of control, which could result in death or
serious injury. (00289a)

23. Test brake system.
a. T urn ignition switch ON. Depress br ake pedal to verify

operation of brake lamp.

b. Test ride motorcycle. Bleed the system if brakes feel

spongy. See 1.16 BLEEDING BRAKES.

NOTE
Avoid making hard stops for the first 100 miles (160 km). This
allows the new pads to become conditioned to the brake discs .

14. Turn caliper over. Verify that pad pin tabs are centered
under forks of pad spring. Adjust pads if necessary.

15. Install new pad pin and tighten to 75-102 in-lbs (8.5-11.5
Nm).

16. See Figure 1-26. Install retaining clip in groo ve of pad pin,
so that lip overhangs caliper housing.

17. Install brake caliper onto brake disc. Align holes in brake
caliper with those in caliper bracket and install two scre ws.
Alternately tighten screws to 43-48 ft-lbs (58.3-65.1 Nm).

1-34 2009 Touring Service: Maintenance

1. Square corner

2. Pad pin tab

3. Pad pin hole

4. Friction material

5. Wear indicator lines
Figure 1-24. Brake Pad

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Figure 1-25. Brake Caliper (Bottom View)

3. Remove two brake caliper mounting screws (with cable
clip/bracket if ABS equipped). Slide brake caliper straight
down to remove from brake disc. Allow the brake caliper
to hang loose.

NOTE
Do not operate the brake lever with the front brake caliper
removed or the caliper pistons may be forced out. Reseating
pistons requires caliper disassembly.

4. Resting motorcycle on jiffy stand, turn front wheel toward

left fork stop until front master cylinder reservoir is level.
Wrap a clean shop cloth around the outside of the reservoir
to protect paint from brake fluid spills.

5. Remove two screws to release co ver from master cylinder

reservoir.

NOTE
Fluid level will rise as pistons are pushed back into the caliper ,
possibly overflowing the master cylinder reservoir. Remove
some fluid from the reservoir if necessary.

6. Alternately push each pad back until pistons are fully

seated in the bores.

7. Pull screen from caliper.

8. See Figure 1-26. Pull retaining clip from groo ve in pad pin.

9. See Figure 1-23. Remove pad pin (metric).

10. Pull on pad pin side of brake pads to release from caliper .

11. Remove pad spring if damaged or worn.

12. If removed, seat new pad spring on flat in caliper, so that

clips on spring engage indentations in caliper. Be sure
that forked end of pad spring is on the pad pin side of the
caliper.

Always replace brake pads in complete sets for correct
and safe brake operation. Improper brake operation could
result in death or serious injury. (00111a)

13. Install new brake pads as follows:

a. See Figure 1-24. Hold inner brake pad, so that pad

1. Pad spring (forked end)

2. Pad pin tab

3. Pad pin retaining clip
Figure 1-26. Brake Caliper (Top View)

Front Brake Calipers

1. If present, carefully cut two cable straps to release front
wheel speed sensor cable and front fender tip lamp wires
from brake hose to left brake caliper.

2. On ABS equipped motorcycles, release front wheel speed
sensor cable from clip as follows:

a. Push on lip at rear of clip to disengage from bracket.
b. Rotate tab (stamped ABS) rearward until clip is per-

pendicular to bracket and remove cable.

14. Turn caliper over. Verify that pad pin tabs are centered

15. Install new pad pin and tighten to 75-102 in-lbs (8.5-11.5

16. See Figure 1-26. Install retaining clip in groo ve of pad pin,

pin tab is on the same side as pad pin hole in caliper.

b. See Figure 1-25. Insert opposite side of brake pad

into caliper engaging square shaped corner of pad in
slot of caliper.

c. Push pad pin tab side of brake pad into caliper until

seated.

d. V erify that brake pad friction material faces brake disc

gap in caliper.

e. Repeat step to install outer brake pad.

under forks of pad spring. Adjust pads if necessary.

Nm).

so that lip overhangs caliper housing.

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17. Engaging two prongs on screen beneath forked end of
pad spring, push on single prong side of screen until
engaged.

18. Install brake caliper as follows:
a. With the bleeder valve topside, install caliper at

bottom of brake disc.

b. Slide brake caliper straight up until holes are aligned

with lugs on fork slider. Star t two mounting screws
(with cable clip/bracket if ABS equipped).

NOTE
Be sure that tab (stamped ABS) on clip is installed in slot
of bracket from inboard side. Clip cannot be installed once
mounting screws are started.

c. Alter nately tighten mounting screws to 28-38 ft-lbs

(37.9-51.5 Nm).

After servicing brakes and before moving motorcycle,
pump brakes to build brake system pressure. Insufficient
pressure can adversely affect brake performance, which
could result in death or serious injury. (00279a)

19. If ABS equipped, install two new cable straps as follows:
a. Install cable strap 2.5 in. (63.5 mm) above the bottom

brake hose crimp capturing front wheel speed sensor
cable and brake hose.

b. Install cable strap 2.5 in. (63.5 mm) below the top

brake hose crimp capturing front wheel speed sensor
cable, brake hose and front fender tip lamp wires, if
equipped.

22. Depress brake lever several times to set brake pads to
proper operating position within caliper.

23. See Figure 1-27. Chec k brake fluid le vel in master cylinder
reservoir. If necessar y, add D.O.T. 4 BRAKE FLUID until
level is flush with step (marked MAX) cast at rear of
reservoir.

24. Install master cylinder reservoir cover . Install cover scre ws
and tighten to 7-10 in-lbs (0.8-1.1 Nm).

After repairing the brake system, test brakes at low speed.
If brakes are not operating properly , testing at high speeds
can cause loss of control, which could result in death or
serious injury. (00289a)

25. Test brake system.
a. Turn ignition switch ON. Depress brake le ver to v erify

operation of brake lamp.

b. Test ride motorcycle. Bleed system if brakes feel

spongy. See 1.16 BLEEDING BRAKES.

NOTE
Avoid making hard stops for the first 100 miles (160 km). This
allows the new pads to become conditioned to the brake discs .

20. If ABS equipped, install front wheel speed sensor cable
in clip as follows:

a. Rotate tab (stamped ABS) until clip is perpendicular

to bracket and install cable.

b. Rotate tab forward until clip is in-line with brac ket and

then apply pressure to tab until lip engages. Gently
pull on cable to verify that clip is properly installed.

21. Repeat applicable steps to replace brake pads in right
side caliper.

After servicing brakes and before moving motorcycle,
pump brakes to build brake system pressure. Insufficient
pressure can adversely affect brake performance, which
could result in death or serious injury. (00279a)

1. Front master cylinder reservoir

2. Rear master cylinder reservoir
Figure 1-27. Brake Fluid Level

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1.16BLEEDING BRAKES

GENERAL

Use denatured alcohol to clean brake system components.
Do not use mineral-based solvents (such as gasoline or
paint thinner), which will deteriorate rubber parts even
after assembly. Deterioration of these components can
cause brake failure, which could result in death or serious
injury. (00291a)

Direct contact of D.O.T. 4 brake fluid with eyes can cause
irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention.
Swallowing large amounts of D.O .T . 4 brake fluid can cause
digestive discomfort. If swallowed, obtain medical atten­tion. Use in well ventilated area. KEEP OUT OF REACH OF
CHILDREN. (00240a)

D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Alwa ys use caution and
protect surfaces from spills whenever brake work is per­formed. F ailure to comply can result in cosmetic damage.
(00239b)

iper/banjo bleeder bolt bore during bleeder valv e installa­tion and prevent proper torquing or sealing.

• ABS equipped motorcycles require the use of DIGITAL
TECHNICIAN II (Part No. HD-48650) to confir m that the
brake lines are properly connected and that air is
adequately bled from ABS unit.

1. Remove bleeder v alv e cap. Install end of a length of clear
plastic tubing over caliper bleeder valve. Place free end
of tube in a clean container.

2. If bleeding rear brake system, stand motorcycle upright,
so that rear master cylinder reservoir is level. If bleeding
front brake system, turn front wheel until front master cyl­inder reservoir is level.

NOTE
Wrap a clean shop cloth around the outside of the master cyl­inder reservoir to protect paint from brake fluid spills.

3. Remove cover from master cylinder reservoir.

4. See Figure 1-28. Add D.O.T. 4 BRAKE FLUID to master

cylinder reservoir as follows:
a. Front master cylinder reservoir: flush with step

(marked MAX) cast at rear of reservoir or 0.20 in. (5.0
mm) from the top.

b. Rear master cylinder reservoir: flush with ledge cast

at front of reservoir or 0.26 in. (6.5 mm) from the top.

Do not allow dirt or debris to enter the master cylinder
reservoir . Dirt or debris in the reservoir can cause improper
operation and equipment damage. (00205c)

Front brake hand lever and rear brake foot pedal must have a
firm feel when brakes are applied. If not, bleed system as
described.

PROCEDURE

TOOL NAMEPART NUMBER

DIGITAL TECHNICIAN IIHD-48650
BASIC VACUUM BRAKE BLEEDERSNAP-ON BB200A

NOTES

• For best results, use the BASIC VACUUM BRAKE
BLEEDER (Part No. Snap-On BB200A) or equivalent tool,
particularly if the brake system was completely drained.
Refer to the instructions provided with the tool. If a vacuum
brake bleeder is not available, use the procedure which
follows.

• When removing or replacing a bleeder valve in the rear
brake caliper or front banjo bleeder bolts, remove the o­ring from the bleeder valve groove or bore and discard.
The o-ring is required only for brake bleeding at the f actory .
Although not sold separately, it may be present in certain
assemblies as currently sold. If care is not taken to remov e
and discard the o-ring, it may become lodged in the cal-

Any time the ABS module, either master cylinder, or any
line between a master cylinder and the ABS module is
disconnected or replaced, Digital Technician II must be
used during the brake bleeding procedure to verify all air
is removed from the system. Failure to do so could result
in air in the hydraulic brake system, reducing brake effi­ciency, which could result in death or serious injury.
(00585b)

5. If vehicle is ABS equipped, connect DIGITAL TECHNICIAN
II (Part No. HD-48650).

6. Pump the brake lev er/pedal to build up h ydraulic pressure.

7. While holding the brake lever/pedal, open brake caliper
bleeder valve about 3/4 turn. Close b leeder v alve as soon
as a loss of hydraulic pressure is detected (or when brake
lever/pedal has mov ed 1/2 to 3/4 of its full range of tra vel).
Allow brake lever/pedal to return slowly to its released
position.

8. Repeat steps 4-6 until all air bubbles are purged and a
solid column of fluid is observed in the bleeder tube. Pay
careful attention to the level of the fluid in the master cyl­inder reservoir.To avoid drawing air into the brake lines,
always add fluid to the master cylinder reservoir before it
empties.

9. Tighten bleeder valve to 80-100 in-lbs (9.0-11.3 Nm).
Install bleeder valve cap.

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NOTE
If bleeding the front brake system, repeat applicable steps to
bleed the line to the second brake caliper.

10. Add brake fluid to the master cylinder reservoir as

described in step 4.

A plugged or covered relief port can cause brake drag or
lock-up, which could lead to loss of control, resulting in
death or serious injury. (00288a)

11. Verify proper operation of the master cylinder relief port.

Actuate the brake hand lever. A slight spur t of fluid will
break the fluid surface in the reservoir if all internal com­ponents are working properly.

12. V erify that the master cylinder cover gask et bellows is not

extended or brake fluid will be ejected from the reservoir.
Install cover and tighten screws as follows:

a. Front master cylinder reservoir: 7-10 in-lbs (0.8-1.1

Nm).

b. Rear master cylinder reservoir: 12-15 in-lbs (1.4-1.7

Nm).

After repairing the brake system, test brakes at low speed.
If brakes are not operating properly , testing at high speeds
can cause loss of control, which could result in death or
serious injury. (00289a)

15. Test ride motorcycle. Repeat the bleeding procedure if
brakes feel spongy.

13. If motorcycle is ABS equipped, disconnect DIGITAL
TECHNICIAN II (Part No. HD-48650).

14. With the Ignition/Light Key Switch turned to IGNITION,
alternately apply front and rear brakes to verify operation
of the brake lamp.

1. Front master cylinder reservoir

2. Rear master cylinder reservoir
Figure 1-28. Brake Fluid Level

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1.17BATTERY MAINTENANCE

GENERAL

Batteries contain sulfuric acid, which could cause severe
burns to eyes and skin. Wear a protective face shield,
rubberized gloves and protective clothing when working
with batteries. KEEP BA TTERIES A W A Y FROM CHILDREN.
(00063a)

Never remove warning label attached to top of battery.
Failure to read and understand all precautions contained
in warning, could result in death or serious injury . (00064a)

Batteries, battery posts, terminals and related accessories
contain lead and lead compounds, and other chemicals
known to the State of California to cause cancer , and birth
defects or other reproductive harm. Wash hands after
handling. (00019e)

All AGM batteries are permanently sealed, maintenance-free,
valve-regulated, lead/calcium and sulfuric acid batteries.The
batteries are shipped pre-charged and ready to be put into
service. Do not attempt to open these batteries for an y reason.

NOTE

For charging information, see 1.17 BATTERY MAINTENANCE,

Charging Battery. For testing infor mation, see ELECTRICAL

DIAGNOSTIC MANUAL.

Figure 1-29. AGM Battery with Warning Label

4.1. Keep flames awayContents are corrosive

2. 5.Wear safety glasses Read instructions

6.3. Keep away from childrenContents are explosive

Figure 1-30. Battery Warning label

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Table 1-11. Antidotes for Battery Acid

TREATMENTCONTACT

Flush with water.External

Internal

Eyes

Drink large quantities of milk or water, f ollowed
by milk of magnesia, vegetable oil or beaten
eggs. Get immediate medical attention.

Flush with water. Get immediate medical
attention.

CLEANING AND INSPECTION

1. Battery top must be clean and dry. Dirt and electrolyte on
top of the battery can cause battery to self-discharge.
Clean battery top with a solution of baking soda (sodium
bicarbonate) and water (5 teaspoons baking soda per
quart or liter of water).When the solution stops bubbling,
rinse off the battery with clean water.

2. Clean cable connectors and battery terminals using a wire
brush or sandpaper. Remove any oxidation.

3. Inspect the battery screws, clamps and cables for
breakage, loose connections and corrosion. Clean clamps.

4. Check the battery posts for melting or damage caused by
overtightening.

5. Inspect the battery for discoloration, raised top or a warped
or distorted case, which might indicate that the battery has
been frozen, overheated or overcharged.

6. Inspect the battery case for cracks or leaks.

1. Purge solenoid

2. HFSM antenna

3. Cable ties

4. Fastener
Figure 1-31.Top Caddy

BATTERY
Disconnection and Removal

1. Remove seat.

2. See Figure 1-31. If present, move purge solenoid (1) for­ward to release from top caddy. Release HFSM antenna
(2) from top caddy and move out of the way.

3. Remove fasteners (4).

4. Cut cable ties (3) and move harnesses to allow more
clearance for the top caddy.

5. See Figure 1-32. Release top caddy from front hold-do wn
and rotate top caddy (1) out of the way.

Disconnect negative (-) battery cable first. If positive (+)
cable should contact ground with negative (-) cable con­nected, the resulting sparks can cause a battery explosion,
which could result in death or serious injury. (00049a)

6. Remove battery negative cable (black) from battery neg­ative (-) terminal.

7. Remove battery positive cable (red) from battery positive
(+) terminal.

8. Grasp lifting strap (2) and pull up to raise battery. When
battery is extracted far enough to get a good grip, grasp
battery and remove the rest of the way.

1. Top caddy

2. Lifting strap
Figure 1-32. Move Top Caddy Aside

Installation and Connection

Connect the cables to the correct battery terminals. Failure
to do so could result in damage to the motorcycle electrical
system. (00215a)

Do not allow positive (+) battery cable to contact ground
with negative (-) cable connected. Resulting sparks can
cause a battery explosion, which could result in death or
serious injury. (00069a)

1. Run lifting strap rearward, first down the center of the
battery tray, then up and across the frame crossmember.

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2. Place the battery into the battery tray, terminal side for­ward.

Connect positive (+) battery cable first. If positive (+) cable
should contact ground with negative (-) cable connected,
the resulting sparks can cause a battery explosion, which
could result in death or serious injury. (00068a)

Do not over-tighten bolts on battery terminals. Use
recommended torque values. Over-tightening battery ter­minal bolts could result in damage to battery terminals.
(00216a)

3. Connect battery positive cable (red) to battery positive (+)
terminal.Tighten bolt to 60-70 in-lbs (6.8-7.9 Nm).

4. Connect battery negative cable (black) to battery negative
(-) terminal.Tighten bolt to 60-70 in-lbs (6.8-7.9 Nm).

Keep battery clean and lightly coat terminals with petro­leum jelly to prevent corrosion. Failure to do so could
result in damage to battery terminals. (00217a)

5. Apply a light coat of petroleum jelly or ELECTRICAL
CONTACT LUBRICANT, Part No. 99861-02 (1 oz tube),
to both battery terminals.

6. See Figure 1-32. Fold lifting strap (2) forward over top of
battery.

7. See Figure 1-31. Rotate top caddy into position above
battery and engage latch on hold-down bracket.

8. If equipped, engage HFSM antenna (2) and purge solenoid
(1) on top caddy .Verify all other connectors and harnesses
are routed below the purge solenoid mounting tongue.

9. Fasten top caddy to frame crossmember. Tighten screws
(4) to 72-96 in-lbs (8.1-10.9 Nm).

10. Secure harnesses to frame with cable ties (3).

11. Install seat.

VOLTMETER TEST

Voltmeter Test

Refer to Table 1-12. The voltmeter test provides a general
indicator of battery condition. Check the v oltage of the battery
to verify that it is in a 100% fully charged condition. If the open
circuit (disconnected) voltage reading is below 12.6V, charge
the battery and then recheck the voltage after the battery has
set for one to two hours. If the voltage reading is 12.7V or
above, perform a load test. See the ELECTRICAL DIA­GNOSTIC MANUAL for the load test procedure.

T able 1-12.Voltmeter Test For Battery Charge Conditions

STATE OF CHARGEVOLTAGE (OCV)

100%12.7 V

75%12.6 V
50%12.3 V
25%12.0 V

0%11.8 V

CHARGING BATTERY
Safety Precautions

Never charge a battery without first reviewing the instructions
for the charger being used. In addition to the manufacturer's
instructions, follow these general safety precautions:

• Always wear eye, face and hand protection.

• Always charge batteries in a well-ventilated area.

• Turn the charger off before connecting the leads to the

battery to avoid dangerous sparks.

• Never try to charge a visibly damaged or frozen battery.

• Connect the charger leads to the battery; red positive (+)

lead to the positive (+) terminal and black negative (-) lead
to the negative (-) terminal. If the battery is still in the
vehicle, connect the negative lead to the chassis g round.
Be sure that the ignition and all electrical accessories are
turned off.

• Make sure that the charger leads to the battery are not
separated, frayed or loose.

• If the battery gets hotter than 110° F (43° C) during char­ging, discontinue charger and allow the battery to cool.

• Always turn the charger off before removing charger leads
from the battery to avoid dangerous sparks.

Batteries contain sulfuric acid, which could cause severe
burns to eyes and skin. Wear a protective face shield,
rubberized gloves and protective clothing when working
with batteries. KEEP BA TTERIES A W A Y FROM CHILDREN.
(00063a)

Never remove warning label attached to top of battery.
Failure to read and understand all precautions contained
in warning, could result in death or serious injury . (00064a)

Using a Battery Charger

Charge the battery if any of the following conditions exist:

• Vehicle lights appear dim.

• Electric starter sounds weak.

• Battery has not been used for an extended period of time.

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Explosive hydrogen gas, whic h escapes during char ging,
could cause death or serious injury. Charge battery in a
well-ventilated area. Keep open flames, electrical sparks
and smoking materials away from battery at all times.
KEEP BATTERIES AWAY FROM CHILDREN. (00065a)

If battery releases an excessive amount of gas during
charging, decrease the charging rate. Overheating can
result in plate distortion, internal shorting, drying out or
damage. (00413b)

Table 1-13. 28 Amp-Hour Battery Charging Rate/Times

1. Perf orm a voltmeter test to determine the state of charge.
See the ELECTRICAL DIAGNOSTIC MANUAL. If battery
needs to be charged, proceed to the next step.

NOTE

The figures listed in the table assume that the battery is char­ging at room temperature. If warmer than room temperature,
use a slightly shorter charging time. If colder, use a slightly
longer charging time.

READING

(VOLTS)

The use of constant current chargers to charge sealed main­tenance-free batteries is not recommended. Any overcharge
will cause dry-out and premature battery failure. If a constant
current charger is the only type available, do not exceed the
charge times listed above and do not continue charging the
battery if it gets hot.When charging, never exceed 15 v olts f or
more than 30 minutes.

Unplug or turn OFF battery charger before connecting
charger cables to battery . Connecting cables with charger
ON can cause a spark and battery explosion, which could
result in death or serious injury. (00066a)

Do not reverse the charger connections described in the
following steps or the charging system of the motorcycle
could be damaged. (00214a)

2. Connect red battery charger lead to the positive (+) ter­minal of the battery.

3. Connect black battery charger lead to the negative (-)
terminal of the battery.

If the battery is still in the vehicle, connect the negative lead
to the chassis ground. Be sure that the ignition and all electrical
accessories are turned off.

4. Step away from the battery and turn on the charger. See
the charging instructions in Table 1-13.

PERCENT

OF CHARGE

NOTE

NOTE

3 AMP

CHARGER

6 AMP

CHARGER

Unplug or turn OFF battery charger before disconnecting
charger cables from battery. Disconnecting clamps with
charger ON can cause a spark and battery explosion, which
could result in death or serious injury. (00067a)

5. After the battery is fully charged, disconnect the black
battery charger lead to the negative (-) terminal of the
battery.

6. Disconnect the red battery charger lead to the positive (+)
terminal of the battery.

7. Mark the charging date on the battery.

8. Perf orm either a conductance test or load test to determine
the condition of the battery. See the ELECTRICAL DIA­GNOSTIC MANUAL.

9. If charging battery because voltmeter test reading was
below 12.6 V, perform voltmeter test. See the ELEC­TRICAL DIAGNOSTIC MANUAL.

10 AMP

CHARGER

20 AMP

CHARGER

----10012.7
25 minutes45 minutes1.25 hours2.5 hours7512.6
50 minutes1.5 hours2.5 hours5 hours5012.3
70 minutes2.25 hours3.75 hours7.5 hours2512.0

1.5 hours3 hours5 hours10 hours011.8

STORAGE

TOOL NAMEPART NUMBER

GLOBAL BATTERY CHARGER99863-01A

Batteries contain sulfuric acid, which could cause severe
burns to eyes and skin. Wear a protective face shield,
rubberized gloves and protective clothing when working
with batteries. KEEP BA TTERIES A W A Y FROM CHILDREN.
(00063a)

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50%

75%

100%

0

¡

¡

105 °F

(40.5 °C)

77 °F (25 °C)

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Do not allow battery to completely discharge.The electro­lyte in a discharged battery will freeze. The more dis­charged a battery is, the more easily it can freeze and crack
the battery case. (00218a)

If the motorcycle is to be stored with the security system armed,
connect a GLOBAL BATTERY CHARGER (Part No. 99863­01A) to maintain battery charge.

If the motorcycle is to be stored with the battery installed, a
GLOBAL BATTERY CHARGER unavailable, and with the
security system not armed, unplug the main fuse.

If the motorcycle will not be operated for sev eral months , such
as during the winter season, remove the battery from the
motorcycle and fully charge.

See Figure 1-33. Self-discharge is a normal condition and
occurs continuously at a rate that depends on the ambient
temperature and the battery's state of charge. Batteries dis­charge at a faster rate at higher ambient temperatures. To
reduce the self-discharge rate, store battery in a cool (not
freezing), dry place.

Charge the battery every month if stored at temperatures below
60° F (16° C). Charge the battery more frequently if stored in
a warm area above 60° F (16° C).

NOTES

• The GLOBAL BA TTER Y CHARGER (Part No. 99863-01A)
may be used to maintain battery charge for extended
periods of time without risk of overcharging or boiling.

• When returning a battery to service after storage, see
ELECTRICAL DIAGNOSTIC MANUAL.

1. Capacity

2. Months of non-use
Figure 1-33. Battery Self-Discharge Rate

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1.18SUSPENSION ADJUSTMENTS

GENERAL

TOOL NAMEPART NUMBER

HD-34633A

Adjust the rear air suspension pressure by adding or removing
air from the air valve located near the upper shock absorber
mount on the left side of the motorcycle. See Figure 1-34.
Always adjust pressures with the motorcycle on the jiffy stand.

Air pressure may be varied to suit load conditions, riding style
and personal comfort. Less initial pressure does not necessarily
result in a softer ride. Refer to the tables below for the recom­mended air suspension pressures.

Do not exceed the motorcycle's Gross Vehicle Weight
Rating (GVWR) or Gross Axle Weight Rating (GAWR).
Exceeding these weight ratings can affect stability and
handling, which could result in death or serious injury.
(00016e)

Use T ab le 1-14 or Table 1-15 as a starting point in determining
suitable rear air suspension pressures. Do not exceed max­imum GVWR when loading vehicle and do not pressurize
system in excess of 50 psi (345 kPa) for FLHX models and 35
psi (241 kPa) for all others.

AIR SUSPENSION PUMP AND
GAUGE

NOTES

• Use AIR SUSPENSION PUMP AND GAUGE (Part
No. HD-34633A) ito adjust suspension air pressure.

• Use a no-loss air gauge to check air pressure. Check
pressure in shocks weekly if in daily use or before each
trip if only used occasionally.

• Improper inflation of rear air suspension components also
can result in a reduction of available suspension travel,
reduced rider comfort and possible damage to shock
absorbers.

Use caution when bleeding air from the suspension.
Moisture combined with lubricant may leak onto the rear
wheel, tire and/or brake components and adversel y affect
traction, which could result in death or serious injury.
(00084a)

Do not exceed maximum air pressure for rear suspension.
Air components fill rapidly. Therefore, use low air line
pressure. Failure to do so may result in possible damage
to components. (00165a)

Figure 1-34. Rear Air Suspension Air Valve

Table 1-14. Rear Suspension Recommended Air Pressure: FLHR/C, FLTR, FLHX

PRESSURETOTAL WEIGHTSHOCK LOAD

kPaPSIKGLB.

00up to 68up to 150Solo rider

0-690-1068-91150-200

69-13810-2091-113200-250
138-20620-30113-136250-300
206-34530-50over 136over 300

69-13810-20up to 68up to 150Solo rider with capacity luggage of 40 lbs (18 kg)
138-20620-3068-91150-200
206-27630-4091-113200-250
276-34540-50113-136250-300

34550over 136over 300

276-34540-50ALLALLRider plus passenger

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Table 1-14. Rear Suspension Recommended Air Pressure: FLHR/C, FLTR, FLHX

If P&A Tour-Pak is installed, add 5-10 psi (34-69 kPa) to shock pressure.
Do not exceed 50 psi (345 kPa) rear shock pressure.

Table 1-15. Rear Suspension Recommended Air Pressure: FLHT/C/U

Do not exceed 50 psi (345 kPa) rear shock pressure.

PRESSURETOTAL WEIGHTSHOCK LOAD

kPaPSIKGLB.

34550ALLALLMaximum GVWR

PRESSURETOTAL WEIGHTSHOCK LOAD

kPaPSIKGLB.

34-695-10up to 68up to 150Solo rider

69-13810-2068-91150-200
138-20620-3091-113200-250
206-27630-40113-136250-300
276-34540-50over 136over 300
172-20625-30up to 68up to 150Solo rider with capacity luggage of 70 lbs (32 kg)
206-27630-4068-91150-200
276-34540-5091-113200-250

34550over 113over 250
34550ALLALLRider plus passenger
34550ALLALLMaximum GVWR

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REPLACING FORK OIL

Fork assemblies must be removed to drain fork oil. See

2.19 FRONT FORK.

1.19FRONT FORK OIL

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1.20SPARK PLUGS

INSPECTION

Disconnecting spark plug cable with engine running can
result in electric shock and death or serious injury.
(00464b)

1. After the engine has cooled to room temperature, discon­nect cables from both spark plugs.

2. Remove spark plugs. If a plug has eroded electrodes,
heavy deposits or a cracked insulator, discard it.

3. See Figure 1-35. Compare your observations of the plug
deposits with the descriptions provided below.

a. A wet, black and shiny deposit on plug base, elec-

trodes and ceramic insulator tip indicates an oil fouled
plug. The condition may be caused by one or more
of the following: worn pistons, worn piston rings, worn
valves, worn valve guides, worn valve seals, a weak
battery or a faulty ignition system.

b. A dry, fluffy or sooty black deposit indicates an air-

fuel mixture that is too rich.

c. A light brown, glassy deposit indicates an overheated

plug. This condition may be accompanied by cracks
in the insulator or by erosion of the electrodes and is
caused by an air-fuel mixture that is too lean, a hot­running engine, valves not seating or improper ignition
timing. The glassy deposit on the spark plug is a
conductor when hot and may cause high-speed mis­firing. A plug with eroded electrodes, heavy deposits
or a cracked insulator must be replaced.

d. A plug with a white, yellow, tan or rusty brown

powdery deposit indicates balanced combustion.
Clean off spark plug deposits at regular intervals.

6. Check condition of threads on cylinder head and plug. If
necessary to remove deposits, apply penetrating oil and
clean out with a thread chaser.

7. Apply LOCTITE ANTI-SEIZE to the spark plug threads.
Install and tighten to 12-18 ft-lbs (16.3-24.4 Nm).

8. Connect spark plug cables. Rear cylinder plug cable
attaches to right coil terminal. Verify that cables are
securely connected to coil and spark plugs.

Figure 1-35.Typical Spark Plug Deposits

SPARK PLUG CABLE INSPECTION

Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)

4. If the plugs require cleaning between tune-ups, proceed
as follows:

a. Degrease firing end of spark plug using ELECTRICAL

CONT A CT CLEANER. Dry plug with compressed air.

b. Use a thin file to flatten spark plug electrodes. A spark

plug with sharp edges on its electrodes requires 25­40% less firing voltage than one with rounded edges.

c. If the plugs cannot be cleaned, replace with new

spark plugs.

5. Check electrode gap with a wire-type feeler gauge. Bend
the outside of the electrode so only a slight drag on the
gauge is felt when passing it between electrodes. Proper
gap measurement is 0.038-0.043 in. (0.97-1.09 mm).

1. Inspect spark plug cables. Replace cables that are worn
or damaged.

a. Check for cracks or loose terminals.
b. Check for loose fit on ignition coil and spark plugs.

2. Check cable boots/caps for cracks or tears. Replace
boots/caps that are worn or damaged.

3. See Figure 1-36. Check spark plug cable resistance with
an ohmmeter. Compare values from test with Table 1-16.
Replace cables not meeting resistance specifications.

Table 1-16. Spark Plug Cable Resistance Values

LENGTHDESCRIPTION

mmIn.

2009 Touring Service: Maintenance 1-47

RESISTANCE

VALUE

(OHMS)

8688-23,17888334.75Front cable
4188-11,17242516.75Rear cable

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1. Ohmmeter positive lead

2. Ohmmeter negative lead

3. Spark plug cable

4. Ohmmeter
Figure 1-36.Testing Resistance

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1.21STEERING HEAD BEARINGS

LUBRICATION

1. See Figure 1-37.Turn handlebar to the r ight fork stop to
access grease fitting at the left side of the steering head.

2. Inject Special Purpose Grease, Part No. 99857-97 until it
exudes from top and bottom of steering head.

Figure 1-37. Steering Head Bearing Grease Fitting

CHECKING

1. Raise the motorcycle so that the front and rear tires are
the same distance from the floor.

2. Verify that motorcycle is in stock configuration. Remove
all non-factory accessories, since they can influence front
end swing momentum (and lead to improper adjustment).

3. See Figure 1-38.T urn the front wheel until contact is made
with the left fork stop and then let go.The wheel should
swing from side to side, finally stopping in either the third
or fourth swing. If it stops in the third swing, it should be
at or after the center or straight-forward position.

4. If the clutch cable or main harness appears to be influen­cing swing momentum, proceed as follo ws and repeat the
previous step:

a. Clutch cable: Disconnect clutch cable at hand lev er.

Release cable from P-clamp fastened to upper fork
bracket (FLHR/C), remove from inner fairing
(FLHT/C/U), or release from cable clip on instrument
nacelle (FLTR). See 2.25 CLUTCH CABLE if neces­sary.

b. Main harness: Remove rivet and P-clamp to release

main harness from steering head. Secure P-clamp
with a new rivet when procedure is complete.

NOTE
A steering head that is too tight can interfere with the vehicle's
ability to absorb a weave. A steering head that is too loose can
interfere with the vehicle's ability to absorb a wobble.

5. To correct a swing pattern that is too shor t or too long,

see 1.21 STEERING HEAD BEARINGS, Adjustment.

1. Too tight- wheel stops in first or second swing

2. Correct- wheel stops in third swing

3. Correct- wheel stops in fourth swing

4. Too loose- wheel stops in fifth swing

ADJUSTMENT

1. Disassemble motorcycle as follows:
a. FLHR/C: Remove headlamp nacelle. See

2.47 HEADLAMP NACELLE: FLHR/C.

b. FLHX, FLHT/C/U: Remove outer fairing and radio

(storage box on FLHT). See 2.37 UPPER FAIRING

AND WINDSHIELD: FLHX, FLHT/C/U and

7.33 ADVANCED AUDIO SYSTEM, respectively.

c. FLTR: Remove instrument bezel. See

2.42 INSTRUMENT BEZEL: FLTR.

Figure 1-38. Check Steering Head Bearing Swing-by

2. See Figure 1-39. Loosen pinch bolts (3) on lower fork
bracket to prevent any binding of the front end when the
adjustment is made.

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1. Fork stem nut

2. Adjuster nut

3. Pinch bolt
Figure 1-39. Fork Stem and Brackets

3. Loosen the fork stem nut (1).

4. See Figure 1-40. Fashion a bearing adjuster tool using a
drill rod 1/4 in. (6.4 mm) in diameter and 16 in. (406.4 mm)
long.

NOTE
See Figure 1-39.Turning the bearing adjuster nut (2) as little
as one notch will make a noticeable difference in the swing
pattern.

5. Turn bearing adjuster nut (2) as follows:

a. To decrease the number of swings, rotate nut clock-

wise.

b. To increase the number of swings, rotate nut coun-

terclockwise.

12. Assemble motorcycle as follows:
a. FLHR/C: Install headlamp nacelle. See 2.47 HEAD-

LAMP NACELLE: FLHR/C.

b. FLHX, FLHT/C/U: Install radio (storage bo x on FLHT)

and outer fairing. See 7.33 ADVANCED AUDIO

SYSTEM and 2.37 UPPER FAIRING AND WIND­SHIELD: FLHX, FLHT/C/U, respectively.

c. FLTR: Install instrument bezel. See 2.42 INSTRU-

MENT BEZEL: FLTR.

13. Install any accessories that were removed during the
checking procedure.

NOTES

• Original equipment fork stem nut has a blue dye coating.
If a replacement nut is being installed, the replacement
nut will not have the blue coating.

• Whenever the stem nut is loosened or removed, the
threads must be lubricated with anti-seize lubricant prior
to assembly and tightening.

6. Remove the stem nut and lubricate threads with a light
coating of anti-seize lubricant.

7. Install stem nut and tighten to 70-80 ft-lbs (94.9-108.4
Nm).

The tightness of the nut will affect the swing pattern.

8. Recheck the swing pattern and adjust as necessary.

9. Tighten pinch bolts to 53-57 ft-lbs (71.9-77.3 Nm).

10. Verify that the fork stem nut is tightened to 70-80 ft-lbs
(94.9-108.4 Nm).

11. Recheck the swing pattern and adjust if necessary.

NOTE

1. All models except FLTR

2. FLTR

3. 1/8 in.

4. 5/32 in.

5. 5/32 in. goes back for 1-1/4 in.

6. 2 in. to start of bend
Figure 1-40. Fashion Bearing Adjuster Tool

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1.22CABLE AND CHASSIS LUBRICATION

GENERAL

Inspect and lubricate the following at scheduled service inter­vals as specified in 1.3 MAINTENANCE SCHEDULE.

• Front brake hand lever.

• Clutch hand lever.

• Clutch cable.

• Foot shift lever pivot (if applicable).

• Rear brake lever pivot.

• Steering head bearings.

• Jiffy stand.

If service is on muddy or dusty roads, clean and lubricate at
shorter intervals.

Use SUPER OIL (Part no. HD-94968-85TV) for hand levers
and cables.

STEERING HEAD BEARINGS

Lubricate the steering head bearings with HARLEY -DA VIDSON
SPECIAL PURPOSE GREASE. See 1.21 STEERING HEAD

BEARINGS for procedure.

JIFFY STAND

Clean and lubricate the jiffy stand. For more information, see

2.53 JIFFY STAND.

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HEADLAMP ALIGNMENT

The automatic-on headlamp feature provides increased
visibility of the rider to other motorists. Be sure headlamp
is on at all times. P oor visibility of rider to other motorists
can result in death or serious injury. (00030b)

NOTE

Vehicles with multiple beam headlamps that are individually
aimed should be adjusted so both lamps converge into one
pattern.

1. V erify that front and rear tire inflation pressures are correct
and that suspension is adjusted to the weight of the prin­cipal rider. See 1.10 TIRES AND WHEELS.

2. Fill fuel tank or add ballast to equal the weight of the fuel
needed.

NOTE
See Figure 1-41. To aid in properly placing the motorcycle, a
perpendicular line (1) can be drawn on the floor. For best res­ults, choose an area with minimum light.

3. See Figure 1-41. Draw a vertical line (2) on the wall.

4. Position motorcycle so that front axle is 25 feet (7.6

meters) from wall.

NOTE
As the weight of the rider will compress the suspension slightly ,
have a person whose weight is appro ximately the same as that
of the principal rider sit on the motorcycle.

5. With the vehicle laden and upright, point the front wheel

straight forward at wall and measure the distance (4) from
the floor to the center of the HIGH BEAM bulb.

6. Draw a horizontal line (5) through the vertical line on the

wall that is 2.1 in. (53.3 mm) lower than the measured bulb
centerline.

1.23HEADLAMP ALIGNMENT

1. Perpendicular line

2. Vertical line

3. 25 feet (7.6 meters)

4. High beam bulb centerline

5. Horizontal line 2.1 in. (53.3 mm) lower than b ulb
centerline

Figure 1-41. Check Headlamp Alignment

NOTE

As the weight of the rider will compress the suspension slightly ,
have a person whose weight is appro ximately the same as that
of the principal rider sit on the motorcycle.

7. See Figure 1-41. Verify headlamp alignment. Turn the
ignition switch to IGNITION and set the headlamp switch
to HIGH beam.

a. The center of the hot spot (brightest area of light

beam) should be centered where the two lines inter­sect.

b. Adjust headlamp alignment if necessary.

MAIN HEADLAMP ADJUSTMENT

1-52 2009 Touring Service: Maintenance

Adjust FLHR/FLHT Headlamp

NOTE

Headlamp adjustment can be performed without removing the
headlamp door (chrome ring).

1. See Figure 1-42. Using adjuster slots in headlamp door,
insert Phillips screwdriver between headlamp housing and
rubber gasket.

2. See Figure 1-43. Adjust beam.
a. Horizontal: Turn the horizontal adjusting screw to

adjust headlamp horizontally.

b. Vertical: Tur n the vertical adjusting screw to adjust

headlamp vertically.

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1. Headlamp door

2. Slot
Figure 1-42. Headlamp Door

1. Vertical adjusting screw

2. Horizontal adjusting screw

Figure 1-43. Adjust Headlamp Alignment: FLHR/FLHT

Adjust FLTR Headlamps

1. See Figure 1-44. Using a 4.5 mm deepwell socket with a
flexible driver, rotate hex adjusters located near bottom
edge of inner fairing.

2. Adjust beam.
a. Horizontal: Tur n either the left or right adjuster to

adjust headlamp horizontally.

b. Vertical: Turn both adjusters equally to adjust head-

lamp vertically. Refer to Table 1-17 for directions to
move headlamp beam.

1. Hex adjuster
Figure 1-44. Headlamp Adjustment: FLTR

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Table 1-17. FLTR Hex Adjuster Rotation

Beam MovementRotationHex Adjuster

To the rightCWLeft Only

CCWRight Only

To the leftCCWLeft Only

CWRight Only

UpwardCWLeft and Right

Equally

DownwardCCWLeft and Right

Equally
CW = Clockwise

CCW = Counter-clockwise

AUXILIARY LAMP ALIGNMENT

NOTE

See Figure 1-45. In countries where travel is on the left side
of the road, shift the auxiliary lamp high intensity patterns (4,

5) to the left.

1. Place the vehicle facing a target wall as described in

1.23 HEADLAMP ALIGNMENT, Headlamp Alignment.

NOTE
As the weight of the rider will compress the suspension slightly ,
have a person whose weight is roughly the same as that of the
principal rider sit on the motorcycle.

2. With a rider seated on the motorcycle, measure the dis­tance from the floor to the centerline of each auxiliary lamp.

3. Measure the distance from the headlamp vertical centerline
to the vertical centerline of each auxiliary lamp.

4. See Figure 1-45. Mark the auxiliary lamp horizontal and
vertical centerlines (2, 3) on the wall.

5. Remove two screws to release turn signal lamp from
mounting bracket.

6. Obtain flare nut socket (Snap-on® FRX181). Loosen the
auxiliary lamp flange nut only enough to allow movement
of the lamp.

7. Turn on the headlamp low beam and cover both the
headlamp and the right side auxiliary lamp. Adjust the left
side auxiliary lamp as necessary so that the entire high
intensity zone (4) is below and to the right of the left side
auxiliary lamp centerlines as shown in Figure 1-45.

8. Cover the headlamp and left side auxiliary lamp. Adjust
the right side auxiliary lamp as necessary so that the entire
high intensity zone (5) is both below and to the right of the
right side auxiliary lamp centerlines as shown in

Figure 1-45.

9. Tighten auxiliary lamp flange nut to 15-18 ft-lbs (20.3-24.4
Nm).

10. Start two screws to secure turn signal lamp to mounting
bracket.Verify that conduit fits in slot at back of bracket
and is not pinched. Tighten screws to 36-60 in-lbs (4.1-

6.8 Nm).

1. Headlamp high beam area

2. Left side auxiliary lamp centerlines

3. Right side auxiliary lamp centerlines

4. Left side auxiliary high intensity beam area

5. Right side auxiliary high intensity beam area
Figure 1-45. Properly Aim Auxiliary Lamps

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INSPECTION
General

Inspect the condition and tightness of the stabilizer links and
engine mounts. Replace fasteners if damaged.

Top Link

1. See Figure 1-46. Check top stabilizer link eyelet to frame
weldment bolt (1): 18-22 ft-lbs (24.4-29.9 Nm).

2. Check top stabilizer link eyelet to top engine mounting
bracket bolt (2):18-22 ft-lbs (24.4-29.9 Nm).

Front Engine Mount

1. See Figure 1-46. Check two engine to front engine
mounting bracket bolts (3):36-40 ft-lbs (49-54 Nm).

2. Check three front engine mount end cap bolts (4): 42-48
ft-lbs (56.9-65.0 Nm).

Rear Frame Fasteners

See Figure 1-47. Check three fasteners on each side that
attach the rear frame to the main frame.The correct torque is
40-50 ft-lbs (54.2-67.8 Nm).

1.24ENGINE MOUNTS

1. Link-to-frame weldment fastener

2. Link-to-engine mounting bracket fastener

3. Engine mount fastener (2)

4. Engine mount end cap fastener
Figure 1-46. Front Mount and Stabilizer

Figure 1-47. Rear Frame Fasteners

2009 Touring Service: Maintenance 1-55

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1.25STORAGE

GENERAL

If the motorcycle will not be operated for sev eral months , such
as during the winter season, there are several things which
should be done to protect parts against corrosion, to preserve
the battery and to prevent the buildup of gum and varnish in
the fuel system.

This work should be performed following Service Manual pro­cedures.

PLACING IN STORAGE

TOOL NAMEPART NUMBER

STORAGE COVER98716-87A

Do not store motorcycle with gasoline in tank within the
home or garage where open flames, pilot lights, sparks or
electric motors are present. Gasoline is extremely flam­mable and highly explosive, which could result in death
or serious injury. (00003a)

Avoid spills. Slowly remove filler cap. Do not fill above
bottom of filler neck insert, leaving air space for fuel
expansion. Secure filler cap after refueling. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00028a)

8. Inspect operation of all electrical equipment and switches.

9. Check tire inflation and inspect tires for wear and/or
damage. See 1.10 TIRES AND WHEELS. If the motorcycle
will be stored for an extended period of time, securely
support the motorcycle under the frame so that all weight
is off the tires.

10. Wash painted and chrome-plated surfaces. Apply a light
film of oil to exposed unpainted surfaces.

Unplug or turn OFF battery charger before connecting
charger cables to battery . Connecting cables with charger
ON can cause a spark and battery explosion, which could
result in death or serious injury. (00066a)

Explosive hydrogen gas, whic h escapes during char ging,
could cause death or serious injury. Charge battery in a
well-ventilated area. Keep open flames, electrical sparks
and smoking materials away from battery at all times.
KEEP BATTERIES AWAY FROM CHILDREN. (00065a)

11. Remove battery from vehicle. Charge battery until the
correct voltage is obtained. Charge the battery every other
month if it is stored at temperatures below 60° F (16° C).
Charge battery once a month if it is stored at temperatures
above 60° F (16° C). See 1.17 BATTERY MAINTENANCE.

Use care when refueling. Pressurized air in fuel tank can
force gasoline to escape through filler tube. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00029a)

1. Prepare the fuel system by filling fuel tank and adding a
gasoline stabilizer. Use one of the commercially available
gasoline stabilizers following the manufacturer's instr uc­tions.

2. Run motorcycle until engine is at normal operating temper­ature. Stop the engine then drain the oil pan, install a new
oil filter, and fill oil pan with the proper grade oil. Check
the transmission lubricant level.

3. Remove the spark plugs, inject a fe w squirts of engine oil
into each cylinder and crank the engine 5-6 revolutions.
Install spark plugs.

4. Inspect rear belt deflection. See 1.13 REAR BELT

DEFLECTION.

5. Inspect rear belt and sprockets. See 1.12 REAR BELT

AND SPROCKETS.

6. Inspect air cleaner filter. See 1.9 AIR CLEANER AND

EXHAUST SYSTEM.

7. Lubricate controls. See 1.22 CABLE AND CHASSIS

LUBRICATION.

Unplug or turn OFF battery charger before disconnecting
charger cables from battery. Disconnecting clamps with
charger ON can cause a spark and battery explosion, which
could result in death or serious injury. (00067a)

12. If the motorcycle is to be covered, use a material that will
breathe, such as STORAGE COVER (Par t No. 98716­87A) or light canvas. Plastic materials that do not breathe
promote the formation of condensation, which leads to
corrosion.

REMOVAL FROM STORAGE

The clutch failing to disengage can cause loss of control,
which could result in death or serious injury. Prior to
starting after extended periods of storage, place transmis­sion in gear and push vehicle back and forth several times
to assure proper clutch disengagement. (00075a)

1. Charge and install the battery.

2. Remove and inspect the spark plugs. Replace if neces­sary.

3. Clean the air cleaner element.

4. If fuel tank was drained, fill fuel tank with fresh gasoline.

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5. Start the engine and run until it reaches normal operating
temperature.

6. Check engine oil level. Check the transmission lubricant
level. Fill to proper levels with correct fluids, if required.

7. Perf orm all of the checks in the PRE-RIDING CHECKLIST
in the Owner's Manual.

2009 Touring Service: Maintenance 1-57

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1.26TROUBLESHOOTING

GENERAL

The Troubleshooting section of this manual is a guide to
diagnose problems. Read the appropriate sections of this
manual before performing any w ork. Impr oper repair and/or
maintenance could result in death or serious injury.
(00528b)

The following check list of possib le operating troubles and their
probable causes will be helpful in keeping a motorcycle in good
operating condition. More than one of these conditions may
be causing the trouble and all should be carefully checked.

NOTE

For further troubleshooting information, see the ELECTRICAL
DIAGNOSTIC MANUAL.

ENGINE
Starter Motor Does Not Operate or Does Not

Turn Engine Over

1. Ignition switch not in IGNITION position.

2. Engine run switch in OFF position.

3. Discharged battery, loose or corroded connections
(solenoid chatters).

4. Starter control circuit, relay, or solenoid faulty.

5. Electric starter shaft pinion gear not engaging or overrun­ning clutch slipping.

6. TSM/TSSM/HFSM Bank Angle Sensor tripped and igni­tion/light key switch not cycled OFF then back to IGNI­TION.

7. Security system activated.

8. Motorcycle in gear and clutch not pulled in.

9. Jiffy stand down and transmission in gear (HDI models
only).

10. Main fuse not in place.

Engine Turns Over But Does Not Start

1. Fuel tank empty.

2. Fouled spark plugs.

3. Discharged battery, loose or damaged battery terminal
connections.

4. Engine lubricant too heavy (winter operation).

NOTE

For cold weather starts, always disengage clutch.

5. Spark plug cables in bad condition and shorting, cable
connections loose or cables connected to incorrect cylin­ders.

6. Damaged wire or loose wire connection at ignition coil,
battery, or ECM connector.

7. Ignition timing incorrect due to faulty ignition coil, ECM or
sensors.

8. Bank Angle Sensor tripped and ignition switch not cycled
OFF then back to IGNITION.

9. Fuel filter clogged.

10. Sticking or damaged valve(s) or wrong length push rod(s).

11. Plugged fuel injectors.

Starts Hard

1. Spark plugs in bad condition or have improper gap or are
partially fouled.

2. Spark plug cables in poor condition.

3. Battery nearly discharged.

4. Damaged wire or loose wire connection at one of the bat­tery terminals, ignition coil or ECM connector.

5. Water or dirt in fuel system.

6. Intake air leak.

7. Fuel tank vent hose, filler cap vent or v apor valve plugged,
or fuel line closed off, restricting fuel flow.

8. Engine lubricant too heavy (winter operation).

NOTE

For cold weather starts, always disengage clutch.

9. Ignition not functioning properly (possible sensor failure).

10. Faulty ignition coil.

11. Valves sticking.

12. Partially plugged fuel injector(s).

Starts But Runs Irregularly or Misses

1. Spark plugs in poor condition or partially fouled.

2. Spark plug cables in poor condition and shorting or leaking.

3. Spark plug gap too close or too wide.

4. Faulty ignition coil, ECM, or sensor.

5. Battery nearly discharged.

6. Damaged wire or loose connection at battery terminals,
ignition coil or ECM connector.

7. Intermittent short circuit due to damaged wire insulation.

8. Water or dirt in fuel system.

9. Fuel tank vent system plugged.

10. Air leak at intake manifold or air cleaner.

11. Loose or dirty ECM connector.

12. Faulty Sensor(s):Temperature Manif old Absolute Pressure
(TMAP), Crank Position (CKP) or Oxygen (O2).

13. Incorrect valve timing.

14. Weak or damaged valve springs.

1-58 2009 Touring Service: Maintenance

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15. Damaged intake or exhaust valve.

16. Partially plugged fuel injector(s).

A Spark Plug Fouls Repeatedly

1. Fuel mixture too rich.

2. Incorrect spark plug for the kind of service.

3. Piston rings badly worn or damaged.

4. Valve guides or seals badly worn.

Pre-Ignition or Detonation (Knocks or Pings)

1. Fuel octane rating too low.

2. Faulty spark plugs.

3. Incorrect spark plug for the kind of service.

4. Excessive carbon deposit on piston head or in combustion
chamber.

5. Ignition timing advanced due to faulty sensor inputs (TMAP
and/or CKP).

6. Ignition timing advanced due to ECM or sensors (CKP,
ET or TMAP) defective.

7. Intake manifold vacuum leak.

Overheating

1. Insufficient oil supply or oil not circulating.

2. Insufficient air flow over engine.

3. Heavy carbon deposits.

4. Ignition timing retarded due to defective ECM or faulty
sensor(s) (TMAP and/or CKP).

5. Leaking valve(s).

Valve Train Noise

1. Low oil pressure caused by oil feed pump not functioning
properly or oil passages obstructed.

2. Faulty hydraulic lifter(s).

3. Bent push rod(s).

4. Incorrect push rod length.

5. Rocker arm binding on shaft.

6. Valve sticking in guide.

7. Chain tensioning spring or shoe worn.

8. Cam(s), cam gear(s) or cam bushing(s) worn.

9. Cam timing incorrect.

Excessive Vibration

1. Wheels bent or damaged and/or tires worn or damaged.

2. Engine/Transmission/Rear Wheel not aligned properly.

3. Primary chain badly worn or links tight as a result of
insufficient lubrication or misalignment.

4. Engine to transmission mounting bolts loose.

5. Upper engine mounting bracket loose/damaged or
mounting bracket pre-loaded.

6. Ignition timing advanced due to faulty sensor inputs (TMAP
and/or CKP)/poorly tuned engine.

7. Internal engine problem.

8. Damaged frame.

9. Stabilizer links worn or loose, or stabilizer link brackets
loose or damaged.

10. Isolators worn or isolator bolts loose or damaged.

11. Rubber mounts loose or worn.

12. Rear fork pivot shaft fasteners loose.

13. Front engine mounting bolts loose.

Check Engine Light Illuminates During
Operation

1. Fault detected. See the ELECTRICAL DIAGNOSTIC
MANUAL for more information.

LUBRICATION SYSTEM
Oil Does Not Return To Oil Reservoir

1. Oil reservoir empty.

2. Oil pump not functioning.

3. Restricted oil lines or fittings.

4. Restricted oil filter.

5. O-ring damaged or missing from oil pump/crankcase
junction (also results in poor engine performance).

Engine Uses Too Much Oil Or Smokes
Excessively

1. Oil reservoir overfilled.

2. Restricted oil return line to oil reservoir.

3. Restricted breather operation.

4. Restricted oil filter.

5. Oil pump misaligned or in poor condition.

6. Piston rings badly worn or broken.

7. Valve guides or seals worn or damaged.

8. O-ring damaged or missing from oil pump/crankcase
junction (also results in poor engine performance).

9. Plugged crankcase scavenge port.

10. Oil diluted with gasoline.

Engine Leaks Oil From Cases, Push Rods,
Hoses, Etc.

1. Loose parts.

2. Imperfect seal at gaskets, push rod co vers, washers, etc.

3. Restricted breather passages or hose to air cleaner.

4. Restricted oil filter.

5. Oil reservoir overfilled.

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6. Lower rocker housing gasket installed incorrectly (upside
down).

7. Restricted oil return line to oil reservoir.

8. Porosity.

Low Oil Pressure

1. Oil reservoir underfilled.

2. Faulty low oil pressure switch.

3. Oil pump o-ring damaged or missing.

4. Bypass valve stuck in open position.

5. Ball missing or leaking in cam support plate.

6. Worn oil pump gerotor(s).

7. Oil diluted with gasoline.

High Oil Pressure

1. Oil reservoir overfilled.

2. Bypass valve stuck in closed position.

ELECTRICAL SYSTEM

NOTE

For diagnostic information see the ELECTRICAL DIAGNOSTIC
MANUAL.

Alternator Does Not Charge

1. Voltage regulator module not grounded.

2. Engine ground wire loose or broken.

3. Faulty voltage regulator module.

4. Loose or broken wires in charging circuit.

5. Faulty stator and/or rotor.

Alternator Charge Rate Is Below Normal

1. Weak or damaged battery.

2. Loose connections.

3. Faulty voltage regulator module.

4. Faulty stator and/or rotor.

Speedometer Operates Erratically

1. Contaminated vehicle speed sensor (remove sensor and
clean off metal particles).

2. Loose connections.

TRANSMISSION
Shifts Hard

1. Primary chaincase overfilled with lubricant.

2. Clutch not fully disengaging.

3. Transmission lubricant too heavy (winter operation).

4. Shifter return spring (inside transmission) bent or broken.

5. Bent shifter rod.

6. Shifter forks (inside transmission) sprung.

7. Corners worn off shifter clutch dog rings (inside transmis­sion).

1. Shifter rod improperly adjusted.

2. Shifter drum (inside transmission) improperly adjusted or
damaged/worn.

3. Shifter engaging parts (inside transmission) badly worn
and rounded.

4. Shifter forks bent.

5. Damaged gears.

Clutch Slips

1. Clutch controls improperly adjusted.

2. Insufficient clutch spring tension.

3. Worn friction discs.

Clutch Drags Or Does Not Release

1. Lubricant level too high in primary chaincase.

2. Clutch controls improperly adjusted.

3. Primary chain badly misaligned or too tight.

4. Insufficient clutch spring tension.

5. Clutch discs warped.

Clutch Chatters

Friction discs or steel discs worn or warped.

HANDLING
Irregularities

1. Improperly loaded motorcycle. Non-standard equipment
on the front end such as heavy radio receivers, extra
lighting equipment or luggage tends to cause unstable
handling.

2. Damaged tire(s) or improper front-rear tire combination.

3. Irregular or peaked front tire tread wear.

4. Incorrect tire pressure.

5. Shock absorber not functioning normally.

6. Incorrect air suspension pressure.

7. Loose wheel axle nuts.Tighten to recommended torque
specification.

8. Excessive wheel hub bearing play.

9. Rear wheel out of alignment with frame and front wheel.

10. Steering head bearings improperly adjusted. Correct
adjustment and replace pitted or worn bearings and races.

11. Loose spokes (laced wheel vehicles only).

12. Tire and wheel unbalanced.

13. Rims and tires out-of-round or eccentric with hub.

14. Rims and tires out-of-true sideways.

1-60 2009 Touring Service: Maintenance

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15. Rear fork pivot assembly: improperly tightened or
assembled, or loose/pitted or damaged pivot bearings.

16. Engine mounts and/or stabilizer links loose, worn or
damaged..

BRAKES
Brake Does Not Hold Normally

1. Master cylinder reservoir low on fluid, system leaking or
pads worn.

2. Brake system contains air bubbles.

3. Master cylinder or caliper piston seals worn or parts
damaged.

4. Brake pads contaminated with grease or oil.

5. Brake pads badly worn.

6. Brake disc badly worn or warped.

7. Brake drags - insufficient brake pedal or hand lever free­play, caliper piston worn or damaged, or excessive brake
fluid in reservoir.

8. Brake fades due to heat build up - brake pads dragging
or excessive braking.

9. Brake fluid leak when under pressure.

2009 Touring Service: Maintenance 1-61

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1.27CRITICAL FASTENERS

INSPECTION

Inspect critical fasteners at the scheduled service intervals.
Replace any fasteners that are damaged or missing.

Checking Torques on Fasteners

Refer to Table 1-18. Attempt to turn the f astener using a torque
wrench set to the minimum torque specification for that
fastener. If the fastener does not rotate, the fastener torque

Table 1-18. Critical Fasteners

clamp screws

handlebar clamp screws

cover screws

cover screws

screws

screws

bracket screws

has been maintained. If the fastener rotates, remove it to
determine if it has a locking agent.

If it has a locking agent, clean all locking material from the
threaded hole. Replace the fastener with a new one or clean
the original fastener threads and apply the appropriate locking
agent (see appropriate procedure). Install and tighten the
fastener to specification.

If the fastener does not hav e a locking agent, install and tighten
to specification.

TORQUEFASTENERSYSTEM

4-5 Nm35-45 in-lbsSwitch housing screwsHand controls

8-12 Nm72-108 in-lbsClutch lever bracket handlebar

8.1-9.5 Nm72-84 in-lbsMaster cylinder reservoir

23-26 Nm17-19 ft-lbsBrake caliper banjo boltsBrakes

17.0-19.7 Nm12.5-14.5 ft-lbsMaster cylinder banjo bolts

17.0-19.7 Nm12.5-14.5 ft-lbsABS module banjo bolts
22-33 Nm16-24 ft-lbsFront brake disc screws
41-61 Nm30-45 ft-lbsRear brake disc screws

0.8-1.1 Nm7-10 in-lbsFront master cylinder reservoir

1.4-1.7 Nm12-15 in-lbsRear master cylinder reservoir

14-17 Nm126-150 in-lbsRear master cylinder to frame

38-52 Nm28-38 ft-lbsFront brake caliper mounting

58-65 Nm43-48 ft-lbsRear brake caliper to caliper

8.5-11.5 Nm75-102 in-lbsBrake caliper pad pin
81-88 Nm60-65 ft-lbsFrontAxle nuts

129-142 Nm95-105 ft-lbsRear

15-20 Nm132-180 in-lbsFront axle holder nutsFront forks

74.6-88.1 Nm55-65 ft-lbsLocknutsPivot shaft

74.6-88.1 Nm55-65 ft-lbsRear fork bracket bolts
46-53 Nm34-39 ft-lbsTransmission to engine boltsOther

See 1.24 ENGINE MOUNTS.Engine mount bolts

54.2-67.8 Nm40-50 ft-lbsRear frame bolts

1-62 2009 Touring Service: Maintenance

TABLE OF CONTENTS

SUBJECT............................................................................................................................PAGE NO.

2.1 FASTENER TORQUE VALUES.................................................................................................2-1

2.2 SPECIFICATIONS.....................................................................................................................2-7

2.3 VEHICLE IDENTIFICATION NUMBER (V.I.N.)........................................................................2-10

2.4 FRONT WHEEL.......................................................................................................................2-11

2.5 REAR WHEEL.........................................................................................................................2-14

2.6 REAR WHEEL COMPENSATOR............................................................................................2-18

2.7 CHECKING RIM RUNOUT......................................................................................................2-21

2.8 WHEEL LACING: 16 INCH FRONT RIM.................................................................................2-22

2.9 WHEEL LACING: 16 INCH REAR RIM...................................................................................2-25

2.10 WHEEL LACING: 17 INCH RIM............................................................................................2-28

2.11 SEALED WHEEL BEARINGS...............................................................................................2-31

2.12 TRUING LACED WHEELS....................................................................................................2-35

2.13 CHECKING CAST WHEEL RUNOUT...................................................................................2-38

2.14 FRONT BRAKE MASTER CYLINDER..................................................................................2-39

2.15 FRONT BRAKE CALIPER.....................................................................................................2-44

2.16 REAR BRAKE MASTER CYLINDER....................................................................................2-45

2.17 REAR BRAKE CALIPER.......................................................................................................2-51

2.18 TIRES....................................................................................................................................2-52

2.19 FRONT FORK.......................................................................................................................2-55

2.20 AIR BAFFLE: FLTR................................................................................................................2-61

2.21 STEERING HEAD BEARINGS..............................................................................................2-62

2.22 REAR AIR SUSPENSION.....................................................................................................2-65

2.23 REAR SHOCK ABSORBERS...............................................................................................2-68

2.24 REAR FORK..........................................................................................................................2-69

2.25 CLUTCH CABLE...................................................................................................................2-72

2.26 HANDLEBARS......................................................................................................................2-75

2.27 MIRRORS..............................................................................................................................2-79

2.28 SEAT......................................................................................................................................2-81

2.29 SADDLEBAGS......................................................................................................................2-84

2.30 SADDLEBAG SERVICE........................................................................................................2-85

2.31 TOUR-PAK.............................................................................................................................2-88

2.32 TOUR-PAK SERVICE............................................................................................................2-91

2.33 TOUR-PAK LIGHTS...............................................................................................................2-94

2.34 TOUR-PAK BACKREST........................................................................................................2-97

2.35 TOUR-PAK SPEAKER BOX: FLHTCU..................................................................................2-99

2.36 LOWER FAIRING AND ENGINE GUARD...........................................................................2-100

2.37 UPPER FAIRING AND WINDSHIELD: FLHX, FLHT/C/U....................................................2-103

2.38 FAIRING CAP: FLHX, FLHT/C/U.........................................................................................2-104

2.39 INNER FAIRING: FLHX, FLHT/C/U.....................................................................................2-105

2.40 AIR DEFLECTORS..............................................................................................................2-109

2.41 UPPER FAIRING AND WINDSHIELD: FLTR......................................................................2-110

2.42 INSTRUMENT BEZEL: FLTR..............................................................................................2-113

2.43 INSTRUMENT NACELLE: FLTR.........................................................................................2-115

2.44 INNER FAIRING: FLTR........................................................................................................2-118

2.45 GLOVE BOX DOOR AND HINGE: FLTR.............................................................................2-122

2.46 WINDSHIELD: FLHR/C.......................................................................................................2-123

2.47 HEADLAMP NACELLE: FLHR/C.........................................................................................2-126

2.48 FRONT FENDER................................................................................................................2-128

2.49 REAR FENDER...................................................................................................................2-129

2.50 REAR FASCIA: FLHX..........................................................................................................2-131

2.51 REAR FRAME.....................................................................................................................2-132

2.52 FOOTBOARDS AND FOOTRESTS....................................................................................2-134

2.53 JIFFY STAND......................................................................................................................2-137

2.54 FRONT ENGINE MOUNT...................................................................................................2-139

CHASSIS

NOTES

HOME

FASTENER TORQUE VALUES IN THIS CHAPTER

The table below lists torque values for all fasteners presented
in this chapter.

screws

screws

screw

2.1FASTENER TORQUE VALUES

NOTESTORQUE VALUEFASTENER

1.1-2.3 Nm10-20 in-lbs2 inch diameter gauge nuts

4.5-5.6 Nm40-50 in-lbsAir valve mount hex nut

20-27 Nm15-20 ft-lbsAuxiliary lamp bracket to fork bracket

23.1-25.8 Nm17-19 ft-lbsBanjo bleeder bolt to front brake caliper

23.1-25.8 Nm17-19 ft-lbsBanjo bolt to caliper

17.6-20.3 Nm13-15 ft-lbsBanjo bolt to master cylinder

17.6-20.3 Nm13-15 ft-lbsBanjo bolt to master cylinder

16.9-19.7 Nm12.5-14.5 ft-lbsBanjo bolt to master cylinder

17.0-19.7 Nm12.5-14.5 ft-lbsBanjo bolt to master cylinder reservoir

22-33 Nm16-24 ft-lbsBrake disc (front) screws

41-61 Nm30-45 ft-lbsBrake disc (rear) screws

9.0-11.3 Nm80-100 in-lbsBrake light switch bracket fastener

20-27 Nm15-20 ft-lbsBrake pedal shaft locknut

20-27 Nm15-20 ft-lbsBrake pedal shaft locknut

2.39 INNER FAIRING: FLHX, FLHT/C/U, Installa­tion

2.20 AIR BAFFLE: FLTR, Air Baffle (FLTR)13.6-16.3 Nm120-144 in-lbsAir baffle hex screws (FLTR)

2.20 AIR BAFFLE: FLTR, Air Baffle (FLTR)13.6-16.3 Nm120-144 in-lbsAir baffle hex screws (FLTR)

2.21 STEERING HEAD BEARINGS, Installation13.6-16.3 Nm120-144 in-lbsAir baffle screws (FLTR)

2.40 AIR DEFLECTORS, Mid-F rame Air Deflectors2.8-4.0 Nm25-35 in-lbsAir deflector bolts

2.40 AIR DEFLECTORS, Air Deflectors (FLHTCU)2.8-3.4 Nm25-30 in-lbsAir deflector screws

2.22 REAR AIR SUSPENSION, Check for Air
Leaks

2.39 INNER FAIRING: FLHX, FLHT/C/U, Installa­tion

2.15 FRONT BRAKE CALIPER, Installation23.1-25.8 Nm17-19 ft-lbsBanjo bleeder bolt to caliper

2.14 FRONT BRAKE MASTER CYLINDER, Front
Brake Line - Non-ABS Equipped

2.16 REAR BRAKE MASTER CYLINDER, Rear
Brake Line: Non-ABS Equipped

2.17 REAR BRAKE CALIPER, Installation23.1-25.8 Nm17-19 ft-lbsBanjo bolt to caliper

2.14 FRONT BRAKE MASTER CYL­INDER, Assembly and Installation

2.16 REAR BRAKE MASTER CYL­INDER, Assembly and Installation

2.16 REAR BRAKE MASTER CYLINDER, Rear
Brake Line: Non-ABS Equipped

2.14 FRONT BRAKE MASTER CYLINDER, Front
Brake Line - Non-ABS Equipped

2.51 REAR FRAME, Rear Frame8.1-10.8 Nm72-96 in-lbsBattery tray screws

2.15 FRONT BRAKE CALIPER, Installation/metric 37.9-51.5 Nm28-38 ft-lbsBrake caliper (front) mounting screws

2.5 REAR WHEEL, Installation/metric 58.3-65.1 Nm43-48 ft-lbsBrake caliper (rear) socket head screws

2.17 REAR BRAKE CALIPER, Installation/metric 58.3-65.1 Nm43-48 ft-lbsBrake caliper (rear) to caliper bracket

2.4 FRONT WHEEL, Installation/Always use new
screws

2.5 REAR WHEEL, Installation/Always use new
screws

2.16 REAR BRAKE MASTER CYLINDER, Rear
Brake Line: Non-ABS Equipped

2.21 STEERING HEAD BEARINGS, Installation13.6-20.3 Nm120-180 in-lbsBrake line bracket to lower fork bracket

2.16 REAR BRAKE MASTER CYL­INDER, Assembly and Installation

2.16 REAR BRAKE MASTER CYLINDER, Rear
Brake Line: Non-ABS Equipped

2.25 CLUTCH CABLE, Installation10.2-13.6 Nm90-120 in-lbsClutch cable fitting

2009 Touring Service: Chassis 2-1

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screws

locknuts (FLTR)

FLHTC/U)

FLHTC/U)

nuts (FLTR)

screws

T27 TORX screws

reservoir screws

strip flange nut

NOTESTORQUE VALUEFASTENER

8-12 Nm72-108 in-lbsClutch lever bracket handlebar clamp

20.3-27.1 Nm15-20 ft-lbsEngine guard T40 TORX screws

2.5-3.2 Nm22-28 in-lbsFairing speaker lower screw (FLHX,

4.0-5.7 Nm35-50 in-lbsFairing speaker upper screws (FLHX,

13.6-20.3 Nm120-180 in-lbsFront brake line bracket screw

4.5-5.7 Nm40-50 in-lbsFront turn signal lamp bracket stud acorn

43.4-48.8 Nm32-36 ft-lbsGuard to frame screws

2.39 INNER FAIRING: FLHX, FLHT/C/U, Installa­tion

2.36 LOWER FAIRING AND ENGINE
GUARD, Engine Guard

2.54 FRONT ENGINE MOUNT, Installation48.8-54.2 Nm36-40 ft-lbsEngine mount bracket fasteners

2.54 FRONT ENGINE MOUNT, Installation56.9-65.0 Nm42-48 ft-lbsEngine mount end cap fasteners

2.44 INNER FAIRING: FLTR, Installation27.1-40.7 Nm20-30 ft-lbsFairing bracket/steering head thru bolt

2.38 F AIRING CAP: FLHX, FLHT/C/U , F airing Cap2.8-3.4 Nm25-30 in-lbsFairing cap screws

2.39 INNER FAIRING: FLHX, FLHT/C/U, Installa­tion

2.39 INNER FAIRING: FLHX, FLHT/C/U, Installa­tion

2.19 FRONT FORK, Installation71.9-77.3 Nm53-57 ft-lbsFork bracket pinch bolt

2.19 FRONT FORK, Installation81.4-94.9 Nm60-70 ft-lbsFork cap bolt

2.19 FRONT FORK, Assembly14.9-24.4 Nm132-216 in-lbsFork damper tube screw (6mm)

2.19 FRONT FORK, Changing Fork Oil8-11 Nm72-96 in-lbsFork oil drain plug

2.21 STEERING HEAD BEARINGS, Installation95-109 Nm70-80 ft-lbsFork stem nut

2.19 FRONT FORK, Changing Fork Oil81.4-94.9 Nm60-70 ft-lbsFork tube plug

2.31 T OUR-P AK, Luggage Rac k/T our-P ak Support20.3-27.1 Nm15-20 ft lbsFrame cover fastener, rear

2.49 REAR FENDER, Installation20-27 Nm15-20 ft-lbsFrame cover fastener, rear

2.4 FRONT WHEEL, Installation/metric 14.9-20.3 Nm132-180 in-lbsFront axle holder nuts

2.4 FRONT WHEEL, Installation/metric 81.4-88.1 Nm60-65 ft-lbsFront axle nut

2.14 FRONT BRAKE MASTER CYLINDER, Front
Brake Line - Non-ABS Equipped

2.54 FRONT ENGINE MOUNT, Installation54.2-67.8 Nm40-50 ft-lbsFront engine mount fasteners

2.48 FRONT FENDER, Installation22-27 Nm16-20 ft-lbsFront fender mount screws

2.41 UPPER FAIRING AND WINDSHIELD:
FLTR, Outer Fairing

2.30 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail

2.26 HANDLEBARS, Adjustment8-12 Nm72-108 in-lbsHandlebar clamp to clutch lev er bracket

2.25 CLUTCH CABLE, Installation6.8-9.0 Nm60-80 in-lbsHandlebar clamp to clutch lever bracket

2.26 HANDLEBARS, Adjustment8-9 Nm72-80 in-lbsHandlebar clamp to master cylinder

2.26 HANDLEBARS, Rubber Mounts40.7-54.2 Nm30-40 ft-lbsHandlebar lower clamp bolts (risers)

2.26 HANDLEBARS, Adjustment21.7-27.1 Nm16-20 ft-lbsHandlebar upper clamp screws

2.26 HANDLEBARS, Installation21.7-27.1 Nm16-20 ft-lbsHandlebar upper clamp screws

2.26 HANDLEBARS, Installation21.7-27.1 Nm16-20 ft-lbsHandlebar upper clamp screws

2.48 FRONT FENDER, Installation1.0-2.0 Nm9-18 in-lbsHeadlamp door screw

2.47 HEADLAMP NACELLE: FLHR/C, Installation1.0-2.0 Nm9-18 in-lbsHeadlamp housing Phillips screws

2.47 HEADLAMP NACELLE: FLHR/C, Installation1.0-2.0 Nm9-18 in-lbsHeadlamp housing Phillips screws

2.48 FRONT FENDER, Installation1.0-2.0 Nm9-18 in-lbsHeadlamp housing screws (FLHR/C/S)

2.47 HEADLAMP NACELLE: FLHR/C, Installation1.7-2.3 Nm15-20 in-lbsHeadlamp nacelle handlebar chrome

2-2 2009 Touring Service: Chassis

HOME

shroud Phillips screws

shroud Phillips screws

acorn nuts

(FLTR)

(FLTR)

screws

screws

TORX screws

clamp screws

screw (FLHX)

bracket stud locknuts (FLTR)

NOTESTORQUE VALUEFASTENER

2.47 HEADLAMP NACELLE: FLHR/C, Installation1.1-2.3 Nm10-20 in-lbsHeadlamp nacelle handlebar clamp

2.47 HEADLAMP NACELLE: FLHR/C, Installation1.1-2.3 Nm10-20 in-lbsHeadlamp nacelle handlebar clamp

2.47 HEADLAMP NACELLE: FLHR/C, Installation8.1-12.2 Nm72-108 in-lbsHeadlamp nacelle to fork bracket stud

2.42 INSTRUMENT BEZEL: FLTR, Bezel2.8-4.0 Nm25-35 in-lbsInstrument bezel screws (FLTR)

20-27 Nm15-20 ft-lbsInstrument nacelle to fork bracket scre ws

20-27 Nm15-20 ft-lbsInstrument nacelle to fork bracket scre ws

10.8-13.6 Nm96-120 in-lbsJiffy stand interlock sensor fastener

4.0-4.5 Nm35-40 in-lbsLower fairing clip stud flange nuts

2.3-2.8 Nm20-25 in-lbsLower fairing glove box tray T20 TORX

2.3-2.8 Nm20-25 in-lbsLower fairing glove box tray T20 TORX

10.2-11.3 Nm90-100 in-lbsLower fairing to engine guard clamp T40

8.1-9.5 Nm72-84 in-lbsMaster cylinder reservoir handlebar

1.1-1.7 Nm10-15 in-lbsOuter fairing long screws (FLTR)

2.3-3.4 Nm20-30 in-lbsOuter fairing screws (FLHX, FLHT/C/U)

0.7-1.4 Nm6-12 in-lbsOuter fairing short screws (FLTR)

48.8-56.9 Nm36-42 ft-lbsPassenger footboard/footrest fastener

48.8-56.9 Nm36-42 ft-lbsPassenger footboard/footrest fastener

20-27 Nm15-20 ft-lbsPassenger footrest pad socket head

3.0-6.0 Nm30-50 in-lbsRail clamp screws

2.43 INSTRUMENT NACELLE: FLTR, Instrument
Nacelle

2.43 INSTRUMENT NACELLE: FLTR, Instrument
Nacelle

2.53 JIFFY STAND, Jiffy Stand Bracket48.8-57.0 Nm36-42 ft-lbsJiffy stand bracket fasteners

2.53 JIFFY STAND, Jiffy Stand Interlock
Sensor/Use Loctite Medium Strength Threadlock er
243 (blue) if reusing screw

2.53 JIFFY STAND, Installation20.3-27.1 Nm15-20 ft-lbsJiffy stand leg stop hex screw

2.51 REAR FRAME, Rear Frame8.1-10.8 Nm72-96 in-lbsLeft electrical caddy fastener

2.36 LOWER FAIRING AND ENGINE
GUARD, Lower Fairing (FLHTCU)

2.36 LOWER FAIRING AND ENGINE
GUARD, Lower Fairing (FLHTCU)

2.36 LOWER FAIRING AND ENGINE
GUARD, Lower Fairing (FLHTCU)

2.36 LOWER FAIRING AND ENGINE
GUARD, Lower Fairing (FLHTCU)

2.31 T OUR-P AK, Luggage Rac k/T our-P ak Support20.3-27.1 Nm15-20 ft lbsLuggage rack fastener

2.49 REAR FENDER, Installation20-27 Nm15-20 ft-lbsLuggage rack screws

2.14 FRONT BRAKE MASTER CYL­INDER, Assembly and Installation

2.27 MIRRORS, FLHX/metric 3.4-4.5 Nm30-40 in-lbsMirror flange nut (FLHX)

2.27 MIRRORS, All Models Except FLHX/metric 6.8-10.8 Nm60-96 in-lbsMirror stem acorn nut

2.41 UPPER FAIRING AND WINDSHIELD:
FLTR, Outer Fairing

2.37 UPPER F AIRING AND WINDSHIELD: FLHX,
FLHT/C/U, Outer Fairing and Windshield

2.41 UPPER FAIRING AND WINDSHIELD:
FLTR, Outer Fairing

2.52 FOOTBOARDS AND FOOTRESTS, Pas­senger Footboard

2.52 FOOTBOARDS AND FOOTRESTS, Pas­senger Footrest: FLHX

2.52 FOOTBOARDS AND FOOTRESTS, Pas­senger Footrest: FLHX/Use Loctite Medium
Strength Threadlocker 243 (blue)

2.44 INNER FAIRING: FLTR, Installation10.9-16.3 Nm96-144 in-lbsRadio bracket/inner fairing to fairing

2.30 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail

2.5 REAR WHEEL, Installation/metric 20-27 Nm15-20 ft-lbsRear axle cone nut (preliminary)

2009 Touring Service: Chassis 2-3

HOME

port fastener

port fastener

port fastener

end cap screws

screws

screws

screws

fastener

saddlebag support screws

screw

screw

fastener

NOTESTORQUE VALUEFASTENER

16.3-20.3 Nm12-15 ft-lbsRear brake light switch

20.3-27.1 Nm15-20 ft-lbsRear fender support-to-saddlebag sup-

74.6-88.1 Nm55-65 ft-lbsRear fork bracket bolts

74.6-89.5 Nm55-66 ft-lbsRear fork pivot shaft nuts

14-17 Nm10.5-12.5 ft-lbsRear master cylinder to engine mount

14.2-17.0 Nm126-150 in-lbsRear master cylinder-to-frame screws

10.8-16.3 Nm96-144 in-lbsRear muffler fastener

48.8-57.0 Nm36-42 ft-lbsRider footboard bracket socket screws

6.8-9.0 Nm60-80 in-lbsRider footboard pivot bolt nut

16.3-20.3 Nm12-15 ft-lbsSaddlebag mounting bracket screw

8.0-14.0 Nm72-120 in-lbsSaddlebag side guard to front guard

8.0-11.0 Nm70-100 in-lbsSaddlebag support rail to front guard

20.0-27.0 Nm15-20 ft-lbsSaddlebag support to fender support

2.16 REAR BRAKE MASTER CYLINDER, Rear
Brake Line: Non-ABS Equipped/Use Loctite Pipe
Sealant with Teflon 565

2.50 REAR FASCIA: FLHX, Installation3.4-5.1 Nm30-45 in-lbsRear fascia flange nuts (FLHX)

2.50 REAR FASCIA: FLHX, Stud Plate3.4-5.1 Nm30-45 in-lbsRear fascia flange nuts (FLHX)

2.50 REAR FASCIA: FLHX, Installation2.0-2.5 Nm18-22 in-lbsRear fascia lamp screws (FLHX)

2.49 REAR FENDER, Installation20-27 Nm15-20 ft-lbsRear fender mounting screws

2.50 REAR FASCIA: FLHX, Stud Plate5.1-9.6 Nm45-85 in-lbsRear fender support-to-fender nut

2.49 REAR FENDER, Installation20-27 Nm15-20 ft-lbsRear fender support -to-saddlebag sup-

2.30 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail

2.50 REAR FASCIA: FLHX, Stud Plate20.3-27.1 Nm15-20 ft-lbsRear fender support-to-saddlebag sup-

2.24 REAR FORK, Installation/Apply two drops of
Loctite Medium Strength Threadlocker 243 (blue)
to threads

2.24 REAR FORK, Installation/Apply two drops of
Loctite Medium Strength Threadlocker 243 (blue)
to threads

2.51 REAR FRAME, Rear Frame54.2-67.8 Nm40-50 ft-lbsrear frame fastener

2.16 REAR BRAKE MASTER CYL­INDER, Assembly and Installation

2.16 REAR BRAKE MASTER CYLINDER, Rear
Brake Line: Non-ABS Equipped

2.30 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail

2.52 FOOTBOARDS AND FOOTRESTS, Rider
Footboards

2.52 FOOTBOARDS AND FOOTRESTS, Rider
Footboards

2.30 SADDLEBAG SER VICE, Saddlebag Hardware2.3-2.8 Nm20-25 in-lbsSaddlebag latch/check strap T15 TORX

2.30 SADDLEBAG SER VICE, Saddlebag Hardware2.3-2.8 Nm20-25 in-lbsSaddlebag latch/check strap T15 TORX

2.30 SADDLEBAG SER VICE, Saddlebag Hardware2.0-2.3 Nm18-20 in-lbsSaddlebag lid check strap T20 TORX

2.28 SEAT, Seat: FLHR/C6.8-10.8 Nm60-96 in-lbsSaddlebag mounting bracket screw

2.30 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail

2.49 REAR FENDER, Installation16.3-20.3 Nm12-15 ft-lbsSaddlebag mounting bracket screw

2.31 T OUR-P AK, Luggage Rac k/T our-P ak Support16.3-20.3 Nm12-15 ft lbsSaddlebag mounting bracket screw

2.29 SADDLEBAGS, Installation16.3-20.3 Nm12-15 ft-lbsSaddlebag mounting bracket to

2.30 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail

2.30 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail

2.30 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail

2-4 2009 Touring Service: Chassis

HOME

fastener

TORX screws

screws

NOTESTORQUE VALUEFASTENER

2.49 REAR FENDER, Installation20-27 Nm15-20 ft-lbsSaddlebag support to fender support

2.28 SEAT, Seat: FLHT, FLTR, FLHX5.4-8.1 Nm48-72 in-lbsSeat mounting screw

2.28 SEAT, Seat: FLHTC/U5.4-8.1 Nm48-72 in-lbsSeat mounting screw

2.28 SEAT, Seat: FLHR/C5.4-8.1 Nm48-72 in-lbsSeat mounting screw

2.28 SEAT, Seat: FLHT, FLTR, FLHX5.4-8.1 Nm48-72 in-lbsSeat strap screw

2.28 SEAT, Seat: FLHTC/U5.4-8.1 Nm48-72 in-lbsSeat strap screw

47.5-54.2 Nm35-40 ft-lbsShock lower mounting bolt

47-54 Nm35-40 ft-lbsShock lower mounting bolt

47.5-54.2 Nm35-40 ft-lbsShock upper mounting bolt

20.0-27.0 Nm15-20 ft-lbsSide rail to saddlebag support screws

1.1-2.3 Nm10-20 in-lbsSpeedometer/tachometer bracket screws

6.2 Nm55 in-lbsSpoke nipple

6.2 Nm55 in-lbsSpoke nipple

2.8-4.0 Nm25-35 in-lbsTour-Pak lockset hex nut

2.4-2.7 Nm21-24 in-lbsTour-Pak passenger backrest flap T25

2.3-2.8 Nm20-25 in-lbsTour-Pak side marker lights T15 TORX

2.3-2.8 Nm20-25 in-lbsTour-Pak tether T15 TORX screw

2.3-2.8 Nm20-25 in-lbsTour-Pak tether T15 TORX screw

2.3-2.8 Nm20-25 in-lbsTour-Pak tether T15 TORX screw

2.23 REAR SHOCK ABSORBERS, Installation/Use
LOCTITE MEDIUM STRENGTH THREADLOCKER
243 (blue)

2.24 REAR FORK, Installation/Apply two or three
drops of Loctite Medium Strength Threadlocker
243 (blue) to threads

2.23 REAR SHOCK ABSORBERS, Installation/Use
LOCTITE MEDIUM STRENGTH THREADLOCKER
243 (blue)

2.30 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail

2.31 TOUR-PAK, Removal/Installation2.8-4.0 Nm25-35 in-lbsSpeaker box mounting bolts

2.39 INNER FAIRING: FLHX, FLHT/C/U, Installa­tion

2.8 WHEEL LACING: 16 INCH FRONT RIM, Pro­cedure

2.9 WHEEL LACING: 16 INCH REAR RIM, Pro­cedure

2.10 WHEEL LACING: 17 INCH RIM, Procedure6.2 Nm55 in-lbsSpoke nipple

2.12 TRUING LACED WHEELS, Radial Truing6.2 Nm55 in-lbsSpoke nipple

2.51 REAR FRAME, Rear Frame8.1-10.8 Nm72-96 in-lbsTop caddy fastener

2.32 TOUR-PAK SERVICE, Lockset2.8-4.0 Nm25-35 in-lbsTour-Pak lockset hex nut

2.35 TOUR-PAK SPEAKER BOX:
FLHTCU, Speaker Box (FLHTCU)

2.32 TOUR-PAK SERVICE, Lockset3.4-5.1 Nm30-45 in-lbsTour-Pak lockset jam nut

2.33 T OUR-PAK LIGHTS, Tour-Pak Lights Harness7.3-7.9 Nm65-70 in-lbsTour-Pak metal plate flange nuts

2.31 TOUR-PAK, Removal/Installation10.8-13.6 Nm96-120 in-lbsTour-Pak mounting bolts

2.31 TOUR-PAK, Adjustment10.8-13.6 Nm96-120 in-lbsTour-Pak mounting bolts

2.33 T OUR-PAK LIGHTS, Tour-Pak Lights Harness10.8-13.6 Nm96-120 in-lbsTour-Pak mounting bolts

2.32 TOUR-PAK SERVICE, Tether Brackets4.5-6.8 Nm40-60 in-lbsT our-P ak passenger backrest flange nuts

2.34 T OUR-PAK BACKREST, Passenger Backrest4.5-6.8 Nm40-60 in-lbsTour-P ak passenger backrest flange nuts

2.34 T OUR-PAK BACKREST, Passenger Backrest
Flap (FLHTCU)

2.33 TOUR-PAK LIGHTS, Side Marker Lights
(FLHTCU)

2.32 TOUR-PAK SERVICE, Hinges/Use Loctite
High Strength Threadlocker 262 (red)

2.32 TOUR-PAK SERVICE, Latches/Lockset
Catch/Use Loctite Medium Strength Threadlocker
243 (blue)

2.32 TOUR-PAK SERVICE, Latches/Lockset
Catch/Use Loctite Medium Strength Threadlocker
243 (blue)

2009 Touring Service: Chassis 2-5

HOME

(Road King Models)

NOTESTORQUE VALUEFASTENER

2.3-2.8 Nm20-25 in-lbsTour-Pak tether T15 TORX screw

2.8-3.4 Nm25-30 in-lbsWindshield screws (FLHX, FLHT/C/U)

0.7-1.5 Nm6-13 in-lbsWindshield wellnut screws (FLTR)

2.32 TOUR-PAK SERVICE, Tether/Use Loctite
High Strength Threadlocker 262 (red)

2.25 CLUTCH CABLE, Installation19-28 Nm14-21 ft-lbsTransmission lubricant drain plug

2.18 TIRES, Installation1.4-1.7 Nm12-15 in-lbsValve stem nut

2.37 UPPER F AIRING AND WINDSHIELD: FLHX,
FLHT/C/U, Outer Fairing and Windshield

2.41 UPPER FAIRING AND WINDSHIELD:
FLTR, Windshield

2.46 WINDSHIELD: FLHR/C, Windshield Window2.3-2.8 Nm20-25 in-lbsWindshield window T27 TORX screws

2-6 2009 Touring Service: Chassis

HOME

SPECIFICATIONS
Chassis Specifications

Table 2-1. Dimensions: 2009 FLHT, FLHTC/U, FLTR and FLHX

rearmost position)

*With 180 lb. (81.7 kg) rider on seat

2.2SPECIFICATIONS

FLHXFLTRFLHTCUFLHTCFLHTITEM

MMIN.MMIN.MMIN.MMIN.MMIN.

1613.9263.541613.9263.541613.9263.541613.9263.541613.9263.54Wheel base

2415.0395.082390.1494.102502.2098.632496.8298.302413.5195.02Overall length (Tour-Pak in

965.2038.00909.3235.80965.2038.00965.2038.00965.2038.00Overall width

119.384.70129.545.10129.545.10129.545.10129.545.10Road clearance

1325.8852.201397.0055.001549.4961.001549.4961.001549.4961.00Overall height

668.0226.30683.2626.90693.4227.30693.4227.30693.4227.30Saddle height*

*With 180 lb. (81.7 kg) rider on seat

Table 2-3. Capacities: 2009 Touring Models

(approximate)

(approximate)

Table 2-2. Dimensions: 2009 FLHR and FLHRC

FLHRCFLHRITEM

MMIN.MMIN.

1613.9263.541613.9263.54Wheel base

2393.1994.222413.5195.02Overall length

952.5037.50949.9637.40Overall width

129.545.10129.545.10Road clearance

1399.5455.101399.5455.10Overall height

683.2626.90693.4227.30Saddle height*

LITERSU.S.ITEM

22.716.00 galFuel tank (total)

3.791.00 galLow fuel warning light on

3.794.00 qt.Oil tank with filter

0.951.00 qt.Transmission

1.321.40 qt.Primary chaincase

2009 Touring Service: Chassis 2-7

HOME

from factory

Table 2-4.Weights: 2009 FLHT, FLHTC/U, FLTR and FLHX

FLHXFLTRFLHTCUFLHTCFLHTITEM

KGLB.KGLB.KGLB.KGLB.KGLB.

350.63773.00355.16783.00386.46852.00375.12827.00351.08774.00Weight as shipped

616.891360.00616.891360.00616.891360.00616.891360.00616.891360.00GVWR

226.80500.00226.80500.00226.80500.00226.80500.00226.80500.00GAWR front

420.48927.00420.48927.00420.48927.00420.48927.00420.48927.00GAWR rear

Table 2-5.Weights: 2009 FLHR and FLHRC

FLHRCFLHRITEM

KGLB.KGLB.

350.63773.00351.53775.00Weight as shipped from factory

616.891360.00616.891360.00GVWR

226.80500.00226.80500.00GAWR front

420.48927.00420.48927.00GAWR rear

NOTES

• Gross vehicle weight rating (GVWR) (maximum allow able
loaded vehicle weight) and corresponding gross axle
weight rating (GAWR) are given on a label located on the
frame steering head.

• For important information regarding tire data and tire
inflation, see 1.10 TIRES AND WHEELS.

Tire Specifications

Use only Harley-Davidson approved tires. See a Harley­Davidson dealer . Using non-approved tires can adversely
affect stability, which could result in death or serious
injury. (00024a)

Table 2-6.Tire Fitment - Tubeless Cast Wheels

WHEEL SIZE

AND POSITION

RIM SIZE AND

CONTOUR

Tire sizes are molded on the sidewall. Refer to the tire fitment
tables below. Rim size and contour are cast or stamped into
the exterior surface of the rim.

Example: T19 x 2.15 MT DOT. "T" indicates that the rim con­forms to Tire and Rim Association standards.The "19" is the
normal diameter of the rim in inches, measured at the bead
seat diameter.The "2.15" is the width of the bead seat meas­ured in inches. "MT" designates the rim contour. "DOT" means
that the rim meets Department of T ransportation Federal Motor
Vehicle Safety Standards.

TIRE SIZERIM VALVE

HOLE DIA.

Dunlop D407F0.45 in. (11.4 mm)T17 x 3.00 MT17 in. - Front

130/80B17 65H

Dunlop D4070.45 in. (11.4 mm)T16 x 5.00 MT16 in. - Rear

180/65B16 81H

2-8 2009 Touring Service: Chassis

HOME

Table 2-7.Tire Fitment - Tube Type Steel Laced Wheels

WHEEL SIZE

& POSITION

WHEEL SIZE

& POSITION

RIM SIZE &

CONTOUR

Table 2-8.Tire Fitment - Tube Type Chrome Aluminum Profile Laced Wheels

RIM SIZE &

CONTOUR

TUBE

SIZE

TUBE

SIZE

TIRE
SIZE

Dunlop D407FMT90-16/MU85-16T16 x 3.00D16 in - Front

130/90-B16 67H

Dunlop D407180/65-16T16 x 5.00 MT16 in - Rear

180/65-16 81H

TIRE
SIZE

Dunlop D407FMT90-16/MU85-16T16 x 3.00 MT16 in - Front

130/90B16 67H130/90-150/80-16

Dunlop D407F130/80-17T17 x 3.00 MT17 in - Front

130/80-B17 65H

Dunlop D407180/65-16T16 x 5.00 MT16 in - Rear

180/65-16 81H

Table 2-9.Tire Pressures: 2009 Touring Models

TIRE PRESSURE (COLD)MODEL

REARFRONT

kPaPSIkPaPSI

2764024836All

2009 Touring Service: Chassis 2-9

1 HD 1 FC 4 1 3 9 Y 600041

1 2 3 4 5 6 7 8 9 10

om00883

HOME

2.3VEHICLE IDENTIFICATION NUMBER (V.I.N.)

VEHICLE IDENTIFICATION NUMBER: TOURING MODELS

The full 17-digit serial number, or V ehicle Identification Number
(V.I.N.), is stamped on the right side of the frame backbone at
the rear of the steering head. A label bearing the V.I.N. code
is also affixed to the left side of the steering head.

Figure 2-1.Typical Harley-Davidson V.I.N.: 2009 Touring Models

Table 2-10. Harley-Davidson V.I.N. Breakdown: 2009 Touring Models

POSSIBLE VALUESDESCRIPTIONPOSITION

1=Originally manufactured for sale within the United StatesMarket designation1
5=Originally manufactured for sale outside of the United States

HD=Harley-DavidsonManufacturer2
1=Heavyweight motorcycle (901 cc or larger)Motorcycle type3
See V.I.N. model tableModel4
4=Twin Cam 96™, 1584 cc air-cooled, fuel-injectedEngine type5
1=RegularIntroduction date6

2=Mid-year
3=California/regular
4=Cosmetic changes and/or special introductory date
5=California/cosmetic changes and/or special introductory date
6=California/mid-year

Can be 0-9 or XV.I.N. check digit7
9=2009Model year8
Y=York, PA U.S.A.Assembly plant9
VariesSequential number10

An abbreviated V.I.N. is stamped between the front and rear
cylinders on the left side of the crankcase.

NOTE

Always give the full 17-digit Vehicle Identification Number when
ordering parts or making any inquiry about your motorcycle.

Table 2-11.V.I.N. Model Codes: 2009 Touring Models

MODELCODEMODELCODE

FB

FS

®

®

FCFLHR Road King

FVFLTR Road Glide
KBFLHTC Electra Glide® ClassicFF

FLHTCU Ultra Classic® Electra Glide
FLHTCU Ultra Classic® Electra Glide® ShrineFLFLHTCU Ultra Classic® Electra Glide® with sidecarFG
FLHT Electra Glide
FLHX Street Glide
FLHRC Road King® ClassicFRFLHR Road King® ShrineFW

®

™

2-10 2009 Touring Service: Chassis

®

1

2

sm05733

HOME

REMOVAL

1. Place the motorcycle on a hydraulic center stand with the
front wheel raised off the ground.

2. Inspect wheel bearings. See 2.11 SEALED WHEEL

BEARINGS.

3. If present, carefully cut three cable straps to release front
wheel speed sensor cable and front fender tip lamp wires
from left caliper brake hose.

4. See Figure 2-2. Remove two brake caliper mounting
fasteners (1). Slide br ak e caliper str aight do wn to remove
from brake disc. Secure caliper to rail of engine guard
using cable strap.

5. If necessary, remove clip (2) to release wheel speed
sensor harness from bracket.

6. Remove brake caliper on right side of wheel.

NOTE
Do not operate the front brake hand lever with the front wheel
removed or the caliper pistons may be forced out. Reseating
pistons requires disassembly of the brake caliper.

7. See Figure 2-3. Insert screwdriver or steel rod through

hole in axle (11) on right side of motorcycle.While holding
axle stationary, remove the axle nut (1) and flat washer
(2).

8. Loosen the two axle holder nuts at bottom of right side

fork slider.

2.4FRONT WHEEL

1. Caliper fasteners

2. Wheel speed sensor cable retainer
Figure 2-2. Remove Front Caliper

9. Using a soft mallet, gently tap end of axle towards right
side of motorcycle. Catching external spacer(s), pull axle
free from fork sliders, front wheel speed sensor (if ABS
equipped), and wheel hub.

NOTE
If ABS equipped, never pull wheel speed sensor cable taut or
use to retain wheel, axle or other components. Always keep
wheel speed sensor (and ABS encoder bearing) away from
magnetic fields (such as magnetic parts trays, magnetic base
dial indicators, alternator rotors, etc.) or damage will occur.

10. If necessary, remove five screws (13) to release brake

discs from hub.

2009 Touring Service: Chassis 2-11

18

16

17

6

7

8

2

1

3

4

13

5

12

9

15

10

4

14

3

11

13

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2. 11.Flat washer Axle

4. 13.Standard bearing T40 TORX screw (10)

6. 15.Front wheel speed sensor Laced wheel, chrome

8. 17.Clip bracket Slotted cast wheel

10.1. Spacer sleeveAxle nut

12.3. Brake disc (left side)External spacer

14.5. Brake disc (right side)ABS encoder bearing

16.7. Cast wheelCable clip

18.9. Laced wheel, smoothieSpacer washer

Figure 2-3. Front Wheel (Exploded View)

CLEANING AND INSPECTION

INSTALLATION

1. Thoroughly clean all parts in solvent (wheel speed sensor
and bearings excepted) and inspect for damage or
excessive wear.

2. Replace brake discs if warped or badly scored. Measure
disc thickness for excessive wear. Minimum acceptable
thickness is stamped on side of disc.

2-12 2009 Touring Service: Chassis

1. See Figure 2-3. If removed, install five new screws (13)
to fasten brake discs to hub. Alternately tighten screws to
16-24 ft-lbs (22-33 Nm).

2. Place wheel into position between fork sliders with the
valve stem on the right side of the motorcycle.