Harley-Davidson Touring 2011 Service Manual

2011 Harley-Davidson Touring Models

Service Manual

99483-11

©2010 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

2011 Harley-Davidson

Touring Models Service

Manual

©2010 H-D.

ALL RIGHTS RESERVED

99483-11

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.

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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.

2011 Harley-Davidson Touring Models Service Manual (99483-11)

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. Chapters and topics in this manual are
sequentially numbered for easy navigation.

For example, a cross-reference shown as 2.2 SPECIFICA-
TIONS refers to chapter 2 CHASSIS, heading 2.2 SPECIFIC­ATIONS.

For quick and easy reference, all pages contain a chapter
number followed by a page number. For example, page 3-5
refers to page 5 in Chapter 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 manual, Harley­Davidson Motor Company will periodically issue service bul­letins to Harley-Davidson dealers. Service bulletins cover
interim engineering changes and supplementary information.
Consult the service bulletins to keep your product knowledge
current and complete.

USE GENUINE REPLACEMENT PARTS

Harley-Davidson parts and accessories are designed for
Harley-Davidson motorcycles. Using non-Harley-Davidson
parts or accessories can adversely affect performance,
stability or handling, which could result in death or serious
injury. (00001b)

To achieve 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 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)

NOTICE indicates a potentially hazardous situation which,
if not avoided, may result in property damage. (00140b)

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 manual are effective
methods for performing service operations.

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

Loctite Sealing and Threadlocking Products

Some procedures in this manual call for the use of Loctite
products. If you have any questions regarding Loctite product
usage or retailer/wholesaler locations, please contact Loctite
Corp. at www.loctite.com.

PRODUCT REGISTERED MARKS

Always wear proper eye protection when using hammers,
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 manual. However, 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 Kent-Moore. For ordering

Apple, Alcantara S.p.A., Allen, Amp Multilock, Bluetooth,
Brembo, Delphi, Deutsch, Dunlop, Dynojet, Fluke, G.E.
Versilube, Garmin, Gunk, Hydroseal, Hylomar, iPhone, iPod,
Kevlar, Lexan, Loctite, Lubriplate, Keps, K&N, Magnaflux,
Marson Thread-Setter Tool Kit, MAXI fuse, Molex, Michelin,
MPZ, Mulitilock, nano, NGK, Novus, Packard, Pirelli, Permatex,
Philips, PJ1, Pozidriv, Robinair, S100, Sems, Snap-on, Teflon,
Threadlocker, Torca, Torco, TORX, Tufoil, Tyco, Ultratorch,
Velcro, X-Acto, XM Satellite Radio, and zūmo 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-Dav­idson 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 Parts....................................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 (Pre-Formed Packings).................................1-4

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

1.3 FUEL AND OIL

Fuel.....................................................................................1-7

Gasoline Blends..................................................................1-7

Engine Lubrication..............................................................1-7

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

1.7 AIR CLEANER AND EXHAUST SYSTEM

Removal............................................................................1-18

Installation.........................................................................1-18

Exhaust System Leak Check............................................1-18

1.8 TIRES AND WHEELS

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

Tires..................................................................................1-20

Tire Replacement.............................................................1-20

Inspection..................................................................1-20

When To Replace Tires.............................................1-20

Wheel Bearings................................................................1-21

Wheel Spokes...................................................................1-21

Identify Wheel Spoke Groups....................................1-21

Wheel Spoke Adjustment..........................................1-21

1.9 PRIMARY CHAINCASE LUBRICANT

General.............................................................................1-23

Changing Primary Chaincase Lubricant...........................1-23

1.10 TRANSMISSION LUBRICANT

Transmission Lubrication..................................................1-25

General......................................................................1-25

Check Lubricant Level...............................................1-25

Changing Transmission Fluid....................................1-25

1.11 CLUTCH

Adjustment........................................................................1-27

1.12 DRIVE BELT AND SPROCKETS

General.............................................................................1-29

Cleaning............................................................................1-29

Inspection.........................................................................1-29

Sprockets...................................................................1-29

Drive Belt...................................................................1-29

Checking Drive Belt Deflection.........................................1-31

Setting Belt Deflection......................................................1-31

Adjustment.................................................................1-31

Assembly...................................................................1-33

1.13 COMPENSATOR SPROCKET
ISOLATOR

Inspection.........................................................................1-34

1.14 CABLE AND CHASSIS LUBRICATION

General.............................................................................1-35

Steering Head Bearings....................................................1-35

Jiffy Stand.........................................................................1-35

Miscellaneous Lubrication................................................1-35

Hinges, Latches, Etc..................................................1-35

TABLE OF CONTENTS

1.4 BULB REQUIREMENTS

General...............................................................................1-9

1.5 MAINTENANCE SCHEDULE

General.............................................................................1-11

1.6 ENGINE OIL AND FILTER

Checking Oil Level............................................................1-15

Oil Level Cold Check.................................................1-15

Oil Level Hot Check...................................................1-15

Changing Oil and Oil Filter................................................1-16

1.15 BRAKES

Fluid Inspection.................................................................1-36

1.16 BRAKE PADS AND DISCS

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

Brake Pads................................................................1-37

Brake Disc Thickness................................................1-37

Brake Disc Lateral Runout........................................1-37

Brake Pad Replacement...................................................1-37

Rear Brake Caliper....................................................1-37

Front Brake Calipers..................................................1-39

III

TABLE OF CONTENTS

1.17 SPARK PLUGS

Inspection.........................................................................1-41

Spark Plug Cable Inspection............................................1-41

1.18 FRONT FORK OIL

Replacing Fork Oil............................................................1-43

1.19 SUSPENSION ADJUSTMENTS

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

1.20 STEERING HEAD BEARINGS

Lubrication........................................................................1-46

Checking...........................................................................1-46

Adjustment........................................................................1-47

1.21 HEADLAMP ALIGNMENT

Headlamp Alignment........................................................1-48

Headlamp Adjustment: Single Headlamp Models............1-48

Headlamp Adjustment: Dual Headlamp Models...............1-49

Auxiliary Lamp Alignment.................................................1-49

1.22 CRITICAL FASTENERS

Inspection.........................................................................1-51

Checking Torques on Fasteners................................1-51

1.23 BATTERY MAINTENANCE

General.............................................................................1-53

Cleaning and Inspection...................................................1-54

Battery..............................................................................1-54

Disconnection and Removal......................................1-54

Installation and Connection.......................................1-54

Voltmeter Test...................................................................1-55

Voltmeter Test............................................................1-55

Charging Battery...............................................................1-55

Safety Precautions....................................................1-55

Using a Battery Charger............................................1-56

Storage.............................................................................1-57

1.24 ENGINE MOUNTS

Inspection.........................................................................1-58

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

Stabilizer Link............................................................1-58

Front Engine Mount...................................................1-58

Rear Frame Fasteners..............................................1-58

1.25 STORAGE

General.............................................................................1-59

Placing in Storage.............................................................1-59

Removal from Storage......................................................1-59

1.26 TROUBLESHOOTING

General.............................................................................1-61

Engine...............................................................................1-61

Starter Motor Does Not Operate or Does Not Turn Engine

Over ..........................................................................1-61

Engine Turns Over But Does Not Start ....................1-61

Starts Hard................................................................1-61

Starts But Runs Irregularly or Misses .......................1-61

A Spark Plug Fouls Repeatedly................................1-62

Pre-Ignition or Detonation (Knocks or Pings)............1-62

Overheating...............................................................1-62

Valve Train Noise.......................................................1-62

Excessive Vibration...................................................1-62

Check Engine Light Illuminates During Operation.....1-62

Lubrication System...........................................................1-62

Oil Does Not Return To Oil Reservoir........................1-62

Engine Uses Too Much Oil Or Smokes Excessively..1-62
Engine Leaks Oil From Cases, Push Rods, Hoses,

Etc.............................................................................1-62

Low Oil Pressure.......................................................1-63

High Oil Pressure......................................................1-63

Electrical System..............................................................1-63

Alternator Does Not Charge......................................1-63

Alternator Charge Rate Is Below Normal..................1-63

Speedometer Operates Erratically............................1-63

Transmission....................................................................1-63

Shifts Hard.................................................................1-63

Jumps Out Of Gear...................................................1-63

Clutch Slips................................................................1-63

Clutch Drags Or Does Not Release..........................1-63

Clutch Chatters..........................................................1-63

Handling............................................................................1-63

Irregularities...............................................................1-63

Brakes...............................................................................1-64

Brake Does Not Hold Normally.................................1-64

CHASSIS

2.1 FASTENER TORQUE VALUES

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

2.2 SPECIFICATIONS

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

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

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

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

Vehicle Identification Number: Touring Models...................2-9

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 WHEEL LACING: FRONT RIM

Wheel Lacing: Angle Flange Hub.....................................2-21

IV TABLE OF CONTENTS

TABLE OF CONTENTS

2.8 WHEEL LACING: 16 INCH REAR RIM

Wheel Lacing: 16 In. Rear Wheel.....................................2-23

2.9 CHECKING AND TRUING WHEELS

General.............................................................................2-26

Checking Wheel Runout...................................................2-26

Checking Lateral Runout...........................................2-26

Checking Radial Runout............................................2-26

Laced Wheel Rim Offset...................................................2-26

Truing Laced Wheels........................................................2-28

Radial Runout............................................................2-28

Lateral Runout...........................................................2-29

2.10 SEALED WHEEL BEARINGS

Inspection.........................................................................2-30

Removal............................................................................2-30

Installation.........................................................................2-31

2.11 TIRES

General.............................................................................2-33

Removal............................................................................2-33

Cleaning, Inspection and Repair......................................2-34

Installation.........................................................................2-34

Tube Type Tires.........................................................2-34

Tubeless Tires...........................................................2-34

Checking Tire Runout.......................................................2-35

Lateral Runout...........................................................2-35

Radial Runout............................................................2-35

Wheel Balancing...............................................................2-36

Weights......................................................................2-36

2.12 FRONT BRAKE MASTER CYLINDER

General.............................................................................2-37

Removal and Disassembly...............................................2-37

Removal....................................................................2-37

Disassembly..............................................................2-37

Cleaning and Inspection...................................................2-39

Assembly and Installation.................................................2-39

Assembly...................................................................2-39

Installation.................................................................2-39

Front Brake Line: Non-ABS Equipped..............................2-39

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

Installation.................................................................2-40

2.13 FRONT BRAKE CALIPER

Removal............................................................................2-42

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

2.14 REAR BRAKE MASTER CYLINDER

General.............................................................................2-43

Removal and Disassembly...............................................2-43

Removal....................................................................2-43

Disassembly..............................................................2-44

Cleaning and Inspection...................................................2-46

Assembly and Installation.................................................2-46

Assembly...................................................................2-46

Installation.................................................................2-46

Rear Brake Line: Non-ABS Equipped..............................2-46

Removal....................................................................2-46

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

2.15 REAR BRAKE CALIPER

Removal............................................................................2-49

Installation.........................................................................2-49

2.16 BLEEDING BRAKES

General.............................................................................2-50

Procedure.........................................................................2-50

2.17 FRONT FORK

Changing Fork Oil.............................................................2-52

Draining.....................................................................2-52

Filling.........................................................................2-52

Removal............................................................................2-53

Disassembly.....................................................................2-53

Cleaning and Inspection...................................................2-55

Assembly..........................................................................2-56

Installation.........................................................................2-56

2.18 STEERING HEAD BEARINGS

Removal............................................................................2-58

Inspection.........................................................................2-59

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

2.19 REAR AIR SUSPENSION

Check for Air Leaks..........................................................2-61

Compression Fitting...................................................2-61

Air Valve Assembly....................................................2-61

Air Tubes...................................................................2-61

2.20 REAR SHOCK ABSORBERS

Removal............................................................................2-63

Cleaning and Inspection...................................................2-63

Disassembly and Assembly..............................................2-63

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

2.21 REAR FORK

Removal............................................................................2-64

Disassembly and Assembly..............................................2-64

Bearing Removal.......................................................2-64

Bearing Installation....................................................2-65

Pivot Shaft/Mount Disassembly.................................2-65

Installation.........................................................................2-66

2.22 CLUTCH CABLE

Removal............................................................................2-67

Installation.........................................................................2-67

2.23 HANDLEBARS

Adjustment........................................................................2-70

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

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

Left Handgrip....................................................................2-72

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

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

Heated Handgrips.............................................................2-72

Remove Left Handgrip..............................................2-72

Install Left Handgrip...................................................2-73

Remove Right Handgrip............................................2-73

Install Right Handgrip................................................2-73

Rubber Mounts.................................................................2-73

TABLE OF CONTENTS V

TABLE OF CONTENTS

Removal....................................................................2-73

Installation.................................................................2-74

2.24 MIRRORS

All Models Except FLHX...................................................2-75

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

Installation.................................................................2-75

FLHX.................................................................................2-75

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

Installation.................................................................2-75

2.25 SEAT

Seat: Models without Tour-Pak.........................................2-76

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

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

Seat: Models with Tour-Pak..............................................2-76

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

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

Seat: Road King Models...................................................2-77

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

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

Seat Retention Nut Replacement.....................................2-77

Seat Bumper.....................................................................2-78

2.26 SADDLEBAGS

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

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

2.27 SADDLEBAG SERVICE

Saddlebag Hardware........................................................2-80

Removal....................................................................2-80

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

Saddlebag Guard/Support Rail.........................................2-81

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

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

Tether Brackets.................................................................2-87

Removing Tether Bracket from Tour-Pak..................2-87

Removing Tether Bracket from Tour-Pak Lid.............2-87

Installing Tether Bracket on Tour-Pak Lid..................2-87

Installing Tether Bracket on Tour-Pak........................2-87

Luggage Rack...................................................................2-87

2.30 TOUR-PAK LIGHTS

General.............................................................................2-88

Side Marker Lights (if equipped).......................................2-88

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

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

Tour-Pak Lights Harness..................................................2-88

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

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

Wrap-Around Lights (if equipped).....................................2-89

Bulb Replacement.....................................................2-89

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

Installation.................................................................2-90

2.31 TOUR-PAK BACKREST

Passenger Backrest..........................................................2-91

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

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

Rubber Isolators...............................................................2-91

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

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

Passenger Backrest Flap..................................................2-92

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

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

2.32 TOUR-PAK SPEAKER BOX

Speaker Box.....................................................................2-93

Removal....................................................................2-93

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

2.28 TOUR-PAK

Removal/Installation.........................................................2-83

Removal....................................................................2-83

Installation.................................................................2-83

Adjustment........................................................................2-84

Luggage Rack/Tour-Pak Support.....................................2-84

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

Assembly and Installation..........................................2-84

2.29 TOUR-PAK SERVICE

Lockset.............................................................................2-85

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

Installation.................................................................2-85

Hinges...............................................................................2-85

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

Installation.................................................................2-85

Latches/Lockset Catch.....................................................2-86

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

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

Catches.............................................................................2-86

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

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

Tether................................................................................2-86

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

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

2.33 LOWER FAIRING AND ENGINE GUARD

Lower Fairing....................................................................2-94

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

Disassembly..............................................................2-94

Assembly...................................................................2-95

Installation.................................................................2-95

Serrated Washer Replacement........................................2-95

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

Installation.................................................................2-95

Engine Guard....................................................................2-95

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

Installation.................................................................2-95

2.34 UPPER FAIRING AND WINDSHIELD:
FORK MOUNTED FAIRING MODELS

Outer Fairing and Windshield...........................................2-97

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

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

2.35 FAIRING CAP: FORK MOUNTED
FAIRING MODELS

Fairing Cap.......................................................................2-98

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

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

VI TABLE OF CONTENTS

TABLE OF CONTENTS

2.36 INNER FAIRING: FORK MOUNTED
FAIRING MODELS

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

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

2.37 AIR DEFLECTORS

Air Deflectors..................................................................2-103

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

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

Mid-Frame Air Deflectors................................................2-103

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

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

2.38 UPPER FAIRING AND WINDSHIELD:
FRAME MOUNTED FAIRING MODELS

Windshield......................................................................2-104

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

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

Outer Fairing...................................................................2-104

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

Installation...............................................................2-105

2.39 INSTRUMENT BEZEL: FRAME
MOUNTED FAIRING MODELS

Bezel...............................................................................2-107

Removal..................................................................2-107

Installation...............................................................2-108

2.40 INSTRUMENT NACELLE: FRAME
MOUNTED FAIRING MODELS

Instrument Nacelle..........................................................2-109

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

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

2.41 INNER FAIRING: FRAME MOUNTED
FAIRING MODELS

Removal..........................................................................2-111

Disassembly............................................................2-112

Installation.......................................................................2-113

Outer Fairing............................................................2-113

Inner Fairing............................................................2-113

2.42 GLOVE BOX DOOR AND HINGE:
FRAME MOUNTED FAIRING MODELS

Glove Box Door and Hinge.............................................2-115

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

Installation...............................................................2-115

2.43 WINDSHIELD: ROAD KING MODELS

Windshield......................................................................2-116

Removal..................................................................2-116

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

Windshield Window........................................................2-116

Removal..................................................................2-116

Installation...............................................................2-117

2.44 HEADLAMP NACELLE: ROAD KING
MODELS

Removal..........................................................................2-119

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

2.45 FRONT FENDER

Removal..........................................................................2-121

Installation.......................................................................2-121

2.46 REAR FENDER

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

Fender Repair.................................................................2-123

Mounting Hardware.................................................2-123

Lights and Harnesses..............................................2-123

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

2.47 REAR FASCIA

Removal..........................................................................2-125

Installation.......................................................................2-125

Stud Plate.......................................................................2-125

Removal..................................................................2-125

Installation...............................................................2-125

Rear Fascia Lamp..........................................................2-125

Removal..................................................................2-125

Installation...............................................................2-125

2.48 REAR FRAME

Rear Frame.....................................................................2-126

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

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

Thread Repair..........................................................2-127

2.49 FOOTBOARDS AND FOOTRESTS

Rider Footboards............................................................2-128

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

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

Disassembly............................................................2-128

Assembly.................................................................2-128

Passenger Footboard.....................................................2-129

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

Disassembly............................................................2-129

Assembly.................................................................2-129

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

Passenger Footrest: FLHX, FLTRX................................2-129

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

Disassembly............................................................2-129

Assembly.................................................................2-130

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

2.50 JIFFY STAND

General...........................................................................2-131

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

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

Jiffy Stand Bracket..........................................................2-132

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

Installation...............................................................2-132

Jiffy Stand Interlock Sensor............................................2-132

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

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

TABLE OF CONTENTS VII

TABLE OF CONTENTS

2.51 FRONT ENGINE MOUNT

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

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

ENGINE

3.1 FASTENER TORQUE VALUES

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

3.2 SPECIFICATIONS

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

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

Oil Cooler Operation.........................................................3-12

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...........................................3-18

Compression Test.............................................................3-18

Cylinder Leakdown Test...................................................3-19

Diagnosing Smoking Engine or High Oil Consumption.....3-19

Check Prior To Cylinder Head Removal....................3-19

Check After Cylinder Head Removal.........................3-19

3.9 OIL COOLER

Removal............................................................................3-20

Installation.........................................................................3-20

3.10 OIL COOLER ADAPTER

Removal............................................................................3-21

Disassembly.....................................................................3-21

Assembly..........................................................................3-21

Installation.........................................................................3-21

3.11 HOW TO USE THIS SECTION

Top End Repair.................................................................3-23

Bottom End Repair...........................................................3-23

Typical Symptoms.............................................................3-23

3.12 TOP END SERVICE

Engine in Chassis.............................................................3-24

Engine Removed from Chassis........................................3-25

3.13 CAM COMPARTMENT SERVICE

Engine in Chassis.............................................................3-26

Engine Removed From Chassis.......................................3-27

3.14 STRIPPING MOTORCYCLE FOR
SERVICE

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

Cam Compartment Service Only...............................3-28

Top End Service........................................................3-28

3.15 ASSEMBLING MOTORCYCLE AFTER
SERVICE

Procedure.........................................................................3-29

After Top End Service................................................3-29

After Cam Compartment Service..............................3-29

3.16 REMOVING ENGINE FROM CHASSIS

Procedure.........................................................................3-30

3.17 INSTALLING ENGINE IN CHASSIS

Procedure.........................................................................3-31

3.18 TOP END OVERHAUL: DISASSEMBLY

General.............................................................................3-32

Rocker Covers..................................................................3-32

Rocker Arm Support Plate................................................3-32

Push Rods, Lifters and Covers.........................................3-34

Cylinder Head...................................................................3-35

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

Piston................................................................................3-36

3.19 BREATHER ASSEMBLY

Disassembly.....................................................................3-38

Early Production........................................................3-38

Late Production.........................................................3-38

Cleaning and Inspection...................................................3-38

Assembly..........................................................................3-38

Early Production........................................................3-38

Late Production.........................................................3-38

3.20 ROCKER ARM SUPPORT PLATE

Disassembly.....................................................................3-40

Cleaning and Inspection...................................................3-40

Inspection..................................................................3-40

Rocker Shaft Fit.........................................................3-40

Rocker Arm Shaft to Bushing....................................3-41

Replace Rocker Arm Bushings.................................3-41

Assembly..........................................................................3-42

3.21 PUSH RODS, LIFTERS AND COVERS

Disassembly.....................................................................3-43

Cleaning and Inspection...................................................3-43

Lifter Inspection................................................................3-44

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

3.22 CYLINDER HEAD

Disassembly.....................................................................3-45

Cleaning............................................................................3-46

Inspection.........................................................................3-46

VIII TABLE OF CONTENTS

TABLE OF CONTENTS

Cylinder Head............................................................3-46

Valve Guides.............................................................3-47

Valves........................................................................3-47

Valve Springs.............................................................3-47

Tapered Keepers.......................................................3-47

Valve Seats................................................................3-47

Valve Guide Replacement................................................3-47

Removal....................................................................3-47

Installation.................................................................3-48

Valve and Seat Refacing..................................................3-51

Assembly..........................................................................3-53

3.23 CYLINDER

Cleaning............................................................................3-56

Inspection.........................................................................3-56

Deglazing Cylinder............................................................3-58

Boring and Honing Cylinder..............................................3-58

3.24 PISTON

Disassembly.....................................................................3-60

Piston Rings..............................................................3-60

Cleaning............................................................................3-60

Inspection.........................................................................3-60

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

Checking Piston Ring Gap........................................3-62

Installing Piston Rings...............................................3-62

3.25 TOP END OVERHAUL: ASSEMBLY

General.............................................................................3-64

Piston................................................................................3-64

Cylinder.............................................................................3-65

Cylinder Head...................................................................3-67

Push Rods, Lifters and Covers.........................................3-71

Rocker Arm Support Plate................................................3-72

Breather and Rocker Cover..............................................3-73

3.26 CAM COMPARTMENT AND
COMPONENTS

Cam Support Plate and Cover Removal..........................3-75

Prepare Engine..........................................................3-75

Cam Chain and Sprockets Removal.........................3-75

Cam Support Plate Removal.....................................3-76

Cam Support Plate Cleaning and Inspection....................3-77

Oil Pressure Valve.....................................................3-77

Cam Support Plate....................................................3-77

Camshafts.........................................................................3-77

Removal....................................................................3-77

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

Oil Pressure Relief Valve..................................................3-79

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

Inspection..................................................................3-79

Installation.................................................................3-79

Cam Needle Bearings.......................................................3-80

Removal....................................................................3-80

Installation.................................................................3-81

Cam Support Plate and Cover Installation.......................3-83

3.27 OIL PUMP

Removal............................................................................3-87

Cleaning and Inspection...................................................3-87

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

3.28 CRANKCASE DISASSEMBLY AND
REPAIR

Crankcase Disassembly...................................................3-90

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

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

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

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

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..................................3-94

Removal....................................................................3-94

Installation.................................................................3-95

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

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

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

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

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

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

3.29 FLYWHEEL AND CONNECTING RODS

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

Measuring Crankshaft Runout..........................................3-99

Crankshaft Removed.................................................3-99

3.30 CRANKCASE ASSEMBLY

Crankcase Assembly......................................................3-101

3.31 OIL PAN

Removal..........................................................................3-103

Installation.......................................................................3-103

FUEL SYSTEM

4.1 FASTENER TORQUE VALUES

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

4.2 SPECIFICATIONS: FUEL SYSTEM

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

4.3 ELECTRONIC FUEL INJECTION (EFI)

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

4.4 AIR CLEANER ASSEMBLY

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

Installation...........................................................................4-6

4.5 FUEL TANK

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

Purge and Disconnect Fuel Line.................................4-8

Remove Tank...............................................................4-8

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

Evaporative Emissions Tube: Non-CA Models...................4-9

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

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

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

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

Installation.................................................................4-10

TABLE OF CONTENTS IX

TABLE OF CONTENTS

4.6 FUEL TANK TOP PLATE

Removal............................................................................4-11

Installation.........................................................................4-12

4.7 FUEL FILTER

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

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

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.............................................................................4-19

4.12 ENGINE TEMPERATURE SENSOR (ET)

Removal............................................................................4-20

Installation.........................................................................4-20

4.13 INDUCTION MODULE

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

Installation.........................................................................4-22

4.14 TEMPERATURE MANIFOLD ABSOLUTE
PRESSURE SENSOR (TMAP)

General.............................................................................4-23

Removal............................................................................4-23

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

4.15 OXYGEN SENSORS (O2)

General.............................................................................4-24

Removal............................................................................4-24

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

4.16 FUEL INJECTORS

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

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

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

4.17 FUEL PUMP

General.............................................................................4-28

Removal............................................................................4-28

Installation.........................................................................4-28

Fuel Pump and Fuel Level Sender Wire Harness............4-29

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

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

4.18 FUEL PRESSURE TEST

General.............................................................................4-30

Testing..............................................................................4-30

4.19 EXHAUST SYSTEM

Mufflers.............................................................................4-32

Removal....................................................................4-32

Installation.................................................................4-32

System Removal...............................................................4-32

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

4.20 ACTIVE EXHAUST (HDI)

Exhaust Valve Actuator.....................................................4-35

Removal....................................................................4-35

Installation.................................................................4-35

Exhaust Valve Actuator Cable..........................................4-35

Removal....................................................................4-35

Installation.................................................................4-35

Active Exhaust Valve........................................................4-35

General......................................................................4-35

4.21 INTAKE LEAK TEST

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

Leak Tester.......................................................................4-36

Parts List....................................................................4-36

Tester Assembly........................................................4-36

Tester Adjustment......................................................4-36

Procedure.........................................................................4-36

4.22 EVAPORATIVE EMISSIONS CONTROL
SYSTEM

General.............................................................................4-38

Vapor Valve.......................................................................4-38

Fuel Vapor Vent Tube.......................................................4-39

Removal....................................................................4-39

Installation.................................................................4-39

Canister-to-Solenoid Tube................................................4-39

Removal....................................................................4-39

Installation.................................................................4-39

Solenoid-to-Induction Module Tube..................................4-39

Removal....................................................................4-39

Installation.................................................................4-39

Purge Solenoid.................................................................4-40

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

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

Charcoal Canister.............................................................4-40

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

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

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

X TABLE OF CONTENTS

TABLE OF CONTENTS

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

5.4 DRIVE COMPONENTS

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

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

5.5 PRIMARY CHAINCASE HOUSING

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

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

5.6 CLUTCH

Removal and Installation..................................................5-14

Clutch Pack Only..............................................................5-14

Partial Disassembly...................................................5-14

Cleaning And Inspection...........................................5-14

Assembly...................................................................5-15

Clutch Pack and Bearing..................................................5-16

Complete Disassembly..............................................5-16

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

5.7 TRANSMISSION SPROCKET

Removal............................................................................5-19

Cleaning and Inspection...................................................5-19

Installation.........................................................................5-19

5.8 DRIVE BELT

Removal and Adjustment.................................................5-21

Adjustment.................................................................5-21

Removal....................................................................5-21

Installation.........................................................................5-21

TRANSMISSION

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

6.5 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

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

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

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

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

Removing 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

ELECTRICAL

7.1 FASTENER TORQUE VALUES

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

7.2 SPECIFICATIONS: ELECTRICAL

Specifications......................................................................7-5

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

7.3 VOLTAGE REGULATOR

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

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

7.4 ELECTRONIC CONTROL MODULE (ECM)

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

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

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

7.5 TURN SIGNAL AND SECURITY MODULE
(TSM/TSSM/HFSM)

General...............................................................................7-8

TABLE OF CONTENTS XI

TABLE OF CONTENTS

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

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

HFSM Antenna...................................................................7-9

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

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

7.6 IGNITION COIL

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

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

7.7 SYSTEM FUSES AND RELAYS

Main Fuse.........................................................................7-11

Removal....................................................................7-11

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

Main Fuse Holder.............................................................7-11

Removal....................................................................7-11

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

System Fuses and Relays................................................7-11

Removal....................................................................7-11

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

Fuse Blocks......................................................................7-12

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

Installation.................................................................7-12

7.8 ELECTRICAL CADDIES

Top Caddy.........................................................................7-13

Removal....................................................................7-13

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

Left Side Caddy................................................................7-13

Removal....................................................................7-13

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

Battery Tray......................................................................7-15

Removal....................................................................7-15

Installation.................................................................7-16

7.9 SECURITY SIREN

Removal............................................................................7-17

Installation.........................................................................7-17

7.10 STARTER

General.............................................................................7-18

Removal............................................................................7-18

Drive Assembly.................................................................7-18

Disassembly..............................................................7-18

Inspection..................................................................7-19

Assembly...................................................................7-19

Solenoid............................................................................7-20

Cover and Plunger Removal.....................................7-20

Short Post Contact: Starter.......................................7-20

Long Post Contact: Battery Positive..........................7-20

Plunger and Cover Installation..................................7-21

Installation.........................................................................7-21

7.11 HEADLAMP: ALL EXCEPT ROAD GLIDE

Headlamp: Single Headlamp Models...............................7-22

Removal....................................................................7-22

Bulb Replacement.....................................................7-22

Installation.................................................................7-22

7.12 HEADLAMP: ROAD GLIDE

Headlamp Adjuster Assembly..........................................7-24

Removal....................................................................7-24

Repair........................................................................7-24

Installation.................................................................7-24

Headlamp Bulb Replacement: Dual Headlamp Models....7-24

Removal....................................................................7-24

Bulb Replacement.....................................................7-24

Installation.................................................................7-25

7.13 AUXILIARY LAMPS AND BRACKETS

Auxiliary Lamp Bulb Replacement....................................7-26

Removal....................................................................7-26

Installation.................................................................7-26

Auxiliary Lamp Housing....................................................7-27

Removal....................................................................7-27

Installation.................................................................7-28

Auxiliary Lamp Bracket.....................................................7-28

Removal....................................................................7-28

Installation.................................................................7-29

Adjustment........................................................................7-29

7.14 TAIL LAMP

Tail Lamp Bulb Replacement............................................7-30

Removal....................................................................7-30

Installation.................................................................7-30

Circuit Board/Chrome Base..............................................7-30

Removal....................................................................7-30

Installation.................................................................7-31

Rear Fender Lights Harness: all except FLHX, FLTRX.....7-31

Removal....................................................................7-31

Installation.................................................................7-32

Rear Fender Lights Harness: FLHX, FLTRX....................7-33

Removal....................................................................7-33

Installation.................................................................7-33

7.15 FENDER TIP LAMPS

Front Fender Tip Lamp.....................................................7-35

Removal....................................................................7-35

Installation.................................................................7-35

Front Fender Tip Lamp Jumper Harness..........................7-35

Removal....................................................................7-35

Installation.................................................................7-36

Rear Fender Tip Lamp......................................................7-37

Removal....................................................................7-37

Installation.................................................................7-38

7.16 TURN SIGNAL LAMPS

Turn Signal Bulb Replacement: Bullet Style.....................7-39

Turn Signal Bulb Replacement: Flat Lens Style...............7-39

Front Turn Signal Lamp....................................................7-39

Removal: Flat Lens Style..........................................7-39

Installation: Flat Lens Style.......................................7-40

Removal: Bullet Style, Fork Mounted........................7-41

Installation: Bullet Style, Fork Mounted.....................7-42

Removal: Bullet Style, Fairing Mounted....................7-42

Installation: Bullet Style, Fairing Mounted.................7-43

Rear Turn Signal Lamp.....................................................7-43

Removal: FLHR/C, FLHTC/U, FLHTK.......................7-43

Installation: FLHR/C, FLHTC/U, FLHTK....................7-44

Removal: FLHX, FLTRX, FLTRU...............................7-44

Installation: FLHX, FLTRX, FLTRU............................7-44

Rear Turn Signal Lamps Bracket......................................7-46

Removal: FLHR/C, FLHTC/U, FLHTK.......................7-46

XII TABLE OF CONTENTS

TABLE OF CONTENTS

Installation: FLHR/C, FLHTC/U, FLHTK....................7-46

Removal: FLHX, FLTRX, FLTRU...............................7-46

Installation: FLHX, FLTRX, FLTRU............................7-47

7.17 IGNITION/LIGHT KEY SWITCH AND
FORK LOCK

Fairing Models..................................................................7-48

Removal....................................................................7-48

Installation.................................................................7-50

Road King Models............................................................7-51

Ignition/Light Key Switch: Removal...........................7-51

Ignition/Light Key Switch: Installation........................7-51

Fork Lock: Removal...................................................7-51

Fork Lock: Installation................................................7-51

7.18 FAIRING CAP SWITCHES: FORK
MOUNTED FAIRING MODELS

Removal............................................................................7-53

Installation.........................................................................7-54

7.19 INSTRUMENT NACELLE SWITCHES:
FRAME MOUNTED FAIRING MODELS

Removal............................................................................7-55

Left Side Switch.........................................................7-55

Right Side Switches...................................................7-56

Installation.........................................................................7-56

Left Side Switch.........................................................7-56

Right Side Switches...................................................7-56

7.20 CRANKSHAFT POSITION SENSOR
(CKP)

General.............................................................................7-59

Removal............................................................................7-59

Installation.........................................................................7-59

7.21 AUTOMATIC COMPRESSION RELEASE
(ACR)

General.............................................................................7-60

Removal............................................................................7-60

Installation.........................................................................7-60

7.22 ALTERNATOR

Removal............................................................................7-62

Cleaning and Inspection...................................................7-62

Installation.........................................................................7-63

7.23 VEHICLE SPEED SENSOR (VSS)

VSS...................................................................................7-64

Removal....................................................................7-64

Installation.................................................................7-64

7.26 STOPLIGHT SWITCHES

Front Stoplight Switch.......................................................7-67

Removal/Installation..................................................7-67

Rear Stoplight Switch.......................................................7-67

Removal....................................................................7-67

Installation.................................................................7-67

7.27 HORN

Inspection.........................................................................7-68

Removal............................................................................7-68

Installation.........................................................................7-68

7.28 CIGARETTE LIGHTER: FAIRING
MODELS

Troubleshooting................................................................7-69

Removal............................................................................7-69

Installation.........................................................................7-69

7.29 GAUGES AND INSTRUMENTS: FAIRING
MODELS

2 Inch Diameter Gauges: Fuel Level, Ambient Air Temperature,

Voltmeter, Oil Pressure.....................................................7-70

Removal....................................................................7-70

Installation.................................................................7-70

Tachometer.......................................................................7-70

Removal....................................................................7-70

Installation.................................................................7-70

Speedometer....................................................................7-71

Removal....................................................................7-71

Installation.................................................................7-71

7.30 INDICATOR LAMPS: FAIRING MODELS

Indicator Lamps................................................................7-72

Removal....................................................................7-72

Installation.................................................................7-72

7.31 GAUGES AND INSTRUMENTS: ROAD
KING MODELS

Fuel Gauge.......................................................................7-73

Removal....................................................................7-73

Installation.................................................................7-73

Speedometer....................................................................7-73

Removal....................................................................7-73

Installation.................................................................7-74

7.32 INDICATOR LAMPS: ROAD KING
MODELS

Indicator Lamps................................................................7-75

Removal....................................................................7-75

Installation.................................................................7-75

7.24 NEUTRAL SWITCH

Removal............................................................................7-65

Installation.........................................................................7-65

7.25 OIL PRESSURE SWITCH AND SENDER

Removal............................................................................7-66

Installation.........................................................................7-66

7.33 ADVANCED AUDIO SYSTEM

Radio................................................................................7-76

Removal....................................................................7-76

Installation.................................................................7-76

Front Fairing Speakers.....................................................7-77

Removal....................................................................7-77

Installation.................................................................7-77

Front Headset Receptacle................................................7-77

TABLE OF CONTENTS XIII

TABLE OF CONTENTS

Removal....................................................................7-77

Installation.................................................................7-77

Rear Headset Receptacle................................................7-78

Rear Passenger Switches................................................7-78

Removal....................................................................7-78

Installation.................................................................7-78

Rear Speakers..................................................................7-80

Removal....................................................................7-80

Installation.................................................................7-80

CB Module........................................................................7-80

Removal....................................................................7-80

Installation.................................................................7-80

7.34 WIRE TROUGH

Removal............................................................................7-81

Installation.........................................................................7-82

7.35 MAIN WIRING HARNESS

Removal: All Models (Part 1)............................................7-83

Removal: Road King Models (Part 2)...............................7-83

Removal: Fork Mounted Fairing Models (Part 2)..............7-84

Removal: Frame Mounted Fairing Models (Part 2)..........7-85

Removal: All Models (Part 3)............................................7-85

Installation: All Models (Part 1).........................................7-87

Installation: Road King Models (Part 2)............................7-89

Installation: Fork Mounted Fairing Models (Part 2)...........7-90

Installation: Frame Mounted Fairing Models (Part 2).......7-90

Installation: All Models (Part 3).........................................7-90

7.36 INTERCONNECT HARNESS

Fork Mounted Fairing Models...........................................7-91

Removal....................................................................7-91

Installation.................................................................7-92

Frame Mounted Fairing Models........................................7-94

Removal....................................................................7-94

Installation.................................................................7-96

7.37 RADIO ANTENNA CABLE

Models Equipped with Tour-Pak.......................................7-98

Removal....................................................................7-98

Installation.................................................................7-98

Models without Tour-Pak..................................................7-99

Removal....................................................................7-99

Installation.................................................................7-99

7.38 REAR AUDIO HARNESS: ULTRA
MODELS

Removal..........................................................................7-101

Installation.......................................................................7-101

7.39 CB ANTENNA CABLE: ULTRA MODELS

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

7.41 TSSM/HFSM MAINTENANCE

General...........................................................................7-121

Fob Battery.....................................................................7-121

Battery Replacement Schedule...............................7-121

Battery Replacement...............................................7-121

Smart Siren (If Installed).................................................7-121

Battery Replacement Schedule...............................7-121

Battery Replacement...............................................7-121

7.42 PERSONAL IDENTIFICATION NUMBER
(PIN)

General...........................................................................7-123

Initial Pin Entry................................................................7-123

Changing the Pin............................................................7-123

Modifying an Existing Pin........................................7-123

7.43 H-DSSS ACTUATION

General...........................................................................7-125

Sidecar Configuration.....................................................7-125

Actuation.........................................................................7-125

Fob Assignment..............................................................7-125

Power Disruption and Configuring..................................7-125

7.44 TSM/HFSM: PASSWORD LEARN

General...........................................................................7-126

Password Learn..............................................................7-126

APPENDIX A CONNECTOR REPAIR

A.1 AUTOFUSE UNSEALED ELECTRICAL
CONNECTORS

Autofuse Unsealed Connector Repair................................A-1

XIV TABLE OF CONTENTS

TABLE OF CONTENTS

General.......................................................................A-1

Disassembly................................................................A-1

Assembly.....................................................................A-1

A.2 DELPHI 100W MICRO-PACK SEALED
CONNECTOR

Delphi 100W Micro-Pack Sealed Connector Repair..........A-2

General.......................................................................A-2

Separating Socket Housing From ECM......................A-2

Mating Socket Housing To ECM.................................A-2

Removing Socket Terminal.........................................A-2

Installing Socket Terminal...........................................A-2

Crimping Terminals.....................................................A-2

A.3 DELPHI 150 METRI-PACK SEALED
CONNECTORS

Delphi 150 Metri-Pack Sealed Connector Repair..............A-4

General.......................................................................A-4

Separating Pin and Socket Housings.........................A-4

Mating Pin and Socket Housings................................A-4

Removing Socket Terminal.........................................A-4

Inserting Socket Terminal............................................A-4

A.4 DELPHI 280 METRI-PACK UNSEALED
CONNECTORS

Fuse Block Repair..............................................................A-6

Removing Socket Terminals.......................................A-6

Installing Socket Terminals.........................................A-6

Crimping Terminals.....................................................A-6

A.5 DELPHI 480 METRI-PACK UNSEALED
CONNECTORS

Delphi 480 Metri-Pack Unsealed Connector Repair..........A-7

General.......................................................................A-7

Separating Pin and Socket Housings.........................A-7

Mating Pin and Socket Housings................................A-7

Removing Socket Terminals.......................................A-7

Installing Socket Terminals.........................................A-7

A.6 DELPHI 630 METRI-PACK UNSEALED
CONNECTORS

Delphi 630 Metri-Pack Unsealed Connector Repair..........A-8

Separating Pin and Socket Housings.........................A-8

Mating Pin and Socket Housings................................A-8

Removing Socket Terminal.........................................A-8

Installing Socket Terminal...........................................A-8

A.7 DELPHI 800 METRI-PACK SEALED MAIN
FUSE HOUSING

Delphi 800 Metri-Pack Sealed Main Fuse Housing

Repair.................................................................................A-9

Removing Socket Terminals.......................................A-9

Installing Socket Terminals.........................................A-9

A.8 DELPHI METRI-PACK TERMINAL
REPAIR

Metri-Pack Terminal Crimps.............................................A-11

Matching Terminal To Crimper..................................A-11

Preparing Wire Lead.................................................A-11

Crimping Wire Core...................................................A-11

Crimping Insulation/Seal...........................................A-11

Inspecting Crimps.....................................................A-12

A.9 DELPHI MICRO 64 SEALED
CONNECTORS

Delphi Micro 64 Sealed Connector Repair.......................A-13

General.....................................................................A-13

Separating Pin and Socket Housings.......................A-13

Mating Pin and Socket Housings..............................A-13

Removing Terminal...................................................A-13

Installing Terminal.....................................................A-14

Preparing Wire Leads for Crimping...........................A-14

Crimping Terminals...................................................A-14

Inspecting Crimps.....................................................A-14

A.10 DELPHI GT 150 SEALED
CONNECTORS

Delphi GT 150 Sealed Connector Repair.........................A-16

General.....................................................................A-16

Separating Pin and Socket Housings.......................A-16

Mating Pin and Socket Housings..............................A-16

Removing Socket Terminals.....................................A-16

Installing Socket Terminals.......................................A-16

A.11 DELPHI GT 280 SEALED 73-TERMINAL
ECM CONNECTOR

Delphi GT 280 Sealed 73-Terminal ECM Connector.......A-18

Separating Socket Housing From ECM....................A-18

Mating Socket Housing To ECM...............................A-18

Socket Terminal.........................................................A-18

ECM Ground Terminal..............................................A-18

A.12 DEUTSCH DT SEALED CONNECTORS

Deutsch DT Sealed Connector Repair.............................A-20

General.....................................................................A-20

Separating Pin and Socket Housings.......................A-20

Mating Pin and Socket Housings..............................A-20

Removing Socket Terminals.....................................A-20

Installing Socket Terminals.......................................A-20

Removing Pin Terminals...........................................A-22

Installing Pin Terminals.............................................A-22

Crimping Terminals...................................................A-23

A.13 DEUTSCH DT SEALED TERMINAL
REPAIR

Deutsch DT Sealed Terminal Crimps...............................A-24

Preparing Wire Leads for Crimping...........................A-24

Crimping Terminal to Lead........................................A-24

Inspecting Crimps.....................................................A-24

A.14 DEUTSCH DTM SEALED MINI
TERMINAL REPAIR

Deutsch DTM Sealed Mini Terminal Crimps....................A-25

Preparing Wire Leads for Crimping...........................A-25

Crimping a Mini Terminal to Wire Lead.....................A-25

Inspecting Crimps.....................................................A-25

TABLE OF CONTENTS XV

TABLE OF CONTENTS

A.15 DEUTSCH DTM SEALED SOLID
BARREL MINI TERMINAL REPAIR

Deutsch DTM Sealed Solid Barrel Terminal Crimps........A-26

Preparing Wire Leads For Crimping.........................A-26

Adjusting Crimper Tool..............................................A-26

Crimping a Barrel Contact To Wire Lead..................A-26

Inspecting Crimps.....................................................A-26

A.16 JAE MX19 SEALED CONNECTORS

JAE MX19 Sealed Connectors.........................................A-28

Connector Housings.................................................A-28

Removing Terminals.................................................A-28

Installing Terminals....................................................A-28

A.17 MOLEX CMC SEALED CONNECTORS

Molex CMC Sealed Connectors.......................................A-29

Separating the Connector.........................................A-29

Removing Terminals.................................................A-29

Installing Terminals....................................................A-29

A.18 MOLEX MX 150 SEALED
CONNECTORS

Molex MX 150 Sealed Connector Repair.........................A-31

Separating Pin and Socket Housings.......................A-31

Mating Pin and Socket Housings..............................A-31

Removing Terminals.................................................A-31

Installing Terminals....................................................A-31

Crimp Terminal to Lead....................................................A-32

Prepare Lead............................................................A-32

Prepare Tool..............................................................A-32

Position Terminal in the Punch/Die...........................A-33

Insert Stripped Lead..................................................A-33

Crimp Terminal to Lead.............................................A-34

Inspect Crimp............................................................A-34

A.19 TYCO 070 MULTILOCK UNSEALED
CONNECTOR

Tyco 070 Multilock Unsealed Connector Repair..............A-35

General.....................................................................A-35

Separating Pin and Socket Housings.......................A-35

Mating Pin and Socket Housings..............................A-35

Removing Terminals from Housing...........................A-35

Inserting Terminals into Housing...............................A-36

Preparing Wire Leads for Crimping...........................A-36

Crimping Terminals to Leads....................................A-37

Inspecting Crimped Terminals...................................A-38

A.20 SEALED SPLICE CONNECTORS

Sealed Splice Connector Repair......................................A-39

General.....................................................................A-39

Preparing Wire Leads...............................................A-39

Splicing Wire Leads..................................................A-39

Inspecting Seals........................................................A-39

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-7

Wire Color Codes........................................................B-7

Wiring Diagram Symbols............................................B-7

2011 Touring Wiring Diagrams...........................................B-9

APPENDIX C ABS

C.1 FASTENER TORQUE VALUES

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

C.2 ABS MODULE

Hydraulic Control Unit (HCU).............................................C-2

Removal......................................................................C-2

Installation...................................................................C-3

Electronic Control Unit (ECU)............................................C-3

Removal......................................................................C-3

Installation...................................................................C-4

C.3 WHEEL SPEED SENSORS

Front Wheel Speed Sensor................................................C-5

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

Installation...................................................................C-5

Rear Wheel Speed Sensor................................................C-6

Removal......................................................................C-6

Installation...................................................................C-6

C.4 ABS BRAKE LINES

Front Master Cylinder to ABS Module...............................C-7

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

Installation...................................................................C-8

ABS Module to Front Brake Calipers.................................C-8

Removal......................................................................C-8

Installation...................................................................C-9

Rear Master Cylinder to ABS Module..............................C-10

Removal....................................................................C-10

Installation.................................................................C-11

ABS Module to Rear Brake Caliper.................................C-12

Removal....................................................................C-12

Installation.................................................................C-12

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

XVI TABLE OF CONTENTS

TABLE OF CONTENTS

APPENDIX E GLOSSARY

E.1 GLOSSARY

Acronyms and Abbreviations.............................................E-1

REFERENCE MATERIAL

TOOLS...........................................................I

TORQUE VALUES......................................VII

INDEX......................................................XXIII

TABLE OF CONTENTS XVII

NOTES

XVIII TABLE OF CONTENTS

TABLE OF CONTENTS

SUBJECT............................................................................................................................PAGE NO.

1.1 FASTENER TORQUE VALUES.................................................................................................1-1

1.2 GENERAL..................................................................................................................................1-3

1.3 FUEL AND OIL..........................................................................................................................1-7

1.4 BULB REQUIREMENTS............................................................................................................1-9

1.5 MAINTENANCE SCHEDULE..................................................................................................1-11

1.6 ENGINE OIL AND FILTER.......................................................................................................1-15

1.7 AIR CLEANER AND EXHAUST SYSTEM...............................................................................1-18

1.8 TIRES AND WHEELS..............................................................................................................1-20

1.9 PRIMARY CHAINCASE LUBRICANT.....................................................................................1-23

1.10 TRANSMISSION LUBRICANT..............................................................................................1-25

1.11 CLUTCH.................................................................................................................................1-27

1.12 DRIVE BELT AND SPROCKETS..........................................................................................1-29

1.13 COMPENSATOR SPROCKET ISOLATOR...........................................................................1-34

1.14 CABLE AND CHASSIS LUBRICATION.................................................................................1-35

1.15 BRAKES................................................................................................................................1-36

1.16 BRAKE PADS AND DISCS....................................................................................................1-37

1.17 SPARK PLUGS......................................................................................................................1-41

1.18 FRONT FORK OIL.................................................................................................................1-43

1.19 SUSPENSION ADJUSTMENTS............................................................................................1-44

1.20 STEERING HEAD BEARINGS..............................................................................................1-46

1.21 HEADLAMP ALIGNMENT.....................................................................................................1-48

1.22 CRITICAL FASTENERS........................................................................................................1-51

1.23 BATTERY MAINTENANCE....................................................................................................1-53

1.24 ENGINE MOUNTS.................................................................................................................1-58

1.25 STORAGE..............................................................................................................................1-59

1.26 TROUBLESHOOTING...........................................................................................................1-61

MAINTENANCE

NOTES

HOME

FASTENER TORQUE VALUES IN THIS CHAPTER

The table below lists torque values for all fasteners presented
in this chapter.

screws

screws

1.1FASTENER TORQUE VALUES

NOTESTORQUE VALUEFASTENER

1.5 MAINTENANCE SCHEDULE, General12.2-14.9 Nm108-132 in-lbsAir cleaner cover bracket screws

12.2-14.9 Nm108-132 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) mounting screws

8.5-11.5 Nm75-102 in-lbsBrake caliper pad pin

8.5-11.5 Nm75-102 in-lbsBrake caliper pad pin

9.5-12.2 Nm84-108 in-lbsClutch inspection cover screw

19.0-28.5 Nm14-21 ft-lbEngine oil drain plug

1.1-1.4 Nm10-12 in-lbsFront master cylinder reservoir cover

1.7 AIR CLEANER AND EXHAUST
SYSTEM, Installation

1.5 MAINTENANCE SCHEDULE, General4.1-6.8 Nm36-60 in-lbsAir cleaner cover screw

1.7 AIR CLEANER AND EXHAUST
SYSTEM, Installation/Use Loctite Medium Strength
Threadlocker 243 (Blue)

1.21 HEADLAMP ALIGNMENT, Auxiliary Lamp
Alignment

1.5 MAINTENANCE SCHEDULE, General6.8-7.9 Nm60-70 in-lbsBattery terminal bolt

1.23 BATTERY MAINTENANCE, Battery6.8-7.9 Nm60-70 in-lbsBattery terminal bolt

1.23 BATTERY MAINTENANCE, Battery6.8-7.9 Nm60-70 in-lbsBattery terminal bolt

1.16 BRAKE PADS AND DISCS, Brake Pad
Replacement/metric

1.16 BRAKE PADS AND DISCS, Brake Pad
Replacement/metric

1.5 MAINTENANCE SCHEDULE, General8.5.-11.5 Nm75-102 in-lbsBrake caliper pad pin

1.16 BRAKE PADS AND DISCS, Brake Pad
Replacement/Always use new pin

1.16 BRAKE PADS AND DISCS, Brake Pad
Replacement/Always use new pin

1.5 MAINTENANCE SCHEDULE, General8.1-13.6 Nm72-120 in-lbsClutch adjuster screw jam nut

1.11 CLUTCH, Adjustment8.1-13.6 Nm72-120 in-lbsClutch adjuster screw jam nut

1.11 CLUTCH, Adjustment13.6 Nm120 in-lbsClutch cable adjustment jam nut

1.9 PRIMARY CHAINCASE LUBRICANT, Chan­ging Primary Chaincase Lubricant

1.5 MAINTENANCE SCHEDULE, General9.5-12.2 Nm84-108 in-lbsClutch inspection cover screws

1.11 CLUTCH, Adjustment9.5-12.2 Nm84-108 in-lbsClutch inspection cover screws

1.5 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

1.20 STEERING HEAD BEARINGS, Adjustment71.9-77.3 Nm53-57 ft-lbsFork bracket pinch bolt

1.20 STEERING HEAD BEARINGS, Adjustment94.9-108.4 Nm70-80 ft-lbsFork stem nut

1.20 STEERING HEAD BEARINGS, Adjustment94.9-108.4 Nm70-80 ft-lbsFork stem nut

1.24 ENGINE MOUNTS, Inspection56.9-65.0 Nm42-48 ft-lbsFront engine mount end cap fastener

1.5 MAINTENANCE SCHEDULE, General1.1-1.4 Nm10-12 in-lbsFront master cylinder reservoir cover

1.16 BRAKE PADS AND DISCS, Brake Pad
Replacement

1.5 MAINTENANCE SCHEDULE, General4.0-5.1 Nm35-45 in-lbsHandlebar switch housing screw

1.5 MAINTENANCE SCHEDULE, General19.0-28.5 Nm14-21 ft-lbsPrimary chaincase drain plug

2011 Touring Service: Maintenance 1-1

HOME

screws

screws

screws

NOTESTORQUE VALUEFASTENER

19.0-28.5 Nm14-21 ft-lbsPrimary chaincase drain plug

128.8-142.4 Nm95-105 ft-lbsRear axle cone nut (final)

20-27 Nm15-20 ft-lbsRear axle cone nut (preliminary)

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

1.9 PRIMARY CHAINCASE LUBRICANT, Chan­ging Primary Chaincase Lubricant

1.12 DRIVE BELT AND SPROCKETS, Setting Belt
Deflection

1.12 DRIVE BELT AND SPROCKETS, Setting Belt
Deflection/For belt adjustment only

1.24 ENGINE MOUNTS, Inspection54.2-67.8 Nm40-50 ft-lbsRear frame-to-main frame fastener

1.5 MAINTENANCE SCHEDULE, General1.4-1.7 Nm12-15 in-lbsRear master cylinder reservoir cover

1.16 BRAKE PADS AND DISCS, Brake Pad
Replacement

1.12 DRIVE BELT AND SPROCKETS, Setting Belt
Deflection

1.5 MAINTENANCE SCHEDULE, General16.3-24.4 Nm12-18 ft-lbsSpark plug

1.17 SPARK PLUGS, Inspection16.3-24.4 Nm12-18 ft-lbsSpark plug

1.5 MAINTENANCE SCHEDULE, General6.2 Nm55 in-lbsSpoke nipple

1.8 TIRES AND WHEELS, Wheel Spokes6.2 Nm55 in-lbsSpoke nipple

1.5 MAINTENANCE SCHEDULE, General8.1-10.9 Nm72-96 in-lbsTop caddy mounting screw

1.23 BATTERY MAINTENANCE, Battery8.1-10.9 Nm72-96 in-lbsTop caddy mounting screw

1.24 ENGINE MOUNTS, Inspection24.4-29.9 Nm18-22 ft-lbsTop stabilizer link bolt

1.24 ENGINE MOUNTS, Inspection24.4-29.9 Nm18-22 ft-lbsTop stabilizer link bolt

1.5 MAINTENANCE SCHEDULE, General19.0-28.5 Nm14-21 ft-lbsTransmission drain plug

1.10 TRANSMISSION LUBRICANT, Transmission
Lubrication

1.5 MAINTENANCE SCHEDULE, General2.8-8.5 Nm25-75 in-lbsTransmission filler/check plug

1.10 TRANSMISSION LUBRICANT, Transmission
Lubrication

1.10 TRANSMISSION LUBRICANT, Transmission
Lubrication

1.21 HEADLAMP ALIGNMENT, Auxiliary Lamp
Alignment

1-2 2011 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 motorcycle, 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 1.5 MAINTENANCE SCHEDULE.

SAFE OPERATING MAINTENANCE

NOTES

•

Do not attempt to tighten engine head bolts or engine
damage may result.

•

During the initial break-in period, use only Harley-Davidson
20W50 engine oil. Failure 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. Drive belt tension and condition.

3. Brakes, steering and throttle for responsiveness.

4. Brake fluid level and condition. Hydraulic lines and fittings
for leaks. Also, check brake pads and discs 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 com­ponent.

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 multiple 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. Never leave
a part suspended in mid-air.

Be sure to check capacity rating and condition of hoists,
slings, chains and cables before 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 part 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 parts are to be reused, follow good shop practice and thor­oughly clean the parts before assembly. Keep all dirt out of
parts to promote better component operation and longer life.
Seals, filters and covers are used in this vehicle to keep out
extraneous dirt and dust. These items must be kept in good
condition to guarantee satisfactory operation.

When instructed to clean fastener threads or threaded holes,
proceed as follows: Clean all threadlocking 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 PJ1 cleaner or equivalent to remove
all traces of oil and contaminants from threads. Clean 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, cover
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 covers before they are removed.
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.

2011 Touring Service: Maintenance 1-3

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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. Check your work when finished to be
sure that everything is done.

Operate the vehicle to perform any final check 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, remove it to determine if it has a thread­locking agent.

If it has a threadlocking agent, clean all threadlocking material
from the threaded hole. Replace the fastener with a new one
or clean the original fastener threads and apply the appropriate
threadlocking product (see the specific procedure). Install and
tighten the fastener to specification.

If the fastener does not use a threadlocking agent, install and
tighten it to specification.

Magnetic Parts Trays

Magnetic parts trays are common in the service facility because
they are convenient and can keep parts from becoming lost
during a repair procedure.

However, hardened steel parts can become magnetized when
held in magnetic parts trays. Metal fragments that would
ordinarily be washed away in the oil and trapped 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 thread repair inserts when threaded holes 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 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 follow 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.

Always use the recommended threadlocking agent for the
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 damaged or defective instruments and gauges.

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.

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.

Only remove bearings if necessary. Removal usually damages
bearings requiring them to be replaced with new parts.

Bushings

Do not remove a bushing unless damaged, excessively worn
or loose in its bore. Press out bushings that must be replaced.

When pressing or driving bushings, be sure to apply pressure
in line with the bushing bore. Use a bearing/bushing driver or
a bar with a smooth, flat end. Never use a hammer to drive
bushings.

Inspect the bushing and the mating parts for oil holes before
installation, and be sure all oil holes are properly aligned during
installation.

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.

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.

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 removal. Do not use the same seal
twice.

O-Rings (Pre-Formed Packings)

Always discard O-rings after removal. Replace with new O­ring. To prevent leaks, lubricate the O-rings before installation.
Apply the same type of lubricant as that being sealed. Be sure

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