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.

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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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that all gasket, O-ring and seal mating surfaces are thoroughly
clean before installation.

Gears

Always check gears for damaged or worn teeth.

Remove burrs and rough spots with a honing stone or crocus
cloth before installation.

Lubricate mating surfaces before pressing gears on shafts.

Shafts

If a shaft does not come out easily, check that all nuts, bolts
or retaining rings have been removed. Check to see if other
parts are in the way before using force to remove.

Shafts fitted to tapered splines should be very tight. If shafts
are not tight, disassemble and inspect tapered splines. Discard
parts that are worn. Be sure tapered splines are clean, dry and
free of burrs before putting them in place. Press mating parts
together tightly.

Clean all rust from the machined surfaces of new parts.

Part Replacement

Always replace worn or damaged parts with new parts.

Exhaust System Leakage

In the event of an exhaust system leak at a muffler or header
pipe connection location, disassemble and clean all mating
surfaces. Replace any damaged components. If the leak still
exists, disassemble and repair the leak by applying a bead of
Permatex Ultra Copper or LOCTITE 5920 Flange Sealant (or
an equivalent oxygen sensor/catalyst-safe alternative).
Assemble components, wipe off any excess sealant and allow
adequate curing time following sealant product instructions
before operating vehicle.

CLEANING

Part Protection

Before cleaning, protect rubber parts (such as hoses, boots
and electrical insulation) from cleaning solutions. Use a grease­proof barrier material. Remove the rubber part if it cannot be
properly protected.

Cleaning Process

Any cleaning method may be used as long as it does not result
in parts damage. Thorough cleaning is necessary for proper
parts inspection. Strip rusted paint areas to bare metal before
priming and repainting.

Rust or Corrosion Removal

Remove rust and corrosion with a wire brush, abrasive cloth,
sand blasting, vapor blasting or rust remover. Use buffing
crocus cloth on highly polished parts that are rusted.

Using compressed air to "spin dry" bearings can cause
bearing to fly apart, which could result in death or serious
injury. (00505b)

Cover bearings with a clean shop towel and allow to air dry.
Do not spin bearings while they are drying. Never use com­pressed air to dry bearings.

When dry, coat bearings with clean oil. Wrap bearings in clean
paper.

TOOL SAFETY

Air Tools

• Always use approved eye protection equipment when
performing any task using air-operated tools.

• On all power tools, use only recommended accessories
with proper capacity ratings.

• Do not exceed air pressure ratings of any power tools.

• Bits should be placed against work surface before air
hammers are operated.

• Disconnect the air supply line to an air hammer before
attaching a bit.

• Never point an air tool at yourself or another person.

• Protect bystanders with approved eye protection.

Wrenches

• Never use an extension on a wrench handle.

• If possible, always pull on a wrench handle and adjust
your stance to prevent a fall if something suddenly
releases.

• Always keep the wrench squarely installed on the fastener.

• Never use a hammer on any wrench other than a
STRIKING FACE wrench.

• Discard any wrench with broken or battered points.

• Never use a pipe wrench to bend, raise or lift a pipe.

Pliers/Cutters/Pry Bars

• Plastic- or vinyl-covered pliers handles are not intended
to act as insulation. Do not use them on live electrical cir­cuits.

• Do not use pliers or cutters for cutting hardened wire
unless they were designed for that purpose.

• Always cut at right angles.

• Do not use any pry bar as a chisel, punch or hammer.

Bearings

Wash bearings in a non-flammable petroleum cleaning solution.
Never use a solution that contains chlorine. Knock out packed
lubricant by tapping the bearing against a wooden block. Wash
bearings again.

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Hammers

• Never strike a hammer against a hardened object, such
as another hammer.

• Always grasp a hammer handle firmly, close to the end.

• Strike the object with the full face of the hammer.

• Never work with a hammer which has a loose head or
cracked handle.

• Discard hammer if face is chipped or mushroomed.

• Wear approved eye protection when using striking tools.

• Protect bystanders with approved eye protection.

Punches/Chisels

• Never use a punch or chisel with a chipped or mush­roomed end. Dress mushroomed chisels and punches
with a grinder.

• Hold a chisel or a punch with a tool holder if possible.

• When using a chisel on a small piece, clamp the piece
firmly in a vise and chip toward the stationary jaw.

• Always wear approved eye protection when using these
tools.

• Protect bystanders with approved eye protection.

Screwdrivers

• Do not use a screwdriver for prying, punching, chiseling,
scoring or scraping.

• Use the right type of screwdriver for the job; match the tip
to the fastener.

• Do not interchange POZIDRIV, PHILLIPS or REED AND
PRINCE screwdrivers.

• Screwdriver handles are not intended to act as insulation.
Do not use them on live electrical circuits.

• Do not use a screwdriver with rounded edges because it
will slip. Redress with a grinder.

Ratchets and Handles

• Periodically clean and lubricate ratchet mechanisms with
a light grade oil. Do not replace parts individually; ratchets
should be rebuilt with the entire contents of service kit.

• Never hammer on a ratchet or put a pipe extension on a
ratchet handle for added leverage.

• Always support the ratchet head when using socket
extensions, but do not put your hand on the head or you
may interfere with the action of its reversing mechanism.

• When breaking a fastener loose, apply a small amount of
pressure as a test to be sure the ratchet's gear wheel is
engaged with the pawl.

Sockets

• Never use hand sockets on power or impact wrenches.
Select only impact sockets for use with air or electric
impact wrenches.

• Select the right size socket for the job.

• Always keep the wrench or socket squarely on the
fastener.

• Replace sockets showing cracks or wear.

• Keep sockets clean.

• Always use approved eye protection when using power
or impact sockets.

Storage Units

• Do not open more than one loaded drawer at a time. Close
each drawer before opening another to prevent the cabinet
from unexpectedly tipping over.

• Close lids and lock drawers and doors before moving
storage units.

• Do not pull on a tool cabinet; push it in front of you.

• Set the brakes on the locking casters after the cabinet has
been rolled into position.

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1.3FUEL AND OIL

FUEL

Always use a good quality unleaded gasoline. Octane ratings
are usually found on the pump. Refer to Table 1-1.

Avoid spills. Slowly remove filler cap. Do not fill above
bottom of filler neck insert, leaving air space for fuel
expansion. Secure filler cap after refueling. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00028a)

Use care when refueling. Pressurized air in fuel tank can
force gasoline to escape through filler tube. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00029a)

Modern service station pumps dispense a high flow of gasoline
into a motorcycle fuel tank making air entrapment and pressur­ization a possibility.

Table 1-1. Octane Ratings

RATINGSPECIFICATION

91 (95 RON)Pump Octane (R+M)/2

GASOLINE BLENDS

Your motorcycle was designed to get the best performance
and efficiency using unleaded gasoline. Most gasoline is
blended with alcohol and/or ether to create oxygenated blends.
The type and amount of alcohol or ether added to the fuel is
important.

Do not use gasoline that contains methanol. Doing so can
result in fuel system component failure, engine damage
and/or equipment malfunction. (00148a)

• Gasoline containing METHYL TERTIARY BUTYL ETHER
(MTBE): Gasoline/MTBE blends are a mixture of gasoline
and as much as 15% MTBE. Gasoline/MTBE blends can
be used in your motorcycle.

• ETHANOL is a mixture of 10% ethanol (Grain alcohol) and
90% unleaded gasoline. Gasoline/ethanol blends can be
used in your motorcycle if the ethanol content does not
exceed 10%.

• REFORMULATED OR OXYGENATED GASOLINES
(RFG): Reformulated gasoline is a term used to describe

gasoline blends that are specifically designed to burn
cleaner than other types of gasoline, leaving fewer tailpipe
emissions. They are also formulated to evaporate less
when you are filling your tank. Reformulated gasolines
use additives to oxygenate the gas. Your motorcycle will
run normally using this type of gas and Harley-Davidson
recommends you use it when possible, as an aid to cleaner
air in our environment.

• Do not use race gas or octane boosters. Use of these fuels
will damage the fuel system.

Some gasoline blends might adversely affect the starting,
driveability or fuel efficiency of the motorcycle. If any of these
problems are experienced, try a different brand of gasoline or
gasoline with a higher octane blend.

ENGINE LUBRICATION

Prolonged or repeated contact with used motor oil may
be harmful to skin and could cause skin cancer. Promptly
wash affected areas with soap and water. (00358b)

If swallowed, do not induce vomiting. Contact a physician
immediately. In case of contact with eyes, immediately
flush with water. Contact a physician if irritation persists.
(00357c)

Do not switch lubricant brands indiscriminately because
some lubricants interact chemically when mixed. Use of
inferior lubricants can damage the engine. (00184a)

Engine oil is a major factor in the performance and service life
of the engine. Always use the proper grade of oil for the lowest
temperature expected before the next scheduled oil change.
Your authorized dealer has the proper oil to suit your require­ments. Refer to Table 1-2.

If it is necessary to add oil and Harley-Davidson oil is not
available, use an oil certified for diesel engines. Acceptable
diesel engine oil designations include: CH-4, CI-4 and CJ-4.

The preferred viscosities for the diesel engine oils in des­cending order are: 20W50, 15W40 and 10W40.

At the first opportunity, see an authorized dealer to change
back to 100 percent Harley-Davidson oil.

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Table 1-2. Recommended Engine Oils

H-D RATINGVISCOSITYH-D TYPE

Synthetic Motorcycle
Lubricant

thetic Blend Motorcycle
Engine Oil

WINTER LUBRICATION

In colder climates, the engine oil should be changed often. If
motorcycle is used frequently for short trips, less than 15 mi
(24 km), in ambient temperatures below 60 °F (16 °C), oil
change intervals should be reduced to 1500 mi (2400 km).
Motorcycles used only for short runs must have a thorough
tank flush-out before new oil is put in. The tank flush-out should
be performed by an authorized dealer or qualified technician.

NOTE

The further below freezing the temperature drops, the shorter
the oil change interval should be.

LOWEST AMBIENT

TEMPERATURE

Water vapor is a normal by-product of combustion in any
engine. During cold weather operation, some of the water vapor
condenses to liquid form on the cool metal surfaces inside the
engine. In freezing weather this water will become slush or ice
and, if allowed to accumulate too long, may block the oil lines
and cause damage to the engine.

If the engine is run frequently and allowed to thoroughly warm
up, most of this water will become vapor again and will be
blown out through the crankcase breather.

If the engine is not run frequently and allowed to thoroughly
warm up, this water will accumulate, mix with the engine oil
and form a sludge that is harmful to the engine.

COLD WEATHER

STARTS BELOW 50 °F

(10 °C)

ExcellentBelow 40 °F (4 °C)HD 360SAE 10W40H-D Multi-grade

ExcellentAbove 40 °F (4 °C)HD 360SAE 20W50Screamin' Eagle SYN3

GoodAbove 40 °F (4 °C)HD 360SAE 20W50Screamin' Eagle Syn-

GoodAbove 40 °F (4 °C)HD 360SAE 20W50H-D Multi-grade

PoorAbove 60 °F (16 °C)HD 360SAE 50H-D Regular Heavy

PoorAbove 80 °F (27 °C)HD 360SAE 60H-D Extra Heavy

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1.4BULB REQUIREMENTS

GENERAL

Use the table to identify the bulb location and part number.
Refer to Table 1-3.

Table 1-3. Bulb Chart

LAMP

lamp

lamps

FLHR/C

DESCRIPTION
(ALL LAMPS 12 VOLT)

FLHTCU, FLHTK, FLTRU (all)

domestic

High beam indicatorInstrument panel

Oil pressure indicator

Neutral indicator

Turn signal indicator

REQUIRED

Instrument panel is illuminated with LEDs. Replace entire assembly upon
failure.

NOTE

The speedometer, tachometer, odometer and indicator lamps
are illuminated with LEDs. LEDs are non-repairable. The entire
assembly must be replaced if an LED fails.

BULBS

Illuminated with LEDs. Replace assembly upon failure.Fuel gauge*

CURRENT

DRAW

AMPERAGE

HARLEY-DAVIDSON

PART NUMBER

68329-034.58/5.01FLHTC/U, FLHR/C, FLHX, FLHTKHeadlamp

68329-034.58/5.02FLTRX, FLTRU

53436-970.321Position lamp, international

68167-040.59/2.101Tail/stop lamp, FLHX, FLTRXTail and stop

68168-89A2.25/0.592Front/runningTurn signal lamp

68572-64B1.752Front international

68163-841.752Front, FLHX (HDI)

68572-64B2.252Rear, FLHR, FLHRC, FLHTC,

68168-89A2.25/0.592Rear, FLHX, FLTRX (domestic)

N/AN/ALEDRear, FLHX, FLTRX (international)*

68163-841.752Rear, FLHX, FLTRX (Canadian)

53788-06 (right side)0.14N/ATour-Pak side lamps*Additional lighting

53789-06 (left side)0.14FLHTCU, FLHTK, FLTRU

68165-640.59/2.102Tour-Pak tail/stop lamps

68193-950.301Fender tip lamps, front

69375-06 (FLHX, FLTRX)N/AN/AFender tip lamps, rear*

59672-09 (all but FLHX, FLTRX)

53436-970.371License plate lamp international

52441-950.352License plate lamp FLHX, FLTRX

68453-052.12Auxiliary lamps

68851-982.72Fog lamps international

N/AN/AN/ASpeedometerGauge lamps

N/AN/AN/AOdometer

N/AN/AN/AEngine

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Table 1-3. Bulb Chart

LAMP

FLHTC/U
FLTRX
FLTRU
FLHX
FLHTK

DESCRIPTION
(ALL LAMPS 12 VOLT)

FLHTC/U, FLHTK, FLHX, FLTRX,
FLTRU

FLHTC/U, FLHTK, FLHX, FLTRX,
FLTRU

Illuminated with LEDs. Replace entire assembly upon failure.Items with *

BULBS

REQUIRED

CURRENT

DRAW

AMPERAGE

HARLEY-DAVIDSON

PART NUMBER

N/AN/AN/ASpeedometerGauge lamps

N/AN/AN/ATachometer

67445-000.241Voltmeter

67445-000.241Oil pressure gauge

67445-000.241Air temperature gauge

67445-000.241Fuel gauge

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1.5MAINTENANCE SCHEDULE

GENERAL

The table below lists the periodic maintenance requirements
for Touring model motorcycles. If you are familiar with the
procedures, just refer to the table for the recommended service
interval. If necessary, see the quick reference table (Table 1-5.)
for the required specifications.

Table 1-4. Regular Service Intervals: 2011 Touring Models

15000 MI

24000 KM

Oil lines and brake
system

Air cleaner

Tires

equipped)

lubricant

ricant

sprockets

sprocket isolators

Brake and clutch
controls

Jiffy stand

Fuel lines and fit­tings

discs

ment and switches

bearings

Air suspension

ings (if applicable)

Fuel door, Tour­Pak, saddlebags (if
equipped)

Battery

Exhaust system

PROCEDUREITEM SERVICED

contact or abrasion

required

inspect tread

ricate

ricate

contact or abrasion

operation and
leakage

and latches

clean connections

cracks, and loose
or missing
fasteners or heat
shields

1000 MI

1600 KM

5000 MI

8000 KM

10000 MI

16000 KM

If more detailed information is needed, turn to the sections
which follow for step-by-step instructions.

Also, throughout this manual, you will be instructed to use
various lubricants, greases and sealants. Refer to Table 1-6.
for the correct part numbers of these items.

20000 MI

32000 KM

25000 MI

40000 KM

30000 MI

48000 KM

35000 MI

56000 KM

40000 MI

64000 KM

XXXReplaceTransmission lub-

XXReplace

XXXXXLubricateSteering head

45000 MI

72000 KM

80000 KM

NOTES50000 MI

XXXXXXXXXXXReplaceEngine oil and filter

1, 3XXXXXXXXXXXInspect for leaks,

XXXXXXXXXXInspect, service as

XXXXXXXXXXXCheck pressure,

1, 5XXXXXCheck torqueWheel spokes (if

XXXXXXReplacePrimary chaincase

1, 3XXXXXXXXXXXInspect for leaks,

XXXXXXXXXXXInspect for wearBrake pads and

XXXXXXXXInspectSpark plugs

XXXXXXXXXXXCheck operationElectrical equip-

1, 6XReplaceFront fork oil

1, 2XXAdjust

XXXXXXXXXXXLubricate hinges

1XXXXXXXXXXXCheck adjustmentClutch

1XXXXXXXXXXXInspect, adjust beltDrive belt and

7Inspect for wearCompensator

1XXXXXXXXXXXCheck and lub-

1XXXXXXXXXXXInspect and lub-

1XXReplaceFuel tank filter

4XXXXXXXXXXXInspect sight glassBrake fluid

1XXXXXXXXXXXCheck pressure,

1XXXXXInspectWindshield bush-

1XXXXXXCheck tightnessCritical fasteners

3Check battery and

3XXXXXXXXXXXInspect for leaks,

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PROCEDUREITEM SERVICED

Road test

and system func­tions

1. Should be performed by an authorized Harley-Davidson dealer, unless you have the proper tools, service data and are mechanically qualified.NOTES:

2. Disassemble, lubricate and inspect every 50,000 miles (80,000 kilometers).

3. Perform annually or at specified intervals, whichever comes first.

4. Change D.O.T. 4 brake fluid and flush system every two years.

5. Perform spoke tension check at the 1000, 5000, 20,000 mile (1600, 8000, 32000 kilometer) services and every 15,000 mile (24000 kilometer)
interval thereafter. Not all vehicles are equipped with spoke wheels. Consult appropriate topic in service manual.

6. Replace fork oil and inspect every 50,000 miles (80,000 kilometers).

7. Perform at each rear tire change.

sight glass. If fluid is low,
remove reservoir cover
and re-check.)

Table 1-4. Regular Service Intervals: 2011 Touring Models

1000 MI

1600 KM

5000 MI

8000 KM

10000 MI

16000 KM

15000 MI
24000 KM

20000 MI

32000 KM

25000 MI

40000 KM

Table 1-5. Quick Reference Maintenance Chart

DATASPECIFICATIONITEM SERVICED

14-21 ft-lbs (19.0-28.5 Nm)Drain plug torqueEngine oil and filter

4 qt. (3.8 L)Oil capacity *

Hand tighten 1/2-3/4 turn after gasket contactFilter

63798-99AChrome filter part number

63731-99ABlack filter part number

Lubricant type and capacityPrimary chain lubricant

FORMULA+ TRANSMISSION AND PRIMARY
CHAIN LUBRICANT (Part No. 99851-05)
or
SYN3 20W50 OIL (Part No. 99824-03/00QT)
Wet: 38 oz. (1124 ml)
Dry: 45 oz. (1331 ml)

14-21 ft-lbs (19.0-28.5 Nm)Primary chaincase drain plug torque

1/2-1 turnAdjuster screw free playClutch adjustment

72-120 in-lbs (8.1-13.6 Nm)Adjuster screw locknut torque

1/16-1/8 in. (1.6-3.2 mm)Free play at hand lever

84-108 in-lbs (9.5-12.2 Nm)Clutch inspection cover torque

Lubricant levelTransmission lubricant

Dipstick at FULL with motorcycle on jiffy stand and
filler plug resting on threads.

Lubricant type and capacity

FORMULA+ TRANSMISSION AND PRIMARY
CHAIN LUBRICATION (Part No. 99851-05)
or
SYN3 20W50 OIL (Part No. 99824-03/00QT)
32 oz (0.95 liters)

14-21 ft-lbs (19.0-28.5 Nm)Transmission drain plug torque

25-75 in-lbs (2.8-8.5 Nm)Transmission filler plug/dipstick torque

Front: 36 psi (248 kPA)Pressure: solo rider or with passengerTire pressure and wear
Rear: 40 psi (276 kPA)

Wear

Replace if less than 1/32 in. (0.8 mm) of tread
pattern

55 in-lbs (6.2 Nm) minimumSpoke nipple torqueWheel spokes

99953-99A (12 oz.)D.O.T. 4 hydraulic brake fluid part numberBrake fluid level (Check

Fluid level (from top of master cylinder reservoir)

Front: 0.20 in. (5.0 mm)
Rear: 0.26 in. (6.5 mm)

Front: 10-12 in-lbs (1.1-1.4 Nm)Master cylinder reservoir cover screw torque
Rear: 12-15 in-lbs (1.4-1.7 Nm)

30000 MI

48000 KM

35000 MI

56000 KM

40000 MI

64000 KM

45000 MI

72000 KM

80000 KM

XXXXXXXXXXXVerify component

NOTES50000 MI

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Table 1-5. Quick Reference Maintenance Chart

DATASPECIFICATIONITEM SERVICED

0.016 in. (0.4 mm)Minimum brake pad thicknessBrake pads and discs

75-102 in-lbs (8.5.-11.5 Nm)Brake caliper pad pin torque

Front: 0.18 in. (4.5 mm)Minimum brake disc thickness
Rear: 0.25 in. (6.3 mm)

0.008 in. (0.20 mm)Maximum brake disc lateral runout (warpage)

Drive belt deflection

strand

Air cleaner cover screw Threadlocker

* Capacity is approximate. When changing oil, initially add 3.5 qt. (3.3 L). Run engine until warm. Check and fill as necessary.

10 lb. (4.5 kg)Upward force applied at midpoint of bottom belt

3/8-7/16 in. (9.5-11.1 mm)FLHR/C, FLHTC/U, FLHTK, FLTRU

1/4-5/16 in. (6.4-7.9 mm)FLHX, FLTRX

108-132 in-lbs (12.2-14.9 Nm)Air cleaner cover bracket screw torqueAir cleaner

36-60 in-lbs (4.1-6.8 Nm)Air cleaner cover screw torque

LOCTITE MEDIUM STRENGTH THREADLOCKER
243 (BLUE)
Part No. 99642-97 (6 ml)

Harley® Lube Part No. 94968-09Lubricant part numberClutch cable

35-45 in-lbs (4.0-5.1 Nm)Handlebar switch housing screw torque

HD-6R12TypeSpark plugs

0.038-0.043 in. (0.97-1.09 mm)Gap

12-18 ft-lbs (16.3-24.4 Nm)Torque

See 2.17 FRONT FORK.AmountFront fork oil

HYDRAULIC FORK OIL (TYPE E)Type and part number
Part No. 99884-80 (16 oz.)

60-70 in-lbs (6.8-7.9 Nm)Terminal bolt torqueBattery

72-96 in-lbs (8.1-10.9 Nm)Top caddy screw torque

CCI #20 Brake Grease

Transmission and Primary Chaincase
Lubricant

H-D 360 20W50 Oil

Motorcycle Engine Oil

Table 1-6. Lubricants, Greases, Sealants

PACKAGEPART NUMBERITEM

1 oz squeeze tube98960-97SILVER GRADE ANTI-SEIZE

squeeze packet42830-05 (included in master cylinder

rebuild kit)

12 oz. bottle99953-99AD.O.T. 4 Brake Fluid

1 oz squeeze tube99861-02Electrical Contact Lubricant

1 qt bottle99851-05Genuine Harley-Davidson Formula+

1 qt bottle99816-2050/00QTGenuine Harley-Davidson

1 qt bottle99813-09Screamin' Eagle 20W50 Synthetic Blend

1 qt bottle99824-03/00QTSYN3 20W50 Full Synthetic Oil

squeeze packet42820-04G40M Brake Grease

1.9 oz squeeze tube99650-02Gray High Performance Sealant

3.5 oz tube99653-85HYLOMAR Gasket and Thread Sealant

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Loctite Prism Primer (770)

Loctite Prism Superbonder (411)

Loctite Superbonder 420 Adhesive

Table 1-6. Lubricants, Greases, Sealants

PACKAGEPART NUMBERITEM

6 ml squeeze tube99818-97Loctite Pipe Sealant With Teflon 565

6 ml squeeze tube99642-97Loctite Threadlocker 243 (blue)

6 ml squeeze tube94759-99Loctite Threadlocker 262 (red)

10 ml bottle98618-03Loctite Threadlocker 272

4 oz. bottle94971-09Screamin' Eagle Assembly Lube

14 oz. cartridge99857-97Special Purpose Grease

1/4 fl. oz94968-09Harley® Lube

16 oz bottle99884-80Type "E" Hydraulic Fork Oil

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1.6ENGINE OIL AND FILTER

CHECKING OIL LEVEL

Check engine oil level at each complete fuel refill.

Do not allow hot oil level to fall below Add/Fill mark on
dipstick. Doing so can result in equipment damage and/or
equipment malfunction. (00189a)

Oil level cannot be accurately measured on a cold engine.
For pre-ride inspection, with motorcycle leaning on jiffy
stand on level ground, oil should register on dipstick
between arrows when engine is cold. Do not add oil to
bring the level to the FULL mark on a COLD engine.
(00185a)

Do not overfill oil tank. Doing so can result in oil carryover
to the air cleaner leading to equipment damage and/or
equipment malfunction. (00190a)

Oil Level Cold Check

1. For pre-ride inspection, place vehicle on level ground and
rest the vehicle on its jiffy stand (unless sidecar is
attached).

2. See Figure 1-1. Remove filler plug/dipstick and wipe off
the dipstick. Insert the dipstick and tighten into the fill
spout.

3. See Figure 1-1. Remove filler plug/dipstick and wipe off
the dipstick. Insert the dipstick and tighten into the fill
spout.

NOTE
The oil level marks for checking with motorcycle upright or on
jiffy stand are on the same side of the dipstick. Be sure to use
the correct portion of dipstick when checking oil level.

4. See Figure 1-2. Remove the dipstick and note the level

of the oil. The level should be between the ADD (1) and
FULL (3) marks. Add oil as necessary to bring the level
to the FULL mark on the dipstick. Do not overfill.

NOTE
Refer to Table 1-2. Use only recommended oil specified in

1.3 FUEL AND OIL, Engine Lubrication.

5. Start engine and carefully check for oil leaks around drain

plug and oil filter.

NOTE
The oil level marks for checking with motorcycle upright or on
jiffy stand are on the same side of the dipstick. Be sure to use
the correct portion of dipstick when checking oil level.

3. See Figure 1-2. Remove the dipstick and verify the level

of the oil. The correct oil level should register midway (2)
between the FULL and ADD marks on the dipstick.

NOTE

If oil level is at or below the ADD mark, add only enough oil to
bring the level to the middle of the two marks on the dipstick.

Oil Level Hot Check

NOTES

•

The engine will require a longer warm up period in colder
weather.

•

Engine oil level hot check should be performed only when
engine is at normal operating temperature.

1. Ride motorcycle until engine is at normal operating tem-

perature.

2. Place vehicle on level ground and rest the vehicle on its

jiffy stand (unless sidecar is attached). Allow engine to
idle for 1-2 minutes. Turn engine off.

Figure 1-1. Engine Oil Filler Cap

1. ADD QT (lower) mark

2. Cold check level

3. FULL (hot check) mark

Figure 1-2. Engine Oil Dipstick

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CHANGING OIL AND OIL FILTER

TOOL NAMEPART NUMBER

OIL FILTER WRENCHHD-42311

OIL FILTER WRENCHHD-44067A

Refer to Table 1-4. Oil should be changed after the first 1000
miles (1600 kilometers) for a new engine and at regular inter­vals in normal service at warm or moderate temperatures.

Oil change intervals should be more frequent in cold weather
or severe operating conditions. See 1.3 FUEL AND OIL, Winter

Lubrication.

Twin Cam equipped vehicles require the premium oil filter (Part
No. 63798-99A Chrome or Part No. 63731-99A Black).

Do not switch lubricant brands indiscriminately because
some lubricants interact chemically when mixed. Use of
inferior lubricants can damage the engine. (00184a)

Be sure that no lubricants or fluids get on tires, wheels or
brakes when changing fluid. Traction can be adversely
affected, which could result in loss of control of the
motorcycle and death or serious injury. (00047d)

1. Ride motorcycle until oil is at normal operating temper­ature. Turn engine off.

2. Remove filler plug/dipstick.

3. See Figure 1-3. Remove the oil drain plug (2). Do not
remove hex plug (3) or transmission drain plug (1). Allow
oil to drain completely.

4. Inspect the oil drain plug O-ring for cuts, tears or signs of
deterioration. Replace as necessary.

Use Harley-Davidson oil filter wrench for filter removal.
This tool can prevent damage to crankshaft position sensor
and/or sensor cable. (00192b)

5. Remove the oil filter using OIL FILTER WRENCH (Part
No. HD-42311) or OIL FILTER WRENCH (Part No. HD­44067A) and hand tools. Do not use with air tools.

6. Clean the oil filter mount flange of any old gasket material.

NOTE
Use the proper grade of oil for the lowest temperature expected
before the next oil change. Refer to Table 1-2 for recommended
oil.

9. Initially add 3.5 quarts (3.3 liters) of engine oil.

10. Verify proper oil level. See 1.6 ENGINE OIL AND FILTER,

Checking Oil Level.

a. Check engine oil level using COLD CHECK pro-

cedure.

b. Start engine and carefully check for oil leaks around

drain plug and oil filter.

c. Check engine oil level using HOT CHECK procedure.

1. Transmission drain plug (right side)

2. Engine oil drain plug and O-ring

3. Hex plug (do not remove)

Figure 1-3. Oil Pan

NOTE

Dispose of oil and oil filter in accordance with local regulations.

7. See Figure 1-4. Lubricate gasket with clean engine oil and

install new oil filter on filter mount. Hand-tighten oil filter
one-half to three-quarters of a turn after gasket first con­tacts filter mounting surface. Do NOT use oil filter wrench
for installation.

8. Install engine oil drain plug and tighten to 14-21 ft-lb (19.0-

28.5 Nm).

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1. Thin film of oil ONLY

2. Oil filter

3. Mounting plate

Figure 1-4. Applying Thin Oil Film

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REMOVAL

1. See Figure 1-5. Remove screw (1) and air cleaner cover
with rubber seal (3).

2. Remove three screws (4) to release cover bracket (5) from
filter element.

3. Remove filter element (6) pulling two breather tubes (8)
from holes on inboard side.

4. Remove and discard gasket (7).

5. Remove breather tubes from breather bolts.

6. Inspect the breather tubes and rubber seal for cuts, tears,
holes or signs of deterioration. Replace as necessary.

Do not use gasoline or solvents to clean filter element.
Flammable cleaning agents can cause an intake system
fire, which could result in death or serious injury. (00101a)

Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)

7. Clean filter element.

a. Wash the paper/wire mesh filter element (and breather

tubes) in lukewarm water with a mild detergent. Do
not strike filter element on a hard surface to dislodge
dirt.

b. Allow filter element to either air dry or blow it dry, from

the inside, with low pressure air. Do NOT use air
cleaner filter oil on the Harley-Davidson paper/wire
mesh air filter element.

c. Hold the filter element up to a strong light source. The

element is sufficiently clean if light is uniformly visible
through the media.

d. Replace the filter element if damaged or if filter media

cannot be adequately cleaned.

1.7AIR CLEANER AND EXHAUST SYSTEM

1. Cover screw

2. Air cleaner cover

3. Rubber seal

4. Cover bracket screw (3)

5. Cover bracket

6. Filter element

7. Gasket

8. Breather tube (2)

Figure 1-5. Air Cleaner Assembly

INSTALLATION

1. Install new gasket (7) on air filter element.

2. Insert breather tubes into holes on inboard side of filter
element approximately 0.25 in (6.4 mm).

NOTE
Air cleaner mounting without installation of the breather tubes
will allow crankcase vapors to be vented into the atmosphere
in violation of legal emissions standards.

3. Install breather tubes onto breather bolts.

4. Place filter element onto backplate with the flat side down.

5. Install cover bracket and tighten screws (4) to 108-132 in-

lbs (12.2-14.9 Nm).

6. Verify that rubber seal is properly seated around perimeter

of air cleaner cover.

7. Fit air cleaner cover into backplate. Apply a small dab of

LOCTITE MEDIUM STRENGTH THREADLOCKER 243
(BLUE) to threads of cover screw. Install screw and tighten
to 36-60 in-lbs (4.1-6.8 Nm).

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EXHAUST SYSTEM LEAK CHECK

Check the exhaust system for leaks at every scheduled service
interval as follows:

HOME

1. Check entire exhaust system for loose or missing
fasteners, broken pipe clamps or brackets, and obvious
signs of leakage (carbon tracks at pipe joints, etc.).

2. Check for loose or broken heat shields. Repair or replace
as necessary.

3. Start engine, cover muffler ends with clean, dry shop
towels and listen for audible signs of exhaust leakage.

4. Correct any leaks detected. See 4.19 EXHAUST SYSTEM
for exhaust system removal and installation procedures.

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1.8TIRES AND WHEELS

GENERAL

Use only tires listed in Table 1-7.

ABS equipped motorcycles must always use tires and wheels
that are the same as the original equipment. The ABS system
monitors rotational speed of the wheels through individual
wheel speed sensors to determine the application of ABS.
Changing to different diameter wheels or different size tires
can alter the rotational speed and upset the calibration of the
ABS, resulting in an adverse effect on its ability to detect and
prevent lockups. Tire inflation pressure that is significantly low
can also have an adverse effect.

TIRES

Match tires, tubes, rim seals, air valves and caps to the
correct wheel rim. Contact a Harley-Davidson dealer. Mis­matching can result in damage to the tire bead, allow tire
slippage on the rim or cause tire failure, which could result
in death or serious injury. (00023b)

Use only Harley-Davidson approved tires. See a Harley­Davidson dealer. Using non-approved tires can adversely
affect stability, which could result in death or serious
injury. (00024a)

NOTES

•

Tubeless tires are used on all Harley-Davidson cast and
disc wheels.

•

Tire sizes are molded on the tire sidewall. Inner tube sizes
are printed on the tube.

•

New tires should be stored on a horizontal tire rack. Avoid
stacking new tires in a vertical stack. The weight of the
stack compresses the tires and closes down the beads.

Check tire pressure and tread:

• As part of the pre-ride inspection.

• At every scheduled service interval.

1. Inspect each tire for punctures, cuts and breaks.

2. Inspect each tire for wear. Replace tires before they reach
the tread wear indicator bars.

NOTE

Missing indicator wear bars represent less than 1/32 in. (0.8
mm) tread pattern depth remaining.

3. Check for proper front and rear tire pressures when tires
are cold. Compare results against Table 1-7.

Table 1-7. Tires

FLTRX, FLHX

TIRE REPLACEMENT

Inspection

Harley-Davidson tires are equipped with wear bars that
run horizontally across the tread. When wear bars become
visible and only 1/32 in. (0.8 mm) tread depth remains,
replace tire immediately. Using a worn tire can adversely
affect stability and handling, which could result in death
or serious injury. Use only Harley-Davidson approved
replacement tires. (00090b)

Arrows on tire sidewalls pinpoint location of wear bar indicators.

PRESSURE (COLD)APPROVED TIRESIZEMOUNTMODEL

kPaPSI

24836Dunlop D408F 130/80B17 65H17 in.frontAll models except FLHRC,

24836Dunlop D408F 130/90B16 67H16 in.frontFLHRC

24836Dunlop D408F 130/70B18 63H18 in.frontFLTRX, FLHX

27640Dunlop D407 180/65B1616 in.rearAll models

Tread wear indicator bars will appear on tire tread surfaces
when 1/32 in (0.8 mm) or less of tire tread remains. Always
replace tires before the tread wear indicator bars appear.

When To Replace Tires

New tires are needed if any of the following conditions exist:

1. Tread wear indicator bars become visible on the tread
surfaces.

2. Tire cords or fabric become visible through cracked side­walls, snags or deep cuts.

3. A bump, bulge or split in the tire.

4. Puncture, cut or other damage to the tire that cannot be
repaired.

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When installing tires on rims, do not rely on tread design to
determine direction of rotation. Always be sure the rotational
arrows molded into the sidewalls point in the direction of rota­tion when the vehicle is moving forward.

Refer to Table 1-7 for approved tires.

Use only Harley-Davidson approved tires. See a Harley­Davidson dealer. Using non-approved tires can adversely
affect stability, which could result in death or serious
injury. (00024a)

WHEEL BEARINGS

Service wheel bearings:

1. Check wheel bearings as outlined in 2.10 SEALED

WHEEL BEARINGS. Replace wheel bearings if end play

exceeds 0.002 in. (0.051 mm).

2. If wheel is already removed, check wheel bearings as fol­lows:

a. See Figure 1-6. Insert finger into wheel bearing and

rotate the inner race in both directions. Repeat step
on opposite side of wheel.

b. Replace the wheel bearings if there is drag, rough

rotation, abnormal noise or anything unusual.

3. Check axle spacers for wear and corrosion. Replace as
necessary.

WHEEL SPOKES

TOOL NAMEPART NUMBER

SPOKE TORQUE WRENCHHD-48985

SPOKE NIPPLE WRENCHHD-94681-80

Spokes that are too tight can draw nipples through the rim
or distort hub flanges. Spokes that are too loose can
continue to loosen when put in service. Either condition
can adversely affect stability and handling, which could
result in death or serious injury. (00286a)

Do not over tighten spoke nipples. Protruding spoke
nipples can damage tube, resulting in rapid tire deflation,
which could cause death or serious injury. (00526d)

When lifting a motorcycle using a jack, be sure jack con­tacts both lower frame tubes where down tubes and lower
frame tubes converge. Never lift by jacking on cross­members, oil pan or other housings. Failure to comply can
cause serious damage resulting in the need to perform
major repair work. (00586c)

Identify Wheel Spoke Groups

Figure 1-6. Inspect Wheel Bearings

NOTE

Spokes are grouped in sets of four.

1. Raise wheel with a suitable lifting device.

2. See Figure 1-7. Starting at the valve stem, identify the first
group of four spokes (1-4).

3. Using a different color for each spoke in the group, draw
an alignment mark across the spoke nipple and onto the
rim.

4. Continue around the wheel marking the rest of the spokes
the same as they were marked in the previous step.

Wheel Spoke Adjustment

NOTES

•

Do not tighten spoke more than 1/4 turn past alignment
mark. If more tension is needed, label spoke and check
after completing rest of wheel.

•

Do not use the torque spoke wrench to loosen spokes.
Use SPOKE NIPPLE WRENCH (Part No. HD-94681-80)
to loosen spokes.

1. See Figure 1-7. Starting with the first group of spokes,
loosen spoke (1) using SPOKE NIPPLE WRENCH (Part
No. HD-94681-80) 1/4 turn.

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2. Using SPOKE TORQUE WRENCH (Part No. HD-48985)
tighten spoke (1) to the value listed in Table 1-8.

a. While tightening, if the torque wrench clicks before

the alignment marks align, continue to turn the spoke
nipple until the marks align.

b. If the alignment marks align and the torque specifica-

tion has not been reached, continue to tighten the
spoke nipple until the correct torque is achieved, but
do not turn spoke nipple more then 1/4 turn past
alignment mark.

3. Repeat previous two steps for spoke (4) in the same group.

4. Continue around the wheel checking spokes 1 and 4 until
all groups are done.

5. Repeat procedure for spokes (2, 3) in each group.

NOTE
When checking any spokes that were labeled, make sure to
use the original alignment mark.

6. Check spokes, if any, that were labeled as not reaching

the proper torque value after tightening 1/4 turn past
alignment mark.

a. Loosen spoke 1/4 turn past original alignment mark

using SPOKE NIPPLE WRENCH (Part No. HD-94681-

80).

b. While tightening, if the torque wrench clicks before

the alignment marks align, continue to turn the spoke
nipple until the marks align.

c. If the alignment marks align and the torque specifica-

tion has not been reached, continue to tighten the
spoke nipple until the correct torque is achieved, but
do not turn spoke nipple more then 1/4 turn past
alignment mark.

7. True the wheel. See 2.9 CHECKING AND TRUING

WHEELS.

Table 1-8. Spoke Nipple Torque Specification

MINIMUM TORQUERIM TYPE

55 in-lbs (6.2 Nm)All

Figure 1-7. Tightening Laced Wheels (typical)

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GENERAL

All models have an automatic chain tensioner. For primary
chain service procedures, see 5.4 DRIVE COMPONENTS.

CHANGING PRIMARY CHAINCASE LUBRICANT

1. Run motorcycle until engine is warmed up to normal
operating temperature.

When draining or adding lubricant, do not allow dirt, debris
or other contaminants to enter the engine. (00198a)

Be sure that no lubricants or fluids get on tires, wheels or
brakes when changing fluid. Traction can be adversely
affected, which could result in loss of control of the
motorcycle and death or serious injury. (00047d)

2. See Figure 1-8. Remove magnetic drain plug at bottom
of primary chaincase. Drain lubricant into suitable con­tainer.

1.9PRIMARY CHAINCASE LUBRICANT

Figure 1-8. Removal/Installation of Chaincase Drain Plug

NOTE

Dispose of lubricant in accordance with local regulations.

3. Clean drain plug. If plug has accumulated a lot of debris,
inspect the condition of chaincase components.

4. Install new O-ring on drain plug.

5. Install drain plug back into primary chaincase cover.
Tighten plug to 14-21 ft-lbs (19.0-28.5 Nm).

6. See Figure 1-9. Remove five TORX screws with captive
washers (3) to detach clutch inspection cover (2) from
primary chaincase cover.

7. Remove the seal (1). Wipe oil from groove in chaincase
cover and mounting surface.

Do not overfill the primary chaincase with lubricant.
Overfilling can cause rough clutch engagement, incomplete
disengagement, clutch drag and/or difficulty in finding
neutral at engine idle. (00199b)

8. Refer to Table 1-9. Pour the specified amount of GENUINE
Harley-Davidson FORMULA+ TRANSMISSION AND
PRIMARY CHAINCASE LUBRICANT (Part No. 99851-05,
quart) in through the clutch inspection cover opening.

Table 1-9. Primary Chaincase Lubricant Refill Capacity

1. Seal

2. Clutch inspection cover

3. Screws with captive washer

Figure 1-9. Clutch Cover

CAPACITYITEM

38 oz (1.12 L) wetPrimary chaincase lubricant

45 oz (1.33 L) dry

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9. Install clutch inspection cover and new seal as follows:

a. Thoroughly wipe all lubricant from cover mounting

surface and groove in chaincase.

b. See Figure 1-9. Position new seal (1) in groove in

clutch inspection cover and press each of the nubs
on seal into the groove. The nubs will retain seal in
position.

c. See Figure 1-10. Insert screw (with captive washer)

through clutch inspection cover and carefully thread
it into the top cover screw hole.

d. Start the remaining four screws (with captive

washers).

e. Alternately tighten screws to 84-108 in-lbs (9.5-12.2

Nm) following torque sequence shown in Figure 1-10.

Figure 1-10. Clutch Cover Torque Sequence

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1.10TRANSMISSION LUBRICANT

TRANSMISSION LUBRICATION

General

The transmission lubricant level should be checked monthly.

Refer to Table 1-4. The transmission should be drained and
refilled with fresh lubricant at specified intervals.

NOTE

When checking the transmission lubricant level, the motorcycle
should be leaning on the jiffy stand. If the motorcycle was
recently moved or ridden, allow a short period of time to
equalize lubricant level in the transmission compartments.

Check Lubricant Level

1. Park motorcycle on its jiffy stand.

2. See Figure 1-11. Remove the filler plug/dipstick and wipe
off dipstick.

3. See Figure 1-12. Place back in filler hole but do not thread
in. (Filler plug/dipstick should rest on top of threaded hole.)
Remove filler plug/dipstick and observe lubricant level.
Level should be between the full and low marks on the
dipstick.

6. Install filler plug/dipstick and tighten to 25-75 in-lbs (2.8-

8.5 Nm).

Table 1-10. Recommended Lubricant

LUBRICANTMODEL

All

FORMULA+ TRANSMISSION AND

PRIMARY CHAIN LUBRICANT

(Part No. 99851-05)

or

SYN3 20W50 OIL

(Part No. 99824-03/00QT quart)

Be sure that no lubricants or fluids get on tires, wheels or
brakes when changing fluid. Traction can be adversely
affected, which could result in loss of control of the
motorcycle and death or serious injury. (00047d)

When draining or adding lubricant, do not allow dirt, debris
or other contaminants to enter the engine. (00198a)

4. Add the recommended GENUINE Harley-Davidson lub­ricant as necessary. Refer to Table 1-10. Do not overfill
or leakage may occur. The transmission fluid capacity is
approximately 32 fluid ounces (0.95 liters).

5. Inspect O-ring for tears or damage. Replace if required.
Wipe any foreign material from plug.

Figure 1-11. Transmission Filler Plug/Dipstick Location

1. FULL

2. ADD

Figure 1-12. Transmission Filler Plug/Dipstick Lubricant

Level

Changing Transmission Fluid

1. See Figure 1-11. Remove the threaded filler plug/dipstick.

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When draining or adding lubricant, do not allow dirt, debris
or other contaminants to enter the engine. (00198a)

3. Inspect the drain plug O-ring for tears or damage. Replace
if required. Wipe any foreign material from plug.

4. Install drain plug and tighten to 14-21 ft-lbs (19.0-28.5
Nm). Fill the transmission with 32 fl. oz. (0.95 liters) of the
recommended GENUINE Harley-Davidson lubricant. Refer
to Table 1-10.

Be sure that no lubricants or fluids get on tires, wheels or
brakes when changing fluid. Traction can be adversely
affected, which could result in loss of control of the
motorcycle and death or serious injury. (00047d)

2. See Figure 1-3. Remove transmission drain plug (1) and
drain lubricant into a suitable container.

NOTE
Dispose of transmission lubricant in accordance with local
regulations.

NOTE
Do not overfill or leakage may occur. The transmission fluid
capacity is approximately 32 fl. oz. (0.95 liters).

5. Install filler plug/dipstick and tighten to 25-75 in-lbs (2.8-

8.5 Nm).

6. Start engine and carefully check for oil leaks around drain

plug.

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ADJUSTMENT

NOTE

Perform the clutch adjustment with the motorcycle at room
temperature. The clearance at the adjuster screw will increase
as the powertrain temperature increases. If adjuster screw is
adjusted with powertrain hot, clearance at push rod bearing
could be insufficient with powertrain cold and clutch slippage
could occur.

1. Stand motorcycle upright and level.

2. Remove clutch inspection cover from primary chaincase
cover.

3. Remove seal ring from clutch inspection cover and discard.

4. See Figure 1-13. Add freeplay to cable.

a. Slide rubber boot (1) off cable adjuster.

b. Loosen jam nut (3) and back away from cable

adjuster.

c. Move adjuster (2) toward jam nut to introduce a large

amount of free play at hand lever.

1.11CLUTCH

1. Rubber boot

2. Cable adjuster

3. Jamnut

4. Cable end

Figure 1-13. Clutch Cable Adjuster

5. See Figure 1-14. Loosen jam nut (1) on clutch adjuster
screw. Turn adjuster screw (2) inward (clockwise) until
lightly seated.

6. Back out adjuster screw 1/2 to 1 full turn. While holding
adjuster screw, tighten jam nut to 72-120 in-lbs (8.1-13.6
Nm).

7. Squeeze clutch lever to maximum limit three times to set
ball and ramp release mechanism.

8. See Figure 1-13. Check freeplay.

a. Turn cable adjuster (2) away from jam nut (3) until

slack is eliminated at hand lever.

b. See Figure 1-15. Pull clutch cable ferrule (2) away

from clutch lever bracket to check free play. Turn
cable adjuster as necessary to obtain 1/16-1/8 in.
(1.6-3.2 mm) free play between end of cable ferrule
and clutch lever bracket.

9. Hold adjuster and tighten jam nut to 120 in-lbs (13.6 Nm).
Cover cable adjuster mechanism with rubber boot.

10. Swab all lubricant from seal ring groove in clutch inspection
cover. Install new seal ring in groove with nubs contacting
ring groove walls.

11. Fasten clutch inspection cover to primary chaincase cover.
Alternately tighten screws to 84-108 in-lbs (9.5-12.2 Nm)
in the sequence shown in Figure 1-10.

1. Jam nut

2. Clutch adjuster screw

Figure 1-14. Clutch Adjuster Screw

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1. Clutch cable

2. Cable ferrule

3. Clutch lever bracket

4. 1/16-1/8 in. (1.6-3.2 mm)

Figure 1-15. Clutch Hand Lever

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GENERAL

When a drive belt is replaced for any reason other than stone
damage, it is recommended that both the transmission sprocket
and rear sprocket also be replaced to increase the longevity
of the new drive belt. In the case of stone damage, inspect
sprockets for damage and replace as required.

Never bend belt forward into a loop smaller than the drive
sprocket diameter. Never bend belt into a reverse loop.
Over bending can damage belt resulting in premature
failure, which could cause loss of control and death or
serious injury. (00339a)

CLEANING

1.12DRIVE BELT AND SPROCKETS

Keep dirt, grease, oil, and debris off the drive belt and
sprockets. Clean the belt with a rag slightly dampened with a
light cleaning agent.

INSPECTION

Sprockets

NOTE

If chrome chips or gouges to rear sprocket are large enough
to be harmful, they will leave a pattern on the belt face.

1. See Figure 1-16. Inspect each tooth (1) of rear sprocket
for:

a. Major tooth damage.

b. Large chrome chips with sharp edges.

c. Gouges caused by hard objects.

d. Excessive loss of chrome plating (see next step).

2. To check if chrome plating has worn off, drag a scribe or
sharp knife point across the bottom of a groove (2)
(between two teeth) with medium pressure.

a. If scribe or knife point slides across groove without

digging in or leaving a visible mark, chrome plating
is still good.

b. If scribe or knife points digs in and leaves a visible

mark, it is cutting the bare aluminum. A knife point
will not penetrate the chrome plating.

3. Replace rear sprocket if major tooth damage or loss of
chrome exists.

1. Tooth

2. Groove

Figure 1-16. Rear Sprocket

Drive Belt

See Figure 1-17. Inspect drive belt for:

• Cuts or unusual wear patterns.

• Outside edge bevelling (8). Some bevelling is common,
but it indicates that sprockets are misaligned.

• Outside ribbed surface for signs of stone puncture (7). If
cracks/damage exists near edge of belt, replace belt
immediately. Damage to center of belt will require belt
replacement eventually, but when cracks extend to edge
of belt, belt failure is imminent.

• Inside (toothed portion) of belt for exposed tensile cords
(normally covered by nylon layer and polyethylene layer).
This condition will result in belt failure and indicates worn
transmission sprocket teeth. Replace belt and transmission
sprocket.

• Signs of puncture or cracking at the base of the belt teeth.
Replace belt if either condition exists.

• Replace belt if conditions 2, 3, 6 or 7 (on edge of belt)
exist.

NOTE

Condition 1 may develop into 2 or 3 over time. Condition 1 is
not grounds for replacing the belt, but it should be watched
closely before condition 2 develops which will require belt
replacement.

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Figure 1-17. Drive Belt Wear Patterns

Table 1-11. Drive Belt Wear Analysis

REQUIRED ACTIONCONDITIONPATTERN

OK to run, but monitor condition.Internal tooth cracks (hairline)1

Replace belt.External tooth cracks2

Replace belt.Missing teeth3

OK to run, but monitor condition.Chipping (not serious)4

OK to run, but monitor condition.Fuzzy edge cord5

Replace belt and sprocket.Hook wear6

Replace belt if damage is on the edge.Stone damage7

OK to run, but monitor condition.Bevel wear (outboard edge only)8

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CHECKING DRIVE BELT DEFLECTION

TOOL NAMEPART NUMBER

BELT TENSION GAUGEHD-35381A

NOTE

Always use BELT TENSION GAUGE (Part No. HD-35381A)
to measure belt deflection. Do not rely on "feel" as this can
result in belts that are under tensioned. Loose belts will fail due
to "ratcheting" (jumping a tooth).

Check deflection:

• As part of pre-ride inspection.

• At every scheduled service interval.

• With transmission in neutral.

• At loosest spot in belt.

• With motorcycle at room temperature.

• With motorcycle upright and rear wheel off the ground or
on jiffy stand without rider or luggage.

1. Remove left side saddlebag.

2. Slide O-ring on gauge toward 0 lbs (0 kg) mark.

3. See Figure 1-18. Fit cradle against bottom of belt midway
between transmission sprocket and rear sprocket.

4. Push upward on knob until O-ring slides to the 10 lbs (4.5
kg) mark on the tool and compare belt deflection to scale
on debris deflector.

NOTE
Each graduation on the scale represents 1/8 in (3.2 mm) of
belt deflection.

5. Measure deflection at several locations around the belt.

Select the loosest measurement and compare with spe­cifications in Table 1-12. Adjust belt as necessary.

Table 1-12. Belt Deflection

MILLIMETERSINCHESMODEL

6.4-7.91/4-5/16FLHX, FLTRX

9.5-11.13/8-7/16Other models

1. Transmission sprocket

2. Rear wheel sprocket

3. 10 lbs (4.5 kg) of force

4. Amount of deflection

Figure 1-18. Checking Belt Deflection

SETTING BELT DEFLECTION

TOOL NAMEPART NUMBER

BELT TENSION GAUGEHD-35381A

AXLE NUT TORQUE ADAPTERHD-47925

Adjustment

1. Remove both saddlebags.

2. Remove and discard E-clip from groove at end of axle.

NOTE
The AXLE NUT TORQUE ADAPTER simplifies the belt
adjustment procedure by allowing the cone nut to be loosened
and tightened without having to remove the right side muffler.
The tool also can be used to rotate the weld nut on the left
side.

3. See Figure 1-19. Install AXLE NUT TORQUE

ADAPTER (Part No. HD-47925) on 1/2 inch breaker bar,
perpendicular to breaker bar. For best clearance with
muffler, install torque adapter on the outboard side.

NOTE
In order to provide adequate room to install tools on the cone
nut and weld nut, it may be necessary to remove bolts fastening
each muffler to the rear of the saddlebag frame and pulling
each muffler away from the end of the axle.

4. Insert tool up between rear wheel and muffler and onto

cone nut. Loosen cone nut.

Since any added length can act as a torque multiplier, the
torque wrench must be perpendicular to the torque adapter.

5. Install AXLE NUT TORQUE ADAPTER (Part No. HD-

47925) on torque wrench, perpendicular to torque wrench.

6. Insert tool up between rear wheel and muffler to capture

cone nut.

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7. See Figure 1-20. Push wheel forward and verify that cam
(5) contacts boss (4) on both sides of rear fork.

8. For purposes of adjustment only, snug the cone nut (6) to
15-20 ft-lbs (20-27 Nm).

9. Use BELT TENSION GAUGE (Part No. HD-35381A) to
check belt deflection as adjustment is made. See

1.12 DRIVE BELT AND SPROCKETS, Checking Drive
Belt Deflection.

NOTE

It may be beneficial to use a second AXLE NUT TORQUE
ADAPTER (Part No. HD-47925) and breaker bar or ratchet to
rotate and hold the weld nut. The position of the breaker bar
or ratchet in relation to the tool is not important and can be
mated in any position that will make use easy.

10. See Figure 1-20. Adjust belt tension by rotating weld nut
(3) on left side of axle; clockwise to tighten the belt or
counterclockwise to loosen the belt. If loosening the belt
tension, push the wheel forward and verify both cams (5)
touch the bosses (4) on both sides after the weld nut is
rotated.

11. When correct tension is obtained, verify the cams touch
the bosses on both sides of the rear fork.

1. Torque wrench

2. Axle nut torque adapter (HD-47925)

Figure 1-19. Install Tool Perpendicular to Torque Wrench

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5.1. Adjuster camIncrease belt deflection

2. 6.Reduce belt deflection Cone nut

7.3. E-clipWeld nut

4. Boss

Figure 1-20. Rear Wheel Adjuster Cams

Assembly

NOTE

It is important that the weld nut does not rotate once belt ten­sion is correct. If the axle moves during tightening of the cone
nut, the belt deflection procedure must be restarted.

1. Hold weld nut and tighten cone nut to 95-105 ft-lbs (128.8-

142.4 Nm).

2. Again, verify the cams touch the bosses on both sides of
the rear fork. Check belt deflection to verify that it is still
within specification.

3. With the flat side out, install new E-clip in groove on right
side of axle.

4. If removed, install fasteners that attach mufflers to the
saddlebag frames and tighten to 96-144 in-lbs (10.9-16.3
Nm).

5. Install saddlebags.

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1.13COMPENSATOR SPROCKET ISOLATOR

INSPECTION

1. Support the vehicle in an upright position in neutral, and
in a fashion that will not allow the rear wheel to rotate. Do
not lift the wheels off the ground.

2. Remove left saddlebag.

3. See Figure 1-21. Hang a weighted string (1) on the left
axle spacer as close as possible to, but not touching, the
rear sprocket.

NOTE

A piece of masking tape on the face of the sprocket will protect
the finish.

4. Place a piece of masking tape on the face of the sprocket
where the marks will be drawn.

NOTE

Do not allow the rear wheel to rotate when rotating the sprocket.
A false measurement will occur.

5. Rotate the rear sprocket by hand in one direction until it
stops. Hold in place.

6. While holding the sprocket, carefully mark the masking
tape along the edge of the sprocket in line with the string.

7. Rotate the rear sprocket in the opposite direction until it
stops and again hold it in place.

8. Make a second mark in line with the string.

9. Measure the distance (2) between the marks along the
edge of the sprocket. If the measurement exceeds 0.400
in (10.2 mm) the rubber isolator must be replaced.

NOTE

Components can be visually inspected when disassembled.
Excessive play in the compensator components are caused
by deteriorated, crumbling, or flaking of the rubber segments.
Wear on the raised "nubs" or small amounts of rubber debris
are normal and do not indicate a worn out isolator. See

2.6 REAR WHEEL COMPENSATOR if the rear wheel com-

pensator needs to be serviced.

1. Weighted string

2. Measured distance

Figure 1-21. Check Compensator Wear

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1.14CABLE AND CHASSIS LUBRICATION

GENERAL

Inspect and lubricate the following at scheduled service inter­vals as specified in 1.5 MAINTENANCE SCHEDULE.

• Front brake hand lever.

• Clutch hand lever.

• Clutch cable.

• Foot shift lever pivot (if applicable).

• Rear brake lever pivot.

• Steering head bearings.

• Jiffy stand.

If motorcycle is operated on muddy or dusty roads, clean and
lubricate more frequently.

Use Harley® Lube (Part no. HD-94968-09) for hand levers and
cables.

STEERING HEAD BEARINGS

Lubricate the steering head bearings with HARLEY-DAVIDSON
SPECIAL PURPOSE GREASE. See 1.20 STEERING HEAD

BEARINGS for procedure.

JIFFY STAND

Clean and lubricate the jiffy stand. For more information, see

2.50 JIFFY STAND.

MISCELLANEOUS LUBRICATION

Hinges, Latches, Etc.

Lubricate the rub points of latches and hinges using Harley®
Lube (Part No. 94968-09) as required.

Lubricate the fingers on the saddlebag latches where they
engage the hinge.

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1.15BRAKES

FLUID INSPECTION

1. Position vehicle for inspection.

a. Front brake: Position vehicle on a flat level surface.

Turn handlebar so front brake master cylinder is
approximately level.

b. Rear brake: Have an assistant hold vehicle upright

on a level surface.

2. See Figure 1-22. View reservoir sight glass and verify fluid
presence.

3. If fluid is not visible through sight glass, check brake
system for fluid leaks. Check that brake pads are properly
installed and not worn beyond service wear limits. Perform
any necessary repairs. See 1.16 BRAKE PADS AND

DISCS.

4. If fluid is still not visible through sight glass, remove cover
and verify fluid level. If necessary, add HARLEY-DAV­IDSON D.O.T. 4 BRAKE FLUID (Part No. 99953-99A) to
reservoir. Replace cover. See 2.16 BLEEDING BRAKES.

5. Front brake hand lever and rear brake foot pedal must
have a firm feel when applied. If not, bleed system using

only HARLEY-DAVIDSON D.O.T. 4 BRAKE FLUID (Part
No. 99953-99A). See 2.16 BLEEDING BRAKES.

1. Sight glass, front master cylinder reservoir

2. Sight glass, rear master cylinder reservoir

Figure 1-22. Brake Fluid Sight Glass (typical)

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1.16BRAKE PADS AND DISCS

INSPECTION

Check brake pads and discs:

• At every scheduled service interval.

• Whenever the components are removed during service
procedures.

Brake Pads

Direct contact of D.O.T. 4 brake fluid with eyes can cause
irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention.
Swallowing large amounts of D.O.T. 4 brake fluid can cause
digestive discomfort. If swallowed, obtain medical atten­tion. Use in well ventilated area. KEEP OUT OF REACH OF
CHILDREN. (00240a)

D.O.T. 4 brake fluid will damage painted and body panel
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is per­formed. Failure to comply can result in cosmetic damage.
(00239b)

Always replace brake pads in complete sets for correct
and safe brake operation. Improper brake operation could
result in death or serious injury. (00111a)

Replace both rear brake pads if the friction material of either
pad is worn to 0.016 in. (0.4 mm) or less above the backing
plate.

Replace all front brake pads (inner and outer pads of both the
left and right side calipers) if the friction material of any single
pad is worn to 0.016 in. (0.4 mm) or less above the backing
plate.

NOTE

Refer to the wear indicator lines for a general indication of pad
wear. See Figure 1-24.

Always install a new pad pin (provided in brake pad service
kit) whenever the brake pads are replaced.

Inspect the brake lines and hoses for damage or wear.

warpage is 0.008 in. (0.2 mm) when measured near the outside
diameter of the disc.

BRAKE PAD REPLACEMENT

Rear Brake Caliper

1. Remove right side saddlebag. See 2.26 SADDLEBAGS,

Removal.

2. If ABS equipped, release rear wheel speed sensor cable
from retainer clip on brake hose.

3. Remove two screws to release brake caliper from caliper
bracket.

4. Remove brake caliper from brake disc.

NOTE
Do not operate the brake pedal with the rear brake caliper
removed or the caliper pistons may be forced out. The caliper
contains no serviceable components and will require replace­ment.

5. Stand motorcycle upright, so that rear master cylinder

reservoir is level. Wrap a clean shop cloth around the
outside of the reservoir to protect paint from brake fluid
spills.

6. Remove cover from master cylinder reservoir.

NOTE
Fluid level will rise as pistons are pushed into the caliper,
possibly overflowing the master cylinder reservoir. Remove
fluid from the reservoir if necessary.

7. Push each pad back until pistons are fully seated in the

bores.

8. See Figure 1-26. Pull retaining clip (3) from groove in pad

pin.

9. See Figure 1-23. Remove pad pin (metric).

10. Pull on pad pin side of brake pads to release from caliper.

11. See Figure 1-26. Remove pad spring (1) if damaged or

worn.

12. If removed, seat new pad spring on flat in caliper, so that

clips on spring engage indentations in caliper. Be sure
that forked end of pad spring is on the pad pin side of the
caliper.

Brake Disc Thickness

The minimum front brake disc thickness is 0.18 in. (4.5 mm)
and is stamped on the side of the disc.

The minimum rear brake disc thickness is 0.25 in. (6.3 mm)
and is stamped on the side of the disc.

Replace any disc that is excessively worn or badly scored.

Brake Disc Lateral Runout

Measure brake disc runout using a dial caliper mounted to a
stationary surface. Maximum brake disc lateral runout or

Always replace brake pads in complete sets for correct
and safe brake operation. Improper brake operation could
result in death or serious injury. (00111a)

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After servicing brakes and before moving motorcycle,
pump brakes to build brake system pressure. Insufficient
pressure can adversely affect brake performance, which
could result in death or serious injury. (00279a)

19. Operate brake pedal several times to set brake pads to
proper operating position.

20. See Figure 1-27. Check brake fluid level in master cylinder
reservoir. If necessary, add D.O.T. 4 BRAKE FLUID until
level is flush with ledge cast at front of reservoir.

21. Install master cylinder reservoir cover and tighten to 12-15
in-lbs (1.4-1.7 Nm).

22. Install right side saddlebag. See 2.26 SADDLEBAGS,

Installation.

After repairing the brake system, test brakes at low speed.
If brakes are not operating properly, testing at high speeds
can cause loss of control, which could result in death or
serious injury. (00289a)

23. Test brake system.

a. Turn ignition switch ON. Depress brake pedal to verify

operation of brake lamp.

b. Test ride motorcycle. Bleed the system if brakes feel

spongy. See 2.16 BLEEDING BRAKES.

1. Rear caliper

2. Front left caliper (screen removed)

Figure 1-23. Brake Caliper Pad Pin

13. Install new brake pads as follows:

a. See Figure 1-24 and Figure 1-25. Insert brake pad

into caliper engaging square corner of pad in slot of
caliper.

b. Push pad pin tab of brake pad into caliper until seated.

c. Verify that brake pad friction material faces brake disc

gap in caliper.

d. Repeat step to install remaining brake pad.

14. Verify that pad pin tabs are centered under forks of pad
spring. Adjust pads if necessary.

15. Install new pad pin and tighten to 75-102 in-lbs (8.5-11.5
Nm).

16. See Figure 1-26. Install retaining clip in groove of pad pin,
so that lip overhangs caliper housing.

17. Install brake caliper onto brake disc and install two screws.
Tighten screws to 43-48 ft-lbs (58.3-65.1 Nm).

18. If ABS equipped, secure sensor cable with clip on brake
hose.

NOTE
Avoid making hard stops for the first 100 miles (160 km). This
allows the new pads to become conditioned to the brake discs.

1. Square corner

2. Pad pin tab

3. Pad pin hole

4. Friction material

5. Wear indicator lines

Figure 1-24. Brake Pad

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Figure 1-25. Brake Caliper (Bottom View)

3. Remove two brake caliper mounting screws. Slide brake
caliper straight down off from brake disc. Allow the brake
caliper to hang by the brake hose.

NOTE
Do not operate the brake lever with the front brake caliper
removed or the caliper pistons may be forced out. The caliper
contains no serviceable components and will require replace­ment.

4. Turn front wheel to left until front master cylinder reservoir

is level. Wrap a clean shop cloth around the outside of the
reservoir to protect paint from brake fluid spills.

5. Remove cover from master cylinder reservoir.

NOTE
Fluid level will rise as pistons are pushed back into the caliper,
possibly overflowing the master cylinder reservoir. Remove
fluid from the reservoir if necessary.

6. Push each pad back until pistons are fully seated in the

bores.

7. Remove screen from caliper.

8. See Figure 1-26. Pull retaining clip from groove in pad pin.

9. See Figure 1-23. Remove pad pin (metric).

10. Pull on pad pin end of brake pads to release from caliper.

11. Remove pad spring if damaged or worn.

12. If removed, seat new pad spring on flat in caliper, so that

clips on spring engage indentations in caliper. Be sure
that forked end of pad spring is on the pad pin side of the
caliper.

Always replace brake pads in complete sets for correct
and safe brake operation. Improper brake operation could
result in death or serious injury. (00111a)

13. Install new brake pads as follows:

a. See Figure 1-24 and Figure 1-25. Insert brake pad

into caliper engaging square corner of pad in slot of
caliper.

1. Pad spring (forked end)

2. Pad pin tab

3. Pad pin retaining clip

Figure 1-26. Brake Caliper (Top View)

Front Brake Calipers

1. If present, carefully cut cable straps to release front wheel
speed sensor cable and front fender tip lamp wires from
brake hose to left brake caliper.

2. On ABS equipped motorcycles, release front wheel speed
sensor cable from clip as follows:

a. Push on lip at rear of clip to disengage from bracket.

b. Rotate tab (stamped ABS) rearward until clip is per-

pendicular to bracket and remove cable.

b. Push pad pin tab of brake pad into caliper until seated.

c. Verify that brake pad friction material faces brake disc

gap in caliper.

d. Repeat step to install remaining brake pad.

14. Verify that pad pin tabs are centered under forks of pad
spring. Adjust pads if necessary.

15. Install new pad pin and tighten to 75-102 in-lbs (8.5-11.5
Nm).

16. See Figure 1-26. Install retaining clip in groove of pad pin,
so that lip overhangs caliper housing.

17. Engage two prongs on screen beneath forked end of pad
spring and push on single prong side of screen until
engaged.

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18. Install brake caliper as follows:

a. Install caliper with bleeder at top (and cable

clip/bracket if ABS equipped and secure with two
mounting screws).

NOTE
Be sure that tab (stamped ABS) on clip is installed in slot
of bracket from inboard side. Clip cannot be installed once
mounting screws are started.

b. Tighten mounting screws to 28-38 ft-lbs (37.9-51.5

Nm).

After servicing brakes and before moving motorcycle,
pump brakes to build brake system pressure. Insufficient
pressure can adversely affect brake performance, which
could result in death or serious injury. (00279a)

19. Install new cable straps to secure brake hose and wheel

speed sensor if equipped.

20. If ABS equipped, install front wheel speed sensor cable
in clip. See C.3 WHEEL SPEED SENSORS.

with the vent holes facing the rear. Install cover screws
and tighten to 10-12 in-lbs (1.1-1.4 Nm).

After repairing the brake system, test brakes at low speed.
If brakes are not operating properly, testing at high speeds
can cause loss of control, which could result in death or
serious injury. (00289a)

24. Test brake system.

a. Turn ignition switch ON. Depress brake lever to verify

operation of brake lamp.

b. Test ride motorcycle. Bleed system if brakes feel

spongy. See 2.16 BLEEDING BRAKES.

NOTE
Avoid making hard stops for the first 100 miles (160 km). This
allows the new pads to become conditioned to the brake discs.

After servicing brakes and before moving motorcycle,
pump brakes to build brake system pressure. Insufficient
pressure can adversely affect brake performance, which
could result in death or serious injury. (00279a)

21. Operate brake lever several times to set brake pads to
proper operating position.

22. See Figure 1-27. Check brake fluid level in master cylinder
reservoir. If necessary, add D.O.T. 4 BRAKE FLUID until
level is flush with step (marked MAX) cast at rear of
reservoir.

23. Verify gasket and sealing surfaces are free of debris and
install master cylinder reservoir cover. Orient the cover

1. Front master cylinder reservoir

2. Rear master cylinder reservoir

Figure 1-27. Brake Fluid Level

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1.17SPARK PLUGS

INSPECTION

Disconnecting spark plug cable with engine running can
result in electric shock and death or serious injury.
(00464b)

NOTE

Allow the engine to cool to room temperature before servicing
spark plugs.

1. Disconnect spark plug cables and remove spark plugs.

2. See Figure 1-28. Inspect the spark plug and compare your
observations with the descriptions provided below.

a. If a spark plug has eroded electrodes, heavy deposits

or a cracked insulator, discard it.

b. A wet, black and shiny deposit on base, electrodes

and ceramic insulator tip indicates an oil fouled spark
plug. The condition may be caused by one or more
of the following: worn pistons, worn piston rings, worn
valves, worn valve guides, worn valve seals, a weak
battery or a faulty ignition system.

c. A dry, fluffy or sooty black deposit indicates an air-

fuel mixture that is too rich.

d. A light brown, glassy deposit indicates an overheated

spark plug. This condition may be accompanied by
cracks in the insulator or by erosion of the electrodes
and is caused by an air-fuel mixture that is too lean,
an overheated engine, valves not seating or improper
ignition timing. The glassy deposit on the spark plug
is a conductor when hot and may cause high-speed
misfiring. A spark plug with eroded electrodes, heavy
deposits or a cracked insulator must be replaced.

e. A spark plug with a white, yellow, tan or rusty brown

powdery deposit indicates balanced combustion.
Clean off spark plug deposits at regular intervals.

4. Check electrode gap with a wire-type feeler gauge. Bend
the outside of the electrode so only a slight drag on the
gauge is felt when passing it between electrodes. Proper
gap measurement is 0.038-0.043 in. (0.97-1.09 mm).

5. Check condition of threads on cylinder head and spark
plug. If necessary to remove deposits, apply penetrating
oil and clean out with a thread chaser.

6. Apply a light coat of SILVER GRADE ANTI-SEIZE (Part
No. 98960-97) to the spark plug threads. Install and tighten
to 12-18 ft-lbs (16.3-24.4 Nm).

7. Connect spark plug cables. The rear cylinder spark plug
cable attaches to the right coil terminal. Verify that the
cables are securely connected to the coil and spark plugs,
and secured to any anchor clips.

Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)

3. If the spark plugs require cleaning between tune-ups,
proceed as follows:

a. Degrease firing end of spark plug using electrical

contact cleaner. Dry with compressed air.

b. Use a thin file to flatten the electrodes. A spark plug

with sharp edges on its electrodes requires 25-40%
less firing voltage than one with rounded edges.

c. If the spark plugs cannot be cleaned, replace with

new spark plugs.

Figure 1-28. Typical Spark Plug Deposits

SPARK PLUG CABLE INSPECTION

1. Inspect spark plug cables. Replace cables that are worn
or damaged.

a. Check for cracks or loose terminals.

b. Check for loose fit on ignition coil and spark plugs.

2. Check cable boots/caps for cracks or tears. Replace
boots/caps that are worn or damaged.

3. See Figure 1-29. Check spark plug cable resistance with
an ohmmeter. Replace cables not meeting resistance
specifications. Refer to Table 1-13.

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Table 1-13. Spark Plug Cable Resistance Values

LENGTHDESCRIPTION

mmIn.

RESISTANCE

VALUE

(OHMS)

8688-23,17888334.75Front cable

4188-11,17242516.75Rear cable

1. Ohmmeter positive lead

2. Ohmmeter negative lead

3. Spark plug cable

4. Ohmmeter

Figure 1-29. Testing Resistance

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1.18FRONT FORK OIL

REPLACING FORK OIL

Fork assemblies must be removed to drain fork oil. See

2.17 FRONT FORK. While removed, inspect fork assemblies.

Look for oil leakage past seals and excessive wear on slider
tubes. Disassemble, clean and repair or replace components
as necessary.

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1.19SUSPENSION ADJUSTMENTS

GENERAL

TOOL NAMEPART NUMBER

AIR SUSPENSION PUMP AND GAUGEHD-34633A

See Figure 1-30. Adjust the rear air suspension pressure by
adding or removing air from the air valve located near the left
upper shock absorber mount. Always adjust pressures with
the motorcycle on the jiffy stand.

Do not exceed the motorcycle's Gross Vehicle Weight
Rating (GVWR) or Gross Axle Weight Rating (GAWR).
Exceeding these weight ratings can affect stability and
handling, which could result in death or serious injury.
(00016e)

Air pressure may be varied to suit load conditions, riding style
and personal comfort. Less initial pressure does not necessarily
result in a softer ride. Use Table 1-14 or Table 1-15 as a
starting point in determining suitable rear air suspension pres­sures. Do not exceed maximum GVWR when loading vehicle
and do not pressurize system in excess of 50 psi (345 kPa).

Do not exceed maximum air pressure for rear suspension.
Air components fill rapidly. Therefore, use low air line
pressure. Failure to do so may result in possible damage
to components. (00165a)

NOTES

•

Use AIR SUSPENSION PUMP AND GAUGE (Part
No. HD-34633A) to adjust suspension air pressure.

•

Use a no-loss air gauge to check air pressure. Check
pressure in shock absorbers weekly if used daily or before
each trip if used occasionally.

•

Improper inflation of rear air suspension components can
result in a reduction of available suspension travel,
reduced rider comfort and possible damage to shock
absorbers.

Use caution when bleeding air from the suspension.
Moisture combined with lubricant may leak onto the rear
wheel, tire and/or brake components and adversely affect
traction, which could result in death or serious injury.
(00084a)

Figure 1-30. Rear Air Suspension Air Valve

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Table 1-14. Recommended Suspension Air Pressure: FLHX, FLTRX, FLHR/C

PRESSURETOTAL WEIGHTSHOCK LOAD

kPaPSIKGLB.

00up to 68up to 150Solo rider

0-690-1068-91150-200

69-13810-2091-113200-250

138-20620-30113-136250-300

206-34530-50over 136over 300

69-13810-20up to 68up to 150Solo rider with capacity luggage of 40 lbs (18 kg)

138-20620-3068-91150-200

206-27630-4091-113200-250

276-34540-50113-136250-300

34550over 136over 300

276-34540-50ALLALLRider plus passenger

34550ALLALLMaximum GVWR

If Tour-Pak is installed, add 5-10 psi (34-69 kPa) to shock pressure. Do not exceed 50 psi (345 kPa) suspension pressure.

Table 1-15. Recommended Suspension Air Pressure: FLHTC, FLHTCU, FLHTK, FLTRU

Do not exceed 50 psi (345 kPa) suspension pressure.

PRESSURETOTAL WEIGHTSHOCK LOAD

kPaPSIKGLB.

34-695-10up to 68up to 150Solo rider

69-13810-2068-91150-200

138-20620-3091-113200-250

206-27630-40113-136250-300

276-34540-50over 136over 300

172-20625-30up to 68up to 150Solo rider with capacity luggage of 70 lbs (32 kg)

206-27630-4068-91150-200

276-34540-5091-113200-250

34550over 113over 250

34550ALLALLRider plus passenger

34550ALLALLMaximum GVWR

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1.20STEERING HEAD BEARINGS

LUBRICATION

1. See Figure 1-31.Turn handlebar to the right fork stop to
access grease fitting at the left side of the steering head.

2. Inject Special Purpose Grease, (Part No. 99857-97) until
it exits from the top and bottom of the steering head.

Figure 1-31. Steering Head Bearing Grease Fitting

CHECKING

When lifting a motorcycle using a jack, be sure jack con­tacts both lower frame tubes where down tubes and lower
frame tubes converge. Never lift by jacking on cross­members, oil pan or other housings. Failure to comply can
cause serious damage resulting in the need to perform
major repair work. (00586c)

1. Raise the motorcycle so that the front and rear tires are
the same distance from the floor.

2. Verify that motorcycle is in stock configuration. Remove
all non-factory accessories, since they can influence front
end swing momentum (and lead to improper adjustment).

3. See Figure 1-32. Turn the front wheel to the left fork stop
and then let go. The wheel should swing from side to side,
finally stopping in the swing specified in Table 1-16. If it
stops in the lesser number swing, it should be at or after
the straight-forward position.

4. If the clutch cable or main harness appears to be influen­cing swing momentum, proceed as follows and repeat the
previous step:

a. Clutch cable: Disconnect clutch cable from hand

lever. Release cable from P-clamp, remove from inner
fairing, or release from cable clip on instrument
nacelle depending on model. See 2.22 CLUTCH

CABLE.

b. Main harness: Remove the rivet and P-clamp to

release main harness from steering head. Secure P­clamp with a new rivet when procedure is complete.

NOTE
A steering head that is too tight can interfere with the vehicle's
ability to absorb a weave. A steering head that is too loose can
interfere with the vehicle's ability to absorb a wobble.

5. To correct a swing pattern, see 1.20 STEERING HEAD

BEARINGS, Adjustment.

Figure 1-32. Steering Head Bearing Swing Count

Table 1-16. Steering Head Bearing Swing Count

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(A)21FLTRX, FLTRU

(A-B)32FLHR, FLHRC

(B-C)43FLHX, FLHTC, FLHTCU, FLHTK

(D)More than 4TOO LOOSE

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ADJUSTMENT

1. Disassemble motorcycle as follows:

a. Road Glide models: Remove headlamp nacelle. See

2.44 HEADLAMP NACELLE: ROAD KING MODELS.

b. Fork mounted fairing models: Remove outer fairing

and radio or storage box as equipped. See

2.34 UPPER FAIRING AND WINDSHIELD: FORK
MOUNTED FAIRING MODELS and 7.33 ADVANCED
AUDIO SYSTEM, respectively.

c. Frame mounted fairing models: Remove instrument

bezel. See 2.39 INSTRUMENT BEZEL: FRAME

MOUNTED FAIRING MODELS.

2. See Figure 1-33. Loosen pinch bolts (3) on lower fork
bracket.

6. Tighten stem nut to 70-80 ft-lbs (94.9-108.4 Nm).

NOTE

Torque of the stem nut will affect the swing pattern.

7. Recheck the swing pattern and adjust as necessary.

8. Tighten pinch bolts to 53-57 ft-lbs (71.9-77.3 Nm).

9. Verify that the fork stem nut is tightened to 70-80 ft-lbs
(94.9-108.4 Nm).

10. Recheck the swing pattern and adjust if necessary.

11. Assemble motorcycle as follows:

a. Road Glide models: Install headlamp nacelle. See

2.44 HEADLAMP NACELLE: ROAD KING MODELS.

b. Fork mounted fairing models: Install radio or

storage box (as equipped) and outer fairing. See

7.33 ADVANCED AUDIO SYSTEM and 2.34 UPPER
FAIRING AND WINDSHIELD: FORK MOUNTED
FAIRING MODELS, respectively.

c. Frame mounted fairing models: Install instrument

bezel. See 2.39 INSTRUMENT BEZEL: FRAME

MOUNTED FAIRING MODELS.

12. Install any accessories that were removed during the
checking procedure.

1. Fork stem nut

2. Adjuster nut

3. Pinch bolt

Figure 1-33. Fork Stem and Brackets

3. Loosen the fork stem nut (1).

4. See Figure 1-34. Fashion a bearing adjuster tool using a
drill rod 1/4 in. (6.4 mm) in diameter and 16 in. (406.4 mm)
long.

NOTES

•

See Figure 1-33. Turning the bearing adjuster nut (2) as
little as one notch will make a noticeable difference in the
swing pattern.

•

Tap forks with a rubber hammer while turning adjuster nut
to prevent forks from binding in lower bracket bores.

5. Turn bearing adjuster nut (2) as follows:

a. To decrease the number of swings, rotate nut clock-

wise.

b. To increase the number of swings, rotate nut coun-

terclockwise.

Original equipment fork stem nut has a blue dye coating. If a
replacement nut is being installed, the replacement nut will not
have the blue coating.

NOTE

1. All models except FLTRX

2. FLTRX

3. 1/8 in (3.2 mm)

4. 5/32 in (4.0 mm)

5. 5/32 in (4.0 mm) goes back for 1-1/4 in (31.8 mm)

6. 2 in (50.8 mm) to start of bend

Figure 1-34. Fashion Bearing Adjuster Tool

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HEADLAMP ALIGNMENT

The automatic-on headlamp feature provides increased
visibility of the rider to other motorists. Be sure headlamp
is on at all times. Poor visibility of rider to other motorists
can result in death or serious injury. (00030b)

NOTE

Vehicles with multiple beam headlamps that are individually
aimed should be adjusted so both lamps converge into one
pattern.

1. Verify that front and rear tire inflation pressures are correct
and that suspension is adjusted to the weight of the prin­cipal rider. See 1.8 TIRES AND WHEELS.

2. Fill fuel tank or add ballast to equal the weight of the fuel
needed.

NOTE
See Figure 1-35. To aid in properly placing the motorcycle, a
perpendicular line (1) can be drawn on the floor. For best res­ults, choose an area with minimum light.

3. Draw a vertical line (2) on the wall.

4. Position motorcycle so that front axle is 25 ft (7.6 m) from

wall.

NOTE
As the weight of the rider will compress the suspension slightly,
have a person whose weight is approximately the same as that
of the principal rider sit on the motorcycle.

5. With the vehicle laden and upright, point the front wheel

straight forward at wall and measure the distance (4) from
the floor to the center of the HIGH BEAM bulb.

6. Draw a horizontal line (5) through the vertical line on the

wall that is 2.1 in (53.3 mm) lower than the measured bulb
centerline.

7. Verify headlamp alignment. With the motorcycle on, set

the headlamp switch to HIGH beam.

a. The center of the hot spot (brightest area of light

beam) should be centered where the two lines inter­sect.

b. Adjust headlamp alignment if necessary.

1.21HEADLAMP ALIGNMENT

1. Perpendicular line

2. Vertical line

3. 25 feet (7.6 meters)

4. High beam bulb centerline

5. Horizontal line 2.1 in. (53.3 mm) lower than bulb
centerline

Figure 1-35. Check Headlamp Alignment

HEADLAMP ADJUSTMENT: SINGLE HEADLAMP MODELS

NOTE

Headlamp adjustment can be performed without removing the
headlamp trim ring.

1. See Figure 1-36. Using adjuster slots in trim ring, insert
Phillips screwdriver between headlamp trim ring and
rubber gasket.

a. Horizontal: Turn the horizontal adjusting screw to

adjust light beam left and right.

b. Vertical: Turn the vertical adjusting screw to adjust

light beam up and down.

2. Adjust the light beam until it is centered as shown in

Figure 1-35.

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1. Horizontal adjuster

2. Vertical adjuster

Figure 1-36. Headlamp Adjusters (typical)

HEADLAMP ADJUSTMENT: DUAL HEADLAMP MODELS

1. See Figure 1-37. Rotate the hex adjusters (metric) located
near the bottom edge of the inner fairing. Refer to

Table 1-17 for adjuster rotation.

a. Horizontal: Turn either the left or right adjuster to

adjust the light beam left and right.

b. Vertical: Turn both adjusters equally to adjust the

light beam up and down.

2. Adjust the light beam until it is centered as shown in

Figure 1-35.

Table 1-17. Adjuster Rotation, Dual Headlamp Models

Beam MovementRotationHex Adjuster

To the rightCWLeft Only

CCWRight Only

To the leftCCWLeft Only

CWRight Only

UpwardCWLeft and Right

Equally

DownwardCCWLeft and Right

Equally

CW = Clockwise
CCW = Counter-clockwise

1. Left side adjuster

2. Right side adjuster

Figure 1-37. Headlamp Adjusters: Dual Headlamp Models

AUXILIARY LAMP ALIGNMENT

TOOL NAMEPART NUMBER

FLARE NUT SOCKETSNAP-ON® FRX181

1. Place the vehicle facing a target wall as described in

1.21 HEADLAMP ALIGNMENT, Headlamp Alignment.

NOTE
As the weight of the rider will compress the suspension slightly,
have a person whose weight is roughly the same as that of the
principal rider sit on the motorcycle.

2. With the vehicle upright and a rider seated on the motor-

cycle, measure the distance from the floor to the centerline
of each auxiliary lamp.

3. Measure the distance from the headlamp vertical centerline

to the vertical centerline of each auxiliary lamp.

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4. See Figure 1-38. Mark the auxiliary lamp horizontal and
vertical centerlines (2, 3) on the wall.

5. Remove two screws to release the turn signal lamp from
the mounting bracket.

6. Using FLARE NUT SOCKET (Part No. Snap-on®
FRX181), loosen the auxiliary lamp flange nut only enough
to allow movement of the lamp.

NOTE

Figure 1-38 depicts the light pattern for vehicles driven on the

right side of the road. In countries where travel is on the left
side of the road, shift the auxiliary lamp high intensity patterns
(4, 5) to the left of center.

7. Turn on the headlamp low beam and cover both the

headlamp and the right side auxiliary lamp. Adjust the left

side auxiliary lamp as necessary so that the entire high
intensity zone (4) is below and to the right of the left side
auxiliary lamp centerlines as shown in Figure 1-38.

8. Cover the headlamp and left side auxiliary lamp. Adjust
the right side auxiliary lamp as necessary so that the entire
high intensity zone (5) is both below and to the right of the
right side auxiliary lamp centerlines as shown in

Figure 1-38.

9. Tighten auxiliary lamp flange nut to 15-18 ft-lbs (20.3-24.4
Nm).

10. Start two screws to secure turn signal lamp to mounting
bracket. Verify that conduit fits in slot at back of bracket
and is not pinched. Tighten screws to 36-60 in-lbs (4.1-

6.8 Nm).

1. Headlamp high beam area

2. Left side auxiliary lamp centerlines

3. Right side auxiliary lamp centerlines

4. Left side auxiliary high intensity beam area

5. Right side auxiliary high intensity beam area

Figure 1-38. Properly Aim Auxiliary Lamps

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1.22CRITICAL FASTENERS

INSPECTION

Inspect critical fasteners at the scheduled service intervals.
Replace any fasteners that are damaged or missing.

Table 1-18. Critical Fasteners

clamp screws

handlebar clamp screws

cover screws

cover screws

screws

screws

bracket screws

Checking Torques on Fasteners

1. Refer to Table 1-18. Attempt to turn the fastener using a
torque wrench set to the minimum torque specification for
that fastener.

a. If the fastener does not rotate, the fastener torque

has been maintained. No further attention is neces­sary at this time.

b. If the fastener rotates, remove it to determine if it has

a locking agent.

c. If it has a locking agent, clean all locking material from

the threaded hole. Replace the fastener with a new
one or clean the original fastener threads and apply
the appropriate locking agent (see appropriate pro­cedure).

d. Install and tighten the fastener to specification.

2. If the fastener does not have a locking agent, install and
tighten to specification.

TORQUEFASTENERSYSTEM

4.0-5.1 Nm35-45 in-lbsSwitch housing screwsHand controls

8.1-12.2 Nm72-108 in-lbsClutch lever bracket handlebar

8.1-12.2 Nm72-108 in-lbsMaster cylinder reservoir

23.0-25.8 Nm17-19 ft-lbsBrake caliper banjo boltsBrakes

17.0-19.7 Nm12.5-14.5 ft-lbsMaster cylinder banjo bolts

17.0-19.7 Nm12.5-14.5 ft-lbsABS module banjo bolts

21.7-32.5 Nm16-24 ft-lbsFront brake disc screws

40.7-61.0 Nm30-45 ft-lbsRear brake disc screws

1.1-1.4 Nm10-12 in-lbsFront master cylinder reservoir

1.4-1.7 Nm12-15 in-lbsRear master cylinder reservoir

14.2-16.9 Nm126-150 in-lbsRear master cylinder to frame

38.0-51.5 Nm28-38 ft-lbsFront brake caliper mounting

58.3-65.1 Nm43-48 ft-lbsRear brake caliper to caliper

8.5-11.5 Nm75-102 in-lbsBrake caliper pad pin

81.3-88.1 Nm60-65 ft-lbsFrontAxle nuts

129.0-142.0 Nm95-105 ft-lbsRear

14.9-20.3 Nm132-180 in-lbsFront axle holder nutsFront forks

74.6-88.1 Nm55-65 ft-lbsFastenersPivot shaft

74.6-88.1 Nm55-65 ft-lbsRear fork bracket bolts

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Table 1-18. Critical Fasteners

TORQUEFASTENERSYSTEM

46.1-52.9 Nm34-39 ft-lbsTransmission to engine boltsOther

See 1.24 ENGINE MOUNTS.Engine mount bolts

Top stabilizer link bolts

54.2-67.8 Nm40-50 ft-lbsRear frame bolts

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1.23BATTERY MAINTENANCE

GENERAL

Batteries contain sulfuric acid, which could cause severe
burns to eyes and skin. Wear a protective face shield,
rubberized gloves and protective clothing when working
with batteries. KEEP BATTERIES AWAY FROM CHILDREN.
(00063a)

Never remove warning label attached to top of battery.
Failure to read and understand all precautions contained
in warning, could result in death or serious injury. (00064a)

Batteries, battery posts, terminals and related accessories
contain lead and lead compounds, and other chemicals
known to the State of California to cause cancer, and birth
defects or other reproductive harm. Wash hands after
handling. (00019e)

All AGM batteries are permanently sealed, maintenance-free,
valve-regulated, lead/calcium and sulfuric acid batteries. The
batteries are shipped pre-charged and ready to be put into
service. Do not attempt to open these batteries for any reason.

NOTE

For charging information, see 1.23 BATTERY MAINTENANCE,

Charging Battery. For testing information, see the electrical

diagnostic manual.

Figure 1-39. AGM Battery with Warning Label

4.1. Keep flames awayContents are corrosive

2. 5.Wear safety glasses Read instructions

6.3. Keep away from childrenContents are explosive

Figure 1-40. Battery Warning label

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Table 1-19. Antidotes for Battery Acid

TREATMENTCONTACT

Flush with water.External

Internal

Eyes

Drink large quantities of milk or water, followed
by milk of magnesia, vegetable oil or beaten
eggs. Get immediate medical attention.

Flush with water. Get immediate medical
attention.

CLEANING AND INSPECTION

1. Battery top must be clean and dry. Dirt and electrolyte on
top of the battery can cause battery to self-discharge.
Clean battery top with a solution of baking soda (sodium
bicarbonate) and water (5 teaspoons baking soda per
quart or liter of water). When the solution stops bubbling,
rinse off the battery with clean water.

2. Clean cable connectors and battery terminals using a wire
brush or sandpaper. Remove any oxidation.

3. Inspect the battery screws, clamps and cables for
breakage, loose connections and corrosion. Clean clamps.

4. Check the battery posts for melting or damage caused by
overtightening.

5. Inspect the battery for discoloration, raised top or a warped
or distorted case, which might indicate that the battery has
been frozen, overheated or overcharged.

6. Inspect the battery case for cracks or leaks.

9. Grasp lifting strap (2) and pull up to raise battery. When
battery is extracted far enough to get a good grip, grasp
battery and remove the rest of the way.

1. Purge solenoid

2. HFSM antenna

3. Cable ties

4. Fastener

5. Hold-down (not visible)

Figure 1-41. Top Caddy

BATTERY

Disconnection and Removal

1. Remove seat.

2. See Figure 1-41. If present, move purge solenoid (1) for­ward to release from top caddy. Release HFSM antenna
(2) from top caddy and move out of the way.

3. Remove fasteners (4).

4. Cut cable ties (3) and move harnesses to allow more
clearance for the top caddy.

5. See Figure 1-42. Release top caddy from front hold-down
bracket and rotate top caddy (1) out of the way.

6. If equipped with security system siren, turn the ignition
switch ON with the hands-free fob present to disarm the
security system.

Disconnect negative (-) battery cable first. If positive (+)
cable should contact ground with negative (-) cable con­nected, the resulting sparks can cause a battery explosion,
which could result in death or serious injury. (00049a)

7. Remove battery negative cable (black) from the battery
negative (-) terminal.

8. Remove battery positive cable (red) from the battery pos­itive (+) terminal.

1. Top caddy

2. Lifting strap

Figure 1-42. Move Top Caddy Aside

Installation and Connection

1. Run lifting strap rearward, first down the center of the
battery tray, then up and across the frame crossmember.

2. Place the battery into the battery tray, terminal side for­ward.

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Connect the cables to the correct battery terminals. Failure
to do so could result in damage to the motorcycle electrical
system. (00215a)

Connect positive (+) battery cable first. If positive (+) cable
should contact ground with negative (-) cable connected,
the resulting sparks can cause a battery explosion, which
could result in death or serious injury. (00068a)

Do not over-tighten bolts on battery terminals. Use
recommended torque values. Over-tightening battery ter­minal bolts could result in damage to battery terminals.
(00216a)

3. Connect battery positive cable (red) to battery positive (+)

terminal. Tighten bolt to 60-70 in-lbs (6.8-7.9 Nm).

4. Connect battery negative cable (black) to battery negative

(-) terminal. Tighten bolt to 60-70 in-lbs (6.8-7.9 Nm).

VOLTMETER TEST

Batteries contain sulfuric acid, which could cause severe
burns to eyes and skin. Wear a protective face shield,
rubberized gloves and protective clothing when working
with batteries. KEEP BATTERIES AWAY FROM CHILDREN.
(00063a)

Never remove warning label attached to top of battery.
Failure to read and understand all precautions contained
in warning, could result in death or serious injury. (00064a)

Voltmeter Test

The voltmeter test provides a general indicator of battery con­dition. Check the voltage of the battery to verify that it is fully
charged. If the open circuit (disconnected) voltage reading is
below 12.6V, charge the battery and check the voltage after
the battery has set for one to two hours. If the voltage reading
is 12.7V or above, perform a load test. See the electrical dia­gnostic manual for the load test procedure. Refer to Table 1-20.

Keep battery clean and lightly coat terminals with petro­leum jelly to prevent corrosion. Failure to do so could
result in damage to battery terminals. (00217a)

5. Apply a light coat of petroleum jelly or ELECTRICAL
CONTACT LUBRICANT, (Part No. 99861-02) (1 oz tube),
to both battery terminals.

6. See Figure 1-42. Fold lifting strap (2) forward over top of
battery.

7. See Figure 1-41. Rotate top caddy into position above
battery and engage latch on hold-down bracket.

8. If equipped, engage HFSM antenna (2) and purge solenoid
(1) on top caddy. Verify all other connectors and harnesses
are routed below the purge solenoid mounting tongue.

9. Fasten top caddy to frame crossmember. Tighten screws
(4) to 72-96 in-lbs (8.1-10.9 Nm).

10. Secure harnesses to frame with cable ties (3).

After installing seat, pull upward on seat to be sure it is
locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or
serious injury. (00070b)

11. Install seat.

Table 1-20. Voltmeter Test For Battery Charge Conditions

STATE OF CHARGEVOLTAGE (OCV)

100%12.7 V

75%12.6 V

50%12.3 V

25%12.0 V

0%11.8 V

CHARGING BATTERY

Safety Precautions

Never charge a battery without first reviewing the instructions
for the charger being used. In addition to the manufacturer's
instructions, follow these general safety precautions:

• Always wear eye, face and hand protection.

• Always charge batteries in a well-ventilated area.

• Turn the charger off before connecting or disconnecting
the leads to the battery to avoid dangerous sparks.

• Never try to charge a visibly damaged or frozen battery.

• Connect the charger leads to the battery; red positive (+)
lead to the positive (+) terminal and black negative (-) lead
to the negative (-) terminal. If the battery is still in the
vehicle, connect the negative lead to the chassis ground.
Be sure that the ignition and all electrical accessories are
turned off.

• Make sure that the charger leads to the battery are not
separated, frayed or loose.

• If the battery temperature exceeds 110 °F (43 °C) during
charging, discontinue charger and allow the battery to
cool.

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Using a Battery Charger

Charge the battery if any of the following conditions exist:

• Vehicle lights appear dim.

• Electric starter sounds weak.

• Battery has not been used for an extended period of time.

Explosive hydrogen gas, which escapes during charging,
could cause death or serious injury. Charge battery in a
well-ventilated area. Keep open flames, electrical sparks
and smoking materials away from battery at all times.
KEEP BATTERIES AWAY FROM CHILDREN. (00065a)

Table 1-21. 28 Amp-Hour Battery Charging Rate/Times (Approximate)

If battery releases an excessive amount of gas during
charging, decrease the charging rate. Overheating can
result in plate distortion, internal shorting, drying out or
damage. (00413b)

1. Perform a voltmeter test to determine the state of charge.
See the electrical diagnostic manual. If battery needs to
be charged, proceed to the next step.

NOTE

The figures listed in the table below show typical charging
times. Charge times may vary. When using an appropriate
automatic charger, allow the charger to determine when char­ging is complete.

READING

(VOLTS)

Do not use battery chargers that produce excessively high
voltage designed for flooded batteries or excessively high
current designed for much larger batteries. Charging should
be limited to no more than 5 amps at no more than 14.6 volts.

Unplug or turn OFF battery charger before connecting
charger cables to battery. Connecting cables with charger
ON can cause a spark and battery explosion, which could
result in death or serious injury. (00066a)

Do not reverse the charger connections described in the
following steps or the charging system of the motorcycle
could be damaged. (00214a)

2. Connect red battery charger lead to the positive (+) ter­minal and black battery charger lead to the negative (-)
terminal of the battery.

PERCENT

OF CHARGE

NOTE

5 AMP

CHARGER

2 AMP

CHARGER

Unplug or turn OFF battery charger before disconnecting
charger cables from battery. Disconnecting clamps with
charger ON can cause a spark and battery explosion, which
could result in death or serious injury. (00067a)

4. After the battery is fully charged, turn the charger OFF
and disconnect the black battery charger lead to the neg­ative (-) terminal of the battery.

5. Disconnect the red battery charger lead to the positive (+)
terminal of the battery.

6. Mark the charging date on the battery.

7. Perform either a conductance test or load test to determine
the condition of the battery. See the electrical diagnostic
manual.

8. If charging a battery because voltmeter test reading was
below 12.6 V, perform voltmeter test. See the electrical
diagnostic manual.

1.5 AMP

CHARGER

0.75 AMP

CHARGER

----10012.7

10 hours 18 minutes5 hours 42 minutes4 hours 30 minutes2 hours 24 minutes7512.6

19 hours 42 minutes10 hours 18 minutes8 hours3 hours 48 minutes5012.3

29 hours15 hours11 hours 30 minutes5 hours 12 minutes2512.0

38 hours 18 minutes19 hours 42 minutes15 hours6 hours 36 minutes011.8

NOTE
If the battery is still in the vehicle, connect the negative lead
to the chassis ground. Be sure that the ignition and all electrical
accessories are turned off.

3. Step away from the battery and turn on the charger. Refer

to Table 1-21.

1-56 2011 Touring Service: Maintenance

3 6 9 12 15

50%

75%

100%

0

¡

¡

105 °F

(40.5 °C)

77 °F (25 °C)

1

2

sm02838

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STORAGE

TOOL NAMEPART NUMBER

GLOBAL BATTERY CHARGER99863-01A

Batteries contain sulfuric acid, which could cause severe
burns to eyes and skin. Wear a protective face shield,
rubberized gloves and protective clothing when working
with batteries. KEEP BATTERIES AWAY FROM CHILDREN.
(00063a)

If the motorcycle is to be stored with the security system armed,
connect a GLOBAL BATTERY CHARGER (Part No. 99863­01A) to maintain battery charge.

If the motorcycle is to be stored with the battery installed,
without a GLOBAL BATTERY CHARGER, and with the security
system not armed, remove the main fuse.

If the motorcycle will not be operated for several months, such
as during the winter season, remove the battery from the
motorcycle and fully charge.

See Figure 1-43. A battery that is removed from the vehicle is
affected by self-discharge. A battery that is stored in the vehicle
is affected by self-discharge and, more significantly, by parasitic
loads. A parasitic load is generated by such things as diode
leakage or maintaining computer memory with the vehicle
turned off. Batteries self-discharge at a faster rate at higher
ambient temperatures. To reduce the self-discharge rate, store
battery in a cool, dry place.

Charge the battery once per month if stored in the vehicle.
Charge the battery every three months if stored out of the
vehicle.

NOTES

•

The GLOBAL BATTERY CHARGER (Part No. 99863-01A)
may be used to maintain battery charge for extended
periods of time without risk of overcharging or boiling.

•

When returning a battery to service after storage, see the
electrical diagnostic manual.

1. Capacity

2. Months of non-use

Figure 1-43. Battery Self-Discharge Rate

2011 Touring Service: Maintenance 1-57

2

1

4

3

sm05710

sm05739

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INSPECTION

General

Inspect the condition and tightness of the stabilizer links and
engine mounts. Replace fasteners if damaged. To properly
check fastener torque, see information in 1.22 CRITICAL

FASTENERS

Stabilizer Link

1. See Figure 1-44. Check top stabilizer link eyelet to frame

weldment bolt (1): 18-22 ft-lbs (24.4-29.9 Nm).

2. Check top stabilizer link eyelet to top engine mounting

bracket bolt (2): 18-22 ft-lbs (24.4-29.9 Nm).

3. Check for lateral movement at each end of the stabilizer

link. Any lateral movement indicates the need to replace
the stabilizer link. Rotational movement does not indicate
excess wear.

Front Engine Mount

1. See Figure 1-44. Check two engine to front engine

mounting bracket bolts (3): 36-40 ft-lbs (49-54 Nm).

2. Check three front engine mount end cap bolts (4): 42-48

ft-lbs (56.9-65.0 Nm).

1.24ENGINE MOUNTS

Rear Frame Fasteners

See Figure 1-45. Check three fasteners on each side that
attach the rear frame to the main frame. The correct torque is
40-50 ft-lbs (54.2-67.8 Nm).

1. Link-to-frame weldment fastener

2. Link-to-engine mounting bracket fastener

3. Engine mount fastener (2)

4. Engine mount end cap fastener

Figure 1-44. Front Mount and Stabilizer

1-58 2011 Touring Service: Maintenance

Figure 1-45. Rear Frame Fasteners

HOME

1.25STORAGE

GENERAL

If the motorcycle will not be operated for several months, such
as during the winter season, there are several things which
should be done to protect parts against corrosion, to preserve
the battery and to prevent the buildup of gum and varnish in
the fuel system.

This work should be performed following service manual pro­cedures.

PLACING IN STORAGE

TOOL NAMEPART NUMBER

STORAGE COVER98716-87A

Do not store motorcycle with gasoline in tank within the
home or garage where open flames, pilot lights, sparks or
electric motors are present. Gasoline is extremely flam­mable and highly explosive, which could result in death
or serious injury. (00003a)

Avoid spills. Slowly remove filler cap. Do not fill above
bottom of filler neck insert, leaving air space for fuel
expansion. Secure filler cap after refueling. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00028a)

9. Check tire inflation and inspect tires for wear and/or
damage. See 1.8 TIRES AND WHEELS. If the motorcycle
will be stored for an extended period of time, securely
support the motorcycle under the frame so that all weight
is off the tires.

10. Wash painted and chrome-plated surfaces. Apply a light
film of oil to exposed unpainted surfaces.

Unplug or turn OFF battery charger before connecting
charger cables to battery. Connecting cables with charger
ON can cause a spark and battery explosion, which could
result in death or serious injury. (00066a)

Explosive hydrogen gas, which escapes during charging,
could cause death or serious injury. Charge battery in a
well-ventilated area. Keep open flames, electrical sparks
and smoking materials away from battery at all times.
KEEP BATTERIES AWAY FROM CHILDREN. (00065a)

11. Remove the battery from the vehicle. Charge the battery
until the correct voltage is obtained. Charge the battery
every other month if it is stored at temperatures below 60
°F (16 °C). Charge battery once a month if it is stored at
temperatures above 60 °F (16 °C). See 1.23 BATTERY

MAINTENANCE.

Use care when refueling. Pressurized air in fuel tank can
force gasoline to escape through filler tube. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00029a)

1. Prepare the fuel system by filling fuel tank and adding a
gasoline stabilizer. Use one of the commercially available
gasoline stabilizers following the manufacturer's instruc­tions.

2. Run motorcycle until engine is at normal operating temper­ature. Stop the engine and change the engine oil and filter.
Check the transmission lubricant level.

3. Remove the spark plugs, inject a few squirts of engine oil
into each cylinder and crank the engine 5-6 revolutions.
Install spark plugs.

4. Inspect drive belt deflection. See 1.12 DRIVE BELT AND

SPROCKETS.

5. Inspect drive belt and sprockets.

6. Inspect air cleaner filter. See 1.7 AIR CLEANER AND

EXHAUST SYSTEM.

7. Lubricate controls. See 1.14 CABLE AND CHASSIS

LUBRICATION.

8. Inspect operation of all electrical equipment and switches.

Unplug or turn OFF battery charger before disconnecting
charger cables from battery. Disconnecting clamps with
charger ON can cause a spark and battery explosion, which
could result in death or serious injury. (00067a)

12. If the motorcycle is to be covered, use a material that will
breathe, such as STORAGE COVER (Part No. 98716­87A) or light canvas. Plastic materials that do not breathe
promote the formation of condensation, which leads to
corrosion.

REMOVAL FROM STORAGE

The clutch failing to disengage can cause loss of control,
which could result in death or serious injury. Prior to
starting after extended periods of storage, place transmis­sion in gear and push vehicle back and forth several times
to assure proper clutch disengagement. (00075a)

1. Charge and install the battery.

2. Remove and inspect the spark plugs. Replace if neces­sary.

3. Clean the air cleaner element.

4. If fuel tank was drained, fill fuel tank with fresh gasoline.

5. Start the engine and run until it reaches normal operating
temperature.

2011 Touring Service: Maintenance 1-59

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6. Check engine oil level. Check the transmission lubricant
level. Fill to proper levels with correct fluids, if required.

7. Perform all of the checks in the PRE-RIDING CHECKLIST
in the owner's manual.

1-60 2011 Touring Service: Maintenance

HOME

1.26TROUBLESHOOTING

GENERAL

The Troubleshooting section of this manual is a guide to
diagnose problems. Read the appropriate sections of this
manual before performing any work. Improper repair and/or
maintenance could result in death or serious injury.
(00528b)

The following check list of possible operating troubles and their
probable causes will be helpful in keeping a motorcycle in good
operating condition. More than one of these conditions may
be causing the trouble and all should be carefully checked.

NOTE

For further troubleshooting information, see the electrical dia­gnostic manual.

ENGINE

Starter Motor Does Not Operate or Does Not
Turn Engine Over

1. Ignition switch not in IGNITION position.

2. Engine run switch in OFF position.

3. Discharged battery, loose or corroded connections
(solenoid chatters).

4. Starter control circuit, relay, or solenoid faulty.

5. Electric starter shaft pinion gear not engaging or overrun­ning clutch slipping.

6. TSM/TSSM/HFSM Bank Angle Sensor tripped and igni­tion/light key switch not cycled OFF then back to IGNI­TION.

7. Security system activated.

8. Motorcycle in gear and clutch not pulled in.

9. Jiffy stand down and transmission in gear (HDI models
only).

10. Main fuse not in place.

Engine Turns Over But Does Not Start

1. Fuel tank empty.

2. Fouled spark plugs.

3. Discharged battery, loose or damaged battery terminal
connections.

4. Engine lubricant too heavy (winter operation).

NOTE

For cold weather starts, always disengage clutch.

5. Spark plug cables in bad condition and shorting, cable
connections loose or cables connected to incorrect cylin­ders.

6. Damaged wire or loose wire connection at ignition coil,
battery, or ECM connector.

7. Ignition timing incorrect due to faulty ignition coil, ECM or
sensors.

8. Bank Angle Sensor tripped and ignition switch not cycled
OFF then back to IGNITION.

9. Fuel filter clogged.

10. Sticking or damaged valve(s) or wrong length push rod(s).

11. Plugged fuel injectors.

Starts Hard

1. Spark plugs in bad condition or have improper gap or are
partially fouled.

2. Spark plug cables in poor condition.

3. Battery nearly discharged.

4. Damaged wire or loose wire connection at one of the bat­tery terminals, ignition coil or ECM connector.

5. Water or dirt in fuel system.

6. Intake air leak.

7. Fuel tank vent hose, filler cap vent or vapor valve plugged,
or fuel line closed off, restricting fuel flow.

8. Engine lubricant too heavy (winter operation).

NOTE

For cold weather starts, always disengage clutch.

9. Ignition not functioning properly (possible sensor failure).

10. Faulty ignition coil.

11. Valves sticking.

12. Partially plugged fuel injector(s).

Starts But Runs Irregularly or Misses

1. Spark plugs in poor condition or partially fouled.

2. Spark plug cables in poor condition and shorting or leaking.

3. Spark plug gap too close or too wide.

4. Faulty ignition coil, ECM, or sensor.

5. Battery nearly discharged.

6. Damaged wire or loose connection at battery terminals,
ignition coil or ECM connector.

7. Intermittent short circuit due to damaged wire insulation.

8. Water or dirt in fuel system.

9. Fuel tank vent system plugged.

10. Air leak at intake manifold or air cleaner.

11. Loose or dirty ECM connector.

12. Faulty Sensor(s): Temperature Manifold Absolute Pressure
(TMAP), Crank Position (CKP) or Oxygen (O2).

13. Incorrect valve timing.

14. Weak or damaged valve springs.

2011 Touring Service: Maintenance 1-61

HOME

15. Damaged intake or exhaust valve.

16. Partially plugged fuel injector(s).

A Spark Plug Fouls Repeatedly

1. Fuel mixture too rich.

2. Incorrect spark plug for the kind of service.

3. Piston rings badly worn or damaged.

4. Valve guides or seals badly worn.

Pre-Ignition or Detonation (Knocks or Pings)

1. Fuel octane rating too low.

2. Faulty spark plugs.

3. Incorrect spark plug for the kind of service.

4. Excessive carbon deposit on piston head or in combustion
chamber.

5. Ignition timing advanced due to faulty sensor inputs (TMAP
and/or CKP).

6. Ignition timing advanced due to ECM or sensors (CKP,
ET or TMAP) defective.

7. Intake manifold vacuum leak.

Overheating

1. Insufficient oil supply or oil not circulating.

2. Insufficient air flow over engine.

3. Heavy carbon deposits.

4. Ignition timing retarded due to defective ECM or faulty
sensor(s) (TMAP and/or CKP).

5. Leaking valve(s).

Valve Train Noise

1. Low oil pressure caused by oil feed pump not functioning
properly or oil passages obstructed.

2. Faulty hydraulic lifter(s).

3. Bent push rod(s).

4. Incorrect push rod length.

5. Rocker arm binding on shaft.

6. Valve sticking in guide.

7. Chain tensioning spring or shoe worn.

8. Cam(s), cam gear(s) or cam bushing(s) worn.

9. Cam timing incorrect.

Excessive Vibration

1. Wheels bent or damaged and/or tires worn or damaged.

2. Engine/Transmission/Rear Wheel not aligned properly.

3. Primary chain badly worn or links tight as a result of
insufficient lubrication or misalignment.

4. Engine to transmission mounting bolts loose.

5. Upper engine mounting bracket loose/damaged or
mounting bracket pre-loaded.

6. Ignition timing advanced due to faulty sensor inputs (TMAP
and/or CKP)/poorly tuned engine.

7. Internal engine problem.

8. Damaged frame.

9. Stabilizer links worn or loose, or stabilizer link brackets
loose or damaged.

10. Rubber mount (front) snubbers not centered and con­tacting side of mount.

11. Rubber mounts (front or rear) loose or worn.

12. Rear fork pivot shaft fasteners loose.

13. Front engine mount bracket bolts loose.

14. Exhaust system binding and causing unnecessary side
loads.

Check Engine Light Illuminates During
Operation

Fault detected. See the electrical diagnostic manual for more
information.

LUBRICATION SYSTEM

Oil Does Not Return To Oil Reservoir

1. Oil reservoir empty.

2. Oil pump not functioning.

3. Restricted oil lines or fittings.

4. Restricted oil filter.

5. O-ring damaged or missing from oil pump/crankcase
junction (also results in poor engine performance).

Engine Uses Too Much Oil Or Smokes
Excessively

1. Oil reservoir overfilled.

2. Restricted oil return line to oil reservoir.

3. Restricted breather operation.

4. Restricted oil filter.

5. Oil pump misaligned or in poor condition.

6. Piston rings badly worn or broken.

7. Valve guides or seals worn or damaged.

8. O-ring damaged or missing from oil pump/crankcase
junction (also results in poor engine performance).

9. Plugged crankcase scavenge port.

10. Oil diluted with gasoline.

Engine Leaks Oil From Cases, Push Rods,
Hoses, Etc.

1. Loose parts.

2. Imperfect seal at gaskets, push rod covers, washers, etc.

1-62 2011 Touring Service: Maintenance

HOME

3. Restricted breather passages or hose to air cleaner.

4. Restricted oil filter.

5. Oil reservoir overfilled.

6. Lower rocker housing gasket installed incorrectly (upside
down).

7. Restricted oil return line to oil reservoir.

8. Porosity.

Low Oil Pressure

1. Oil reservoir underfilled.

2. Faulty low oil pressure switch.

3. Oil pump O-ring damaged or missing.

4. Bypass valve stuck in open position.

5. Ball missing or leaking in cam support plate.

6. Worn oil pump gerotor(s).

7. Oil diluted with gasoline.

High Oil Pressure

1. Oil reservoir overfilled.

2. Bypass valve stuck in closed position.

ELECTRICAL SYSTEM

NOTE

For diagnostic information see the electrical diagnostic manual.

Alternator Does Not Charge

1. Voltage regulator module not grounded.

2. Engine ground wire loose or damaged.

3. Faulty voltage regulator module.

4. Loose or damaged wires in charging circuit.

5. Faulty stator and/or rotor.

Alternator Charge Rate Is Below Normal

1. Weak or damaged battery.

2. Loose connections.

3. Faulty voltage regulator module.

4. Faulty stator and/or rotor.

Speedometer Operates Erratically

1. Contaminated vehicle speed sensor (remove sensor and
clean off metal particles).

2. Loose connections.

TRANSMISSION

Shifts Hard

1. Primary chaincase overfilled with lubricant.

2. Clutch not fully disengaging.

3. Transmission lubricant too heavy (winter operation).

4. Shifter return spring (inside transmission) bent or broken.

5. Bent shifter rod.

6. Shifter forks (inside transmission) sprung.

7. Corners worn off shifter clutch dog rings (inside transmis­sion).

Jumps Out Of Gear

1. Shifter rod improperly adjusted.

2. Shifter drum (inside transmission) improperly adjusted or
damaged/worn.

3. Shifter engaging parts (inside transmission) badly worn
and rounded.

4. Shifter forks bent.

5. Damaged gears.

Clutch Slips

1. Clutch controls improperly adjusted.

2. Insufficient clutch spring tension.

3. Worn friction discs.

Clutch Drags Or Does Not Release

1. Lubricant level too high in primary chaincase.

2. Clutch controls improperly adjusted.

3. Primary chain badly misaligned or too tight.

4. Insufficient clutch spring tension.

5. Clutch discs warped.

Clutch Chatters

Friction discs or steel discs worn or warped.

HANDLING

Irregularities

1. Improperly loaded motorcycle. Non-standard equipment
on the front end such as heavy radio receivers, extra
lighting equipment or luggage tends to cause unstable
handling.

2. Damaged tire(s) or improper front-rear tire combination.

3. Irregular or peaked front tire tread wear.

4. Incorrect tire pressure.

5. Shock absorber not functioning normally.

6. Incorrect air suspension pressure.

7. Loose wheel axle nuts. Tighten to recommended torque
specification.

8. Excessive wheel hub bearing play.

9. Rear wheel out of alignment with frame and front wheel.

10. Steering head bearings improperly adjusted. Correct
adjustment and replace pitted or worn bearings and races.

11. Loose spokes (laced wheel vehicles only).

12. Tire and wheel unbalanced.

2011 Touring Service: Maintenance 1-63

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13. Rims and tires out-of-round or eccentric with hub.

14. Rims and tires out-of-true sideways.

15. Rear fork pivot assembly: improperly tightened or
assembled, or loose/pitted or damaged pivot bearings.

16. Engine mounts and/or stabilizer links loose, worn or
damaged.

BRAKES

Brake Does Not Hold Normally

1. Brake fluid reservoir low, system leaking or pads worn.

2. Brake system contains air bubbles.

3. Master cylinder/caliper piston seals worn or parts dam­aged.

4. Brake pads contaminated with grease or oil.

5. Brake pads badly worn.

6. Brake disc badly worn or warped.

7. Brake drags - insufficient brake pedal or hand lever free­play, caliper piston worn or damaged, or excessive brake
fluid in reservoir.

8. Brake fades due to heat build up - brake pads dragging
or excessive braking.

9. Brake fluid leak when under pressure.

1-64 2011 Touring Service: Maintenance

TABLE OF CONTENTS

SUBJECT............................................................................................................................PAGE NO.

2.1 FASTENER TORQUE VALUES.................................................................................................2-1

2.2 SPECIFICATIONS.....................................................................................................................2-6

2.3 VEHICLE IDENTIFICATION NUMBER (V.I.N.)..........................................................................2-9

2.4 FRONT WHEEL.......................................................................................................................2-11

2.5 REAR WHEEL.........................................................................................................................2-14

2.6 REAR WHEEL COMPENSATOR............................................................................................2-18

2.7 WHEEL LACING: FRONT RIM................................................................................................2-21

2.8 WHEEL LACING: 16 INCH REAR RIM...................................................................................2-23

2.9 CHECKING AND TRUING WHEELS......................................................................................2-26

2.10 SEALED WHEEL BEARINGS...............................................................................................2-30

2.11 TIRES.....................................................................................................................................2-33

2.12 FRONT BRAKE MASTER CYLINDER..................................................................................2-37

2.13 FRONT BRAKE CALIPER.....................................................................................................2-42

2.14 REAR BRAKE MASTER CYLINDER.....................................................................................2-43

2.15 REAR BRAKE CALIPER.......................................................................................................2-49

2.16 BLEEDING BRAKES.............................................................................................................2-50

2.17 FRONT FORK........................................................................................................................2-52

2.18 STEERING HEAD BEARINGS..............................................................................................2-58

2.19 REAR AIR SUSPENSION.....................................................................................................2-61

2.20 REAR SHOCK ABSORBERS................................................................................................2-63

2.21 REAR FORK..........................................................................................................................2-64

2.22 CLUTCH CABLE....................................................................................................................2-67

2.23 HANDLEBARS.......................................................................................................................2-70

2.24 MIRRORS..............................................................................................................................2-75

2.25 SEAT......................................................................................................................................2-76

2.26 SADDLEBAGS.......................................................................................................................2-79

2.27 SADDLEBAG SERVICE........................................................................................................2-80

2.28 TOUR-PAK.............................................................................................................................2-83

2.29 TOUR-PAK SERVICE............................................................................................................2-85

2.30 TOUR-PAK LIGHTS...............................................................................................................2-88

2.31 TOUR-PAK BACKREST........................................................................................................2-91

2.32 TOUR-PAK SPEAKER BOX..................................................................................................2-93

2.33 LOWER FAIRING AND ENGINE GUARD.............................................................................2-94

2.34 UPPER FAIRING AND WINDSHIELD: FORK MOUNTED FAIRING MODELS....................2-97

2.35 FAIRING CAP: FORK MOUNTED FAIRING MODELS.........................................................2-98

2.36 INNER FAIRING: FORK MOUNTED FAIRING MODELS......................................................2-99

2.37 AIR DEFLECTORS..............................................................................................................2-103

2.38 UPPER FAIRING AND WINDSHIELD: FRAME MOUNTED FAIRING MODELS...............2-104

2.39 INSTRUMENT BEZEL: FRAME MOUNTED FAIRING MODELS........................................2-107

2.40 INSTRUMENT NACELLE: FRAME MOUNTED FAIRING MODELS..................................2-109

2.41 INNER FAIRING: FRAME MOUNTED FAIRING MODELS.................................................2-111

2.42 GLOVE BOX DOOR AND HINGE: FRAME MOUNTED FAIRING MODELS......................2-115

2.43 WINDSHIELD: ROAD KING MODELS................................................................................2-116

2.44 HEADLAMP NACELLE: ROAD KING MODELS.................................................................2-119

2.45 FRONT FENDER.................................................................................................................2-121

2.46 REAR FENDER...................................................................................................................2-122

2.47 REAR FASCIA.....................................................................................................................2-125

2.48 REAR FRAME.....................................................................................................................2-126

2.49 FOOTBOARDS AND FOOTRESTS....................................................................................2-128

2.50 JIFFY STAND.......................................................................................................................2-131

2.51 FRONT ENGINE MOUNT....................................................................................................2-134

CHASSIS

NOTES

HOME

FASTENER TORQUE VALUES IN THIS CHAPTER

The table below lists torque values for all fasteners presented
in this chapter.

screws (FLHT/C/U)

screw

screw

2.1FASTENER TORQUE VALUES

NOTESTORQUE VALUEFASTENER

1.1-2.3 Nm10-20 in-lbs2 inch diameter gauge nuts

4.5-5.6 Nm40-50 in-lbsAir valve mount hex nut

20-27 Nm15-20 ft-lbsAuxiliary lamp bracket to fork bracket

23.1-25.8 Nm17-19 ft-lbsBanjo bleeder bolt to front caliper

16.9-19.7 Nm12.5-14.5 ft-lbsBanjo bolt to front master cylinder

16.9-19.7 Nm12.5-14.5 ft-lbsBanjo bolt to front master cylinder

23.1-25.8 Nm17-19 ft-lbsBanjo bolt to rear caliper

16.9-19.7 Nm12.5-14.5 ft-lbsBanjo bolt to rear master cylinder

16.9-19.7 Nm12.5-14.5 ft-lbsBanjo bolt to rear master cylinder

21.7-32.5 Nm16-24 ft-lbsBrake disc (front) screws

41-61 Nm30-45 ft-lbsBrake disc (rear) screws

9.0-11.3 Nm80-100 in-lbsBrake light switch bracket fastener

13.6-20.3 Nm120-180 in-lbsBrake line bracket-to-lower fork bracket

20.3-27.1 Nm15-20 ft-lbsBrake pedal shaft locknut

20.3-27.1 Nm15-20 ft-lbsBrake pedal shaft locknut

20.3-27.1 Nm15-20 ft-lbsEngine guard screws

2.36 INNER FAIRING: FORK MOUNTED FAIRING
MODELS, Installation

2.37 AIR DEFLECTORS, Mid-Frame Air Deflectors2.8-4.0 Nm25-35 in-lbsAir deflector bolts

2.37 AIR DEFLECTORS, Air Deflectors2.8-3.4 Nm25-30 in-lbsAir deflector screws

2.19 REAR AIR SUSPENSION, Check for Air
Leaks

2.36 INNER FAIRING: FORK MOUNTED FAIRING
MODELS, Installation

2.12 FRONT BRAKE MASTER CYLINDER, Front
Brake Line: Non-ABS Equipped

2.13 FRONT BRAKE CALIPER, Installation23.1-25.8 Nm17-19 ft-lbsBanjo bleeder bolt to front caliper

2.12 FRONT BRAKE MASTER CYL­INDER, Assembly and Installation

2.12 FRONT BRAKE MASTER CYLINDER, Front
Brake Line: Non-ABS Equipped

2.14 REAR BRAKE MASTER CYLINDER, Rear
Brake Line: Non-ABS Equipped

2.15 REAR BRAKE CALIPER, Installation23.1-25.8 Nm17-19 ft-lbsBanjo bolt to rear caliper

2.14 REAR BRAKE MASTER CYL­INDER, Assembly and Installation

2.14 REAR BRAKE MASTER CYLINDER, Rear
Brake Line: Non-ABS Equipped

2.48 REAR FRAME, Rear Frame8.1-10.8 Nm72-96 in-lbsBattery tray screws

2.13 FRONT BRAKE CALIPER, Installation/metric37.9-51.5 Nm28-38 ft-lbsBrake caliper (front) mounting screws

2.5 REAR WHEEL, Installation/metric58.3-65.1 Nm43-48 ft-lbsBrake caliper (rear) mounting screws

2.15 REAR BRAKE CALIPER, Installation/metric58.3-65.1 Nm43-48 ft-lbsBrake caliper (rear) mounting screws

2.16 BLEEDING BRAKES, Procedure9.0-11.3 Nm80-100 in-lbsBrake caliper bleeder valve

2.4 FRONT WHEEL, Installation/Always use new
screws

2.5 REAR WHEEL, Installation/Always use new
screws

2.14 REAR BRAKE MASTER CYLINDER, Rear
Brake Line: Non-ABS Equipped

2.12 FRONT BRAKE MASTER CYLINDER, Front
Brake Line: Non-ABS Equipped

2.18 STEERING HEAD BEARINGS, Installation13.6-20.3 Nm120-180 in-lbsBrake line bracket-to-lower fork bracket

2.14 REAR BRAKE MASTER CYL­INDER, Assembly and Installation

2.14 REAR BRAKE MASTER CYLINDER, Rear
Brake Line: Non-ABS Equipped

2.33 LOWER FAIRING AND ENGINE
GUARD, Engine Guard

2011 Touring Service: Chassis 2-1

HOME

(frame mounted fairing)

FLHTC/U)

FLHTC/U)

screws

mounted fairing

screws

screws

screws

strip flange nut

shroud screws

shroud screws

acorn nuts

NOTESTORQUE VALUEFASTENER

2.51 FRONT ENGINE MOUNT, Installation48.8-54.2 Nm36-40 ft-lbsEngine mount bracket fasteners

2.51 FRONT ENGINE MOUNT, Installation56.9-65.0 Nm42-48 ft-lbsEngine mount end cap fasteners

27.1-40.7 Nm20-30 ft-lbsFairing bracket-to-steering head locknuts

2.8-3.4 Nm25-30 in-lbsFairing cap screws

2.5-3.2 Nm22-28 in-lbsFairing speaker lower screw (FLHX,

4.0-5.7 Nm35-50 in-lbsFairing speaker upper screws (FLHX,

6.8-9.5 Nm60-84 in-lbsFront turn signal lamp acorn nuts, frame

43.4-48.8 Nm32-36 ft-lbsGuard to frame screws

8.1-12.2 Nm72-108 in-lbsHandlebar clamp to master cylinder

1.0-2.0 Nm9-18 in-lbsHeadlamp housing screws

1.0-2.0 Nm9-18 in-lbsHeadlamp housing screws

1.7-2.3 Nm15-20 in-lbsHeadlamp nacelle handlebar chrome

1.1-2.3 Nm10-20 in-lbsHeadlamp nacelle handlebar clamp

1.1-2.3 Nm10-20 in-lbsHeadlamp nacelle handlebar clamp

8.1-12.2 Nm72-108 in-lbsHeadlamp nacelle to fork bracket stud

2.41 INNER FAIRING: FRAME MOUNTED
FAIRING MODELS, Installation

2.35 FAIRING CAP: FORK MOUNTED FAIRING
MODELS, Fairing Cap

2.36 INNER FAIRING: FORK MOUNTED FAIRING
MODELS, Installation

2.36 INNER FAIRING: FORK MOUNTED FAIRING
MODELS, Installation

2.17 FRONT FORK, Installation71.9-77.3 Nm53-57 ft-lbsFork bracket pinch bolt

2.17 FRONT FORK, Installation81.4-94.9 Nm60-70 ft-lbsFork cap bolt

2.17 FRONT FORK, Assembly14.9-24.4 Nm132-216 in-lbsFork damper tube screw (metric)

2.17 FRONT FORK, Changing Fork Oil8-11 Nm72-96 in-lbsFork oil drain plug

2.17 FRONT FORK, Changing Fork Oil81.4-94.9 Nm60-70 ft-lbsFork tube plug

2.28 TOUR-PAK, Luggage Rack/Tour-Pak Support20.3-27.1 Nm15-20 ft lbsFrame cover fastener, rear

2.46 REAR FENDER, Installation20.3-27.1 Nm15-20 ft-lbsFrame cover fastener, rear

2.4 FRONT WHEEL, Installation/metric14.9-20.3 Nm132-180 in-lbsFront axle holder nuts

2.4 FRONT WHEEL, Installation/metric81.4-88.1 Nm60-65 ft-lbsFront axle nut

2.51 FRONT ENGINE MOUNT, Installation54.2-67.8 Nm40-50 ft-lbsFront engine mount fasteners

2.45 FRONT FENDER, Installation22-27 Nm16-20 ft-lbsFront fender mount screws

2.16 BLEEDING BRAKES, Procedure1.1-1.4 Nm10-12 in-lbsFront master cylinder reservoir cover

2.38 UPPER FAIRING AND WINDSHIELD: FRAME
MOUNTED FAIRING MODELS, Outer Fairing

2.27 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail

2.22 CLUTCH CABLE, Installation8.1-12.0 Nm72-108 in-lbsHandlebar clamp to clutch lever bracket

2.23 HANDLEBARS, Adjustment8.1-12.0 Nm72-108 in-lbsHandlebar clamp to clutch lever bracket

2.12 FRONT BRAKE MASTER CYL­INDER, Assembly and Installation

2.23 HANDLEBARS, Rubber Mounts40.7-54.2 Nm30-40 ft-lbsHandlebar lower clamp bolts (risers)

2.23 HANDLEBARS, Adjustment21.7-27.1 Nm16-20 ft-lbsHandlebar upper clamp screws

2.23 HANDLEBARS, Installation21.7-27.1 Nm16-20 ft-lbsHandlebar upper clamp screws

2.23 HANDLEBARS, Installation21.7-27.1 Nm16-20 ft-lbsHandlebar upper clamp screws

2.44 HEADLAMP NACELLE: ROAD KING
MODELS, Installation

2.44 HEADLAMP NACELLE: ROAD KING
MODELS, Installation

2.44 HEADLAMP NACELLE: ROAD KING
MODELS, Installation

2.44 HEADLAMP NACELLE: ROAD KING
MODELS, Installation

2.44 HEADLAMP NACELLE: ROAD KING
MODELS, Installation

2.44 HEADLAMP NACELLE: ROAD KING
MODELS, Installation

2-2 2011 Touring Service: Chassis

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fairing models)

(frame mounted fairing models)

screws

mounted fairing

fairing)

mounted fairing

fastener

fastener

FLTRX)

(frame mounted fairing)

NOTESTORQUE VALUEFASTENER

2.8-4.0 Nm25-35 in-lbsInstrument bezel screws (frame mounted

20.3-27.1 Nm15-20 ft-lbsInstrument nacelle to fork bracket screws

10.8-13.6 Nm96-120 in-lbsJiffy stand interlock sensor fastener

4.0-4.5 Nm35-40 in-lbsLower fairing clip stud flange nuts

2.3-2.8 Nm20-25 in-lbsLower fairing glove box tray screws

2.3-2.8 Nm20-25 in-lbsLower fairing glove box tray screws

10.2-11.3 Nm90-100 in-lbsLower fairing to engine guard clamp

1.1-1.7 Nm10-15 in-lbsOuter fairing long screws, frame

2.3-3.4 Nm20-30 in-lbsOuter fairing screws (fork mounted

0.7-1.4 Nm6-12 in-lbsOuter fairing short screws, frame

48.8-56.9 Nm36-42 ft-lbsPassenger footboard/footrest fastener

5.4-8.1 Nm48-72 in lbsPassenger footboard/footrest lower

48.8-56.9 Nm36-42 ft-lbsPassenger footboard/footrest upper

20-27 Nm15-20 ft-lbsPassenger footrest pad screw (FLHX,

10.9-16.3 Nm96-144 in-lbsRadio bracket-to-fairing bracket locknuts

3.4-5.6 Nm30-50 in-lbsRail clamp screws

16.3-20.3 Nm12-15 ft-lbsRear brake light switch

2.39 INSTRUMENT BEZEL: FRAME MOUNTED
FAIRING MODELS, Bezel

2.40 INSTRUMENT NACELLE: FRAME MOUNTED
FAIRING MODELS, Instrument Nacelle

2.50 JIFFY STAND, Jiffy Stand Bracket48.8-57.0 Nm36-42 ft-lbsJiffy stand bracket fasteners

2.50 JIFFY STAND, Jiffy Stand Interlock
Sensor/Use Loctite Medium Strength Threadlocker
243 (blue) if reusing screw

2.50 JIFFY STAND, Leg Installation20.3-27.1 Nm15-20 ft-lbsJiffy stand leg stop hex screw

2.48 REAR FRAME, Rear Frame8.1-10.8 Nm72-96 in-lbsLeft electrical caddy fastener

2.33 LOWER FAIRING AND ENGINE
GUARD, Lower Fairing

2.33 LOWER FAIRING AND ENGINE
GUARD, Lower Fairing

2.33 LOWER FAIRING AND ENGINE
GUARD, Lower Fairing

2.33 LOWER FAIRING AND ENGINE
GUARD, Lower Fairing

2.28 TOUR-PAK, Luggage Rack/Tour-Pak Support20.3-27.1 Nm15-20 ft lbsLuggage rack screws

2.46 REAR FENDER, Installation20.3-27.1 Nm15-20 ft-lbsLuggage rack screws

2.24 MIRRORS, FLHX/metric3.4-4.5 Nm30-40 in-lbsMirror flange nut (FLHX)

2.24 MIRRORS, All Models Except FLHX/metric6.8-10.8 Nm60-96 in-lbsMirror stem acorn nut

2.38 UPPER FAIRING AND WINDSHIELD: FRAME
MOUNTED FAIRING MODELS, Outer Fairing

2.34 UPPER FAIRING AND WINDSHIELD: FORK
MOUNTED FAIRING MODELS, Outer Fairing and
Windshield

2.38 UPPER FAIRING AND WINDSHIELD: FRAME
MOUNTED FAIRING MODELS, Outer Fairing

2.49 FOOTBOARDS AND FOOTRESTS, Pas­senger Footrest: FLHX, FLTRX

2.49 FOOTBOARDS AND FOOTRESTS, Pas­senger Footboard

2.49 FOOTBOARDS AND FOOTRESTS, Pas­senger Footboard

2.49 FOOTBOARDS AND FOOTRESTS, Pas­senger Footrest: FLHX, FLTRX/Use Loctite Medium
Strength Threadlocker 243 (blue)

2.41 INNER FAIRING: FRAME MOUNTED
FAIRING MODELS, Installation

2.27 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail

2.5 REAR WHEEL, Installation/metric20-27 Nm15-20 ft-lbsRear axle cone nut (preliminary)

2.14 REAR BRAKE MASTER CYLINDER, Rear
Brake Line: Non-ABS Equipped/Use Loctite Pipe
Sealant with Teflon 565

2.47 REAR FASCIA, Installation3.4-5.1 Nm30-45 in-lbsRear fascia flange nuts

2.47 REAR FASCIA, Installation2.0-2.5 Nm18-22 in-lbsRear fascia lamp screws

2.47 REAR FASCIA, Rear Fascia Lamp2.0-2.5 Nm18-22 in-lbsRear fascia lamp screws

2.46 REAR FENDER, Fender Repair20.3-27.1 Nm15-20 ft-lbsRear fender mounting boss

2.46 REAR FENDER, Installation20.3-27.1 Nm15-20 ft-lbsRear fender mounting screws

2011 Touring Service: Chassis 2-3

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port fastener

port fastener

port fastener

screws

screw

screw

fastener

fastener

NOTESTORQUE VALUEFASTENER

2.47 REAR FASCIA, Installation5.1-9.6 Nm45-85 in-lbsRear fender support-to-fender nut

2.47 REAR FASCIA, Stud Plate5.1-9.6 Nm45-85 in-lbsRear fender support-to-fender nut

2.46 REAR FENDER, Installation20.3-27.1 Nm15-20 ft-lbsRear fender support -to-saddlebag sup-

20.3-27.1 Nm15-20 ft-lbsRear fender support-to-saddlebag sup-

74.6-88.1 Nm55-65 ft-lbsRear fork bracket screws

74.6-88.2 Nm55-65 ft-lbsRear fork pivot shaft fasteners

14.2-17.0 Nm126-150 in-lbsRear master cylinder-to-frame screws

14.2-17.0 Nm126-150 in-lbsRear master cylinder-to-frame screws

10.8-16.3 Nm96-144 in-lbsRear muffler fastener

48.8-57.0 Nm36-42 ft-lbsRider footboard bracket screws

6.8-9.0 Nm60-80 in-lbsRider footboard pivot bolt nut

16.3-20.3 Nm12-15 ft-lbsSaddlebag mounting bracket screw

8.1-13.6 Nm72-120 in-lbsSaddlebag side guard to front guard

7.9-11.3 Nm70-100 in-lbsSaddlebag support rail to front guard

20.3-27.1 Nm15-20 ft-lbsSaddlebag support to fender support

2.27 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail

2.47 REAR FASCIA, Stud Plate20.3-27.1 Nm15-20 ft-lbsRear fender support-to-saddlebag sup-

2.21 REAR FORK, Installation/Apply two drops of
Loctite Medium Strength Threadlocker 243 (blue)
to threads

2.21 REAR FORK, Installation/Apply two drops of
Loctite Medium Strength Threadlocker 243 (blue)
to threads

2.48 REAR FRAME, Rear Frame54.2-61.0 Nm40-45 ft-lbsRear frame-to-main frame fastener

2.16 BLEEDING BRAKES, Procedure1.4-1.7 Nm12-15 in-lbsRear master cylinder reservoir cover

2.14 REAR BRAKE MASTER CYL­INDER, Assembly and Installation

2.14 REAR BRAKE MASTER CYLINDER, Rear
Brake Line: Non-ABS Equipped

2.27 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail

2.49 FOOTBOARDS AND FOOTRESTS, Rider
Footboards

2.49 FOOTBOARDS AND FOOTRESTS, Rider
Footboards

2.27 SADDLEBAG SERVICE, Saddlebag Hardware2.3-2.8 Nm20-25 in-lbsSaddlebag latch/check strap screws

2.27 SADDLEBAG SERVICE, Saddlebag Hardware2.3-2.8 Nm20-25 in-lbsSaddlebag latch/check strap screws

2.27 SADDLEBAG SERVICE, Saddlebag Hardware2.0-2.3 Nm18-20 in-lbsSaddlebag lid check strap screws

2.25 SEAT, Seat: Road King Models6.8-10.8 Nm60-96 in-lbsSaddlebag mounting bracket screw

2.26 SADDLEBAGS, Installation16.3-20.3 Nm12-15 ft-lbsSaddlebag mounting bracket screw

2.27 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail

2.28 TOUR-PAK, Luggage Rack/Tour-Pak Support16.3-20.3 Nm12-15 ft lbsSaddlebag mounting bracket screw

2.46 REAR FENDER, Installation16.3-20.3 Nm12-15 ft-lbsSaddlebag mounting bracket screw

2.27 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail

2.27 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail

2.27 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail

2.46 REAR FENDER, Installation20.3-27.1 Nm15-20 ft-lbsSaddlebag support to fender support

2.25 SEAT, Seat Bumper9.0-13.6 Nm80-120 in-lbsSeat bumper fastener

2.25 SEAT, Seat: Models without Tour-Pak5.4-8.1 Nm48-72 in-lbsSeat mounting screw

2.25 SEAT, Seat: Models with Tour-Pak5.4-8.1 Nm48-72 in-lbsSeat mounting screw

2.25 SEAT, Seat: Road King Models5.4-8.1 Nm48-72 in-lbsSeat mounting screw

2.25 SEAT, Seat: Models without Tour-Pak5.4-8.1 Nm48-72 in-lbsSeat strap screw

2.25 SEAT, Seat: Models with Tour-Pak5.4-8.1 Nm48-72 in-lbsSeat strap screw

2-4 2011 Touring Service: Chassis

HOME

screws

mounted fairing)

Models)

NOTESTORQUE VALUEFASTENER

16.3-23.0 Nm12-17 ft-lbsShock absorber compression fitting

16.3-23.0 Nm12-17 ft-lbsShock absorber compression fitting

47.5-54.2 Nm35-40 ft-lbsShock lower mounting bolt

47.5-54.2 Nm35-40 ft-lbsShock lower mounting bolt

47.5-54.2 Nm35-40 ft-lbsShock upper mounting bolt

20.3-27.1 Nm15-20 ft-lbsSide rail to saddlebag support screws

1.1-2.3 Nm10-20 in-lbsSpeedometer/tachometer bracket screws

6.2 Nm55 in-lbsSpoke nipple

2.3-2.8 Nm20-25 in-lbsTour-Pak latch screw

2.4-2.7 Nm21-24 in-lbsTour-Pak passenger backrest flap

2.3-2.8 Nm20-25 in-lbsTour-Pak side marker lights screws

2.3-2.8 Nm20-25 in-lbsTour-Pak tether screw

2.3-2.8 Nm20-25 in-lbsTour-Pak tether screw

2.8-3.4 Nm25-30 in-lbsWindshield screws (fork mounted fairing)

0.7-1.5 Nm6-13 in-lbsWindshield wellnut screws (frame

2.3-2.8 Nm20-25 in-lbsWindshield window screws (Road King

2.19 REAR AIR SUSPENSION, Check for Air
Leaks

2.20 REAR SHOCK ABSORBERS, Disassembly
and Assembly

2.20 REAR SHOCK ABSORBERS, Installation/Use
LOCTITE MEDIUM STRENGTH THREADLOCKER
243 (blue)

2.21 REAR FORK, Installation/Apply two or three
drops of Loctite Medium Strength Threadlocker
243 (blue) to threads

2.20 REAR SHOCK ABSORBERS, Installation/Use
LOCTITE MEDIUM STRENGTH THREADLOCKER
243 (blue)

2.27 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail

2.32 TOUR-PAK SPEAKER BOX, Speaker Box2.8-4.0 Nm25-35 in-lbsSpeaker box fasteners

2.28 TOUR-PAK, Removal/Installation2.8-4.0 Nm25-35 in-lbsSpeaker box mounting screws

2.36 INNER FAIRING: FORK MOUNTED FAIRING
MODELS, Installation

2.9 CHECKING AND TRUING WHEELS, Truing
Laced Wheels

2.48 REAR FRAME, Rear Frame8.1-10.8 Nm72-96 in-lbsTop caddy mounting screw

2.29 TOUR-PAK SERVICE, Latches/Lockset
Catch/Use Loctite Medium Strength Threadlocker
243 (blue)

2.29 TOUR-PAK SERVICE, Lockset2.8-4.0 Nm25-35 in-lbsTour-Pak lockset hex nut

2.29 TOUR-PAK SERVICE, Lockset3.4-5.1 Nm30-45 in-lbsTour-Pak lockset jam nut

2.29 TOUR-PAK SERVICE, Luggage Rack6.8-9.5 Nm60-84 in-lbsTour-Pak luggage rack fastener

2.30 TOUR-PAK LIGHTS, Tour-Pak Lights Harness7.3-7.9 Nm65-70 in-lbsTour-Pak metal plate flange nuts

2.30 TOUR-PAK LIGHTS, Tour-Pak Lights Harness10.8-13.6 Nm96-120 in-lbsTour-Pak mounting bolts

2.28 TOUR-PAK, Removal/Installation10.8-13.6 Nm96-120 in-lbsTour-Pak mounting screws

2.28 TOUR-PAK, Adjustment10.8-13.6 Nm96-120 in-lbsTour-Pak mounting screws

2.29 TOUR-PAK SERVICE, Tether Brackets4.5-6.8 Nm40-60 in-lbsTour-Pak passenger backrest flange nuts

2.31 TOUR-PAK BACKREST, Passenger Backrest4.5-6.8 Nm40-60 in-lbsTour-Pak passenger backrest flange nuts

2.31 TOUR-PAK BACKREST, Passenger Backrest
Flap

2.30 TOUR-PAK LIGHTS, Side Marker Lights (if
equipped)

2.29 TOUR-PAK SERVICE, Hinges/Use Loctite
High Strength Threadlocker 262 (red)

2.29 TOUR-PAK SERVICE, Tether/Use Loctite
High Strength Threadlocker 262 (red)

2.22 CLUTCH CABLE, Installation19.0-28.5 Nm14-21 ft-lbsTransmission drain plug

2.11 TIRES, Installation1.4-1.7 Nm12-15 in-lbsValve stem nut

2.34 UPPER FAIRING AND WINDSHIELD: FORK
MOUNTED FAIRING MODELS, Outer Fairing and
Windshield

2.38 UPPER FAIRING AND WINDSHIELD: FRAME
MOUNTED FAIRING MODELS, Windshield

2.43 WINDSHIELD: ROAD KING
MODELS, Windshield Window

2011 Touring Service: Chassis 2-5

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SPECIFICATIONS

Chassis Specifications

most position)

*With 180 lb. (81.7 kg) rider on seat

2.2SPECIFICATIONS

Table 2-1. Dimensions: FLHTC, FLHTCU, FLHTK, FLTRU

FLTRUFLHTKFLHTCUFLHTCITEM

MMIN.MMIN.MMIN.MMIN.

161363.5161363.5161363.5161363.5Wheel base

250798.7250498.6250498.6249798.3Overall length (Tour-Pak in rear-

91936.296538.096538.096538.0Overall width

1305.11305.11305.11305.1Road clearance

139755.0154961.0154961.0154961.0Overall height

69327.369327.369327.369327.3Saddle height*

*With 180 lb. (81.7 kg) rider on seat

Table 2-3. Capacities

(approximate)

(approximate)

Table 2-2. Dimensions: FLHR, FLHRC, FLTRX, FLHX

FLHXFLTRXFLHRCFLHRITEM

MMIN.MMIN.MMIN.MMIN.

161363.5161363.5161363.5161363.5Wheel base

241395.0241395.0239394.2241395.0Overall length

96538.090935.895337.595037.4Overall width

1194.71305.11305.11305.1Road clearance

132652.2127050.0140055.1140055.1Overall height

66326.166326.167826.767326.5Saddle height*

LITERSU.S.ITEM

22.716.00 galFuel tank (total)

3.791.00 galLow fuel warning light on

3.794.00 qt.Engine oil with filter

0.951.00 qt.Transmission

1.321.40 qt.Primary chaincase

2-6 2011 Touring Service: Chassis

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factory

factory

Table 2-4. Weights: FLHTC, FLHTCU, FLHTK, FLTRU

FLTRUFLHTKFLHTCUFLHTCITEM

KGLB.KGLB.KGLB.KGLB.

385.6850388.7857386.5852375.1827Weight as shipped from

616.91360616.91360616.91360616.91360GVWR

226.8500226.8500226.8500226.8500GAWR front

420.5927420.5927420.5927420.5927GAWR rear

Table 2-5. Weights: FLHR, FLHRC, FLTRX, FLHX

FLHXFLTRXFLHRCFLHRITEM

KGLB.KGLB.KGLB.KGLB.

356.1785350.2772350.6773351.5775Weight as shipped from

616.91360616.91360616.91360616.91360GVWR

226.8500226.8500226.8500226.8500GAWR front

420.5927420.5927420.5927420.5927GAWR rear

NOTES

•

Gross vehicle weight rating (GVWR) (maximum allowable
loaded vehicle weight) and corresponding gross axle
weight rating (GAWR) are given on a label located on the
frame steering head.

•

For important information regarding tire data and tire
inflation, see 1.8 TIRES AND WHEELS.

Tire Specifications

Use only Harley-Davidson approved tires. See a Harley­Davidson dealer. Using non-approved tires can adversely
affect stability, which could result in death or serious
injury. (00024a)

Table 2-6. Tire Fitment - Tubeless Cast Wheels

WHEEL SIZE

AND POSITION

RIM SIZE AND

CONTOUR

Tire sizes are molded on the sidewall. Refer to the tire fitment
tables below. Rim size and contour are cast or stamped into
the exterior surface of the rim.

Example: T19 x 2.15 MT DOT. "T" indicates that the rim con­forms to Tire and Rim Association standards. The "19" is the
normal diameter of the rim in inches, measured at the bead
seat diameter. The "2.15" is the width of the bead seat meas­ured in inches. "MT" designates the rim contour. "DOT" means
that the rim meets Department of Transportation Federal Motor
Vehicle Safety Standards.

APPROVED TIRERIM VALVE

HOLE DIA.

Dunlop D408F0.45 in. (11.4 mm)T18 x 3.50 MT18 in. - Front

130/70B18 63H

Dunlop D408F0.45 in. (11.4 mm)T17 x 3.00 MT17 in. - Front

130/80B17 65H

Dunlop D4070.45 in. (11.4 mm)T16 x 5.00 MT16 in. - Rear

180/65B16 81H

2011 Touring Service: Chassis 2-7

HOME

Table 2-7. Tire Fitment - Tube Type Steel Laced Wheels

WHEEL SIZE

& POSITION

WHEEL SIZE

& POSITION

RIM SIZE &

CONTOUR

Table 2-8. Tire Fitment - Tube Type Chrome Aluminum Profile Laced Wheels

RIM SIZE &

CONTOUR

TUBE

SIZE

TUBE

SIZE

APPROVED

TIRE

Dunlop D408FMT90-16/MU85-16T16 x 3.00D16 in - Front

130/90-B16 67H130/90-150/80-16

Dunlop D407180/65-16T16 x 5.00 MT16 in - Rear

180/65-16 81H

APPROVED

TIRE

Dunlop D408FMT90-16/MU85-16T16 x 3.00 MT16 in - Front

130/90B16 67H130/90-150/80-16

Dunlop D408F130/80-17T17 x 3.00 MT17 in - Front

130/80-B17 65H

Dunlop D407180/65-16T16 x 5.00 MT16 in - Rear

180/65-16 81H

FLTRX, FLHX

Table 2-9. Tires

PRESSURE (COLD)APPROVED TIRESIZEMOUNTMODEL

kPaPSI

24836Dunlop D408F 130/80B17 65H17 in.frontAll models except FLHRC,

24836Dunlop D408F 130/90B16 67H16 in.frontFLHRC

24836Dunlop D408F 130/70B18 63H18 in.frontFLTRX, FLHX

27640Dunlop D407 180/65B1616 in.rearAll models

2-8 2011 Touring Service: Chassis