Harley-Davidson Touring 2013 Service Manual

2013 Harley-Davidson Touring Models

Service Manual

99483-13

©2012 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

2013 Harley-Davidson

Touring Models Service

Manual

©2012 H-D.

ALL RIGHTS RESERVED

99483-13

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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Street: Department:

City: State: Zip:

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

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

2013 Harley-Davidson Touring Models Service Manual (99483-13)

NOTES

ABOUT THIS MANUAL

GENERAL

This service manual has been prepared with the following
purposes in mind:

• To acquaint the user with the construction of the Harley­Davidson product and assist in the performance of basic
maintenance and repair.

• To introduce the professional Harley-Davidson technician
to 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
SPECIFICATIONS 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.

PREPARATION FOR SERVICE

TOOL NAMEPART NUMBER

DIGITAL TECHNICIAN IIHD-48650

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.
Start each job with a clean work area. This will allow the repair
to proceed as smoothly as possible. It will also reduce the
incidence of misplaced tools and parts. Clean a motorcycle
that is excessively dirty before work starts. Cleaning will occa­sionally uncover sources of trouble. Gather any tools, instru­ments and any parts needed for the job before work begins.
Interrupting a job to locate tools or parts is a distraction and
causes needless delay.

NOTES

•

To avoid unnecessary disassembly, carefully read all
related service information before repair work begins.

•

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), it must first be
disarmed. Keep the fob close to the vehicle or use
DIGITAL TECHNICIAN II (Part No. HD-48650) to disable
the system. Activate 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.

FOREWORD

I

WARNINGS AND CAUTIONS

Statements in this manual preceded by the following words
are of special significance.

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)

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.

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
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, contact Loctite Corp. at
www.loctite.com.

PRODUCT REGISTERED MARKS

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 zumo are among the
trademarks of their respective owners.

H-D MICHIGAN, INC. TRADEMARK
INFORMATION

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

Bar & Shield, Cross Bones, Digital Tech, Digital Technician,
Digital Technician II, Dyna, Electra Glide, Evolution, Fat Bob,
Fat Boy, Forty-Eight, Glaze, Gloss, H-D, H-Dnet.com, Harley,
Harley-Davidson, HD, Heritage Softail, Iron 883, Low Rider,
Night Rod, Nightster, Night Train, Profile, Revolution, Road
Glide, Road King, Road Tech, Rocker, Screamin' Eagle, Sev­enty-Two, Softail, Sportster, Street Glide, Street Rod, Sun Ray,
Sunwash, Super Glide, SuperLow, Switchback, SYN3, Tech­Link, TechLink II, Tour-Pak, Twin Cam 88, Twin Cam 88B,
Twin Cam 96, Twin Cam 96B, Twin Cam 103, Twin Cam 103B,
Twin Cam 110, Twin Cam 110B, Ultra Classic, V-Rod, VRSC,
XR1200X and Harley-Davidson Genuine Motor Parts and
Genuine Motor Accessories are among the trademarks of H­D 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.

Read and follow warnings and directions on all products.
Failure to follow warnings and directions can result in
death or serious injury. (00470b)

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

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

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

Part Replacement........................................................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................................................1-6

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

Installation.........................................................................1-19

Exhaust System Leak Check............................................1-20

Exhaust System Leakage..........................................1-20

1.8 TIRES AND WHEELS

General.............................................................................1-21

Tires..................................................................................1-21

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

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

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

Wheel Bearings................................................................1-22

Wheel Spokes...................................................................1-22

Identify Wheel Spoke Groups....................................1-23

Wheel Spoke Adjustment..........................................1-23

1.9 PRIMARY CHAINCASE LUBRICANT

General.............................................................................1-24

Changing Primary Chaincase Lubricant...........................1-24

1.10 TRANSMISSION LUBRICANT

Checking Transmission Lubricant.....................................1-26

Changing Transmission Lubricant....................................1-26

1.11 CLUTCH

Adjustment........................................................................1-28

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...................................................................1-32

1.13 REAR 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

1.15 BRAKES

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

Brake Lines.......................................................................1-36

TABLE OF CONTENTS

1.4 BULB REQUIREMENTS

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

1.5 MAINTENANCE SCHEDULE

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

1.6 ENGINE OIL AND FILTER

Engine Oil Level................................................................1-16

Oil Level Cold Check.................................................1-16

Oil Level Hot Check...................................................1-16

Changing Oil and Oil Filter................................................1-17

1.7 AIR CLEANER AND EXHAUST SYSTEM

Removal............................................................................1-19

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

1.17 SPARK PLUGS

Removal............................................................................1-41

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

Cleaning............................................................................1-41

Installation.........................................................................1-41

III

TABLE OF CONTENTS

Spark Plug Cable Inspection............................................1-42

1.18 STEERING HEAD BEARINGS

Lubrication........................................................................1-43

Checking...........................................................................1-43

Adjustment........................................................................1-44

1.19 REAR SUSPENSION ADJUSTMENTS

Air Suspension..................................................................1-46

Manual Suspension Preload.............................................1-47

1.20 CRITICAL FASTENERS

Inspection.........................................................................1-49

Checking Torques on Fasteners................................1-49

1.21 BATTERY MAINTENANCE

General.............................................................................1-50

Cleaning and Inspection...................................................1-51

Battery..............................................................................1-51

Disconnection and Removal......................................1-51

Installation and Connection.......................................1-51

Voltmeter Test...................................................................1-52

Voltmeter Test............................................................1-52

Charging Battery...............................................................1-52

Safety Precautions....................................................1-52

Using a Battery Charger............................................1-53

Storage.............................................................................1-53

1.22 HEADLAMP ALIGNMENT

Headlamp Alignment........................................................1-55

Headlamp Adjustment: Single Headlamp Models............1-55

Headlamp Adjustment: Dual Headlamp Models...............1-56

Auxiliary/Fog Lamp Alignment..........................................1-57

1.23 ENGINE MOUNTS

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

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

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

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

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

1.24 STORAGE

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

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

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

1.25 TROUBLESHOOTING

General.............................................................................1-60

Engine...............................................................................1-60

Starter Motor Does Not Operate or Does Not Turn Engine

Over ..........................................................................1-60

Engine Turns Over But Does Not Start ....................1-60

Starts Hard................................................................1-60

Starts But Runs Irregularly or Misses .......................1-60

A Spark Plug Fouls Repeatedly................................1-61

Pre-Ignition or Detonation (Knocks or Pings)............1-61

Overheating...............................................................1-61

Valve Train Noise.......................................................1-61

Excessive Vibration...................................................1-61

Check Engine Light Illuminates During Operation.....1-61

Lubrication System...........................................................1-61

Oil Does Not Return To Oil Reservoir........................1-61

Engine Uses Too Much Oil Or Smokes Excessively..1-61
Engine Leaks Oil From Cases, Push Rods, Hoses,

Etc.............................................................................1-61

Low Oil Pressure.......................................................1-62

High Oil Pressure......................................................1-62

Electrical System..............................................................1-62

Alternator Does Not Charge......................................1-62

Alternator Charge Rate Is Below Normal..................1-62

Speedometer Operates Erratically............................1-62

Transmission....................................................................1-62

Shifts Hard.................................................................1-62

Jumps Out Of Gear...................................................1-62

Clutch Slips................................................................1-62

Clutch Drags Or Does Not Release..........................1-62

Clutch Chatters..........................................................1-62

Handling............................................................................1-62

Irregularities...............................................................1-62

Brakes...............................................................................1-63

Brake Does Not Hold Normally.................................1-63

CHASSIS

2.1 FASTENER TORQUE VALUES

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

2.2 SPECIFICATIONS

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

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

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

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

Vehicle Identification Number: Touring Models.................2-11

2.4 FRONT WHEEL

Removal............................................................................2-13

Cleaning and Inspection...................................................2-14

Installation.........................................................................2-15

2.5 REAR WHEEL

Removal............................................................................2-16

Cleaning and Inspection...................................................2-17

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

2.6 REAR WHEEL COMPENSATOR

Isolator Replacement........................................................2-20

Removal....................................................................2-20

Installation.................................................................2-20

Sprocket Bearing Replacement........................................2-20

Removal....................................................................2-20

Installation.................................................................2-20

2.7 WHEEL LACING: FRONT RIM

Wheel Lacing: Angle Flange Hub.....................................2-22

2.8 WHEEL LACING: 16 INCH REAR RIM

Wheel Lacing: 16 In. Rear Wheel.....................................2-24

IV TABLE OF CONTENTS

TABLE OF CONTENTS

2.9 CHECKING AND TRUING WHEELS

General.............................................................................2-27

Checking Wheel Runout...................................................2-27

Checking Radial Runout............................................2-27

Checking Lateral Runout...........................................2-27

Laced Wheel Rim Offset...................................................2-28

Truing Laced Wheels........................................................2-30

Radial Runout............................................................2-30

Lateral Runout...........................................................2-30

2.10 SEALED WHEEL BEARINGS

Inspection.........................................................................2-32

Removal............................................................................2-32

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

2.11 TIRES

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

Removal............................................................................2-35

Cleaning, Inspection and Repair......................................2-35

Installation.........................................................................2-36

Tube Type Tires.........................................................2-36

Tubeless Tires: Cast Wheels.....................................2-36

Tubeless Tires: Laced Wheels..................................2-37

Checking Tire Runout.......................................................2-38

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

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

Wheel Balancing...............................................................2-39

Static vs Dynamic......................................................2-39

Weights......................................................................2-39

2.12 FRONT BRAKE MASTER CYLINDER

General.............................................................................2-40

Removal and Disassembly...............................................2-40

Removal....................................................................2-40

Disassembly..............................................................2-40

Cleaning and Inspection...................................................2-42

Assembly and Installation.................................................2-42

Assembly...................................................................2-42

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

Front Brake Line: Non-ABS Equipped..............................2-42

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

Installation.................................................................2-43

2.13 FRONT BRAKE CALIPER

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

Installation.........................................................................2-45

2.14 REAR BRAKE MASTER CYLINDER

General.............................................................................2-46

Removal and Disassembly...............................................2-46

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

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

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

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

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

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

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

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

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

2.15 REAR BRAKE CALIPER

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

Installation.........................................................................2-52

2.16 BLEEDING BRAKES

General.............................................................................2-53

Procedure.........................................................................2-53

2.17 FRONT FORK

Removal............................................................................2-55

Disassembly.....................................................................2-55

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

Disassembly..............................................................2-55

Cleaning and Inspection...................................................2-57

Assembly..........................................................................2-58

Filling.........................................................................2-59

Installation.........................................................................2-59

2.18 STEERING HEAD BEARINGS

Removal............................................................................2-60

Inspection.........................................................................2-61

Installation.........................................................................2-62

2.19 REAR AIR SUSPENSION

Check for Air Leaks..........................................................2-63

Compression Fitting...................................................2-63

Air Valve Assembly....................................................2-63

Air Tubes...................................................................2-63

Shock Absorber Removal.................................................2-64

Cleaning and Inspection...................................................2-64

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

Shock Absorber Installation..............................................2-64

2.20 REAR SHOCK ABSORBERS: MANUAL
ADJUST

Repair...............................................................................2-65

2.21 REAR FORK

Removal............................................................................2-66

Disassembly and Assembly..............................................2-66

Bearing Removal.......................................................2-66

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

Pivot Shaft/Mount Disassembly.................................2-67

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

2.22 CLUTCH CABLE

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

Installation.........................................................................2-69

2.23 HANDLEBARS

Adjustment........................................................................2-71

Removal............................................................................2-71

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

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

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

Installation.................................................................2-73

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

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

Installation.................................................................2-73

Heated Handgrips.............................................................2-73

TABLE OF CONTENTS V

TABLE OF CONTENTS

Remove Left Handgrip..............................................2-73

Install Left Handgrip...................................................2-74

Remove Right Handgrip............................................2-74

Install Right Handgrip................................................2-74

Rubber Mounts.................................................................2-75

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

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

2.24 MIRRORS

All Models Except FLHX...................................................2-76

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

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

FLHX.................................................................................2-76

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

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

2.25 SEAT

Seat: Models without Tour-Pak.........................................2-77

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

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

Seat: Models with Tour-Pak..............................................2-78

Removal....................................................................2-78

Installation.................................................................2-78

Seat: Road King Models...................................................2-78

Removal....................................................................2-78

Installation.................................................................2-78

Seat Retention Nut Replacement.....................................2-79

Seat Bumper.....................................................................2-79

2.26 SADDLEBAGS

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

Installation.........................................................................2-80

2.27 SADDLEBAG SERVICE

Saddlebag Hardware........................................................2-81

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

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

Saddlebag Guard/Support Rail.........................................2-82

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

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

Removal....................................................................2-87

Installation.................................................................2-87

Tether................................................................................2-88

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

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

Tether Brackets.................................................................2-88

Removing Tether Bracket from Tour-Pak..................2-88

Removing Tether Bracket from Tour-Pak Lid.............2-88

Installing Tether Bracket on Tour-Pak Lid..................2-88

Installing Tether Bracket on Tour-Pak........................2-88

Luggage Rack...................................................................2-88

2.30 TOUR-PAK LIGHTS

General.............................................................................2-90

Side Marker Lights (if equipped).......................................2-90

Removal....................................................................2-90

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

Tour-Pak Lights Harness..................................................2-90

Removal....................................................................2-90

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

Wrap-Around Lights (if equipped).....................................2-91

Bulb Replacement.....................................................2-91

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

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

2.31 TOUR-PAK BACKREST

Passenger Backrest..........................................................2-93

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

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

Rubber Isolators...............................................................2-93

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

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

Passenger Backrest Flap..................................................2-94

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

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

2.32 TOUR-PAK SPEAKER BOX

Speaker Box.....................................................................2-95

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

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

2.28 TOUR-PAK

Removal/Installation.........................................................2-84

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

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

Adjustment........................................................................2-85

Luggage Rack/Tour-Pak Support.....................................2-85

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

Assembly and Installation..........................................2-85

2.29 TOUR-PAK SERVICE

Lockset.............................................................................2-86

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

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

Hinges...............................................................................2-86

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

Installation.................................................................2-87

Latches/Lockset Catch.....................................................2-87

Removal....................................................................2-87

Installation.................................................................2-87

Catches.............................................................................2-87

VI TABLE OF CONTENTS

2.33 LOWER FAIRING AND ENGINE GUARD

Lower Fairing....................................................................2-96

Removal....................................................................2-96

Disassembly..............................................................2-97

Assembly...................................................................2-97

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

Serrated Washer Replacement........................................2-98

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

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

Engine Guard....................................................................2-98

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

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

2.34 UPPER FAIRING AND WINDSHIELD:
FORK MOUNTED FAIRING MODELS

Outer Fairing and Windshield.........................................2-100

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

Installation...............................................................2-100

TABLE OF CONTENTS

2.35 FAIRING CAP: FORK MOUNTED
FAIRING MODELS

Fairing Cap.....................................................................2-101

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

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

2.36 INNER FAIRING: FORK MOUNTED
FAIRING MODELS

Removal..........................................................................2-102

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

2.37 AIR DEFLECTORS

Fairing Air Deflectors......................................................2-106

Removal: Fork Mounted Fairing Models.................2-106

Installation: Fork Mounted Fairing Models..............2-106

Removal: Frame Mounted Fairing Models..............2-106

Installation: Frame Mounted Fairing Models...........2-106

Mid-Frame Air Deflectors................................................2-106

Removal..................................................................2-106

Installation...............................................................2-106

2.38 UPPER FAIRING AND WINDSHIELD:
FRAME MOUNTED FAIRING MODELS

Windshield......................................................................2-108

Removal..................................................................2-108

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

Outer Fairing...................................................................2-108

Removal..................................................................2-108

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

2.39 INSTRUMENT BEZEL: FRAME
MOUNTED FAIRING MODELS

Bezel...............................................................................2-111

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

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

2.40 INSTRUMENT NACELLE: FRAME
MOUNTED FAIRING MODELS

Instrument Nacelle..........................................................2-112

Removal..................................................................2-112

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

2.41 INNER FAIRING: FRAME MOUNTED
FAIRING MODELS

Removal..........................................................................2-114

Inner Fairing............................................................2-114

Fairing Bracket........................................................2-115

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

Fairing Bracket........................................................2-116

Inner Fairing............................................................2-116

2.42 GLOVE BOX DOOR AND HINGE:
FRAME MOUNTED FAIRING MODELS

Glove Box Door and Hinge.............................................2-118

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

Installation...............................................................2-118

2.43 WINDSHIELD: ROAD KING MODELS

Windshield......................................................................2-119

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

Installation...............................................................2-119

Windshield Window........................................................2-119

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

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

2.44 HEADLAMP NACELLE: ROAD KING
MODELS

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

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

2.45 FRONT FENDER

Removal..........................................................................2-124

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

2.46 REAR FENDER

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

Fender Repair.................................................................2-127

Mounting Hardware.................................................2-127

Lights and Harnesses..............................................2-127

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

2.47 REAR FASCIA

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

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

Stud Plate.......................................................................2-129

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

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

Rear Fascia Lamp..........................................................2-129

2.48 REAR FRAME

Rear Frame.....................................................................2-130

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

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

Thread Repair..........................................................2-131

2.49 FOOTBOARDS AND FOOTRESTS

Rider Footboards............................................................2-132

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

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

Disassembly............................................................2-132

Assembly.................................................................2-133

Passenger Footboard.....................................................2-133

Removal..................................................................2-133

Disassembly............................................................2-133

Assembly.................................................................2-133

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

Passenger Footrest: FLHX, FLTRX................................2-134

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

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

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

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

2.50 JIFFY STAND

General...........................................................................2-135

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

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

Jiffy Stand Bracket..........................................................2-136

TABLE OF CONTENTS VII

TABLE OF CONTENTS

Removal..................................................................2-136

Installation...............................................................2-136

Jiffy Stand Interlock Sensor............................................2-136

Removal..................................................................2-136

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

2.51 FRONT ENGINE MOUNT

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

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

2.52 MEDALLIONS, SERIALIZED BADGES
AND TANK EMBLEMS

Removal..........................................................................2-140

Installation.......................................................................2-140

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

Pushrods, Lifters and Covers...........................................3-34

Cylinder Head...................................................................3-34

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

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

3.19 BREATHER ASSEMBLY

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

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

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

3.20 ROCKER ARM SUPPORT PLATE

Disassembly.....................................................................3-39

Cleaning and Inspection...................................................3-39

Inspection..................................................................3-39

Rocker Shaft Fit.........................................................3-39

Rocker Arm Shaft to Bushing....................................3-40

Replace Rocker Arm Bushings.................................3-40

Assembly..........................................................................3-41

3.21 PUSHRODS, LIFTERS AND COVERS

Disassembly.....................................................................3-42

Cleaning and General Inspection.....................................3-42

VIII TABLE OF CONTENTS

TABLE OF CONTENTS

Lifter Inspection................................................................3-43

Assembly..........................................................................3-43

3.22 CYLINDER HEAD

Disassembly.....................................................................3-44

Cleaning............................................................................3-45

Inspection.........................................................................3-45

Cylinder Head............................................................3-45

Valve Guides.............................................................3-46

Valves........................................................................3-46

Valve Springs.............................................................3-46

Tapered Keepers.......................................................3-46

Valve Seats................................................................3-46

Valve Guide Replacement................................................3-46

Removal....................................................................3-46

Installation.................................................................3-47

Valve and Seat Refacing..................................................3-50

Assembly..........................................................................3-52

3.23 CYLINDER

Cleaning............................................................................3-54

Inspection.........................................................................3-54

Deglazing Cylinder............................................................3-56

Boring and Honing Cylinder..............................................3-56

3.24 PISTON

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

Piston Rings..............................................................3-58

Cleaning............................................................................3-58

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

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

Checking Piston Ring Gap........................................3-60

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

3.25 TOP END OVERHAUL: ASSEMBLY

General.............................................................................3-62

Piston................................................................................3-62

Cylinder.............................................................................3-63

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

Push Rods, Lifters and Covers.........................................3-69

Rocker Arm Support Plate................................................3-70

Breather and Rocker Cover..............................................3-71

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

Cam Support Plate and Cover Installation.......................3-80

3.27 OIL PUMP

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

Cleaning and Inspection...................................................3-84

Installation.........................................................................3-85

3.28 CRANKCASE DISASSEMBLY AND
REPAIR

Crankcase Disassembly...................................................3-86

Cleaning and Inspection...................................................3-86

Right Crankcase Half........................................................3-87

Main Bearing Removal..............................................3-87

Main Bearing Installation...........................................3-87

Piston Jets Removal..................................................3-88

Piston Jets Installation...............................................3-88

Left Crankcase Half..........................................................3-88

Main Bearing Removal..............................................3-88

Main Bearing Installation...........................................3-89

Sprocket Shaft Bearing Inner Race..................................3-90

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

Installation.................................................................3-91

Cylinder Studs..................................................................3-93

Removal....................................................................3-93

Installation.................................................................3-93

Pipe Plug and Oil Fittings.................................................3-94

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

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

3.29 FLYWHEEL AND CONNECTING RODS

General.............................................................................3-95

Symptoms..................................................................3-95

No Oil Pressure.........................................................3-95

Vibration....................................................................3-95

Inspection.........................................................................3-95

Measuring Crankshaft Runout..........................................3-95

Crankshaft Installed...................................................3-95

Crankshaft Removed.................................................3-96

3.30 CRANKCASE ASSEMBLY

Crankcase Assembly........................................................3-98

3.26 CAM COMPARTMENT AND
COMPONENTS

Cam Support Plate and Cover Removal..........................3-72

Prepare Engine..........................................................3-72

Cam Chain and Sprockets Removal.........................3-72

Cam Support Plate Removal.....................................3-73

Cam Support Plate Cleaning and Inspection....................3-74

Oil Pressure Valve.....................................................3-74

Cam Support Plate....................................................3-74

Camshafts.........................................................................3-75

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

Installation.................................................................3-75

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

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

Inspection..................................................................3-77

Installation.................................................................3-77

Cam Needle Bearings.......................................................3-77

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

3.31 OIL PAN

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

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

FUEL SYSTEM

4.1 FASTENER TORQUE VALUES

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

4.2 SPECIFICATIONS: FUEL SYSTEM

Specifications......................................................................4-2

4.3 AIR CLEANER ASSEMBLY

Removal..............................................................................4-3

Installation...........................................................................4-3

TABLE OF CONTENTS IX

TABLE OF CONTENTS

4.4 FUEL TANK

Console...............................................................................4-5

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

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

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

Purge and Disconnect Fuel Line.................................4-5

Remove Tank...............................................................4-5

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

Vent Tube: Models Without EVAP System.........................4-6

Removal......................................................................4-6

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

Fuel Supply Check Valve/Tube...........................................4-7

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

Installation...................................................................4-7

4.5 FUEL TANK TOP PLATE

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

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

4.6 FUEL FILTER

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

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

4.7 FUEL PRESSURE REGULATOR

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

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

4.8 FUEL LEVEL SENDER

Removal............................................................................4-12

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

4.9 TWIST GRIP SENSOR

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

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

Twist Grip Sensor Jumper Harness..................................4-15

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

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

4.10 THROTTLE CONTROL ACTUATOR
(TCA)

General.............................................................................4-16

4.11 INDUCTION MODULE

Removal............................................................................4-17

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

4.12 TEMPERATURE MANIFOLD ABSOLUTE
PRESSURE SENSOR (TMAP)

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

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

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

4.13 OXYGEN SENSORS (O2)

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

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

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

4.14 FUEL INJECTORS

General.............................................................................4-22

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

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

4.15 FUEL PUMP

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

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

Installation.........................................................................4-24

Fuel Pump and Fuel Level Sender Wire Harness............4-25

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

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

4.16 FUEL PRESSURE TEST

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

Testing..............................................................................4-26

4.17 EXHAUST SYSTEM

Mufflers.............................................................................4-28

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

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

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

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

4.18 ACTIVE EXHAUST (HDI)

Exhaust Valve Actuator.....................................................4-31

Removal....................................................................4-31

Installation.................................................................4-31

Exhaust Valve Actuator Cable..........................................4-31

Removal....................................................................4-31

Installation.................................................................4-31

Active Exhaust Valve........................................................4-31

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

4.19 INTAKE LEAK TEST

General.............................................................................4-32

Leak Tester.......................................................................4-32

Parts List....................................................................4-32

Tester Assembly........................................................4-32

Tester Adjustment......................................................4-32

Procedure.........................................................................4-32

4.20 EVAPORATIVE EMISSIONS CONTROL
SYSTEM

General.............................................................................4-34

Vapor Valve.......................................................................4-34

Fuel Vapor Vent Tube.......................................................4-35

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

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

Canister-to-Solenoid Tube................................................4-35

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

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

Solenoid-to-Induction Module Tube..................................4-35

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

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

Purge Solenoid.................................................................4-35

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

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

Charcoal Canister.............................................................4-36

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

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

X TABLE OF CONTENTS

TABLE OF CONTENTS

DRIVE

5.1 FASTENER TORQUE VALUES

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

5.2 SPECIFICATIONS: DRIVE

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

5.3 PRIMARY CHAINCASE COVER

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

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

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

5.4 DRIVE COMPONENTS

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

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

5.5 PRIMARY CHAINCASE HOUSING

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

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

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

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

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

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

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

Installation.................................................................5-11

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

6.3 TRANSMISSION

Power Flow.........................................................................6-4

Neutral.........................................................................6-4

1st Gear.......................................................................6-4

2nd Gear......................................................................6-4

3rd Gear......................................................................6-4

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

5th Gear.......................................................................6-4

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

6.4 SHIFTER LINKAGE

Shifter Rod Adjustment.......................................................6-6

Heel-Toe Shift Levers.........................................................6-6

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

Repair..........................................................................6-6

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

Shifter Rod Lever, Front......................................................6-6

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

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

6.5 CLUTCH RELEASE COVER

Removal and Disassembly.................................................6-8

Cleaning and Inspection.....................................................6-8

Assembly and Installation...................................................6-9

6.6 TRANSMISSION ASSEMBLY

Removal............................................................................6-10

Disassembly.....................................................................6-11

Shifter Cam/Shifter Forks..........................................6-11

Mainshaft...................................................................6-13

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

Removing Bearing Housing Bearings.......................6-16

Cleaning and Inspection...................................................6-17

Assembly..........................................................................6-17

Installing Bearing Housing Bearings.........................6-17

Countershaft..............................................................6-17

Mainshaft...................................................................6-18

Shifter Cam/Shifter Forks..........................................6-18

Installation.........................................................................6-20

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

6.7 MAIN DRIVE GEAR AND BEARING

Removal............................................................................6-22

Cleaning and Inspection...................................................6-23

Needle Bearing Replacement...................................6-24

Mainshaft Seal Replacement............................................6-25

Installation.........................................................................6-26

Installing Main Drive Gear Bearing............................6-26

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

Installing Main Drive Gear Large Seal.......................6-27

6.8 TRANSMISSION CASE

Removal............................................................................6-29

Installation.........................................................................6-29

Disassembly.....................................................................6-30

Shifter Arm Assembly................................................6-30

Cleaning and Inspection...................................................6-30

Assembly..........................................................................6-31

Countershaft Needle Bearing Replacement..............6-31

Shifter Pawl Lever Assembly.....................................6-31

TABLE OF CONTENTS XI

TABLE OF CONTENTS

ELECTRICAL

7.1 FASTENER TORQUE VALUES

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

7.2 SPECIFICATIONS: ELECTRICAL

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

7.3 ELECTRONIC CONTROL MODULE (ECM)

ECM....................................................................................7-5

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

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

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

General...............................................................................7-6

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

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

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

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

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

7.5 IGNITION COIL

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

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

7.6 SYSTEM FUSES AND RELAYS

Main Fuse...........................................................................7-9

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

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

System Fuses and Relays..................................................7-9

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

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

Main Fuse Holder...............................................................7-9

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

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

Fuse Blocks......................................................................7-10

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

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

7.7 ELECTRICAL CADDIES

Top Caddy.........................................................................7-11

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

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

Left Side Caddy................................................................7-11

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

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

Battery Tray......................................................................7-14

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

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

7.8 SECURITY SIREN

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

Installation.........................................................................7-15

7.9 STARTER

General.............................................................................7-16

Removal............................................................................7-16

Drive Assembly.................................................................7-16

Disassembly..............................................................7-16

Inspection..................................................................7-16

Assembly...................................................................7-17

Solenoid............................................................................7-17

Cover and Plunger Removal.....................................7-17

Short Post Contact: Starter.......................................7-17

Long Post Contact: Battery Positive..........................7-18

Plunger and Cover Installation..................................7-18

Installation.........................................................................7-18

7.10 HEADLAMP: ALL EXCEPT ROAD GLIDE

Headlamp: Single Headlamp Models...............................7-20

Removal....................................................................7-20

Bulb Replacement.....................................................7-20

Installation.................................................................7-20

7.11 HEADLAMP: ROAD GLIDE

Headlamp Adjuster Assembly..........................................7-22

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

Repair........................................................................7-22

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

Headlamp Bulb Replacement: Dual Headlamp Models....7-22

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

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

Installation.................................................................7-23

7.12 AUXILIARY/FOG LAMPS AND
BRACKETS

Auxiliary/Fog Lamp Bulb Replacement............................7-24

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

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

Auxiliary/Fog Lamp Housing.............................................7-25

Removal....................................................................7-25

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

Auxiliary/Fog Lamp Bracket..............................................7-27

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

Installation.................................................................7-27

Adjustment........................................................................7-27

7.13 TAIL LAMP

Tail Lamp Bulb Replacement............................................7-28

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

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

Circuit Board/Chrome Base..............................................7-28

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

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

Rear Fender Lights Harness: all except FLHX, FLTRX.....7-29

Removal....................................................................7-29

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

Rear Fascia Lamp............................................................7-31

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

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

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

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

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

7.14 FENDER TIP LAMPS

Front Fender Tip Lamp.....................................................7-33

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

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

Front Fender Tip Lamp Jumper Harness..........................7-33

XII TABLE OF CONTENTS

TABLE OF CONTENTS

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

Installation.................................................................7-34

Rear Fender Tip Lamp......................................................7-35

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

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

7.15 TURN SIGNAL LAMPS

Turn Signal Bulb Replacement: Bullet Style.....................7-37

Turn Signal Bulb Replacement: Flat Lens Style...............7-37

Front Turn Signal Lamp....................................................7-37

Removal: Flat Lens Style..........................................7-37

Installation: Flat Lens Style.......................................7-38

Removal: Bullet Style, Fork Mounted........................7-39

Installation: Bullet Style, Fork Mounted.....................7-40

Removal: Bullet Style, Fairing Mounted....................7-40

Installation: Bullet Style, Fairing Mounted.................7-41

Rear Turn Signal Lamp.....................................................7-41

Removal: FLHR/C, FLHTC/U, FLHTK.......................7-41

Installation: FLHR/C, FLHTC/U, FLHTK....................7-42

Removal: FLHX, FLTRX, FLTRU...............................7-42

Installation: FLHX, FLTRX, FLTRU............................7-42

Rear Turn Signal Lamps Bracket......................................7-44

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

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

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

Installation: FLHX, FLTRX, FLTRU............................7-45

7.16 IGNITION/LIGHT KEY SWITCH AND
FORK LOCK

Fairing Models..................................................................7-46

Removal....................................................................7-46

Installation.................................................................7-48

Road King Models............................................................7-49

Ignition/Light Key Switch: Removal...........................7-49

Ignition/Light Key Switch: Installation........................7-49

Fork Lock: Removal...................................................7-49

Fork Lock: Installation................................................7-49

7.17 FAIRING CAP SWITCHES: FORK
MOUNTED FAIRING MODELS

Removal............................................................................7-51

Installation.........................................................................7-51

7.18 INSTRUMENT NACELLE SWITCHES:
FRAME MOUNTED FAIRING MODELS

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

Left Side Switch.........................................................7-53

Right Side Switches...................................................7-53

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

Left Side Switch.........................................................7-54

Right Side Switches...................................................7-54

Final Assembly..........................................................7-54

7.19 CRANKSHAFT POSITION SENSOR
(CKP)

General.............................................................................7-55

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

Installation.........................................................................7-55

7.20 ENGINE TEMPERATURE SENSOR (ET)

Removal............................................................................7-56

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

7.21 AUTOMATIC COMPRESSION RELEASE
(ACR)

General.............................................................................7-57

Removal............................................................................7-57

Installation.........................................................................7-57

7.22 VOLTAGE REGULATOR

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

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

7.23 ALTERNATOR

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

Cleaning and Inspection...................................................7-60

Installation.........................................................................7-61

7.24 VEHICLE SPEED SENSOR (VSS)

VSS...................................................................................7-62

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

Installation.................................................................7-62

7.25 NEUTRAL SWITCH

Removal............................................................................7-63

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

7.26 OIL PRESSURE SWITCH AND SENDER

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

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

7.27 STOP LAMP SWITCHES

Front Stop Lamp Switch...................................................7-65

Removal/Installation..................................................7-65

Rear Stop Lamp Switch....................................................7-65

Removal....................................................................7-65

Installation.................................................................7-65

7.28 HORN

Inspection.........................................................................7-66

Removal............................................................................7-66

Installation.........................................................................7-66

7.29 CIGARETTE LIGHTER: FAIRING
MODELS

Troubleshooting................................................................7-68

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

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

7.30 GAUGES AND INSTRUMENTS: FAIRING
MODELS

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

Voltmeter, Oil Pressure.....................................................7-69

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

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

Tachometer.......................................................................7-69

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

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

TABLE OF CONTENTS XIII

TABLE OF CONTENTS

Speedometer....................................................................7-70

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

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

7.31 INDICATOR LAMPS: FAIRING MODELS

Indicator Lamps................................................................7-71

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

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

7.32 GAUGES AND INSTRUMENTS: ROAD
KING MODELS

Fuel Gauge.......................................................................7-72

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

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

Speedometer....................................................................7-72

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

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

7.33 INDICATOR LAMPS: ROAD KING
MODELS

Indicator Lamps................................................................7-74

Removal....................................................................7-74

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

7.34 ADVANCED AUDIO SYSTEM

Radio................................................................................7-75

Removal....................................................................7-75

Installation.................................................................7-75

Front Fairing Speakers.....................................................7-76

Removal....................................................................7-76

Installation.................................................................7-76

Front Headset Receptacle................................................7-76

Removal....................................................................7-76

Installation.................................................................7-76

Rear Headset Receptacle................................................7-77

Rear Passenger Switches................................................7-77

Removal....................................................................7-77

Installation.................................................................7-77

Rear Speakers..................................................................7-78

Removal....................................................................7-78

Installation.................................................................7-78

CB Module........................................................................7-79

Removal....................................................................7-79

Installation.................................................................7-79

7.35 WIRE TROUGH

Removal............................................................................7-80

Installation.........................................................................7-81

7.36 MAIN WIRING HARNESS

Removal: All Models (Part 1)............................................7-82

Removal: Road King Models (Part 2)...............................7-82

Removal: Fork Mounted Fairing Models (Part 2)..............7-83

Removal: Frame Mounted Fairing Models (Part 2)..........7-84

Removal: All Models (Part 3)............................................7-84

Installation: All Models (Part 1).........................................7-86

Installation: Road King Models (Part 2)............................7-88

Installation: Fork Mounted Fairing Models (Part 2)...........7-89

Installation: Frame Mounted Fairing Models (Part 2).......7-89

Installation: All Models (Part 3).........................................7-89

7.37 INTERCONNECT HARNESS

Fork Mounted Fairing Models...........................................7-90

Removal....................................................................7-90

Installation.................................................................7-92

Frame Mounted Fairing Models........................................7-93

Removal....................................................................7-93

Installation.................................................................7-95

7.38 RADIO ANTENNA CABLE

Models Equipped with Tour-Pak.......................................7-96

Removal....................................................................7-96

Installation.................................................................7-96

Models without Tour-Pak..................................................7-97

Removal....................................................................7-97

Installation.................................................................7-97

7.39 REAR AUDIO HARNESS: ULTRA
MODELS

Removal............................................................................7-99

Installation.........................................................................7-99

7.40 CB ANTENNA CABLE: ULTRA MODELS

Removal..........................................................................7-101

Installation.......................................................................7-101

7.41 HANDLEBAR SWITCH ASSEMBLIES

Removal..........................................................................7-103

Right Handlebar Controls........................................7-103

Left Handlebar Controls..........................................7-103

Specific Repair Procedures: Upper Switch Housings.....7-103

Right Side Handlebar (All Models)..........................7-103

Left Side Handlebar (All Models).............................7-105

Specific Repair Procedures: Right Side Lower Switch

Housings.........................................................................7-106

Preliminary Instructions...........................................7-106

Turn-Right Signal Switch (All Models).....................7-106

Front Stop Lamp Switch (All Models)......................7-106

Mode Select Switch (Classic and Ultra Models)......7-106

Cruise Set/Resume Switch (Road King Classic and Ultra

Models)....................................................................7-107

Final Instructions.....................................................7-108

Specific Repair Procedures: Left Side Lower Switch

Housings.........................................................................7-109

Preliminary Instructions...........................................7-109

Turn-Left Signal Switch (All Models).......................7-109

Clutch Interlock Switch............................................7-109

Audio Control Switch (Classic and Ultra Models).....7-111

CB Push-To-Transmit Switch (Ultra Models)...........7-111

Cruise On/Off Switch (Road King Classic Models)..7-111

Final Instructions.....................................................7-112

General Repair Procedures............................................7-112

Installation.......................................................................7-114

Right Handlebar Controls........................................7-114

Left Handlebar Controls..........................................7-115

7.42 TSSM/HFSM MAINTENANCE

General...........................................................................7-118

Fob Battery.....................................................................7-118

Battery Replacement Schedule...............................7-118

Battery Replacement...............................................7-118

Smart Siren (If Installed).................................................7-118

XIV TABLE OF CONTENTS

TABLE OF CONTENTS

Battery Replacement Schedule...............................7-118

Battery Replacement...............................................7-118

7.43 PERSONAL IDENTIFICATION NUMBER
(PIN)

General...........................................................................7-119

Initial PIN Entry...............................................................7-119

Changing the PIN...........................................................7-119

Modifying an Existing PIN.......................................7-119

7.44 H-DSSS ACTUATION

General...........................................................................7-121

Actuation.........................................................................7-121

Fob Assignment..............................................................7-121

Power Disruption and Configuring..................................7-121

7.45 TSM/HFSM: PASSWORD LEARN

General...........................................................................7-122

Password Learn..............................................................7-122

APPENDIX A CONNECTOR REPAIR

A.1 AUTOFUSE UNSEALED ELECTRICAL
CONNECTORS

Autofuse Unsealed Connector Repair................................A-1

General.......................................................................A-1

Disassembly................................................................A-1

Assembly.....................................................................A-1

A.2 BOSCH COMPACT 1.1M CONNECTOR

Bosch Compact 1.1M Connector.......................................A-2

General.......................................................................A-2

Housings.....................................................................A-2

Removing Socket Terminal.........................................A-2

Installing Socket Terminal...........................................A-2

Installing Socket Terminals.........................................A-7

Crimping Terminals.....................................................A-7

A.6 DELPHI 480 METRI-PACK UNSEALED
CONNECTORS

Delphi 480 Metri-Pack Unsealed Connector Repair..........A-8

General.......................................................................A-8

Separating Pin and Socket Housings.........................A-8

Mating Pin and Socket Housings................................A-8

Removing Socket Terminals.......................................A-8

Installing Socket Terminals.........................................A-8

A.7 DELPHI 630 METRI-PACK UNSEALED
CONNECTORS

Delphi 630 Metri-Pack Unsealed Connector Repair..........A-9

Separating Pin and Socket Housings.........................A-9

Mating Pin and Socket Housings................................A-9

Removing Socket Terminal.........................................A-9

Installing Socket Terminal...........................................A-9

A.8 DELPHI 800 METRI-PACK SEALED MAIN
FUSE HOUSING

Delphi 800 Metri-Pack Sealed Main Fuse Housing

Repair...............................................................................A-10

Removing Socket Terminals.....................................A-10

Installing Socket Terminals.......................................A-10

A.9 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.3 DELPHI 100W MICRO-PACK SEALED
CONNECTOR

Delphi 100W Micro-Pack Sealed Connector Repair..........A-3

General.......................................................................A-3

Separating Socket Housing From ECM......................A-3

Mating Socket Housing To ECM.................................A-3

Removing Socket Terminal.........................................A-3

Installing Socket Terminal...........................................A-3

Crimping Terminals.............................................................A-4

A.4 DELPHI 150 METRI-PACK SEALED
CONNECTORS

Delphi 150 Metri-Pack Sealed Connector Repair..............A-5

General.......................................................................A-5

Separating Pin and Socket Housings.........................A-5

Mating Pin and Socket Housings................................A-5

Removing Socket Terminal.........................................A-5

Inserting Socket Terminal............................................A-5

A.5 DELPHI 280 METRI-PACK UNSEALED
CONNECTORS

Fuse Block Repair..............................................................A-7

Removing Socket Terminals.......................................A-7

A.10 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.11 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

TABLE OF CONTENTS XV

TABLE OF CONTENTS

A.12 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.13 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.14 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.15 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

A.16 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.17 JAE MX19 SEALED CONNECTORS

JAE MX19 Sealed Connectors.........................................A-28

Connector Housings.................................................A-28

Removing Terminals.................................................A-28

Installing Terminals....................................................A-28

Crimping Terminals...........................................................A-28

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.20 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.21 TYCO GET 64 SEALED CONNECTOR

Tyco GET 64 Sealed Connector......................................A-39

General.....................................................................A-39

Housings...................................................................A-39

Removing Socket Terminals.....................................A-39

Installing Socket Terminals.......................................A-39

Crimping Terminals...........................................................A-40

A.22 TYCO MCP SEALED CONNECTOR

Tyco MCP Sealed Connector...........................................A-41

General.....................................................................A-41

Housing.....................................................................A-41

Removing the Large Terminals.................................A-41

Removing the Small Terminals.................................A-41

Installing Terminals....................................................A-42

Crimping Terminals...........................................................A-42

A.23 SEALED SPLICE CONNECTORS

Sealed Splice Connector Repair......................................A-43

General.....................................................................A-43

Preparing Wire Leads...............................................A-43

Splicing Wire Leads..................................................A-43

Inspecting Seals........................................................A-43

APPENDIX B WIRING

A.18 MOLEX CMC SEALED CONNECTORS

Molex CMC Sealed Connectors.......................................A-29

Separating the Connector.........................................A-29

Removing Terminals.................................................A-29

Installing Terminals....................................................A-29

Crimping Terminals...........................................................A-30

A.19 MOLEX MX 150 SEALED
CONNECTORS

Molex MX 150 Sealed Connector Repair.........................A-31

Separating Pin and Socket Housings.......................A-31

XVI TABLE OF CONTENTS

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

2013 Touring Wiring Diagrams...........................................B-9

TABLE OF CONTENTS

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 (WSS)....................................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

APPENDIX E GLOSSARY

E.1 GLOSSARY

Acronyms and Abbreviations.............................................E-1

REFERENCE MATERIAL

TOOLS...........................................................I

TORQUE VALUES.......................................IX

INDEX......................................................XXV

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.......................................................................................................1-16

1.7 AIR CLEANER AND EXHAUST SYSTEM...............................................................................1-19

1.8 TIRES AND WHEELS..............................................................................................................1-21

1.9 PRIMARY CHAINCASE LUBRICANT.....................................................................................1-24

1.10 TRANSMISSION LUBRICANT..............................................................................................1-26

1.11 CLUTCH.................................................................................................................................1-28

1.12 DRIVE BELT AND SPROCKETS..........................................................................................1-29

1.13 REAR 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 STEERING HEAD BEARINGS..............................................................................................1-43

1.19 REAR SUSPENSION ADJUSTMENTS.................................................................................1-46

1.20 CRITICAL FASTENERS........................................................................................................1-49

1.21 BATTERY MAINTENANCE....................................................................................................1-50

1.22 HEADLAMP ALIGNMENT.....................................................................................................1-55

1.23 ENGINE MOUNTS.................................................................................................................1-58

1.24 STORAGE..............................................................................................................................1-59

1.25 TROUBLESHOOTING...........................................................................................................1-60

MAINTENANCE

NOTES

HOME

FASTENER TORQUE VALUES IN THIS CHAPTER

The table below lists torque values for all fasteners presented
in this chapter.

cover screws

cover screws

cover screws

cover 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/fog lamp flange nut

6.8-7.9 Nm60-70 in-lbsBattery terminal bolt

6.8-7.9 Nm60-70 in-lbsBattery terminal bolt

37.9-51.5 Nm28-38 ft-lbsBrake caliper, front, mounting screws

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

58.3-65.1 Nm43-48 ft-lbsBrake caliper, rear, mounting screws

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

1.3-1.7 Nm11.5-15.0 in-lbsBrake master cylinder, front, reservoir

1.4-1.7 Nm12-15 in-lbsBrake master cylinder, rear, reservoir

9.5-12.2 Nm84-108 in-lbsClutch inspection cover screws

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 243 MEDIUM
STRENGTH THREADLOCKER AND SEALANT
(blue)

1.22 HEADLAMP ALIGNMENT, Auxiliary/Fog Lamp
Alignment

1.5 MAINTENANCE SCHEDULE, General6.8-7.9 Nm60-70 in-lbsBattery terminal bolt

1.9 PRIMARY CHAINCASE LUBRICANT, Chan­ging Primary Chaincase Lubricant

1.12 DRIVE BELT AND SPROCKETS, Checking
Drive Belt Deflection

1.21 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/Always use new part

1.16 BRAKE PADS AND DISCS, Brake Pad
Replacement/metric

1.16 BRAKE PADS AND DISCS, Brake Pad
Replacement/Always use new part

1.5 MAINTENANCE SCHEDULE, General8.5.-11.5 Nm75-102 in-lbsBrake caliper pad pin

1.5 MAINTENANCE SCHEDULE, General1.3-1.7 Nm11.5-15.0 in-lbsBrake master cylinder, front, reservoir

1.16 BRAKE PADS AND DISCS, Brake Pad
Replacement

1.5 MAINTENANCE SCHEDULE, General1.4-1.7 Nm12-15 in-lbsBrake master cylinder, rear, reservoir

1.16 BRAKE PADS AND DISCS, Brake Pad
Replacement

1.5 MAINTENANCE SCHEDULE, General8.1-13.6 Nm72-120 in-lbsClutch adjuster screw jamnut

1.11 CLUTCH, Adjustment8.1-13.6 Nm72-120 in-lbsClutch adjuster screw jamnut

1.11 CLUTCH, Adjustment13.6 Nm120 in-lbsClutch cable adjustment jamnut

1.5 MAINTENANCE SCHEDULE, General9.5-12.2 Nm84-108 in-lbsClutch inspection cover screws

1.9 PRIMARY CHAINCASE LUBRICANT, Chan­ging Primary Chaincase Lubricant/Torque
sequence

1.11 CLUTCH, Adjustment9.5-12.2 Nm84-108 in-lbsClutch inspection cover screws

1.23 ENGINE MOUNTS, Inspection48.8-54.2 Nm36-40 ft-lbsEngine mount bracket to engine screws

1.23 ENGINE MOUNTS, Inspection56.9-65.0 Nm42-48 ft-lbsEngine mount end cap screws, front

2013 Touring Service: Maintenance 1-1

HOME

screws

NOTESTORQUE VALUEFASTENER

1.5 MAINTENANCE SCHEDULE, General19.0-28.5 Nm14-21 ft-lbsEngine oil drain plug

19.0-28.5 Nm14-21 ft-lbsEngine oil drain plug

10.8-16.3 Nm96-144 in-lbsMuffler to saddlebag support screws

19.0-28.5 Nm14-21 ft-lbsPrimary chaincase drain plug

20-27 Nm15-20 ft-lbsRear axle cone nut, 1st torque

128.8-142.4 Nm95-105 ft-lbsRear axle cone nut, final torque

2.8-8.5 Nm25-75 in-lbsTransmission dipstick

19.0-28.5 Nm14-21 ft-lbsTransmission drain plug

2.8-8.5 Nm25-75 in-lbsTransmission filler plug/dipstick

4.1-6.8 Nm36-60 in-lbsTurn signal lamp to mounting bracket

1.6 ENGINE OIL AND FILTER, Changing Oil and
Oil Filter

1.23 ENGINE MOUNTS, Inspection40.7-47.5 Nm30-35 ft-lbsEngine stabilizer link bolt

1.23 ENGINE MOUNTS, Inspection40.7-47.5 Nm30-35 ft-lbsEngine stabilizer link bolt

1.18 STEERING HEAD BEARINGS, Adjustment71.9-77.3 Nm53-57 ft-lbsFork bracket pinch bolt

1.18 STEERING HEAD BEARINGS, Adjustment94.9-108.4 Nm70-80 ft-lbsFork stem nut

1.5 MAINTENANCE SCHEDULE, General4.0-5.1 Nm35-45 in-lbsHandlebar switch housing screws

1.12 DRIVE BELT AND SPROCKETS, Setting Belt
Deflection

1.5 MAINTENANCE SCHEDULE, General19.0-28.5 Nm14-21 ft-lbsPrimary chaincase drain plug

1.9 PRIMARY CHAINCASE LUBRICANT, Chan­ging Primary Chaincase Lubricant

1.12 DRIVE BELT AND SPROCKETS, Setting Belt
Deflection/For belt adjustment only

1.12 DRIVE BELT AND SPROCKETS, Setting Belt
Deflection

1.23 ENGINE MOUNTS, Inspection54.2-61.0 Nm40-45 ft-lbsRear frame to main frame screws

1.5 MAINTENANCE SCHEDULE, General16.3-24.4 Nm12-18 ft-lbsSpark plug

1.17 SPARK PLUGS, Installation16.3-24.4 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 screws

1.21 BATTERY MAINTENANCE, Battery8.1-10.9 Nm72-96 in-lbsTop caddy screws

1.5 MAINTENANCE SCHEDULE, General2.8-8.5 Nm25-75 in-lbsTransmission dipstick

1.10 TRANSMISSION LUBRICANT, Checking
Transmission Lubricant

1.5 MAINTENANCE SCHEDULE, General19.0-28.5 Nm14-21 ft-lbsTransmission drain plug

1.10 TRANSMISSION LUBRICANT, Changing
Transmission Lubricant

1.10 TRANSMISSION LUBRICANT, Changing
Transmission Lubricant

1.22 HEADLAMP ALIGNMENT, Auxiliary/Fog Lamp
Alignment

1-2 2013 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)

Perform necessary set-up tasks before customer delivery. See
applicable model year predelivery and set-up 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 GENUINE
HARLEY-DAVIDSON H-D 360 MOTORCYCLE OIL
20W50. Failure to use the recommended oil will result in
improper break-in of the engine cylinders and piston rings.

Inspect motorcycle on a regular basis for additional mainten­ance needs. Routinely check components between regular
maintenance intervals. Always inspect motorcycle after periods
of storage before riding.

Check:

1. Tires for correct pressure, excessive wear or any signs of
tire damage.

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/fog lamp, tail lamp, stop 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 parts catalog.

Safety

Safety is always the most important consideration when per­forming any job.

• Always have a complete understanding of the task.

• 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. If a hoist
and adjustable lifting beam or sling are needed to remove some
parts, verify that:

• The lengths of multiple chains or cables from the hoist to
the part are equal and parallel.

• Slings, chains and cables are positioned directly over the
center of the part.

• No obstructions will interfere with the lifting operation.

• Parts are not left suspended.

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. Verify that
no 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

Always clean around lines or covers before they are removed.
Plug, tape or cap holes and openings to keep out dirt, dust and
debris. Clean and inspect all parts as they are removed. Verify
all holes and passages are clean and open. After cleaning,
cover all parts with clean lint-free cloth, paper or other material.
Verify the part is clean when installed.

Thoroughly clean all parts to be reused before assembly. Clean
parts promote better component operation and longer life.
Seals, filters and covers used in this vehicle keep out
extraneous dirt and dust. Keep these items in good condition
to guarantee satisfactory operation.

2013 Touring Service: Maintenance 1-3

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When instructed to clean fastener threads or threaded holes,
always:

• 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.

• Clear all threaded holes with low pressure compressed
air.

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.

Disassembly and Assembly

Always assemble or disassemble one part at a time. Do not
work on two assemblies simultaneously. Make all necessary
adjustments. Inspect your work when finished to verify 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

Check torque using a torque wrench set to the minimum spe­cification for that fastener. If the fastener does not rotate, the
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 material from the
threaded hole. Replace the fastener with a new one or clean
the original fastener threads and apply the appropriate
threadlocking product. 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 from normal wear are usually trapped in the
oil filter or by the magnetic drain plug. Magnetized parts in the
engine can retain these fragments, potentially causing acceler­ated engine wear and damage.

Never place parts that will be returned to service inside the
vehicle's powertrain such as gears, thrust washers and espe­cially bearings 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 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, thoroughly clean
all fasteners and threaded holes. Always use the recommended
threadlocking agent for the specific procedure.

Wiring, Hoses and Lines

Replace 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

Always use the proper tools and fixtures when servicing 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, always verify
that the chamfered side of the bearing 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.

Only remove bearings if necessary. Removal usually damages
bearings requiring replacement with new parts.

Bushings

Do not remove a bushing unless damaged, excessively worn
or loose in its bore. Press out bushings requiring replacement.

When pressing or driving bushings, always 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.

Verify that all oil holes are properly aligned during installation.

Gaskets

Always discard gaskets after removal. Replace with new gas­kets. Never use the same gasket twice. Verify that gasket holes
match up with holes in the mating part. 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.

Do not remove seals unless necessary. Only remove seals to
gain access to other parts or if seal damage or wear dictates
replacement.

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