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.

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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.

1-4 2013 Touring Service: Maintenance

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Leaking oil or grease usually means that a seal is damaged.
Replace leaking seals to prevent overheated bearings.

Always discard seals after removal. Do not use the same seal
twice.

O-Rings

Always discard O-rings after removal. Many O-rings are similar
in size and appearance. Always use new O-rings keeping them
packaged until use to avoid confusion. To prevent leaks, lub­ricate the O-rings before installation with the same type of
lubricant as that being sealed. Be sure that all gasket, O-ring
and seal mating surfaces are thoroughly clean before installa­tion.

Gears

Always check gears for damaged or worn teeth.

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

Lubricate mating surfaces before pressing gears on shafts.

Shafts

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

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

Clean all rust from the machined surfaces of new parts.

Part Replacement

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)

Always install new genuine Harley-Davidson parts and
accessories. This will provide best service life and maintain
compliance with noise and emissions regulations.

Installing non-Harley-Davidson, off-road or competition parts
can void warranty or result in an unsafe vehicle.

CLEANING

Part Protection

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

Rust or Corrosion Removal

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

Bearings

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

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

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

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

TOOL SAFETY

Air Tools

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

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

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

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

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

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

• Protect bystanders with approved eye protection.

Wrenches

• Never use an extension on a wrench handle.

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

• Always keep the wrench squarely installed on the fastener.

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

• Discard any wrench with damaged or battered points.

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

Cleaning Process

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

2013 Touring Service: Maintenance 1-5

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Pliers/Cutters/Pry Bars

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

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

• Always cut at right angles.

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

Hammers

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

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

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

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

• Discard hammer if face is chipped or mushroomed.

• Wear approved eye protection when using striking tools.

• Protect bystanders with approved eye protection.

Punches/Chisels

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

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

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

• Always wear approved eye protection when using these
tools.

• Protect bystanders with approved eye protection.

Screwdrivers

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

• Use the right type of screwdriver for the job. Match the tip
of a screwdriver to the fastener.

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

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

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

Ratchets and Handles

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

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

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

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

Sockets

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

• Select the right size socket for the job.

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

• Replace sockets showing cracks or wear.

• Keep sockets clean.

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

Storage Units

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

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

• Do not pull on a tool cabinet. Always push tool cabinets
in front of you.

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

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1.3FUEL AND OIL

FUEL

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

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

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

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

Table 1-1. Octane Ratings

RATINGSPECIFICATION

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

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

• Do not use racing fuel or fuel containing methanol. Use
of these fuels will damage the fuel system.

• The only octane booster Harley-Davidson recommends
is SCREAMIN' EAGLE SUPER OCTANE BOOST (avail­able only in the U.S.). This is the only octane booster that
has been extensively tested and approved for use with
Harley-Davidson engines and components.

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

ENGINE LUBRICATION

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

GASOLINE BLENDS

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

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

• Gasoline/METHYL TERTIARY BUTYL ETHER (MTBE)
blends are a mixture of gasoline and as much as 15%
MTBE. Gasoline/MTBE blends use in your motorcycle is
approved.

• ETHANOL fuel is a mixture of ethanol (grain alcohol) and
unleaded gasoline and can have an impact on fuel
mileage. Fuels with an ethanol content of up to 10% may
be used in your motorcycle without affecting vehicle per­formance. U.S. EPA regulations currently indicate that
fuels with 15% ethanol (E15) are restricted from use in
motorcycles at the time of this publication. Some motor­cycles are calibrated to operate with higher ethanol con­centrations to meet the fuel standards in certain countries.

• REFORMULATED OR OXYGENATED GASOLINES
(RFG) describes gasoline blends that are specifically

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

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

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

This motorcycle was originally equipped with GENUINE
HARLEY-DAVIDSON H-D 360 MOTORCYCLE OIL 20W50.
H-D 360 is the preferred oil under normal operating conditions.
If operation under extreme cold or heat are expected, refer to

Table 1-2 for alternative choices.

If necessary and H-D 360 is not available, add oil certified for
diesel engines. Acceptable designations include: CH-4, CI-4
and CJ-4. The preferred viscosities, in descending order are:
20W50, 15W40 and 10W40.

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

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Table 1-2. Recommended Engine Oils

Motorcycle Lubricant

Motorcycle Oil

Motorcycle Oil

Motorcycle Oil

Motorcycle Oil

WINTER LUBRICATION

Change engine oil often in colder climates. If motorcycle is
frequently used for trips less than 15 mi (24 km), in ambient
temperatures below 60 °F (16 °C), reduce oil change intervals
to 1500 mi (2400 km).

NOTE

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

Water vapor is a normal by-product of combustion in any
engine. During cold weather operation, some water vapor

RATINGVISCOSITYTYPE

condenses to liquid form on the cool metal surfaces inside the
engine. In freezing weather this water will become slush or ice.
Over time, accumulated slush or ice may block the oil lines
and cause engine damage.

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

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

LOWEST AMBIENT

TEMPERATURE

COLD WEATHER

STARTS BELOW

50 °F (10 °C)

ExcellentAbove 30 °F (-1 °C)HD 360SAE 20W50Screamin' Eagle SYN 3 Full Synthetic

GoodAbove 40 °F (4 °C)HD 360SAE 20W50Genuine Harley-Davidson H-D 360

PoorAbove 60 °F (16 °C)HD 360SAE 50Genuine Harley-Davidson H-D 360

PoorAbove 80 °F (27 °C)HD 360SAE 60Genuine Harley-Davidson H-D 360

ExcellentBelow 40 °F (4 °C)HD 360SAE 10W40Genuine Harley-Davidson H-D 360

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1.4BULB REQUIREMENTS

GENERAL

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

Table 1-3. Bulb Chart

LAMP

Tail and stop
lamp

Instrument panel
lamps

FLHR/C

DESCRIPTION
(ALL LAMPS 12 VOLT)

international FLHX, FLTRX

FLHTK, FLTRU

FLHTC/U, FLHTK, FLHR, FLTRU

(Canadian)

High beam, Oil pressure, Neutral
and Turn signal indicator *

REQUIRED

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

NOTE

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

BULBS

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

CURRENT

DRAW

AMPERAGE

N/AN/AFender tip lamps, rear*

HARLEY-DAVIDSON

PART NUMBER

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

68329-034.58/5.02FLTRX, FLTRU

53436-970.321Position lamp, international

68167-040.59/2.101All models except domestic and

68168-89A2.25/0.592Front/running (domestic)Turn signal lamp

68572-64B2.252Front (international)

68163-841.752Front, FLHX (HDI)

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

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

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

68572-64B2.252Rear, FLHX, FLTRX (Canadian)

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

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

68168-89A2.25/0.592Tour-Pak tail/stop lamps

68193-950.301Fender tip lamps, front

69375-10 (FLHX, FLTRX domestic,

not Canadian)

59672-09

(all but FLHX, FLTRX domestic)

69378-09N/A1License plate lamp international *

52441-950.352License plate lamp FLHX, FLTRX

68453-052.12Auxiliary lamps

68453-052.12Fog lamps international

N/AN/AN/ASpeedometerGauge lamps

N/AN/AN/AOdometer

N/AN/AN/AEngine

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Table 1-3. Bulb Chart

LAMP

FLHTC/U
FLTRX
FLTRU
FLHX

FLHTK

DESCRIPTION
(ALL LAMPS 12 VOLT)

FLHTC/U, FLHX, FLTRX, FLTRU

FLHTC/U, FLHX, FLTRX, FLTRU

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

BULBS

REQUIRED

CURRENT

DRAW

AMPERAGE

HARLEY-DAVIDSON

PART NUMBER

N/AN/AN/ASpeedometerGauge lamps

N/AN/AN/ATachometer

67445-000.241Voltmeter

67445-000.241Oil pressure gauge

67445-000.241Air temperature gauge

67445-000.241Fuel gauge

N/AN/AN/ASpeedometerGauge lamps

N/AN/AN/ATachometer

67477-100.241Voltmeter

67477-100.241Oil pressure gauge

67477-100.241Air temperature gauge

67477-100.241Fuel gauge

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1.5MAINTENANCE SCHEDULE

GENERAL

screws

Brake master cylinder, front,
reservoir cover screws

reservoir cover screws

Air cleaner cover bracket
screws

screws

TORQUE VALUEFASTENER

in-lbs

in-lbs

procedures, just refer to the table for the recommended service
interval. If necessary, see the quick reference table (Table 1-5.)
for the required specifications.

19.0-28.5 Nm14-21 ft-lbsEngine oil drain plug

19.0-28.5 Nm14-21 ft-lbsPrimary chaincase drain plug

8.1-13.6 Nm72-120 in-lbsClutch adjuster screw jamnut

9.5-12.2 Nm84-108 in-lbsClutch inspection cover

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

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

19.0-28.5 Nm14-21 ft-lbsTransmission drain plug

2.8-8.5 Nm25-75 in-lbsTransmission dipstick

6.2 Nm55 in-lbsSpoke nipple

1.3-1.7 Nm11.5-15.0

1.4-1.7 Nm12-15 in-lbsBrake master cylinder, rear,

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

12.2-14.9 Nm108-132

4.1-6.8 Nm36-60 in-lbsAir cleaner cover screw

4.0-5.1 Nm35-45 in-lbsHandlebar switch housing

16.3-24.4 Nm12-18 ft-lbsSpark plug

6.8-7.9 Nm60-70 in-lbsBattery terminal bolt

8.1-10.9 Nm72-96 in-lbsTop caddy screws

The table below lists the periodic maintenance requirements
for Touring model motorcycles. If you are familiar with the

Table 1-4. Regular Service Intervals: 2013 Touring Models

MI

KM

15000

MI

24000

KM

Oil lines and brake
system

Air cleaner

Tires

equipped)

lubricant

ricant

sprockets

ators

Brake and clutch
controls

Jiffy stand

PROCEDUREITEM SERVICED

contact or abrasion

required

inspect tread

ricate

ricate

1000 MI

1600 KM

5000 MI

8000 KM

10000

16000

MI

KM

45000

MI

72000

KM

20000

32000

Inspect for wear at each rear tire change.Rear sprocket isol-

25000

MI

40000

KM

30000

MI

48000

KM

35000

MI

56000

KM

40000

MI

64000

KM

NOTES50000

MI

80000

KM

3, 7XXXXXXXXXXXReplaceEngine oil and filter

1, 3XXXXXXXXXXXInspect for leaks,

7XXXXXXXXXXInspect, service as

3XXXXXXXXXXXCheck pressure,

1, 5, 7XXXXXCheck tightnessWheel spokes (if

7XXXXXXReplacePrimary chaincase

7XXXReplaceTransmission lub-

1, 7XXXXXXXXXXXCheck adjustmentClutch

1XXXXXXXXXXXInspect, adjust beltDrive belt and

1XXXXXXXXXXXCheck and lub-

1XXXXXXXXXXXInspect and lub-

2013 Touring Service: Maintenance 1-11

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Fuel lines and fit­tings

discs

ment and switches

bearings

bearings

Air suspension
(if equipped)

ings (if applicable)

Fuel door, Tour­Pak, saddlebags (if
equipped)

Exhaust system

Road test

Table 1-4. Regular Service Intervals: 2013 Touring Models

MI

KM

45000

MI

72000

KM

XXXXXLubricateSteering head

PROCEDUREITEM SERVICED

contact or abrasion

operation and
leakage

and latches

cracks, and loose
or missing
fasteners or heat
shields

and system func­tions

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

2. Disassemble, lubricate and inspect every 50,000 mi (80,000 km).

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

4. Change DOT 4 brake fluid and flush system every two years.

5. Perform spoke tension check at 1000 mi (1600 km), 5000 mi (8000 km), 20,000 mi (32,000 km) services and every 15,000 mi (24,000 km)
interval thereafter. Not all vehicles are equipped with spoke wheels. Consult appropriate topic in service manual.

6. Disassemble, inspect, rebuild forks and replace fork oil every 50,000 mi (80,000 km).

7. Perform maintenance more frequently in severe riding conditions (such as extreme temperatures, dusty environments, mountainous or rough
roads, long storage conditions, short runs, heavy stop/go traffic or poor fuel quality).

8. Perform every two years or at specified intervals, whichever comes first.

1000 MI

1600 KM

5000 MI
8000 KM

10000

16000

15000

MI

24000

KM

Check battery and clean connections annually.Battery

20000

MI

32000

KM

25000

MI

40000

KM

30000

MI

48000

KM

35000

MI

56000

KM

40000

MI

64000

KM

NOTES50000

MI

80000

KM

1, 3XXXXXXXXXXXInspect for leaks,

1Replace every 100,000 mi (160,000 km).Fuel filter element

4XXXXXXXXXXXInspect sight glassBrake fluid

XXXXXXXXXXXInspect for wearBrake pads and

8XReplaceSpark plugs

XXXXXXXXXXXCheck operationElectrical equip-

1, 6XRebuildFront forks

1, 2XXAdjustSteering head

1, 7XXXXXXXXXXXCheck pressure,

1XXXXXInspectWindshield bush-

XXXXXXXXXXXLubricate hinges

1XXXXXXCheck tightnessCritical fasteners

3, 7XXXXXXXXXXXInspect for leaks,

XXXXXXXXXXXVerify component

Table 1-5. Quick Reference Maintenance Chart

Lubricant type and capacityPrimary chain lubricant

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DATASPECIFICATIONITEM SERVICED

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

4 qt. (3.8 L)Oil capacity *

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

FORMULA+ TRANSMISSION AND PRIMARY
CHAINCASE LUBRICANT
or
SCREAMIN' EAGLE SYN3 FULL SYNTHETIC
MOTORCYCLE LUBRICANT 20W50
Wet: 38 oz. (1124 ml)
Dry: 45 oz. (1331 ml)

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

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

Drive belt deflection

Table 1-5. Quick Reference Maintenance Chart

Lubricant levelTransmission lubricant

Lubricant type and capacity **

Wear

Fluid level (from top of master cylinder reservoir)

strand

Air cleaner cover screw Threadlocker

DATASPECIFICATIONITEM SERVICED

1/2-1 turnAdjuster screw free playClutch adjustment

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

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

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

Dipstick between ADD and FULL marks with
motorcycle on jiffy stand and filler plug resting on
threads.

FORMULA+ TRANSMISSION AND PRIMARY
CHAIN LUBRICATION
or
SCREAMIN' EAGLE SYN3 FULL SYNTHETIC
MOTORCYCLE LUBRICANT 20W50
32 oz (0.95 L)

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

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

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

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

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

DOT 4 BRAKE FLUIDTypeBrake fluid level (Check

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

Front: 11.5-15.0 in-lbs (1.3-1.7 Nm)Master cylinder reservoir cover screw torque
Rear: 12-15 in-lbs (1.4-1.7 Nm)

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

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

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

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

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

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

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

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

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

LOCTITE 243 MEDIUM STRENGTH THREAD­LOCKER AND SEALANT (blue)

HARLEY LUBELubricant part numberClutch cable

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

HD-6R12TypeSpark plugs

0.038-0.043 in (0.97-1.09 mm)Gap

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

See 2.17 FRONT FORK.AmountFront fork oil

TYPE 'E' HYDRAULIC FORK OILType

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Table 1-5. Quick Reference Maintenance Chart

DATASPECIFICATIONITEM SERVICED

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

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

* Capacity is approximate. When changing oil, initially add 3.0 qt (2.8 L). Run engine until warm. Check and fill as necessary.
** Capacity is approximate. When changing lubricant, initially add 28 oz (0.83 L). Check and fill as necessary.

Table 1-6. Lubricants, Greases, Sealants

PACKAGEPART NUMBERITEM

5 oz tube021200-19718 *3M 847 Adhesive

15 oz. aerosol3M General Purpose Adhesive Remover

1 oz squeeze tube98960-97Anti-Seize Lubricant

16 oz bottle62600029Big Piston Fork Oil (Sportster XR only)

42830-05CCI #20 Brake Grease

Lubricant

and Coolant (V-Rod only)

Motorcycle Oil

Loctite 246 Medium Strength/High Temperature Threadlocker
(blue)

Loctite 411 Prism Instant Adhesive

Loctite 420 Super Bonder Adhesive

Loctite 770 Prism Primer

squeeze packet (included in master cylinder
rebuild kit)

12 oz bottle99953-99ADOT 4 Brake Fluid

2 cc packet94674-99Dow Corning Moly 44 Grease

1 oz squeeze tube99861-02Electrical Contact Lubricant

1 qt bottle99851-05Formula+ Transmission and Primary Chaincase

squeeze packet42820-04G40M Brake Grease

1 gal container99822-02Genuine Harley-Davidson Extended Life Antifreeze

1 qt bottle99816-2050/00QTGenuine Harley-Davidson H-D 360 20W50

10 g tube99839-95Harley-Davidson Adhesive (Griplock)

1.9 oz squeeze tube99650-02Harley-Davidson High Performance Sealant - Gray

6 oz can98261-91VHarley-Davidson Leather Dressing

1 oz tube11300005Harley-Davidson Seal Grease

1/4 oz needle dispenser94968-09Harley® Lube

3.5 oz tube99653-85Hylomar Gasket and Thread Sealant

6 mL tube99811-97Loctite 222 Low Strength Threadlocker and Sealant (purple)

6 mL tube99642-97Loctite 243 Medium Strength Threadlocker and Sealant (blue)

50 mL bottle11100005

6 mL tube94759-99Loctite 262 High Strength Threadlocker and Sealant (red)

50 mL bottle11100006

6 mL tube99818-97Loctite 565 Thread Sealant

1.75 oz bottle98968-99Loctite 7649 Cleaner/Primer

1.9 oz tube99650-02RTV Silicone Sealer

4 oz bottle94971-09Screamin' Eagle Assembly Lube

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Lubricant 20W50

* Not a Harley-Davidson part number

Table 1-6. Lubricants, Greases, Sealants

PACKAGEPART NUMBERITEM

1 qt bottle99824-03/00QTScreamin' Eagle SYN3 Full Synthetic Motorcycle

14 oz cartridge99857-97ASpecial Purpose Grease

16 oz bottle62600026Type "E" Hydraulic Fork Oil

1 lb can99855-89Wheel Bearing Grease

14 oz cartridge99856-92

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1.6ENGINE OIL AND FILTER

ENGINE OIL LEVEL

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

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

NOTE

The oil level marks for checking with motorcycle upright or on
jiffy stand are on the same side of the dipstick. Carefully read
dipstick when checking oil level.

Check engine oil level at each complete fuel refill.

Oil Level Cold Check

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

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

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

4. See Figure 1-2. Remove filler plug/dipstick and check oil
level. Oil level must register between the ADD QT and
FULL HOT marks. If oil level is at or below the ADD QT
mark, add only enough oil to bring the level to the FULL
HOT mark. Do not overfill.

NOTE
Use only recommended oil specified in 1.3 FUEL AND OIL,

Engine Lubrication.

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

plug and oil filter.

NOTE
Oil level on a cold engine should never be above the midway
point.

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

Remove filler plug/dipstick and check oil level. The correct
oil level is midway (2) between the ADD QT and FULL
HOT marks on the dipstick.

NOTE

If oil level is at or below the ADD QT mark, add only enough
oil to bring the level midway (2) between the ADD QT and FULL
HOT marks. Never bring the level to the FULL HOT mark on
a cold engine.

Oil Level Hot Check

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

NOTE

Perform engine oil level hot check only with engine at normal
operating temperature.

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

perature.

2. Place vehicle on level ground resting on its jiffy stand

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

Figure 1-1. Engine Oil Filler Cap

1. ADD QT (lower) mark

2. Cold check level

3. FULL (hot check) mark

Figure 1-2. Engine Oil Dipstick

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CHANGING OIL AND OIL FILTER

TOOL NAMEPART NUMBER

OIL FILTER WRENCHHD-42311

OIL FILTER WRENCHHD-44067A

TORQUE VALUEFASTENER

19.0-28.5 Nm14-21 ft-lbsEngine oil drain plug

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

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

Lubrication.

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

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

8. Install engine oil drain plug and tighten to 14-21 ft-lbs
(19.0-28.5 Nm).

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

9. Initially add 3.0 quarts (2.8 liters) of engine oil.

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

Engine Oil Level.

a. Check engine oil level using COLD CHECK pro-

cedure.

b. Start engine and carefully check for oil leaks around

drain plug and oil filter.

c. Check engine oil level using HOT CHECK procedure.

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

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

2. Remove filler plug/dipstick.

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

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

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

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

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

NOTE

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

7. See Figure 1-4. Lubricate gasket with clean engine oil and
install new oil filter on filter mount. Hand-tighten oil filter
one-half to three-quarters of a turn after gasket first con­tacts filter mounting surface. Do NOT use oil filter wrench
for installation.

1. Transmission drain plug (right side)

2. Engine oil drain plug and O-ring

3. Hex plug (do not remove)

Figure 1-3. Oil Pan

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1. Thin film of oil ONLY

2. Oil filter

3. Mounting plate

Figure 1-4. Applying Thin Oil Film

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REMOVAL

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

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

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

4. Remove and discard gasket (7).

5. Remove breather tubes from breather bolts.

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

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

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

7. Clean filter element.

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

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

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

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

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

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

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

cannot be adequately cleaned.

1.7AIR CLEANER AND EXHAUST SYSTEM

1. Cover screw

2. Air cleaner cover

3. Rubber seal

4. Cover bracket screw (3)

5. Cover bracket

6. Filter element

7. Gasket

8. Breather tube (2)

Figure 1-5. Air Cleaner Assembly

INSTALLATION

TORQUE VALUEFASTENER

Air cleaner cover bracket
screws

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

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

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

3. Install breather tubes onto breather bolts.

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

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

in-lbs (12.2-14.9 Nm).

6. Verify that rubber seal is properly seated around perimeter

of air cleaner cover.

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

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

in-lbs

12.2-14.9 Nm108-132

4.1-6.8 Nm36-60 in-lbsAir cleaner cover screw

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EXHAUST SYSTEM LEAK CHECK

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

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

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

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

4. Correct any leaks detected.

Exhaust System Leakage

If an exhaust system leak is evident at a muffler or header pipe
connection, disassemble and clean all mating surfaces. See

4.17 EXHAUST SYSTEM.

• Replace any damaged components and assemble.

• If leak continues, disassemble and apply Permatex Ultra
Copper or LOCTITE 5920 FLANGE SEALANT. If not
available, use an equivalent O2 sensor/catalyst-safe
alternative.

• Assemble components. Wipe off any excess sealant.

• Allow adequate curing time following sealant product
instructions before operating vehicle.

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1.8TIRES AND WHEELS

GENERAL

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

Be sure tires are properly inflated, balanced, undamaged,
and have adequate tread. Inspect your tires regularly and
see a Harley-Davidson dealer for replacements. Riding
with excessively worn, unbalanced, improperly inflated,
overloaded or damaged tires can lead to tire failure and
adversely affect stability and handling, which could result
in death or serious injury. (00014b)

Install new seal before mounting tire. Riding motorcycle
without seal in place can sever valve stem causing rapid
air loss leading to the loss of control, which could result
in death or serious injury. (00622b)

Always maintain proper tire pressure as specified in Table 1-7.
Do not load tires beyond GAWR specified in Table 2-4 and

Table 2-5. Underinflated, over-inflated or overloaded tires can

fail.

Use only tires listed in Table 1-7.

NOTE

ABS equipped motorcycles must always use properly inflated
tires and wheels that are the same as the original equipment.
The ABS system monitors rotational speed of the wheels
through individual wheel speed sensors to determine the
application of ABS.

Different diameter wheels or tires can:

•

Alter the rotational speed which can upset the calibration
of the ABS.

•

Adversely effect its ability to detect and prevent lockups.

Operating with inflation pressure other than those specified in

Table 1-7 can reduce ABS performance.

TIRES

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

NOTES

•

Tubeless tires are used on all Harley-Davidson cast and
disc wheels, and tubeless profile laced wheels with MTM
designation.

•

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

•

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

Check tire pressure and tread:

• As part of the pre-ride inspection.

• At every scheduled service interval.

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

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

Be sure tires are properly inflated, balanced, undamaged,
and have adequate tread. Inspect your tires regularly and
see a Harley-Davidson dealer for replacements. Riding
with excessively worn, unbalanced, improperly inflated,
overloaded or damaged tires can lead to tire failure and
adversely affect stability and handling, which could result
in death or serious injury. (00014b)

NOTE

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

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

NOTE
Harley-Davidson does not perform any testing with only
nitrogen in tires. Harley-Davidson neither recommends nor
discourages the use of pure nitrogen to inflate tires.

FLTRX, FLHX

Table 1-7. Specified Tires

PRESSURE (COLD)SPECIFIED TIRESIZEMOUNTMODEL

kPaPSI

24836Dunlop D408F 130/80B17 65H17 infrontAll models except FLHRC,

24836Dunlop D408F 130/90B16 67H16 infrontFLHRC

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Table 1-7. Specified Tires

PRESSURE (COLD)SPECIFIED TIRESIZEMOUNTMODEL

kPaPSI

24836Dunlop D408F 130/70B18 63H18 infrontFLTRX, FLHX

27640Dunlop D407 180/65B16 81H16 inrearAll models

TIRE REPLACEMENT

Inspection

Replace tire immediately with a Harley-Davidson specified
tire when wear bars become visible or only 1/32 in (0.8
mm) tread depth remains. Riding with a worn tire could
result in death or serious injury. (00090c)

Harley-Davidson tires are equipped with wear bars that run
horizontally across the tread. When a tire is worn to the point
that the wear bars are visible, or 1/32 in. (0.8 mm) tread depth
remains, the tire can:

• Be more easily damaged leading to tire failure.

• Provide reduced traction.

• Adversely affect stability and handling.

Arrows on tire sidewalls pinpoint location of wear bar indicators.

When To Replace Tires

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

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

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

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

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

NOTES

•

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

•

Never install a tire and inner tube on a laced rim with
TUBELESS and MTM designations etched into the rim.
These rims are specially designed for tubeless use only.

•

Replace rim strip and rim seal whenever the tire is
removed.

WHEEL BEARINGS

Service wheel bearings:

1. Check wheel bearings as outlined in 2.10 SEALED

WHEEL BEARINGS. Replace wheel bearings if end play

exceeds 0.002 in. (0.051 mm).

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

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

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

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

rotation, abnormal noise or anything unusual.

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

Figure 1-6. Inspect Wheel Bearings

WHEEL SPOKES

TOOL NAMEPART NUMBER

SPOKE TORQUE WRENCHHD-48985

SPOKE NIPPLE WRENCHHD-94681-80

TORQUE VALUEFASTENER

6.2 Nm55 in-lbsSpoke nipple

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

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Do not over tighten spoke nipples. Protruding spoke
nipples can damage rim seal, resulting in rapid tire defla­tion, which could cause death or serious injury. (00611b)

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

Identify Wheel Spoke Groups

NOTE

Spokes are grouped in sets of four.

1. Raise wheel with a suitable lifting device.

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

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

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

Wheel Spoke Adjustment

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

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

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

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

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

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

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

80).

b. While tightening, if the torque wrench clicks before

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

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

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

7. True the wheel. See 2.9 CHECKING AND TRUING

WHEELS.

Table 1-8. Spoke Nipple Torque Specification

MINIMUM TORQUERIM TYPE

55 in-lbs (6.2 Nm)All

NOTES

•

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

•

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

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

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

a. While tightening, if the torque wrench clicks before

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

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

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

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

Figure 1-7. Tightening Laced Wheels (typical)

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1.9PRIMARY CHAINCASE LUBRICANT

GENERAL

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

CHANGING PRIMARY CHAINCASE LUBRICANT

TORQUE VALUEFASTENER

19.0-28.5 Nm14-21 ft-lbsPrimary chaincase drain plug

9.5-12.2 Nm84-108 in-lbsClutch inspection cover

screws

6.8-7.9 Nm60-70 in-lbsBattery terminal bolt

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

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

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

2. See Figure 1-8. Drain lubricant into suitable container.

9. Place motorcycle in an upright position to fill primary
chaincase.

10. Pour specified amount of FORMULA+ TRANSMISSION
AND PRIMARY CHAINCASE LUBRICANT through clutch
inspection cover opening. Refer to Table 1-9.

Table 1-9. Primary Chaincase Lubricant Refill Capacity

CAPACITYITEM

38 oz (1.12 L) wetPrimary chaincase lubricant

45 oz (1.33 L) dry

NOTE

Dispose of lubricant in accordance with local regulations.

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

4. Install new O-ring on drain plug.

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

To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)

6. Disconnect negative battery cable.

7. See Figure 1-9. Remove screws with captive washers (3)
to detach clutch inspection cover (2).

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

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

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

1. Seal

2. Clutch inspection cover

3. Screws with captive washer

Figure 1-9. Clutch Cover

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11. Install clutch inspection cover and new seal:

a. Thoroughly wipe all lubricant from cover mounting

surface and groove in chaincase cover.

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

clutch inspection cover. Press each of the nubs on
seal into the groove.

c. Secure inspection cover with screws with captive

washers (3).

d. See Figure 1-10. Tighten in sequence shown to 84-

108 in-lbs (9.5-12.2 Nm).

12. Connect battery negative cable. Tighten to 60-70 in-lbs

(6.8-7.9 Nm)

Figure 1-10. Clutch Cover Torque Sequence

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CHECKING TRANSMISSION LUBRICANT

TORQUE VALUEFASTENER

2.8-8.5 Nm25-75 in-lbsTransmission dipstick

Table 1-10. Recommended Lubricant

1.10TRANSMISSION LUBRICANT

LUBRICANT

CHAIN LUBRICANT
or
SCREAMIN' EAGLE SYN3 FULL SYNTHETIC
MOTORCYCLE LUBRICANT 20W50

*Approximate. Check and add as needed to bring level within
specification.

1. Park the motorcycle on a level surface leaning on the jiffy
stand.

2. See Figure 1-11. Remove the transmission lubricant dip­stick. Wipe the dipstick clean.

3. Insert dipstick into transmission. Thread dipstick in until
O-ring makes contact with case. Do not tighten.

4. See Figure 1-12. Remove the dipstick. Check lubricant
level on dipstick.

Mixing mineral-based lubricants with SYN-3 in the trans­mission can damage the transmission. (00452b)

5. The level should be between the A and F marks. Add
lubricant if necessary. Refer to Table 1-10.

6. Install the dipstick. Tighten to 25-75 in-lbs (2.8-8.5 Nm).

REFILL
QUANTITY *

28 oz (0.83 L)FORMULA+ TRANSMISSION AND PRIMARY

1. Add

2. Full

Figure 1-12. Transmission Dipstick Lubricant Level

CHANGING TRANSMISSION LUBRICANT

TORQUE VALUEFASTENER

19.0-28.5 Nm14-21 ft-lbsTransmission drain plug

2.8-8.5 Nm25-75 in-lbsTransmission filler plug/dip-

stick

1. See Figure 1-11. Remove transmission filler plug/dipstick.

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

Figure 1-11. Transmission Dipstick Location

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

2. See Figure 1-13. Remove transmission drain plug. Drain
lubricant into a suitable container.

NOTE
Dispose of transmission lubricant in accordance with local
regulations.

3. Clean and inspect drain plug and O-ring.

Do not over-tighten filler or drain plug. Doing so could
result in a lubricant leak. (00200b)

4. Install drain plug with O-ring. Tighten to 14-21 ft-lbs (19.0-

28.5 Nm). Do not over-tighten.

5. Fill the transmission with 28 oz (0.83 L) of recommended

Harley-Davidson lubricant. Refer to Table 1-10.

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6. Check lubricant level and add enough lubricant to bring
the level between the A(dd) and F(ull) marks. See

1.10 TRANSMISSION LUBRICANT, Checking Transmis­sion Lubricant.

7. Install filler plug/dipstick. Tighten to 25-75 in-lbs (2.8-8.5
Nm).

1. Transmission drain plug (right side)

2. Engine oil drain plug and O-ring

3. Hex plug (do not remove)

Figure 1-13. Oil Pan

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ADJUSTMENT

TORQUE VALUEFASTENER

8.1-13.6 Nm72-120 in-lbsClutch adjuster screw jamnut

13.6 Nm120 in-lbsClutch cable adjustment

jamnut

9.5-12.2 Nm84-108 in-lbsClutch inspection cover

screws

NOTE

Perform the clutch adjustment with the motorcycle at room
temperature. Clearance at the adjuster screw will increase as
the powertrain temperature increases. If adjustment is made
with powertrain hot, clearance at pushrod bearing could be
insufficient with powertrain cold. Clutch slippage could occur.

1. Stand motorcycle upright and level.

2. Remove clutch inspection cover from primary chaincase
cover.

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

4. See Figure 1-14. Add freeplay to cable.

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

b. Loosen jamnut (3) and back away from cable adjuster.

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

amount of free play at hand lever.

1.11CLUTCH

1. Rubber boot

2. Cable adjuster

3. Jamnut

4. Cable end

Figure 1-14. Clutch Cable Adjuster

5. See Figure 1-15. Loosen jamnut (1) on clutch adjuster
screw. Turn adjuster screw (2) inward (clockwise) until
lightly seated.

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

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

8. See Figure 1-14. Check freeplay.

a. Turn cable adjuster (2) until slack is eliminated at

hand lever.

b. See Figure 1-16. Pull clutch cable ferrule (2) away

from clutch lever bracket to check free play. Turn
cable adjuster as necessary to obtain 1/16-1/8 in.
(1.6-3.2 mm) free play (4).

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

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

11. See Figure 1-10. Secure clutch inspection cover. Tighten
screws in sequence to 84-108 in-lbs (9.5-12.2 Nm).

1. Jamnut

2. Clutch adjuster screw

Figure 1-15. Clutch Adjuster Screw

1. Clutch cable

2. Cable ferrule

3. Clutch lever bracket

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

Figure 1-16. Clutch Cable Free Play

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GENERAL

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

In the case of stone damage to belt, inspect the sprockets for
damage and replace as required. If replacing belt, always
replace both transmission and rear sprockets.

CLEANING

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

INSPECTION

Sprockets

NOTE

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

1. See Figure 1-17. Inspect each tooth (1) of rear sprocket
for:

a. Major tooth damage.

b. Large chrome chips with sharp edges.

c. Gouges caused by hard objects.

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

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

a. If scribe or knife point slides across groove without

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

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

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

1.12DRIVE BELT AND SPROCKETS

1. Tooth

2. Groove

Figure 1-17. Rear Sprocket

Drive Belt

See Figure 1-18. Inspect drive belt for:

• Cuts or unusual wear patterns.

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

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

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

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

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

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

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

NOTE

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Figure 1-18. Drive Belt Wear Patterns

Table 1-11. Drive Belt Wear Analysis

REQUIRED ACTIONCONDITIONPATTERN

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

Replace belt.External tooth cracks2

Replace belt.Missing teeth3

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

OK to run, but monitor condition.Fuzzy edge cord5

Replace belt and sprocket.Hook wear6

Replace belt if damage is on the edge.Stone damage7

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

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CHECKING DRIVE BELT DEFLECTION

TOOL NAMEPART NUMBER

BELT TENSION GAUGEHD-35381A

TORQUE VALUEFASTENER

6.8-7.9 Nm60-70 in-lbsBattery terminal bolt

NOTE

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

Check deflection:

• At every scheduled service interval.

• With transmission in neutral.

• At loosest spot in belt.

• With motorcycle at room temperature.

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

1. Transmission sprocket

2. Rear wheel sprocket

3. 10 lbs (4.5 kg) of force

4. Amount of deflection

Figure 1-19. Checking Belt Deflection

SETTING BELT DEFLECTION

TOOL NAMEPART NUMBER

To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)

1. Disconnect negative battery cable. See 1.21 BATTERY

MAINTENANCE, Battery.

2. Remove left side saddlebag.

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

4. See Figure 1-19. Fit cradle against bottom of belt midway
between transmission sprocket and rear sprocket.

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

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

6. Measure deflection at several locations around the belt.

Select the loosest measurement and compare with spe­cifications in Table 1-12. Belt must be adjusted if not within
specification.

7. Connect battery negative cable. Tighten to 60-70 in-lbs

(6.8-7.9 Nm).

Table 1-12. Belt Deflection

MILLIMETERSINCHESMODEL

6.4-11.11/4-7/16FLHX, FLTRX

9.5-14.33/8-9/16Other models

torque

screws

Adjustment

1. Remove both saddlebags.

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

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

3. See Figure 1-20. Install AXLE NUT TORQUE ADAPTER
(Part No. HD-47925) perpendicular to breaker bar. For
best clearance with muffler, install torque adapter on the
outboard side.

To install tools on the cone nut and weld nut, it may be benefi­cial to remove bolts fastening each muffler to the saddlebag
frame to allow movement of the mufflers.

4. Insert tool up between rear wheel and muffler and onto
cone nut. Loosen cone nut.

BELT TENSION GAUGEHD-35381A

AXLE NUT TORQUE ADAPTERHD-47925

TORQUE VALUEFASTENER

20-27 Nm15-20 ft-lbsRear axle cone nut, 1st torque

95-105 ft-lbsRear axle cone nut, final

NOTE

NOTE

128.8-142.4
Nm

10.8-16.3 Nm96-144 in-lbsMuffler to saddlebag support

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

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

47925) on torque wrench, perpendicular to torque wrench.

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

cone nut.

7. See Figure 1-21. Push wheel forward and verify that cam

(5) contacts boss (4) on both sides of rear fork.

8. For purposes of adjustment only, snug the cone nut (6) to

15-20 ft-lbs (20-27 Nm).

9. Use BELT TENSION GAUGE (Part No. HD-35381A) to

check belt deflection as adjustment is made. See

1.12 DRIVE BELT AND SPROCKETS, Checking Drive
Belt Deflection.

NOTE

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

10. See Figure 1-21. Rotate weld nut (3) on left side of axle
to adjust belt tension; clockwise to tighten or counterclock­wise to loosen. If loosening the belt tension, push the
wheel forward. Verify both cams (5) touch the bosses (4)
on both sides after the weld nut is rotated.

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

Assembly

NOTE

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

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

142.4 Nm).

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

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

4. If removed, install fasteners that attach mufflers to the
saddlebag frames and tighten to 96-144 in-lbs (10.8-16.3
Nm).

5. Install saddlebags.

1. Torque wrench

2. Axle nut torque adapter (HD-47925)

Figure 1-20. Install Tool Perpendicular to Torque Wrench

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5.1. Adjuster camIncrease belt deflection

2. 6.Reduce belt deflection Cone nut

7.3. E-clipWeld nut

4. Boss

Figure 1-21. Rear Wheel Adjuster Cams

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1.13REAR SPROCKET ISOLATOR

INSPECTION

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

2. Remove left saddlebag.

3. See Figure 1-22. Hang a weighted string (1) on the left
axle spacer as close as possible to, but not touching, the
rear sprocket.

NOTE

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

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

NOTE

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

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

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

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

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

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

NOTE

Visually inspect components when disassembled. Excessive
play in the compensator components are caused by deterior­ated, crumbling or flaking of the rubber segments. Wear on
the raised "nubs" or small amounts of rubber debris are normal.
This type of wear does not indicate a worn out isolator. See

2.6 REAR WHEEL COMPENSATOR if the rear wheel com-

pensator needs to be serviced.

1. Weighted string

2. Measured distance

Figure 1-22. Check Compensator Wear

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1.14CABLE AND CHASSIS LUBRICATION

GENERAL

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

• Front brake hand lever.

• Clutch hand lever.

• Clutch cable.

• Foot shift lever pivot (if applicable).

• Rear brake lever pivot.

• Steering head bearings.

• Jiffy stand.

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

Use HARLEY LUBE for hand levers and cables.

STEERING HEAD BEARINGS

Lubricate the steering head bearings with HARLEY-DAVIDSON
SPECIAL PURPOSE GREASE. See 1.18 STEERING HEAD

BEARINGS for procedure.

JIFFY STAND

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

2.50 JIFFY STAND.

MISCELLANEOUS LUBRICATION

Hinges, Latches, Etc.

Lubricate the rub points of latches and hinges using HARLEY
LUBE as required.

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

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FLUID INSPECTION

1. Position vehicle for inspection.

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

Turn handlebar so front brake master cylinder is
approximately level.

b. Rear brake: Have an assistant hold vehicle upright

on a level surface.

2. See Figure 1-23. View reservoir sight glass and verify fluid
presence.

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

DISCS.

4. If fluid is still not visible through sight glass, remove cover
and verify fluid level. If necessary, add DOT 4 BRAKE
FLUID to reservoir. Replace cover. See 2.16 BLEEDING

BRAKES.

5. Front brake hand lever and rear brake foot pedal must
have a firm feel when applied. If not, bleed system using
only DOT 4 BRAKE FLUID. See 2.16 BLEEDING

BRAKES.

1.15BRAKES

1. Sight glass, front master cylinder reservoir

2. Sight glass, rear master cylinder reservoir

Figure 1-23. Brake Fluid Sight Glass (typical)

BRAKE LINES

Inspect brake lines for leaks, contact or abrasion. Refer to

Table 1-13.

Table 1-13. Brake Line Inspection

Slight mark in paint or plating*

Copper colored-paint/plating worn off*

Silver colored base material-no noticeable feel of wear*

Brake fluid leak or other damage

Slight dent or flattening of ribs*

Brake fluid leak or other damage

(steel, rubber, plastic or braided)

* If there is line contact, reposition the line. If base material is visible, prevent corrosion with touch-up paint.

Slight dent in covering*

Slight dent or flattening of plastic covering*

Brake fluid leak or other damage

REMEDYINSPECTIONLINE TYPE

OK/MonitorNo marksSteel lines

ReplaceSilver colored base material-noticeable feel of wear*

OK/MonitorNo marksRubber hose

ReplaceWorn to bottom of ribs

OK/MonitorNo marksProtective cover

ReplaceWorn or cut-through covering-exposed brake line material

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1.16BRAKE PADS AND DISCS

INSPECTION

Check brake pads and discs:

• At every scheduled service interval.

• Whenever the components are removed during service
procedures.

Brake Pads

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

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

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

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

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

NOTE

See Figure 1-25. Refer to the wear indicator lines for a general
indication of pad wear.

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

Inspect the brake lines and hoses for damage or wear.

Brake Disc Thickness

The minimum brake disc thickness is stamped on the side of
the disc:

• Front: 0.18 in. (4.5 mm)

• Rear: 0.18 in. (4.5 mm)

Replace any disc that is excessively worn or badly scored.

Brake Disc Lateral Runout

Measure brake disc runout using a dial indicator mounted to
a stationary surface. Maximum brake disc lateral runout is

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

BRAKE PAD REPLACEMENT

TORQUE VALUEFASTENER

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

58.3-65.1 Nm43-48 ft-lbsBrake caliper, rear, mounting

screws

1.4-1.7 Nm12-15 in-lbsBrake master cylinder, rear,

reservoir cover screws

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

37.9-51.5 Nm28-38 ft-lbsBrake caliper, front, mounting

screws

Brake master cylinder, front,
reservoir cover screws

in-lbs

1.3-1.7 Nm11.5-15.0

Rear Brake Caliper

1. Remove right side saddlebag. See 2.26 SADDLEBAGS,

Removal.

2. ABS equipped: Release rear wheel speed sensor cable
from retainer clip on brake hose.

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

4. Remove brake caliper from brake disc.

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

5. Stand motorcycle upright with rear master cylinder reser-

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

6. Remove master cylinder reservoir cover.

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

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

bores.

8. See Figure 1-27. Pull retaining clip (3) from groove in pad

pin.

9. See Figure 1-24. Remove pad pin (metric).

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

11. See Figure 1-27. Remove pad spring (1) if damaged or

worn.

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

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

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

18. ABS equipped: Secure sensor cable with clip on brake

hose.

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

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

20. See Figure 1-28. Check brake fluid level in master cylinder
reservoir. If necessary, add DOT 4 BRAKE FLUID until
level is flush with ledge cast at front of reservoir.

21. Install master cylinder reservoir cover with screws. Tighten
to 12-15 in-lbs (1.4-1.7 Nm).

22. Install right side saddlebag. See 2.26 SADDLEBAGS,

Installation.

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

23. Test brake system.

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

operation of stop lamp.

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

spongy. See 2.16 BLEEDING BRAKES.

1. Rear caliper

2. Front left caliper (screen removed)

Figure 1-24. Brake Caliper Pad Pin

13. Install new brake pads:

a. See Figure 1-25 and Figure 1-26. Insert brake pad

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

b. Push pad pin tab into caliper until seated.

c. Verify that brake pad friction material faces brake disc

gap in caliper.

d. Repeat step to install remaining brake pad.

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

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

16. See Figure 1-27. Install retaining clip in groove of pad pin,
so that lip overhangs caliper housing.

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

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

1. Square corner

2. Pad pin tab

3. Pad pin hole

4. Friction material

5. Wear indicator lines

Figure 1-25. Brake Pad

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Figure 1-26. Brake Caliper (Bottom View)

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

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

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

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

5. Remove cover from master cylinder reservoir.

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

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

bores.

7. Remove screen from caliper.

8. See Figure 1-27. Pull retaining clip from groove in pad pin.

9. See Figure 1-24. Remove pad pin (metric).

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

11. Remove pad spring if damaged or worn.

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

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

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

13. Install new brake pads:

a. See Figure 1-25 and Figure 1-26. Insert brake pad

into caliper engaging square corner of pad in slot of

1. Pad spring (forked end)

2. Pad pin tab

3. Pad pin retaining clip

Figure 1-27. Brake Caliper (Top View)

Front Brake Calipers

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

2. ABS equipped: Release front wheel speed sensor cable
from clip:

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

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

pendicular to bracket and remove cable.

14. Verify that pad pin tabs are centered under forks of pad

15. Install new pad pin. Tighten to 75-102 in-lbs (8.5-11.5

16. See Figure 1-27. Install retaining clip in groove of pad pin,

17. Engage two prongs on screen beneath forked end of pad

caliper.

b. Push pad pin tab into caliper until seated.

c. Verify that brake pad friction material faces brake disc

gap in caliper.

d. Repeat step to install remaining brake pad.

spring. Adjust pads if necessary.

Nm).

so that lip overhangs caliper housing.

spring and push on single prong side of screen until
engaged.

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18. Install brake caliper:

a. Install caliper with bleeder at top (and cable

clip/bracket if ABS equipped). Secure with two screws.

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

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

Nm).

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

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

speed sensor if equipped.

20. ABS equipped: Install front wheel speed sensor cable in

clip. See C.3 WHEEL SPEED SENSORS.

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

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

22. See Figure 1-28. Check brake fluid level in master cylinder
reservoir. If necessary, add DOT 4 BRAKE FLUID until
level is flush with step (marked MAX) cast at rear of
reservoir.

23. Verify gasket and sealing surfaces are free of debris. Install

master cylinder reservoir cover. Tighten to 11.5-15.0 in-lbs
(1.3-1.7 Nm).

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

24. Test brake system.

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

operation of stop lamp.

b. Test ride motorcycle. Bleed system if brakes feel

spongy. See 2.16 BLEEDING BRAKES.

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

Orient the cover with the vent holes facing the rear.

NOTE

1. Front master cylinder reservoir

2. Rear master cylinder reservoir

Figure 1-28. Brake Fluid Level

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1.17SPARK PLUGS

REMOVAL

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

NOTE

Allow the engine to cool before servicing.

1. Disconnect spark plug cables.

2. Remove spark plugs.

INSPECTION

NOTE

Discard plugs with eroded electrodes, heavy deposits or a
cracked insulator.

See Figure 1-29. Compare plug deposits to Table 1-14.

Table 1-14. Spark Plug Deposit Analysis

POSSIBLE CAUSEDEPOSITSPLUG*

Wet, black and shiny1

2

and black

Light brown and

3

glassy**
May be accompanied
by cracks in the insu­lator or by electrode
erosion.

White, gray or tan

4

and powdery

* See Figure 1-29.
** The glassy deposit on a spark plug may cause high-speed
misfiring.

Worn pistons
Worn piston rings
Worn valves
Worn valve guides
Worn valve seals
Weak battery
Faulty ignition system

Air-fuel mixture too richDry, fluffy or sooty

Air-fuel mixture too lean
Hot running engine
Valves not seating
Improper ignition timing

Balanced combustion
Clean off deposits at regular
intervals.

Figure 1-29. Spark Plug Deposits

CLEANING

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

If the plugs require cleaning between tune-ups:

1. Clean electrodes and insulator with electrical contact
cleaner. Dry plug with compressed air.

2. Use a thin file to flatten electrodes.

NOTE
Electrodes with sharp edges require 25-40 percent less voltage
than ones with rounded edges.

3. Check condition of threads in cylinder head. If necessary

to remove deposits, apply penetrating oil and clean out
with a thread chaser. Verify that plug threads are clean.

4. If necessary, replace with new spark plugs.

INSTALLATION

TORQUE VALUEFASTENER

16.3-24.4 Nm12-18 ft-lbsSpark plug

1. Verify proper gap before installing new or cleaned spark

plugs.

a. Select a wire-type feeler gauge within specification.

Refer to Table 1-15.

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NOTE
The spark plug gap is within specification when there is a
slight drag on the gauge.

b. Pass the wire gauge between the center and the outer

electrodes.

c. If necessary use the proper tool to bend the outer

electrode to bring the gap to within specification.

2. Apply ANTI-SEIZE LUBRICANT to the spark plug threads.
Tighten to 12-18 ft-lbs (16.3-24.4 Nm).

3. See Figure 1-30. Connect spark plug cables. Verify cables
are connected to coil, spark plugs and anchor clips or
harness caddies.

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

3. See Figure 1-31. Check spark plug cable resistance with
an ohmmeter. Replace cables not meeting resistance
specifications. Refer to Table 1-16.

Table 1-16. Spark Plug Cable Resistance Values

LENGTHDESCRIPTION

mmIn.

RESISTANCE

VALUE

(OHMS)

8688-23,17888334.75Front cable

4188-11,17242516.75Rear cable

Figure 1-30. Spark Plug Wires

Table 1-15. Spark Plug Gap

0.97-1.090.038-0.043HD-6R12All Models

SPARK PLUG CABLE INSPECTION

1. Inspect spark plug cables. Replace if necessary.

a. Check for cracks or loose terminals.

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

1. Ohmmeter positive lead

2. Ohmmeter negative lead

3. Spark plug cable

4. Ohmmeter

mminTYPEMODEL

Figure 1-31. Testing Resistance

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1.18STEERING HEAD BEARINGS

LUBRICATION

1. See Figure 1-32. Turn handlebar to the right fork stop to
access grease fitting at the left side of the steering head.

2. Inject SPECIAL PURPOSE GREASE until it exits from the
top and bottom of the steering head.

Figure 1-32. Steering Head Bearing Grease Fitting

CHECKING

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

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

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

3. See Figure 1-33. Turn the front wheel to the left fork stop
and then let go. The wheel should swing from side to side,
finally stopping in the swing specified in Table 1-17. If it
stops in the lesser number swing, it should be at or after
the straight-forward position.

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

a. Clutch cable: Disconnect clutch cable from hand

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

CABLE.

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

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

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

5. To correct a swing pattern, see 1.18 STEERING HEAD

BEARINGS, Adjustment.

Figure 1-33. Steering Head Bearing Swing Count

Table 1-17. Steering Head Bearing Swing Count

Art ReferenceMaximumMinimumModel

(A)21FLTRX, FLTRU

(A-B)32FLHR, FLHRC

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

(D)More than 4TOO LOOSE

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ADJUSTMENT

TORQUE VALUEFASTENER

70-80 ft-lbsFork stem nut

1. Disassemble motorcycle:

a. Road King models: Remove headlamp nacelle. See

2.44 HEADLAMP NACELLE: ROAD KING MODELS.

b. Fork mounted fairing models: Remove outer fairing

and radio or storage box as equipped. See

2.34 UPPER FAIRING AND WINDSHIELD: FORK
MOUNTED FAIRING MODELS and 7.34 ADVANCED
AUDIO SYSTEM, respectively.

c. Frame mounted fairing models: Remove instrument

bezel. See 2.39 INSTRUMENT BEZEL: FRAME

MOUNTED FAIRING MODELS.

2. See Figure 1-34. Loosen pinch bolts (3) on lower fork
bracket.

3. Loosen the fork stem nut (1).

4. See Figure 1-35. Fashion a bearing adjuster tool using a
drill rod 1/4 in. (6.4 mm) in diameter and 16 in. (406.4 mm)
long.

94.9-108.4
Nm

71.9-77.3 Nm53-57 ft-lbsFork bracket pinch bolt

10. Assemble motorcycle:

a. Road King models: Install headlamp nacelle. See

2.44 HEADLAMP NACELLE: ROAD KING MODELS.

b. Fork mounted fairing models: Install radio or

storage box (as equipped) and outer fairing. See

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

c. Frame mounted fairing models: Install instrument

bezel. See 2.39 INSTRUMENT BEZEL: FRAME

MOUNTED FAIRING MODELS.

11. Install any accessories that were removed.

NOTES

•

See Figure 1-34. Turning the bearing adjuster nut (2) as
little as one notch will make a noticeable difference in the
swing pattern.

•

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

5. Turn bearing adjuster nut (2):

a. To decrease the number of swings, rotate nut

clockwise.

b. To increase the number of swings, rotate nut

counterclockwise.

NOTE
Original equipment fork stem nut has a blue dye coating. A
replacement nut will not have the blue coating.

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

NOTE
Torque of the stem nut will affect the swing pattern.

7. Recheck the swing pattern and adjust as necessary.

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

9. Verify that the fork stem nut is tightened to specification

and recheck the swing pattern. Adjust if necessary.

1. Fork stem nut

2. Adjuster nut

3. Pinch bolt

Figure 1-34. Fork Stem and Brackets

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1. All models except FLTRX

2. FLTRX

3. 1/8 in (3.2 mm)

4. 5/32 in (4.0 mm)

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

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

Figure 1-35. Fashion Bearing Adjuster Tool

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1.19REAR SUSPENSION ADJUSTMENTS

AIR SUSPENSION

TOOL NAMEPART NUMBER

AIR SUSPENSION PUMP AND GAUGEHD-34633A

See Figure 1-36. Adjust the rear air suspension by adding or
removing air from the air valve located near the left upper shock
absorber mount. Always adjust pressures with the motorcycle
on the jiffy stand.

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

Air pressure may be varied to suit load conditions, riding style
and personal comfort.

• Less initial pressure does not necessarily result in a softer

ride. Refer to Table 1-18 or Table 1-19 as a starting point
for rear air suspension pressures.

• Do not exceed maximum GVWR when loading vehicle.

• Do not pressurize system in excess of 50 psi (345 kPa).

NOTES

•

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

•

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

•

Improper inflation can result in a reduction of available
suspension travel. This reduces rider comfort and may
cause damage to shock absorbers.

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

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

Table 1-18. Recommended Suspension Air Pressure: Models With Tour-Pak

70 lbs (32 kg)

Do not exceed 50 psi (345 kPa) suspension pressure.
*Refer to Table 2-4 for maximum added weight allowed on the motorcycle.

Figure 1-36. Rear Air Suspension Air Valve

PRESSURETOTAL WEIGHTSHOCK LOAD

kPaPSI

34-695-10up to 150 lb (68 kg)Solo rider

69-13810-20150-200 lb (68-91 kg)

138-20620-30200-250 lb (91-113 kg)

206-27630-40250-300 lb (113-136 kg)

276-34540-50300 lb (136 kg) to maximum added weight allowed*

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

206-27630-40150-200 lb (68-91 kg)

276-34540-50200-250 lb (91-113 kg)

34550250 lb (113 kg) to maximum added weight allowed*

34550Any weight up to maximum added weight allowed*Rider plus passenger

34550Maximum added weight allowed*Maximum loaded vehicle

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Table 1-19. Recommended Suspension Air Pressure: Models Without Tour-Pak

40 lbs (18 kg)

If an optional Tour-Pak is installed, add 5-10 psi (34-69 kPa) to shock pressure.
Do not exceed 50 psi (345 kPa) suspension pressure.
*Refer to Table 2-5 for maximum added weight allowed on the motorcycle.

PRESSURETOTAL WEIGHTSHOCK LOAD

kPaPSI

00up to 150 lb (68 kg)Solo rider

0-690-10150-200 lb (68-91 kg)

69-13810-20200-250 lb (91-113 kg)

138-20620-30250-300 lb (113-136 kg)

206-34530-50300 lb (136 kg) to maximum added weight allowed*

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

138-20620-30150-200 lb (68-91 kg)

206-27630-40200-250 lb (91-113 kg)

276-34540-50250-300 lb (113-136 kg)

34550300 lb (136 kg) to maximum added weight allowed*

276-34540-50Any weight up to maximum added weight allowed*Rider plus passenger

34550Maximum added weight allowed*Maximum loaded vehicle

MANUAL SUSPENSION PRELOAD

Adjust the shock absorber preload for the weight the motorcycle
is to carry.

• Increase preload to accommodate the total load on the
motorcycle.

• Reduce the preload if carrying less weight.

1. Remove the left saddlebag.

2. See Figure 1-37. Rotate the preload adjustment knob
counterclockwise until it stops. This is the minimum preload
position.

3. Refer to Table 1-20. Rotate the preload adjustment knob
clockwise the recommended number of turns to increase
the preload for the total weight of the rider, passenger and
cargo. The knob will click after each half rotation.

4. Install the left saddlebag.

Table 1-20. Recommended Preload Settings

LOADPRELOAD

TURNS FROM

MINIMUM

Figure 1-37. Preload Adjustment Knob

LOADPRELOAD

TURNS FROM

MINIMUM

310 lb (141 kg)10Less than 220 lb (100 kg)0

320 lb (145 kg)11220 lb (100 kg)1

330 lb (150 kg)12230 lb (104 kg)2

340 lb (154 kg)13240 lb (109 kg)3

350 lb (159 kg)14250 lb (113 kg)4

360 lb (163 kg)15260 lb (118 kg)5

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Table 1-20. Recommended Preload Settings

LOADPRELOAD

TURNS FROM

MINIMUM

Load includes the total weight of the rider, passenger, riding gear, accessories and cargo.

TURNS FROM

MINIMUM

19300 lb (136 kg)9

LOADPRELOAD

370 lb (168 kg)16270 lb (122 kg)6

380 lb (172 kg)17280 lb (127 kg)7

390 lb (177 kg)18290 lb (132 kg)8

400 lb (181 kg) to maximum added weight
allowed (refer to Table 1-20)

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1.20CRITICAL FASTENERS

INSPECTION

Checking Torques on Fasteners

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

Table 1-21. Critical Fasteners

clamp screws

handlebar clamp screws

cover screws

cover screws

screws

screws

bracket screws

Engine stabilizer link

1. Attempt to turn the fastener using a torque wrench set to
the minimum torque specification for that fastener. Refer
to Table 1-21.

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

has been maintained. No further attention is neces­sary.

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

a locking agent.

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

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

d. Install fastener. Tighten to specification.

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

TORQUEFASTENERSYSTEM

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

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

8.1-12.2 Nm72-108 in-lbsMaster cylinder reservoir

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

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

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

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

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

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

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

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

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

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

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

81.3-88.1 Nm60-65 ft-lbsFrontAxle nuts

129.0-142.0 Nm95-105 ft-lbsRear

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

74.6-88.1 Nm55-65 ft-lbsFastenersPivot shaft

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

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

See 1.23 ENGINE MOUNTS.Engine mount bolts

54.2-61.0 Nm40-45 ft-lbsRear frame bolts

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1.21BATTERY MAINTENANCE

GENERAL

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

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

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

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

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

NOTE

For charging information, see 1.21 BATTERY MAINTENANCE,

Charging Battery. For testing information, see the electrical

diagnostic manual.

Figure 1-38. AGM Battery with Warning Label

4.1. Keep flames awayContents are corrosive

2. 5.Wear safety glasses Read instructions

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Figure 1-39. Battery Warning Label

6.3. Keep away from childrenContents are explosive

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Table 1-22. Antidotes for Battery Acid

TREATMENTCONTACT

Flush with water.External

Internal

Eyes

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

Flush with water. Get immediate medical
attention.

CLEANING AND INSPECTION

NOTE

Battery top must be clean and dry. Dirt and electrolyte on top
of the battery causes battery to self-discharge.

1. Clean battery top with a solution of baking soda (sodium
bicarbonate) and water (5 teaspoons baking soda per
quart or liter of water).

2. When the solution stops bubbling, rinse off the battery with
clean water.

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

4. Inspect the battery screws, and cables for breakage, loose
connections and corrosion.

5. Check the battery terminals for melting or damage caused
by over-tightening.

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

7. Inspect the battery case for cracks or leaks.

BATTERY

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

7. Disconnect the battery cables, negative cable first.

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

1. Purge solenoid

2. HFSM antenna

3. Cable straps

4. Fastener

5. Hold-down (not visible)

Figure 1-40. Top Caddy

TORQUE VALUEFASTENER

6.8-7.9 Nm60-70 in-lbsBattery terminal bolt

8.1-10.9 Nm72-96 in-lbsTop caddy screws

Disconnection and Removal

1. Remove seat.

2. See Figure 1-40. If present, move purge solenoid (1) for­ward to release from top caddy. Release HFSM antenna
(2) from top caddy and move out of the way.

3. Remove fasteners (4).

4. Cut cable straps (3). Move harnesses to allow more
clearance for the top caddy.

5. See Figure 1-41. Release top caddy from front hold-down
bracket and rotate top caddy (1) out of the way.

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

1. Top caddy

2. Lifting strap

Figure 1-41. Move Top Caddy Aside

Installation and Connection

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

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

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

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

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

3. Turn the ignition switch to the OFF position.

4. Connect battery cables, positive cable first. Tighten to
60-70 in-lbs (6.8-7.9 Nm).

VOLTMETER TEST

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

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

Voltmeter Test

The voltmeter test provides a general indicator of battery con­dition. Check the voltage of the battery to verify that it is fully
charged.

1. If the open circuit (disconnected) voltage reading is below

12.6 V:

a. Charge the battery.

b. Check the voltage after the battery has set for at least

one hour.

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

5. Apply a light coat of petroleum jelly or ELECTRICAL
CONTACT LUBRICANT to both battery terminals.

6. See Figure 1-41. Fold lifting strap (2) forward over top of
battery.

7. See Figure 1-40. Rotate top caddy into position above
battery and engage latch on hold-down bracket.

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

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

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

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

11. Install seat.

2. If the voltage reading is 12.7 V or above:

a. Perform a battery diagnostic test. See the electrical

diagnostic manual for the load test procedure.

b. Refer to Table 1-23.

Table 1-23. Voltmeter Test For Battery Charge Conditions

STATE OF CHARGEVOLTAGE (OCV)

100%12.7 V

75%12.6 V

50%12.3 V

25%12.0 V

0%11.8 V

CHARGING BATTERY

Safety Precautions

An automatic, constant monitoring battery charger/tender with
a charging rate of 5 amps or less at less than 14.6 volts is
recommended. The use of constant current chargers (including
trickle chargers) to charge sealed AGM batteries is not
recommended.

Any overcharge will cause dry-out and premature battery
failure. Always review charger instructions before charging a

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battery. In addition to the manufacturer's instructions, follow
these general safety precautions:

• Always wear eye, face and hand protection.

• Always charge batteries in a well-ventilated area.

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

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

• Connect the charger leads to the battery. Red positive
lead to the positive terminal. Black negative lead to the
negative terminal. If the battery is still in the vehicle, con­nect the negative lead to the chassis ground. Verify that
the ignition and all electrical accessories are turned off.

• Verify that charger leads to battery are not separated,
frayed or loose.

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

Using a Battery Charger

Charge the battery if:

• Vehicle lights appear dim.

• Electric starter sounds weak.

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

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

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

1. Check charge state with voltmeter test. If battery voltage
is less than 12.7 volts, see the next step.

NOTES

•

Most constant monitoring battery chargers are completely
automatic. They can be left connected to both AC power
and to the battery that is being charged. When leaving this
type of charger connected for extended periods of time,
periodically check the battery to see if it is unusually warm.
This is an indication that the battery may have a weak cell
or internal short. Read the manufacturer's instructions for
the charger.

•

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

14.6 volts.

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

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

2. Connect red battery charger lead to the positive terminal
and black battery charger lead to the negative terminal of
the battery.

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

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

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

4. After the battery is fully charged, turn the charger OFF.

Disconnect the black battery charger lead to the negative
terminal of the battery.

5. Disconnect the red battery charger lead to the positive

terminal of the battery.

6. Mark the charging date on the battery.

7. Perform a battery diagnostic test to determine the condition

of the battery. See the electrical diagnostic manual.

8. If charging a battery because voltmeter test reading was

below 12.6 V, perform voltmeter test. See the electrical
diagnostic manual.

STORAGE

TOOL NAMEPART NUMBER

GLOBAL BATTERY CHARGER99863-01A

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

If the motorcycle is stored with the security system armed,
connect an automatic, constant monitoring battery
charger/tender to maintain battery charge. Refer to the Harley­Davidson Parts and Accessories catalog.

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3 6 9 12 15

50%

75%

100%

0

¡

¡

105 °F

(40.5 °C)

77 °F (25 °C)

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

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

See Figure 1-42. A battery that is removed from the vehicle is
affected by self-discharge. A battery that is stored in the vehicle
is affected by self-discharge and, more significantly, by parasitic
loads. A parasitic load is caused by things like diode leakage
or maintaining computer memory with the vehicle turned off.

Batteries self-discharge at a faster rate at higher ambient
temperatures. To reduce the self-discharge rate, store battery
in a cool, dry place.

Charge the battery every two weeks if stored in the vehicle.
Charge the battery once per month if stored out of the vehicle.

NOTE

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

1. Capacity

2. Months of non-use

Figure 1-42. Battery Self-Discharge Rate

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HEADLAMP ALIGNMENT

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

NOTE

Adjust the headlamps of motorcycles with multiple beam
headlamps to converge into one pattern.

1. Check the tire pressure.

2. Adjust the rear shocks for the rider and intended load.

3. Fill fuel tank or add an equal amount of ballast.

NOTE

Choose a wall in minimum light.

4. See Figure 1-43. Park the motorcycle in a line (1) perpen­dicular to the wall.

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

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

7. With the motorcycle loaded, point the front wheel straight
forward at wall. Measure the distance (4) from the floor to
the center of the high beam bulb.

8. Draw a horizontal line (5) through the vertical line on the
wall. Place line 2.1 in (53.3 mm) lower than the measured
bulb centerline.

NOTE
The headlamp is aligned when the light beam hot spot is
centered over the intersection of the lines.

9. Verify headlamp alignment. Adjust as necessary.

1.22HEADLAMP ALIGNMENT

1. Perpendicular line

2. Vertical line

3. 25 ft (7.6 m)

4. High beam bulb centerline

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

Figure 1-43. Check Headlamp Alignment

HEADLAMP ADJUSTMENT: SINGLE HEADLAMP MODELS

NOTE

Do not remove trim ring for headlamp adjustment.

1. See Figure 1-44. Insert screwdriver through adjuster slots
in trim ring.

a. Horizontal: Turn the horizontal adjusting screw to

adjust light beam left and right.

b. Vertical: Turn the vertical adjusting screw to adjust

light beam up and down.

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

Figure 1-43.

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1. Horizontal adjuster

2. Vertical adjuster

Figure 1-44. Headlamp Adjusters (typical)

HEADLAMP ADJUSTMENT: DUAL HEADLAMP MODELS

1. See Figure 1-45. Rotate the hex adjusters (metric) located
near the bottom edge of the inner fairing. Refer to

Table 1-24 for adjuster rotation.

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

adjust the light beam left and right.

b. Vertical: Turn both adjusters equally to adjust the

light beam up and down.

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

Figure 1-43.

Table 1-24. Adjuster Rotation, Dual Headlamp Models

Beam MovementRotationHex Adjuster

To the rightCWLeft Only

CCWRight Only

To the leftCCWLeft Only

CWRight Only

UpwardCWLeft and Right

Equally

DownwardCCWLeft and Right

Equally

CW = Clockwise
CCW = Counterclockwise

1. Left side adjuster

2. Right side adjuster

Figure 1-45. Headlamp Adjusters: Dual Headlamp Models

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AUXILIARY/FOG LAMP ALIGNMENT

TOOL NAMEPART NUMBER

FLARE NUT SOCKETSNAP-ON® FRX181

TORQUE VALUEFASTENER

20.3-24.4 Nm15-18 ft-lbsAuxiliary/fog lamp flange nut

4.1-6.8 Nm36-60 in-lbsTurn signal lamp to mounting

bracket screws

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

1.22 HEADLAMP ALIGNMENT, Headlamp Alignment.

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

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

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

3. Measure the horizontal distance from the headlamp vertical

centerline to the vertical centerline of each auxiliary/fog
lamp.

4. See Figure 1-46. Mark the auxiliary/fog lamp horizontal

and vertical centerlines (2, 3) on the wall.

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

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

NOTE

Figure 1-46 depicts the light pattern for vehicles driven on the

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

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

headlamp and the right auxiliary/fog lamp. Adjust the left
auxiliary/fog lamp so the entire high intensity zone (4) is
below and to the right of the left auxiliary/fog lamp
centerlines as shown in Figure 1-46.

8. Cover the headlamp and left auxiliary/fog lamp. Adjust the

right auxiliary/fog lamp so the entire high intensity zone
(5) is both below and to the right of the right auxiliary/fog
lamp centerlines as shown in Figure 1-46.

9. Tighten auxiliary/fog lamp flange nut to 15-18 ft-lbs (20.3-

24.4 Nm).

10. Start two screws to secure turn signal lamp to mounting

bracket. Verify that conduit fits in slot at back of bracket
and is not pinched. Tighten screws to 36-60 in-lbs (4.1-

6.8 Nm).

1. Headlamp high beam area

2. Left side auxiliary/fog lamp centerlines

3. Right side auxiliary/fog lamp centerlines

4. Left side auxiliary/fog high intensity beam area

5. Right side auxiliary/fog high intensity beam area

Figure 1-46. Properly Aim Auxiliary/Fog Lamps

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INSPECTION

TORQUE VALUEFASTENER

40.7-47.5 Nm30-35 ft-lbsEngine stabilizer link bolt

40.7-47.5 Nm30-35 ft-lbsEngine stabilizer link bolt

48.8-54.2 Nm36-40 ft-lbsEngine mount bracket to

engine screws

56.9-65.0 Nm42-48 ft-lbsEngine mount end cap screws,

front

54.2-61.0 Nm40-45 ft-lbsRear frame to main frame

screws

General

Inspect the condition and tightness of the stabilizer links and
engine mounts. Replace fasteners if damaged. To properly
check fastener torque, see 1.20 CRITICAL FASTENERS

Stabilizer Link

1. See Figure 1-47. Check top stabilizer link eyelet to frame
weldment bolt (1). The bolt must not rotate with torque
wrench set to 30-35 ft-lbs (40.7-47.5 Nm).

2. Check top stabilizer link eyelet to top engine mounting
bracket bolt (2). The bolt must not rotate with torque
wrench set to 30-35 ft-lbs (40.7-47.5 Nm).

3. Check for lateral movement at each end of the stabilizer
link. Any lateral movement indicates the need to replace
the stabilizer link. Rotational movement does not indicate
excess wear.

Front Engine Mount

1. See Figure 1-47. Check two engine to front engine
mounting bracket screws (3). The screws must not rotate
with torque wrench set to 36-40 ft-lbs (48.8-54.2 Nm).

2. Check three front engine mount end cap screws (4). The
screws must not rotate with torque wrench set to 42-48 ft­lbs (56.9-65.0 Nm).

1.23ENGINE MOUNTS

1. Link-to-frame weldment bolt

2. Link-to-engine mounting bracket bolt

3. Engine mount screws (2)

4. Engine mount end cap screws

Figure 1-47. Front Mount and Stabilizer

Rear Frame Fasteners

See Figure 1-48. Check three screws on each side that attach
the rear frame to the main frame. The screws must not rotate
with torque wrench set to 40-45 ft-lbs (54.2-61.0 Nm).

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Figure 1-48. Rear Frame Fasteners

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GENERAL

1.24STORAGE

Always prepare motorcycle for extended storage following
service manual procedures. This will help protect parts against
corrosion, preserve the battery and prevent buildup of gum
and varnish in the fuel system.

PLACING IN STORAGE

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

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

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

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

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

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

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

SPROCKETS.

5. Inspect drive belt and sprockets.

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

EXHAUST SYSTEM.

7. Lubricate controls. See 1.14 CABLE AND CHASSIS

LUBRICATION.

8. Inspect operation of all electrical equipment and switches.

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

AND WHEELS.

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

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

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

11. Remove the battery from the vehicle. Charge the battery
until the correct voltage is obtained. Charge the battery
every other month if it is stored at temperatures below 60
°F (16 °C). Charge battery once a month if it is stored at
temperatures above 60 °F (16 °C). See 1.21 BATTERY

MAINTENANCE.

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

12. If the motorcycle is to be covered, use a material that will
breathe, such as a Harley-Davidson storage cover or light
canvas. Plastic materials that do not breathe promote the
formation of condensation which leads to corrosion.

REMOVAL FROM STORAGE

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

1. Charge and install the battery.

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

3. Clean the air cleaner element.

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

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

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

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

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1.25TROUBLESHOOTING

GENERAL

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

Use the symptoms listed for general troubleshooting. More
than one condition may be present at a time. Check all possible
items to keep motorcycle in good operating condition.

NOTE

See the electrical diagnostic manual for additional information.

ENGINE

Starter Motor Does Not Operate or Does Not
Turn Engine Over

1. Ignition switch not in IGNITION position.

2. Engine run switch in OFF position.

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

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

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

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

7. Security system activated.

8. Motorcycle in gear and clutch not pulled in.

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

10. Main fuse not in place.

Engine Turns Over But Does Not Start

1. Fuel tank empty.

2. Fouled spark plugs.

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

4. Engine lubricant too heavy (winter operation).

NOTE

For cold weather starts, always disengage clutch.

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

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

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

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

9. Fuel filter clogged.

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

11. Plugged fuel injectors.

Starts Hard

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

2. Spark plug cables in poor condition.

3. Battery nearly discharged.

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

5. Water or dirt in fuel system.

6. Intake air leak.

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

8. Engine lubricant too heavy (winter operation).

NOTE

For cold weather starts, always disengage clutch.

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

10. Faulty ignition coil.

11. Valves sticking.

12. Partially plugged fuel injector(s).

Starts But Runs Irregularly or Misses

1. Spark plugs in poor condition or partially fouled.

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

3. Spark plug gap too close or too wide.

4. Faulty ignition coil, ECM, or sensor.

5. Battery nearly discharged.

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

7. Intermittent short circuit due to damaged wire insulation.

8. Water or dirt in fuel system.

9. Fuel tank vent system plugged.

10. Air leak at intake manifold or air cleaner.

11. Loose or dirty ECM connector.

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

13. Incorrect valve timing.

14. Weak or damaged valve springs.

15. Damaged intake or exhaust valve.

16. Partially plugged fuel injector(s).

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A Spark Plug Fouls Repeatedly

1. Fuel mixture too rich.

2. Incorrect spark plug for the kind of service.

3. Piston rings badly worn or damaged.

4. Valve guides or seals badly worn.

Pre-Ignition or Detonation (Knocks or Pings)

1. Fuel octane rating too low.

2. Faulty spark plugs.

3. Incorrect spark plug for the kind of service.

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

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

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

7. Intake manifold vacuum leak.

Overheating

1. Insufficient oil supply or oil not circulating.

2. Insufficient air flow over engine.

3. Heavy carbon deposits.

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

5. Leaking valve(s).

Valve Train Noise

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

2. Faulty hydraulic lifter(s).

3. Bent push rod(s).

4. Incorrect push rod length.

5. Rocker arm binding on shaft.

6. Valve sticking in guide.

7. Chain tensioning spring or shoe worn.

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

9. Cam timing incorrect.

Excessive Vibration

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

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

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

4. Engine to transmission mounting bolts loose.

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

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

7. Internal engine problem.

8. Damaged frame.

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

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

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

12. Rear fork pivot shaft fasteners loose.

13. Front engine mount bracket bolts loose.

14. Exhaust system binding and causing unnecessary side
loads.

Check Engine Light Illuminates During
Operation

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

LUBRICATION SYSTEM

Oil Does Not Return To Oil Reservoir

1. Oil reservoir empty.

2. Oil pump not functioning.

3. Restricted oil lines or fittings.

4. Restricted oil filter.

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

Engine Uses Too Much Oil Or Smokes
Excessively

1. Oil reservoir overfilled.

2. Restricted oil return line to oil reservoir.

3. Restricted breather operation.

4. Restricted oil filter.

5. Oil pump misaligned or in poor condition.

6. Piston rings badly worn or broken.

7. Valve guides or seals worn or damaged.

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

9. Plugged crankcase scavenge port.

10. Oil diluted with gasoline.

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

1. Loose parts.

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

3. Restricted breather passages or hose to air cleaner.

4. Restricted oil filter.

5. Oil reservoir overfilled.

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

7. Restricted oil return line to oil reservoir.

8. Porosity.

Low Oil Pressure

1. Oil reservoir underfilled.

2. Faulty low oil pressure switch.

3. Oil pump O-ring damaged or missing.

4. Bypass valve stuck in open position.

5. Ball missing or leaking in cam support plate.

6. Worn oil pump gerotor(s).

7. Oil diluted with gasoline.

High Oil Pressure

1. Oil reservoir overfilled.

2. Bypass valve stuck in closed position.

ELECTRICAL SYSTEM

NOTE

For diagnostic information see the electrical diagnostic manual.

Alternator Does Not Charge

1. Voltage regulator module not grounded.

2. Engine ground wire loose or damaged.

3. Faulty voltage regulator module.

4. Loose or damaged wires in charging circuit.

5. Faulty stator and/or rotor.

Alternator Charge Rate Is Below Normal

1. Weak or damaged battery.

2. Loose connections.

3. Faulty voltage regulator module.

4. Faulty stator and/or rotor.

Speedometer Operates Erratically

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

2. Loose connections.

TRANSMISSION

Shifts Hard

1. Primary chaincase overfilled with lubricant.

2. Clutch not fully disengaging.

3. Transmission lubricant too heavy (winter operation).

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

5. Bent shifter rod.

6. Shifter forks (inside transmission) sprung.

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

Jumps Out Of Gear

1. Shifter rod improperly adjusted.

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

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

4. Shifter forks bent.

5. Damaged gears.

Clutch Slips

1. Clutch controls improperly adjusted.

2. Insufficient clutch spring tension.

3. Worn friction discs.

Clutch Drags Or Does Not Release

1. Lubricant level too high in primary chaincase.

2. Clutch controls improperly adjusted.

3. Primary chain badly misaligned or too tight.

4. Insufficient clutch spring tension.

5. Clutch discs warped.

Clutch Chatters

Friction discs or steel discs worn or warped.

HANDLING

Irregularities

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

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

3. Irregular or peaked front tire tread wear.

4. Incorrect tire pressure.

5. Shock absorber not functioning normally.

6. Incorrect air suspension pressure.

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

8. Excessive wheel hub bearing play.

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

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

11. Loose spokes (laced wheel vehicles only).

12. Tire and wheel unbalanced.

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

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

1-62 2013 Touring Service: Maintenance

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

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

BRAKES

Brake Does Not Hold Normally

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

2. Brake system contains air bubbles.

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

4. Brake pads contaminated with grease or oil.

5. Brake pads badly worn.

6. Brake disc badly worn or warped.

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

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

9. Brake fluid leak when under pressure.

2013 Touring Service: Maintenance 1-63

NOTES

1-64 2013 Touring Service: Maintenance

TABLE OF CONTENTS

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

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

2.2 SPECIFICATIONS.....................................................................................................................2-7

2.3 VEHICLE IDENTIFICATION NUMBER (V.I.N.)........................................................................2-11

2.4 FRONT WHEEL.......................................................................................................................2-13

2.5 REAR WHEEL.........................................................................................................................2-16

2.6 REAR WHEEL COMPENSATOR............................................................................................2-20

2.7 WHEEL LACING: FRONT RIM................................................................................................2-22

2.8 WHEEL LACING: 16 INCH REAR RIM...................................................................................2-24

2.9 CHECKING AND TRUING WHEELS......................................................................................2-27

2.10 SEALED WHEEL BEARINGS...............................................................................................2-32

2.11 TIRES.....................................................................................................................................2-35

2.12 FRONT BRAKE MASTER CYLINDER..................................................................................2-40

2.13 FRONT BRAKE CALIPER.....................................................................................................2-45

2.14 REAR BRAKE MASTER CYLINDER.....................................................................................2-46

2.15 REAR BRAKE CALIPER.......................................................................................................2-52

2.16 BLEEDING BRAKES.............................................................................................................2-53

2.17 FRONT FORK........................................................................................................................2-55

2.18 STEERING HEAD BEARINGS..............................................................................................2-60

2.19 REAR AIR SUSPENSION.....................................................................................................2-63

2.20 REAR SHOCK ABSORBERS: MANUAL ADJUST................................................................2-65

2.21 REAR FORK..........................................................................................................................2-66

2.22 CLUTCH CABLE....................................................................................................................2-69

2.23 HANDLEBARS.......................................................................................................................2-71

2.24 MIRRORS..............................................................................................................................2-76

2.25 SEAT......................................................................................................................................2-77

2.26 SADDLEBAGS.......................................................................................................................2-80

2.27 SADDLEBAG SERVICE........................................................................................................2-81

2.28 TOUR-PAK.............................................................................................................................2-84

2.29 TOUR-PAK SERVICE............................................................................................................2-86

2.30 TOUR-PAK LIGHTS...............................................................................................................2-90

2.31 TOUR-PAK BACKREST........................................................................................................2-93

2.32 TOUR-PAK SPEAKER BOX..................................................................................................2-95

2.33 LOWER FAIRING AND ENGINE GUARD.............................................................................2-96

2.34 UPPER FAIRING AND WINDSHIELD: FORK MOUNTED FAIRING MODELS..................2-100

2.35 FAIRING CAP: FORK MOUNTED FAIRING MODELS.......................................................2-101

2.36 INNER FAIRING: FORK MOUNTED FAIRING MODELS....................................................2-102

2.37 AIR DEFLECTORS..............................................................................................................2-106

2.38 UPPER FAIRING AND WINDSHIELD: FRAME MOUNTED FAIRING MODELS...............2-108

2.39 INSTRUMENT BEZEL: FRAME MOUNTED FAIRING MODELS........................................2-111

2.40 INSTRUMENT NACELLE: FRAME MOUNTED FAIRING MODELS..................................2-112

2.41 INNER FAIRING: FRAME MOUNTED FAIRING MODELS.................................................2-114

2.42 GLOVE BOX DOOR AND HINGE: FRAME MOUNTED FAIRING MODELS......................2-118

2.43 WINDSHIELD: ROAD KING MODELS................................................................................2-119

2.44 HEADLAMP NACELLE: ROAD KING MODELS.................................................................2-122

2.45 FRONT FENDER.................................................................................................................2-124

2.46 REAR FENDER...................................................................................................................2-126

2.47 REAR FASCIA.....................................................................................................................2-129

2.48 REAR FRAME.....................................................................................................................2-130

2.49 FOOTBOARDS AND FOOTRESTS....................................................................................2-132

2.50 JIFFY STAND.......................................................................................................................2-135

2.51 FRONT ENGINE MOUNT....................................................................................................2-138

2.52 MEDALLIONS, SERIALIZED BADGES AND TANK EMBLEMS.........................................2-140

CHASSIS

NOTES

HOME

FASTENER TORQUE VALUES IN THIS CHAPTER

The table below lists torque values for all fasteners presented
in this chapter.

screws: FLHTC/U, FLHTK, FLHX

screw

screw

cover screws

screws

screws

cover screws

2.1FASTENER TORQUE VALUES

NOTESTORQUE VALUEFASTENER

2.37 AIR DEFLECTORS, Fairing Air Deflectors2.8-3.4 Nm25-30 in-lbsAir deflector screws

4.5-5.6 Nm40-50 in-lbsAir valve mount hex nut

20-27 Nm15-20 ft-lbsAuxiliary/fog lamp bracket to fork bracket

23.1-25.8 Nm17-19 ft-lbsBanjo bleeder bolt to front caliper

16.9-19.7 Nm12.5-14.5 ft-lbsBanjo bolt to front master cylinder

16.9-19.7 Nm12.5-14.5 ft-lbsBanjo bolt to front master cylinder

23.1-25.8 Nm17-19 ft-lbsBanjo bolt to rear caliper

16.9-19.7 Nm12.5-14.5 ft-lbsBanjo bolt to rear master cylinder

16.9-19.7 Nm12.5-14.5 ft-lbsBanjo bolt to rear master cylinder

21.7-32.5 Nm16-24 ft-lbsBrake disc, front, screws

41-61 Nm30-45 ft-lbsBrake disc, rear, screws

13.6-20.3 Nm120-180 in-lbsBrake line bracket to lower fork bracket

14.2-17.0 Nm126-150 in-lbsBrake master cylinder, rear, mounting

14.2-17.0 Nm126-150 in-lbsBrake master cylinder, rear, mounting

20.3-27.1 Nm15-20 ft-lbsBrake pedal shaft locknut

2.19 REAR AIR SUSPENSION, Check for Air
Leaks

2.36 INNER FAIRING: FORK MOUNTED FAIRING
MODELS, Installation

2.12 FRONT BRAKE MASTER CYLINDER, Front
Brake Line: Non-ABS Equipped

2.13 FRONT BRAKE CALIPER, Installation23.1-25.8 Nm17-19 ft-lbsBanjo bleeder bolt to front caliper

2.12 FRONT BRAKE MASTER CYL­INDER, Assembly and Installation

2.12 FRONT BRAKE MASTER CYLINDER, Front
Brake Line: Non-ABS Equipped

2.14 REAR BRAKE MASTER CYLINDER, Rear
Brake Line: Non-ABS Equipped

2.15 REAR BRAKE CALIPER, Installation23.1-25.8 Nm17-19 ft-lbsBanjo bolt to rear caliper

2.14 REAR BRAKE MASTER CYL­INDER, Assembly and Installation

2.14 REAR BRAKE MASTER CYLINDER, Rear
Brake Line: Non-ABS Equipped

2.48 REAR FRAME, Rear Frame8.1-10.8 Nm72-96 in-lbsBattery tray screws

2.16 BLEEDING BRAKES, Procedure8.1-12.2 Nm72-108 in-lbsBrake bleeder valve, front

2.16 BLEEDING BRAKES, Procedure8.5-11.5 Nm75-102 in-lbsBrake bleeder valve, rear

2.13 FRONT BRAKE CALIPER, Installation/metric37.9-51.5 Nm28-38 ft-lbsBrake caliper, front, mounting screws

2.5 REAR WHEEL, Installation/metric58.3-65.1 Nm43-48 ft-lbsBrake caliper, rear, mounting screws

2.15 REAR BRAKE CALIPER, Installation/metric58.3-65.1 Nm43-48 ft-lbsBrake caliper, rear, mounting screws

2.4 FRONT WHEEL, Installation/Always use new
screws

2.5 REAR WHEEL, Installation/Always use new
part

2.12 FRONT BRAKE MASTER CYLINDER, Front
Brake Line: Non-ABS Equipped

2.18 STEERING HEAD BEARINGS, Installation13.6-20.3 Nm120-180 in-lbsBrake line bracket-to-lower fork bracket

2.16 BLEEDING BRAKES, Procedure1.3-1.7 Nm11.5-15.0 in-lbsBrake master cylinder, front, reservoir

2.14 REAR BRAKE MASTER CYL­INDER, Assembly and Installation

2.14 REAR BRAKE MASTER CYLINDER, Rear
Brake Line: Non-ABS Equipped

2.16 BLEEDING BRAKES, Procedure1.4-1.7 Nm12-15 in-lbsBrake master cylinder, rear, reservoir

2.14 REAR BRAKE MASTER CYL­INDER, Assembly and Installation

2013 Touring Service: Chassis 2-1

HOME

(frame mounted fairing)

FLHTC/U)

FLHTC/U)

senger

senger

NOTESTORQUE VALUEFASTENER

20.3-27.1 Nm15-20 ft-lbsBrake pedal shaft locknut

20.3-27.1 Nm15-20 ft-lbsEngine guard screws

27.1-40.7 Nm20-30 ft-lbsFairing bracket-to-steering head locknuts

2.8-3.4 Nm25-30 in-lbsFairing cap screws

2.5-3.2 Nm22-28 in-lbsFairing speaker lower screw (FLHX,

4.0-5.7 Nm35-50 in-lbsFairing speaker upper screws (FLHX,

5.4-8.1 Nm48-72 in lbsFootboard/footrest lower fastener, pas-

48.8-56.9 Nm36-42 ft-lbsFootboard/footrest upper fastener, pas-

48.8-56.9 Nm36-42 ft-lbsFootboard bracket screws, rider

6.8-9.0 Nm60-80 in-lbsFootboard pivot bolt nut, rider

48.8-56.9 Nm36-42 ft-lbsFootrest mounting fastener

20.3-27.1 Nm15-20 ft-lbsFootrest pad screw (FLHX, FLTRX)

2.14 REAR BRAKE MASTER CYLINDER, Rear
Brake Line: Non-ABS Equipped

2.21 REAR FORK, Installation7.3-9.6 Nm65-85 in-lbsDebris deflector screw

2.33 LOWER FAIRING AND ENGINE
GUARD, Engine Guard

2.51 FRONT ENGINE MOUNT, Installation48.8-54.2 Nm36-40 ft-lbsEngine mount bracket to engine screws

2.51 FRONT ENGINE MOUNT, Installation56.9-65.0 Nm42-48 ft-lbsEngine mount end cap screws, front

2.51 FRONT ENGINE MOUNT, Installation54.2-67.8 Nm40-50 ft-lbsEngine rubber mount screws, front

2.41 INNER FAIRING: FRAME MOUNTED
FAIRING MODELS, Installation

2.35 FAIRING CAP: FORK MOUNTED FAIRING
MODELS, Fairing Cap

2.36 INNER FAIRING: FORK MOUNTED FAIRING
MODELS, Installation

2.36 INNER FAIRING: FORK MOUNTED FAIRING
MODELS, Installation

2.45 FRONT FENDER, Removal2.8-3.4 Nm25-30 in-lbsFender, front, bumper cushion nut

2.45 FRONT FENDER, Removal1.7-2.8 Nm15-25 in-lbsFender, front, bumper cushion screws

2.45 FRONT FENDER, Removal7.3-8.5 Nm65-75 in-lbsFender, front, bumper nuts

2.45 FRONT FENDER, Removal2.3-3.1 Nm20-28 in-lbsFender, front, fender tip lamp screws

2.45 FRONT FENDER, Removal2.3-2.8 Nm20-25 in-lbsFender, front, fender tip screws

2.45 FRONT FENDER, Removal21.7-27.1 Nm16-20 ft-lbsFender, front, mounting screws

2.45 FRONT FENDER, Removal1.1-1.7 Nm10-15 in-lbsFender, front, trim skirt screws

2.45 FRONT FENDER, Removal1.1-1.7 Nm10-15 in-lbsFender, front, trim T-bolt nut

2.46 REAR FENDER, Fender Repair20.3-27.1 Nm15-20 ft-lbsFender, rear, mounting boss

2.46 REAR FENDER, Installation20.3-27.1 Nm15-20 ft-lbsFender, rear, mounting screws

2.47 REAR FASCIA, Installation5.1-9.6 Nm45-85 in-lbsFender, rear, support to fender nut

2.47 REAR FASCIA, Stud Plate5.1-9.6 Nm45-85 in-lbsFender, rear, support to fender nut

2.49 FOOTBOARDS AND FOOTRESTS, Pas­senger Footboard

2.49 FOOTBOARDS AND FOOTRESTS, Pas­senger Footboard

2.49 FOOTBOARDS AND FOOTRESTS, Rider
Footboards

2.49 FOOTBOARDS AND FOOTRESTS, Rider
Footboards

2.49 FOOTBOARDS AND FOOTRESTS, Pas­senger Footrest: FLHX, FLTRX

2.49 FOOTBOARDS AND FOOTRESTS, Pas­senger Footrest: FLHX, FLTRX/Use LOCTITE 243
MEDIUM STRENGTH THREADLOCKER AND
SEALANT (blue)

2.17 FRONT FORK, Installation71.9-77.3 Nm53-57 ft-lbsFork bracket pinch bolt

2.17 FRONT FORK, Installation81.4-94.9 Nm60-70 ft-lbsFork cap bolt

2.17 FRONT FORK, Assembly14.9-24.4 Nm132-216 in-lbsFork damper tube screw (metric)

2.17 FRONT FORK, Assembly8-11 Nm72-96 in-lbsFork oil drain plug

2.17 FRONT FORK, Assembly81.4-94.9 Nm60-70 ft-lbsFork tube plug

2.28 TOUR-PAK, Luggage Rack/Tour-Pak Support20.3-27.1 Nm15-20 ft lbsFrame cover fastener, rear

2.46 REAR FENDER, Installation20.3-27.1 Nm15-20 ft-lbsFrame cover fastener, rear

2-2 2013 Touring Service: Chassis

HOME

bracket screws

screws

screws

screws

nut

shroud screws

acorn nuts

fairing models)

(frame mounted fairing models)

screws

mounted fairing models

NOTESTORQUE VALUEFASTENER

2.4 FRONT WHEEL, Installation/metric14.9-20.3 Nm132-180 in-lbsFront axle holder nuts

2.4 FRONT WHEEL, Installation/metric94.9-101.7 Nm70-75 ft-lbsFront axle nut

1.1-2.3 Nm10-20 in-lbsGauges, 2 inch diameter gauge nuts

1.1-2.3 Nm10-20 in-lbsGauges, speedometer/tachometer

8.1-12.2 Nm72-108 in-lbsHandlebar clamp to master cylinder

1.0-2.0 Nm9-18 in-lbsHeadlamp housing screws

1.0-2.0 Nm9-18 in-lbsHeadlamp housing screws

1.7-2.3 Nm15-20 in-lbsHeadlamp nacelle chrome strip flange

1.1-2.3 Nm10-20 in-lbsHeadlamp nacelle handlebar clamp

8.1-12.2 Nm72-108 in-lbsHeadlamp nacelle to fork bracket stud

1.1-1.7 Nm10-15 in-lbsInstrument bezel screws (frame mounted

20.3-27.1 Nm15-20 ft-lbsInstrument nacelle to fork bracket screws

10.8-13.6 Nm96-120 in-lbsJiffy stand interlock sensor fastener

3.4-4.5 Nm30-35 in-lbsLower fairing cap flange nuts

2.3-2.8 Nm20-25 in-lbsLower fairing glove box tray screws

2.3-2.8 Nm20-25 in-lbsLower fairing glove box tray screws

10.2-11.3 Nm90-100 in-lbsLower fairing to engine guard clamp

10.8-16.3 Nm96-144 in-lbsMuffler to saddlebag support screws

1.1-1.7 Nm10-15 in-lbsOuter fairing long screws: Frame

2.36 INNER FAIRING: FORK MOUNTED FAIRING
MODELS, Installation

2.36 INNER FAIRING: FORK MOUNTED FAIRING
MODELS, Installation

2.22 CLUTCH CABLE, Installation8.1-12.2 Nm72-108 in-lbsHandlebar clamp to clutch lever bracket

2.23 HANDLEBARS, Adjustment8.1-12.2 Nm72-108 in-lbsHandlebar clamp to clutch lever bracket

2.12 FRONT BRAKE MASTER CYL­INDER, Assembly and Installation

2.23 HANDLEBARS, Rubber Mounts40.7-54.2 Nm30-40 ft-lbsHandlebar lower clamp bolts (risers)

2.23 HANDLEBARS, Adjustment21.7-27.1 Nm16-20 ft-lbsHandlebar upper clamp screws

2.23 HANDLEBARS, Installation21.7-27.1 Nm16-20 ft-lbsHandlebar upper clamp screws

2.44 HEADLAMP NACELLE: ROAD KING
MODELS, Installation

2.44 HEADLAMP NACELLE: ROAD KING
MODELS, Installation

2.44 HEADLAMP NACELLE: ROAD KING
MODELS, Installation

2.44 HEADLAMP NACELLE: ROAD KING
MODELS, Installation

2.44 HEADLAMP NACELLE: ROAD KING
MODELS, Installation

2.39 INSTRUMENT BEZEL: FRAME MOUNTED
FAIRING MODELS, Bezel

2.40 INSTRUMENT NACELLE: FRAME MOUNTED
FAIRING MODELS, Instrument Nacelle

2.50 JIFFY STAND, Jiffy Stand Bracket48.8-57.0 Nm36-42 ft-lbsJiffy stand bracket fasteners

2.50 JIFFY STAND, Jiffy Stand Interlock
Sensor/Use LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue) if reusing
screw

2.50 JIFFY STAND, Leg Installation20.3-27.1 Nm15-20 ft-lbsJiffy stand leg stop hex screw

2.48 REAR FRAME, Rear Frame8.1-10.8 Nm72-96 in-lbsLeft electrical caddy fastener

2.33 LOWER FAIRING AND ENGINE
GUARD, Lower Fairing

2.33 LOWER FAIRING AND ENGINE
GUARD, Lower Fairing

2.33 LOWER FAIRING AND ENGINE
GUARD, Lower Fairing

2.33 LOWER FAIRING AND ENGINE
GUARD, Lower Fairing

2.37 AIR DEFLECTORS, Mid-Frame Air Deflectors2.8-4.0 Nm25-35 in-lbsMid-frame air deflector screws

2.24 MIRRORS, FLHX/metric2.3-3.4 Nm20-30 in-lbsMirror flange nut: FLHX

2.24 MIRRORS, All Models Except FLHX/metric6.8-10.8 Nm60-96 in-lbsMirror stem acorn nut

2.27 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail

2.38 UPPER FAIRING AND WINDSHIELD: FRAME
MOUNTED FAIRING MODELS, Outer Fairing

2013 Touring Service: Chassis 2-3

HOME

fairing models

mounted fairing models

(frame mounted fairing)

screw

screws

screw

fastener

fastener

port fastener

port fastener

port fastener

NOTESTORQUE VALUEFASTENER

2.3-3.4 Nm20-30 in-lbsOuter fairing screws: Fork mounted

0.7-1.4 Nm6-12 in-lbsOuter fairing short screws: Frame

10.9-16.3 Nm96-144 in-lbsRadio bracket-to-fairing bracket locknuts

3.4-5.1 Nm30-45 in-lbsRear fascia flange nuts

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

74.6-88.1 Nm55-65 ft-lbsRear fork pivot shaft fasteners

43.4-48.8 Nm32-36 ft-lbsSaddlebag guard to frame screws

13.6-16.3 Nm120-144 in-lbsSaddlebag mounting bracket screw

3.4-5.6 Nm30-50 in-lbsSaddlebag rail clamp screws

8.1-13.6 Nm72-120 in-lbsSaddlebag side guard to front guard

20.3-27.1 Nm15-20 ft-lbsSaddlebag side rail to saddlebag support

7.9-11.3 Nm70-100 in-lbsSaddlebag support rail to front guard

20.3-27.1 Nm15-20 ft-lbsSaddlebag support to fender support

20.3-27.1 Nm15-20 ft-lbsSaddlebag support to lower fender sup-

2.34 UPPER FAIRING AND WINDSHIELD: FORK
MOUNTED FAIRING MODELS, Outer Fairing and
Windshield

2.38 UPPER FAIRING AND WINDSHIELD: FRAME
MOUNTED FAIRING MODELS, Outer Fairing

2.41 INNER FAIRING: FRAME MOUNTED
FAIRING MODELS, Installation

2.5 REAR WHEEL, Installation/metric20-27 Nm15-20 ft-lbsRear axle cone nut, 1st torque

2.47 REAR FASCIA, Installation/Apply LOCTITE
243 MEDIUM STRENGTH THREADLOCKER AND
SEALANT (blue)

2.47 REAR FASCIA, Installation2.0-2.5 Nm18-22 in-lbsRear fascia lamp screws

2.21 REAR FORK, Installation/Apply two drops of
LOCTITE 243 MEDIUM STRENGTH THREAD­LOCKER AND SEALANT (blue) to threads

2.21 REAR FORK, Installation/Apply two drops of
LOCTITE 243 MEDIUM STRENGTH THREAD­LOCKER AND SEALANT (blue) to threads

2.48 REAR FRAME, Rear Frame54.2-61.0 Nm40-45 ft-lbsRear frame-to-main frame fastener

2.27 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail

2.27 SADDLEBAG SERVICE, Saddlebag Hardware2.3-2.8 Nm20-25 in-lbsSaddlebag latch/check strap screws

2.27 SADDLEBAG SERVICE, Saddlebag Hardware2.3-2.8 Nm20-25 in-lbsSaddlebag latch/check strap screws

2.27 SADDLEBAG SERVICE, Saddlebag Hardware2.0-2.3 Nm18-20 in-lbsSaddlebag lid check strap screws

2.25 SEAT, Seat: Road King Models13.6-16.3 Nm120-144 in-lbsSaddlebag mounting bracket screw

2.26 SADDLEBAGS, Installation13.6-16.3 Nm120-144 in-lbsSaddlebag mounting bracket screw

2.27 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail

2.28 TOUR-PAK, Luggage Rack/Tour-Pak Support13.6-16.3 Nm120-144 in-lbsSaddlebag mounting bracket screw

2.46 REAR FENDER, Installation13.6-16.3 Nm120-144 in-lbsSaddlebag mounting bracket screw

2.27 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail

2.27 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail

2.27 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail

2.27 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail

2.27 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail

2.46 REAR FENDER, Installation20.3-27.1 Nm15-20 ft-lbsSaddlebag support to fender support

2.27 SADDLEBAG SERVICE, Saddlebag
Guard/Support Rail

2.46 REAR FENDER, Installation20.3-27.1 Nm15-20 ft-lbsSaddlebag support to lower fender sup-

2.47 REAR FASCIA, Stud Plate20.3-27.1 Nm15-20 ft-lbsSaddlebag support to lower fender sup-

2.25 SEAT, Seat Bumper3.6-4.1 Nm32-36 in-lbsSeat bumper screw

2.25 SEAT, Seat: Models without Tour-Pak5.4-8.1 Nm48-72 in-lbsSeat mounting screw

2.25 SEAT, Seat: Models with Tour-Pak5.4-8.1 Nm48-72 in-lbsSeat mounting screw

2-4 2013 Touring Service: Chassis

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screws

NOTESTORQUE VALUEFASTENER

2.25 SEAT, Seat: Road King Models5.4-8.1 Nm48-72 in-lbsSeat mounting screw

2.25 SEAT, Seat: Models without Tour-Pak5.4-8.1 Nm48-72 in-lbsSeat strap screw

2.25 SEAT, Seat: Models with Tour-Pak5.4-8.1 Nm48-72 in-lbsSeat strap screw

16.3-23.0 Nm12-17 ft-lbsShock absorber air tube fitting

16.3-23.0 Nm12-17 ft-lbsShock absorber air tube fitting

47.5-54.2 Nm35-40 ft-lbsShock absorber mounting bolt

47.5-54.2 Nm35-40 ft-lbsShock absorber mounting bolt

6.2 Nm55 in-lbsSpoke nipple

16.3-20.3 Nm12-15 ft-lbsStop lamp switch, rear

9.0-11.3 Nm80-100 in-lbsStop lamp switch bracket fastener

2.3-2.8 Nm20-25 in-lbsTour-Pak latch screw

2.4-2.7 Nm21-24 in-lbsTour-Pak passenger backrest flap

2.3-2.8 Nm20-25 in-lbsTour-Pak side marker lights screws

2.3-2.8 Nm20-25 in-lbsTour-Pak tether screw

2.3-2.8 Nm20-25 in-lbsTour-Pak tether screw

2.19 REAR AIR SUSPENSION, Check for Air
Leaks

2.19 REAR AIR SUSPENSION, Disassembly and
Assembly

2.19 REAR AIR SUSPENSION, Shock Absorber
Installation/Use LOCTITE 243 MEDIUM
STRENGTH THREADLOCKER AND SEALANT
(blue)

2.21 REAR FORK, Installation/Use LOCTITE 243
MEDIUM STRENGTH THREADLOCKER AND
SEALANT (blue)

2.28 TOUR-PAK, Removal/Installation2.8-4.0 Nm25-35 in-lbsSpeaker box screws, rear

2.32 TOUR-PAK SPEAKER BOX, Speaker Box2.8-4.0 Nm25-35 in-lbsSpeaker box screws, rear

2.9 CHECKING AND TRUING WHEELS, Truing
Laced Wheels

2.14 REAR BRAKE MASTER CYLINDER, Rear
Brake Line: Non-ABS Equipped/Use LOCTITE 565
THREAD SEALANT

2.14 REAR BRAKE MASTER CYLINDER, Rear
Brake Line: Non-ABS Equipped

2.48 REAR FRAME, Rear Frame8.1-10.9 Nm72-96 in-lbsTop caddy screws

2.29 TOUR-PAK SERVICE, Latches/Lockset
Catch/Use LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue)

2.29 TOUR-PAK SERVICE, Lockset2.8-4.0 Nm25-35 in-lbsTour-Pak lockset hex nut

2.29 TOUR-PAK SERVICE, Lockset3.4-5.1 Nm30-45 in-lbsTour-Pak lockset jamnut

2.29 TOUR-PAK SERVICE, Luggage Rack6.8-9.5 Nm60-84 in-lbsTour-Pak luggage rack fastener

2.30 TOUR-PAK LIGHTS, Tour-Pak Lights Harness7.3-7.9 Nm65-70 in-lbsTour-Pak metal plate flange nuts

2.28 TOUR-PAK, Removal/Installation10.8-13.6 Nm96-120 in-lbsTour-Pak mounting screws

2.28 TOUR-PAK, Adjustment10.8-13.6 Nm96-120 in-lbsTour-Pak mounting screws

2.30 TOUR-PAK LIGHTS, Tour-Pak Lights Harness10.8-13.6 Nm96-120 in-lbsTour-Pak mounting screws

2.29 TOUR-PAK SERVICE, Tether Brackets4.5-6.8 Nm40-60 in-lbsTour-Pak passenger backrest flange nuts

2.31 TOUR-PAK BACKREST, Passenger Backrest4.5-6.8 Nm40-60 in-lbsTour-Pak passenger backrest flange nuts

2.31 TOUR-PAK BACKREST, Passenger Backrest
Flap

2.30 TOUR-PAK LIGHTS, Side Marker Lights (if
equipped)

2.28 TOUR-PAK, Luggage Rack/Tour-Pak Support20.3-27.1 Nm15-20 ft lbsTour-Pak support/luggage rack screws

2.46 REAR FENDER, Installation20.3-27.1 Nm15-20 ft-lbsTour-Pak support/luggage rack screws

2.29 TOUR-PAK SERVICE, Hinges/Use LOCTITE
262 HIGH STRENGTH THREADLOCKER AND
SEALANT (red)

2.29 TOUR-PAK SERVICE, Tether/Use LOCTITE
262 HIGH STRENGTH THREADLOCKER AND
SEALANT (red)

2.22 CLUTCH CABLE, Installation19.0-28.5 Nm14-21 ft-lbsTransmission drain plug

2013 Touring Service: Chassis 2-5

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Frame mounted fairing models

models

fairing models

models

NOTESTORQUE VALUEFASTENER

6.8-9.5 Nm60-84 in-lbsTurn signal lamp, front, acorn nuts:

2.8-3.4 Nm25-30 in-lbsWindshield screws: Fork mounted fairing

0.7-1.5 Nm6-13 in-lbsWindshield screws: Frame mounted

2.3-2.8 Nm20-25 in-lbsWindshield window screws: Road King

2.38 UPPER FAIRING AND WINDSHIELD: FRAME
MOUNTED FAIRING MODELS, Outer Fairing

2.11 TIRES, Installation1.4-1.7 Nm12-15 in-lbsValve stem nut

2.11 TIRES, Installation1.4-1.7 Nm12-15 in-lbsValve stem nut

2.34 UPPER FAIRING AND WINDSHIELD: FORK
MOUNTED FAIRING MODELS, Outer Fairing and
Windshield

2.38 UPPER FAIRING AND WINDSHIELD: FRAME
MOUNTED FAIRING MODELS, Windshield

2.43 WINDSHIELD: ROAD KING
MODELS, Windshield Window

2-6 2013 Touring Service: Chassis

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SPECIFICATIONS

Chassis Specifications

*With 180 lb. (81.7 kg) rider on seat

2.2SPECIFICATIONS

Table 2-1. Dimensions: FLHTC, FLHTCU, FLHTK, FLTRU

FLTRUFLHTKFLHTCUFLHTCITEM

MMIN.MMIN.MMIN.MMIN.

250798.7250498.6250498.6249798.3Length

91936.296538.096538.096538.0Overall Width

139755.0154961.0154961.0154961.0Overall Height

161363.5161363.5161363.5161363.5Wheel base

1305.11305.11305.11305.1Road clearance

69327.369327.369327.369327.3Saddle height*

Table 2-2. Dimensions: FLHR, FLHRC, FLTRX, FLHX

*With 180 lb. (81.7 kg) rider on seat

Table 2-3. Capacities

LU.S.ITEM

22.76.0 galFuel tank (total)

3.81.0 galLow fuel warning light on

3.794.00 qtEngine oil with filter *

0.951.00 qtTransmission **

(approximate)

1.321.40 qtPrimary chaincase

(approximate)

* When refilling, initially add 3.0 qt (2.84 L) and add as needed
to bring level within specification.
** When refilling, initially add 28 oz (0.83 L) and add as
needed to bring level within specification.

FLHXFLTRXFLHRCFLHRITEM

MMIN.MMIN.MMIN.MMIN.

241395.0241395.0239394.2241395.0Length

96538.090935.895337.595037.4Overall Width

132652.2127050.0140055.1140055.1Overall Height

161363.5161363.5161363.5161363.5Wheel base

1194.71305.11305.11305.1Road clearance

66326.166326.167826.767326.5Saddle height*

2013 Touring Service: Chassis 2-7

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Table 2-4. Weights: FLHTC, FLHTCU, FLHTK, FLTRU

allowed**

*The total weight of the motorcycle as delivered with all oil/fluids and approximately 90% of fuel.
**The total weight of accessories, cargo, riding gear, passenger and rider cannot exceed this weight.

Table 2-5. Weights: FLHR, FLHRC, FLTRX, FLHX

allowed**

*The total weight of the motorcycle as delivered with all oil/fluids and approximately 90% of fuel.
**The total weight of accessories, cargo, riding gear, passenger and rider cannot exceed this weight.

FLTRUFLHTKFLHTCUFLHTCITEM

KGLB.KGLB.KGLB.KGLB.

402.8888408.7901403.3889391.9864Running weight*

214.1472208.2459213.6471225.0496Maximum added weight

616.91360616.91360616.91360616.91360GVWR

226.8500226.8500226.8500226.8500GAWR front

420.5927420.5927420.5927420.5927GAWR rear

FLHXFLTRXFLHRCFLHRITEM

KGLB.KGLB.KGLB.KGLB.

372.9822370.6817367.4810368.3812Running weight*

244.0538246.3543249.5550248.6548Maximum added weight

616.91360616.91360616.91360616.91360GVWR

226.8500226.8500226.8500226.8500GAWR front

420.5927420.5927420.5927420.5927GAWR rear

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

• GVWR is the sum of the weight of the motorcycle,
accessories, and the maximum weight of the rider, pas­senger and cargo that can be safely carried.

• GAWR is the maximum amount of weight that can be
safely carried on each axle.

• The GVWR and GAWR are shown on the information
plate, located on the frame down tube.

NOTES

•

The maximum additional weight allowed on the motorcycle
equals the Gross Vehicle Weight Rating (GVWR) minus
the running weight. For example, a motorcycle with GVWR
of 1200 lbs (544 kg) having a running weight of 800 lbs
(363 kg), would allow a maximum of an additional 400 lbs
(181 kg) combined weight of the rider, passenger, riding
gear, cargo and installed accessories.

•

For important information regarding tire data and tire
inflation, see 1.8 TIRES AND WHEELS.

Tire Specifications

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

NOTE

ABS equipped motorcycles must always use properly inflated
tires and wheels that are the same as the original equipment.
The ABS system monitors rotational speed of the wheels
through individual wheel speed sensors to determine the
application of ABS.

Different diameter wheels or tires can:

•

Alter the rotational speed which can upset the calibration
of the ABS.

•

Adversely effect its ability to detect and prevent lockups.

Operating with inflation pressure other than those specified in

Table 2-9 can reduce ABS performance.

Tire sizes are molded on the sidewall. Refer to the tire fitment
tables below. Rim size and contour are cast or stamped into
the exterior surface of the rim.

2-8 2013 Touring Service: Chassis