2018 HARLEY-DAVIDSON® SERVICE MANUAL: TOURING MODELS
Foreword
Foreword
General
Manual Layout
How to Use This Service Manual
Shop Practices
Use Genuine Replacement Parts
Cleaning
Disposal and Recycling
Tools and Materials
Product Registered Marks
H-D U.S.A., LLC Trademark Information
Contents
Safety
Safety
Safety
Maintenance
FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter
General
Servicing a New Motorcycle
Secure the Motorcycle for Service
Safe Operating Maintenance
Shop Practices
Disposal and Recycling
Repair and Replacement Procedures
Cleaning
Tool Safety
FUEL AND OIL
Fuel
Gasoline Blends
Engine Lubrication
Low Temperature Lubrication
MAINTENANCE SCHEDULE
General -[JPN]
ENGINE OIL AND FILTER
Check Engine Oil Level
Change Oil and Oil Filter
AIR CLEANER ELEMENT
Remove
Clean and Inspect
Install
EXHAUST SYSTEM
Leak Check
COOLANT
Cooling System
Freeze Point Test
Drain and Fill Cooling System
TIRES AND WHEELS
General
Tires
Replace Tire
Wheel Bearings
Wheel Spokes
PRIMARY CHAINCASE LUBRICANT
Change Primary Chaincase Lubricant
TRANSMISSION LUBRICANT
Check Transmission Lubricant
Change Transmission Lubricant
HYDRAULIC CLUTCH FLUID
General
Check Clutch Fluid
Replace Clutch Fluid
BRAKES
Inspect Brake Fluid
Replace Brake Fluid
Inspect Brake Lines
BRAKE PADS AND DISCS
Inspect
Replace Brake Pads
DRIVE BELT AND SPROCKETS
General
Cleaning
Inspect
Check Drive Belt Deflection
Adjust Belt Deflection
REAR SPROCKET ISOLATOR
Inspect
CABLE AND CHASSIS LUBRICATION
Chassis Lubrication
SPARK PLUGS
Prepare
Remove
Inspect
Clean
Install
Complete
STEERING HEAD BEARINGS
Check and Adjust Swing-Back
Inspect and Lubricate
REAR SUSPENSION ADJUSTMENTS
Manual Suspension Preload
BATTERY MAINTENANCE
General
Clean and Inspect
Battery
Voltage Test
Charging Battery
Battery Tender Connector
Storage
HEADLAMP ALIGNMENT
Check Headlamp Alignment
Adjust Headlamp
Adjust Auxiliary/Fog Lamps
STORAGE
General
Place in Storage
Remove from Storage
TROUBLESHOOTING
General
Engine
Lubrication System
Electrical System
Transmission
Handling
BRAKES
Chassis
FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter
Specifications
Specifications
Vehicle Identification Number (VIN)
Vehicle Identification Number (VIN)
FRONT WHEEL
Remove
Install
Disassemble
Clean and Inspect
Assemble
REAR WHEEL
Prepare
Remove
Install
Complete
Disassemble
Clean and Inspect
Assemble
REAR WHEEL COMPENSATOR
Prepare
Remove
Install
Disassemble
Clean and Inspect
Assemble
Complete
WHEEL LACING: FRONT RIM
Lace Wheel: Angle Flange Hub
WHEEL LACING: 16 INCH REAR RIM
Lace Wheel: 16 In. Rear Wheel
WHEEL RUNOUT
Prepare
Inspect
Complete
Laced Wheel Rim Offset
True Laced Wheels
SEALED WHEEL BEARINGS
Inspect
Remove
Install
Tires
General
Remove
Clean, Inspect and Repair
Install
Check Tire Runout
Balance Wheel
FRONT BRAKE MASTER CYLINDER
Prepare
Remove
Install
Clean and Inspect
Complete
Disassemble
Assemble
FRONT BRAKE CALIPER
Remove
Install
REAR BRAKE MASTER CYLINDER
General
Prepare
Remove
Install
Clean and Inspect
Complete
Disassemble
Assemble
REAR BRAKE CALIPER
Remove
Install Brake Lines
Front Brake Line: Non-ABS
Rear Brake Line: Non-ABS
Brake Line: Front Master Cylinder to ABS Module
Brake Line: ABS Module to Front Caliper
Brake Line: Rear Master Cylinder to ABS Module
Brake Line: ABS Module to Rear Caliper BLEED BRAKES
Fill and Bleed ABS Module
Reflex™ Linked Brakes with ABS Operation
ABS Module FRONT FORK
Check For Oil Leak
Prepare
Remove
Install
Complete
Clean and Inspect
Disassemble
Assemble
STEERING HEAD BEARINGS
Prepare
Remove
Install
Upper Fork Bracket Complete
Disassemble
Assemble
Rear Suspension
Remove Shock Absorber
Clean and Inspect
Install Shock Absorber
Manual Adjust Shock Absorber Repair
REAR FORK
Remove
Install
Disassemble
Assemble
CLUTCH MASTER CYLINDER AND RESERVOIR
Remove
Disassemble
Cleaning and Inspection
Install
Assemble
HYDRAULIC CLUTCH HAND LEVER
Remove
Install
CLUTCH FLUID LINE
Prepare
Remove
Install
Complete
BLEED CLUTCH CONTROL SYSTEM
Drain and Fill
Bleed Hydraulic Clutch System
HANDLEBAR
Adjust
Remove
Install
Left Hand Grip
Remove Harnesses, Internally Wired Handlebar
Install Harnesses, Internally Wired Handlebar
Right Hand Grip
Handlebar Clamps and Rubber Mounts
HEATED HAND GRIPS
Mirrors
All Models Except FLHX, FLHXS
FLHX, FLHXS
SEAT
SEAT
Seat Retention Nut
Seat Bumper
SADDLEBAGS
Remove
Install
SADDLEBAG SERVICE
Repair Saddlebag
Saddlebag Support
TOUR-PAK
Removal and Installation
Tour-Pak Support
TOUR-PAK SERVICE
Tour-Pak Liner
Tour-Pak Seal
Hinges
Tour-Pak Lock
Latch Handle and Catch
Tether
Luggage Rack
Ground Plate
TOUR-PAK BACKREST
Passenger Backrest
Rubber Isolators
Passenger Backrest Flap
FAIRING LOWERS AND ENGINE GUARD
Fairing Lower: Air-Cooled
Fairing Lower: Twin-Cooled
Engine Guard
OUTER FAIRING AND WINDSHIELD: FORK MOUNTED FAIRING MODELS
Outer Fairing and Windshield
DASH PANEL: FORK MOUNTED FAIRING MODELS
Dash Panel
INNER FAIRING: FORK MOUNTED FAIRING MODELS
Rotate Inner Fairing
Remove and Install Inner Fairing Assembly
Replace Inner Fairing Shell
Fairing Vent
Upper Support Bracket
Media Compartment
INSTRUMENT BEZEL: FRAME MOUNTED FAIRING MODELS
Instrument Bezel
INSTRUMENT NACELLE: FRAME MOUNTED FAIRING MODELS
Instrument Nacelle
OUTER FAIRING AND WINDSHIELD: FRAME MOUNTED FAIRING MODELS
WINDSHIELD
Top Air Duct
Outer Fairing
INNER FAIRING: FRAME MOUNTED FAIRING MODELS
Removal
Installation
Fairing Air Duct
Inner Fairing Shell Replacement
Radio Support Bracket
STORAGE COMPARTMENTS: FRAME MOUNTED FAIRING MODELS
Storage Compartment, Door and Hinge
Air Deflectors
Fairing Air Deflectors
Mid-Frame Air Deflectors
WINDSHIELD: ROAD KING MODELS
WINDSHIELD
Windshield Window
HEADLAMP NACELLE: ROAD KING MODELS
Removal
Installation
Front Fender
Removal
Installation
REAR FENDER
Removal
Fender Repair
Installation
REAR FASCIA
Removal
Installation
Stud Plate
Rear Fascia Lamp
Rear Frame
Rear Frame
FOOTBOARDS AND FOOTRESTS
Rider Footboards
Passenger Footboard
Passenger Footrest: FLHX, FLHXS, FLTRX, FLTRXS
Passenger Footrest: Low Models
Jiffy Stand
Remove Leg
Install Leg
Jiffy Stand Bracket
Jiffy Stand Interlock Sensor
FRONT ENGINE MOUNT
Prepare
Remove
Installation
Stabilizer Link
Complete
MEDALLIONS, BADGES AND TANK EMBLEMS
Removal
Installation
Engine
FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter
Specifications
Specifications
SERVICE WEAR LIMITS
Specifications
ENGINE OIL FLOW
Oil Flow
Oil Pump Operation
General
Operation
BREATHER OPERATION
Crankcase Ventilation
Oil Pressure
Oil Pressure Indicator Lamp
Oil Pressure Check
Troubleshooting
Compression Test
Cylinder Leakdown Test
Diagnose Valve Train Noise
Diagnosing Smoking Engine or High Oil Consumption
OIL COOLER AND DOWNTUBE 
Prepare
Remove
Install
Complete
Disassemble Fan from Oil Cooler
Assemble Fan to Oil Cooler
Oil Check Valve
OIL COOLANT LINES
Prepare
Remove
Install
Complete
HOW TO USE THIS SECTION
Top End Repair
Bottom End Repair
Typical Symptoms
PREPARE MOTORCYCLE FOR SERVICE
Engine in Chassis
ASSEMBLE MOTORCYCLE AFTER SERVICE
Engine in Chassis TOP END SERVICE
Engine in Chassis
Engine Removed from Chassis CAM COMPARTMENT SERVICE
Replace Camshaft
BOTTOM END SERVICE
Engine Removed from Chassis REMOVE ENGINE
Remove
INSTALL ENGINE
Install
UPPER ROCKER COVERS
Prepare
Remove
Install
Complete
LOWER ROCKER COVERS
Prepare
Remove
Install
Complete BREATHERS
Prepare
Remove
Install
Complete Rocker Arms
Prepare
Remove
Install
Complete
Clean and Inspect
Pushrods, Lifters and Covers
Prepare
Remove
Clean and Inspect
Inspect Lifters
Assemble Pushrod Cover
Install
Complete
CYLINDER HEAD
Prepare
Remove
Cleaning
Install
Complete
Disassemble
Inspect
Assemble
Valve and Seat Repair
CYLINDERS
Prepare
Remove
Clean and Inspect
Deglaze Cylinder
Install
Complete
PISTONS
Prepare
Remove
Install
Complete
Disassemble
Cleaning
Inspect
Check Piston Ring Gap
Assemble
CAM COMPARTMENT AND COMPONENTS
Prepare
Remove
Cam Component Inspection
Install
Complete
Camshaft Needle Bearings
Oil Pump
Prepare
Remove
Disassemble and Inspect
Assemble
Install
Complete
Crankcase
Prepare
Disassemble
Assemble
Sprocket Shaft Bearing Inner Race
Complete
Cylinder Studs
Repair Right Crankcase Half
Cleaning and Inspection
Repair Left Crankcase Half
Plugs and Oil Fittings
FLYWHEEL AND CONNECTING RODS
Symptoms
Inspection
Measuring Crankshaft Runout
OIL PAN
Prepare
Remove
Install
Complete
Fuel System
FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter
SPECIFICATIONS: FUEL SYSTEM
Specifications
Fuel Pressure Test
Prepare
Test
Complete
Intake Leak Test
Leak Tester
Procedure
AIR CLEANER ASSEMBLY
Remove
Install
FUEL TANK
Console
Removal
Fuel Door
Installation
Vent Tube: Models Without EVAP System
Fuel Supply Check Valve/Tube
FUEL TANK TOP PLATE
Removal
Installation
Fuel Filter
Removal
Installation
FUEL PRESSURE REGULATOR
Removal
Installation
FUEL LEVEL SENDER
Removal
Installation
TWIST GRIP SENSOR (TGS)
Remove
Install
Mechanical Diagnosis
INDUCTION MODULE
Prepare
Remove
Install
Complete
Disassemble
Assemble
TEMPERATURE MANIFOLD ABSOLUTE PRESSURE SENSOR (TMAP)
Prepare
Remove
Install
Complete
HEATED OXYGEN SENSORS (HO2)
Remove
Install
Fuel Injectors
Prepare
Remove
Install
Complete
FUEL PUMP
General
Removal
Fuel Pump and Fuel Level Sender Wire Harness
Installation
EXHAUST SYSTEM
Mufflers
Prepare
Remove Exhaust System
Install Exhaust System
Complete
EVAPORATIVE EMISSIONS CONTROL SYSTEM
General
Vapor Valve
Fuel Vapor Vent Tube
Canister-to-Solenoid Tube
Charcoal Canister
Purge Solenoid
Solenoid-to-Induction Module Tube
Cooling System
FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter
SPECIFICATIONS: COOLING SYSTEM
General
COOLING SYSTEM OPERATION
Operation
TESTING AND DIAGNOSTICS
Troubleshooting
Pressure Cap Test
System Pressure Test
Leak Detection Dye Test
COOLING SYSTEM REPAIR
Crimp Clamps
Coolant Bottle
Remove Upper Coolant Lines
Install Upper Coolant Lines
Coolant Downtubes
Horizontal Coolant Tube
Radiator
Coolant Pump
COOLING FAN
Drive
FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter
SPECIFICATIONS: DRIVE
Specifications
PRIMARY CHAINCASE COVER
Prepare
Remove
Install
Complete
DRIVE COMPONENTS
Prepare
Remove
Install
Complete
PRIMARY CHAINCASE HOUSING
Prepare
Remove
Inspect
Mainshaft Bearing and Seal
Install
Mainshaft Bearing Inner Race
Complete
Shifter Shaft Bushing
CLUTCH: ASSIST AND SLIP
Removal and Installation
Clutch Pack Only
Complete Clutch Disassembly
HYDRAULIC CLUTCH RELEASE BEARING AND PUSHROD
Prepare
Remove
Install
Complete
Disassemble
Assemble
TRANSMISSION SPROCKET
Prepare
Remove
Clean and Inspect
Install
Complete
Drive Belt
Remove
Install Transmission
FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter
SPECIFICATIONS: TRANSMISSION
Specifications
SERVICE WEAR LIMITS
TRANSMISSION OPERATION
Power Flow
SHIFTER LINKAGE
Shifter Rod
Heel-Toe Shift Levers Shifter Rod Lever, Front
TRANSMISSION SIDE COVERS
Prepare
Remove
Install
Complete
SECONDARY CLUTCH ACTUATOR
Prepare
Remove
Install
Complete
Transmission
Prepare
Remove
Install
Complete
Disassemble
Cleaning and Inspection
Assemble
MAIN DRIVE GEAR AND BEARING
Prepare
Remove
Clean and Inspect
Install
Replace Mainshaft Seal
Complete
Replace Needle Bearings
TRANSMISSION CASE
Prepare
Remove
Install
Disassemble
Complete
Clean and Inspect
Assemble
Electrical
FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter
SPECIFICATIONS: ELECTRICAL
Specifications
System Fuses and Relays
Main Fuse
System Fuses and Relays
Fuse Blocks
ELECTRONIC CONTROL MODULE (ECM)
ECM
BODY CONTROL MODULE (BCM)
Removal
Installation
ELECTRICAL CADDIES
Fairing and Steering Head Caddies
Top Caddy
Left Side Caddy
Right Side Caddy
Battery Tray
Lower Backbone Caddy
IGNITION COIL AND SPARK PLUG CABLES
Removal
Install
SPARK PLUG CABLES
Inspect Spark Plug Cables STARTER
Removal
Install
HEADLAMP
Headlamp: All But FLTR Models
Headlamp: FLTR Models Rear Lighting
Replace Tail Lamp Bulb
Tail Lamp Base
Rear Fascia Lamp FENDER TIP LAMPS
Front Fender Tip Lamp
Rear Fender Tip Lamp TOUR-PAK LIGHTS
Tour-Pak Side Lamps/Trim Strips
Tour-Pak Lights Harness
Wrap-Around Lamp (if equipped) Turn Signal Lamps
Turn Signal Bulb Replacement: Bullet Style
Turn Signal Bulb Replacement: Flat Lens Style
Front Turn Signal Lamp
Rear Turn Signal Lamp
Rear Turn Signal Lamps Bracket Ignition Switch and Fork Lock
Fairing Models
Road King Models
ACCESSORY SWITCHES
Fork-Mounted Fairing Models
Frame-Mounted Fairing Models
Nacelle Switches
CRANKSHAFT POSITION SENSOR (CKP)
Remove
Installation KNOCK SENSOR (KS)
Prepare
Remove
Install
Complete
ENGINE TEMPERATURE SENSOR (ET)
Prepare
Remove
Install
Complete
ENGINE COOLANT TEMPERATURE SENSOR (ECT)
Coolant Temperature Sensor
Automatic Compression Release (ACR)
Prepare
Remove
Install Complete
Vehicle Speed Sensor (VSS)
VSS
WHEEL SPEED SENSORS
Front Wheel Speed Sensor (WSS)
Rear Wheel Speed Sensor
NEUTRAL SWITCH
Removal
Installation
Oil Pressure Switch
Removal
Install
STOP LAMP SWITCHES
Front Stop Lamp Switch
Rear Stop Lamp Switch
VOLTAGE REGULATOR
Prepare
Remove
Install
Complete
ALTERNATOR
Prepare
Remove
Cleaning and Inspection
Install
Complete
HORN
Removal
Installation
FAIRING POWER OUTLET
Removal
Installation
GAUGES AND INSTRUMENTS: FAIRING MODELS
Ambient Air Temperature Sensor
2-Inch Diameter Gauges
Speedometer/Tachometer Instrument Cluster: Fork-Mounted Fairing
Speedometer/Tachometer Instrument Cluster: Frame Mounted Fairing
GAUGES AND INSTRUMENTS: ROAD KING MODELS
Fuel Gauge
SPEEDOMETER
INDICATOR LAMPS: ROAD KING MODELS
INDICATOR LAMPS
Boom! Box Infotainment System
Radio Face Protective Film
Radio: Fork-Mounted Fairing
CB Module: Fork Mounted Fairing
GPS Antenna
Front Fairing Speakers: Fork Mounted Fairing
Radio: Frame Mounted Fairing
Front Fairing Speaker and Enclosure: Frame-Mounted Fairing
Rear Speaker Enclosures
Passenger Audio Controls
Rider Headset Connector
ANTENNA CABLES
Removal
Installation
WIRE TROUGH
Remove
Install
MAIN WIRING HARNESS
Removal: All Models (Part 1)
Removal: Road King Models (Part 2)
Removal: Fork Mounted Fairing Models (Part 2)
Removal: Frame Mounted Fairing Models (Part 2)
Removal: All Models (Part 3)
Installation: All Models (Part 1)
Installation: Road King Models (Part 2)
Installation: Fork-Mounted Fairing Models (Part 2)
Installation: Frame-Mounted Fairing Models (Part 2)
Installation: All Models (Part 3)
FAIRING HARNESS
Harness Service: Fork-Mounted Fairing
Harness Service: Frame Mounted Fairing
HANDLEBAR SWITCH PACKS
Removal
Install
Switch Pack Harness
Handlebar Switch Caps
Security System Maintenance
Fob Battery
Smart Siren (If Equipped)
Security System Antenna
SECURITY SYSTEM ACTUATION
Sidecar Configuration
Activation
Fob Assignment
AUXILIARY/FOG LAMPS AND BRACKETS
Replace Auxiliary/Fog Lamp Bulb
Auxiliary/Fog Lamp Housing
Turn Signal/Auxiliary/Fog Lamp Bracket
Adjustment
SECURITY SIREN
Removal
Installation
Personal Identification Number (PIN)
General
Changing the PIN
Wiring
WIRING DIAGRAMS
General
Wiring Diagrams
WIRE HARNESS CONNECTORS
General
Reference
GLOSSARY
Acronyms and Abbreviations
METRIC CONVERSION
Conversion Table
FLUID CONVERSION
United States System
Metric System
British Imperial System
TORQUE CONVERSION
United States System
Metric System
Backmatter
Backmatter
Backmatter
Backmatter
This manual has been created to inform Harley-Davidson technicians about the construction of Harley-Davidson products and the latest tested and approved maintenance and repair techniques.
Safety
Refer to the Safety section before performing any procedures on a vehicle.
Sections
This service manual is organized into chapters, sections and topics. Sections in chapters 4, 6, 7, 8 are laid out as follows:
Prepare
Remove
Install
Disassemble (if applicable)
Clean/Inspect (if applicable)
Assemble (if applicable)
Complete
Topics
The purpose of the Prepare topics is to to provide an outline of procedures required before beginning a specific task. Links to the necessary procedures are provided in the topic.
The Remove and Install topics allow the technician to only remove and install the component - which may be all that is required. If a component can be repaired, Disassemble, Assemble and Clean/Inspect topics are provided as appropriate.
Complete topics provide a list of procedures that need to be performed to return the vehicle to ride-ready condition. If additional removal procedures need to be performed, move to the next section without performing the Complete topics in the current section.
Procedural Steps
Each topic contains steps to complete the procedure. These steps are laid out in numeric and alpha steps.
The purpose of the numeric steps is to provide the experienced technician with high-level information to complete the procedure.
The alpha steps provide a less-experienced technician with step-by-step instructions to perform the procedure.
Cross-References and Page Numbers
A cross-reference shown as 2.2 SPECIFICATIONS refers to chapter 2 CHASSIS, heading 2.2 SPECIFICATIONS.
All pages contain a chapter number followed by a page number. For example, page 3-5 refers to page 5 in Chapter 3.
Item References and Quantities
In figure legends and tables, the number in parentheses that follows the part name indicates the quantity of that part necessary for one complete assembly.
Example:
2. Rocker cover screw (4)
In a procedure step or paragraph, the number in parentheses that follows a part name indicates the legend item of the part in the figure referenced by the text.
Example:
1. Remove rocker cover screws (2).
Acronyms and Abbreviations
Acronyms and abbreviations are used in this document. See the Acronyms and Abbreviations for a list of acronyms, abbreviations and definitions.
Removing Parts
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.
Always tag hoses, wiring or tubes to verify proper installation.
Cleaning
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. See Cleaning.
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.
WARNING
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.
General
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.
Always clean around lines or covers before they are removed. When cleaning parts:
Plug, tape or cap holes and openings to keep out dirt, dust and debris.
Clean and inspect all parts as they are removed.
Cover all clean parts with clean lint-free cloth, paper or other material.
Verify that the part is clean when installed.
Cleaning Threads and Threaded Holes
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.
To attain proper clamp load, always clean fastener threads and threaded holes prior to assembly.
NOTE
Never use a thread-cutting tap or die to clean threads.
Clean all threadlocking material from fastener threads and threaded holes.
Use a wire brush or thread-chasing die to clean fastener threads.
Use a thread chaser 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.
Cleaning Plastic and Rubber Parts
Never use cleaners containing chlorine or ammonia on plastic parts. Chlorine will cause parts to become distorted and brittle resulting in cracks. Ammonia will cause cloudiness and brittleness in windshields and cause non-painted parts to form a white haze.
Before cleaning, protect rubber parts (such as hoses, boots and electrical insulation) from cleaning solutions. Use a grease-proof 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.
WARNING
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. Allow bearings 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.
Many communities maintain facilities for recycling used fluids, plastics and metals. Dispose of or recycle used oil, lubricants, fuel, coolant, brake fluid and batteries in accordance with local regulations.
WARNING
Read and follow warnings and directions on all products. Failure to follow warnings and directions can result in death or serious injury. (00470b)
Some service procedures require the use of tools designed for a specific purpose. These tools should be used when and as recommended.
When reference is made in this manual to a brand name product, tool or instrument, an equivalent product, tool or instrument may be substituted.
Special Tools
Special tools mentioned in this manual with a part number that begins with an "HD", "J" or "B" must be purchased, serviced or warrantied through a Harley-Davidson dealer.
Specific use of special tools is not discussed in this manual. Refer to the tool instruction sheet for instructions. If the tool instructions are misplaced, a copy can be obtained online at H-Dnet.com > My Toolbox > Edit > Bosch Tool Site.
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.
Apple, Alcantara S.p.A., Allen, Amp Multilock, Bluetooth, Brembo, City Navigator, 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, Road Tech, Robinair, S100, Sems, SiriusXM, Snap-on, Teflon, Threadlocker, Torca, Torco, TORX, Tufoil, Tyco, Ultratorch, Velcro, X-Acto and XM Satellite Radio are among the trademarks of their respective owners.
Bar & Shield, Boom!, Cross Bones, Cruise Drive, CVO, 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, Milwaukee-Eight, Night Rod, Nightster, Night Train, Profile, Reflex, Revolution, Road Glide, Road King, Road Tech, Rocker, Screamin' Eagle, Seventy-Two, Softail, Sportster, Street Glide, Street Rod, Sun Ray, Sunwash, Super Glide, SuperLow, Supersmart, Switchback, SYN3, TechLink, TechLink II, Tour-Pak, Tri Glide, Twin Cam 88, Twin Cam 88B, Twin Cam 96, Twin Cam 96B, Twin Cam 103, Twin Cam 103B, Twin Cam 110, Twin Cam 110B, TwinCooled, Ultra Classic, V-Rod, VRSC and Harley-Davidson Genuine Motor Parts and Genuine Motor Accessories are among the trademarks of H-D U.S.A., LLC.
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.
Harley-Davidson service manuals are intended for use by professional, qualified and experienced technicians. Attempting the procedures found within this manual without the proper training, tools and equipment could result in death or injury to you or others. This could also damage the vehicle, or cause the vehicle to operate improperly.
Safety is always the most important consideration when performing any job.
Always have a complete understanding of the task.
Use common sense.
Use proper tools for the task.
Protect yourself and bystanders with approved eye protection.
Harley-Davidson does not evaluate or advise the technicians of every way in which service might be performed, or all possible hazardous consequences of every method, or undertaken such a broad evaluation. Before using a tool not recommended by Harley-Davidson, make sure that technician or rider safety will not be jeopardized as a result.
Warnings against the use of specific service methods which could damage the motorcycle or render it unsafe are stated in this manual. These warnings are not all-inclusive. Inadequate safety precautions could result in death or serious injury.
Safety Messages
Statements in this manual preceded by the following words are of special significance.
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. (00119a)
CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. (00139a)
NOTICE
NOTICE indicates a potentially hazardous situation which, if not avoided, may result in property damage. (00140b)
NOTE
Refers to important information. It is recommended that you take special notice of these items.
Customer Safety
WARNING
The rider's safety depends upon proper motorcycle service and maintenance. If a procedure in this manual is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the procedure. Improper service or maintenance could result in death or serious injury. (00627b)
Proper service and repair is important for the safe, reliable operation of all mechanical products. The service
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