Харлей дэвидсон сервис мануал

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

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.

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.

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

procedures recommended and described in this manual are effective methods for performing service operations and are essential to your customer’s safety and the reliable and safe operation of your customer’s vehicle.

Personal Protection

WARNING

Always wear safety glasses or goggles when performing service or maintenance procedures. Flying objects or materials can cause serious eye injury or death.Wear protective gear that is appropriate to the situation. Helmets, gloves, boots and other protective clothing can prevent serious injury or death.Wear ear protection when loud noises are present. Loud noises can damage ears and cause hearing loss. (00628b)

Tool Safety

Some of these service operations require the use of tools specially designed for the purpose. Follow the manufacturer’s suggested usage and safety instructions. If using a tool other than that recommended by HarleyDavidson, be sure that the tool is appropriate for the service or maintenance procedure and is being used in accordance with the tool’s safety instructions.

Product Safety

WARNING

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

When reference is made to a specific brand name product, tool or instrument, an equivalent product, tool or instrument may be substituted.

Some referenced or recommended products contain chemicals known to the State of California to cause cancer and birth defects or other reproductive harm as indicated on the product label or at the point of purchase.

Hazardous Materials

WARNING

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

Keep hazardous products out of the reach of children.

Many products (oils, lubricants, solvents, sealants and cleaners, etc.) can cause death or serious injury if inhaled, absorbed, injected, ingested or improperly contacted. If hazardous contact is made with a product, follow the instructions on the product label and, if necessary, contact poison control or a medical facility.

Some products are flammable and/or explosive as indicated on the product label or at the point of purchase. Keep these products away from flame and intense heat.

Some products are corrosive as indicated on the product label. Wear appropriate protective gear to prevent skin contact. Use service covers to prevent damage to cosmetic surfaces on the motorcycle.

Some products contain chemicals known to the State of California to cause cancer and birth defects or other reproductive harm as indicated on the product label or at the point of purchase.

Fuel

WARNING

Keep gasoline away from ignition sources. Gasoline is extremely flammable and highly explosive and, if ignited, could result in death or serious injury. (00634b)

Stop the engine when refueling or servicing the fuel system.

Do not allow open flame, sparks, radiant heat or other ignition sources near gasoline.

Do not store motorcycle with gasoline in tank within the home or garage where ignition sources, such as open flames, pilot lights, sparks or electric motors are present.

Do not overfill fuel tank. Allow for fuel expansion .

Do not use gasoline as a cleaner or solvent.

Gasoline can leak or drain from loosened or improperly tightened fuel fittings or from removed fuel components.

Clean spilled gasoline immediately. Dispose of waste materials properly.

Battery

WARNING

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

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 out of the reach of children.

Do not remove warning label attached to top of battery.

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.

Coolant

Coolant contains toxic chemicals which could cause death or serious injuries if ingested. Do not induce vomiting. Call a physician immediately.

Irritation to skin or eyes can occur from vapors or direct contact. Flush thoroughly with water if contact is made.

Use in a well ventilated area.

Hydraulic (Brake) Fluid

Direct contact with brake fluid to the eyes can cause irritation. Flush thoroughly with water if contact is made.

Do not swallow brake fluid. Swallowing brake fluid can cause digestive discomfort. Call a physician immediately.

Brake fluid will cause cosmetic damage to painted surfaces. Always use caution and protect surfaces from spills whenever brake work is performed.

Engine Oil

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.

Do not swallow oil. If swallowed, do not induce vomiting. Contact a physician immediately.

Direct contact with eyes can cause irritation. Flush thoroughly with water if contact is made. Contact a physician if irritation persists.

Electrical Systems

WARNING

Improper service or maintenance of the electrical system can cause damage to the electrical system. This may

result in component failure. In certain situations, a component failure during operation could lead to a loss of control, which could result in death or serious injury. (00637b)

Always use replacement fuses that are of the specified type and amperage rating.

Do NOT pull on electrical wires. Pulling on electrical wires may damage wire conductivity.

Route wires and harnesses properly to prevent chafing, stripping, pinching, crimping or cutting wires. Damaged wires can cause short circuits and component damage or failure.

Do NOT overload the vehicle’s charging system. If the electrical accessories consume more electrical current than the charging system can produce, the battery may be discharged and cause damage to the motorcycle’s electrical system.

Do NOT exceed the maximum amperage rating of the fuse or circuit breaker protecting a modified circuit.

Avoid directly heating electrical system components other than the connectors on which heat shrink work is being performed.

WARNING

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 General.

Special Tools

WARNING

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 motorcycle.

Set Motorcycle Upright

1.Place motorcycle upright on a level surface or suitable lift if available.

2.Verify that motorcycle is level.

3.Secure with tie-downs.

Raise Front or Rear Wheel for Service

1. Verify that motorcycle is level.

NOTICE

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 cross-members, oil pan, mounting brackets, components or housings. Failure to comply can cause serious damage resulting in the need to perform major repair work. (00586d)

2.Use a FAT JACK (Part Number:HD-45968) or similar to raise the motorcycle to service a front or rear wheel.

3.Secure with tie-downs.

NOTE

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 results in improper break-in of the engine cylinders and piston rings.

Inspect motorcycle regularly for more 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.

5.Check brake pads and discs for wear.

6.Cables for fraying, crimping and free operation.

7.Engine oil and transmission fluid levels.

8.Headlamp, auxiliary/fog lamp, tail lamp, stop lamp, horn and turn signal operation.

Repair Notes

General maintenance practices are given in this section.

NOTE

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.

Do not 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 interfere with the lifting operation.

Parts are not left suspended.

WARNING

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 that all holes and passages are clean and open. After cleaning, cover all parts with clean lint-free cloth, paper or other material. Verify that 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.

Cleaning Fastener Threads

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.

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 fastener torque has been maintained. If the fastener rotates, remove it to determine if it has a threadlocking agent.

If it has a threadlocking agent, clean all 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. 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 from inside the vehicle’s powertrain on a magnetic parts tray.

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.

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. Since 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. Verify 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

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)

Always install new genuine Harley-Davidson parts and accessories. This provides 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.

Protecting Rubber Parts

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.

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.

Never use cleaners containing chlorine or ammonia on plastic parts. Chlorine causes parts to become distorted and brittle resulting in cracks. Ammonia causes cloudiness and brittleness in windshields and non-painted parts to form a white haze.

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 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.

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. Rebuild ratchets 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. 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 make sure that 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.

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

WARNING

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)

WARNING

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. This can cause air entrapment and pressurization.

Table 1. Octane Rating

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.

NOTICE

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 percent 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 percent may be used in your motorcycle without affecting vehicle performance. U.S. EPA regulations currently indicate that fuels with 15 percent 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 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.

Using fuel additives other than those approved for use by Harley-Davidson may damage the engine, fuel system and other 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.

CAUTION

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)

CAUTION

If engine oil is 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. (00357d)

NOTICE

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

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 for alternative choices.

If 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.

Table 1. Recommended Engine Oils