TOURING MODELS

2017 HARLEY-DAVIDSON
SERVICE MANUAL

XXXXXXXXXXX
 IMPORTANT NOTICE

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.

Harley-Davidson Motor Company

 2017 Harley-Davidson
Touring Models Service
Manual

©2016 H-D
AL L RIGHTS RESERVED
94000383

Printed in the U.S.A.

VISIT THE HARLE Y-DAVIDSON WEB SITE

http://ww w.harley-davidson.com
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FOREWORD
GENERAL
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.
MANUAL LAYOUT
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.
HOW TO USE THIS SERVICE MANUAL
Cross-References and Page Numbers
A cross-reference shown as 2.2 SPECIFICATIONS refers to
chapter 2 CHASSIS, heading 2.2 SPECIFICATIONS.
94000383
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 GLOSSARY (Page B-4) for a list of acronyms,
abbreviations and definitions.
SHOP PRACTICES
FOREWORD
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 General, Cleaning
(Page 2-5).
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.
I
USE GENUINE REPLACEMENT PARTS
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
Harley-Davidson replacement parts.
CLEANING
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
II
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.
DISPOSAL AND RECYCLING
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.
TOOLS AND 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)
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
Tools mentioned in this manual with a part number that begins
with an "HD", "J" or "B" must be ordered through your local
Harley-Davidson dealer. Special tools may only be purchased,
serviced or warrantied through a Harley-Davidson dealership.
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.
94000383
PRODUCT REGISTERED MARKS
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.
H-D U.S.A., LLC TRADEMARK
INFORMATION
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,
94000383
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, Twin-Cooled,
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.
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.
III
NOTES
TABLE OF CONTENTS
SAFETY
1.1 SAFETY
Safety..................................................................................1-1
Safety Messages..........................................................1-1
Customer Safety...........................................................1-1
Personal Protection.......................................................1-1
Tool Safety....................................................................1-1
Product Safety..............................................................1-1
Hazardous Materials.....................................................1-1
Electrical Systems.........................................................1-2
MAINTENANCE
2.1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter..............................2-1
2.2 GENERAL
Servicing a New Motorcycle...............................................2-3
Secure the Motorcycle for Service......................................2-3
Set Motorcycle Upright..................................................2-3
Raise Front or Rear Wheel for Service.........................2-3
Safe Operating Maintenance..............................................2-3
Shop Practices....................................................................2-3
Repair Notes.................................................................2-3
Safety............................................................................2-3
Removing Parts............................................................2-3
Cleaning........................................................................2-4
Cleaning Fastener Threads..........................................2-4
Disassembly and Assembly..........................................2-4
Checking Torques on Fasteners...................................2-4
Magnetic Parts Trays....................................................2-4
Repair and Replacement Procedures................................2-4
Hardware and Threaded Parts......................................2-4
Threadlocking Agents...................................................2-4
Wiring, Hoses and Lines...............................................2-4
Instruments and Gauges...............................................2-4
Bearings........................................................................2-4
Bushings.......................................................................2-5
Gaskets.........................................................................2-5
Lip-Type Seals..............................................................2-5
O-Rings.........................................................................2-5
Gears............................................................................2-5
Shafts............................................................................2-5
Part Replacement.........................................................2-5
Disposal and Recycling......................................................2-5
Cleaning..............................................................................2-5
Protecting Rubber Parts................................................2-5
Cleaning Process..........................................................2-5
Rust or Corrosion Removal...........................................2-5
Bearings........................................................................2-6
Tool Safety..........................................................................2-6
Air Tools........................................................................2-6
Wrenches......................................................................2-6
Pliers/Cutters/Pry Bars..................................................2-6
Hammers......................................................................2-6
Punches/Chisels...........................................................2-6
Screwdrivers.................................................................2-6
Ratchets and Handles...................................................2-6
Sockets.........................................................................2-6
Storage Units................................................................2-7
2.3 FUEL AND OIL
Fuel.....................................................................................2-8
Gasoline Blends..................................................................2-8
Engine Lubrication..............................................................2-8
Low Temperature Lubrication.............................................2-9
2.4 MAINTENANCE SCHEDULE
General.............................................................................2-10
2.5 ENGINE OIL AND FILTER
Check Engine Oil Level....................................................2-15
Oil Level Cold Check..................................................2-15
Oil Level Hot Check....................................................2-15
Change Oil and Oil Filter..................................................2-15
2.6 AIR CLEANER ELEMENT
Remove............................................................................2-17
Clean and Inspect.............................................................2-17
Install................................................................................2-17
2.7 EXHAUST SYSTEM
Leak Check.......................................................................2-18
2.8 COOLANT
Cooling System.................................................................2-19
TABLE OF CONTENTS
Checking Coolant Level..............................................2-19
Clean Radiators..........................................................2-19
Freeze Point Test..............................................................2-20
Drain and Fill Cooling System..........................................2-20
Drain System..............................................................2-20
Power Fill and Bleed...................................................2-21
Manual Fill and Bleed.................................................2-21
2.9 TIRES AND WHEELS
General.............................................................................2-23
Tires..................................................................................2-23
Replace Tire.....................................................................2-24
Inspection....................................................................2-24
When To Replace Tires...............................................2-24
Wheel Bearings................................................................2-24
Wheel Spokes...................................................................2-24
Identify Wheel Spoke Groups.....................................2-25
Adjust Wheel Spokes..................................................2-25
2.10 PRIMARY CHAINCASE LUBRICANT
Change Primary Chaincase Lubricant..............................2-26
2.11 TRANSMISSION LUBRICANT
Check Transmission Lubricant.........................................2-28
Change Transmission Lubricant.......................................2-28
2.12 HYDRAULIC CLUTCH FLUID
General.............................................................................2-30
Check Clutch Fluid............................................................2-30
Replace Clutch Fluid.........................................................2-30
2.13 BRAKES
Inspect Brake Fluid...........................................................2-32
Replace Brake Fluid.........................................................2-32
Inspect Brake Lines..........................................................2-33
2.14 BRAKE PADS AND DISCS
Inspect..............................................................................2-34
Brake Pads.................................................................2-34
TABLE OF CONTENTS V
TABLE OF CONTENTS
Brake Disc...................................................................2-34
Replace Brake Pads.........................................................2-34
Prepare.......................................................................2-34
Remove.......................................................................2-34
Install...........................................................................2-35
Complete.....................................................................2-36
2.15 DRIVE BELT AND SPROCKETS
General.............................................................................2-37
Cleaning............................................................................2-37
Inspect..............................................................................2-37
Sprockets....................................................................2-37
Drive Belt....................................................................2-37
Check Drive Belt Deflection..............................................2-38
Adjust Belt Deflection........................................................2-39
Prepare.......................................................................2-39
Adjust..........................................................................2-39
Assemble....................................................................2-40
Complete.....................................................................2-40
2.16 REAR SPROCKET ISOLATOR
Inspect..............................................................................2-42
2.17 CABLE AND CHASSIS LUBRICATION
Chassis Lubrication..........................................................2-43
2.18 SPARK PLUGS
Prepare.............................................................................2-44
Remove............................................................................2-44
Inspect..............................................................................2-44
Clean................................................................................2-44
Install................................................................................2-44
Complete..........................................................................2-45
2.19 STEERING HEAD BEARINGS
Check and Adjust Swing-Back.........................................2-46
Measure Swing-Back..................................................2-46
Adjust Swing-Back......................................................2-47
Inspect and Lubricate.......................................................2-48
2.20 REAR SUSPENSION ADJUSTMENTS
Manual Suspension Preload.............................................2-49
2.21 BATTERY MAINTENANCE
General.............................................................................2-51
Clean and Inspect.............................................................2-52
Battery..............................................................................2-52
Disconnection and Removal.......................................2-52
Installation and Connection.........................................2-52
Voltage Test......................................................................2-53
Battery Tender Connector.................................................2-53
Charging Battery...............................................................2-54
Safety Precautions......................................................2-54
Using a Battery Charger.............................................2-54
Storage.............................................................................2-54
2.22 HEADLAMP ALIGNMENT
Check Headlamp Alignment.............................................2-56
Adjust Headlamp..............................................................2-56
Adjust Auxiliary/Fog Lamps..............................................2-57
2.23 STORAGE
General.............................................................................2-59
TABLE OF CONTENTS VI
Place in Storage...............................................................2-59
Remove from Storage.......................................................2-59
2.24 TROUBLESHOOTING
General.............................................................................2-60
Engine...............................................................................2-60
Starter Motor Does Not Operate or Does Not Turn Engine
Over............................................................................2-60
Engine Turns Over But Does Not Start.......................2-60
Starts Hard..................................................................2-60
Starts But Runs Irregularly or Misses.........................2-60
A Spark Plug Fouls Repeatedly..................................2-61
Pre-Ignition or Detonation (Knocks or Pings)..............2-61
Overheating................................................................2-61
Valve Train Noise........................................................2-61
Excessive Vibration.....................................................2-61
Check Engine Light Illuminates During Operation......2-61
Lubrication System...........................................................2-61
Oil Does Not Return To Oil Reservoir.........................2-61
Engine Uses Too Much Oil Or Smokes Excessively....2-61
Engine Leaks Oil From Cases, Pushrods, Hoses,
Etc...............................................................................2-62
Low Oil Pressure.........................................................2-62
High Oil Pressure........................................................2-62
Electrical System..............................................................2-62
Alternator Does Not Charge........................................2-62
Alternator Charge Rate Is Below Normal....................2-62
Speedometer Operates Erratically..............................2-62
Transmission....................................................................2-62
Shifts Hard..................................................................2-62
Jumps Out Of Gear.....................................................2-62
Clutch Slips.................................................................2-62
Clutch Drags Or Does Not Release............................2-62
Clutch Chatters...........................................................2-62
Handling............................................................................2-62
Irregularities................................................................2-62
BRAKES...........................................................................2-63
Brake Does Not Hold Normally...................................2-63
CHASSIS
3.1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter..............................3-1
3.2 SPECIFICATIONS
Specifications....................................................................3-10
Chassis Specifications................................................3-10
Tire Specifications.......................................................3-11
3.3 VEHICLE IDENTIFICATION NUMBER
(VIN)
Vehicle Identification Number (VIN)..................................3-13
General.......................................................................3-13
Location......................................................................3-13
Abbreviated VIN..........................................................3-13
3.4 FRONT WHEEL
Remove............................................................................3-15
Install................................................................................3-15
Disassemble.....................................................................3-16
Clean and Inspect.............................................................3-16
Assemble..........................................................................3-16
TABLE OF CONTENTS
3.5 REAR WHEEL
Prepare.............................................................................3-18
Remove............................................................................3-18
Install................................................................................3-19
Complete..........................................................................3-20
Disassemble.....................................................................3-20
Clean and Inspect.............................................................3-21
Assemble..........................................................................3-21
3.6 REAR WHEEL COMPENSATOR
Prepare.............................................................................3-22
Remove............................................................................3-22
Install................................................................................3-22
Complete..........................................................................3-22
Disassemble.....................................................................3-22
Clean and Inspect.............................................................3-23
Assemble..........................................................................3-23
3.7 WHEEL LACING: FRONT RIM
Lace Wheel: Angle Flange Hub........................................3-24
3.8 WHEEL LACING: 16 INCH REAR RIM
Lace Wheel: 16 In. Rear Wheel........................................3-26
3.9 WHEEL RUNOUT
Prepare.............................................................................3-29
Inspect..............................................................................3-29
Wheel Stand...............................................................3-29
Lateral Runout............................................................3-29
Radial Runout.............................................................3-29
Complete..........................................................................3-30
Laced Wheel Rim Offset...................................................3-30
True Laced Wheels...........................................................3-31
Adjust Radial Runout..................................................3-31
Adjust Lateral Runout.................................................3-31
3.10 SEALED WHEEL BEARINGS
Inspect..............................................................................3-33
Remove............................................................................3-33
Install................................................................................3-35
3.11 TIRES
General.............................................................................3-36
Remove............................................................................3-36
Clean, Inspect and Repair................................................3-36
Install................................................................................3-37
Tube-Type Tires..........................................................3-37
Tubeless Tires: Cast Wheels......................................3-37
Check Tire Runout............................................................3-38
Lateral Runout............................................................3-38
Radial Runout.............................................................3-38
Balance Wheel..................................................................3-38
Static vs Dynamic.......................................................3-38
Weights.......................................................................3-39
3.12 FRONT BRAKE MASTER CYLINDER
Prepare.............................................................................3-40
Remove............................................................................3-40
Install................................................................................3-40
Complete..........................................................................3-40
Disassemble.....................................................................3-40
Clean and Inspect.............................................................3-41
Assemble..........................................................................3-41
3.13 FRONT BRAKE CALIPER
Remove............................................................................3-43
Install................................................................................3-43
3.14 REAR BRAKE MASTER CYLINDER
General.............................................................................3-44
Prepare.............................................................................3-44
Remove............................................................................3-44
Install................................................................................3-44
Complete..........................................................................3-45
Disassemble.....................................................................3-45
Clean and Inspect.............................................................3-46
Assemble..........................................................................3-46
3.15 REAR BRAKE CALIPER
Remove............................................................................3-47
Install................................................................................3-47
3.16 BRAKE LINES
Front Brake Line: Non-ABS..............................................3-48
Prepare.......................................................................3-48
Remove.......................................................................3-48
Install...........................................................................3-48
Complete.....................................................................3-49
Rear Brake Line: Non-ABS...............................................3-49
Prepare.......................................................................3-49
Remove.......................................................................3-49
Install...........................................................................3-49
Complete.....................................................................3-51
Brake Line: Front Master Cylinder to ABS Module...........3-51
Prepare.......................................................................3-51
Remove.......................................................................3-52
Front Line Routing......................................................3-52
Install...........................................................................3-53
Complete.....................................................................3-54
Brake Line: ABS Module to Front Caliper.........................3-54
Prepare.......................................................................3-55
Remove.......................................................................3-55
Install...........................................................................3-55
Complete.....................................................................3-56
Brake Line: Rear Master Cylinder to ABS Module...........3-56
Prepare.......................................................................3-56
Remove.......................................................................3-56
Install...........................................................................3-57
Complete.....................................................................3-58
Brake Line: ABS Module to Rear Caliper.........................3-58
Prepare.......................................................................3-58
Remove.......................................................................3-59
Install...........................................................................3-59
Complete.....................................................................3-59
3.17 ABS MODULE
Reflex™ Linked Brakes with ABS Operation....................3-60
ABS Module......................................................................3-60
Prepare.......................................................................3-60
Remove.......................................................................3-60
Install...........................................................................3-61
Complete.....................................................................3-61
3.18 BLEED BRAKES
Fill and Bleed....................................................................3-62
3.19 FRONT FORK
Check For Oil Leak...........................................................3-64
TABLE OF CONTENTS VII
TABLE OF CONTENTS
Fork Oil Seals.............................................................3-64
Check Oil Leak............................................................3-64
Prepare.............................................................................3-64
Remove............................................................................3-64
Install................................................................................3-65
Complete..........................................................................3-65
Disassemble.....................................................................3-66
Clean and Inspect.............................................................3-67
Assemble..........................................................................3-68
Filling and Final Assembly..........................................3-69
3.20 STEERING HEAD BEARINGS
Prepare.............................................................................3-70
Remove............................................................................3-70
Install................................................................................3-70
Complete..........................................................................3-70
Disassemble.....................................................................3-71
Assemble..........................................................................3-71
Upper Fork Bracket...........................................................3-71
Remove.......................................................................3-71
Install...........................................................................3-72
3.21 REAR SUSPENSION
Remove Shock Absorber..................................................3-74
Prepare.......................................................................3-74
Remove.......................................................................3-74
Clean and Inspect.............................................................3-74
Install Shock Absorber......................................................3-74
Install...........................................................................3-74
Complete.....................................................................3-74
Manual Adjust Shock Absorber Repair.............................3-74
3.22 REAR FORK
Remove............................................................................3-76
Install................................................................................3-76
Disassemble.....................................................................3-77
Remove Bearings.......................................................3-77
Disassemble Pivot Shaft/Mount..................................3-77
Assemble..........................................................................3-78
Install Bearings...........................................................3-78
3.23 CLUTCH MASTER CYLINDER AND
RESERVOIR
Remove............................................................................3-79
Install................................................................................3-79
Disassemble.....................................................................3-80
Cleaning and Inspection...................................................3-80
Assemble..........................................................................3-80
3.24 HYDRAULIC CLUTCH HAND LEVER
Remove............................................................................3-81
Install................................................................................3-81
3.25 CLUTCH FLUID LINE
Prepare.............................................................................3-82
Remove............................................................................3-82
Install................................................................................3-82
Complete..........................................................................3-83
3.26 BLEED CLUTCH CONTROL SYSTEM
Drain and Fill.....................................................................3-85
Drain...........................................................................3-85
Fill................................................................................3-85
TABLE OF CONTENTS VIII
Bleed Hydraulic Clutch System........................................3-85
3.27 HANDLEBAR
Adjust................................................................................3-87
Remove............................................................................3-87
Install................................................................................3-90
Remove Harnesses, FLTR Models...................................3-91
Install Harnesses, FLTR Models.......................................3-91
Pull Wire Leads...........................................................3-91
Left Hand Grip..................................................................3-92
Removal......................................................................3-92
Installation...................................................................3-92
Right Hand Grip................................................................3-92
Removal......................................................................3-92
Installation...................................................................3-92
Handlebar Clamps and Rubber Mounts...........................3-92
HEATED HAND GRIPS....................................................3-93
Remove Left Hand Grip..............................................3-93
Install Left Hand Grip..................................................3-93
Remove Right Hand Grip............................................3-94
Install Right Hand Grip................................................3-94
3.28 MIRRORS
All Models Except FLHX, FLHXS.....................................3-95
Removal......................................................................3-95
Installation...................................................................3-95
FLHX, FLHXS...................................................................3-95
Removal......................................................................3-95
Installation...................................................................3-95
3.29 SEAT
SEAT.................................................................................3-96
Removal......................................................................3-96
Installation...................................................................3-96
Seat Retention Nut...........................................................3-97
Seat Bumper.....................................................................3-97
3.30 SADDLEBAGS
Remove............................................................................3-98
All Except FLHRC.......................................................3-98
FLHRC........................................................................3-98
Install................................................................................3-98
All Except FLHRC.......................................................3-98
FLHRC........................................................................3-98
3.31 SADDLEBAG SERVICE
Repair Saddlebag.............................................................3-99
Lock............................................................................3-99
Strikes.........................................................................3-99
Cover..........................................................................3-99
Cover Seal................................................................3-100
Hinge.........................................................................3-100
Latch Assembly.........................................................3-100
Saddlebag Support.........................................................3-101
Removal....................................................................3-101
Installation.................................................................3-101
3.32 TOUR-PAK
Removal and Installation................................................3-103
Removal....................................................................3-103
Installation.................................................................3-103
Tour-Pak Support............................................................3-104
Removal....................................................................3-104
TABLE OF CONTENTS
Installation.................................................................3-104 3.37 DASH PANEL: FORK MOUNTED
Disassembly/Assembly.............................................3-104 FAIRING MODELS
3.33 TOUR-PAK SERVICE Dash Panel.....................................................................3-117
Removal....................................................................3-117
Tour-Pak Liner................................................................3-105
Installation.................................................................3-117
Removal....................................................................3-105
Installation.................................................................3-105 3.38 INNER FAIRING: FORK MOUNTED
Tour-Pak Seal.................................................................3-105 FAIRING MODELS
Inspection..................................................................3-105
Rotate Inner Fairing........................................................3-118
Replacement.............................................................3-105
Rotate for Service.....................................................3-118
Tour-Pak Lock.................................................................3-105
Rotate Into Place......................................................3-118
Removal....................................................................3-105
Remove and Install Inner Fairing Assembly...................3-118
Installation.................................................................3-105
Removal....................................................................3-118
Hinges.............................................................................3-105
Installation.................................................................3-119
Removal....................................................................3-105
Replace Inner Fairing Shell............................................3-119
Installation.................................................................3-106
Removal....................................................................3-119
Latch Handle and Catch.................................................3-106
Installation.................................................................3-120
Removal....................................................................3-106
Fairing Vent.....................................................................3-121
Installation.................................................................3-106
Cleaning....................................................................3-121
Tether..............................................................................3-106
Removal....................................................................3-121
Removal....................................................................3-106
Installation.................................................................3-121
Installation.................................................................3-106
Vent Repair...............................................................3-122
Luggage Rack.................................................................3-107
Upper Support Bracket...................................................3-122
Ground Plate...................................................................3-107
Removal....................................................................3-122
Removal....................................................................3-107
Installation.................................................................3-123
Installation.................................................................3-107
Media Compartment.......................................................3-123
3.34 TOUR-PAK BACKREST Removal....................................................................3-123
Installation.................................................................3-123
Passenger Backrest........................................................3-109
Replace Cable..........................................................3-123
Removal....................................................................3-109
Replace Cover..........................................................3-124
Installation.................................................................3-109
Replace Latch...........................................................3-124
Rubber Isolators.............................................................3-109
Removal....................................................................3-109 3.39 INSTRUMENT BEZEL: FRAME
Installation.................................................................3-109 MOUNTED FAIRING MODELS
Passenger Backrest Flap...............................................3-109
Instrument Bezel.............................................................3-125
Removal....................................................................3-109
Removal....................................................................3-125
Installation.................................................................3-109
Installation.................................................................3-125
3.35 FAIRING LOWERS AND ENGINE 3.40 INSTRUMENT NACELLE: FRAME
GUARD MOUNTED FAIRING MODELS
Fairing Lower: Air-Cooled...............................................3-110
Instrument Nacelle..........................................................3-126
Remove.....................................................................3-110
Removal....................................................................3-126
Install.........................................................................3-110
Installation.................................................................3-126
Disassembly..............................................................3-110
Assembly..................................................................3-112 3.41 OUTER FAIRING AND WINDSHIELD:
Fairing Lower: Twin-Cooled............................................3-112 FRAME MOUNTED FAIRING MODELS
Removal....................................................................3-113
WINDSHIELD.................................................................3-127
Installation.................................................................3-113
Removal....................................................................3-127
Repair.......................................................................3-113
Installation.................................................................3-127
Engine Guard..................................................................3-114
Top Air Duct....................................................................3-127
Removal....................................................................3-114
Removal....................................................................3-127
Installation.................................................................3-114
Installation.................................................................3-127
3.36 OUTER FAIRING AND WINDSHIELD: Cleaning Air Duct......................................................3-127
FORK MOUNTED FAIRING MODELS Repair Button Mechanism.........................................3-127
Outer Fairing...................................................................3-128
Outer Fairing and Windshield.........................................3-115
Removal....................................................................3-128
Removal....................................................................3-115
Installation.................................................................3-129
Installation.................................................................3-115
Fairing Perimeter Trim..............................................3-115 3.42 INNER FAIRING: FRAME MOUNTED
Headlamp Mount.......................................................3-115 FAIRING MODELS
Fairing Vent Bezel.....................................................3-116
Removal..........................................................................3-131
Inner Fairing Assembly.............................................3-131
Fairing Mounting Bracket..........................................3-132
Installation.......................................................................3-132

TABLE OF CONTENTS IX
TABLE OF CONTENTS
Fairing Mounting Bracket..........................................3-132
Inner Fairing Assembly.............................................3-133
Fairing Air Duct...............................................................3-133
Removal....................................................................3-133
Installation.................................................................3-133
Repair Air Duct..........................................................3-133
Inner Fairing Shell Replacement....................................3-134
Removal....................................................................3-134
Installation.................................................................3-135
Radio Support Bracket....................................................3-135
Removal....................................................................3-135
Installation.................................................................3-136
3.43 STORAGE COMPARTMENTS: FRAME
MOUNTED FAIRING MODELS
Storage Compartment, Door and Hinge.........................3-138
Replace Storage Compartment Door........................3-138
Remove Media Storage Compartment.....................3-138
Install Media Storage Compartment.........................3-138
Remove Storage Compartment Door/Hinge.............3-138
Install Storage Compartment Door/Hinge.................3-138
Storage Compartment Media Cable.........................3-139
3.44 AIR DEFLECTORS
Fairing Air Deflectors......................................................3-140
Removal: Fork-mounted fairing models....................3-140
Installation: Fork-mounted fairing models.................3-140
Removal: Frame-mounted fairing models.................3-140
Installation: Frame-mounted fairing models..............3-140
Mid-Frame Air Deflectors................................................3-140
Removal....................................................................3-140
Installation.................................................................3-140
3.45 WINDSHIELD: ROAD KING MODELS
WINDSHIELD.................................................................3-142
Remove.....................................................................3-142
Install.........................................................................3-142
Windshield Window........................................................3-142
Removal....................................................................3-142
Installation.................................................................3-143
3.46 HEADLAMP NACELLE: ROAD KING
MODELS
Removal..........................................................................3-144
Installation.......................................................................3-144
3.47 FRONT FENDER
Removal..........................................................................3-146
Repair.......................................................................3-146
Installation.......................................................................3-147
3.48 REAR FENDER
Removal..........................................................................3-149
Fender Repair.................................................................3-150
Mounting Hardware...................................................3-150
Stud Plate.................................................................3-150
Lights and Harnesses...............................................3-150
Installation.......................................................................3-150
3.49 REAR FASCIA
Removal..........................................................................3-152
Installation.......................................................................3-152
Stud Plate.......................................................................3-152
TABLE OF CONTENTS X
Removal....................................................................3-152
Installation.................................................................3-152
Rear Fascia Lamp..........................................................3-152
3.50 REAR FRAME
Rear Frame.....................................................................3-153
Removal....................................................................3-153
Installation.................................................................3-154
Thread Repair...........................................................3-154
3.51 FOOTBOARDS AND FOOTRESTS
Rider Footboards............................................................3-155
Removal....................................................................3-155
Installation.................................................................3-155
Disassembly..............................................................3-155
Assembly..................................................................3-156
Passenger Footboard.....................................................3-156
Removal....................................................................3-156
Disassembly..............................................................3-156
Assembly..................................................................3-156
Installation.................................................................3-156
Passenger Footrest: FLHX, FLHXS, FLTRX, FLTRXS....3-156
Removal....................................................................3-157
Disassembly..............................................................3-157
Assembly..................................................................3-157
Installation.................................................................3-157
Passenger Footrest: Low Models...................................3-157
Removal....................................................................3-157
Disassembly..............................................................3-157
Assembly..................................................................3-157
Installation.................................................................3-158
Replace Pad and Adjust Footrest.............................3-158
3.52 JIFFY STAND
Remove Leg...................................................................3-159
Install Leg.......................................................................3-159
Jiffy Stand Bracket..........................................................3-159
Removal....................................................................3-159
Installation.................................................................3-160
Jiffy Stand Interlock Sensor............................................3-160
Removal....................................................................3-160
Installation.................................................................3-160
3.53 FRONT ENGINE MOUNT
Prepare...........................................................................3-161
Remove..........................................................................3-161
Installation.......................................................................3-161
Complete........................................................................3-161
Stabilizer Link.................................................................3-162
Remove.....................................................................3-162
Install.........................................................................3-162
Stabilizer Link Bracket..............................................3-162
3.54 MEDALLIONS, BADGES AND TANK
EMBLEMS
Removal..........................................................................3-163
Installation.......................................................................3-163
ENGINE
4.1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter..............................4-1
TABLE OF CONTENTS
4.2 SPECIFICATIONS
Specifications......................................................................4-3
4.3 SERVICE WEAR LIMITS
Specifications......................................................................4-5
4.4 ENGINE OIL FLOW
Oil Flow...............................................................................4-7
Internal Oil Distribution: All............................................4-8
External Oil Distribution: Air Cooled Only.....................4-9
4.5 OIL PUMP OPERATION
General.............................................................................4-10
Operation..........................................................................4-10
4.6 BREATHER OPERATION
Crankcase Ventilation.......................................................4-12
4.7 OIL PRESSURE
Oil Pressure Indicator Lamp.............................................4-13
Oil Pressure Check...........................................................4-13
4.8 TROUBLESHOOTING
Compression Test.............................................................4-14
Cylinder Leakdown Test...................................................4-14
Diagnose Valve Train Noise.............................................4-15
Diagnosing Smoking Engine or High Oil Consumption.....4-15
Check Before Cylinder Head Removal:......................4-15
Check After Cylinder Head Removal:.........................4-15
4.9 OIL COOLER AND DOWNTUBE
Prepare.............................................................................4-16
Remove............................................................................4-16
Downtube Assembly with Components......................4-16
Oil Cooler Only............................................................4-16
Remove Downtube Components................................4-16
Install................................................................................4-17
Install Components to Downtube Assembly...............4-17
Install Downtube Assembly with Components............4-17
Oil Cooler Only............................................................4-18
Complete..........................................................................4-18
Disassemble Fan from Oil Cooler.....................................4-18
Assemble Fan to Oil Cooler..............................................4-18
4.10 OIL COOLANT LINES
Prepare.............................................................................4-19
Remove............................................................................4-19
Install................................................................................4-19
Complete..........................................................................4-20
4.11 HOW TO USE THIS SECTION
Top End Repair.................................................................4-21
Bottom End Repair...........................................................4-21
Typical Symptoms.............................................................4-21
4.12 PREPARE MOTORCYCLE FOR
SERVICE
Engine in Chassis.............................................................4-22
4.13 ASSEMBLE MOTORCYCLE AFTER
SERVICE
Engine in Chassis.............................................................4-23
4.14 TOP END SERVICE
Engine in Chassis.............................................................4-24
Engine Removed from Chassis........................................4-24
4.15 CAM COMPARTMENT SERVICE
Replace Camshaft............................................................4-26
4.16 BOTTOM END SERVICE
Engine Removed from Chassis........................................4-27
4.17 REMOVE ENGINE
Remove............................................................................4-28
4.18 INSTALL ENGINE
Install................................................................................4-29
4.19 UPPER ROCKER COVERS
Prepare.............................................................................4-30
Remove............................................................................4-30
Install................................................................................4-30
Complete..........................................................................4-30
4.20 LOWER ROCKER COVERS
Prepare.............................................................................4-32
Remove............................................................................4-32
Install................................................................................4-32
Complete..........................................................................4-32
4.21 BREATHERS
Prepare.............................................................................4-33
Remove............................................................................4-33
Install................................................................................4-33
Complete..........................................................................4-33
4.22 ROCKER ARMS
Prepare.............................................................................4-34
Remove............................................................................4-34
Install................................................................................4-34
Complete..........................................................................4-34
Clean and Inspect.............................................................4-34
4.23 PUSHRODS, LIFTERS AND COVERS
Prepare.............................................................................4-35
Remove............................................................................4-35
Assemble Pushrod Cover.................................................4-35
Install................................................................................4-36
Complete..........................................................................4-37
Clean and Inspect.............................................................4-37
Inspect Lifters...................................................................4-37
4.24 CYLINDER HEAD
Prepare.............................................................................4-38
Remove............................................................................4-38
Cleaning............................................................................4-38
Install................................................................................4-38
Complete..........................................................................4-39
Disassemble.....................................................................4-39
Inspect..............................................................................4-40
Cylinder Head.............................................................4-40
Valve Guides...............................................................4-40
Valves and Valve Seats...............................................4-41
Valve Springs..............................................................4-41
Tapered Keepers.........................................................4-41
Valve Seats.................................................................4-41
TABLE OF CONTENTS XI
TABLE OF CONTENTS
Assemble..........................................................................4-41
Valve and Seat Repair......................................................4-42
4.25 CYLINDERS
Prepare.............................................................................4-43
Remove............................................................................4-43
Clean and Inspect.............................................................4-43
Deglaze Cylinder..............................................................4-43
Install................................................................................4-44
Complete..........................................................................4-45
4.26 PISTONS
Prepare.............................................................................4-46
Remove............................................................................4-46
Install................................................................................4-46
Complete..........................................................................4-47
Disassemble.....................................................................4-48
Cleaning............................................................................4-48
Inspect..............................................................................4-48
Check Piston Ring Gap....................................................4-49
Assemble..........................................................................4-49
4.27 CAM COMPARTMENT AND
COMPONENTS
Prepare.............................................................................4-51
Remove............................................................................4-51
Cam Component Inspection.............................................4-52
Camshaft.....................................................................4-52
Cam Support Plate......................................................4-52
Cam Drive Components..............................................4-52
Install................................................................................4-52
Complete..........................................................................4-54
Camshaft Needle Bearings...............................................4-54
Remove.......................................................................4-54
Install...........................................................................4-54
4.28 OIL PUMP
Prepare.............................................................................4-56
Remove............................................................................4-56
Disassemble and Inspect.................................................4-56
Assemble..........................................................................4-57
Install................................................................................4-57
Complete..........................................................................4-57
4.29 CRANKCASE
Prepare.............................................................................4-58
Disassemble.....................................................................4-58
Cleaning and Inspection...................................................4-58
Assemble..........................................................................4-59
Complete..........................................................................4-60
Repair Right Crankcase Half............................................4-60
Remove Main Bearing................................................4-60
Install Main Bearing....................................................4-61
Remove Piston Jets....................................................4-61
Install Piston Jets........................................................4-62
Repair Left Crankcase Half..............................................4-62
Remove Main Bearing................................................4-62
Install Main Bearing....................................................4-62
Sprocket Shaft Bearing Inner Race..................................4-63
Remove.......................................................................4-63
Install...........................................................................4-64
Cylinder Studs..................................................................4-64
Remove.......................................................................4-64
TABLE OF CONTENTS XII
Install...........................................................................4-64
Plugs and Oil Fittings........................................................4-64
Remove.......................................................................4-64
Install...........................................................................4-64
4.30 FLYWHEEL AND CONNECTING RODS
Symptoms.........................................................................4-66
Overview.....................................................................4-66
No Oil Pressure...........................................................4-66
Vibration......................................................................4-66
Inspection.........................................................................4-66
Measuring Crankshaft Runout..........................................4-66
Crankshaft Installed....................................................4-66
Crankshaft Removed..................................................4-67
4.31 OIL PAN
Prepare.............................................................................4-69
Remove............................................................................4-69
Install................................................................................4-69
Complete..........................................................................4-69
FUEL SYSTEM
5.1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter..............................5-1
5.2 SPECIFICATIONS: FUEL SYSTEM
Specifications......................................................................5-2
5.3 FUEL PRESSURE TEST
Prepare...............................................................................5-3
Test.....................................................................................5-3
Complete............................................................................5-3
5.4 INTAKE LEAK TEST
Leak Tester.........................................................................5-4
Parts List.......................................................................5-4
Tester Assembly............................................................5-4
Tester Adjustment.........................................................5-4
Procedure...........................................................................5-4
5.5 AIR CLEANER ASSEMBLY
Remove..............................................................................5-5
Install..................................................................................5-5
5.6 FUEL TANK
Removal..............................................................................5-6
Purge and Disconnect Fuel Supply Line.......................5-6
Remove Tank................................................................5-6
Installation...........................................................................5-6
Console...............................................................................5-7
Removal........................................................................5-7
Installation.....................................................................5-7
Fuel Door............................................................................5-7
Replace Door................................................................5-7
Replace Lock................................................................5-7
Vent Tube: Models Without EVAP System.........................5-7
Removal........................................................................5-7
Installation.....................................................................5-8
Fuel Supply Check Valve/Tube...........................................5-8
Remove.........................................................................5-8
Install.............................................................................5-8
TABLE OF CONTENTS
5.7 FUEL TANK TOP PLATE
Removal..............................................................................5-9
Installation.........................................................................5-10
5.8 FUEL FILTER
Removal............................................................................5-11
Installation.........................................................................5-11
5.9 FUEL PRESSURE REGULATOR
Removal............................................................................5-12
Installation.........................................................................5-12
5.10 FUEL LEVEL SENDER
Removal............................................................................5-13
Installation.........................................................................5-13
5.11 TWIST GRIP SENSOR (TGS)
Remove............................................................................5-14
Install................................................................................5-14
5.12 INDUCTION MODULE
Prepare.............................................................................5-17
Remove............................................................................5-17
Install................................................................................5-18
Complete..........................................................................5-18
Disassemble.....................................................................5-18
Assemble..........................................................................5-18
5.13 TEMPERATURE MANIFOLD ABSOLUTE
PRESSURE SENSOR (TMAP)
Prepare.............................................................................5-20
Remove............................................................................5-20
Install................................................................................5-20
Complete..........................................................................5-20
5.14 FUEL INJECTORS
Prepare.............................................................................5-21
Remove............................................................................5-21
Install................................................................................5-21
Complete..........................................................................5-21
5.15 HEATED OXYGEN SENSORS (HO2)
Remove............................................................................5-22
Install................................................................................5-22
5.16 FUEL PUMP
General.............................................................................5-24
Removal............................................................................5-24
Installation.........................................................................5-24
Fuel Pump and Fuel Level Sender Wire Harness............5-25
Removal......................................................................5-25
Installation...................................................................5-25
5.17 EXHAUST SYSTEM
Mufflers.............................................................................5-26
Removal......................................................................5-26
Installation...................................................................5-26
Prepare.............................................................................5-26
Remove Exhaust System.................................................5-26
Install Exhaust System.....................................................5-27
Complete..........................................................................5-28
5.18 EVAPORATIVE EMISSIONS CONTROL
SYSTEM
General.............................................................................5-29
Vapor Valve.......................................................................5-29
Fuel Vapor Vent Tube.......................................................5-30
Removal......................................................................5-30
Installation...................................................................5-30
Canister-to-Solenoid Tube................................................5-30
Removal......................................................................5-30
Installation...................................................................5-30
Solenoid-to-Induction Module Tube..................................5-30
Removal......................................................................5-30
Installation...................................................................5-30
Purge Solenoid.................................................................5-30
Removal......................................................................5-30
Installation...................................................................5-31
Charcoal Canister.............................................................5-31
Removal......................................................................5-31
Installation...................................................................5-31
COOLING SYSTEM
6.1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter..............................6-1
6.2 SPECIFICATIONS: COOLING SYSTEM
General...............................................................................6-2
6.3 COOLING SYSTEM OPERATION
Operation............................................................................6-3
6.4 TESTING AND DIAGNOSTICS
Troubleshooting..................................................................6-4
High Engine Temperature.............................................6-4
Coolant Leaks...............................................................6-4
Pressure Cap Test..............................................................6-4
System Pressure Test.........................................................6-4
Leak Detection Dye Test.....................................................6-5
6.5 COOLING SYSTEM REPAIR
Crimp Clamps.....................................................................6-6
Removal........................................................................6-6
Installation.....................................................................6-6
Coolant Bottle.....................................................................6-6
Removal........................................................................6-6
Installation.....................................................................6-6
Remove Upper Coolant Lines............................................6-7
Install Upper Coolant Lines................................................6-7
Hose and Manifold Installation......................................6-7
Coolant Downtubes............................................................6-8
Remove.........................................................................6-8
Install.............................................................................6-8
Horizontal Coolant Tube.....................................................6-9
Removal........................................................................6-9
Installation.....................................................................6-9
Radiator..............................................................................6-9
Removal........................................................................6-9
Installation.....................................................................6-9
Coolant Pump...................................................................6-10
Remove Coolant Pump...............................................6-10
Install Coolant Pump...................................................6-10
COOLING FAN.................................................................6-10
Removal......................................................................6-10
TABLE OF CONTENTS XIII
TABLE OF CONTENTS
Installation...................................................................6-11 7.8 TRANSMISSION SPROCKET
DRIVE Prepare.............................................................................7-18
Remove............................................................................7-18
Clean and Inspect.............................................................7-18
7.1 FASTENER TORQUE VALUES Install................................................................................7-18
Fastener Torque Values in this Chapter..............................7-1 Complete..........................................................................7-19
7.2 SPECIFICATIONS: DRIVE 7.9 DRIVE BELT
Specifications......................................................................7-2 Remove............................................................................7-20
Install................................................................................7-20
7.3 PRIMARY CHAINCASE COVER
Prepare...............................................................................7-3
TRANSMISSION
Remove..............................................................................7-3
Install..................................................................................7-3 8.1 FASTENER TORQUE VALUES
Complete............................................................................7-4
Fastener Torque Values in this Chapter..............................8-1
7.4 DRIVE COMPONENTS 8.2 SPECIFICATIONS: TRANSMISSION
Prepare...............................................................................7-5
Specifications......................................................................8-2
Remove..............................................................................7-5
SERVICE WEAR LIMITS....................................................8-2
Install..................................................................................7-6
Complete............................................................................7-8 8.3 TRANSMISSION OPERATION
7.5 PRIMARY CHAINCASE HOUSING Power Flow.........................................................................8-3
Neutral..........................................................................8-3
Prepare...............................................................................7-9
First Gear......................................................................8-3
Remove..............................................................................7-9
Second Gear.................................................................8-3
Inspect................................................................................7-9
Third Gear.....................................................................8-3
Install..................................................................................7-9
Fourth Gear...................................................................8-3
Complete..........................................................................7-10
Fifth Gear......................................................................8-3
Mainshaft Bearing and Seal.............................................7-10
Sixth Gear.....................................................................8-3
Remove.......................................................................7-10
Install...........................................................................7-10 8.4 SHIFTER LINKAGE
Mainshaft Bearing Inner Race..........................................7-11
Shifter Rod..........................................................................8-5
Remove.......................................................................7-11
Replace.........................................................................8-5
Install...........................................................................7-11
Adjust............................................................................8-5
Shifter Shaft Bushing........................................................7-11
Heel-Toe Shift Levers.........................................................8-5
7.6 CLUTCH: ASSIST AND SLIP Removal........................................................................8-5
Repair...........................................................................8-5
Removal and Installation..................................................7-12
Installation.....................................................................8-5
Clutch Pack Only..............................................................7-12
Shifter Rod Lever, Front......................................................8-6
Prepare.......................................................................7-12
Removal........................................................................8-6
Disassemble...............................................................7-12
Installation.....................................................................8-6
Clean and Inspect.......................................................7-12
Assemble....................................................................7-12 8.5 TRANSMISSION SIDE COVERS
Complete.....................................................................7-13
Prepare...............................................................................8-7
Complete Clutch Disassembly..........................................7-14
Remove..............................................................................8-7
Prepare.......................................................................7-14
Outer Cover..................................................................8-7
Disassemble...............................................................7-14
Inner Cover...................................................................8-7
Assemble....................................................................7-14
Install..................................................................................8-7
Complete.....................................................................7-15
Inner Cover...................................................................8-7
7.7 HYDRAULIC CLUTCH RELEASE Outer Cover..................................................................8-7
BEARING AND PUSHROD Complete............................................................................8-7
Prepare.............................................................................7-16 8.6 SECONDARY CLUTCH ACTUATOR
Remove............................................................................7-16
Prepare...............................................................................8-9
Install................................................................................7-16
Remove..............................................................................8-9
Measure Release Plate Movement.............................7-16
Install..................................................................................8-9
Install Clutch Inspection Cover...................................7-16
Complete............................................................................8-9
Complete..........................................................................7-17
Disassemble.....................................................................7-17 8.7 TRANSMISSION
Assemble..........................................................................7-17
Prepare.............................................................................8-10
Remove............................................................................8-10
Install................................................................................8-10

TABLE OF CONTENTS XIV

TABLE OF CONTENTS
Complete..........................................................................8-11
Disassemble.....................................................................8-11
Remove Shift Cam and Shifter Forks.........................8-11
Remove Mainshaft......................................................8-13
Remove Countershaft.................................................8-13
Remove Bearing Housing Bearings............................8-14
Cleaning and Inspection...................................................8-15
Assemble..........................................................................8-15
Install Bearing Housing Bearings................................8-15
Install Countershaft.....................................................8-16
Install Mainshaft..........................................................8-16
Install Shifter Cam/Shifter Forks.................................8-17
8.8 MAIN DRIVE GEAR AND BEARING
Prepare.............................................................................8-19
Remove............................................................................8-19
Clean and Inspect.............................................................8-20
Install................................................................................8-20
Complete..........................................................................8-21
Replace Needle Bearings.................................................8-21
Replace Mainshaft Seal....................................................8-22
8.9 TRANSMISSION CASE
Prepare.............................................................................8-24
Remove............................................................................8-24
Install................................................................................8-24
Complete..........................................................................8-25
Disassemble.....................................................................8-25
Remove Shifter Pawl Lever........................................8-25
Remove Oil Return Tube/Cover..................................8-25
Clean and Inspect.............................................................8-26
Assemble..........................................................................8-26
Install Oil Return Tube/Cover......................................8-26
Replace Countershaft Needle Bearing.......................8-26
Install Shifter Pawl Lever............................................8-27
ELECTRICAL
9.1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter..............................9-1
9.2 SPECIFICATIONS: ELECTRICAL
Specifications......................................................................9-5
9.3 SYSTEM FUSES AND RELAYS
Main Fuse...........................................................................9-6
Removal........................................................................9-6
Installation.....................................................................9-6
System Fuses and Relays..................................................9-6
Removal........................................................................9-6
Installation.....................................................................9-6
Fuse Blocks........................................................................9-6
Main Fuse Holder..........................................................9-6
System Fuse Block.......................................................9-6
9.4 ELECTRONIC CONTROL MODULE (ECM)
ECM....................................................................................9-7
Removal........................................................................9-7
Installation.....................................................................9-7
9.5 BODY CONTROL MODULE (BCM)
Removal..............................................................................9-8
Installation...........................................................................9-8
9.6 ELECTRICAL CADDIES
Fairing and Steering Head Caddies...................................9-9
Top Caddy...........................................................................9-9
Removal........................................................................9-9
Installation.....................................................................9-9
Left Side Caddy..................................................................9-9
Removal........................................................................9-9
Installation...................................................................9-10
Right Side Caddy..............................................................9-10
Removal......................................................................9-10
Installation...................................................................9-11
Battery Tray......................................................................9-11
Removal......................................................................9-11
Installation...................................................................9-11
Lower Backbone Caddy...................................................9-12
Remove.......................................................................9-12
Install...........................................................................9-12
9.7 IGNITION COIL AND SPARK PLUG
CABLES
Removal............................................................................9-13
Install................................................................................9-13
SPARK PLUG CABLES....................................................9-13
Prepare.......................................................................9-13
Remove.......................................................................9-13
Install...........................................................................9-13
Complete.....................................................................9-13
Inspect Spark Plug Cables...............................................9-14
9.8 STARTER
Removal............................................................................9-15
Install................................................................................9-15
9.9 HEADLAMP
Headlamp: All But FLTR Models.......................................9-16
Removal......................................................................9-16
Installation...................................................................9-16
Bulb Replacement: Halogen Type..............................9-16
Bulb Replacement: LED Type.....................................9-16
Headlamp: FLTR Models..................................................9-16
Removal......................................................................9-16
Installation...................................................................9-17
9.10 AUXILIARY/FOG LAMPS AND
BRACKETS
Replace Auxiliary/Fog Lamp Bulb....................................9-18
Removal......................................................................9-18
Installation...................................................................9-18
Auxiliary/Fog Lamp Housing.............................................9-18
Removal......................................................................9-18
Installation...................................................................9-19
Turn Signal/Auxiliary/Fog Lamp Bracket..........................9-19
Removal......................................................................9-19
Installation...................................................................9-20
Adjustment........................................................................9-20
9.11 REAR LIGHTING
Replace Tail Lamp Bulb....................................................9-21
Removal......................................................................9-21
Installation...................................................................9-21
Tail Lamp Base.................................................................9-21
Removal......................................................................9-21
Installation...................................................................9-22
TABLE OF CONTENTS XV
TABLE OF CONTENTS
Rear Fender Lights Harness: all except FLHX, FLHXS, FLTRX,
FLTRXS............................................................................9-22
Removal......................................................................9-22
Installation...................................................................9-23
Rear Fascia Lamp............................................................9-24
Removal......................................................................9-24
Installation...................................................................9-24
Rear Fender Lights Harness: FLHX, FLHXS, FLTRX,
FLTRXS............................................................................9-24
Removal......................................................................9-24
Installation...................................................................9-24
9.12 FENDER TIP LAMPS
Front Fender Tip Lamp.....................................................9-26
Removal......................................................................9-26
Installation...................................................................9-26
Rear Fender Tip Lamp......................................................9-26
Removal......................................................................9-26
Installation...................................................................9-27
9.13 TOUR-PAK LIGHTS
Tour-Pak Side Lamps/Trim Strips.....................................9-28
Removal......................................................................9-28
Installation...................................................................9-28
Tour-Pak Lights Harness..................................................9-28
Removal......................................................................9-28
Installation...................................................................9-28
Wrap-Around Lamp (if equipped).....................................9-29
Removal......................................................................9-29
Repair.........................................................................9-30
Installation...................................................................9-30
9.14 TURN SIGNAL LAMPS
Turn Signal Bulb Replacement: Bullet Style.....................9-31
Turn Signal Bulb Replacement: Flat Lens Style...............9-31
Front Turn Signal Lamp....................................................9-31
Removal: Flat Lens Style............................................9-32
Installation: Flat Lens Style.........................................9-32
Removal: Bullet Style, Fork-Mounted.........................9-32
Installation: Bullet Style, Fork-Mounted......................9-33
Removal: Bullet Style, Fairing Mounted......................9-33
Installation: Bullet Style, Fairing Mounted...................9-33
Lamp Repair: Bullet Style...........................................9-34
Rear Turn Signal Lamp.....................................................9-34
Removal: All but FLHX, FLHXS, FLTRX, FLTRXS.....9-34
Installation: All but FLHX, FLHXS, FLTRX, FLTRXS...9-35
Removal: FLHX, FLHXS, FLTRX, FLTRXS................9-35
Installation: FLHX, FLHXS, FLTRX, FLTRXS.............9-36
Lamp Repair...............................................................9-36
Rear Turn Signal Lamps Bracket......................................9-36
Removal: All but FLHX, FLHXS, FLTRX, FLTRXS.....9-36
Installation: All but FLHX, FLHXS, FLTRX, FLTRXS...9-37
Removal: FLHX, FLHXS, FLTRX, FLTRXS................9-37
Installation: FLHX, FLHXS, FLTRX, FLTRXS.............9-38
9.15 IGNITION SWITCH AND FORK LOCK
Fairing Models..................................................................9-39
Removal......................................................................9-39
Installation...................................................................9-39
Road King Models............................................................9-40
Remove Ignition/Light Key Switch..............................9-40
Install Ignition/Light Key Switch..................................9-40
Remove Fork Lock......................................................9-41
TABLE OF CONTENTS XVI
Install Fork Lock..........................................................9-41
9.16 ACCESSORY SWITCHES
Fork-Mounted Fairing Models...........................................9-42
Removal......................................................................9-42
Installation...................................................................9-42
Frame-Mounted Fairing Models.......................................9-42
Removal......................................................................9-42
Installation...................................................................9-43
Nacelle Switches..............................................................9-43
Removal......................................................................9-43
Installation...................................................................9-43
9.17 CRANKSHAFT POSITION SENSOR
(CKP)
Remove............................................................................9-44
Installation.........................................................................9-44
9.18 KNOCK SENSOR (KS)
Prepare.............................................................................9-45
Remove............................................................................9-45
Install................................................................................9-45
Complete..........................................................................9-45
9.19 ENGINE TEMPERATURE SENSOR (ET)
Prepare.............................................................................9-46
Remove............................................................................9-46
Install................................................................................9-46
Complete..........................................................................9-46
9.20 ENGINE COOLANT TEMPERATURE
SENSOR (ECT)
Coolant Temperature Sensor............................................9-47
Remove.......................................................................9-47
Install...........................................................................9-47
9.21 AUTOMATIC COMPRESSION RELEASE
(ACR)
Prepare.............................................................................9-48
Remove............................................................................9-48
Install................................................................................9-48
Complete..........................................................................9-48
9.22 VOLTAGE REGULATOR
Prepare.............................................................................9-50
Remove............................................................................9-50
Install................................................................................9-50
Complete..........................................................................9-51
9.23 ALTERNATOR
Prepare.............................................................................9-52
Remove............................................................................9-52
Cleaning and Inspection...................................................9-52
Install................................................................................9-52
Complete..........................................................................9-53
9.24 VEHICLE SPEED SENSOR (VSS)
VSS...................................................................................9-54
Removal......................................................................9-54
Installation...................................................................9-54
9.25 WHEEL SPEED SENSORS
Front Wheel Speed Sensor (WSS)...................................9-55
TABLE OF CONTENTS
Removal......................................................................9-55
Installation...................................................................9-55
Rear Wheel Speed Sensor...............................................9-56
Removal......................................................................9-56
Installation...................................................................9-56
9.26 NEUTRAL SWITCH
Removal............................................................................9-57
Installation.........................................................................9-57
9.27 OIL PRESSURE SWITCH
Removal............................................................................9-58
Install................................................................................9-58
9.28 STOP LAMP SWITCHES
Front Stop Lamp Switch...................................................9-59
Removal/Installation....................................................9-59
Rear Stop Lamp Switch....................................................9-59
Remove.......................................................................9-59
Install...........................................................................9-59
9.29 HORN
Removal............................................................................9-60
Installation.........................................................................9-60
9.30 FAIRING POWER OUTLET
Removal............................................................................9-62
Installation.........................................................................9-62
9.31 GAUGES AND INSTRUMENTS: FAIRING
MODELS
Ambient Air Temperature Sensor.....................................9-63
2-Inch Diameter Gauges...................................................9-63
Removal......................................................................9-63
Installation...................................................................9-63
Speedometer/Tachometer Instrument Cluster: Fork-Mounted
Fairing...............................................................................9-63
Removal......................................................................9-63
Installation...................................................................9-64
Speedometer/Tachometer Instrument Cluster: Frame Mounted
Fairing...............................................................................9-64
Removal......................................................................9-64
Installation...................................................................9-64
9.32 GAUGES AND INSTRUMENTS: ROAD
KING MODELS
Fuel Gauge.......................................................................9-65
Removal......................................................................9-65
Installation...................................................................9-65
SPEEDOMETER..............................................................9-65
Removal......................................................................9-65
Installation...................................................................9-66
9.33 INDICATOR LAMPS: ROAD KING
MODELS
INDICATOR LAMPS.........................................................9-67
Removal......................................................................9-67
Installation...................................................................9-67
9.34 BOOM! BOX INFOTAINMENT SYSTEM
Radio Face Protective Film...............................................9-68
Replacement...............................................................9-68
Radio: Fork-Mounted Fairing............................................9-68
Removal......................................................................9-68
Installation...................................................................9-68
CB Module: Fork Mounted Fairing....................................9-69
Removal......................................................................9-69
Installation...................................................................9-70
CB Module Bracket.....................................................9-70
GPS Antenna....................................................................9-70
Prepare.......................................................................9-70
Remove.......................................................................9-70
Install...........................................................................9-70
Complete.....................................................................9-70
Front Fairing Speakers: Fork Mounted Fairing.................9-70
Removal......................................................................9-71
Installation...................................................................9-71
Speaker Grille.............................................................9-71
Radio: Frame Mounted Fairing.........................................9-71
Removal......................................................................9-72
Installation...................................................................9-72
Front Fairing Speaker and Enclosure: Frame-Mounted
Fairing...............................................................................9-72
Speaker Grille.............................................................9-73
Speaker Only..............................................................9-73
Remove Speaker Enclosure.......................................9-73
Install Speaker Enclosure...........................................9-74
Rear Speaker Enclosures.................................................9-74
Removal......................................................................9-74
Installation...................................................................9-74
Disassembly................................................................9-75
Assembly....................................................................9-75
Passenger Audio Controls................................................9-76
Rider Headset Connector.................................................9-76
Removal......................................................................9-76
Installation...................................................................9-76
9.35 ANTENNA CABLES
Removal............................................................................9-77
Main Cable..................................................................9-77
Cable Extension: Models with Tour-Pak.....................9-77
Cable Extension: FLHX, FLHXS, FLTRX, FLTRXS.....9-77
Installation.........................................................................9-77
Main Cable..................................................................9-77
Cable Extension: Models with Tour-Pak.....................9-78
Cable Extension: FLHX, FLHXS, FLTRX, FLTRXS.....9-78
9.36 WIRE TROUGH
Remove............................................................................9-80
Install................................................................................9-81
9.37 MAIN WIRING HARNESS
Removal: All Models (Part 1)............................................9-82
Removal: Road King Models (Part 2)...............................9-82
Removal: Fork Mounted Fairing Models (Part 2)..............9-82
Removal: Frame Mounted Fairing Models (Part 2)..........9-83
Removal: All Models (Part 3)............................................9-84
Installation: All Models (Part 1).........................................9-85
Installation: Road King Models (Part 2)............................9-89
Installation: Fork-Mounted Fairing Models (Part 2)..........9-89
Installation: Frame-Mounted Fairing Models (Part 2).......9-90
Installation: All Models (Part 3).........................................9-90
9.38 FAIRING HARNESS
Harness Service: Fork-Mounted Fairing...........................9-91
Removal......................................................................9-91
Repair.........................................................................9-91
Installation...................................................................9-91
TABLE OF CONTENTS XVII
TABLE OF CONTENTS
Harness Service: Frame Mounted Fairing........................9-92 B.2 FLUID CONVERSION
Removal......................................................................9-92
United States System.........................................................B-2
Installation...................................................................9-93
Metric System.....................................................................B-2
9.39 HANDLEBAR SWITCH PACKS British Imperial System.......................................................B-2
Removal............................................................................9-94 B.3 TORQUE CONVERSION
Handlebar Controls.....................................................9-94
United States System.........................................................B-3
Install................................................................................9-95
Metric System.....................................................................B-3
Right Handlebar Controls............................................9-95
Left Handlebar Controls..............................................9-96 B.4 GLOSSARY
Switch Pack Harness........................................................9-96
Acronyms and Abbreviations.............................................B-4
Remove.......................................................................9-96
Install...........................................................................9-97 REFERENCE MATERIAL
Handlebar Switch Caps....................................................9-98
9.40 SECURITY SYSTEM MAINTENANCE TOOLS...........................................................I
Fob Battery.......................................................................9-99 Torque Values..............................................V
Battery Replacement Schedule..................................9-99
Battery Replacement..................................................9-99 Index.........................................................XIX
Smart Siren (If Equipped).................................................9-99
Battery Replacement Schedule..................................9-99
Battery Replacement..................................................9-99
Security System Antenna.................................................9-99
Removal......................................................................9-99
Installation.................................................................9-100
9.41 PERSONAL IDENTIFICATION NUMBER
(PIN)
General...........................................................................9-101
Changing the PIN...........................................................9-101
Modifying an Existing PIN.........................................9-101
9.42 SECURITY SYSTEM ACTUATION
Sidecar Configuration.....................................................9-102
Activation........................................................................9-102
Fob Assignment..............................................................9-102
9.43 SECURITY SIREN
Removal..........................................................................9-103
Installation.......................................................................9-103
APPENDIX A WIRING
A.1 CONNECTORS
Connector Locations..........................................................A-1
Function/Location.........................................................A-1
Place and Color............................................................A-1
Connector Number.......................................................A-1
Repair Instructions........................................................A-1
A.2 WIRING DIAGRAMS
Wiring Diagram Information................................................A-7
Wire Color Codes.........................................................A-7
Wiring Diagram Symbols..............................................A-7
2017 Touring Wiring Diagrams...........................................A-8
APPENDIX B REFERENCE
B.1 METRIC CONVERSION
Conversion Table................................................................B-1

TABLE OF CONTENTS XVIII

SUBJECT PAGE NO.
1.1 SAFETY ................................................................................................................................ 1-1

SAFETY
NOTES
SAFETY
SAFETY
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)
94000383
1.1
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 Harley-Davidson, 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.
1-1
• 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.
1-2
• 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.
94000383
SUBJECT PAGE NO.
2.1 FASTENER TORQUE VALUES ............................................................................................ 2-1
2.2 GENERAL ............................................................................................................................. 2-3
2.3 FUEL AND OIL ...................................................................................................................... 2-8
2.4 MAINTENANCE SCHEDULE ............................................................................................. 2-10
2.5 ENGINE OIL AND FILTER .................................................................................................. 2-15
2.6 AIR CLEANER ELEMENT .................................................................................................. 2-17
2.7 EXHAUST SYSTEM ........................................................................................................... 2-18
2.8 COOLANT ........................................................................................................................... 2-19
2.9 TIRES AND WHEELS ......................................................................................................... 2-23
2.10 PRIMARY CHAINCASE LUBRICANT .............................................................................. 2-26
2.11 TRANSMISSION LUBRICANT .......................................................................................... 2-28
2.12 HYDRAULIC CLUTCH FLUID .......................................................................................... 2-30
2.13 BRAKES ............................................................................................................................ 2-32
2.14 BRAKE PADS AND DISCS ............................................................................................... 2-34
2.15 DRIVE BELT AND SPROCKETS ...................................................................................... 2-37
2.16 REAR SPROCKET ISOLATOR ........................................................................................ 2-42
2.17 CABLE AND CHASSIS LUBRICATION ............................................................................ 2-43
2.18 SPARK PLUGS ................................................................................................................. 2-44
2.19 STEERING HEAD BEARINGS ......................................................................................... 2-46
2.20 REAR SUSPENSION ADJUSTMENTS ............................................................................ 2-49
2.21 BATTERY MAINTENANCE ............................................................................................... 2-51
2.22 HEADLAMP ALIGNMENT ................................................................................................ 2-56

MAINTENANCE
2.23 STORAGE ......................................................................................................................... 2-59
2.24 TROUBLESHOOTING ...................................................................................................... 2-60
NOTES
FASTENER TORQUE VALUES 2.1
FASTENER TORQUE VALUES IN THIS
CHAPTER

The table below lists torque values for all fasteners presented
in this chapter.

FASTENER TORQUE VALUE NOTES

Air cleaner cover screw 36–60 in-lbs 4.1–6.8 N·m 2.6 AIR CLEANER ELEMENT, Install
Apply LOCTITE 243 (blue) to the threads of screw.
Air filter element screws 40–60 in-lbs 4.5–6.8 N·m 2.6 AIR CLEANER ELEMENT, Install
Auxiliary/fog lamp flange nut: Models 20–24 ft-lbs 27.1–32.5 N·m 2.22 Headlamp Alignment, Adjust Auxiliary/Fog
with bullet style turn signal lamps Lamps
Auxiliary/fog lamp flange nut: Models 15–18 ft-lbs 20.3–24.4 N·m 2.22 Headlamp Alignment, Adjust Auxiliary/Fog
with flat lens turn signal lamps Lamps
Battery terminal bolt 60–70 in-lbs 6.8–7.9 N·m 2.21 Battery Maintenance, Battery
Brake bleeder screw, front 72–108 in-lbs 8.1–12.2 N·m 2.13 BRAKES, Replace Brake Fluid
Brake bleeder screw, rear 75–102 in-lbs 8.5–11.5 N·m 2.13 BRAKES, Replace Brake Fluid
Brake caliper, front, mounting screws 28–38 ft-lbs 37.9–51.5 N·m 2.14 BRAKE PADS AND DISCS, Replace Brake
Pads
metric
Brake caliper, rear, mounting screws 43–48 ft-lbs 58.3–65.1 N·m 2.14 BRAKE PADS AND DISCS, Replace Brake
Pads
metric
Brake caliper pad pin 75–102 in-lbs 8.5–11.5 N·m 2.14 BRAKE PADS AND DISCS, Replace Brake
Pads
Always use new part
Brake master cylinder, front, reservoir 12–15 in-lbs 1.4–1.7 N·m 2.13 BRAKES, Replace Brake Fluid
cover screws
Brake master cylinder, rear, reservoir 12–15 in-lbs 1.4–1.7 N·m 2.13 BRAKES, Replace Brake Fluid
cover screws
Brake master cylinder reservoir cover 12–15 in-lbs 1.4–1.7 N·m 2.14 BRAKE PADS AND DISCS, Replace Brake
screws Pads
Clutch actuator bleeder screw 56–75 in-lbs 6.3–8.5 N·m 2.12 HYDRAULIC CLUTCH FLUID, Replace Clutch
Fluid
Clutch inspection cover screws 84–108 in-lbs 9.5–12.2 N·m 2.10 Primary Chaincase Lubricant, Change Primary
Chaincase Lubricant
Torque sequence
Clutch reservoir cover screws 12–15 in-lbs 1.4–1.7 N·m 2.12 HYDRAULIC CLUTCH FLUID, Replace Clutch
Fluid
Engine oil drain plug 14–21 ft-lbs 19–28.5 N·m 2.5 ENGINE OIL AND FILTER, Change Oil and Oil
Filter
Muffler to saddlebag support screws 14–18 ft-lbs 19–24.4 N·m 2.15 DRIVE BELT AND SPROCKETS, Adjust Belt
Deflection
Primary chaincase drain plug 14–21 ft-lbs 19–28.5 N·m 2.10 Primary Chaincase Lubricant, Change Primary
Chaincase Lubricant
Rear axle cone nut, final torque 95–105 ft-lbs 128.8–142.4 N·m 2.15 DRIVE BELT AND SPROCKETS, Adjust Belt
Deflection
Rear axle cone nut, first torque 15–20 ft-lbs 20–27 N·m 2.15 DRIVE BELT AND SPROCKETS, Adjust Belt
Deflection
For belt adjustment only
Spark plug 89–133 in-lbs 10–15 N·m 2.18 Spark Plugs, Install
Spoke nipple 55 in-lbs 6.2 N·m 2.9 TIRES AND WHEELS, Wheel Spokes
Top caddy screws 72–96 in-lbs 8.1–10.9 N·m 2.21 Battery Maintenance, Battery

94000383 2-1
FASTENER TORQUE VALUE NOTES
Transmission drain plug 14–21 ft-lbs 19–28.5 N·m 2.11 Transmission Lubricant, Change Transmission
Lubricant
Transmission filler plug/dipstick 25–75 in-lbs 2.8–8.5 N·m 2.11 Transmission Lubricant, Check Transmission
Lubricant
Transmission filler plug/dipstick 25–75 in-lbs 2.8–8.5 N·m 2.11 Transmission Lubricant, Change Transmission
Lubricant
Turn signal lamp to auxiliary/fog lamp 96–120 in-lbs 10.9–13.5 N·m 2.22 Headlamp Alignment, Adjust Auxiliary/Fog
bracket screw: Bullet style turn signal Lamps
lamps
Turn signal lamp to auxiliary/fog lamp 36–60 in-lbs 4.1–6.8 N·m 2.22 Headlamp Alignment, Adjust Auxiliary/Fog
bracket screws: Flat lens turn signal Lamps
lamps
Upper steering stem, final torque: Fork 63 in-lbs 7.1 N·m 2.19 STEERING HEAD BEARINGS, Inspect and
mounted fairing models Lubricate
Upper steering stem, final torque: Frame 192 in-lbs 21.7 N·m 2.19 STEERING HEAD BEARINGS, Inspect and
mounted fairing models Lubricate
Upper steering stem, final torque: Road 108 in-lbs 12.2 N·m 2.19 STEERING HEAD BEARINGS, Inspect and
King models Lubricate
Upper steering stem, final torque: Trike 108 in-lbs 12.2 N·m 2.19 STEERING HEAD BEARINGS, Inspect and
models Lubricate
Upper steering stem, first torque 35 ft-lbs 47.5 N·m 2.19 STEERING HEAD BEARINGS, Inspect and
Lubricate
Upper steering stem pinch screw 22–26 ft-lbs 29.8–35.2 N·m 2.19 STEERING HEAD BEARINGS, Check and
Adjust Swing-Back

2-2 94000383
GENERAL
SERVICING A NEW MOTORCYCLE
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)
2.2
• 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:
Perform necessary set-up tasks before customer delivery. See
applicable model year predelivery and set-up instructions. 1. Tires for correct pressure, excessive wear or any signs of
tire damage.
The performance of new motorcycle initial service is required
to keep warranty in force and to verify proper emissions 2. Drive belt tension and condition.
systems operation. See MAINTENANCE SCHEDULE
3. Brakes, steering and throttle for responsiveness.
(Page 2-10).
4. Brake fluid level and condition. Hydraulic lines and fittings
SECURE THE MOTORCYCLE FOR SERVICE for leaks.
5. Check brake pads and discs for wear.
PART NUMBER TOOL NAME
HD-45968 FAT JACK 6. Cables for fraying, crimping and free operation.
7. Engine oil and transmission fluid levels.
WARNING
8. Headlamp, auxiliary/fog lamp, tail lamp, stop lamp, horn
Be sure to check capacity rating and condition of hoists, and turn signal operation.
slings, chains and cables before use. Exceeding capacity
ratings or using lifting devices that are in poor condition SHOP PRACTICES
can lead to an accident, which could result in death or
serious injury. (00466c) Repair Notes
Always use blocking or proper stands to support motorcycle. General maintenance practices are given in this section.

NOTE
Set Motorcycle Upright
• Repair = Disassembly/Assembly.
1. Place motorcycle upright on a level surface or suitable lift
if available.
• Replacement = Substitute a new part for existing
component.
2. Verify that motorcycle is level.
3. Secure with tie-downs. All special tools and torque values are noted at the point of
use.
Raise Front or Rear Wheel for Service All required parts or materials can be found in the parts catalog.
1. Verify that motorcycle is level.
Safety
NOTICE Safety is always the most important consideration when
performing any job.
When lifting a motorcycle using a jack, be sure jack
contacts both lower frame tubes where down tubes and • Always have a complete understanding of the task.
lower frame tubes converge. Never lift by jacking on
• Use common sense.
cross-members, oil pan, mounting brackets, components
or housings. Failure to comply can cause serious damage • Use the proper tools.
resulting in the need to perform major repair work. (00586d) • Protect yourself and bystanders with approved eye
protection.
2. Use a FAT JACK (PART NUMBER: HD-45968) or similar
to raise the motorcycle to service a front or rear wheel. Do not just do the job, do the job safely.

3. Secure with tie-downs. Removing Parts

Always consider the weight of a part when lifting. Use a hoist
SAFE OPERATING MAINTENANCE whenever necessary. Do not lift heavy parts by hand. If a hoist
and adjustable lifting beam or sling are needed to remove some
NOTE parts, verify that:
• Do not attempt to tighten engine head bolts or engine • The lengths of multiple chains or cables from the hoist to
damage may result. the part are equal and parallel.

94000383 2-3
• 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.
2-4
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.
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 reusing 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.
94000383
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.
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.
94000383
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.
DISPOSAL AND RECYCLING
Help protect our environment! 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. Many
Harley-Davidson parts and accessories are made of plastics
and metals which can also be recycled.
CLEANING
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.
2-5
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.
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.
• Placed bits 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 yourself and 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.
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.
2-6
• 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 yourself and 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 yourself and 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. 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.
94000383
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.

94000383 2-7
FUEL AND OIL
FUEL
Always use a good quality unleaded gasoline. Octane ratings
are usually found on the pump. Refer to Table 2-1.
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 2-1. Octane Rating
SPECIFICATION RATING
Pump Octane (R+M)/2 91 (95 RON)
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.
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.
2-8
2.3
• 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.
ENGINE LUBRICATION
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 2-2.
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 2-2 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.
94000383
 Table 2-2. Recommended Engine Oils
TYPE VISCOSITY RATING LOWEST AMBIENT COLD-WEATHER
TEMPERATURE STARTS BELOW
50 °F (10 °C)
Screamin' Eagle SYN3 Full Synthetic SAE 20W50 HD 360 Above 30 °F (-1 °C) Excellent
Motorcycle Lubricant
Genuine Harley-Davidson H-D 360 Mo- SAE 20W50 HD 360 Above 40 °F (4 °C) Good
torcycle Oil
Genuine Harley-Davidson H-D 360 Mo- SAE 50 HD 360 Above 60 °F (16 °C) Poor
torcycle Oil
Genuine Harley-Davidson H-D 360 Mo- SAE 60 HD 360 Above 80 °F (27 °C) Poor
torcycle Oil

LOW TEMPERATURE LUBRICATION

Change engine oil often in colder climates. If motorcycle is

frequently ridden less than 15 mi (24 km), in ambient
temperatures below 60 °F (16 °C), reduce oil change intervals
to 1500 mi (2,400 km).

NOTE
Lower ambient temperatures require more frequent oil changes.

Water vapor is a normal by-product of combustion . During

cold-weather operation, some water vapor condenses to liquid
form on the cool surfaces inside the engine. In freezing
weather, this water becomes slush or ice. If the engine is not
warmed to operating temperature, accumulated slush or ice
blocks the oil lines and causes engine damage. Over time,
water will accumulate, mix with the engine oil and form a sludge
that is harmful to the engine.

If the engine is allowed to warm to normal operating

temperature, most of the water evaporates and exits through
the crankcase breather.

94000383 2-9
MAINTENANCE SCHEDULE 2.4
GENERAL Use the quick reference maintenance chart for torque values,
lubricants or cross references to maintenance procedures.
At each regular service interval, perform the required Refer to Table 2-4.
maintenance. Refer to Table 2-3. Use the lubricants, greases and sealants table to identify
maintenance supplies. Refer to Table 2-5.
Table 2-3. Regular Service Intervals: 2017 Harley-Davidson Touring Models
ITEM SERVICED 1000 mi 5000 mi 10000 mi 15000 mi 20000 mi 25000 mi 30000 mi 35000 mi 40000 mi 45000 mi 50000 mi NOTES
1600 km 8000 km 16000 km 24000 km 32000 km 40000 km 48000 km 56000 km 64000 km 72000 km 80000 km
Check operation of electrical X X X X X X X X X X X
equipment and switches
Check front tire pressure, in- X X X X X X X X X X X 1
spect tread
Check front wheel spoke X X X X X 2, 3, 4
tightness (if equipped)
Inspect front brake fluid at X X X X X X X X X X X 5
level at sight glass
Inspect clutch fluid system X X X X X X X X X X X 6
for leaks, contact or abrasion
Check front brake and hy- X X X X X X 1, 2, 7
draulic clutch reservoir cover
screw torque
Check hand control fastener X X X X X X 1, 2, 7
switch housing screw torque
Check clutch lever handlebar X X X X X X 1, 2, 7
clamp screw torque
Check master cylinder X X X X X X 1, 2, 7
handlebar clamp screw
torque
Inspect, lubricate and adjust X X 2, 8
steering head bearings
Inspect windshield bushings X X X X X 2
(if equipped)
Inspect air cleaner, service X X X X X X X X X X 4
as required
Replace engine oil and filter X X X X X X X X X X X 1, 4
Check engine coolant freeze X X X X X X X X X X X
point, inspect for leaks
Coolant Replace coolant every 30000 mi (48,000 km) 2
Clean radiators or oil cooler X X X X X X X X X X X
Replace primary chaincase X X X X X X 4
lubricant
Replace transmission lubric- X X X 4
ant
Inspect oil lines and brake X X X X X X X X X X X 1, 2
system for leaks, contact or
abrasion
Inspect fuel lines and fittings X X X X X X X X X X X 1, 2
for leaks, contact or abrasion
Inspect rear brake fluid at X X X X X X X X X X X 5
level at sight glass
Check rear brake reservoir X X X X X X 1, 2, 7
cover screw torque
Inspect brake pads and X X X X X X X X X X X
discs for wear
Check front axle nut torque X X X X X X 1, 2, 7
Inspect and lubricate jiffy X X X X X X X X X X X 2, 4
stand
Check, adjust and lubricate X X X X X X X X X X X
(with HARLEY LUBE) brake
and clutch controls
Check tightness of rear X X X X X 2, 3, 4
wheel spokes (if equipped)

2-10 94000383
 Table 2-3. Regular Service Intervals: 2017 Harley-Davidson Touring Models
ITEM SERVICED 1000 mi 5000 mi 10000 mi 15000 mi 20000 mi 25000 mi 30000 mi 35000 mi 40000 mi 45000 mi 50000 mi NOTES
1600 km 8000 km 16000 km 24000 km 32000 km 40000 km 48000 km 56000 km 64000 km 72000 km 80000 km
Check rear tire pressure, in- X X X X X X X X X X X 1
spect tread
Inspect and adjust drive belt X X X X X X X X X X X 2
and sprockets
Check rear axle nut torque X X X X X X 1, 2, 7
Inspect exhaust system for X X X X X X X X X X X 4
leaks, cracks and loose, or
missing fasteners or exhaust
shields
Battery Check battery, terminal torque and clean connections annually. Lubricate terminals with ELECTRICAL CONTACT LUBRICANT. 1
Spark plugs Replace spark plugs every two years or every 30000 mi (48,000 km), whichever comes first.
Lubricate fuel door hinge X X X X X X X X X X X
and latch with HARLEY
LUBE
Rebuild front forks X 2, 9
Fuel filter Replace fuel filter every 100000 mi (160,000 km). 2, 4
Rear sprocket isolators Inspect rear sprocket isolators for wear at each rear tire change.
Brake and clutch systems Flush brake and clutch systems and replace DOT 4 hydraulic brake and clutch fluids every two years 2
Road test to verify compon- X X X X X X X X X X X
ent and system functions
NOTES: 1. Perform annually or at specified intervals, whichever comes first.
2. Should be performed by an authorized Harley-Davidson dealer, unless you have the proper tools, service data and are mechanically
qualified.
3. Perform spoke tension check at 1000 mi (1,600 km), 5000 mi (8,000 km), 20000 mi (32,000 km) services and every 15000 mi
(24,000 km) interval thereafter. Not all vehicles are equipped with spoke wheels. Consult appropriate topic in service manual.
4. 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.
5. Brake fluid level will drop as brake pads wear.
6. Clutch fluid level will rise as clutch wears.
7. For torque instructions, see Shop Practices in the service manual.
8. Disassemble, lubricate, inspect and adjust every 25000 mi (40,000 km).
9. Disassemble, inspect, rebuild forks and replace fork oil every 50000 mi (80,000 km).

NOTE • Always check for and complete open recalls and product
Whenever a vehicle is in for maintenance: programs.
• Always verify that the latest calibration is installed.
Table 2-4. Quick Reference Maintenance and Torque Chart: Touring
ITEM SERVICED SPECIFICATION DATA
Air cleaner Air filter element screw torque 40-60 in-lbs (4.5-6.8 Nm)
Air cleaner cover screw torque 36-60 in-lbs (4.1-6.8 Nm)
Air cleaner cover screw threadlocker Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue).
Axle nuts Front 70-75 ft-lbs (94.9-101.7 Nm)
Rear 95-105 ft-lbs (129.0-142.0 Nm)
Battery Terminal bolt torque 60-70 in-lbs (6.8-7.9 Nm)
Top caddy screw torque 72-96 in-lbs (8.1-10.9 Nm)
Brake fluid level (Fluid Type DOT 4 BRAKE FLUID
level must be at or above Fluid level Front: FILL level boss
the minimum mark on Rear: Ledge at front of reservoir
glass. If fluid level is be-
low minimum mark, re- Master cylinder reservoir cover screw torque Front: 12-15 in-lbs (1.4-1.7 Nm)
move reservoir cover Rear: 12-15 in-lbs (1.4-1.7 Nm)
and recheck.)
Brake pads and discs Minimum brake pad thickness 0.016 in (0.4 mm)
Minimum brake disc thickness Front: 0.18 in (4.5 mm)
Rear: 0.25 in (6.3 mm)
Maximum brake disc lateral runout (warpage) 0.008 in (0.2 mm)

94000383 2-11
 Table 2-4. Quick Reference Maintenance and Torque Chart: Touring
ITEM SERVICED SPECIFICATION DATA
Clutch fluid level. Re- Type DOT 4 BRAKE FLUID
move reservoir cover to Fluid level (with new clutch) *** FILL level boss
check. Level must be at
or above boss. Clutch reservoir cover screw torque 12-15 in-lbs (1.4-1.7 Nm)
Drive belt deflection Upward force applied at midpoint of bottom belt 10 lb (4.5 kg)
strand
FLHR, FLHRC, FLHTCU, FLHTCU TC, FLHTK **** ⅜–9/16 in (9.5–14.3 mm)
(standard shock absorbers)
FLHX, FLHXS, FLTRX, FLTRXS ¼–7/16 in (6.4–11.1 mm)
FLHTCUL, FLHTCUL TC, FLHTKL ****
(low profile shock absorbers)
Engine coolant Coolant type GENUINE HARLEY-DAVIDSON EXTENDED LIFE
ANTIFREEZE AND COOLANT
Coolant capacity 0.8 qt (0.8 L)
Engine oil and filter Drain plug torque 14-21 ft-lbs (19.0-28.5 Nm)
Oil capacity * 4.75 qt (4.5 L)
Filter Hand tighten 1/2-3/4 turn after gasket contact
Front fork oil Amount See FRONT FORK (Page 3-64).
Type TYPE 'E' HYDRAULIC FORK OIL
Hand controls Switch housing screws 35-45 in-lbs (4.0-5.1 Nm)
Clutch master cylinder clamp screws 60-80 in-lbs (6.8-9.0 Nm)
Brake master cylinder clamp screws 60-80 in-lbs (6.8-9.0 Nm)
Primary chain lubricant Lubricant type and capacity ***** FORMULA+ TRANSMISSION AND PRIMARY
CHAINCASE LUBRICANT
or
SCREAMIN' EAGLE SYN3 FULL SYNTHETIC
MOTORCYCLE LUBRICANT 20W50
Wet: 30 fl oz (0.9 L)
Dry: 34 fl oz (1 L)
Clutch inspection cover screw torque 84-108 in-lbs (9.5-12.2 Nm)
Primary chaincase drain plug torque 14-21 ft-lbs (19.0-28.5 Nm)
Spark plugs Gap 0.031 –0.035 in (0.8–0.9 mm)
Torque 89-133 in-lbs (10-15 Nm)
Tire pressure and wear Pressure: solo rider or with passenger Front: 36 psi (248 kPa)
Rear: 40 psi (276 kPa)
Wear Replace if less than 1/32 in (0.8 mm) of tread pat-
tern
Transmission lubricant Lubricant level Dipstick between ADD and FULL marks with motor-
cycle on jiffy stand and filler plug threaded in until
O-ring touches the case.
Lubricant type and capacity ** FORMULA+ TRANSMISSION AND PRIMARY
CHAIN LUBRICATION
or
SCREAMIN' EAGLE SYN3 FULL SYNTHETIC
MOTORCYCLE LUBRICANT 20W50
32 fl oz (0.95 L)
Transmission drain plug torque 14-21 ft-lbs (19.0-28.5 Nm)
Transmission dipstick torque 25-75 in-lbs (2.8-8.5 Nm)

2-12 94000383
 Table 2-4. Quick Reference Maintenance and Torque Chart: Touring
ITEM SERVICED SPECIFICATION DATA
Wheel spokes Spoke nipple torque 55 in-lbs (6.2 Nm) minimum
* Capacity is approximate. When changing oil, initially add 4.0 qt (3.8 L). Run engine until warm. Check and fill as necessary.
** Capacity is approximate. When changing lubricant, initially add 28 fl oz (0.83 L). Check and fill as necessary.
*** Clutch fluid level will rise as clutch wears.
**** Includes model variations such as CVO and Low models
***** Amount is approximate. Fill to bottom of pressure plate OD with vehicle upright.

Table 2-5. Lubricants, Greases, Sealants

ITEM PART NUMBER PACKAGE
3M 847 Adhesive 021200-19718 * 5 oz tube
3M General Purpose Adhesive Remover 15 oz aerosol
Anti-Seize Lubricant 98960-97 1 oz squeeze tube
CCI #20 Brake Grease 42830-05 squeeze packet
DOT 4 Brake Fluid 99953-99A 12 oz bottle
Dow Corning Moly 44 Grease 94674-99 2 cc packet
Electrical Contact Lubricant 11300004 1 oz squeeze tube
Formula+ Transmission and Primary Chaincase 99851-05 1 qt bottle
Lubricant
G40M Brake Grease 42820-04 squeeze packet
Genuine Harley-Davidson Extended Life Antifreeze 99822-02 1 gal container
and Coolant
Genuine Harley-Davidson H-D 360 20W50 99816-2050/00QT 1 qt bottle
Motorcycle Oil
Harley-Davidson Adhesive (Griplock) 99839-95 10 g tube
Harley-Davidson High Performance Sealant - Gray 99650-02 1.9 oz squeeze tube
Harley-Davidson Leather Dressing 98261-91V 6 oz can
Harley-Davidson Seal Grease 11300005 1 oz tube
Harley Lube 94968-09 1/4 oz needle dispenser
Hylomar Gasket and Thread Sealant 99653-85 3.0 oz tube
Loctite 222 Low Strength Threadlocker and Sealant (purple) 99811-97 6 mL tube
Loctite 243 Medium Strength Threadlocker and Sealant (blue) 99642-97 6 mL tube
11100005 50 mL bottle
Loctite 246 Medium Strength/High Temperature Threadlocker
(blue)
Loctite 262 High Strength Threadlocker and Sealant (red) 94759-99 6 mL tube
Loctite 271 High Strength Threadlocker and Sealant (red) 6 mL tube
11100006 50 mL bottle
Loctite 411 Prism Instant Adhesive
Loctite 420 Super Bonder Adhesive
Loctite 565 Thread Sealant 99818-97 6 mL tube
Loctite 770 Prism Primer
Loctite 7649 Cleaner/Primer 98968-99 1.75 oz bottle
Screamin' Eagle Assembly Lube 11300002 4 oz tube
Screamin' Eagle SYN3 Full Synthetic Motorcycle 99824-03/00QT 1 qt bottle
Lubricant 20W50
Special Purpose Grease 99857-97A 14 oz cartridge
Type "E" Hydraulic Fork Oil 62600026 16 oz bottle

94000383 2-13
 Table 2-5. Lubricants, Greases, Sealants
ITEM PART NUMBER PACKAGE
Wheel Bearing Grease 99855-89 1 lb can
99856-92 14 oz cartridge
* Not a Harley-Davidson part number

2-14 94000383
ENGINE OIL AND FILTER 2.5
CHECK ENGINE OIL LEVEL 3. See Figure 2-1. Check oil level.
a. Remove filler plug/dipstick.
CAUTION
b. Wipe off the dipstick.
Prolonged or repeated contact with used motor oil may
c. Insert the dipstick and tighten into the fill spout.
be harmful to skin and could cause skin cancer. Promptly
wash affected areas with soap and water. (00358b) d. Remove filler plug/dipstick.

NOTICE
Do not overfill oil. Doing so can result in oil carryover to
the air cleaner leading to equipment damage and/or
equipment malfunction. (00190b) 4.
NOTE
• Oil level can be checked with motorcycle upright or on jiffy
stand. Both marks are on the same side of the dipstick.
Carefully read dipstick when checking oil level.
• Check engine oil level at each complete fuel refill.
e. See Figure 2-2. Check oil level. Oil level must register
between the ADD QT and FULL HOT marks on the
dipstick.
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.
om01566

Oil Level Cold Check

1. Place vehicle on level ground resting on the jiffy stand.
NOTE
Oil level on a cold engine should never be above the midway
point.

2. See Figure 2-1. Check engine oil level.

a. Remove filler plug/dipstick.
b. Wipe off the dipstick.
c. Insert the dipstick and tighten into the fill spout.
d. Remove filler plug/dipstick. Figure 2-1. Engine Oil Filler Plug
e. See Figure 2-2. Check oil level. The correct cold oil sm08693
level is midway (2) between the ADD QT (1) and FULL
HOT (3) marks on the dipstick.
3
3. If oil level is at or below the ADD QT mark, add only
enough oil to bring the level to the ADD QT mark. 1
4. Start and idle engine on jiffy stand for two minutes. Turn
off engine.
5. Check oil level. Add only enough to bring level midway
between the ADD QT (1) and FULL HOT (3).
2
Oil Level Hot Check
NOTICE

Do not allow hot oil level to fall below Add/Fill mark on 1. ADD QT mark
dipstick. Doing so can result in equipment damage and/or 2. Cold check level
equipment malfunction. (00189a) 3. FULL HOT mark
Figure 2-2. Engine Oil Dipstick
NOTE
Perform engine oil level hot check only with engine oil at normal
CHANGE OIL AND OIL FILTER
operating temperature.
PART NUMBER TOOL NAME
1. Ride motorcycle until engine oil reaches at least 200 °F HD-42311 OIL FILTER WRENCH
(93 °C) or higher. HD-44067A OIL FILTER WRENCH
2. Allow engine to idle for 1-2 minutes on jiffy stand. Turn off
engine. FASTENER TORQUE VALUE
Engine oil drain plug 14–21 ft-lbs 19–28.5 N·m

94000383 2-15
 WARNING Table 2-6. Initial Oil Fill

Be sure that no lubricants or fluids get on tires, wheels or ITEM QUANTITY

brakes when changing fluid. Traction can be adversely Engine oil initial fill 4.5 qt (4.3 L)
affected, which could result in loss of control of the
motorcycle and death or serious injury. (00047d) 10. Verify proper oil level. See ENGINE OIL AND FILTER,
Check Engine Oil Level (Page 2-15).
NOTICE
a. Perform engine oil level cold check.
Do not switch lubricant brands indiscriminately because
some lubricants interact chemically when mixed. Use of b. Start engine and carefully check for oil leaks around
inferior lubricants can damage the engine. (00184a) drain plug and oil filter.
c. Perform engine oil level hot check.
• Change engine oil at the first 1000 mi (1,600 km) for a new
engine. After the initial service, change oil at regular intervals
in normal service at warm or moderate temperatures. Refer sm08587

to Table 2-3.
• Change oil at more frequent intervals in cold weather or
severe operating conditions. See FUEL AND OIL, Low
Temperature Lubrication (Page 2-9).
1. Run motorcycle until engine is at normal operating
temperature. Turn off engine.
2
2. Remove filler plug/dipstick.
NOTE
Replace drain plug O-ring if damaged.
1
3. See Figure 2-3. Remove the oil drain plug (2) and O-ring. 3
Allow oil to drain completely.
NOTE
Use P&A Oil Catcher (Part No. 62700199) or equivalent to
keep drain oil off crankcase when removing oil filter. Residual 1. Transmission drain plug (right side)
drain oil could falsely appear as a crankcase oil leak at a later 2. Engine oil drain plug and O-ring
time. 3. Hex plug (do not remove)
Figure 2-3. Oil Pan
4. Remove the oil filter using OIL FILTER WRENCH (PART sm01414
NUMBER: HD-42311) or OIL FILTER WRENCH (PART
NUMBER: HD-44067A) and hand tools. Do not use with
air tools.

5. Clean the oil filter mount flange.

6. Clean any residual oil for crankcase and transmission

housing.

7. See Figure 2-4. Install new oil filter.

a. Lubricate gasket with a thin film of clean engine oil.

Figure 2-4. Lubricating New Oil Filter Gasket
b. Install new oil filter.

c. 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.

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

8. Install engine oil drain plug and O-ring. Tighten to

14–21 ft-lbs (19–28.5 N·m).

9. Add an initial volume of engine oil. Refer to Table 2-6.

2-16 94000383
AIR CLEANER ELEMENT 2.6
REMOVE c. Install screws (3). Tighten to 40–60 in-lbs
(4.5–6.8 N·m).
1. See Figure 2-5. Remove air cleaner cover.
2. Install air cleaner cover.
a. Remove screw (1).
b. Remove cover (2). a. Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue) to threads
2. Remove filter element. of screw (1).
a. Remove screws (3).
b. Install cover (2).
b. Remove filter element (4) while pulling breather tube
(5) from element. c. Install screw (1). Tighten to 36–60 in-lbs
(4.1–6.8 N·m).
CLEAN AND INSPECT
sm08515

1. See Figure 2-5. Remove breather tube (5) from breather 4

bolts.
3
NOTE
• Do not strike filter element on a hard surface to dislodge 2
dirt.
• Do not use air cleaner filter oil on the Harley-Davidson
paper/wire mesh air filter element. 1 5

2. Inspect the breather tube and fittings for damage.

6
WARNING
Do not use gasoline or solvents to clean filter element.
Flammable cleaning agents can cause an intake system 1. Cover screw
fire, which could result in death or serious injury. (00101a) 2. Cover
3. Screw (3)
3. Clean filter element. 4. Filter element
5. Breather tube assembly
6. Rubber seal
a. Wash the filter element and breather tubes in
lukewarm water with a mild detergent. Figure 2-5. Air Cleaner Assembly

b. Allow filter element to air dry or use low-pressure

compressed air from the inside.

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

The element is sufficiently clean when light is
uniformly visible through the media.

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

cannot be adequately cleaned.

4. Verify that rubber seal (6) is properly seated and not

damaged.

INSTALL

FASTENER TORQUE VALUE

Air cleaner cover screw 36–60 in-lbs 4.1–6.8 N·m
Air filter element screws 40–60 in-lbs 4.5–6.8 N·m

1. See Figure 2-5. Install filter element.

a. Install breather tube (5).

b. Install filter element (4) while pushing breather tube

into element.

94000383 2-17
EXHAUST SYSTEM 2.7
LEAK CHECK

1. Check exhaust system for obvious signs of leakage such

as carbon tracks and marks at pipe joints.
a. Check for loose or missing fasteners.
b. Check for cracked pipe clamps or brackets.
c. Check for loose or cracked exhaust shields.

2. Check exhaust system for audible signs of leakage.

a. Start engine.
b. Cover end of muffler with clean, dry shop towel.
c. Listen for signs of exhaust leakage.

3. Correct any detected leaks.

a. See EXHAUST SYSTEM (Page 5-26). Disassemble
exhaust system.
b. Clean all mating surfaces.
c. Repair or replace damaged components.
d. Assemble exhaust system.

NOTE
If leak continues, disassemble and apply PERMATEX ULTRA
COPPER or LOCTITE 5920 FLANGE SEALANT or equivalent
oxygen sensor/catalyst-safe alternative to mating surfaces.

2-18 94000383
COOLANT 2.8
COOLING SYSTEM c. Install rubber plug.

5. Install access panel.

CAUTION
At operating temperature, radiators and oil coolers contain sm06890
hot fluids. Contact with a radiator or oil cooler can result
in minor or moderate burns. (00141b) 3 4
NOTICE

Use only Genuine Harley-Davidson Extended Life

Antifreeze and Coolant. Use of other coolants/mixtures
may lead to engine damage. (00179b) 1

GENUINE HARLEY-DAVIDSON EXTENDED LIFE

ANTIFREEZE AND COOLANT is pre-diluted and ready to use
full strength. It provides temperature protection to -34° F (-36.7°
C). DO NOT add water.
2
NOTICE

De-ionized water must be used with the antifreeze in the

cooling system. Hard water can cause scale accumulation
in water passages which reduces cooling system
1. Cold full line, vehicle upright
efficiency, leading to overheating and engine damage.
2. Cold full line, vehicle on jiffy stand
(00195a)
3. Rubber plug
4. Pressure cap
If GENUINE HARLEY-DAVIDSON EXTENDED LIFE
ANTIFREEZE AND COOLANT is unavailable, a mixture of Figure 2-6. Coolant Level
de-ionized water and ethylene glycol-based antifreeze may be
used. At the first opportunity, change back to GENUINE Clean Radiators
HARLEY-DAVIDSON EXTENDED LIFE ANTIFREEZE AND NOTICE
COOLANT.
Clean the inlet surface of the radiator regularly. Leaves
Checking Coolant Level and other debris can collect on the radiator surface and
degrade radiator performance which could lead to engine
NOTE overheating and engine damage. (00197c)
Check coolant level with engine cold.
1. See Figure 2-7. Remove grille panel from lower fairing.
1. Place motorcycle on level ground.
a. Carefully pry on curved edge of panel to release latches.
2. Remove access panel from lower right fairing. Pry the
center top and pull out to release retainers. b. Remove from fascia.

NOTE 2. Clean debris from radiator fins.

See Figure 2-6. The coolant bottle has two lines. Use the
3. Install grille panel.
angled full line (2) when the motorcycle is leaning on the jiffy
stand.

3. See Figure 2-6. Check that coolant level in coolant bottle

is at or slightly above the COLD full line (1).
NOTE
• Do not remove the pressure cap (4). Fill the coolant bottle
by removing the rubber plug (3).
• If the coolant bottle is empty when the engine is cold, inspect
the system for leaks. Repair as needed. Fill system with
coolant and perform bleed procedure. See Coolant, Drain
and Fill Cooling System (Page 2-20).

4. If level is below COLD line on tank:

a. Remove rubber plug (3).
b. Add GENUINE HARLEY-DAVIDSON EXTENDED LIFE
ANTIFREEZE AND COOLANT until fluid level is at or
slightly above the COLD line.

94000383 2-19
 sm07989a
WARNING
Do not loosen or remove pressure cap when engine is hot.
The cooling system is under pressure and hot coolant and
steam can escape from pressure cap, which could cause
severe burns. Allow engine to cool before servicing the
cooling system. (00091b)

Drain System
NOTE
Use 24 INCH HOSE CLAMP TOOL (PART NUMBER:
HD-52004) to reach rotated or difficult to reach spring clamps.

1. Remove main fuse.

2. Remove access panel from right lower fairing.
NOTE
Do not remove pressure cap.

Figure 2-7. Lower Fairing Grille Panel 3. See Figure 2-6. Remove rubber plug (3).
FREEZE POINT TEST 4. Remove pump cover.
NOTE
PART NUMBER TOOL NAME
Hose barb on the pump is fragile. Use caution when removing
HD-23688 BATTERY TESTER coolant hose.
HD-26568 BATTERY TESTER
5. See Figure 2-8. Disconnect hoses (1, 2) from pump.
1. Allow engine to cool.
6. Disconnect hose (3) from right coolant downtube. Lower
2. Remove pressure cap. hose to drain.
3. Place a few drops of coolant from the filler neck onto the 7. Drain and discard used coolant.
prism of either the BATTERY TESTER (PART NUMBER:
HD-26568) or the BATTERY TESTER (PART NUMBER: NOTE
HD-23688). Verify that the hose clamp is installed between the raised barb
and pump body. Do not install the clamp directly over the raised
4. Hold the prism up to a light.
area.
5. The coolant freeze point is the mark where the dark area
begins on the ETHYLENE GLYCOL temperature scale. 8. Connect hose (1, 2) to pump.
6. Compare the freeze point of the coolant to the anticipated a. Install spring clamps.
operating or storage temperatures. Replace as required.
See Coolant (Page 2-19). b. Verify that hoses are installed completely with the hose
end touching the pump housing
a. If the indicated freeze point is less than specified on the
container, replace with GENUINE HARLEY-DAVIDSON 9. Connect hose (3) to right coolant downtube. Secure with
EXTENDED LIFE ANTIFREEZE & COOLANT spring clamp.
(HD-99822-02).
10. Install pump cover.
b. If anticipated cold temperatures exceed that of
Harley-Davidson premixed antifreeze, replace with a 11. Install main fuse.
mixture of de-ionized water and ethylene glycol
antifreeze. Follow the directions on the container to
create a mixture with a freeze point that will exceed the
expected cold temperature.

7. Install the pressure cap.

DRAIN AND FILL COOLING SYSTEM

PART NUMBER TOOL NAME

HD-52004 24 INCH HOSE CLAMP TOOL
MCR102A MATCO VACUUM VENTURI COOLING
SYSTEM REFILLER
MPT10128 COOLING SYSTEM ADAPTER

2-20 94000383
 sm08611 sm08326a

3
2

1 4
Figure 2-9. Matco Vacuum Venturi Cooling System Refiller
NOTE
See Figure 2-10. Verify that pressure cap is completely
tightened. Tab (1) must contact stop (2) for proper system
operation.

1. Pump outlet hose 10. Install pressure cap. Secure filler neck to retainer on
2. Pump inlet hose coolant bottle.
3. Hose from left radiator
4. Pump electrical connector 11. Fill coolant bottle to the cold fill line. Install rubber plug.
Figure 2-8. Drain Cooling System 12. Start engine and check for leaks when hot.
NOTE
Power Fill and Bleed
Coolant level in the coolant bottle typically rises slightly when
NOTICE the engine is at operating temperature. The level returns to the
COLD line when the system has cooled down.
Use only Genuine Harley-Davidson Extended Life
Antifreeze and Coolant. Use of other coolants/mixtures 13. Verify level in coolant bottle after system has cooled.
may lead to engine damage. (00179b)
14. Install access panel.
NOTE
• See Figure 2-9. Harley-Davidson recommends using Manual Fill and Bleed
MATCO VACUUM VENTURI COOLING SYSTEM
REFILLER (PART NUMBER: MCR102A) along with NOTICE
COOLING SYSTEM ADAPTER (PART NUMBER: Use only Genuine Harley-Davidson Extended Life
MPT10128) or equivalent. This allows for a vacuum test of Antifreeze and Coolant. Use of other coolants/mixtures
the complete system and effective filling with coolant. may lead to engine damage. (00179b)
• Follow the manufacturer's instructions supplied with the tool.
A general overview follows. 1. Park motorcycle.
a. 2-wheel: Lean on jiffy stand.
1. Stand motorcycle upright (not leaning on jiffy stand).)
b. Trike: Raise front wheel and right rear wheel about 6 in
2. Pull filler neck from retainer on coolant bottle. Remove
(152 mm).
pressure cap.
3. Attach vacuum filler tool to filler neck. 2. Pull filler neck from retainer on coolant bottle. Remove
pressure cap.
4. Connect to low-pressure, compressed air.
NOTE
5. Immerse coolant pick-up hose into new coolant mixture.
Fill hose and tool with coolant to purge air. • System capacity is approximately 0.8 qt (0.8 L).

6. Turn on air valve and observe vacuum gauge. When gauge • Use a squeeze bottle similar to a dishwashing liquid bottle
has stabilized, turn off air valve. to simplify the procedure.

7. Observe vacuum gauge to verify that it remains steady. • A complete filling and bleeding will take 10-15 minutes.

8. Open coolant valve to allow system to fill. 3. Fill system through filler neck until coolant is visible. Allow
9. Remove tool from filler neck. coolant to bleed down for a few seconds and repeat.
4. Bleed cooling system:
a. Turn ignition switch ON. Turn run switch ON. Do not
start engine.

94000383 2-21
 b. Turn throttle to greater than 50% and hold for at least
3 seconds. Coolant pump and fans start. Release
throttle.
c. As the pump runs, continue to add coolant until filler
neck remains topped off. Turn throttle full open until
pump and fans stop.
d. Wait 10-15 seconds and repeat above two steps until
no more coolant can be added.
NOTE
The pump and fans run indefinitely in bleed mode until
ignition is turned OFF or the throttle is held full open, unlike
operational mode.

e. Turn ignition switch OFF. Pump and fans stop.

NOTE
See Figure 2-10. Verify that pressure cap is completely
tightened. Tab (1) must contact stop (2) for proper system
operation.

5. Install pressure cap. Secure filler neck to retainer on

coolant bottle.
6. Fill coolant bottle to the COLD full line. Install rubber plug.
7. Start engine and check for leaks when hot.
NOTE
Coolant level in the coolant bottle typically rises slightly when
the engine is at operating temperature. The level returns to the
COLD line when the system has cooled down.

8. Verify level in coolant bottle after system has cooled.

9. Install access panel.

sm08015

1 2

1. Pressure cap tab

2. Secondary stop
Figure 2-10. Pressure Cap Installation

2-22 94000383
TIRES AND WHEELS
GENERAL
WARNING
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)
WARNING
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)
WARNING
Do not use liquid tire balancers or sealants in aluminum
wheels. Using liquid tire balancers or sealants can cause
rapid corrosion of the rim surface, which could cause tire
deflation. Tire deflation can cause loss of vehicle control,
which could result in death or serious injury. (00631b)
Always maintain proper tire pressure. Refer to Table 2-7.
Do not load tires beyond GAWR. Refer to Table 3-4 and Table
3-5.
Under-inflated, over-inflated or overloaded tires can fail.
Use only tires listed in Table 2-7.
NOTE
ABS models must use properly inflated tires and wheels that
are the same as the original equipment. The ABS 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 affect its ability to detect and prevent lockups.
Operating with over- or under-inflated tires can reduce ABS
performance.
TIRES
WARNING
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)
94000383
2.9
NOTE
• Tubeless tires are used on all Harley-Davidson cast and
disc wheels.
• Tire sizes are molded on the tire sidewall. Inner tube sizes
are printed on the tube.
• New tires should be stored on a horizontal tire rack. Avoid
stacking new tires in a vertical stack. The weight of the stack
compresses the tires and closes down the beads.
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 affect its ability to detect and prevent lockups.
Operating with inflation pressure other than those specified in
Table 2-7 can reduce ABS performance.
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.
WARNING
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 tire pressures when tires are cold (68 °F (20 °C)).
Refer to Table 2-7. Increase tire pressure by 1 psi (6.9 kPa)
for every 10 °F (5 °C) in ambient air temperature above
this point.
NOTE
Harley-Davidson does not perform any testing with 100 percent
nitrogen in tires. Harley-Davidson neither recommends nor
discourages the use of pure nitrogen to inflate tires.
2-23
 Table 2-7. Specified Tires
MODEL MOUNT SIZE SPECIFIED TIRE PRESSURE (COLD
68 °F (20 °C)) *
psi kPa
FLHTCU, FLHTK, FLHTKL, front 17 in Dunlop D408F 130/80B17 M/C 65H 36 248
FLTRU, FLHR (cast)
FLHRC (laced) front 16 in Dunlop D402F MT90B16 M/C 72H (wide whitewall) 36 248
FLHX, FLHXS, FLTRX, FLTRXS front 19 in Dunlop D408F 130/60B19 M/C 61H 36 248
All with cast wheels rear 16 in Dunlop D407T 180/65B16 M/C 81H 40 276
FLHRC (laced) rear 16 in Dunlop D407 180/65B16 M/C 81H (wide whitewall) 40 276
* Tire pressure will vary with changes in ambient and tire temperature. Check pressure with tires cold (68 °F (20 °C)). Increase
tire pressure by 1 psi (6.9 kPa) for every 10 °F (5 °C) in ambient air temperature above this point.

REPLACE TIRE WHEEL BEARINGS

Inspection Inspect wheel bearings at every tire change:

WARNING 1. Check wheel bearings as outlined in SEALED WHEEL

Use only Harley-Davidson specified tires. See a
Harley-Davidson dealer. Using non-specified tires can
adversely affect stability, handling or braking, which could
result in death or serious injury. (00024b)
WARNING
Replace tire immediately with a Harley-Davidson specified
tire when wear bars become visible or only tread depth
remains. Riding with a worn tire could result in death or
serious injury. (00090c)
BEARINGS (Page 3-33). Replace wheel bearings if end
play exceeds 0.002 in (0.051 mm).
2. If wheel is removed, check wheel bearings:
a. 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 if
necessary.

Harley-Davidson tires have wear bars that run horizontally WHEEL SPOKES
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 PART NUMBER TOOL NAME
tire can: HD-48985 SPOKE TORQUE WRENCH
• Be more easily damaged leading to tire failure. HD-94681-80 SPOKE WRENCH

• Provide reduced traction. FASTENER TORQUE VALUE

• Adversely affect stability and handling. Spoke nipple 55 in-lbs 6.2 N·m

Arrows on tire sidewalls pinpoint location of wear bar indicators. WARNING

Tread wear indicator bars appear on tire tread surfaces when
1/32 in (0.8 mm) or less of tire tread remains. Always replace
tires before the tread wear indicator bars appear.
When To Replace Tires
New tires are needed if any of the following conditions exist:
1. Tread wear indicator bars become visible on the tread
surfaces.
2. Tire cords or fabric become visible through cracked
sidewalls, snags or deep cuts.
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)
WARNING
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.
(00611c)

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

4. Puncture, cut or other damage to the tire that cannot be
repaired.
When installing tires on rims, do not rely on tread design to
determine direction of rotation. Always make sure the rotational
arrows molded into the sidewalls point in the direction of
forward rotation.
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)

Refer to Table 2-7 for specified tires.

2-24 94000383
Identify Wheel Spoke Groups Table 2-8. Spoke Nipple Torque Specification
NOTE RIM TYPE MINIMUM TORQUE
Spokes are grouped in sets of four. All 55 in-lbs (6.2 N·m)

1. Raise the wheel.

sm06507
2 3 1
2. See Figure 2-11. Starting at the valve stem, identify the
4
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 steps.

Adjust Wheel Spokes

NOTE
• Do not tighten spoke more than one-quarter 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 WRENCH (PART NUMBER: HD-94681-80) to
loosen spokes.

1. See Figure 2-11. Starting with the first group of spokes,

loosen spoke (1) one-quarter turn using SPOKE WRENCH
(PART NUMBER: HD-94681-80). Figure 2-11. Tightening Laced Wheels (typical)
2. Using SPOKE TORQUE WRENCH (PART NUMBER:
HD-48985) tighten spoke (1) to the value listed in Table
2-8.
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 marks align and torque specification has not been
reached, tighten the spoke nipple until the correct torque
is achieved. Do not turn spoke nipple more than
one-quarter turn past alignment mark.

3. Repeat previous two steps for spoke (4) in the same group.
4. Continue around the wheel checking spokes 1 and 4 until
all groups are done.
5. Repeat procedure for spokes (2, 3) in each group.
NOTE
When checking any spokes that were labeled, make sure to
use the original alignment mark.

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

the proper torque value after tightening one-quarter turn
past alignment mark.
a. Loosen spoke one-quarter turn past original alignment
mark using SPOKE WRENCH (PART NUMBER:
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 marks align and torque specification has not been
reached, tighten the spoke nipple until the correct torque
is achieved. Do not turn spoke nipple more than
one-quarter turn past alignment mark.

7. True the wheel. See WHEEL RUNOUT (Page 3-29).

94000383 2-25
PRIMARY CHAINCASE LUBRICANT 2.10
CHANGE PRIMARY CHAINCASE
8. Add lubricant.
LUBRICANT
a. Pour specified amount of FORMULA+
FASTENER TORQUE VALUE
TRANSMISSION AND PRIMARY CHAINCASE
Clutch inspection cover 84–108 in-lbs 9.5–12.2 N·m LUBRICANT through clutch inspection cover
screws opening. Refer to Table 2-9.
Primary chaincase drain plug 14–21 ft-lbs 19–28.5 N·m
b. See Figure 2-13. Proper level is approximately at
1. Run motorcycle until engine is at normal operating bottom of pressure plate OD.
temperature. Turn off engine.
Table 2-9. Primary Chaincase Lubricant
WARNING
ITEM DRY FILL** WET FILL***
Be sure that no lubricants or fluids get on tires, wheels or Oz L L Oz
brakes when changing fluid. Traction can be adversely
affected, which could result in loss of control of the Amount* 34 1.0 30 0.9
motorcycle and death or serious injury. (00047d) * Amount is approximate. Fill to bottom of pressure plate OD
with vehicle upright.
2. Secure motorcycle upright (not leaning on jiffy stand) on ** Cover was removed and installed.
a level surface. *** Lubricant was drained through the drain plug only.

3. See Figure 2-12. Drain primary chaincase. sm08706

4. Clean drain plug magnet. If plug has excessive debris,

inspect the condition of chaincase components.

5. Install drain plug and new O-ring. Tighten to 14–21 ft-lbs

(19–28.5 N·m).

om00114a

Figure 2-13. Primary Lubricant Level

9. Install clutch inspection cover and new seal:

a. Thoroughly wipe all lubricant from cover mounting

surface and groove in chaincase cover.

b. See Figure 2-14. Position new seal (1) in groove in

Figure 2-12. Removal/Installation of Chaincase Drain Plug clutch inspection cover (2). Press each of the nubs
on seal into the groove.
6. See Figure 2-14. Remove screws (3) and clutch inspection
cover (2). c. Secure clutch inspection cover (2) with screws with
captive washers (3).
7. Remove seal (1). Wipe oil from groove in chaincase cover
and mounting surface. d. See Figure 2-15. Tighten in sequence shown to
84–108 in-lbs (9.5–12.2 N·m).
NOTICE

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)

2-26 94000383
 om00709

1
3

1. Seal
2. Clutch inspection cover
3. Screw and captive washer (5)
Figure 2-14. Clutch Cover

om02155

4 3

2 5

Figure 2-15. Clutch Cover Tightening Sequence

94000383 2-27
TRANSMISSION LUBRICANT 2.11
CHECK TRANSMISSION LUBRICANT om01041

FASTENER TORQUE VALUE

Transmission filler 25–75 in-lbs 2.8–8.5 N·m
plug/dipstick

NOTE
Check transmission fluid with the motorcycle at ambient
temperature. Inspect transmission dipstick O-ring. Replace if 2
necessary. 1

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

2. See Figure 2-16. Remove transmission filler plug/dipstick.

Wipe dipstick clean.
1. Add (A)
3. Install filler plug/dipstick until O-ring contacts the case. Do 2. Full (F)
not tighten.
Figure 2-17. Transmission Lubricant Level
4. See Figure 2-17. Remove filler plug/dipstick. Check Table 2-10. Transmission Lubricant
lubricant level on dipstick. Proper oil level is between the
Add (A) (1) and Full (F) (2) marks. MODEL LUBRICANT
All FORMULA+ TRANSMISSION AND PRIMARY
NOTICE CHAIN LUBRICANT

Mixing mineral-based lubricants with SYN-3 in the CHANGE TRANSMISSION LUBRICANT

transmission can damage the transmission. (00452b)

FASTENER TORQUE VALUE

5. If lubricant level is low, add recommended Harley-Davidson
Transmission drain plug 14–21 ft-lbs 19–28.5 N·m
lubricant to bring level to between the A mark and the F
marks. Refer to Table 2-10. Transmission filler 25–75 in-lbs 2.8–8.5 N·m
plug/dipstick
6. Install filler plug/dipstick. Tighten to 25–75 in-lbs
1. See Figure 2-16. Remove transmission filler plug/dipstick.
(2.8–8.5 N·m).

WARNING
om01567
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 2-18. Remove transmission drain plug. Drain

transmission.

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

NOTICE

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

(19–28.5 N·m). Do not over-tighten.
Figure 2-16. Transmission Filler Plug/Dipstick Location
5. Fill the transmission with 28 fl oz (0.83 L) of recommended
Harley-Davidson lubricant. Refer to Table 2-10.

6. Check lubricant level. Add enough lubricant to bring the

level between the add (A) and full (F) marks. See
Transmission Lubricant, Check Transmission Lubricant
(Page 2-28).

2-28 94000383
7. Install filler plug/dipstick. Tighten to 25–75 in-lbs
(2.8–8.5 N·m).

sm08588

1
3

1. Transmission drain plug (right side)

2. Engine oil drain plug and O-ring
3. Hex plug (do not remove)
Figure 2-18. Transmission Drain

94000383 2-29
HYDRAULIC CLUTCH FLUID 2.12
GENERAL FASTENER TORQUE VALUE
Clutch reservoir cover screws 12–15 in-lbs 1.4–1.7 N·m
The clutch is hydraulically actuated. The master cylinder
creates pressure in the clutch fluid line. This pressure activates NOTE
the secondary clutch actuator. The secondary clutch actuator • Flush clutch system and replace DOT 4 fluid every two years
piston extends and contacts a pushrod to disengage the clutch. per maintenance schedule.

CAUTION • This procedure is meant to replace fluid without introducing

air. If any air enters lines during this procedure, revert to
Direct contact of D.O.T. 4 brake fluid with eyes can cause BLEED CLUTCH CONTROL SYSTEM (Page 3-85).
irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention. 1. Remove transmission outer side cover. See
Swallowing large amounts of D.O.T. 4 brake fluid can cause TRANSMISSION SIDE COVERS (Page 8-7).
digestive discomfort. If swallowed, obtain medical
attention. Use in well ventilated area. KEEP OUT OF REACH
2. Install BASIC VACUUM BRAKE BLEEDER (PART
OF CHILDREN. (00240a)
NUMBER: BB200A) to bleeder screw.
NOTICE
3. Position vehicle or handlebar so master cylinder reservoir
D.O.T. 4 hydraulic brake fluid is used in the hydraulic is level.
clutch. Do not use other types of fluids as they are not
compatible and could cause equipment damage. (00353a)
4. Wrap a clean shop towel around the outside of the master
NOTICE cylinder reservoir to protect paint from brake fluid spills.

D.O.T. 4 brake fluid will damage painted and body panel 5. Clean master cylinder reservoir cover before removal.
surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is
6. Remove cover from master cylinder reservoir.
performed. Failure to comply can result in cosmetic
damage. (00239b)
WARNING
• If DOT 4 brake fluid contacts painted surfaces,
A plugged or covered relief port can cause clutch drag,
IMMEDIATELY flush area with clear water.
which could lead to loss of control, resulting in death or
CHECK CLUTCH FLUID serious injury. (00583b)

NOTE 7. Verify master cylinder operation.

• Flush clutch system and replace DOT 4 fluid every two years
per maintenance schedule. a. Add DOT 4 fluid as necessary.
• Adding or removing fluid should never be required during
b. Operate clutch lever.
normal wear, except for fluid replacement as specified in
the maintenance schedule. Fluid level in reservoir will rise
NOTE
with clutch wear.
Carefully monitor fluid level in the master cylinder reservoir.
• Do not remove reservoir cover to inspect fluid level for Add fluid before it empties to avoid drawing air into the brake
periodic maintenance inspections. lines.
• Check that clutch hand lever returns completely. If lever
does not return completely, problems similar to over-filling c. A slight bulge of fluid will break the fluid surface in
can result. the reservoir if internal components are working
properly.
1. Inspect hydraulic clutch system for wear and leakage.
8. Operate vacuum bleeder while maintaining fluid level in
a. Follow hydraulic line routing looking for abnormal wear.
master cylinder reservoir.
b. Verify that retaining clips and cable straps secure line
adequately. a. Open bleeder screw about 3/4 turn.
c. Look for evidence of leakage.
b. Continue until 3 fl oz (89 ml) has been replaced.
REPLACE CLUTCH FLUID c. Tighten bleeder screw to 56–75 in-lbs (6.3–8.5 N·m).

PART NUMBER TOOL NAME 9. Install transmission outer side cover. See TRANSMISSION
BB200A BASIC VACUUM BRAKE BLEEDER SIDE COVERS (Page 8-7).

FASTENER TORQUE VALUE 10. Fill reservoir to specified level.

Clutch actuator bleeder screw 56–75 in-lbs 6.3–8.5 N·m

2-30 94000383
11. Install master cylinder reservoir cover. Tighten to
12–15 in-lbs (1.4–1.7 N·m).

12. Verify clutch operation.

94000383 2-31
BRAKES 2.13
INSPECT BRAKE FLUID FASTENER TORQUE VALUE
Brake bleeder screw, rear 75–102 in-lbs 8.5–11.5 N·m
NOTE Brake master cylinder, front, 12–15 in-lbs 1.4–1.7 N·m
• Flush brake system and replace DOT 4 fluids every two reservoir cover screws
years per maintenance schedule. Brake master cylinder, rear, 12–15 in-lbs 1.4–1.7 N·m
• Fluid should never need to be added or removed from the reservoir cover screws
system during normal wear, except for fluid replacement as
specified in the maintenance schedule. Reservoir volume NOTE
is adequate to provide fluid to the wear limits of the pads • Flush brake system and replace DOT 4 fluids every two
and rotors. years per maintenance schedule.
• Fluid level in reservoir will decrease with brake wear. • BASIC VACUUM BRAKE BLEEDER (PART NUMBER:
BB200A) or equivalent tool is required.
1. Check front brake lever and foot pedal. Each must have • This procedure is meant to replace fluid without introducing
a firm feel when applied. Repeat the bleeding procedure air. If any air enters lines during this procedure, revert to
if brakes feel spongy. See BLEED BRAKES (Page 3-62). BLEED BRAKES (Page 3-62).
2. Position vehicle on a flat level surface.
a. Front brake: Position motorcycle and handlebar so 1. Remove bleeder screw cap. Install vacuum brake bleeder
that master cylinder reservoir is level. to bleeder screw.

b. Rear brake: Position motorcycle so that master cylinder

NOTE
reservoir is level.
• Wrap a clean shop towel around the outside of the master
cylinder reservoir to protect paint from brake fluid spills.
3. See Figure 2-19. View reservoir sight glass. Fluid level
must be at or above the minimum mark on glass. If fluid • Clean master cylinder reservoir cover before removal.
level is below minimum mark:
a. Check brake system for fluid leaks. 2. Position vehicle or handlebar so master cylinder reservoir
is level.
b. Check that brake pads and rotors are properly installed
and not worn beyond service wear limits. See BRAKE
PADS AND DISCS (Page 2-34). NOTE
A bulge may not be seen on models having remote reservoirs.
c. Check fluid level in brake reservoir. If necessary, add
DOT 4 BRAKE FLUID to reservoir. See Table 2-11.
3. Remove cover from master cylinder reservoir.

om01495
NOTE
Pay careful attention to fluid level in the master cylinder
reservoir. Add fluid before it empties to avoid drawing air into
the brake lines.

4. Add brake fluid as necessary. Verify proper operation of

the master cylinder relief port by actuating the brake pedal
1 or lever. A slight bulge of fluid will break the fluid surface
in the reservoir if internal components are working properly.
Refer to Table 2-11.

5. Operate vacuum bleeder while maintaining fluid level in

master cylinder reservoir.
2
a. Following the sequence in Table 2-13, open bleeder
screw about 3/4 turn.
1. Front master cylinder reservoir b. Continue until specified volume has been replaced.
2. Rear master cylinder reservoir Refer to Table 2-13.
Figure 2-19. Sight Glass Minimum Marks
REPLACE BRAKE FLUID c. Tighten bleeder screw to specification. Refer to Table
2-12. Install bleeder screw cap.

PART NUMBER TOOL NAME

6. Repeat with each caliper following the sequence in Table
BB200A BASIC VACUUM BRAKE BLEEDER 2-13 until all brake lines have been serviced.

FASTENER TORQUE VALUE

7. Fill reservoir to specified level. Refer to Table 2-11.
Brake bleeder screw, front 72–108 in-lbs 8.1–12.2 N·m

2-32 94000383
8. Refer to Table 2-12. Clean gasket and sealing surfaces Table 2-12. Torque Specifications
of debris. Install master cylinder reservoir cover:
COMPONENT TORQUE
a. Front master cylinder reservoir: Install the cover Bleeder screw, front 72–108 in-lbs (8.1–12.2 N·m)
with the vent holes facing the rear. Install cover Bleeder screw, rear 75–102 in-lbs (8.5–11.5 N·m)
screws. Tighten to specification.
Front cover 12–15 in-lbs (1.4–1.7 N·m)
b. Rear master cylinder reservoir: Install cover Rear cover 12–15 in-lbs (1.4–1.7 N·m)
screws. Tighten to specification.
Table 2-13. Bleeding Sequence
9. Apply brakes to check proper lamp operation.
SYSTEM CIRCUIT VOLUME
TYPE
WARNING
Non-ABS Front left 3 fl oz (89 ml)
After repairing the brake system, test brakes at low speed. Front right 3 fl oz (89 ml)
If brakes are not operating properly, testing at high speeds
can cause loss of control, which could result in death or Rear 3 fl oz (89 ml)
serious injury. (00289a) ABS Front left 6 fl oz (178 ml)
Front right 3 fl oz (89 ml)
10. Test ride motorcycle. Repeat the bleeding procedure if
brakes feel spongy. Rear 3 fl oz (89 ml)

Table 2-11. Fluid Level

INSPECT BRAKE LINES
ITEM SPECIFICATION Inspect brake lines for leaks, contact or abrasion. Refer to
Front reservoir Boss or ridge Table 2-14.
Rear reservoir Ledge or range window
Table 2-14. Brake Line Inspection
LINE TYPE INSPECTION REMEDY
Steel lines No marks
Slight mark in paint or plating*
Okay/Monitor
Copper colored-paint/plating worn off*
Silver colored base material-no noticeable feel of wear*
Silver colored base material-noticeable feel of wear*
Replace
Brake fluid leak or other damage
Flexible lines No marks
Okay/Monitor
Slight dent in protective cover or flattening of ribs*
Worn through protective cover or to bottom of ribs
Replace
Brake fluid leak or other damage
Protective cover No marks
(steel, rubber, plastic or braided) Slight dent in covering* Okay/Monitor
Slight dent or flattening of plastic covering*
Worn or cut-through covering-exposed brake line material
Replace
Brake fluid leak or other damage
* If there is line contact, reposition the line. If base material is visible, prevent corrosion with touch-up paint.

94000383 2-33
BRAKE PADS AND DISCS 2.14
INSPECT 2. Front caliper
a. Cut cable straps securing WSS cable and front fender
Check brake pads and discs: tip lamp wires to left brake hose.
• At every scheduled service interval. b. ABS models: Release front WSS cable from clip: Push
on lip at rear of clip to disengage from bracket. Rotate
• Whenever components are removed during service
tab (stamped ABS) rearward until clip is perpendicular
procedures.
to bracket. Remove cable.
Inspect brake lines and hoses for damage or wear. See
BRAKES, Inspect Brake Lines (Page 2-33). Remove
Brake Pads 1. See Figure 2-20 or Figure 2-21. Remove caliper.

NOTE a. Remove screws (2) to release brake caliper.

See Figure 2-22. Wear indicator grooves provide visual b. Remove brake caliper from brake disc.
indication of pad wear.
NOTE
1. Inspect for grit and debris buildup at caliper piston areas. Do not operate the brakes with the brake caliper removed. The
Clean if necessary. caliper pistons can be forced out.
a. Rinse area with warm soapy water.
2. Remove cover from master cylinder reservoir.
b. Dry using low-pressure compressed air.
a. Stand motorcycle upright with master cylinder reservoir
2. Replace all brake pads on a given wheel if the friction level.
material of any single pad is worn to 0.016 in (0.4 mm) or b. Wrap a clean shop towel around the outside of the
less . master cylinder reservoir to protect paint from brake
fluid spills.
Brake Disc
c. Remove cover.
NOTE
Minimum acceptable thickness is stamped on side of disc. 3. Remove grit and debris from caliper piston area.
a. Rinse area with warm soapy water.
1. Measure thickness.
b. Dry using low-pressure compressed air.
a. Measure thickness with a micrometer.
b. Replace disc if disc is scored or measured thickness is NOTE
less than: Front: 0.180 in (4.5 mm)Rear: 0.250 in As pistons are pushed back into the caliper, fluid level may
(6.3 mm) overflow reservoir. Remove fluid from reservoir if necessary.

2. Measure runout. 4. Remove pads.

a. Measure runout near the outside diameter of the disc a. Front caliper: Remove screen from caliper.
using a dial indicator.
b. Push each pad back until pistons are fully seated in
b. Replace disc if runout is 0.008 in (0.2 mm) or greater. caliper bores.

REPLACE BRAKE PADS c. Remove retaining clip (4) from pad pin.
d. Remove pad pin (5) (metric).
FASTENER TORQUE VALUE e. Pull on pad pin end of brake pads to release from
Brake caliper pad pin 75–102 in-lbs 8.5–11.5 N·m caliper.
Brake caliper, front, mounting 28–38 ft-lbs 37.9–51.5 N·m
f. Remove pad spring (7) if damaged or worn.
screws
Brake caliper, rear, mounting 43–48 ft-lbs 58.3–65.1 N·m
screws
Brake master cylinder 12–15 in-lbs 1.4–1.7 N·m
reservoir cover screws

Prepare
1. Rear caliper
a. Remove right saddlebag. See SADDLEBAGS, Remove
(Page 3-98).
b. ABS models: Release WSS cable from retainer clip
on brake hose.

2-34 94000383
 sm04988 sm04987
3 10

9 4

4
1

1
5

2
5

2 8
7 7 6
6
1. Caliper
1. Caliper 2. Caliper bracket screw (2)
2. Caliper mounting screw (2) 3. Caliper bracket
3. Screen 4. Retaining clip
4. Retaining clip 5. Pad pin
5. Pad pin 6. Brake pads
6. Brake pads 7. Pad spring
7. Pad spring 8. Rubber bumper
Figure 2-20. Front Brake Caliper Assembly 9. Bleeder screw
10. Bleeder screw cap
Figure 2-21. Rear Brake Caliper Assembly

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

1. If removed, install new pad spring (7).

a. Install on flat in caliper so clips on spring engage

indentations in caliper.

b. Make sure that forked end of pad spring is on the

pad pin side of the caliper.

2. Install new brake pads.

a. See Figure 2-22. Insert brake pad into caliper,

engaging square corner (1) of pad in slot of caliper.

b. Push pad pin tab (2) into caliper until seated.

c. Verify that brake pad friction material (4) faces brake

disc gap in caliper.

d. Repeat step to install remaining brake pad.

e. Center pad pin tabs under forks of pad spring.

94000383 2-35
 f. See Figure 2-20 or Figure 2-21. Install new pad pin 6. Test brakes.
(5). Tighten to 75–102 in-lbs (8.5–11.5 N·m).
a. Apply brakes to check proper operation.
g. Install retaining clip (4) in groove of pad pin with lip
overhanging caliper housing. b. Check brake lamp operation.

h. Front caliper: Engage two prongs on screen NOTE

beneath forked end of pad spring. Push on single
Avoid making hard stops for the first 100 mi (160 km). This
prong side of screen until engaged.
allows the new pads to become conditioned to the brake discs.

3. Install brake caliper. c. Test ride motorcycle. Repeat the bleeding procedure
if brakes feel spongy. See BLEED BRAKES
a. Front caliper: Install cable clip/bracket (ABS models) (Page 3-62).
and caliper with bleeder at top.

sm04673a
b. Install two screws (2).
2
3
c. Front caliper: Tighten to 28–38 ft-lbs
(37.9–51.5 N·m).

d. Rear caliper: Tighten to 43–48 ft-lbs

(58.3–65.1 N·m).

Complete
1. Front caliper:

a. ABS models: Install WSS cable in clip. See WHEEL 4

SPEED SENSORS (Page 9-55). 5 1
b. Install new cable straps to secure fender tip lamp 1. Square corner
wires and WSS cable to left brake hose. 2. Pad pin tab
3. Pad pin hole
2. Rear caliper: 4. Friction material
5. Wear indicator grooves
a. ABS models: Install WSS cable to retainer clip on Figure 2-22. Brake Pad
brake hose.
sm04727a

b. Install right saddlebag. See SADDLEBAGS, Remove

(Page 3-98). 1 2

WARNING
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)

3. Operate brake several times to set brake pads to proper

operating position.

4. See Figure 2-23. Check fluid level in brake master cylinder

reservoir. 1. Front master cylinder reservoir full mark
2. Rear master cylinder reservoir full mark
5. Install master cylinder reservoir cover with screws. Tighten Figure 2-23. Brake Fluid Level
to 12–15 in-lbs (1.4–1.7 N·m).

WARNING
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)

2-36 94000383
DRIVE BELT AND SPROCKETS 2.15
GENERAL sm03283

WARNING 1
Never bend belt forward into a loop smaller than the drive 2
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.
1. Tooth
CLEANING 2. Groove
Figure 2-24. Rear Sprocket
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.
Drive Belt
See Figure 2-25 and Table 2-15. Inspect drive belt for:
INSPECT
• Cuts or unusual wear patterns.

Sprockets • Outside edge beveling (8). Some beveling is common, but

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 2-24. Inspect each tooth (1) of rear sprocket
for:
• major damage
• large chrome chips with sharp edges
• gouges
• excessive loss of chrome plating
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.
it indicates that sprockets are misaligned.
• Outside ribbed surface for signs of stone puncture (7). If
cracks or other 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.
NOTE
Condition 1 may develop into 2 or 3 over time. Condition 1 is
not grounds for replacing the belt, but it should be watched
closely before condition 2 develops which will require belt
replacement.

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

chrome exists.

94000383 2-37
 • As part of pre-ride inspection.
sm06897a
• At every scheduled service interval.
• With transmission in neutral.
• With motorcycle at ambient temperature.
1 2
• With motorcycle upright or on jiffy stand with rear wheel on
the ground.
• With the vehicle unladen: no rider, no luggage and empty
saddlebags.

3 4 WARNING
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before
proceeding. (00251b)

1. Disarm security system. Remove main fuse. See System

5 6 Fuses and Relays, Main Fuse (Page 9-6).
2. Shift transmission to neutral.
3. See Figure 2-26. Measure belt deflection using BELT
TENSION GAUGE (PART NUMBER: HD-35381-A):
a. Slide O-ring (4) to 0 lb (0 kg) mark (3).
7 8 b. Models equipped with belt deflection window: Fit
belt cradle (2) against bottom of drive belt in line with
belt deflection window.
Figure 2-25. Drive Belt Wear Patterns
c. All other models: Fit belt cradle (2) against bottom of
Table 2-15. Drive Belt Wear Analysis drive belt halfway between drive pulleys.
NO. * CONDITION REQUIRED ACTION d. Press upward on knob (6) until O-ring slides down to
10 lb (4.5 kg) mark (5) and hold steady.
1 Internal tooth cracks OK to run, but monitor condi-
(hairline) tion.
4. Measure belt deflection:
2 External tooth cracks Replace belt.
a. Models equipped with belt deflection window: See
3 Missing teeth Replace belt. Figure 2-28. Measure belt deflection as viewed through
4 Chipping OK to run, but monitor condi- belt deflection viewing window while holding gauge
(not serious) tion. steady. Each deflection graduation is approximately
1/16 in (1.59 mm).
5 Fuzzy edge cord OK to run, but monitor condi-
tion. b. All other models: See Figure 2-27. Measure amount
of deflection (4) while holding gauge steady.
6 Hook wear Replace belt and sprocket.
7 Stone damage Replace belt if damage is on 5. Compare with specifications. Adjust as necessary. Refer
the edge. to Table 2-16.
8 Bevel wear OK to run, but monitor condi- 6. Install main fuse.
(outboard edge only) tion.
* See
Figure 2-
25

CHECK DRIVE BELT DEFLECTION

PART NUMBER TOOL NAME

HD-35381-A BELT TENSION GAUGE

NOTE
Always use BELT TENSION GAUGE (PART NUMBER:
HD-35381-A) to measure belt deflection. Failure to use tension
gauge may cause under-tensioned belts. Loose belts can fail
due to "ratcheting" (jumping a tooth) which causes tensile cord
crimping and breakage.

Check deflection:

2-38 94000383
 sm02452 om00156

2
1

4 6
5
1
3
2

3
0 10

1. Transmission sprocket
1. Belt tension gauge 2. Rear wheel sprocket
2. Belt cradle 3. 10 lb (4.5 kg) of force
3. 0 lb (0 kg) mark 4. Amount of deflection
4. O-ring Figure 2-28. Checking Belt Deflection
5. 10 lb (4.5 kg) mark
6. Knob Table 2-16. Belt Deflection
Figure 2-26. Belt Tension Gauge MODEL IN MM

sm01441a
FLHX, FLHXS, FLTRX, FLTRXS
2 and FLHTKL * 1/4-7/16 6.4-11.1
(low profile shock absorbers)
All except FLHX, FLHXS, FLTRX,
FLTRXS and FLHTKL * 3/8-9/16 9.5-14.3
(standard shock absorbers)
* Includes model variations such as CVO

ADJUST BELT DEFLECTION

PART NUMBER TOOL NAME

HD-47925 AXLE NUT TORQUE ADAPTER

1 FASTENER TORQUE VALUE

Muffler to saddlebag support 14–18 ft-lbs 19–24.4 N·m
screws
1. Drive belt Rear axle cone nut, final 95–105 ft-lbs 128.8–142.4N·m
2. Deflection graduation torque
Figure 2-27. Belt Deflection Window Rear axle cone nut, first torque 15–20 ft-lbs 20–27 N·m

Prepare
1. Disarm security system. Remove main fuse. See System
Fuses and Relays, Main Fuse (Page 9-6).
2. Remove both saddlebags.
3. If AXLE NUT TORQUE ADAPTER (PART NUMBER:
HD-47925) is not available, remove both mufflers. See
EXHAUST SYSTEM (Page 5-26).

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

NOTE
Detaching the mufflers from the saddlebag frames will improve
access.

94000383 2-39
2. See Figure 2-29. Install AXLE NUT TORQUE ADAPTER
(PART NUMBER: HD-47925) perpendicular to breaker
bar. For best clearance with muffler, install torque adapter
on the outboard side.
NOTE
The torque wrench must be perpendicular to the torque adapter
to obtain proper torque.
NOTE
• It is beneficial to use a second AXLE NUT TORQUE
ADAPTER (PART NUMBER: 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.
• Check belt deflection as adjustment is made. See DRIVE
BELT AND SPROCKETS, Check Drive Belt Deflection
(Page 2-38).

3. Loosen cone nut. 7. See Figure 2-30. Adjust belt tension.

a. Rotate weld nut (3) on left side to adjust belt tension.
4. Install AXLE NUT TORQUE ADAPTER (PART NUMBER: Turn clockwise to tighten or counterclockwise to loosen.
HD-47925) on torque wrench, perpendicular to torque
wrench. b. If loosening the belt tension, push the wheel forward.
c. Verify both cams (5) touch the bosses (4) on both sides
5. See Figure 2-30. Push wheel forward. Verify that cam (5) after the weld nut is rotated.
contacts boss (4) on both sides of rear fork.
Assemble
6. Snug cone nut (6) to 15–20 ft-lbs (20–27 N·m).
NOTE
Do not allow the weld nut to rotate once belt tension is correct.
sm04528a

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

2
(128.8–142.4 N·m).

2. Again, verify the cams touch the bosses on both sides of

the rear fork and that belt deflection is still within
specification.

3. With the flat side out, install new E-clip in groove on right
side of axle.
1

Complete
1. If removed, install fasteners that attach mufflers to the
saddlebag frames and tighten to 14–18 ft-lbs
(19–24.4 N·m).

2. Install saddlebags.

3. Install main fuse. See System Fuses and Relays, Main

Fuse (Page 9-6).

1. Torque wrench
2. Axle nut torque adapter (HD-47925)
Figure 2-29. Install Tool Perpendicular to Torque Wrench

2-40 94000383
 sm07467a
6

1
4
4

2 5
5 3
7

1. Increase belt tension 5. Adjuster cam

2. Reduce belt tension 6. Cone nut
3. Weld nut 7. E-clip
4. Boss
Figure 2-30. Rear Wheel Adjuster Cams

94000383 2-41
REAR SPROCKET ISOLATOR 2.16
INSPECT
sm06800

1. Support the vehicle in an upright position in neutral. Do

not lift the wheels off the ground.
2. Remove left saddlebag.
1
3. See Figure 2-31. Hang a weighted string (1) on the left
axle spacer as close as possible to, but not touching, the
rear sprocket.
4. Place a piece of masking tape on the face of the sprocket 2
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.
6. While holding the sprocket in place, mark the masking
tape in line with the string.
7. Rotate the rear sprocket in the opposite direction until it 1. Weighted string
stops. 2. Measured distance
Figure 2-31. Check Compensator Wear
8. While holding the sprocket in place, make a second mark
in line with the string.
9. Measure the distance (2) along the edge of the sprocket
between the marks. If the measurement exceeds 0.400 in
(10.2 mm) replace the rubber isolator.
NOTE
Visually inspect components when disassembled. See REAR
WHEEL COMPENSATOR (Page 3-22) to repair the rear wheel
compensator.
• Excessive play in the compensator components is caused
by deteriorated 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.

2-42 94000383
CABLE AND CHASSIS LUBRICATION 2.17
CHASSIS LUBRICATION

Inspect and lubricate the following components according to

the maintenance schedule. Refer to Table 2-3.

• Front brake lever pivot

• Clutch control hand lever pivot
• Foot shift lever pivot
• Rear brake lever pivot
• Hinges and latches (such as fuel door and footrests)
• Locks, as required
• Jiffy stand (use ANTI-SEIZE LUBRICANT)

Use HARLEY LUBE unless otherwise specified.

If motorcycle is operated on muddy or dusty roads, clean and

lubricate more frequently.

94000383 2-43
SPARK PLUGS 2.18
PREPARE Table 2-17. Spark Plug Deposit Analysis

1. Remove main fuse. See System Fuses and Relays PLUG DEPOSITS POSSIBLE CAUSE
(Page 9-6). 1 Wet, black and shiny Worn pistons
NOTE Worn piston rings
Worn valves
Fuel tank removal improves access to the right spark plugs.
Worn valve guides
Worn valve seals
2. Remove fuel tank. See FUEL TANK (Page 5-6). Weak battery
REMOVE Faulty ignition system
2 Dry, fluffy or sooty Air-fuel mixture too rich
WARNING and black
3 Light brown and Air-fuel mixture too lean
Disconnecting spark plug cable with engine running can
glassy* Hot running engine
result in electric shock and death or serious injury.
May be accompanied Valves not seating
(00464b)
by cracks in the insu- Improper ignition timing
NOTE lator or by electrode
• Never remove spark plugs until heads have cooled. erosion.

• Use HD-52006 (Adjustable Spark Plug Wire Puller) to 4 White, gray or tan Balanced combustion
remove stubborn spark plug boots. and powdery Clean off deposits at regular
intervals.
1. Disconnect spark plug cables. * The glassy deposit on a spark plug may cause high-speed
2. Remove spark plugs. misfiring.

INSPECT CLEAN
NOTE WARNING
Discard plugs with eroded electrodes, heavy deposits or a
cracked insulator. 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
See Figure 2-32. Compare plug deposits to Table 2-17.
use your hand to check for air leaks or to determine air
flow rates. (00061a)
sm00099a

1 2 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. Use a

penetrating oil and clean out with a thread chaser. Verify
3 4 that plug threads are clean.
4. If necessary, replace with new spark plugs.
INSTALL

FASTENER TORQUE VALUE

Spark plug 89–133 in-lbs 10–15 N·m

1. Verify proper gap before installing new or cleaned spark

plugs.
Figure 2-32. Spark Plug Deposits
a. Select a wire-type feeler gauge within specification.
Refer to Table 2-18.
b. Pass the wire gauge between the electrodes.

2-44 94000383
 c. Use the proper tool to bend the outer electrode to bring
the gap to within specification.

2. Install spark plug.

a. Apply ANTI-SEIZE LUBRICANT to threads.
b. Tighten to specification. Refer to Table 2-18.

3. See Figure 2-33. Connect spark plug cables. Check

connections at coil, spark plugs and anchor clips or
harness caddies.

Table 2-18. Spark Plug

MODELS TYPE GAP TORQUE
All Models HD-6R10 0.031 –0.035 in 89–133 in-lbs
(0.8–0.9 mm) (10–15 N·m)

sm08658

1
3

2 4
1. Left rear
2. Right rear
3. Left front
4. Right front
Figure 2-33. Spark Plug Cables
COMPLETE

1. Install fuel tank. See FUEL TANK (Page 5-6).

2. Install main fuse. See System Fuses and Relays
(Page 9-6).

94000383 2-45
STEERING HEAD BEARINGS
CHECK AND ADJUST SWING-BACK
FASTENER TORQUE VALUE
Upper steering stem pinch 22–26 ft-lbs 29.8–35.2 N·m
screw
WARNING
Properly adjust fork stem bearings. Improper adjustments
can adversely affect stability and handling, which could
result in death or serious injury. (00301c)
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)
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.
• This procedure is for 2-wheel vehicles only. Trike does not
require this check due to the use of a steering damper.
Measure Swing-Back
2.19
9. Place a stationary pointer with the tip near the cardboard.
With the front wheel straight forward, center the pointer
on the cardboard.
NOTE
To avoid confusion, use three different colors to make the
following marks.
10. See Figure 2-34. Lightly tap the front tire to the left until it
just begins to swing back toward center. Using the first
color, mark the point (1) where it began to swing back.
11. Repeat by lightly tapping the front tire to the right. Using
the first color, mark the point (1) where it began to swing
back.
12. Repeat two more times in each direction to validate marks.
13. Measure outboard 1 in (25.4 mm) from each mark (1).
Using the second color, mark these points (2).
14. Turn the front end until the pointer is at the left mark (2)
and release. Using the third color, mark where the swing
stops (3).
15. Turn the front end until the pointer is at the right mark (2)
and release. Using the third color, mark where the swing
stops (3).
NOTE
Marks (3) must fall between marks (1) and (2). If marks (3) are
between marks (1), steering is too loose. Proceed to Adjusting
Swing-Back later in this section.

1. Vehicle must be in original equipment configuration.
Remove all accessory weight, such as a windshield bag
and contents or handlebar-mounted navigation unit. These
items can influence the way the front fork swings.
2. Models with cable clutch: Disconnect clutch cable from
hand control. Secure out of the way.
3. Models with hydraulic clutch: Leave fully assembled.
NOTE
Lower frame rails MUST be level in both directions for a valid
check.
16. Repeat two more times to validate final swing-back marks
in each direction.
17. Measure the distance (4) between final swing-back marks
(3). The readings must be within the values specified in
Table 2-19.
18. A measurement greater than specification indicates that
the steering stem is too tight. A measurement less than
specification indicates that the steering stem is too loose.
To adjust, see Adjusting Swing-Back below.

4. Lift entire vehicle until tires are off the ground. Place a
block under the rear tire. Gently lower vehicle until tire
contacts block.
5. Using a level, verify that the lower frame rails are level
front to rear and left to right.
6. Swing the front end from stop-to-stop to check for smooth
movement.
7. Verify that there is no clunk:
a. Grasp both forks near the front axle.
b. Shake forks front to rear checking for a clunk. A clunk
indicates loose fork stem. If clunk is heard, disassemble
steering head and inspect before proceeding. See
STEERING HEAD BEARINGS, Inspect and Lubricate
(Page 2-48).

8. Tape a lightweight piece of cardboard 8 –10 in (20–25 cm)

wide centered and even with fender tip.

2-46 94000383
 c. Frame-mounted fairing models: Remove
sm08057
3 2 instrument nacelle. See INSTRUMENT NACELLE:
2 3 1
FRAME MOUNTED FAIRING MODELS (Page 3-126).

NOTE
Protect front fender from damage.

2. See Figure 2-35. Loosen upper steering stem pinch screw

(1).

3. Adjust steering stem:

a. Engage a 1/4 inch drive extension (3) six inches long

into the bottom of upper steering stem (2).
4 3
3
b. Based on swing-back dimension, tighten (4) (to
increase dimension) or loosen (5) (to decrease
dimension) the upper steering stem a few degrees.

NOTE
It is important that all original mass be in place to accurately
measure swing-back.

c. Tighten steering stem pinch screw to 22–26 ft-lbs

(29.8–35.2 N·m).

1. Initial swing-back marks 4. Temporarily install all removed original equipment

2. Measure out 1 in (25.4 mm) components. Do not tighten fasteners.
3. Final swing-back marks
4. Final dimension 5. Check swing-back. Repeat until swing-back is within
Figure 2-34. Marking and Measuring Swing Points specification.

Table 2-19. Steering Swing-Back 6. Assemble motorcycle:

MODEL SPECIFICATION
a. Road King models: Install headlamp. See
Fairing models: fork 1.7 –2.6 in (4.3–6.6 cm)
HEADLAMP (Page 9-16).
mounted
Fairing models: FLTRU 2.7 –3.3 in (6.9–8.4 cm) b. Fork-mounted fairing models: Install outer fairing.
Fairing models: FLTRX, 5.2 –5.7 in (13.2–14.5 cm) See OUTER FAIRING AND WINDSHIELD: FORK
FLTRXS MOUNTED FAIRING MODELS (Page 3-115).

Road King 3.4 –4.8 in (8.6–12.2 cm) c. Frame-mounted fairing models: Install instrument
Trike N/A nacelle. See INSTRUMENT NACELLE: FRAME
MOUNTED FAIRING MODELS (Page 3-126).
Adjust Swing-Back
7. Install any accessories removed earlier.
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.
• This procedure is for 2-wheel vehicles only. Trike does not
require this check due to the use of a steering damper.

1. Disassemble motorcycle:

a. Road King models: Remove headlamp. See

HEADLAMP (Page 9-16).

b. Fork-mounted fairing models: Remove outer

fairing. See OUTER FAIRING AND WINDSHIELD:
FORK MOUNTED FAIRING MODELS (Page 3-115).

94000383 2-47
 3. Remove upper fork bracket and handlebar as an assembly.
sm08063
Support out of the way. See STEERING HEAD
BEARINGS, Upper Fork Bracket (Page 3-71).
1
4. Remove upper steering stem. See STEERING HEAD
BEARINGS (Page 3-70).

2 NOTE
Remove grease with a clean cloth or finger. Do not use solvent.

3 5. Raise motorcycle until lower stem bearing has exited far

enough to clean grease from bearing cup and cone.

4 6. Wipe grease from upper and lower bearing cups and

cones. Inspect parts for wear or damage.

7. Pack bearings with SPECIAL PURPOSE GREASE.

5
8. Lower motorcycle until lower bearing just seats. Do not
1. Upper steering stem pinch screw place entire weight of vehicle on bearing.
2. Upper steering stem
3. 1/4 in drive extension 9. Apply SPECIAL PURPOSE GREASE to the threads of the
4. Tighten upper and lower steering stems.
5. Loosen
Figure 2-35. Adjust Steering Stem Bearings 10. Install upper steering stem. Tighten to 35 ft-lbs (47.5 N·m).
INSPECT AND LUBRICATE
11. Lower vehicle until forks begin to compress.

FASTENER TORQUE VALUE

12. Loosen upper steering stem 90-100 degrees. Tighten to
Upper steering stem, final 63 in-lbs 7.1 N·m specification. Refer to Table 2-20.
torque: Fork mounted fairing
models
13. Install upper fork bracket and handlebar. Assemble
Upper steering stem, final 192 in-lbs 21.7 N·m motorcycle. See STEERING HEAD BEARINGS
torque: Frame mounted fairing (Page 3-70).
models
Upper steering stem, final 108 in-lbs 12.2 N·m 14. Check swing-back. See STEERING HEAD BEARINGS,
torque: Road King models Check and Adjust Swing-Back (Page 2-46).
Upper steering stem, final 108 in-lbs 12.2 N·m
torque: Trike models Table 2-20. Steering Stem Torque
Upper steering stem, first 35 ft-lbs 47.5 N·m
torque MODEL TORQUE
Fairing models: fork 63 in-lbs (7.1 N·m)
1. Disassemble motorcycle: mounted
Fairing models: frame 192 in-lbs (21.7 N·m)
a. Road King models: Remove headlamp nacelle. mounted
See HEADLAMP NACELLE: ROAD KING MODELS
(Page 3-144). Road King 108 in-lbs (12.2 N·m)
Trike 108 in-lbs (12.2 N·m)
b. Fork-mounted fairing models: Remove inner
fairing. See INNER FAIRING: FORK MOUNTED
FAIRING MODELS, Remove and Install Inner Fairing
Assembly (Page 3-118).

c. Frame-mounted fairing models: Remove the

instrument nacelle. See INSTRUMENT NACELLE:
FRAME MOUNTED FAIRING MODELS (Page 3-126).

2. Raise front end until tire is just touching surface.

NOTE
The upper fork bracket acts as a fork stop. Place wooden block
between lower fork bracket and frame to avoid damage.

2-48 94000383
REAR SUSPENSION ADJUSTMENTS 2.20
MANUAL SUSPENSION PRELOAD om01417

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

• Increase the preload to accommodate more weight.

• Reduce the preload if carrying less weight.
1. Remove the left saddlebag.
NOTE
A preload table wallet card is provided at the back of the
owner's manual for convenience.

2. See Figure 2-36. Rotate the knob to the desired setting

for the expected load. The knob will click after each half
turn. Refer to Table 2-21, Table 2-22 or Table 2-23.
3. Turn the knob half turns to fine tune the ride if desired.
4. Install the left saddlebag.

Figure 2-36. Preload Adjustment Knob

Table 2-21. Suspension Preload Table: Standard Length Shocks, with Tour-Pak
ADDITIONAL WEIGHT OF PASSENGER, CARGO AND ACCESSORIES
LB 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180
KG 0 5 9 14 18 23 27 32 36 41 45 50 54 59 64 68 73 77 82
RIDER WEIGHT
LB KG Full Turns of Knob
150 68 0 0 0 1 2 3 4 5 6 6 7 8 9 10 11 12 13 14 15
160 73 0 0 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 15
170 77 0 0 1 2 3 4 5 6 7 8 9 10 10 11 12 13 14 15 16
180 82 0 1 2 3 4 4 5 6 7 8 9 10 11 12 13 14 15 16 17
190 86 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 14 15 16 17
200 91 1 2 3 4 5 6 7 8 9 9 10 11 12 13 14 15 16 17 18
210 95 2 3 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 18
220 100 2 3 4 5 6 7 8 9 10 11 12 13 13 14 15 16 17 18 19
230 104 3 4 5 6 7 7 8 9 10 11 12 13 14 15 16 17 18 19 20
240 109 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 17 18 19 20
250 113 4 5 6 7 8 9 10 11 12 12 13 14 15 16 17 18 19 20 21
260 118 5 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 20 21
270 123 5 6 7 8 9 10 11 12 13 14 15 16 16 17 18 19 20 21 22

Table 2-22. Suspension Preload Table: Standard Length Shocks, without Tour-Pak
ADDITIONAL WEIGHT OF PASSENGER, CARGO AND ACCESSORIES
LB 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180
KG 0 5 9 14 18 23 27 32 36 41 45 50 54 59 64 68 73 77 82
RIDER WEIGHT
LB KG Full Turns of Knob

94000383 2-49
 Table 2-22. Suspension Preload Table: Standard Length Shocks, without Tour-Pak
ADDITIONAL WEIGHT OF PASSENGER, CARGO AND ACCESSORIES
150 68 0 0 0 2 3 5 7 8 10 12 13 15 17 18 20 22 23 -
160 73 0 0 1 3 4 6 8 9 11 13 14 16 18 19 21 23 -
170 77 0 0 2 4 6 7 9 10 12 14 15 17 19 20 22 23 -
180 82 0 1 3 5 7 8 10 11 13 15 16 18 20 21 23 -
190 86 1 3 4 6 8 9 11 13 14 16 17 19 21 22 23 -
200 91 2 4 5 7 9 10 12 14 15 17 18 20 22 23 -
210 95 3 5 6 8 10 11 13 15 16 18 19 21 23 -
220 100 4 6 7 9 11 12 14 16 17 19 21 22 23 -
230 104 5 7 8 10 12 14 15 17 18 20 22 23 -
240 109 6 8 9 11 13 15 16 18 19 21 23 -
250 113 7 9 10 12 14 16 17 19 20 22 23 -
260 118 8 10 11 13 15 17 18 20 22 23 -
270 122 9 11 13 14 16 18 19 21 23 -

Table 2-23. Suspension Preload Table: Low Length Shocks, with or without Tour-Pak
ADDITIONAL WEIGHT OF PASSENGER, CARGO AND ACCESSORIES
LB 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180
KG 0 5 9 14 18 23 27 32 36 41 45 50 54 59 64 68 73 77 82
RIDER WEIGHT
LB KG Full Turns of Knob
150 68 0 0 0 1 2 3 4 6 7 8 9 10 11 13 14 15 16 17 18
160 73 0 0 0 2 3 4 5 6 7 9 10 11 12 13 14 16 17 18 19
170 77 0 0 1 2 3 5 6 7 8 9 10 12 13 14 15 16 18 19 20
180 82 0 1 2 3 4 5 7 8 9 10 11 12 14 15 16 17 18 19 21
190 86 0 1 3 4 5 6 7 9 10 11 12 13 14 16 17 18 19 20 21
200 91 1 2 3 5 6 7 8 9 10 12 13 14 15 16 17 19 20 21 22
210 95 2 3 4 5 7 8 9 10 11 12 14 15 16 17 18 19 21 22 23
220 100 3 4 5 6 7 8 10 11 12 13 14 16 17 18 19 20 21 23 -
230 104 3 4 6 7 8 9 10 12 13 14 15 16 17 19 20 21 22 23 -
240 109 4 5 6 8 9 10 11 12 13 15 16 17 18 19 21 22 23 -
250 113 5 6 7 8 10 11 12 13 14 15 17 18 19 20 21 22 23 -
260 118 6 7 8 9 10 11 13 14 15 16 17 19 20 21 22 23 -
270 122 6 8 9 10 11 12 13 15 16 17 18 19 20 22 23 -

2-50 94000383
BATTERY MAINTENANCE
GENERAL
WARNING
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)
2.21
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 Battery Maintenance, Charging
Battery (Page 2-54). See the electrical diagnostic manual for
information about testing and troubleshooting this part.
om01163

WARNING
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)

WARNING
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)

NOTICE

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)

Figure 2-37. Battery Warning Label

AGM batteries are permanently sealed, maintenance-free,
valve-regulated, lead/calcium and sulfuric acid batteries. The

sm02241

1 2 3 4 5 6

1. Contents are corrosive 4. Keep flames away

2. Wear safety glasses 5. Read instructions
3. Contents are explosive 6. Keep away from children
Figure 2-38. Battery Warning Label

94000383 2-51
 Table 2-24. Antidotes for Battery Acid 9. Models with security system: Disarm security system.
See SECURITY SIREN, Removal (Page 9-103).
CONTACT TREATMENT
External Flush with water. WARNING
Internal Drink large quantities of milk or water, followed
Disconnect negative (-) battery cable first. If positive (+)
by milk of magnesia, vegetable oil or beaten
cable should contact ground with negative (-) cable
eggs. Get immediate medical attention.
connected, the resulting sparks can cause a battery
Eyes Flush with water. Get immediate medical atten- explosion, which could result in death or serious injury.
tion. (00049a)

CLEAN AND INSPECT 10. See Figure 2-40. Disconnect both battery cables, negative
battery cable first.
NOTE
Battery top must be clean and dry. Dirt and electrolyte on top 11. Pull up battery strap to raise battery. When battery is
of the battery causes self-discharge. extracted far enough to get a good grip, grasp battery and
remove completely.
1. Clean battery top.
a. Mix a solution of five teaspoons of baking soda (sodium Installation and Connection
bicarbonate) per liter or quart of water.
1. Run battery strap rearward across the bottom of the battery
b. Apply to battery top. tray, then up and across the frame crossmember.

2. When the solution stops bubbling, rinse off battery with
clean water.
3. Clean cable connectors and battery terminals with a wire
brush or sandpaper. Remove any oxidation.
4. Inspect the battery terminal screws and cables for
breakage, loose connections and corrosion.
5. Check the battery terminals for melting or damage.
6. Inspect the battery for discoloration, raised top or a warped
or distorted case. Replace as necessary.
7. Inspect the battery case for cracks or leaks.
BATTERY
2. See Figure 2-40. Place the battery into the battery tray,
terminal side forward.
WARNING
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)
NOTICE
Connect the cables to the correct battery terminals. Failure
to do so could result in damage to the motorcycle electrical
system. (00215a)

FASTENER TORQUE VALUE NOTICE

Battery terminal bolt
Top caddy screws
Disconnection and Removal
60–70 in-lbs 6.8–7.9 N·m
72–96 in-lbs 8.1–10.9 N·m
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)

1. Remove seat.
3. Connect both battery cables, positive battery cable first.
Tighten to 60–70 in-lbs (6.8–7.9 N·m).
2. See Figure 2-39. Release ECM (1) from top caddy. Move
out of the way.
NOTICE
3. If present, move purge solenoid (2) forward to release from Keep battery clean and lightly coat terminals with
top caddy. petroleum jelly to prevent corrosion. Failure to do so could
result in damage to battery terminals. (00217a)
4. Models with security system: Release HFSM antenna
(3) from top caddy and move out of the way. 4. Apply a light coat of petroleum jelly or ELECTRICAL
CONTACT LUBRICANT to both battery terminals.
5. Release connectors (7) from anchors on top caddy.
5. Fold battery strap forward over top of battery.
6. Remove fasteners (5).
6. See Figure 2-39. Place top caddy into position and engage
7. Cut cable straps (4). Move harnesses to allow more latch on hold-down bracket.
clearance for the top caddy.
7. Fasten top caddy to frame crossmember with fasteners
8. Push top caddy forward to disengage front of caddy from (5). Tighten to 72–96 in-lbs (8.1–10.9 N·m).
front hold-down bracket. Remove top caddy.

2-52 94000383
8. Engage HFSM antenna (3) and purge solenoid (2) on top
caddy. Verify that all other connectors and harnesses are
routed below the purge solenoid mounting tongue.
9. Secure connectors (7) to anchors on top caddy.
VOLTAGE TEST
The voltage test provides a general indicator of battery
condition. Check the voltage of the battery to verify that it is
fully charged. Refer to Table 2-25.

10. Latch ECM (1) into place on top caddy. 1. If the open circuit (disconnected) voltage reading is below
12.6 V:
11. Secure harnesses to frame with cable straps (4). a. Charge the battery.
b. Check the voltage after the battery has set for at least
12. Install seat. After installing seat, pull up on the seat to be one hour.
sure it is secure.
2. If the voltage reading is 12.7 V or above:
sm07543a a. Perform a battery diagnostic test. See the electrical
diagnostic manual for the load test procedure.

Table 2-25. Voltage Test For Battery Charge Conditions

2
VOLTAGE (VDC) STATE OF CHARGE
12.7 VDC 100%
1
6 12.6 VDC 75%
5
12.3 VDC 50%
12.0 VDC 25%

3 11.8 VDC 0%
7
BATTERY TENDER CONNECTOR
4
All Touring models are conveniently equipped with a battery
1. ECM tender connector located under the left side cover. Use any
2. Purge solenoid battery tender available from the Harley-Davidson Genuine
3. HFSM antenna Motor Parts & Accessories catalog.
4. Cable straps
5. Screws (2) See Figure 2-41. To eliminate the need to remove the side
6. Hold-down (not visible) cover each time the tender is connected, route the harness
7. Connectors (2) through the slot (2). Secure the connector to either the
saddlebag guard or passenger footrest to prevent entanglement
Figure 2-39. Top Caddy
in the belt or rear wheel. Apply ELECTRICAL CONTACT
om01435b
LUBRICANT to the terminals and keep the connector capped
to prevent moisture damage when not in use.

om01780b

2
1

2
1. Lifting strap
2. Positive terminal 1. Battery tender connector
3. Negative terminal 2. Route connector through slot
Figure 2-40. Battery Compartment Figure 2-41. Battery Tender Connector (under left side
cover)

94000383 2-53
CHARGING BATTERY
Safety Precautions
An automatic, constant monitoring battery charger/tender with
a charging rate of 5 amps maximum at no more 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 causes dry-out and premature battery failure.
Always review charger instructions before charging a 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 off the charger 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. 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.
WARNING
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)
NOTICE
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.
WARNING
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)
2-54
NOTICE
Do not reverse the charger connections described in the
following steps or the charging system of the motorcycle
could be damaged. (00214a)
NOTE
• 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 check if it is unusually warm.
This is an indication that the battery has 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.
NOTE
If the battery is still in the vehicle, connect the battery charger
to the battery tender connector. Verify that the ignition and all
electrical accessories are turned off.
2. Connect red battery charger lead to the positive terminal
and black battery charger lead to the negative terminal of
the battery.
3. Step away from the battery and turn on the charger.
WARNING
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 from the
negative terminal of the battery.
5. Disconnect the red battery charger lead from 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
WARNING
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)
94000383
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
Harley-Davidson Parts and Accessories catalog.

If the motorcycle is stored with the battery installed, without a

Harley-Davidson constant monitoring battery charger/tender,
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 2-42. 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 a Harley-Davidson constant monitoring battery
charger/tender to maintain battery charge for extended periods
of time without risk of overcharging or boiling.

sm02838

1 77 °F (25 °C)
105 °F (40.5 °C)
100%

75%
¡

¡
50%

2 0 3 6 9 12 15

1. Capacity
2. Months of non-use
Figure 2-42. Battery Self-Discharge Rate

94000383 2-55
HEADLAMP ALIGNMENT 2.22
CHECK HEADLAMP ALIGNMENT sm05861

1. Check tire pressure.

2. Adjust rear shocks for the rider and intended load. 5 2
3. Fill fuel tank or add an equal amount of ballast.
NOTE
Choose a wall in minimum light.

4. See Figure 2-43. Park the motorcycle on a line (1)

perpendicular to the wall. 1 4
3
5. Position motorcycle with the front axle 25 ft (7.6 m) from
wall.
6. Draw a vertical centerline (2) on the wall aligned with line
(1). 1. Perpendicular line
2. Vertical line
NOTE 3. 25 ft (7.6 m)
The upper lens is low beam on LED headlamps. 4. High beam bulb centerline
5. Horizontal line 2.1 in (53.3 mm) lower than high
7. With the motorcycle loaded, point the front wheel straight beam centerline
forward at wall. Measure the distance (4) from the floor to Figure 2-43. Headlamp Alignment: Quartz Halogen Type
the bulb centerline:
sm05861a
a. Quartz halogen: Center of high beam bulb.
b. LED, fork-mounted fairing: Center of low beam bulb.
c. LED, frame-mounted fairing: Center of headlamp 5 2
face.

8. Draw a horizontal line (5) through the vertical line:

a. Quartz halogen: See Figure 2-43. 2.1 in (53.3 mm)
lower than the measured distance.
b. LED, fork-mounted fairing: See Figure 2-44. At the 1 4
measured distance. 3
c. LED, frame-mounted fairing: See Figure 2-43. 2.1 in
(53.3 mm) lower than the measured distance. 1. Perpendicular line
2. Vertical line
9. The headlamp is aligned when the light beam hot spot is 3. 25 ft (7.6 m)
located as shown. 4. Low beam bulb centerline
5. Horizontal line
a. Quartz halogen: See Figure 2-47. Hot spot centered
on mark with headlamp set to high beam. Figure 2-44. Headlamp Alignment: LED Type (typical)

b. LED, fork-mounted fairing: See Figure 2-48. Top of ADJUST HEADLAMP

hot spot at mark with headlamp set to low beam.
NOTE
c. LED, frame-mounted fairing: See Figure 2-49. Center
Do not remove trim ring for headlamp adjustment.
of hot spot at mark with headlamp set to high beam.

1. Set headlamp beam:

a. Quartz halogen: Set headlamp to high beam.
b. LED, fork-mounted fairing: Set headlamp to low
beam.
c. LED, frame-mounted fairing: Set headlamp to high
beam.

2. All except frame-mounted fairing: See Figure 2-45.

Insert a 5/32 in ball end hex wrench through adjuster slots
in trim ring.
a. Horizontal: Turn the horizontal adjusting screw (1) to
adjust light beam left and right.

2-56 94000383
 b. Vertical: Turn the vertical adjusting screw (2) to adjust ADJUST AUXILIARY/FOG LAMPS
light beam up and down.
c. See Figure 2-47 or Figure 2-48. Adjust headlamp light PART NUMBER TOOL NAME
beam. FRX181 FLARE NUT SOCKET

NOTE FASTENER TORQUE VALUE

• Frame-mounted fairing models allow only vertical Auxiliary/fog lamp flange nut: 20–24 ft-lbs 27.1–32.5 N·m
adjustment. Models with bullet style turn
• Any of three tools can be used: 9 mm socket, 6 mm hex or signal lamps
T15 Torx. Auxiliary/fog lamp flange nut: 15–18 ft-lbs 20.3–24.4 N·m
Models with flat lens turn
3. Frame-mounted fairing models: See Figure 2-46. signal lamps
Turn signal lamp to 96–120 in-lbs 10.9–13.5 N·m
a. Turn the adjuster to adjust light beam up and down.
auxiliary/fog lamp bracket
b. See Figure 2-49. Adjust headlamp light beam. screw: Bullet style turn signal
lamps
om01372 Turn signal lamp to 36–60 in-lbs 4.1–6.8 N·m
auxiliary/fog lamp bracket
2 screws: Flat lens turn signal
lamps

NOTE
Have a person weighing roughly the same as the principal rider
sit on the motorcycle.

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

1 Headlamp Alignment, Check Headlamp Alignment
(Page 2-56).

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

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

3. Measure the horizontal distance from the headlamp vertical

1. Horizontal adjuster centerline to the vertical centerline of each auxiliary/fog
2. Vertical adjuster lamp.
Figure 2-45. Headlamp Adjusters: All except Frame-
Mounted Fairing (typical) 4. See Figure 2-47 or Figure 2-48. Mark the auxiliary/fog
lamp horizontal and vertical centerlines (2, 3) on the wall.
om01995

5. Remove the turn signal lamp from the mounting bracket.

6. Using FLARE NUT SOCKET (PART NUMBER: FRX181),

loosen the auxiliary/fog lamp flange nut only enough to
allow movement of the lamp.

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

headlamp and the right auxiliary/fog lamp.

a. Quartz halogen: 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 2-47.

b. LED: Adjust the left auxiliary/fog lamp so the entire

high intensity zone (4) is below the centerline as
shown in Figure 2-48.

8. Repeat procedure with right lamp.

Figure 2-46. Headlamp Adjuster: FLTRU, FLTRX, FLTRXS

94000383 2-57
9. Tighten auxiliary/fog lamp nut: 10. Install turn signal:

a. Models with flat lens turn signal lamps: a. Models with flat lens turn signal lamps: Start two
15–18 ft-lbs (20.3–24.4 N·m). screws to secure turn signal lamp to mounting
bracket. Verify that conduit fits in slot at back of
b. Models with bullet style turn signal lamps: bracket and is not pinched. Tighten to 36–60 in-lbs
20–24 ft-lbs (27.1–32.5 N·m). (4.1–6.8 N·m).

b. Models with bullet style turn signal lamps: Secure

turn signal lamp to mounting bracket. Tighten to
96–120 in-lbs (10.9–13.5 N·m).

sm03622

1
3
2

4 5

1. Headlamp high beam area 4. Left auxiliary/fog high intensity beam area
2. Left auxiliary/fog lamp centerlines 5. Right auxiliary/fog high intensity beam area
3. Right auxiliary/fog lamp centerlines
Figure 2-47. Properly Aim Lamps: Quartz Halogen Type

sm07763
1
2 3

4 5

6
1. Headlamp centerline
2. Left auxiliary/fog lamp centerline
3. Right auxiliary/fog lamp centerline
4. Left auxiliary/fog lamp beam area
5. Right auxiliary/fog lamp beam area
6. Headlamp low beam area
Figure 2-48. Headlamp Pattern: LED Type with Auxili-
ary/Fog Lamps

sm08391
2

1. Headlamp centerline minus 2.1 in (53.3 mm)

2. Headlamp high beam area
Figure 2-49. Headlamp Pattern: Frame-Mounted Fairing
Models

2-58 94000383
STORAGE
GENERAL
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.
PLACE IN STORAGE
WARNING
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)
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)
1. Fill fuel tank. Add a gasoline stabilizer 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. Run engine to circulate fresh oil.
3. Remove and inspect the spark plugs. Replace if necessary.
Inject a few squirts of engine oil into each cylinder and
crank the engine 5-6 revolutions. Install spark plugs.
4. Adjust drive belt deflection. See DRIVE BELT AND
SPROCKETS (Page 2-37).
5. Inspect drive belt and sprockets.
6. Inspect and clean the air cleaner filter. See AIR CLEANER
ELEMENT (Page 2-17).
7. Lubricate controls. See CABLE AND CHASSIS
LUBRICATION (Page 2-43).
8. Verify that freeze point of engine coolant is below the
lowest expected temperature during storage.
9. Inspect operation of all electrical equipment and switches.
10. Check tire inflation and inspect tires for wear and/or
damage. If the motorcycle is stored for an extended period,
lift and securely support the motorcycle so that all weight
is off the tires. See TIRES AND WHEELS (Page 2-23).
94000383
2.23
11. Wash painted and chrome-plated surfaces. Apply a light
film of oil to exposed unpainted surfaces.
WARNING
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)
WARNING
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)
12. The battery can be maintained while removed or installed:
a. Removed: 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 Battery
Maintenance (Page 2-51).
b. Installed: Connect a Harley-Davidson battery tender.
WARNING
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)
13. Only cover motorcycle with a breathable material 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.
REMOVE FROM STORAGE
WARNING
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. Fill fuel tank.
3. Verify that engine coolant is at the proper level.
4. Run motorcycle until engine is at normal operating
temperature.
5. Check engine oil level.
6. Check the transmission lubricant level.
7. Perform all of the checks in the PRE-RIDING CHECKLIST
in the owner's manual.
2-59
TROUBLESHOOTING 2.24
GENERAL 7. Ignition timing incorrect due to faulty ignition coil, ECM or
sensors.
WARNING 8. Bank Angle Sensor tripped and ignition switch not cycled
OFF then back to IGNITION.
The Troubleshooting section of this manual is a guide to
diagnose problems. Read the appropriate sections of this 9. Fuel filter clogged.
manual before performing any work. Improper repair and/or 10. Sticking or damaged valve(s) or wrong length pushrod(s).
maintenance could result in death or serious injury.
(00528b) 11. Plugged fuel injectors.

Use the symptoms listed for general troubleshooting. More Starts Hard
than one condition may be present at a time. Check all possible 1. Spark plugs in bad condition or have improper gap or are
items to keep motorcycle in good operating condition. partially fouled.

NOTE 2. Spark plug cables in poor condition.

• See the electrical diagnostic manual for additional 3. Battery nearly discharged.
information.
4. Damaged wire or loose wire connection at ignition coil,
• See TESTING AND DIAGNOSTICS, Troubleshooting battery or ECM connector.
(Page 6-4) for additional cooling system troubleshooting.
5. Water or dirt in fuel system.
ENGINE
6. Intake air leak.
7. Fuel tank vent hose, filler cap vent or vapor valve plugged,
Starter Motor Does Not Operate or Does Not or fuel line closed off, restricting fuel flow.
Turn Engine Over
8. Engine lubricant too heavy (winter operation).
1. Ignition switch not in IGNITION position.
NOTE
2. Engine run switch in OFF position.
For cold-weather starts, always disengage clutch.
3. Discharged battery, loose or corroded connections
(solenoid chatters). 9. Ignition not functioning properly (possible sensor failure).
4. Starter control circuit, relay or solenoid faulty. 10. Faulty ignition coil.
5. Electric starter shaft pinion gear not engaging or 11. Valves sticking.
overrunning clutch slipping.
12. Partially plugged fuel injector(s).
6. TSM/TSSM/HFSM Bank Angle Sensor tripped and
ignition/light key switch not cycled OFF then back to Starts But Runs Irregularly or Misses
IGNITION.
1. Spark plugs in poor condition or partially fouled.
7. Security system activated.
2. Spark plug cables in poor condition and shorting or leaking.
8. Motorcycle in gear and clutch not pulled in.
3. Spark plug gap too close or too wide.
9. Jiffy stand down and transmission in gear (HDI models
only). 4. Faulty ignition coil, ECM or sensor.

10. Main fuse not in place. 5. Battery nearly discharged.

6. Damaged wire or loose wire connection at ignition coil,
Engine Turns Over But Does Not Start battery or ECM connector.
1. Fuel tank empty. 7. Intermittent short circuit due to damaged wire insulation.
2. Fouled spark plugs. 8. Water or dirt in fuel system.
3. Discharged battery, loose or damaged battery terminal 9. Fuel tank vent system plugged.
connections.
10. Air leak at intake manifold or air cleaner.
4. Engine lubricant too heavy (winter operation).
11. Loose or dirty ECM connector.
NOTE
12. Faulty Sensor(s): Temperature Manifold Absolute Pressure
For cold-weather starts, always disengage clutch.
(TMAP), Crank Position (CKP) or Oxygen (O2).
5. Spark plug cables in bad condition and shorting, cable 13. Incorrect valve timing.
connections loose or cables connected to incorrect 14. Weak or damaged valve springs.
cylinders.
15. Damaged intake or exhaust valve.
6. Damaged wire or loose wire connection at ignition coil,
battery or ECM connector. 16. Partially plugged fuel injector(s).

2-60 94000383
A Spark Plug Fouls Repeatedly Excessive Vibration
1. Fuel mixture too rich. 1. Wheels bent or damaged and/or tires worn or damaged.
2. Incorrect spark plug for the kind of service. 2. Engine/Transmission/Rear Wheel not aligned properly.
3. Piston rings badly worn or damaged. 3. Primary chain badly worn or links tight as a result of
insufficient lubrication or misalignment.
4. Valve guides or seals badly worn.
4. Engine to transmission mounting bolts loose.
Pre-Ignition or Detonation (Knocks or Pings) 5. Upper engine mounting bracket loose/damaged or
1. Fuel octane rating too low. mounting bracket pre-loaded.
2. Faulty spark plugs. 6. Ignition timing advanced due to faulty sensor inputs (TMAP
and/or CKP)/poorly tuned engine.
3. Incorrect spark plug for the kind of service.
7. Internal engine problem.
4. Excessive carbon deposit on piston head or in combustion
chamber. 8. Damaged frame.
5. Ignition timing advanced due to faulty sensor inputs (TMAP 9. Stabilizer links worn or loose, or stabilizer link brackets
and/or CKP). loose or damaged.
6. Ignition timing advanced due to ECM or sensors (CKP, 10. Rubber mount (front) snubbers not centered and contacting
ET or TMAP) defective. side of mount.
7. Intake manifold vacuum leak. 11. Rubber mounts (front or rear) loose or worn.
12. Rear fork pivot shaft fasteners loose.
Overheating
13. Front engine mount bracket bolts loose.
1. Insufficient oil supply or oil not circulating.
14. Exhaust system binding and causing unnecessary side
2. Insufficient air flow over engine.
loads.
3. Heavy carbon deposits.
4. Ignition timing retarded due to defective ECM or faulty
Check Engine Light Illuminates During
sensor(s) (TMAP and/or CKP).
Operation
5. Leaking valve(s). Fault detected. For diagnostic information see the electrical
diagnostic manual.
6. Low coolant level. *
LUBRICATION SYSTEM
7. Restricted radiator air flow. *
8. Defective thermostat. *
Oil Does Not Return To Oil Reservoir
9. Coolant pump or fans inoperative. *
1. Oil reservoir empty.
10. Vent hose crimped. *
2. Oil pump not functioning.
11. Air in coolant. *
3. Restricted oil lines or fittings.
* Twin-Cooled only
4. Restricted oil filter.
Valve Train Noise 5. O-ring damaged or missing from oil pump/crankcase
junction (also results in poor engine performance).
NOTE
Some valve train noise at start-up is normal until lifters fill with Engine Uses Too Much Oil Or Smokes
oil. Excessively
1. Oil reservoir overfilled.
1. Low oil pressure caused by oil feed pump not functioning
properly or oil passages obstructed. 2. Restricted oil return line to oil reservoir.
2. Faulty hydraulic lifter(s). 3. Restricted breather operation.
3. Bent pushrod(s). 4. Restricted oil filter.
4. Incorrect pushrod length. 5. Oil pump misaligned or in poor condition.
5. Rocker arm binding on shaft. 6. Piston rings badly worn or broken.
6. Valve sticking in guide. 7. Valve guides or seals worn or damaged.
7. Chain tensioning spring or shoe worn. 8. O-ring damaged or missing from oil pump/crankcase
junction (also results in poor engine performance).
8. Cam(s), cam gear(s) or cam bushing(s) worn.
9. Plugged crankcase scavenge port.
9. Cam timing incorrect.
10. Oil diluted with gasoline.

94000383 2-61
Engine Leaks Oil From Cases, Pushrods, Hoses, TRANSMISSION
Etc.
1. Loose parts. Shifts Hard
2. Imperfect seal at gaskets, pushrod covers, washers, etc. 1. Primary chaincase overfilled.
3. Restricted breather passages or hose to air cleaner. 2. Clutch not fully disengaging.
4. Restricted oil filter. 3. Transmission lubricant too heavy (winter operation).
5. Oil reservoir overfilled. 4. Shifter return spring (inside transmission) bent or otherwise
6. Lower rocker housing gasket installed incorrectly (upside damaged.
down). 5. Bent shifter rod.
7. Restricted oil return line to oil reservoir. 6. Shifter forks sprung.
8. Porosity. 7. Corners worn off shifter clutch dog rings (inside
transmission).
Low Oil Pressure
1. Oil reservoir underfilled. Jumps Out Of Gear
2. Faulty low oil pressure switch. 1. Shifter rod improperly adjusted.

3. Oil pump O-ring damaged or missing. 2. Shifter drum improperly adjusted or damaged/worn.

4. Bypass valve stuck in open position. 3. Shifter engaging parts badly worn and rounded.

5. Ball missing or leaking in cam support plate. 4. Bent shifter forks .

6. Worn oil pump gerotor(s). 5. Damaged gears.

7. Oil diluted with gasoline. Clutch Slips

High Oil Pressure 1. Reservoir overfull.

1. Oil reservoir overfilled. 2. Clutch lever not returning completely.

2. Bypass valve stuck in closed position. 3. Damaged or binding secondary clutch actuator.

ELECTRICAL SYSTEM 4. Insufficient clutch spring tension.

5. Worn friction discs.
NOTE
For diagnostic information see the electrical diagnostic manual. Clutch Drags Or Does Not Release
1. Lubricant level too high in primary chaincase.
Alternator Does Not Charge 2. Air in hydraulic clutch system.
1. Voltage regulator module not grounded. 3. Primary chain badly misaligned or too tight.
2. Engine ground wire loose or damaged. 4. Insufficient clutch spring tension.
3. Faulty voltage regulator module. 5. Clutch discs warped.
4. Loose or damaged wires in charging circuit.
Clutch Chatters
5. Faulty stator and/or rotor.
Friction discs or steel discs worn or warped.
Alternator Charge Rate Is Below Normal HANDLING
1. Weak or damaged battery.
2. Loose connections. Irregularities
3. Faulty voltage regulator module. 1. Improperly loaded motorcycle. Non-standard equipment
such as heavy radio receivers, extra lighting equipment
4. Faulty stator and/or rotor.
excess or unsecured luggage may cause unstable
handling.
Speedometer Operates Erratically
2. Load (people and gear) exceeds maximum GVWR.
1. Contaminated vehicle speed sensor (remove sensor and
clean off metal particles). 3. Damaged tire(s) or improper front-rear tire combination.
2. Loose connections. 4. Irregular or peaked front tire tread wear.
5. Incorrect tire pressure.
6. Shock absorber not functioning normally.
7. Incorrect suspension adjustment.

2-62 94000383
8. Loose wheel axle nuts. Tighten to recommended torque BRAKES
specification.
9. Excessive wheel hub bearing play. Brake Does Not Hold Normally
10. Rear wheel out of alignment with frame and front wheel.
1. Brake fluid reservoir low, system leaking or pads worn.
11. Steering head bearings improperly adjusted. Correct
2. Brake system contains air bubbles.
adjustment and replace pitted or worn bearings and races.
3. Master cylinder/caliper piston seals worn or parts
12. Loose spokes (laced wheel vehicles only).
damaged.
13. Tire and wheel unbalanced.
4. Brake pads contaminated with grease or oil.
14. Rims and tires out-of-round or eccentric with hub.
5. Brake pads badly worn.
15. Rims and tires out-of-true sideways.
6. Brake disc badly worn or warped.
16. Rear fork pivot assembly: improperly tightened or
7. Brake drags - insufficient brake pedal or hand lever free
assembled, or loose/pitted or damaged pivot bearings.
play, caliper piston worn or damaged, or excessive brake
17. Engine mounts and/or stabilizer links loose, worn or fluid in reservoir.
damaged.
8. Brake fades due to heat build up - brake pads dragging or
18. Incorrect, non-specified tire mounted on front or rear wheel. excessive braking.
9. Brake fluid leak when under pressure.

94000383 2-63
NOTES
SUBJECT PAGE NO.
3.1 FASTENER TORQUE VALUES ............................................................................................ 3-1
3.2 SPECIFICATIONS .............................................................................................................. 3-10
3.3 VEHICLE IDENTIFICATION NUMBER (VIN) ..................................................................... 3-13
3.4 FRONT WHEEL .................................................................................................................. 3-15
3.5 REAR WHEEL .................................................................................................................... 3-18
3.6 REAR WHEEL COMPENSATOR ....................................................................................... 3-22
3.7 WHEEL LACING: FRONT RIM ........................................................................................... 3-24
3.8 WHEEL LACING: 16 INCH REAR RIM .............................................................................. 3-26
3.9 WHEEL RUNOUT ............................................................................................................... 3-29
3.10 SEALED WHEEL BEARINGS ........................................................................................... 3-33
3.11 TIRES ................................................................................................................................ 3-36
3.12 FRONT BRAKE MASTER CYLINDER ............................................................................. 3-40
3.13 FRONT BRAKE CALIPER ................................................................................................ 3-43
3.14 REAR BRAKE MASTER CYLINDER ................................................................................ 3-44
3.15 REAR BRAKE CALIPER ................................................................................................... 3-47
3.16 BRAKE LINES ................................................................................................................... 3-48
3.17 ABS MODULE ................................................................................................................... 3-60
3.18 BLEED BRAKES ............................................................................................................... 3-62
3.19 FRONT FORK ................................................................................................................... 3-64
3.20 STEERING HEAD BEARINGS ......................................................................................... 3-70
3.21 REAR SUSPENSION ........................................................................................................ 3-74
3.22 REAR FORK ..................................................................................................................... 3-76
3.23 CLUTCH MASTER CYLINDER AND RESERVOIR .......................................................... 3-79
3.24 HYDRAULIC CLUTCH HAND LEVER .............................................................................. 3-81

CHASSIS
3.25 CLUTCH FLUID LINE ....................................................................................................... 3-82
3.26 BLEED CLUTCH CONTROL SYSTEM ............................................................................ 3-85
3.27 HANDLEBAR .................................................................................................................... 3-87
3.28 MIRRORS ......................................................................................................................... 3-95
3.29 SEAT ................................................................................................................................. 3-96
3.30 SADDLEBAGS .................................................................................................................. 3-98
3.31 SADDLEBAG SERVICE ................................................................................................... 3-99
3.32 TOUR-PAK ...................................................................................................................... 3-103
3.33 TOUR-PAK SERVICE ..................................................................................................... 3-105
3.34 TOUR-PAK BACKREST ................................................................................................. 3-109
3.35 FAIRING LOWERS AND ENGINE GUARD .................................................................... 3-110
3.36 OUTER FAIRING AND WINDSHIELD: FORK MOUNTED FAIRING MODELS ............. 3-115
3.37 DASH PANEL: FORK MOUNTED FAIRING MODELS ................................................... 3-117
3.38 INNER FAIRING: FORK MOUNTED FAIRING MODELS ............................................... 3-118
3.39 INSTRUMENT BEZEL: FRAME MOUNTED FAIRING MODELS ................................... 3-125
3.40 INSTRUMENT NACELLE: FRAME MOUNTED FAIRING MODELS .............................. 3-126
3.41 OUTER FAIRING AND WINDSHIELD: FRAME MOUNTED FAIRING MODELS .......... 3-127
3.42 INNER FAIRING: FRAME MOUNTED FAIRING MODELS ............................................ 3-131
3.43 STORAGE COMPARTMENTS: FRAME MOUNTED FAIRING MODELS ...................... 3-138
3.44 AIR DEFLECTORS ......................................................................................................... 3-140
3.45 WINDSHIELD: ROAD KING MODELS ........................................................................... 3-142
3.46 HEADLAMP NACELLE: ROAD KING MODELS ............................................................ 3-144
3.47 FRONT FENDER ............................................................................................................ 3-146
3.48 REAR FENDER .............................................................................................................. 3-149
3.49 REAR FASCIA ................................................................................................................ 3-152
3.50 REAR FRAME ................................................................................................................. 3-153
3.51 FOOTBOARDS AND FOOTRESTS ............................................................................... 3-155
3.52 JIFFY STAND .................................................................................................................. 3-159
3.53 FRONT ENGINE MOUNT ............................................................................................... 3-161
3.54 MEDALLIONS, BADGES AND TANK EMBLEMS .......................................................... 3-163
NOTES
FASTENER TORQUE VALUES 3.1
FASTENER TORQUE VALUES IN THIS
CHAPTER

The table below lists torque values for all fasteners presented
in this chapter.

FASTENER TORQUE VALUE NOTES

ABS module locknuts 53–88 in-lbs 6–10 N·m 3.17 ABS Module, ABS Module
Banjo bleeder bolt to front caliper 17–19 ft-lbs 23.1–25.8 N·m 3.13 FRONT BRAKE CALIPER, Install
Banjo bleeder bolt to front caliper 17–19 ft-lbs 23.1–25.8 N·m 3.16 Brake Lines, Front Brake Line: Non-ABS
Banjo bleeder bolt to front caliper 17–19 ft-lbs 23.1–25.8 N·m 3.16 Brake Lines, Brake Line: ABS Module to Front
Caliper
Banjo bolt to ABS module, 10 mm 17–19 ft-lbs 23.1–25.8 N·m 3.16 Brake Lines, Brake Line: ABS Module to Front
Caliper
Banjo bolt to ABS module, 10 mm 17–19 ft-lbs 23.1–25.8 N·m 3.16 Brake Lines, Brake Line: ABS Module to Rear
Caliper
Banjo bolt to ABS module, 10 mm 17–19 ft-lbs 23.1–25.8 N·m 3.17 ABS Module, ABS Module
Banjo bolt to ABS module, 12 mm 28–30 ft-lbs 38–40.6 N·m 3.16 Brake Lines, Brake Line: Front Master Cylinder
to ABS Module
Banjo bolt to ABS module, 12 mm 28–30 ft-lbs 38–40.6 N·m 3.16 Brake Lines, Brake Line: Rear Master Cylinder
to ABS Module
Banjo bolt to ABS module, 12 mm 28–30 ft-lbs 38–40.6 N·m 3.17 ABS Module, ABS Module
Banjo bolt to front master cylinder 17–19 ft-lbs 23.1–25.8 N·m 3.12 FRONT BRAKE MASTER CYLINDER, Install
Banjo bolt to front master cylinder 17–19 ft-lbs 23.1–25.8 N·m 3.16 Brake Lines, Front Brake Line: Non-ABS
Banjo bolt to front master cylinder 17–19 ft-lbs 23.1–25.8 N·m 3.16 Brake Lines, Brake Line: Front Master Cylinder
to ABS Module
Banjo bolt to rear caliper 17–19 ft-lbs 23.1–25.8 N·m 3.15 REAR BRAKE CALIPER, Install
Banjo bolt to rear caliper 17–19 ft-lbs 23.1–25.8 N·m 3.16 Brake Lines, Rear Brake Line: Non-ABS
Banjo bolt to rear caliper 17–19 ft-lbs 23.1–25.8 N·m 3.16 Brake Lines, Brake Line: ABS Module to Rear
Caliper
Banjo bolt to rear master cylinder 17–19 ft-lbs 23.1–25.8 N·m 3.14 REAR BRAKE MASTER CYLINDER, Install
Banjo bolt to rear master cylinder 17–19 ft-lbs 23.1–25.8 N·m 3.16 Brake Lines, Rear Brake Line: Non-ABS
Banjo bolt to rear master cylinder 17–19 ft-lbs 23.1–25.8 N·m 3.16 Brake Lines, Brake Line: Rear Master Cylinder
to ABS Module
Battery tray screws 132–156 in-lbs 14.9–17.6 N·m 3.16 Brake Lines, Brake Line: Front Master Cylinder
to ABS Module
Battery tray screws 132–156 in-lbs 14.9–17.6 N·m 3.16 Brake Lines, Brake Line: ABS Module to Front
Caliper
Battery tray screws 132–156 in-lbs 14.9–17.6 N·m 3.17 ABS Module, ABS Module
Battery tray screws 132–156 in-lbs 14.9–17.6 N·m 3.50 Rear Frame, Rear Frame
Brake bleeder screw, front 72–108 in-lbs 8.1–12.2 N·m 3.18 BLEED BRAKES, Fill and Bleed
Brake bleeder screw, rear 75–102 in-lbs 8.5–11.5 N·m 3.18 BLEED BRAKES, Fill and Bleed
Brake caliper, front, mounting screws 28–38 ft-lbs 37.9–51.5 N·m 3.13 FRONT BRAKE CALIPER, Install
metric
Brake caliper, rear, mounting screws 43–48 ft-lbs 58.3–65.1 N·m 3.5 REAR WHEEL, Complete
metric
Brake caliper, rear, mounting screws 43–48 ft-lbs 58.3–65.1 N·m 3.15 REAR BRAKE CALIPER, Install
metric
Brake disc, front, screws (metric) 16–24 ft-lbs 21.7–32.5 N·m 3.4 FRONT WHEEL, Assemble
Always use new screws
Brake disc, rear, screws 30–45 ft-lbs 41–61 N·m 3.5 REAR WHEEL, Assemble
Always use new part

94000383 3-1
FASTENER TORQUE VALUE NOTES
Brake line, rear, P-clamp screw 80–100 in-lbs 9–11.3 N·m 3.16 Brake Lines, Rear Brake Line: Non-ABS
Brake line, rear, P-clamp screw 80–100 in-lbs 9–11.3 N·m 3.16 Brake Lines, Brake Line: Rear Master Cylinder
to ABS Module
Brake line bracket to lower fork bracket 12–18 in-lbs 1.4–2 N·m 3.20 STEERING HEAD BEARINGS, Assemble
screws
Brake master cylinder, front, clamp 60–80 in-lbs 6.8–9 N·m 3.12 FRONT BRAKE MASTER CYLINDER, Install
screws
Brake master cylinder, front, clamp 60–80 in-lbs 6.8–9 N·m 3.27 HANDLEBAR, Install
screws
Brake master cylinder, front, reservoir 12–15 in-lbs 1.4–1.7 N·m 3.18 BLEED BRAKES, Fill and Bleed
cover screws
Brake master cylinder, rear, mounting 126–150 in-lbs 14.2–17 N·m 3.14 REAR BRAKE MASTER CYLINDER, Install
screws
Brake master cylinder, rear, mounting 126–150 in-lbs 14.2–17 N·m 3.53 FRONT ENGINE MOUNT, Complete
screws
Brake master cylinder, rear, reservoir 12–15 in-lbs 1.4–1.7 N·m 3.18 BLEED BRAKES, Fill and Bleed
cover screws
Brake pedal shaft locknut 15–20 ft-lbs 20.3–27.1 N·m 3.14 REAR BRAKE MASTER CYLINDER, Install
Brake pedal shaft locknut 15–20 ft-lbs 20.3–27.1 N·m 3.53 FRONT ENGINE MOUNT, Complete
Clutch actuator bleeder screw 56–75 in-lbs 6.3–8.5 N·m 3.26 BLEED CLUTCH CONTROL SYSTEM, Bleed
Hydraulic Clutch System
Clutch fluid line flare nut 133–186 in-lbs 15–21 N·m 3.25 CLUTCH FLUID LINE, Install
Clutch lever bracket clamp screws 60–80 in-lbs 6.8–9 N·m 3.27 HANDLEBAR, Install
Clutch master cylinder banjo bolt 14–22.8 ft-lbs 19–31 N·m 3.23 CLUTCH MASTER CYLINDER AND
RESERVOIR, Install
Clutch master cylinder banjo bolt 14–22.8 ft-lbs 19–31 N·m 3.25 CLUTCH FLUID LINE, Install
Clutch master cylinder clamp screws 60–80 in-lbs 6.8–9 N·m 3.23 CLUTCH MASTER CYLINDER AND
RESERVOIR, Install
Tighten top screw first.
Clutch reservoir cover screws 12–15 in-lbs 1.4–1.7 N·m 3.23 CLUTCH MASTER CYLINDER AND
RESERVOIR, Install
Clutch reservoir cover screws 12–15 in-lbs 1.4–1.7 N·m 3.26 BLEED CLUTCH CONTROL SYSTEM, Bleed
Hydraulic Clutch System
Dash panel screws 25–30 in-lbs 2.8–3.4 N·m 3.37 DASH PANEL: FORK MOUNTED FAIRING
MODELS, Dash Panel
Debris deflector screw 65–85 in-lbs 7.3–9.6 N·m 3.22 REAR FORK, Install
Engine guard lower screws 15–20 ft-lbs 20.3–27.1 N·m 3.35 FAIRING LOWERS AND ENGINE GUARD,
Engine Guard
Engine guard upper screw 22–28 ft-lbs 29.8–37.9 N·m 3.35 FAIRING LOWERS AND ENGINE GUARD,
Engine Guard
Engine mount end cap screws, front 42–48 ft-lbs 56.9–65 N·m 3.16 Brake Lines, Rear Brake Line: Non-ABS
Engine mount end cap screws, front 42–48 ft-lbs 56.9–65 N·m 3.16 Brake Lines, Brake Line: Rear Master Cylinder
to ABS Module
Engine mount end cap screws, front 42–48 ft-lbs 56.9–65 N·m 3.53 FRONT ENGINE MOUNT, Installation
Engine mount flange nut 50–60 ft-lbs 67.8–81.3 N·m 3.53 FRONT ENGINE MOUNT, Installation
Engine stabilizer bracket screws 50–60 ft-lbs 67.8–81.3 N·m 3.53 FRONT ENGINE MOUNT, Stabilizer Link
Engine stabilizer link screws 30–35 ft-lbs 40.7–47.5 N·m 3.53 FRONT ENGINE MOUNT, Installation
Engine stabilizer link screws 30–35 ft-lbs 40.7–47.5 N·m 3.53 FRONT ENGINE MOUNT, Stabilizer Link
Engine stabilizer link screws 30–35 ft-lbs 40.7–47.5 N·m 3.53 FRONT ENGINE MOUNT, Stabilizer Link
Fairing air deflector screws: fork moun- 15–25 in-lbs 1.7–2.8 N·m 3.44 Air Deflectors, Fairing Air Deflectors
ted fairing

3-2 94000383
FASTENER TORQUE VALUE NOTES
Fairing air deflector screws: Frame- 8–15 in-lbs 0.9–1.7 N·m 3.43 STORAGE COMPARTMENTS: FRAME
mounted fairing MOUNTED FAIRING MODELS, Storage Compart-
ment, Door and Hinge
Fairing air deflector screws: Frame- 8–15 in-lbs 0.9–1.7 N·m 3.44 Air Deflectors, Fairing Air Deflectors
mounted fairing
Fairing air duct latch screws 9–13 in-lbs 1–1.5 N·m 3.42 INNER FAIRING: FRAME MOUNTED FAIR-
ING MODELS, Fairing Air Duct
Fairing air duct to inner fairing: frame 8–15 in-lbs 0.9–1.7 N·m 3.42 INNER FAIRING: FRAME MOUNTED FAIR-
mounted fairing ING MODELS, Inner Fairing Shell Replacement
Fairing air duct to inner fairing: Frame- 8–15 in-lbs 0.9–1.7 N·m 3.42 INNER FAIRING: FRAME MOUNTED FAIR-
mounted fairing ING MODELS, Fairing Air Duct
Fairing double studs 120–180 in-lbs 13.6–20.3 N·m 3.38 INNER FAIRING: FORK MOUNTED FAIRING
MODELS, Rotate Inner Fairing
Fairing double studs 120–180 in-lbs 13.6–20.3 N·m 3.38 INNER FAIRING: FORK MOUNTED FAIRING
MODELS, Remove and Install Inner Fairing As-
sembly
Fairing lower inner panel screws 65–75 in-lbs 7.3–8.5 N·m 3.35 FAIRING LOWERS AND ENGINE GUARD,
Fairing Lower: Air-Cooled
Fairing mount to steering head locknuts: 20–30 ft-lbs 27.1–40.7 N·m 3.42 INNER FAIRING: FRAME MOUNTED FAIR-
Frame-mounted fairing ING MODELS, Installation
Fairing speaker enclosure to fairing 48–60 in-lbs 5.4–6.8 N·m 3.38 INNER FAIRING: FORK MOUNTED FAIRING
screws MODELS, Replace Inner Fairing Shell
Fairing speaker enclosure to fairing 48–60 in-lbs 5.4–6.8 N·m 3.42 INNER FAIRING: FRAME MOUNTED FAIR-
screws ING MODELS, Inner Fairing Shell Replacement
Fairing speaker grille screws 9–13 in-lbs 1–1.5 N·m 3.38 INNER FAIRING: FORK MOUNTED FAIRING
MODELS, Replace Inner Fairing Shell
Fairing support bracket-to-engine guard 40–50 in-lbs 4.5–5.7 N·m 3.42 INNER FAIRING: FRAME MOUNTED FAIR-
screws ING MODELS, Installation
Fairing support bracket-to-engine guard 40–50 in-lbs 4.5–5.7 N·m 3.43 STORAGE COMPARTMENTS: FRAME
screws MOUNTED FAIRING MODELS, Storage Compart-
ment, Door and Hinge
Fairing support bracket-to-inner fairing 48–60 in-lbs 5.4–6.8 N·m 3.42 INNER FAIRING: FRAME MOUNTED FAIR-
screws: Frame-mounted fairing ING MODELS, Installation
Fairing support bracket-to-inner fairing 48–60 in-lbs 5.4–6.8 N·m 3.43 STORAGE COMPARTMENTS: FRAME
screws: Frame-mounted fairing MOUNTED FAIRING MODELS, Storage Compart-
ment, Door and Hinge
Fairing vent to inner fairing: fork mounted 20–30 in-lbs 2.3–3.4 N·m 3.38 INNER FAIRING: FORK MOUNTED FAIRING
fairing MODELS, Fairing Vent
Fairing vent to inner fairing: fork mounted 20–30 in-lbs 2.3–3.4 N·m 3.38 INNER FAIRING: FORK MOUNTED FAIRING
fairing MODELS, Fairing Vent
Fender, front, fender tip lamp nuts 20–25 in-lbs 2.3–2.8 N·m 3.47 Front Fender, Removal
Fender, front, fender tip screws 20–25 in-lbs 2.3–2.8 N·m 3.47 Front Fender, Removal
Fender, front, mounting screws 16–20 ft-lbs 21.7–27.1 N·m 3.47 Front Fender, Removal
Fender, front, mounting screws 16–20 ft-lbs 21.7–27.1 N·m 3.47 Front Fender, Installation
Fender, front, trim skirt screws/nuts 10–15 in-lbs 1.1–1.7 N·m 3.47 Front Fender, Removal
Fender, front, trim strip T-bolt nut 10–15 in-lbs 1.1–1.7 N·m 3.47 Front Fender, Removal
Fender, rear, mounting boss 15–20 ft-lbs 20.3–27.1 N·m 3.48 REAR FENDER, Fender Repair
Fender, rear, mounting screws 15–20 ft-lbs 20.3–27.1 N·m 3.48 REAR FENDER, Installation
Fender, rear, stud plate 60–96 in-lbs 6.8–10.8 N·m 3.48 REAR FENDER, Fender Repair
Fender, rear, support to fender nut 45–85 in-lbs 5.1–9.6 N·m 3.49 REAR FASCIA, Installation
Fender, rear, support to fender nut 45–85 in-lbs 5.1–9.6 N·m 3.49 REAR FASCIA, Stud Plate
Footboard/footrest lower fastener, pas- 48–72 in-lbs 5.4–8.1 N·m 3.51 FOOTBOARDS AND FOOTRESTS, Passen-
senger ger Footboard

94000383 3-3
FASTENER TORQUE VALUE NOTES
Footboard/footrest lower fastener, pas- 48–72 in-lbs 5.4–8.1 N·m 3.51 FOOTBOARDS AND FOOTRESTS, Passen-
senger ger Footrest: Low Models
Footboard/footrest lower fastener, pas- 48–72 in-lbs 5.4–8.1 N·m 3.51 FOOTBOARDS AND FOOTRESTS, Passen-
senger: FLHX, FLHXS, FLTRX, FLTRXS ger Footrest: FLHX, FLHXS, FLTRX, FLTRXS
Footboard/footrest upper fastener, pas- 36–42 ft-lbs 48.8–56.9 N·m 3.51 FOOTBOARDS AND FOOTRESTS, Passen-
senger ger Footboard
Footboard/footrest upper fastener, pas- 36–42 ft-lbs 48.8–56.9 N·m 3.51 FOOTBOARDS AND FOOTRESTS, Passen-
senger ger Footrest: Low Models
Footboard/footrest upper fastener, pas- 36–42 ft-lbs 48.8–56.9 N·m 3.51 FOOTBOARDS AND FOOTRESTS, Passen-
senger: FLHX, FLHXS, FLTRX, FLTRXS ger Footrest: FLHX, FLHXS, FLTRX, FLTRXS
Footboard bracket screws, rider 36–42 ft-lbs 48.8–56.9 N·m 3.51 FOOTBOARDS AND FOOTRESTS, Rider
Footboards
Footboard feeler screws 96–108 in-lbs 10.8–12.2 N·m 3.51 FOOTBOARDS AND FOOTRESTS, Rider
Footboards
Footboard pivot bolt nut, rider 60–80 in-lbs 6.8–9 N·m 3.51 FOOTBOARDS AND FOOTRESTS, Rider
Footboards
Footrest pad screw: FLHX, FLHXS, 15–20 ft-lbs 20.3–27.1 N·m 3.51 FOOTBOARDS AND FOOTRESTS, Passen-
FLTRX, FLTRXS ger Footrest: FLHX, FLHXS, FLTRX, FLTRXS
Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue).
Footrest pad screw (FLHX, FLHXS, 15–20 ft-lbs 20.3–27.1 N·m 3.51 FOOTBOARDS AND FOOTRESTS, Passen-
FLTRX, FLTRXS) ger Footrest: Low Models
Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue).
Footrest pad screw (FLHX, FLHXS, 15–20 ft-lbs 20.3–27.1 N·m 3.51 FOOTBOARDS AND FOOTRESTS, Passen-
FLTRX, FLTRXS) ger Footrest: Low Models
Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue).
Fork bracket to fork pinch screws 14–18 ft-lbs 19–24.4 N·m 3.19 FRONT FORK, Install
Alternately tighten each screw twice.
Fork bracket to fork pinch screws 14–18 ft-lbs 19–24.4 N·m 3.19 FRONT FORK, Install
Alternately tighten each screw twice.
Fork bracket to fork pinch screws 14–18 ft-lbs 19–24.4 N·m 3.19 FRONT FORK, Install
Fork bracket to fork pinch screws 14–18 ft-lbs 19–24.4 N·m 3.20 STEERING HEAD BEARINGS, Upper Fork
Bracket
Fork bracket to steer stem pinch screw 22–26 ft-lbs 29.8–35.2 N·m 3.20 STEERING HEAD BEARINGS, Upper Fork
Bracket
Fork damper tube screw (metric) 30–37 ft-lbs 40–50 N·m 3.19 FRONT FORK, Assemble
Fork slider cover screws 24–48 in-lbs 2.7–5.4 N·m 3.19 FRONT FORK, Install
Apply LOCTITE 246 MEDIUM STRENGTH
THREADLOCKER (blue) to the threads of screws
Fork tube plug 22–59 ft-lbs 30–80 N·m 3.19 FRONT FORK, Assemble
Front axle nut 70–75 ft-lbs 94.9–101.7 N·m 3.4 FRONT WHEEL, Install
metric
Front axle pinch screw 18–22 ft-lbs 24.4–29.8 N·m 3.4 FRONT WHEEL, Install
metric
Gauges, 2 inch diameter gauge screws 8–15 in-lbs 0.9–1.7 N·m 3.38 INNER FAIRING: FORK MOUNTED FAIRING
MODELS, Replace Inner Fairing Shell
Gauges, 2 inch diameter gauge screws 8–15 in-lbs 0.9–1.7 N·m 3.42 INNER FAIRING: FRAME MOUNTED FAIR-
ING MODELS, Inner Fairing Shell Replacement
Gauges, instrument cluster screws 10–20 in-lbs 1.1–2.3 N·m 3.38 INNER FAIRING: FORK MOUNTED FAIRING
MODELS, Replace Inner Fairing Shell
Handlebar clamp shroud screws 10–20 in-lbs 1.1–2.3 N·m 3.46 HEADLAMP NACELLE: ROAD KING MOD-
ELS, Installation

3-4 94000383
FASTENER TORQUE VALUE NOTES
Handlebar lower clamp bolt 30–40 ft-lbs 40.7–54.2 N·m 3.27 HANDLEBAR, Handlebar Clamps and Rubber
Mounts
Handlebar upper clamp screws 16–20 ft-lbs 21.7–27.1 N·m 3.27 HANDLEBAR, Adjust
Handlebar upper clamp screws 16–20 ft-lbs 21.7–27.1 N·m 3.27 HANDLEBAR, Install
Handlebar upper clamp screws 16–20 ft-lbs 21.7–27.1 N·m 3.27 HANDLEBAR, Install
Headlamp door screw 9–18 in-lbs 1–2 N·m 3.36 OUTER FAIRING AND WINDSHIELD: FORK
MOUNTED FAIRING MODELS, Outer Fairing and
Windshield
Headlamp door screw 9–18 in-lbs 1–2 N·m 3.46 HEADLAMP NACELLE: ROAD KING MOD-
ELS, Installation
Headlamp mount to fairing 22–32 in-lbs 2.5–3.6 N·m 3.36 OUTER FAIRING AND WINDSHIELD: FORK
MOUNTED FAIRING MODELS, Outer Fairing and
Windshield
Headlamp mount to nacelle screws 9–18 in-lbs 1–2 N·m 3.46 HEADLAMP NACELLE: ROAD KING MOD-
ELS, Installation
Headlamp nacelle acorn nuts: FLHR/C 96–132 in-lbs 10.8–14.9 N·m 3.46 HEADLAMP NACELLE: ROAD KING MOD-
ELS, Installation
Headlamp nacelle acorn nuts: FLHR/C 96–132 in-lbs 10.8–14.9 N·m 3.46 HEADLAMP NACELLE: ROAD KING MOD-
ELS, Installation
Headlamp nacelle chrome strip flange 15–20 in-lbs 1.7–2.3 N·m 3.46 HEADLAMP NACELLE: ROAD KING MOD-
nut ELS, Installation
Hydraulic line multi-clamp screw 10–15 in-lbs 1.1–1.7 N·m 3.16 Brake Lines, Rear Brake Line: Non-ABS
Hydraulic line multi-clamp screw 10–15 in-lbs 1.1–1.7 N·m 3.16 Brake Lines, Brake Line: Rear Master Cylinder
to ABS Module
Hydraulic line multi-clamp screw 10–15 in-lbs 1.1–1.7 N·m 3.25 CLUTCH FLUID LINE, Install
Ignition switch housing nut 13–15 ft-lbs 17.5–20.9 N·m 3.37 DASH PANEL: FORK MOUNTED FAIRING
MODELS, Dash Panel
Inner fairing to mount screws: frame- 96–144 in-lbs 10.9–16.3 N·m 3.42 INNER FAIRING: FRAME MOUNTED FAIR-
mounted fairing ING MODELS, Radio Support Bracket
Inner fairing-to-mount screws: Frame- 96–144 in-lbs 10.9–16.3 N·m 3.42 INNER FAIRING: FRAME MOUNTED FAIR-
mounted fairing ING MODELS, Installation
Instrument bezel screws 10–15 in-lbs 1.1–1.7 N·m 3.39 INSTRUMENT BEZEL: FRAME MOUNTED
FAIRING MODELS, Instrument Bezel
Instrument nacelle to fork bracket screws 96–115 in-lbs 10.8–13 N·m 3.40 INSTRUMENT NACELLE: FRAME MOUNTED
FAIRING MODELS, Instrument Nacelle
Jiffy stand bracket fasteners 36–42 ft-lbs 48.8–57 N·m 3.52 Jiffy Stand, Jiffy Stand Bracket
Jiffy stand interlock sensor fastener 96–120 in-lbs 10.8–13.6 N·m 3.52 Jiffy Stand, Jiffy Stand Interlock Sensor
Use LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue) if reusing
screw
Jiffy stand leg stop hex screw 15–20 ft-lbs 20.3–27.1 N·m 3.52 Jiffy Stand, Install Leg
Left electrical caddy fastener 72–96 in-lbs 8.1–10.8 N·m 3.50 Rear Frame, Rear Frame
Lower fairing, lower clamp 90–100 in-lbs 10.2–11.3 N·m 3.35 FAIRING LOWERS AND ENGINE GUARD,
Fairing Lower: Air-Cooled
Lower fairing, lower clamp 90–100 in-lbs 10.2–11.3 N·m 3.35 FAIRING LOWERS AND ENGINE GUARD,
Fairing Lower: Twin-Cooled
Lower fairing, upper clamp nuts 30–35 in-lbs 3.4–3.9 N·m 3.35 FAIRING LOWERS AND ENGINE GUARD,
Fairing Lower: Air-Cooled
Lower fairing, upper clamp nuts 30–35 in-lbs 3.4–3.9 N·m 3.35 FAIRING LOWERS AND ENGINE GUARD,
Fairing Lower: Twin-Cooled
Lower fairing cap flange nut 30–35 in-lbs 3.4–3.9 N·m 3.35 FAIRING LOWERS AND ENGINE GUARD,
Fairing Lower: Air-Cooled
Lower fairing cap flange nut 30–35 in-lbs 3.4–3.9 N·m 3.35 FAIRING LOWERS AND ENGINE GUARD,
Fairing Lower: Twin-Cooled

94000383 3-5
FASTENER TORQUE VALUE NOTES
Lower fairing glove box screws 12–16.8 in-lbs 1.4–1.9 N·m 3.35 FAIRING LOWERS AND ENGINE GUARD,
Fairing Lower: Air-Cooled
Lower fairing glove box tray screws 12–18 in-lbs 1.4–2 N·m 3.35 FAIRING LOWERS AND ENGINE GUARD,
Fairing Lower: Air-Cooled
Lower fairing vent knob screw 12–18 in-lbs 1.4–2 N·m 3.35 FAIRING LOWERS AND ENGINE GUARD,
Fairing Lower: Air-Cooled
Media compartment screw, lower 8–12 in-lbs 0.9–1.3 N·m 3.38 INNER FAIRING: FORK MOUNTED FAIRING
MODELS, Replace Inner Fairing Shell
Media compartment screw, lower 8–12 in-lbs 0.9–1.3 N·m 3.38 INNER FAIRING: FORK MOUNTED FAIRING
MODELS, Media Compartment
Media compartment screw, upper 25–35 in-lbs 2.8–4 N·m 3.38 INNER FAIRING: FORK MOUNTED FAIRING
MODELS, Upper Support Bracket
Mid-frame air deflector screws 25–35 in-lbs 2.8–4 N·m 3.44 Air Deflectors, Mid-Frame Air Deflectors
Mirror flange nut: FLHX/S 20–30 in-lbs 2.3–3.4 N·m 3.28 Mirrors, FLHX, FLHXS
metric
Mirror stem acorn nut 60–96 in-lbs 6.8–10.8 N·m 3.28 Mirrors, All Models Except FLHX, FLHXS
metric
Muffler to saddlebag support screws 14–18 ft-lbs 19–24.4 N·m 3.31 SADDLEBAG SERVICE, Saddlebag Support
Outer fairing lower screws (also air de- 8–15 in-lbs 0.9–1.7 N·m 3.41 OUTER FAIRING AND WINDSHIELD:
flector): frame mounted fairing FRAME MOUNTED FAIRING MODELS, Outer
Fairing
Outer fairing screws: fork mounted fairing 20–30 in-lbs 2.3–3.4 N·m 3.36 OUTER FAIRING AND WINDSHIELD: FORK
MOUNTED FAIRING MODELS, Outer Fairing and
Windshield
Outer fairing upper screws (near speak- 20–30 in-lbs 2.3–3.4 N·m 3.41 OUTER FAIRING AND WINDSHIELD:
ers): frame mounted fairing FRAME MOUNTED FAIRING MODELS, Outer
Fairing
Outer transmission cover screws 100–120 in-lbs 11.2–13.6 N·m 3.26 BLEED CLUTCH CONTROL SYSTEM, Bleed
Hydraulic Clutch System
Passenger backrest flange nuts 108–132 in-lbs 12.2–14.9 N·m 3.34 TOUR-PAK BACKREST, Passenger Backrest
Passenger backrest flap screws 21–24 in-lbs 2.4–2.7 N·m 3.34 TOUR-PAK BACKREST, Passenger Backrest
Flap
Power outlet, front 13–17 in-lbs 1.5–1.9 N·m 3.38 INNER FAIRING: FORK MOUNTED FAIRING
MODELS, Replace Inner Fairing Shell
Power outlet, front 13–17 in-lbs 1.5–1.9 N·m 3.42 INNER FAIRING: FRAME MOUNTED FAIR-
ING MODELS, Inner Fairing Shell Replacement
Radio support bracket to inner fairing 48–60 in-lbs 5.4–6.8 N·m 3.42 INNER FAIRING: FRAME MOUNTED FAIR-
screws: FLTR ING MODELS, Inner Fairing Shell Replacement
Radio support bracket to inner fairing 48–60 in-lbs 5.4–6.8 N·m 3.42 INNER FAIRING: FRAME MOUNTED FAIR-
screws: FLTR ING MODELS, Inner Fairing Shell Replacement
Radio support bracket to inner fairing 48–60 in-lbs 5.4–6.8 N·m 3.42 INNER FAIRING: FRAME MOUNTED FAIR-
screws: FLTR ING MODELS, Radio Support Bracket
Rear axle cone nut, first torque 15–20 ft-lbs 20–27 N·m 3.5 REAR WHEEL, Install
metric
Rear fascia flange nuts 30–45 in-lbs 3.4–5.1 N·m 3.49 REAR FASCIA, Installation
Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue).
Rear fascia lamp screws 18–22 in-lbs 2–2.5 N·m 3.49 REAR FASCIA, Installation
Rear fork bracket screws 55–65 ft-lbs 74.6–88.1 N·m 3.22 REAR FORK, Install
Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue).
Rear fork pivot shaft screws 55–65 ft-lbs 74.6–88.1 N·m 3.22 REAR FORK, Install
Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue).
Rear frame to main frame fastener 40–45 ft-lbs 54.2–61 N·m 3.50 Rear Frame, Rear Frame

3-6 94000383
FASTENER TORQUE VALUE NOTES
Saddlebag face plate/hinge screw 40–45 in-lbs 4.5–5.1 N·m 3.31 SADDLEBAG SERVICE, Repair Saddlebag
Saddlebag face plate/hinge screw 40–45 in-lbs 4.5–5.1 N·m 3.31 SADDLEBAG SERVICE, Repair Saddlebag
Saddlebag face plate/hinge screw 40–45 in-lbs 4.5–5.1 N·m 3.31 SADDLEBAG SERVICE, Repair Saddlebag
Saddlebag guard to frame screw, lower 32–36 ft-lbs 43.4–48.8 N·m 3.31 SADDLEBAG SERVICE, Saddlebag Support
Saddlebag guard to frame screw, upper 32–36 ft-lbs 43.4–48.8 N·m 3.31 SADDLEBAG SERVICE, Saddlebag Support
Saddlebag hinge to latch assembly 30–35 in-lbs 3.4–3.9 N·m 3.31 SADDLEBAG SERVICE, Repair Saddlebag
screw
Saddlebag hinge to saddlebag screw 40–45 in-lbs 4.5–5.1 N·m 3.31 SADDLEBAG SERVICE, Repair Saddlebag
Saddlebag latch assembly screws 40–45 in-lbs 4.5–5.1 N·m 3.31 SADDLEBAG SERVICE, Repair Saddlebag
Saddlebag latch handle screw 40–45 in-lbs 4.5–5.1 N·m 3.31 SADDLEBAG SERVICE, Repair Saddlebag
Saddlebag lock lever nut 25–35 in-lbs 2.8–3.9 N·m 3.31 SADDLEBAG SERVICE, Repair Saddlebag
Saddlebag lock lever nut 25–35 in-lbs 2.8–3.9 N·m 3.31 SADDLEBAG SERVICE, Repair Saddlebag
Saddlebag lock lever nut 25–35 in-lbs 2.8–3.9 N·m 3.31 SADDLEBAG SERVICE, Repair Saddlebag
Saddlebag lock screw 20–30 in-lbs 2.3–3.4 N·m 3.31 SADDLEBAG SERVICE, Repair Saddlebag
Saddlebag strike screw 15–20 in-lbs 1.7–2.3 N·m 3.31 SADDLEBAG SERVICE, Repair Saddlebag
Saddlebag support casting to frame 15–20 ft-lbs 20.3–27.1 N·m 3.31 SADDLEBAG SERVICE, Saddlebag Support
screw
Saddlebag support to lower fender sup- 15–20 ft-lbs 20.3–27.1 N·m 3.49 REAR FASCIA, Stud Plate
port screw
Saddlebag support tube screw 70–100 in-lbs 7.9–11.3 N·m 3.31 SADDLEBAG SERVICE, Saddlebag Support
Saddlebag support tube to support cast- 30–37 ft-lbs 40.7–50.2 N·m 3.31 SADDLEBAG SERVICE, Saddlebag Support
ing fastener, large
Saddlebag support tube to support cast- 15–20 ft-lbs 20.3–27.1 N·m 3.31 SADDLEBAG SERVICE, Saddlebag Support
ing fastener, small
Saddlebag tether screw 40–45 in-lbs 4.5–5.1 N·m 3.31 SADDLEBAG SERVICE, Repair Saddlebag
Saddlebag tether screw 40–45 in-lbs 4.5–5.1 N·m 3.31 SADDLEBAG SERVICE, Repair Saddlebag
Seat bumper fastener: FLHX, FLHXS 32–36 ft-lbs 43.4–48.8 N·m 3.29 SEAT, Seat Bumper
and FLTRX, FLTRXS
Seat mounting screw 48–72 in-lbs 5.4–8.1 N·m 3.29 SEAT, SEAT
Seat strap bracket screw 120–144 in-lbs 13.6–16.3 N·m 3.31 SADDLEBAG SERVICE, Saddlebag Support
Seat strap screw 48–72 in-lbs 5.4–8.1 N·m 3.29 SEAT, SEAT
Shock absorber mounting bolt 63–70 ft-lbs 85.4–95 N·m 3.21 Rear Suspension, Install Shock Absorber
Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue).
Shock absorber mounting bolt 63–70 ft-lbs 85.4–95 N·m 3.22 REAR FORK, Install
Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue).
Speedometer bracket acorn nuts: FLHP 72–108 in-lbs 8.1–12.2 N·m 3.46 HEADLAMP NACELLE: ROAD KING MOD-
ELS, Installation
Spoke nipple 55 in-lbs 6.2 N·m 3.9 WHEEL RUNOUT, True Laced Wheels
Stop lamp switch, rear 12–15 ft-lbs 16.3–20.3 N·m 3.16 Brake Lines, Rear Brake Line: Non-ABS
Use LOCTITE 565 THREAD SEALANT
Stop lamp switch, rear 12–15 ft-lbs 16.3–20.3 N·m 3.16 Brake Lines, Brake Line: Rear Master Cylinder
to ABS Module
Use LOCTITE 565 THREAD SEALANT
Storage compartment door hinge screws 8–15 in-lbs 0.9–1.7 N·m 3.43 STORAGE COMPARTMENTS: FRAME
MOUNTED FAIRING MODELS, Storage Compart-
ment, Door and Hinge
Storage compartment door screws 8–15 in-lbs 0.9–1.7 N·m 3.43 STORAGE COMPARTMENTS: FRAME
MOUNTED FAIRING MODELS, Storage Compart-
ment, Door and Hinge

94000383 3-7
FASTENER TORQUE VALUE NOTES
Storage compartment door screws 8–15 in-lbs 0.9–1.7 N·m 3.43 STORAGE COMPARTMENTS: FRAME
MOUNTED FAIRING MODELS, Storage Compart-
ment, Door and Hinge
Storage compartment screws 48–60 in-lbs 5.4–6.8 N·m 3.42 INNER FAIRING: FRAME MOUNTED FAIR-
ING MODELS, Inner Fairing Shell Replacement
Storage compartment screws 48–60 in-lbs 5.4–6.8 N·m 3.43 STORAGE COMPARTMENTS: FRAME
MOUNTED FAIRING MODELS, Storage Compart-
ment, Door and Hinge
Suspension air valve nut 40–50 in-lbs 4.5–5.6 N·m 3.31 SADDLEBAG SERVICE, Saddlebag Support
Top caddy screws 72–96 in-lbs 8.1–10.8 N·m 3.50 Rear Frame, Rear Frame
Top duct door mechanism 6–8 in-lbs 0.7–0.9 N·m 3.41 OUTER FAIRING AND WINDSHIELD:
FRAME MOUNTED FAIRING MODELS, Top Air
Duct
Tour-Pak adapter mounting screws (APC 60–72 in-lbs 6.8–8.1 N·m 3.32 TOUR-PAK, Removal and Installation
models)
Tour-Pak catch screws 25–35 in-lbs 2.8–3.9 N·m 3.33 TOUR-PAK SERVICE, Latch Handle and
Catch
Tour-Pak fasteners 60–72 in-lbs 6.8–8.1 N·m 3.29 SEAT, SEAT
Tour-Pak hinge screw 25–35 in-lbs 2.8–3.9 N·m 3.33 TOUR-PAK SERVICE, Hinges
Tour-Pak latch handle 25–35 in-lbs 2.8–3.9 N·m 3.33 TOUR-PAK SERVICE, Latch Handle and
Catch
Tour-Pak lockset screws 25–35 in-lbs 2.8–3.9 N·m 3.33 TOUR-PAK SERVICE, Tour-Pak Lock
Tour-Pak luggage rack fastener 40–48 in-lbs 4.5–5.4 N·m 3.33 TOUR-PAK SERVICE, Luggage Rack
Tour-Pak mounting nuts 60–72 in-lbs 6.8–8.1 N·m 3.32 TOUR-PAK, Removal and Installation
Tour-Pak mounting nuts 60–72 in-lbs 6.8–8.1 N·m 3.32 TOUR-PAK, Removal and Installation
Tour-Pak mounting nuts 60–72 in-lbs 6.8–8.1 N·m 3.33 TOUR-PAK SERVICE, Ground Plate
Tour-Pak side marker lamp screws 20–25 in-lbs 2.3–2.8 N·m 3.33 TOUR-PAK SERVICE, Ground Plate
Tour-Pak support cover screws 8–18 in-lbs 0.9–2 N·m 3.32 TOUR-PAK, Tour-Pak Support
Tour-Pak support screws 15–20 ft-lbs 20.3–27.1 N·m 3.32 TOUR-PAK, Tour-Pak Support
Tour-Pak tether anchor screws 16–22 in-lbs 1.8–2.5 N·m 3.33 TOUR-PAK SERVICE, Tour-Pak Liner
Tour-Pak tether anchor screws 16–22 in-lbs 1.8–2.5 N·m 3.33 TOUR-PAK SERVICE, Tether
Tour-Pak tether reel screws 16–22 in-lbs 1.8–2.5 N·m 3.33 TOUR-PAK SERVICE, Tether
Turn signal lamp mounting screw, front: 48–60 in-lbs 5.4–6.8 N·m 3.41 OUTER FAIRING AND WINDSHIELD:
frame mounted fairing FRAME MOUNTED FAIRING MODELS, Outer
Fairing
Upper steering stem, final torque: Fork 63 in-lbs 7.1 N·m 3.20 STEERING HEAD BEARINGS, Install
mounted fairing models
Upper steering stem, final torque: Frame 192 in-lbs 21.7 N·m 3.20 STEERING HEAD BEARINGS, Install
mounted fairing models
Upper steering stem, final torque: Road 108 in-lbs 12.2 N·m 3.20 STEERING HEAD BEARINGS, Install
King models
Upper steering stem, final torque: Trike 108 in-lbs 12.2 N·m 3.20 STEERING HEAD BEARINGS, Install
models
Upper steering stem, first torque 35 ft-lbs 47.5 N·m 3.20 STEERING HEAD BEARINGS, Install
Upper support bracket to inner fairing 10–20 in-lbs 1.1–2.2 N·m 3.38 INNER FAIRING: FORK MOUNTED FAIRING
screws MODELS, Replace Inner Fairing Shell
Upper support bracket to inner fairing 10–20 in-lbs 1.1–2.2 N·m 3.38 INNER FAIRING: FORK MOUNTED FAIRING
screws MODELS, Upper Support Bracket
Upper support bracket to radio (storage 25–35 in-lbs 2.8–4 N·m 3.38 INNER FAIRING: FORK MOUNTED FAIRING
box) screws MODELS, Upper Support Bracket
Upper support bracket to speaker enclos- 48–60 in-lbs 5.4–6.8 N·m 3.38 INNER FAIRING: FORK MOUNTED FAIRING
ure screws MODELS, Upper Support Bracket
Valve stem nut 12–15 in-lbs 1.4–1.7 N·m 3.11 Tires, Install

3-8 94000383
FASTENER TORQUE VALUE NOTES
Windshield screws: Fork-mounted fairing 25–30 in-lbs 2.8–3.4 N·m 3.36 OUTER FAIRING AND WINDSHIELD: FORK
models MOUNTED FAIRING MODELS, Outer Fairing and
Windshield
Windshield screws: Frame mounted 8–12 in-lbs 0.9–1.4 N·m 3.41 OUTER FAIRING AND WINDSHIELD:
fairing models FRAME MOUNTED FAIRING MODELS, WIND-
SHIELD
Windshield screws: Frame-mounted 8–12 in-lbs 0.9–1.4 N·m 3.41 OUTER FAIRING AND WINDSHIELD:
fairing models FRAME MOUNTED FAIRING MODELS, Outer
Fairing
Windshield window screws: Road King 20–25 in-lbs 2.3–2.8 N·m 3.45 WINDSHIELD: ROAD KING MODELS,
models Windshield Window

94000383 3-9
SPECIFICATIONS 3.2
SPECIFICATIONS

Chassis Specifications
Table 3-1. Dimensions: FLHTCU, FLHTK, FLHTKL, FLTRU
ITEM FLHTCU FLHTKL FLTRU
FLHTK
in mm in mm in mm
Length 102.3 2600 101.8 2585 102.2 2595
Overall Width 37.8 960 37.9 962 36.3 921
Overall height 56.7 1440 54.6 1386 56.5 1434
Wheel base 64.0 1625 64.0 1625 64.0 1625
Road clearance 5.4 138 4.6 115 4.7 120
Seat height* 27.5 699 25.6 652 27.2 690
*With 180 lb (81.7 kg) rider on seat

Table 3-2. Dimensions: FLHR, FLHRC, FLHX, FLHXS, FLTRX, FLTRXS

ITEM FLHR FLHRC FLHX, FLHXS FLTRX, FLTRXS
IN MM IN MM IN MM IN MM
Length 96.5 2450 96.0 2438 95.4 2424 95.4 2424
Overall width 37.8 960 36.9 936 37.8 960 38.3 974
Overall height 57.5 1460 56.7 1440 52.6 1335 52.2 1325
Wheel base 64.0 1625 64.0 1625 64.0 1625 64.0 1625
Road clearance 5.3 135 5.5 139 4.8 122 4.8 122
Saddle height* 26.3 667 27.4 696 26.1 663 25.9 658
*With 180 lb (81.7 kg) rider on seat

Table 3-3. Capacities

Table 3-3. Capacities
ITEM U.S. METRIC
ITEM U.S. METRIC
Primary chaincase 34 oz 1.0 L
Fuel tank (total) 6.0 gal 22.7 L (dry fill; approximate) ***
Low fuel warning light on 1.0 gal 3.8 L Coolant, Twin-Cooled models 0.8 qt 0.8 L
(approximate) (approximate)
Engine oil capacity with filter * * When refilling, initially add 4.5 qt (4.3 L). Add more as
Twin-Cooled (new system) 5.0 qt 4.7 L needed to bring level within specification.
** When refilling, initially add 28 fl oz (0.83 L)Add more as
Air-Cooled (new system) 5.2 qt 4.9 L needed to bring level within specification.
Service oil change (all) 4.75 qt 4.5 L *** Amount is approximate. Fill to bottom of pressure plate
OD with vehicle upright.
Transmission ** 32 oz 0.95 L
(approximate)
Table 3-4. Weights: FLHTCU,FLHTK, FLHTKL, FLTRU
ITEM FLHTCU FLHTK FLTRU
FLHTKL
lb kg lb kg lb kg
Running weight* 894 406 909 413 929 422
Maximum added weight allowed** 466 211 451 204 431 195
GVWR 1360 617 1360 617 1360 617
GAWR front 500 227 500 227 500 227
GAWR rear 927 420 927 420 927 420
* 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 must not exceed this weight.

3-10 94000383
 Table 3-5. Weights: FLHR, FLHRC, FLHX, FLHXS, FLTRX, FLTRXS
ITEM FLHR FLHRC FLHX, FLHXS FLTRX, FLTRXS
LB KG LB KG LB KG LB KG
Running weight* 826 375 830 377 830 377 853 367
Maximum added weight 534 242 530 240 530 240 507 250
allowed**
GVWR 1360 617 1360 617 1360 617 1360 617
GAWR front 500 227 500 227 500 227 500 227
GAWR rear 927 420 927 420 927 420 927 420
* 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 must not exceed this weight.

WARNING NOTE
ABS equipped motorcycles must always use properly inflated
Do not exceed the motorcycle's Gross Vehicle Weight
tires and wheels that are the same as the original equipment.
Rating (GVWR) or Gross Axle Weight Rating (GAWR).
The ABS system monitors rotational speed of the wheels
Exceeding these weight ratings can lead to component
through individual wheel speed sensors to determine the
failure and adversely affect stability, handling and
application of ABS.
performance, which could result in death or serious injury.
(00016f) Different diameter wheels or tires can:

• GVWR is the sum of the weight of the motorcycle, • Alter the rotational speed which can upset the calibration of
accessories and the maximum weight of the rider, passenger the ABS.
and cargo that can be safely carried. • Adversely effect its ability to detect and prevent lockups.
• GAWR is the maximum amount of weight that can be safely Operating with inflation pressure other than those specified in
carried on each axle. Table 3-8 can reduce ABS performance.
• The GVWR and GAWR are shown on the information plate,
on the frame downtube. Tire model and size is molded on the sidewall. Refer to the tire
fitment tables below. Rim size and contour are cast or stamped
NOTE
into the exterior surface of the rim.
• The maximum additional weight allowed on the motorcycle
equals the Gross Vehicle Weight Rating (GVWR) minus the Example: T19 x 2.15 MT DOT
running weight. For example, a motorcycle with GVWR of
1,200 lb (544 kg) having a running weight of 800 lb (363 kg), • "T" indicates that the rim conforms to Tire and Rim
would allow a maximum of an additional 400 lb (181 kg) Association standards.
combined weight of the rider, passenger, riding gear, cargo • The "19" is the diameter of the rim in inches, measured at
and installed accessories. the bead seat diameter.
• For important information regarding tire data and tire • The "2.15" is the width of the bead seat measured in inches.
inflation, see TIRES AND WHEELS (Page 2-23). "MT" designates the rim contour.
• "DOT" means that the rim meets U.S. Department of
Tire Specifications Transportation Federal Motor Vehicle Safety Standards.
WARNING
Use only Harley-Davidson specified tires. See a
Harley-Davidson dealer. Using non-specified tires can
adversely affect stability, handling or braking, which could
result in death or serious injury. (00024b)
Table 3-6. Tire Fitment - Tubeless Cast Wheels
WHEEL SIZE RIM SIZE AND RIM VALVE
APPROVED TIRE
AND POSITION CONTOUR HOLE DIA.
Dunlop D408F
19 in - Front T19 x 3.50 MT 0.45 in (11.4 mm)
130/60B19 61H
Dunlop D408F
17 in - Front T17 x 3.00 MT 0.45 in (11.4 mm)
130/80B17 65H
Dunlop D407T
16 in - Rear T16 x 5.00 MT 0.45 in (11.4 mm)
180/65B16 81H

94000383 3-11
 Table 3-7. Tire Fitment - Tube Type Steel Laced Wheels
WHEEL SIZE RIM SIZE & TUBE APPROVED
& POSITION CONTOUR SIZE TIRE
16 in - Front T16 x 3.00D MT90-16/MU85-16 Dunlop D402F
130/90-150/80-16 MT90-B16 M/C 72H
16 in - Rear T16 x 5.00 MT 180/65-16 Dunlop D407
180/65-16 81H

Table 3-8. Specified Tires

MODEL MOUNT SIZE SPECIFIED TIRE PRESSURE (COLD
68 °F (20 °C)) *
psi kPa
FLHTCU, FLHTK, FLHTKL, front 17 in Dunlop D408F 130/80B17 M/C 65H 36 248
FLTRU, FLHR (cast)
FLHRC (laced) front 16 in Dunlop D402F MT90B16 M/C 72H (wide whitewall) 36 248
FLHX, FLHXS, FLTRX, FLTRXS front 19 in Dunlop D408F 130/60B19 M/C 61H 36 248
All with cast wheels rear 16 in Dunlop D407T 180/65B16 M/C 81H 40 276
FLHRC (laced) rear 16 in Dunlop D407 180/65B16 M/C 81H (wide whitewall) 40 276
* Tire pressure will vary with changes in ambient and tire temperature. Check pressure with tires cold (68 °F (20 °C)). Increase
tire pressure by 1 psi (6.9 kPa) for every 10 °F (5 °C) in ambient air temperature above this point.

3-12 94000383
VEHICLE IDENTIFICATION NUMBER (VIN) 3.3
VEHICLE IDENTIFICATION NUMBER (VIN)
om01391

General
See Figure 3-2. A unique 17-digit serial or Vehicle Identification
Number (VIN) is assigned to each motorcycle. Refer to Table
3-9.

Location
See Figure 3-1. The full 17-digit VIN is stamped on the right 2
side of the frame near the steering head. In some destinations,
a printed VIN label is also attached on the front downtube.
1
Abbreviated VIN
An abbreviated VIN showing the vehicle model, engine type,
model year, and sequential number is stamped on the left side
of the crankcase between the engine cylinders.

NOTE
Always give the full 17-digit Vehicle Identification Number when
ordering parts or making any inquiry about your motorcycle.
1. Stamped VIN
2. VIN label
Figure 3-1. VIN Locations

om00883l

1 2 3 4 5 6 7 8 9

1HD 1 KE D A 9 H B 600041
Figure 3-2. Typical Harley-Davidson VIN: 2017 Harley-Davidson Touring Models
Table 3-9. Harley-Davidson VIN Breakdown: 2017 Touring Models
POSITION DESCRIPTION POSSIBLE VALUES
1 World manufacturer identifier 1HD=Originally manufactured in the United States
5HD=Originally manufactured in the United States for sale outside of the
United States
932=Originally manufactured in Brazil
MEG=Originally manufactured in India
2 Motorcycle type 1=Heavyweight motorcycle (901 cm3 or larger)
3 Model See VIN model table
4 Engine type C=Milwaukee-Eight™ 107 Engine, 1753 cm3
D=Twin-Cooled™ Milwaukee-Eight™ 107 Engine, 1753 cm3
5 Calibration/configuration, introduc- Normal Introduction Mid-year or Special Introduction
tion 1=Domestic (DOM) 2, 4=Domestic (DOM)
3=California (CAL) 5, 6=California (CAL)
A=Canada (CAN) B=Canada (CAN)
C=HDI D=HDI
E=Japan (JPN) F=Japan (JPN)
G=Australia (AUS) H=Australia (AUS)
J=Brazil (BRZ) K=Brazil (BRZ)
L=Asia Pacific (APC) M=Asia Pacific (APC)
N=India (IND) P=India (IND)
6 VIN check digit Can be 0-9 or X
7 Model year H=2017

94000383 3-13
 Table 3-9. Harley-Davidson VIN Breakdown: 2017 Touring Models
POSITION DESCRIPTION POSSIBLE VALUES
8 Assembly plant B=York, PA U.S.A.
D=H-D Brazil-Manaus, Brazil (CKD)
N=Haryana India (Bawal District Rewari)
9 Sequential number Varies

Table 3-10. VIN Model Codes: 2017 Touring Models

CODE MODEL CODE MODEL
FB FLHR Road King® KH FLTRX Road Glide®
FC FLHTCU Electra Glide® Ultra Classic® KK FLHTKL Ultra Limited Low
FR FLHRC Road King® Classic KN FLHTK Ultra Limited Shrine
KB FLHX Street Glide® KR FLHXS Street Glide® Special
KE FLHTK Ultra Limited KT FLTRXS Road Glide® Special
KG FLTRU Road Glide® Ultra

3-14 94000383
FRONT WHEEL 3.4
REMOVE sm05733a

NOTICE

When lifting a motorcycle using a jack, be sure jack 1

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

1. Raise the front end of the motorcycle.

2. Check wheel bearings. See SEALED WHEEL BEARINGS
(Page 3-33).
3. Measure brake disc runout. See BRAKE PADS AND
DISCS (Page 2-34).
4. See Figure 3-3. Remove both brake calipers. Temporarily
secure calipers to engine guard.
1. Caliper fasteners
a. ABS models: Cut cable straps to release front WSS 2. Wheel speed sensor cable retainer
and fender tip lamp cables from left caliper brake hose. Figure 3-3. Remove Front Caliper
b. Remove screws (1).
sm07612
c. Left side: Allow WSS cable to remain in retainer (2).
12 6
5
d. Remove caliper from disc.
4
NOTE
Do not operate the front brake hand lever with the calipers
removed or the pistons may be forced out. The caliper contains 8 7
no serviceable components and would require replacement. 3
3
5. See Figure 3-4. Remove wheel. 2 9
8
a. Remove the axle nut (6) and flat washer (5).
1 10
b. Loosen axle pinch screw at bottom of right side fork
slider. 11
NOTE
Never pull WSS cable taut or use to retain wheel, axle or 1. Axle
other components. Always keep the WSS and ABS 2. Outer spacer
encoder bearing away from magnetic fields. Items such 3. Bearing (2)
as magnetic parts trays, magnetic base dial indicators, 4. Inner spacer
alternator rotors will damage sensor. 5. Flat washer
6. Nut
7. WSS
c. Remove the axle (1) from right side of motorcycle. Catch
8. Screw, brake disc
outer spacer(s) (2) and front wheel speed sensor (WSS)
9. Bushing (cast wheels)
(7) (if ABS equipped) as the axle is removed.
10. Spring washer (cast wheels)
11. Cast wheel (typical)
12. Laced wheel
Figure 3-4. Front Wheel (typical)
INSTALL

FASTENER TORQUE VALUE

Front axle nut 70–75 ft-lbs 94.9–101.7N·m
Front axle pinch screw 18–22 ft-lbs 24.4–29.8 N·m

NOTE
• See Figure 3-4. Install outer spacers (2) with grooves on
the outboard side.

94000383 3-15
• ABS models: Install WSS (7) with index pin on the outboard
sm07482
side.
• Left and right spacers are interchangeable on non-ABS
models.

1. Install front wheel.

a. See Figure 3-4. Apply a light coat of ANTI-SEIZE

LUBRICANT to axle (1), bearing bores and bore of 1
spacer (4).

b. Place wheel into position with the valve stem on the

right side.

c. Install axle through right fork, outer spacer, wheel

hub, front WSS (ABS models) or second outer
spacer, and left fork.

d. Install flat washer (5) and axle nut (6). 2

e. ABS models: Rotate WSS until it contacts rear of
fork slider. Back off just enough to maintain clearance
between the WSS wire stem and fork slider.

2. Tighten axle nut to 70–75 ft-lbs (94.9–101.7 N·m).

NOTE
ABS models: See Figure 3-3. Verify that WSS cable is 1. WSS cable, fender tip lamp cable, brake hose
installed in bracket and that retainer is secure. Retainer cannot 2. WSS cable, brake hose
be installed once mounting screws are started.
Figure 3-5. Secure Cables and Brake Hose

3. Push and hold right fork slider inboard until it contacts

DISASSEMBLE
external spacer. Tighten axle pinch screw to 18–22 ft-lbs
(24.4–29.8 N·m). 1. See Figure 3-4. Remove front brake disc.
a. Remove and discard screws (8) (metric).
4. Install brake calipers and sensor cable retainer (ABS
models). See FRONT BRAKE CALIPER (Page 3-43). b. Cast wheels: Remove bushings (9) and spring washers
(10).
5. See Figure 3-5. ABS models: Secure WSS and fender c. Remove front brake disc.
tip lamp cables with new cable straps (1, 2). d. Repeat with opposite side.

2. Remove front tire. See Tires (Page 3-36).

3. Remove and discard sealed wheel bearings. See SEALED
WHEEL BEARINGS (Page 3-33).
4. Remove wheel bearing spacer (4).
5. Clean all parts, except bearings and WSS, for inspection.
CLEAN AND INSPECT

1. Clean parts in solvent (WSS and bearings excepted).

2. Measure disc thickness for excessive wear. Minimum
acceptable thickness is stamped on side of disc. Replace
disc if warped, badly scored or worn beyond service limit.
3. Inspect wheel for damage.
4. Check wheel runout. See WHEEL RUNOUT (Page 3-29).
ASSEMBLE

FASTENER TORQUE VALUE

Brake disc, front, screws 16–24 ft-lbs 21.7–32.5 N·m
(metric)

3-16 94000383
1. Install tire. See Tires (Page 3-36).

NOTE
• When installing front brake discs, align the rivets with the
rivets on the opposite disc.
• See Figure 3-4. Cast wheels: Install bushings (9) and spring
washers (10) under screws (8).

2. See Figure 3-4. Install inner spacer (4) and new sealed
wheel bearings (3). See SEALED WHEEL BEARINGS
(Page 3-33).

NOTICE

Do not re-use brake disc/rotor screws. Re-using these

screws can result in torque loss and damage to brake
components. (00319c)

3. See Figure 3-4. Install brake discs using new screws (8)
(metric). Tighten in a cross-wise pattern to 16–24 ft-lbs
(21.7–32.5 N·m).

94000383 3-17
REAR WHEEL 3.5
PREPARE 1. Remove axle.
a. See Figure 3-6. Remove E-clip (1) from axle (17).
1. Remove saddlebags. See SADDLEBAGS (Page 3-98).
b. See Figure 3-8. Hold weld nut on left side and loosen
2. Raise the rear of the motorcycle. cone nut using AXLE NUT TORQUE ADAPTER (PART
3. Inspect wheel bearings. See SEALED WHEEL BEARINGS NUMBER: HD-47925).
(Page 3-33). c. See Figure 3-6. Remove cone nut (2) and adjuster cam
4. Measure brake disc runout. See BRAKE PADS AND (3) from axle.
DISCS (Page 2-34). d. Rotate weld nut to loosen drive belt.
5. Measure sprocket isolator wear. See REAR SPROCKET e. Remove the axle from the left side. Catch external
ISOLATOR (Page 2-42). spacers (5, 16), caliper bracket and rear WSS (6) (ABS
6. Remove left muffler. See EXHAUST SYSTEM (Page 5-26). equipped) as the axle is removed.

7. Models with manual adjust shock absorbers: Remove NOTE

left side lower saddlebag support rail. See SADDLEBAG
SERVICE, Saddlebag Support (Page 3-101).
8. ABS models: Release rear WSS cable from rear brake
hose.
9. Remove rear brake caliper but do not disconnect the brake
hose. Set brake caliper on passenger footboard. See
REAR BRAKE CALIPER (Page 3-47).
NOTE
Do not operate brakes with the caliper removed or the caliper
pistons may be forced out. The caliper contains no serviceable
components and would require replacement.
• Always keep the WSS (6) and ABS encoder bearing away
from magnetic fields. Keep wheel speed sensor and ABS
encoder bearing away from magnetic fields.
• Never pull WSS cable taut or use to retain wheel, axle or
other components.
2. Remove caliper bracket from anchor weldment on rear
fork.
NOTE
If vehicle has hot exhaust, place a shop towel over exhaust
cross-over pipe.

REMOVE 3. Remove belt from compensator sprocket (16).

NOTE
PART NUMBER TOOL NAME Hold sprocket while removing rear wheel to prevent it from
HD-47925 AXLE NUT TORQUE ADAPTER dropping.

4. Remove wheel.

3-18 94000383
 sm07613

13 17
16

12 15
14

11
6 10
7

5
8 9

1 4
2 3

1. E-clip 10. Spacer sleeve

2. Cone nut 11. Left wheel bearing, standard
3. Adjuster cam 12. Isolator
4. Screw (5) 13. Compensator sprocket
5. External spacer (thick) 14. Spacer, compensator
6. Rear wheel speed sensor 15. Sprocket bearing (2)
7. Brake disc 16. External spacer (thin)
8. Right wheel bearing, standard or ABS 17. Axle
9. Wheel, typical
Figure 3-6. Rear Wheel (typical)
INSTALL WARNING
Never bend belt forward into a loop smaller than the drive
FASTENER TORQUE VALUE sprocket diameter. Never bend belt into a reverse loop.
Rear axle cone nut, first torque 15–20 ft-lbs 20–27 N·m Over bending can damage belt resulting in premature
failure, which could cause loss of control and death or
1. See Figure 3-7. Inspect caliper bracket. Replace rubber serious injury. (00339a)
bumper (2) if necessary.
d. Seat caliper bracket on anchor weldment of rear fork.
a. Lubricate anchor of new bumper with isopropyl
alcohol or glass cleaner. e. Apply ANTI-SEIZE LUBRICANT to axle (17), bearing
bores and bore of spacer sleeve (10).
b. Pull rubber bead through hole to the inboard side of
the caliper bracket. f. Slide axle through left side of rear fork, external
spacer (thin) (16), sprocket (13), wheel hub, rear
2. See Figure 3-6. Install rear wheel. WSS (ABS equipped) or external spacer (thick) (5),
caliper bracket and right side of rear fork.
a. Verify that sprocket (13) is fully seated in wheel.
g. Rotate axle with flat on threaded end topside.
b. Place wheel in rear fork.
h. Apply a light coat of ANTI-SEIZE LUBRICANT to the
c. Install belt over sprocket. Slide wheel back. inboard face of the cone nut (2) avoiding contact with
threads.

i. Install adjuster cam (3) and cone nut. Finger-tighten

only.

94000383 3-19
 5. See Figure 3-6. Install a new E-clip (6) with the flat side
sm08577
out.

sm04028

1. Caliper bracket
2. Rubber bumper
Figure 3-7. Caliper Bracket

sm04528a
Figure 3-9. Rear Wheel Speed Sensor Index Pin (ABS
2 Equipped)
COMPLETE

FASTENER TORQUE VALUE

Brake caliper, rear, mounting 43–48 ft-lbs 58.3–65.1 N·m
screws

1. Install the brake caliper with two screws. Tighten to

1 43–48 ft-lbs (58.3–65.1 N·m).

2. Secure rear WSS cable to the brake hose. Locate the

conduit clip approximately 1.25 in (31.8 mm) in front of
the brake hose crimp.

3. Adjust drive belt deflection. See DRIVE BELT AND

SPROCKETS (Page 2-37).

4. Install the left side lower saddlebag support rail if removed.

See SADDLEBAG SERVICE, Saddlebag Support
(Page 3-101).

5. Install left muffler. See EXHAUST SYSTEM (Page 5-26).

6. Install saddlebags. See SADDLEBAGS (Page 3-98).

DISASSEMBLE
1. Torque wrench
2. Axle nut torque adapter (HD-47925) 1. Remove sprocket and rubber isolator. See REAR WHEEL
Figure 3-8. Install Tool Perpendicular to Torque Wrench COMPENSATOR (Page 3-22).

3. ABS models: Route WSS cable. 2. Remove tire. See Tires (Page 3-36).
3. See Figure 3-6. Remove brake disc (7).
a. Route forward and outboard of caliper bracket. Then
along the top of the rear fork. a. If wheel will be assembled with the same disc, mark
both the wheel and disc so that it can be installed in its
b. See Figure 3-9. Rotate WSS counterclockwise until original position.
index pin contacts caliper bracket. b. Remove and discard screws (4).
c. Remove brake disc.
4. Tighten the cone nut to a preliminary torque of 15–20 ft-lbs
(20–27 N·m). The final torque is done during the belt
4. Remove bearings and inner spacer. See SEALED WHEEL
adjustment procedure.
BEARINGS (Page 3-33).

3-20 94000383
CLEAN AND INSPECT

1. Clean parts in solvent (WSS and bearings excepted).

2. Measure disc thickness. Minimum acceptable thickness
is stamped on side of disc. Replace disc if warped, badly
scored or worn beyond service limit.
3. Inspect the compensator.
a. Check for wear, tooth damage, cracks or pitting.
b. Check isolator for crumbling, flaking, excessive wear
or general deterioration.
c. Check sprocket bearing.

4. Inspect wheel for damage.

5. Check wheel runout. See WHEEL RUNOUT (Page 3-29).
ASSEMBLE

FASTENER TORQUE VALUE

Brake disc, rear, screws 30–45 ft-lbs 41–61 N·m

NOTICE

Do not re-use brake disc/rotor screws. Re-using these

screws can result in torque loss and damage to brake
components. (00319c)
NOTE
Install brake disc in its original position.

1. Install bearings and inner spacer. See SEALED WHEEL

BEARINGS (Page 3-33).

2. See Figure 3-6. Install brake disc (7) using new screws
(4). Tighten screws in a cross-wise pattern to 30–45 ft-lbs
(41–61 N·m).

3. Install tire. See Tires (Page 3-36).

4. Install rubber isolator and sprocket (13). See REAR

WHEEL COMPENSATOR (Page 3-22).

94000383 3-21
REAR WHEEL COMPENSATOR 3.6
PREPARE sm05781a

1. Check compensator sprocket isolator for wear. See REAR 1

WHEEL COMPENSATOR (Page 3-22).
2. Remove rear wheel. See REAR WHEEL (Page 3-18). 2
REMOVE
1. See Figure 3-10. Remove rear wheel compensator.
a. Pull sprocket (1) from rear wheel (3).
b. Remove isolator (2) from wheel. Discard isolator.

sm08519

1 3

1. Rib
2. Isolator segment
2 3. Sprocket lug gap
5
4 Figure 3-11. Install Isolator in Wheel
COMPLETE

1. Install rear wheel. See REAR WHEEL (Page 3-18).

DISASSEMBLE
3
PART NUMBER TOOL NAME
1. Rear sprocket
2. Isolator HD-48921 REAR WHEEL COMPENSATOR
3. Rear wheel SPROCKET BEARING
4. Spacer REMOVER/INSTALLER
5. Sprocket bearing (2)
1. See Figure 3-10. Remove sprocket bearings (5).
Figure 3-10. Rear Wheel Compensator
a. See Figure 3-12. Support the base (1) of REAR WHEEL
INSTALL COMPENSATOR SPROCKET BEARING
REMOVER/INSTALLER (PART NUMBER: HD-48921)
1. Install new rear wheel compensator. on a suitable press with the large OD facing up and the
a. See Figure 3-11. Lubricate each segment (2) of new long pin facing down.
isolator with equal mix of isopropyl alcohol and water. b. Slide sleeve (2) over the short pin.
b. Push new isolator into wheel. Verify that each isolator c. Slide the sprocket inboard side up over the sleeve until
segment is completely installed and is flush with each it rests on the base.
rib (1).
d. Slide the small OD of driver (3) over the sleeve until it
c. See Figure 3-10. Push sprocket (1) onto wheel (3). contacts the spacer.
e. Apply pressure to the driver until bearings drop into
base.

2. Remove tool.
3. See Figure 3-10. Discard bearings (5).

3-22 94000383
 sm04547

1 2 3

1. Base
2. Sleeve
3. Driver
Figure 3-12. Rear Wheel Compensator Bearing Remover/In-
staller (HD-48921)
CLEAN AND INSPECT
1. Clean all parts thoroughly. Verify that sprocket bearing
bore is clean and dry.
2. Inspect each tooth of the rear wheel sprocket for wear or
damage. Replace as necessary. See REAR WHEEL
COMPENSATOR (Page 3-22).
ASSEMBLE

PART NUMBER TOOL NAME

HD-48921 REAR WHEEL COMPENSATOR
SPROCKET BEARING
REMOVER/INSTALLER

1. See Figure 3-10. Install spacer (4) and new sprocket

bearings (5).
a. See Figure 3-12. Support the base (1) of REAR WHEEL
COMPENSATOR SPROCKET BEARING
REMOVER/INSTALLER (PART NUMBER: HD-48921)
on a suitable press with the large OD facing up and the
long pin facing down.
b. Slide sleeve (2) over the short pin.
c. Slide the sprocket outboard side up over the sleeve
until it rests on the base.
d. Install spacer in the sprocket with the small diameter
facing down.
e. Set first new bearing in place.
f. Center the large OD of driver (3) onto the bearing. Verify
that the driver contacts complete radius of the outer
bearing race.
g. Apply pressure to the driver until the bearing is firmly
seated in the counterbore of the sprocket.
h. Repeat for second new bearing.

94000383 3-23
WHEEL LACING: FRONT RIM 3.7
LACE WHEEL: ANGLE FLANGE HUB sm06503

NOTE
• See Figure 3-13. The following procedure is valid for wheels
that use an angle flange hub regardless of rim style or
diameter.
• Disc mounting surface for primary brake side of hub has
one or two grooves.
1
sm06505
1
2

1. Outer spoke
2. Inner spoke
Figure 3-14. Spokes Gathered
7. See Figure 3-15. Install lower flange outer spokes and
loosely install spoke nipples. Start at the first hole
2 counterclockwise (1) from valve stem hole.
8. Install remaining outer spokes in every fourth hole.
1. Outer spoke hole
2. Inner spoke hole 9. Install lower flange inner spokes and loosely install spoke
nipples:
Figure 3-13. Angle Flange Hub
a. Starting at the second hole counterclockwise (2) from
1. Place hub on workbench with primary brake side up.
first spoke installed, install inner spoke.
2. Install all spokes in the lower flange.
b. Install remaining inner spokes in every fourth hole.
3. See Figure 3-14. Flip hub over. Gather all outer spokes
and hold upright with a rubber band. Repeat with the inner 10. Carefully release upper flange inner spokes and fan out
spokes using a second rubber band. around rim, rotating them clockwise.
4. Install spokes in remaining flange. 11. Starting at the first hole counterclockwise (3) from first
spoke installed, install inner spoke. Install remaining inner
5. Rotate the lower flange spokes as far as they go:
spokes in every fourth hole.
a. Outer spokes clockwise.
12. Carefully release upper flange outer spokes and fan out
b. Inner spokes counterclockwise. around rim, rotating them counterclockwise.
13. Install outer spokes in remaining holes (4).
6. Center the rim over the hub and spokes assembly and
support on wooden blocks approximately 1.5 in (38.1 mm) 14. Verify that spoke heads are seated. See WHEEL RUNOUT
thick. (Page 3-29).

NOTE a. Evenly hand-tighten spoke nipples until snug.

Install nipples until approximately ⅛ in (3.2 mm) of spoke thread b. Only tighten until slack is removed.
is still visible.
c. Proper torque is applied when the wheel is trued.
d. Adjust offset and true the wheel.

3-24 94000383
 sm06507
2 3 1
4

Figure 3-15. Center Valve Rim

94000383 3-25
WHEEL LACING: 16 INCH REAR RIM 3.8
LACE WHEEL: 16 IN. REAR WHEEL sm06031

1. See Figure 3-16. Divide spokes into two groups.

a. Outer spokes (short heads) (1).
b. Inner spokes (long heads) (2).
1
NOTE
See Figure 3-17. The spoke holes in the wheel hub are
staggered, alternating between inner holes (2) (nearer hub
center) and outer holes (1) (nearer hub edge).

sm06086
2
1 2

1. Outer spoke (short head)

2. Inner spoke (long head)
Figure 3-18. Lacing Wheel Hub

sm06032

1. Short head (outer spoke)

2. Long head (inner spoke)
Figure 3-16. Spoke Heads

sm01786

Figure 3-19. Arrange Spokes

1. Outer spoke hole
2. Inner spoke hole NOTE
Figure 3-17. Spoke Hole Pattern See Figure 3-20. Tape placed across brake disc flange and
spoke heads will hold spokes up away from lower row of
2. Lubricate all spoke threads and nipple shoulders with tire spokes, making it easier to gather upper spokes.
mounting lubricant.
3. See Figure 3-18. Place hub on workbench with the brake 6. See Figure 3-20. Group upper spokes (brake-side) into
disc side down. Insert outer spokes (1) (short-head) into bundles of two as shown. Join an outer spoke (1) with the
the outer holes and inner spokes (2) (long-head) in the inner spoke (2) that is located four places clockwise.
inner holes. Secure with tape (3) approximately 1 in (25 mm) from
threaded end.
4. See Figure 3-19. After spokes are installed, flip wheel hub
over. Swing outer spokes counterclockwise and inner
spokes clockwise as shown. Each inner spoke crosses
four outer spokes, and each outer spoke crosses four inner
spokes.
5. Install all outer spokes, then all inner spokes on brake-side
flange. Swing inner spokes counterclockwise and outer
spokes clockwise on brake-side flange, each crossing four
of the opposite type.

3-26 94000383
 sm06033 3 2 sm06034
1
1

3
4
2
2
2
1
3

1. Outer spoke (short head)

2. Inner spoke (long head) 1. Valve stem location
3. Tape 2. Wooden blocks
Figure 3-20. Bundling Spokes 3. Beginning spoke location
Figure 3-21. Place Rim
7. Make sure that all spokes on compensator-side flange are
still arranged properly and pointing in the correct direction: NOTE
See Figure 3-22. It is recommended that the first spoke be
a. All outer spokes (short-head) point counterclockwise,
installed near the valve stem hole (5). Place spoke nipples
crossing four inner spokes.
through several rim holes to determine the hole direction. Only
b. All inner spokes (long-head) point clockwise, crossing one spoke will fit into the spoke nipple correctly. When
four outer spokes (short-head). connecting the spoke to the spoke nipple, finger-tighten two
to three threads.
c. Angle all spokes as far as they will go without
overlapping the next LIKE spoke.
9. See Figure 3-22. Begin with the outer spokes (short-head)
NOTE of the lower (compensator) flange. Using the spoke
alignment method discussed previously, locate a spoke
• Verify that all inner spokes lay inboard and outer spokes lay
hole (1) just left of the valve stem hole (5) that points
outboard.
toward an outer spoke.
• See Figure 3-21. The valve stem hole location (1) is
a. Secure spoke to nipple. Skip three rim holes and repeat
centered on the rim so rim orientation is not important.
with the next outer spoke. Follow pattern to complete
lower (compensator) flange outer spokes (short-head).
8. See Figure 3-21. Center the rim over the hub/spoke
assembly and support on wooden blocks (2) approximately b. Once completed, check for three empty holes between
1.5 in (38.1 mm) thick. Rotate so valve stem hole (1) is each spoke.
near a pair of taped spokes.
10. Install the lower (compensator) flange inner spokes
(long-head) next. Choose a beginning spoke (2) near the
valve stem hole (5).
a. Each inner spoke (long-head) points clockwise and
crosses four outer spokes (short-head).
b. Secure spoke to nipple. Complete installing lower flange
inner spokes (long-head).

94000383 3-27
 sm06010a sm06011a

5
4 2
1
3

4 2 5
1
3
Figure 3-23. Completed 16 Inch Rear Wheel
15. Verify that completed wheel resembles Figure 3-23.
16. Verify that spoke heads are seated. Evenly hand-tighten
spoke nipples until snug. Only tighten until slack is
removed. Proper torque is applied when the wheel is trued.
17. Adjust offset and true the wheel. See WHEEL RUNOUT
(Page 3-29).

1. Compensator-side outer spoke

2. Compensator-side inner spoke
3. Brake-side inner spoke
4. Brake-side outer spoke
5. Valve stem hole
Figure 3-22. Begin Lacing
NOTE
Do not move outer spokes (short-head) under inner spokes
(long-head) when removing the tape or they will become
trapped underneath the inner row of spokes.

11. See Figure 3-21. Remove tape from each upper bundle
and fan the spokes out toward the rim.
NOTE
All upper flange inner spokes (long-head) point
counterclockwise and outer spokes (long-head) clockwise.

12. See Figure 3-22. Choose a beginning spoke near the valve
stem hole (5). Start with a brake-side inner spoke (3)
(long-head) first.
a. Secure spoke to nipple. Follow pattern to complete
brake-side flange inner spokes (long-head).
b. Once completed, check for one empty hole after every
third spoke.

13. Install brake-side outer spoke (4) (short-head).

14. Secure spoke to nipple. Complete upper flange outer
spokes (short-head).

3-28 94000383
WHEEL RUNOUT 3.9
PREPARE sm02465

1. Remove wheel. See FRONT WHEEL (Page 3-15) or REAR

WHEEL (Page 3-18).
2. Check wheel bearings. See SEALED WHEEL BEARINGS
(Page 3-33).
INSPECT

PART NUMBER TOOL NAME

HD-99500-80 WHEEL TRUING STAND

Wheel Stand
1. Mount wheel in a WHEEL TRUING STAND (PART
NUMBER: HD-99500-80).
a. Install the truing arbor in the wheel hub so that the hub
spins freely on its bearings.

2. Mount a gauge rod or a dial indicator to the base of the

truing stand.

Lateral Runout
NOTE
Check runout on all wheels before installing a new tire. If either
measurement is not within specification:
• Cast wheel: Replace the wheel. Figure 3-24. Checking Lateral Runout

• Laced wheel: Adjust spokes to true the wheel. See steps in sm03117a

this section.

1. Check lateral wheel runout.

a. See Figure 3-24. Adjust the gauge rod or indicator at
the rim bead safety hump.
b. Rotate the wheel and measure the lateral distance at
several locations.
c. Compare readings to specifications. Refer to Table
3-11.
1

Radial Runout
1. Check radial wheel runout.
a. See Figure 3-25. Point the gauge rod or indicator at the
rim tire bead safety hump.
b. Rotate the wheel and measure the lateral distance at
several locations. 2
4
c. Compare readings to specifications. Refer to Table
3-11.
3
2. Replace or adjust as necessary.

Table 3-11. Wheel Rim Runout

MEASUREMENT MAXIMUM
1. Wheel truing and balancing stand
Lateral 0.030 in (0.76 mm)
2. Radial runout
Radial 0.030 in (0.76 mm) 3. Gauge rod
4. Bead safety hump
Figure 3-25. Checking Radial Runout

94000383 3-29
COMPLETE NOTE
• Always loosen the appropriate spokes before tightening the
1. Install wheel. See FRONT WHEEL (Page 3-15) or REAR other two. Reversing this procedure causes the rim to
WHEEL (Page 3-18). become out-of-round. For example: If the right side is less
than specification, loosen the two spokes on the hub right
LACED WHEEL RIM OFFSET side. Then tighten the two spokes attached to the hub left
side.
PART NUMBER TOOL NAME
• Tighten or loosen spokes one flat at a time and recheck
HD-94681-80 SPOKE WRENCH measurement.
HD-99500-80 WHEEL TRUING STAND
• Always work on groups that are opposite each other to
1. See Figure 3-26. Prepare rim. maintain radial runout.

a. Place a piece of tape to mark the center of each group 4. If the dimension is not correct, adjust the four spokes using
of four spokes as shown. SPOKE WRENCH (PART NUMBER: HD-94681-80). Turn
b. Mark groups directly opposite one another and all four spokes an equal number of turns until offset is at
approximately 90 degrees apart. specification.

c. Use different colors of tape or number each group. 5. Repeat the previous step for all groups on the wheel.
6. Check wheel runout. See WHEEL RUNOUT, True Laced
sm01235
Wheels (Page 3-31).

1 2 sm03223

3
Figure 3-27. Checking Wheel Hub Offset Dimension (Typ-
ical)
DO NOT Figure
MOVE3-26. Marking
TAPE Spoke
(2, 4) Groups
LOCATIONS.
THEY
2. SeeMUST BEMount
Figure 3-27. IN THE
CENTER OF ATRUING
wheel in WHEEL GROUP OF FOUR.
STAND Table 3-12. Laced Wheel Offset Dimensions
(PART NUMBER: HD-99500-80) so hub turns freely on
RIM RIM RIM SIZE OFFSET (A)
its bearings.
TYPE LOCATION IN MM
NOTE
Disc mounting surface for primary brake side of hub has one Steel Front (1) 16 x 3 1.551-1.571 39.4-39.9
or two grooves. Laced
Rear (2) 16 x 5 1.098-1.118 27.9-28.4

3. Measure offset.
sm08045
a. Lay a straightedge across the primary brake disc
mounting surface and one of the marked spoke groups.
b. See Figure 3-28. Measure the distance from the <body>Replace or adjust as necessary.</body>
straightedge to the location shown to determine distance 1 2
A.
c. Compare to dimensions in Table 3-12.

Figure 3-28. Laced Wheel Hub Offset Dimension

3-30 94000383
TRUE LACED WHEELS WARNING
Spokes that are too tight can draw nipples through the rim
PART NUMBER TOOL NAME or distort hub flanges. Spokes that are too loose can
HD-48985 SPOKE TORQUE WRENCH continue to loosen when put in service. Either condition
HD-94681-80 SPOKE WRENCH can adversely affect stability and handling, which could
HD-99500-80 WHEEL TRUING STAND result in death or serious injury. (00286a)

FASTENER TORQUE VALUE sm03117a

Spoke nipple 55 in-lbs 6.2 N·m

NOTE
• Dial indicators are more accurate than gauge rods.
• Perform radial truing before lateral truing.

Adjust Radial Runout

1. See Figure 3-29. Mount wheel in WHEEL TRUING STAND 1
(PART NUMBER: HD-99500-80).
2. Adjust the gauge rod (3) near to the tire bead safety hump
(4). If using a dial indicator, place the tip on the safety bead
hump.
3. Straight flange hub: Seat each spoke head in the hub
flange using a flat nose punch and mallet.
NOTE
• Always loosen the appropriate spokes before tightening the 2
4
other two. Reversing this procedure causes the rim to
become out of round.
• Tighten or loosen spoke. Then recheck measurement. Small 3
changes in the spokes can make large changes in the
runout.
• Always work on groups that are opposite each other to
maintain radial runout.
1. Wheel truing and balancing stand
4. Spin the rim slowly. Check radial runout (2). The rim must 2. Radial runout
be true within 0.030 in (0.76 mm). 3. Gauge rod
4. Bead safety hump
a. Use SPOKE WRENCH (PART NUMBER:
Figure 3-29. Checking Radial Runout
HD-94681-80).
b. If the rim contacts the gauge on or near a marked group Table 3-13. Spoke Nipple Torque Specification
of spokes, loosen the spokes in the group on the
RIM TYPE MINIMUM TORQUE
opposite side of the rim. Then tighten the spokes in the
group where the rim makes contact an equal number All 55 in-lbs (6.2 N·m)
of turns.
c. If the rim contacts the gauge between two marked Adjust Lateral Runout
groups, loosen the spokes in both groups on the NOTE
opposite side of the rim. Then tighten the spoke groups Dial indicators are more accurate than gauge rods.
on the side of the rim that makes contact an equal
number of turns.
1. See Figure 3-30. Adjust the gauge rod (3) near to the rim
bead flange. If using a dial indicator, place the tip against
5. When the wheel is true, start at the valve stem hole and
the bead flange.
tighten any loose spoke nipples one turn at a time until
they are snug. 2. Rotate the rim slowly to check lateral runout (2). If runout
exceeds 0.030 in (0.76 mm), adjust spokes:
6. Working alternately across the wheel, use SPOKE
TORQUE WRENCH (PART NUMBER: HD-48985) evenly NOTE
tighten all spokes to specification listed in Table 3-13. • Always loosen the appropriate spokes before tightening the
7. Straight flange hub: Verify that each spoke head is seated other two. Reversing this procedure causes the rim to
in the hub flange using a flat nose punch and mallet. become out of round.

8. Verify that radial runout is still within specification. • Tighten or loosen spoke. Then recheck measurement. Small
changes in the spokes can make large changes in the
9. Proceed to lateral runout. runout.

94000383 3-31
• Always work on groups that are opposite each other to
maintain radial runout.

3. Working in groups of four, loosen two spokes on the tight

side and tighten the two spokes on the loose side.
4. Repeat with each group until wheel is within specification.
5. Verify that all spoke nipples are tightened to the
specification. Refer to Table 3-13.
6. File or grind off ends of spokes that protrude through the
nipples to prevent puncturing tube or rim seal.

sm03115

1. Wheel truing and balancing stand

2. Lateral runout
3. Gauge rod
Figure 3-30. Checking Lateral Runout

3-32 94000383
SEALED WHEEL BEARINGS 3.10
INSPECT 1. Remove wheel. See FRONT WHEEL (Page 3-15) or REAR
WHEEL (Page 3-18).
NOTICE 2. Rear wheel: Remove sprocket.

When lifting a motorcycle using a jack, be sure jack NOTE

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)
1. Raise the wheel.
2. Turn the wheel through several rotations.
NOTE
• Keep wheel speed sensor and ABS encoder bearing away
from magnetic fields.
• When checking end play, pull or push on the wheel not the
brake disc. Pulling or pushing brake disc can distort disc
causing a false end play reading.
3. Check end play:
a. See Figure 3-31. Mount a magnetic base dial indicator
to the brake disc. Set the indicator contact point on the
end of the axle.
b. Firmly push the wheel to one side. Zero the dial indicator
gauge.
c. Firmly pull the wheel back. Note the reading of the dial
indicator.
d. Repeat the procedure to verify the reading.
e. Replace the bearings if end play exceeds 0.002 in
(0.051 mm) or if there is drag, rough rotation or
abnormal noise.
sm07626
• Primary side of the wheel is the brake rotor side. For dual
disc front wheels, the primary side is the left side.
• Remove the primary side bearing first.
3. See Figure 3-32. Assemble WHEEL BEARING
INSTALLER/REMOVER (PART NUMBER: HD-44060D).
a. Lubricate forcing screw.
b. Install nut (2), washer (3) and bearing (4) on screw.
c. Insert assembly through hole in bridge (5).
NOTE
Choose the appropriate collet to remove the bearing.
• Non-ABS models: Use COLLET (PART NUMBER:
HD-44060-10A).
• ABS models: Use COLLET (PART NUMBER:
HD-44060-11A).
4. Install ball bearing inside collet (6). Fasten collet and ball
bearing to forcing screw (1).
NOTE
• See Figure 3-33. If the puller bridge does not have adequate
support, place a scrap brake disc having the small center
hole to support the puller bridge.
• OE disc removal is not necessary. Place the scrap disc
directly over the OE disc mounting screws.
• If the OE disc has been removed, place tape or other
protective material between hub and scrap disc to prevent
cosmetic damage.

5. Remove bearings.
a. See Figure 3-32. Hold end of forcing screw (1) and turn
collet (6) to expand edges of collet.
b. See Figure 3-34. Hold forcing screw (1) and turn nut
(2) to remove bearing.
c. See Figure 3-35. Remove spacer sleeve (6) from inside
wheel hub.
d. Repeat on opposite side.

6. Discard all bearings.

Figure 3-31. Wheel Bearing Inspection (Front Wheel Shown)

REMOVE

PART NUMBER TOOL NAME

HD-44060-10A COLLET
HD-44060-11A COLLET
HD-44060D WHEEL BEARING
INSTALLER/REMOVER

94000383 3-33
 sm07627 sm07628a

2 1
3
4
2
5

1. Forcing screw
2. Nut
3. Washer 1. Forcing screw
4. Bearing 2. Nut
5. Bridge
Figure 3-34. Removing Bearing
6. Collet with ball bearing inside
Figure 3-32. Wheel Bearing Removal Tool sm04499
3 4
sm08429
1

6 39
5

Figure 3-33. Using Scrap Brake Disc

6
3

2
4
5

1. Front wheel
2. Rear wheel
3. Brake disc (primary)
4. ABS encoder bearing
5. Standard bearing
6. Spacer sleeve
Figure 3-35. Wheel Bearing Assemblies

3-34 94000383
INSTALL sm07629

PART NUMBER TOOL NAME

HD-44060D WHEEL BEARING
INSTALLER/REMOVER 1

NOTICE

Replace both bearing assemblies even if one assembly

appears to be good. Mismatched bearings can lead to
excessive wear and premature replacement. (00532c)
2
NOTE
• Install first bearing on primary brake disc side of hub.
• Install ABS bearing on the primary brake disc side of the 1. Threaded rod
wheel. 2. Support plate
• Primary side of the wheel is the brake rotor side. For dual Figure 3-36. Assembling Installation Tool
disc front wheels, the primary side is the left side.
sm07630
• Disc mounting surface for primary brake side of hub has
one or two grooves.
6
1. See Figure 3-36. Assemble WHEEL BEARING
INSTALLER/REMOVER (PART NUMBER: HD-44060D). 5
a. Lubricate threaded rod. 4
b. Install support plate (2) onto rod (1).
c. Insert assembly through wheel from the side opposite
the primary brake side.

NOTE
Bearing orientation is important. 1
3
2
2. See Figure 3-37. Place new bearing on the rod.
a. Non-ABS bearing: Lettered side against installer (5).
b. ABS bearing: Red side inward and tan side against 1. Threaded rod
installer (5). 2. Nut
3. Washer
c. Place 1-inch installer (Part No. HD-44060-8) (5), bearing
4. Bearing
(4), washer (3) and nut (2) over rod.
5. Installer
6. Wheel bearing
3. Install bearings.
Figure 3-37. Installing Bearings
a. Hold hex end of threaded rod (1) and turn nut (2).
b. Bearing is fully seated when nut can no longer be
turned.
c. Remove tool.
d. Install spacer sleeve inside wheel hub.
e. Reverse tool.
f. Install opposite side bearing until bearing contacts
spacer sleeve.

4. Rear wheel: Install sprocket.

5. Install wheel. See FRONT WHEEL (Page 3-15) or REAR
WHEEL (Page 3-18).

94000383 3-35
TIRES 3.11
GENERAL sm02177b

WARNING
1
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)

Always maintain proper tire pressure. Refer to Table 3-8. Do

not load tires beyond GAWR specified in Table 3-4 or Table
3-5. Underinflated, over-inflated or overloaded tires can fail.

NOTE
• Check runout on wheel before installing a new tire. See
WHEEL RUNOUT (Page 3-29).
• Store new tires on a horizontal tire rack. Storing in a vertical
stack compresses the tires and closes the beads.
• Inspect tires for punctures, cuts, breaks and wear at least
weekly.
• See Figure 3-38. The tread wear indicators appear when
1/32 in (0.8 mm) or less tread remains. Always replace tires 2
before tread is worn to the indicators.
Replace tire if:

• Tread is worn to the tire wear indicators. 1. Sidewall

2. Tread surface
• Tire cords or fabric are visible.
Figure 3-38. Tread Wear Indicators (Typical)
• Tire has a bump, bulge or split.
REMOVE
• Puncture that cannot be repaired.

See TIRES AND WHEELS (Page 2-23) for recommended tires. NOTE
Take care when replacing tire to prevent cosmetic damage to
wheel.

1. Remove wheel. See FRONT WHEEL, Remove

(Page 3-15) or REAR WHEEL, Remove (Page 3-18).
2. Deflate tire.
NOTE
Replace tube only: Do not completely remove tire from rim
to replace tube. Remove one side to access tube and inspect
tire.

3. Loosen both tire beads from rim flange.

4. Remove tire.
CLEAN, INSPECT AND REPAIR
1. Clean.
a. Clean the inside of tire and outer surface of tube.
b. Clean rim bead area with a stiff wire brush.

2. Inspect.
a. Verify that wheel is true. See WHEEL RUNOUT
(Page 3-29).
b. Check tire tread depth.

3-36 94000383
 c. Inspect tire for punctures or tears. Small punctures can NOTE
be repaired. • For correct tire and tube types, see Specifications
(Page 3-10).
WARNING
• When replacing a tube-type tire, replace the inner tube.
Replace punctured or damaged tires. In some cases, small
• Always use a rim strip on tube-type laced wheels.
punctures in the tread area may be repaired from within
the removed tire by a Harley-Davidson dealer. Speed
1. See Figure 3-39. Tube-type laced wheels:
should NOT exceed for the first 24 hours after repair, and
the repaired tire should NEVER be used over . Failure to a. Verify that no spokes protrude through nipples.
follow this warning could lead to tire failure and result in
b. Install a rim strip.
death or serious injury. (00015b)
c. Align the valve stem hole in rim strip with valve stem
3. Repair. hole in rim.
a. Patch inner tubes only as an emergency measure. d. Install tube and tire.
Replace a damaged or patched tube as soon as
possible. 2. Balance wheel. See Tires (Page 3-36).
b. Repair tread on tubeless tires if puncture is ¼ in 3. Check tire lateral and radial runout. See WHEEL RUNOUT
(6.4 mm) or smaller. (Page 3-29).
c. Make repairs from inside the tire. 4. Install wheel. See REAR WHEEL (Page 3-18) or REAR
WHEEL (Page 3-18).
d. Always combine a patch and plug when repairing tire.
sm02466a
INSTALL

FASTENER TORQUE VALUE

Valve stem nut 12–15 in-lbs 1.4–1.7 N·m

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

WARNING
Harley-Davidson front and rear tires are not the same.
Interchanging front and rear tires can cause tire failure,
which could result in death or serious injury. (00026a)

WARNING
Do not exceed manufacturer's recommended pressure to
seat beads. Exceeding recommended bead seat pressure
can cause tire rim assembly to burst, which could result
in death or serious injury. (00282a)
Figure 3-39. Installed Rim Strip

For tire pressures, see TIRES AND WHEELS, Tires Tubeless Tires: Cast Wheels
(Page 2-23).
WARNING
NOTE
• Mount tires with arrows molded into the tire sidewall pointing Only install original equipment tire valves and valve caps.
in the direction of forward rotation. A valve, or valve and cap combination, that is too long or
too heavy can strike adjacent components and damage
• If tire has a balance dot on the sidewall, align the balance the valve, causing rapid tire deflation. Rapid tire deflation
dot with the valve stem. can cause loss of vehicle control, which could result in
death or serious injury. (00281a)
Tube-Type Tires
Replace damaged or leaking valve stems.
WARNING
1. See Figure 3-40. Metal valve stem.
Match tires, tubes, rim strips or seals, air valves and caps
to the correct wheel. Contact a Harley-Davidson dealer.
a. Install rubber grommet (5) on valve stem.
Mismatching can lead to tire damage, allow tire slippage
on the wheel or cause tire failure, which could result in
b. Insert valve stem into rim hole.
death or serious injury. (00023c)

94000383 3-37
 c. Install metal washer (4) and nut (3). b. If rim runout is not within specification, adjust spokes
on laced wheel or replace cast wheel. See WHEEL
d. Tighten to 12–15 in-lbs (1.4–1.7 N·m). RUNOUT (Page 3-29).

2. Rubber valve stem. sm01803

a. Cut old valve stem to remove.

b. Install new valve stem.

c. Verify that valve stem is securely seated.

3. Install tire.

4. Balance wheel. See Tires (Page 3-36).

5. Check tire lateral and radial runout. See WHEEL RUNOUT

(Page 3-29).

6. Install wheel. See REAR WHEEL (Page 3-18) or REAR Figure 3-41. Checking Tire Lateral Runout
WHEEL (Page 3-18).
Radial Runout
sm07581 1. Check tire pressure.
1
3 2. See Figure 3-42. Spin the wheel on the axle and measure
radial runout at the tread centerline.
4
3. If tire runout exceeds 0.090 in (2.29 mm), remove tire from
rim and check rim radial runout. See WHEEL RUNOUT
(Page 3-29).
5 a. If rim runout is within specification, replace faulty tire.
b. If rim runout is not within specification, adjust spokes
on laced wheel or replace cast wheel. See WHEEL
RUNOUT (Page 3-29).
2

sm01804
1. Bolt-on valve stem
2. Snap-in valve stem
3. Nut
4. Metal washer
5. Rubber grommet
Figure 3-40. Tubeless Tire Valve Stems
CHECK TIRE RUNOUT

Lateral Runout
NOTE
• Measure runout with wheel installed on motorcycle or using
a wheel stand.
• Avoid measuring on raised letters or vents.

1. Check tire pressure.

2. See Figure 3-41. Spin the wheel and measure lateral
runout from a fixed point to a smooth area on the tire
sidewall.
3. If lateral runout exceeds 0.090 in (2.29 mm), remove tire
from rim and check rim lateral runout. See WHEEL
RUNOUT (Page 3-29).
a. If rim runout is within specification, replace faulty tire.
Figure 3-42. Checking Tire Radial Runout
BALANCE WHEEL
Static vs Dynamic
Wheel balancing is recommended to improve handling.
Balanced wheels reduce vibration especially at high speeds.

3-38 94000383
Static balancing produces satisfactory results for normal NOTE
highway speeds. Dynamic balancing can produce better results See Figure 3-43. When installing wheel weights, consider
for deceleration. cosmetics. Snaking (1) is not to exceed 0.040 in (1.02 mm)
(2) of straight. The angle alignment of individual segments is
Weights not to exceed three degrees (3).
NOTE
• If more than 3.5 oz (99.2 g) of weight is required to balance 2. Remove paper backing from the weight. Press firmly in
wheel, rotate the tire 180 degrees on the rim and again place and hold for ten seconds.
balance the assembly. Balance wheels to within 0.5 oz
(14 g). sm07192b

1
• All wheel weights currently supplied by Harley-Davidson
are made from zinc which is lighter than lead. The weight
of each zinc segment is 0.18 oz (5 g) as compared to
0.25 oz (7 g) for lead. Weights are stamped for easy
identification.
• If adding more than 1.5 oz (43 g) of weight at one location, 2
divide the amount to apply half to each side of rim. 3
• On cast wheels without a flat area near the bead, place the
weights cross-wise through the opening.

1. See Figure 3-44. Place weights on a smooth surface of

the wheel rim such that centrifugal force keeps them in 1. Snaking
place. Make sure that the area of application is clean, dry 2. Not to exceed 0.040 in (1.02 mm)
and free of oil and grease. 3. Not to exceed 3 degrees
Figure 3-43. Weight Segment Alignment

sm06487

1 2 3 4

1. Laced steel 3. Cast (typical with flat bead area)

2. Laced profile 4. Cast (special with no flat bead area)
Figure 3-44. Wheel Weight Placement

94000383 3-39
FRONT BRAKE MASTER CYLINDER 3.12
PREPARE FASTENER TORQUE VALUE
Brake master cylinder, front, 60–80 in-lbs 6.8–9 N·m
• If DOT 4 brake fluid contacts painted surfaces, clamp screws
IMMEDIATELY flush area with clear water.
NOTICE
1. Remove main fuse. See System Fuses and Relays
(Page 9-6). Avoid leakage. Be sure gaskets, banjo bolt(s), brake line
2. Drain brake fluid. and master cylinder bore are clean and undamaged before
assembly. (00322a)
a. Remove reservoir cover.
b. Remove banjo bolt from master cylinder. 1. See Figure 3-45. Engage ear (1) in recess (2).
c. Discard sealing washers.
2. Install clamp (4).
d. Allow fluid to drain into container.
e. Wrap banjo fitting with piece of shop towel to absorb a. Install two screws (3).
any loss of brake fluid.
b. Position for rider comfort.
REMOVE
c. Beginning with the top screw, tighten screws to
60–80 in-lbs (6.8–9 N·m).
1. See Figure 3-45. Remove screws (3).
2. Remove clamp (4). Remove hand control assembly. 3. Install brake line.

sm05016
3 a. Install banjo bolt, brake line and new sealing
washers.

2 4 b. Verify that brake line does not touch the handlebar

or fairing when handlebar is

c. Tighten to 17–19 ft-lbs (23.1–25.8 N·m).

COMPLETE
1. Fill and bleed front brake system. See BLEED BRAKES
(Page 3-62).
2. Install main fuse. See System Fuses and Relays
(Page 9-6).
DISASSEMBLE

NOTE
1 Do not scratch or nick banjo sealing surface during handling.

1. See Figure 3-46. Remove retaining ring (8). Discard

1. Ear retaining ring.
2. Recess
2. Remove pivot pin (6) and brake lever (7).
3. Screw (2)
4. Clamp 3. Remove dust boot and pushrod assembly (9).
Figure 3-45. Hand Control Assembly (typical) 4. While holding pressure against piston assembly (11),
INSTALL remove retaining ring (10).
5. Remove and discard piston assembly and spring.
FASTENER TORQUE VALUE
6. If necessary, remove anti-bubble button (14).
Banjo bolt to front master 17–19 ft-lbs 23.1–25.8 N·m
cylinder

3-40 94000383
 sm05012
2

4
13 14
1 5

12
6

11
10
9 7

1. Master cylinder reservoir 8. Retaining ring

2. Cover screw (2) 9. Pushrod/dust boot
3. Cover 10. Retaining ring
4. Gasket 11. Piston assembly
5. Sight glass/O-ring 12. Handlebar clamp
6. Pivot pin 13. Clamp screw (2)
7. Brake hand lever 14. Anti-bubble button
Figure 3-46. Front Brake Master Cylinder Assembly
CLEAN AND INSPECT 3. Inspect parts for wear or damage.
a. Inspect banjo seating surface for scratches or nicks.
WARNING
b. Inspect piston bore.
Use denatured alcohol to clean brake system components. c. Inspect dust boot retaining groove.
Do not use mineral-based solvents (such as gasoline or
paint thinner), which will deteriorate rubber parts even d. Inspect dust boot and reservoir cover gasket.
after assembly. Deterioration of these components can e. Inspect lever and pivot pin.
cause brake failure, which could result in death or serious
injury. (00291a) ASSEMBLE
• Even residual mineral-based oils and grease can deteriorate
rubber brake components. NOTE
Never install a used piston assembly or spring. Always install
• Wash hands before handling brake components. new parts.
• Never use oily rags to wipe brake components.
1. See Figure 3-46. Lightly lubricate piston bore and OD of
1. Clean all parts thoroughly.
piston seals with DOT 4 BRAKE FLUID.
2. Using a clean air supply, clear piston bore, reservoir and
2. Install new piston assembly (11).
drilled passages. Do not use a wire or similar instrument.
a. Push and hold piston assembly into bore.

94000383 3-41
 b. Install new retaining ring (10) with the flat side in.
c. Verify that retaining ring is completely seated in groove.

3. Install pushrod/dust boot (9). Verify that dust boot is secure

in groove of piston bore.
NOTE
Anti-bubble button (14) is a friction fit. Install with convex side
up (see inset).

4. Install anti-bubble button (14).

5. Loosely install cover (3) with gasket (4).
6. Install lever, pivot pin (6) and new retaining ring (8).

3-42 94000383
FRONT BRAKE CALIPER 3.13
REMOVE b. Install caliper with screws (2). Tighten to 28–38 ft-lbs
(37.9–51.5 N·m).
• If DOT 4 brake fluid contacts painted surfaces,
IMMEDIATELY flush area with clear water. 3. ABS models:

NOTE
a. Verify that WSS cable is secure in clip.
If only replacing brake pads, see BRAKE PADS AND DISCS
(Page 2-34). b. See Figure 3-48. Install new cable straps (1, 2) to
secure WSS and fender tip lamp cables.
1. Remove banjo bleeder bolt. Discard sealing washers.
2. See Figure 3-47. Remove caliper mounting screws (2). 4. Install brake line, banjo bleeder bolt and new sealing
Remove caliper (1) from brake disc. washers to caliper. Tighten to 17–19 ft-lbs (23.1–25.8 N·m).

sm04988 5. Install bleeder screw if removed.

3
a. If present, discard the O-ring from the bleeder screw
groove or bore in banjo bleeder bolt.

4 b. Install bleeder screw finger-tight.

6. Bleed brake system. See BLEED BRAKES (Page 3-62).

1
sm07482

2
7
6

1. Caliper
2. Caliper mounting screw (2)
3. Screen
2
4. Retaining clip
5. Pad pin
6. Brake pads
7. Pad spring
Figure 3-47. Front Brake Caliper Assembly
INSTALL

FASTENER TORQUE VALUE

Banjo bleeder bolt to front 17–19 ft-lbs 23.1–25.8 N·m 1. WSS cable, fender tip lamp cable, brake hose
caliper 2. WSS cable, brake hose
Brake caliper, front, mounting 28–38 ft-lbs 37.9–51.5 N·m Figure 3-48. Secure Cables and Brake Hose
screws

1. See Figure 3-47. Assemble caliper. See BRAKE PADS

AND DISCS (Page 2-34).

2. Install caliper.

a. ABS models: Install WSS cable clip and bracket

when installing left caliper.

94000383 3-43
REAR BRAKE MASTER CYLINDER 3.14
GENERAL sm05022a

• If DOT 4 brake fluid contacts painted surfaces,

1
IMMEDIATELY flush area with clear water.

NOTICE

Do not allow dirt or debris to enter the master cylinder

reservoir. Dirt or debris in the reservoir can cause improper 3
operation and equipment damage. (00205c)
PREPARE
• If DOT 4 brake fluid contacts painted surfaces,
IMMEDIATELY flush area with clear water. 6 5
1. Remove main fuse. See System Fuses and Relays 4 2
(Page 9-6).
2. Stand motorcycle upright (not leaning on jiffy stand) on a 1. Rear brake pedal
level surface. 2. O-ring (2)
3. Clevis pin
3. Remove right side rider footboard. See FOOTBOARDS
4. Cotter pin
AND FOOTRESTS (Page 3-155).
5. Flat washer
4. Drain brake fluid. 6. Master cylinder reservoir
a. Remove reservoir cover. Figure 3-49. Rear Master Cylinder/Brake Pedal Assembly

b. Remove banjo bolt from master cylinder. INSTALL

c. Discard sealing washers.
FASTENER TORQUE VALUE
d. Allow fluid to drain into container. Banjo bolt to rear master 17–19 ft-lbs 23.1–25.8 N·m
e. Wrap banjo fitting with piece of shop towel to absorb cylinder
any loss of brake fluid. Brake master cylinder, rear, 126–150 in-lbs 14.2–17 N·m
mounting screws
REMOVE Brake pedal shaft locknut 15–20 ft-lbs 20.3–27.1 N·m

1. Remove master cylinder and pedal assembly. 1. See Figure 3-49. Assemble master cylinder to brake pedal.

a. Remove screws securing master cylinder.

a. Install master cylinder assembly onto brake pedal
b. Remove locknut and flat washer securing brake pedal. flange.
c. Pull brake pedal/master cylinder assembly from pedal b. Install clevis pin (3) from the outboard side.
shaft.
d. Discard O-rings from each side of brake pedal shaft c. Install flat washer (5) and cotter pin (4) on clevis pin.
bore.
2. Install brake pedal master cylinder assembly.
2. See Figure 3-49. Disassemble master cylinder from brake
pedal. a. Apply a light coat of WHEEL BEARING GREASE to
a. Remove cotter pin (4) and flat washer (5) from clevis the brake pedal shaft and bore.
pin.
b. Install new O-ring (2) on each side of bore.
b. Remove clevis pin (3).
c. Install brake pedal/master cylinder assembly on the
c. Separate master cylinder assembly from brake pedal.
pedal shaft.

d. Install flat washer and new locknut.

e. Install screws securing master cylinder. Tighten to

126–150 in-lbs (14.2–17 N·m).

f. Tighten brake pedal shaft locknut to 15–20 ft-lbs

(20.3–27.1 N·m).

3. Install brake line, banjo bolt and new sealing washers.

Tighten to 17–19 ft-lbs (23.1–25.8 N·m).

3-44 94000383
 sm05021c

7 9

10
11
8
12

13 3
2
14
16
15
4

17

1. Master cylinder reservoir 10. E-clip

2. Cover screw (2) 11. Flat washer
3. Cover 12. Pedal return spring
4. Gasket 13. Retaining ring
5. Screw (2) 14. Special washer
6. Cotter pin 15. Pushrod
7. Flat washer 16. Piston assembly
8. Clevis pin 17. Sight glass/O-ring
9. Dust boot
Figure 3-50. Rear Brake Master Cylinder Assembly
COMPLETE 1. See Figure 3-50. Remove dust boot (9).

1. Fill and bleed brake system. See BLEED BRAKES 2. Push and hold flat washer (11). Remove E-clip (10) from
(Page 3-62). pushrod. Carefully release spring tension.

2. Install right side rider footboard. See FOOTBOARDS AND 3. Remove flat washer (11) and pedal return spring (12).
FOOTRESTS (Page 3-155). 4. Push and hold end of piston. Remove retaining ring (13).
3. Install main fuse. See System Fuses and Relays 5. Remove pushrod (15) and special washer (14).
(Page 9-6).
6. Pull piston assembly from piston bore.
DISASSEMBLE

NOTE
Do not scratch or nick banjo sealing surface during handling.

94000383 3-45
CLEAN AND INSPECT

WARNING
Use denatured alcohol to clean brake system components.
Do not use mineral-based solvents (such as gasoline or
paint thinner), which will deteriorate rubber parts even
after assembly. Deterioration of these components can
cause brake failure, which could result in death or serious
injury. (00291a)

• Even residual mineral-based oils and grease can deteriorate

rubber brake components.
• Wash hands before handling brake components.
• Never use oily rags to wipe brake components.
1. Clean all parts thoroughly.
2. Verify that reservoir is completely free of dust, dirt or
residue.
3. Using a clean air supply, clear piston bore, reservoir and
drilled passages. Do not use a wire or similar instrument.
4. Inspect parts for wear or damage.
a. Inspect banjo seating surface for scratches or nicks.
b. Inspect piston bore.
c. Inspect dust boot retaining groove.
d. Inspect dust boot and reservoir cover gasket.
e. Inspect E-clip for wear or distortion.
f. Inspect retaining ring groove and E-clip groove for
damage.
g. Inspect springs for stretching, distortion, kinks, cracks
or fractured coils.

ASSEMBLE
1. Lightly lubricate piston bore and OD of piston seals with
DOT 4 BRAKE FLUID.
2. See Figure 3-50. Insert piston assembly (16) into piston
bore.
3. Slide special washer (14), with collar facing outer end of
pushrod, and new retaining ring (13) over pushrod.
4. Hold piston assembly in and install retaining ring with flat
side in. Verify that retaining ring is seated in groove.
5. Seat pedal return spring (12) on retaining ring.
6. Slide flat washer (11) over pushrod.
7. Compress pedal return spring and install E-clip (10) in
inboard groove of pushrod.
8. Install dust boot (9).

3-46 94000383
REAR BRAKE CALIPER 3.15
REMOVE 1. See Figure 3-51. Install caliper bracket (3), if removed.
See REAR WHEEL (Page 3-18).
NOTE
If only replacing brake pads, see BRAKE PADS AND DISCS 2. Assemble caliper. See BRAKE PADS AND DISCS
(Page 2-34). (Page 2-34).

1. Remove right saddlebag. See SADDLEBAGS (Page 3-98). 3. Install caliper with screws (2). Tighten to 43–48 ft-lbs
(58.3–65.1 N·m).
NOTE
Wrap banjo fittings with pieces of lint-free shop towel to absorb 4. Install brake line, banjo bleeder bolt and new sealing
any loss of brake fluid. washers to caliper. Tighten to 17–19 ft-lbs (23.1–25.8 N·m).

2. Remove banjo bolt. Discard sealing washers. 5. Install bleeder screw if removed.
3. See Figure 3-51. Remove screws (2).
a. If present, discard the O-ring from the bleeder screw
4. Remove caliper from brake disc. groove or bore in banjo bleeder bolt.
5. If necessary, remove caliper bracket (3). See REAR
WHEEL (Page 3-18). b. Install bleeder screw finger-tight.

sm04987 6. Bleed brake system. See BLEED BRAKES (Page 3-62).

10
4 7. Install right saddlebag. See SADDLEBAGS (Page 3-98).
9

7 6 8

1. Caliper
2. Caliper bracket screw (2)
3. Caliper bracket
4. Retaining clip
5. Pad pin
6. Brake pads
7. Pad spring
8. Rubber bumper
9. Bleeder screw
10. Bleeder screw cap
Figure 3-51. Rear Brake Caliper Assembly
INSTALL

FASTENER TORQUE VALUE

Banjo bolt to rear caliper 17–19 ft-lbs 23.1–25.8 N·m
Brake caliper, rear, mounting 43–48 ft-lbs 58.3–65.1 N·m
screws

94000383 3-47
BRAKE LINES 3.16
FRONT BRAKE LINE: NON-ABS d. Remove banjo bolts from both front brake calipers.
Discard sealing washers.
PART NUMBER TOOL NAME e. Remove brake line.
BB200A BASIC VACUUM BRAKE BLEEDER
sm07669
FASTENER TORQUE VALUE
Banjo bleeder bolt to front 17–19 ft-lbs 23.1–25.8 N·m 3
caliper
2
Banjo bolt to front master 17–19 ft-lbs 23.1–25.8 N·m
cylinder

Prepare
1. Road King models:
a. Remove right side headlamp nacelle. See HEADLAMP 1
NACELLE: ROAD KING MODELS (Page 3-144).
b. See Figure 3-52. Cut cable straps (1, 2).

2. Fairing models, fork-mounted:

a. Rotate the upper fairing. See INNER FAIRING: FORK 1. Clutch line to brake line: fork mounted fairing
MOUNTED FAIRING MODELS (Page 3-118). and Road King models only
2. Clutch line and brake line to right riser
b. See Figure 3-52. Cut cable straps (1, 2).
3. Clutch line to left riser
c. Low models: Cut cable strap near lower bend on Figure 3-52. Capture Clutch and Brake Fluid Lines
handlebar.
sm03520
3. Fairing models, frame-mounted:
a. Remove instrument nacelle. See INSTRUMENT
NACELLE: FRAME MOUNTED FAIRING MODELS
(Page 3-126).
b. See Figure 3-52. Cut cable strap (2).

NOTE
• Clean master cylinder reservoir cover before removal.
• For best results, use the BASIC VACUUM BRAKE
BLEEDER (PART NUMBER: BB200A) or equivalent tool to
drain the brake systems.

4. Drain front brake lines.

a. Remove master cylinder reservoir cover.
b. Attach vacuum brake bleeder to either front caliper Figure 3-53. Capture Brake Hose and Front Fender Tip
bleeder screw. Loosen screw 3/4 turn. Lamp Wires
c. Operate vacuum bleeder to evacuate all fluid from
master cylinder and line. Install
d. Repeat with remaining caliper. 1. Secure brake line in lower fork bracket retainer.
e. Wipe out any remaining fluid inside master cylinder
reservoir with a clean, lint-free cloth. a. Position the brake line in retainer.

b. Latch retainer closed.

Remove
c. Install a cable strap around retainer to secure retainer
1. Remove front brake line.
closed.
a. Remove banjo bolt from master cylinder. Discard sealing
washers. 2. Install brake line.
b. See Figure 3-53. Cut cable straps from left brake hose.
a. Install brake line, banjo bolt and new sealing washers
c. Remove front brake line from retainer on lower fork
to master cylinder. Tighten to 17–19 ft-lbs
bracket.
(23.1–25.8 N·m).

3-48 94000383
 b. Install brake line, banjo/bleeder bolt and new sealing
washers to caliper. Tighten to 17–19 ft-lbs
(23.1–25.8 N·m).
c. See Figure 3-53. Secure fender tip lamp and WSS
wires to left brake hose with new cable straps.
Complete
1. Road King models:
a. See Figure 3-52. Secure brake line and clutch line to
right riser with new cable strap (2).
b. Secure brake line to clutch line with new cable strap
(1).
c. Install right side headlamp nacelle. See HEADLAMP
NACELLE: ROAD KING MODELS (Page 3-144).
2. Fairing models, fork-mounted:
3. Remove right side passenger footboard/footpeg. See
FOOTBOARDS AND FOOTRESTS (Page 3-155).
4. Stand motorcycle upright (not leaning on jiffy stand) on a
level surface.
NOTE
• Clean master cylinder reservoir cover before removal.
• For best results, use the BASIC VACUUM BRAKE
BLEEDER (PART NUMBER: BB200A) or equivalent tool to
drain the brake systems.
5. Drain rear brake line.
a. Remove master cylinder reservoir cover.
b. Attach vacuum brake bleeder to caliper bleeder screw.
Loosen screw 3/4 turn.
c. Operate vacuum bleeder to evacuate all fluid from
master cylinder and line.

a. See Figure 3-52. Secure brake line and clutch line to d. Wipe out any remaining fluid inside master cylinder
right riser with new cable strap (2). reservoir with a clean, lint-free cloth.

b. Secure brake line to clutch line with new cable strap

(1). Remove
c. Low models: Secure brake line and harnesses near 1. See Figure 3-55. Remove right footboard/rear brake master
lower bend on handlebar with new cable strap. cylinder.

d. Install upper fairing. See INNER FAIRING: FORK a. Remove banjo bolt (13) from master cylinder reservoir.
MOUNTED FAIRING MODELS (Page 3-118). Discard sealing washers.
e. Verify that the brake line does not touch the handlebar b. Support front of engine.
or fairing when handlebar is turned. Adjust as needed. c. Remove three screws securing front right engine mount
end cap.
3. Fairing models, frame-mounted:
d. Pull off end cap mount with footboard, master cylinder
a. See Figure 3-52. Secure brake line and clutch line to and brake pedal attached.
right riser with new cable strap (2).
b. Install instrument nacelle. See INSTRUMENT 2. See Figure 3-54. Remove brake line from multi-clamp.
NACELLE: FRAME MOUNTED FAIRING MODELS a. Remove HO2 sensor wires from clip on clamp.
(Page 3-126).
b. Remove screw (4).
4. Bleed brake system. See BLEED BRAKES (Page 3-62). c. Open clamp to release brake line.
REAR BRAKE LINE: NON-ABS
3. Remove brake line.
PART NUMBER TOOL NAME a. Remove banjo bolt (2) from rear brake caliper. Discard
BB200A BASIC VACUUM BRAKE BLEEDER sealing washers (1).
b. Free rear brake line from electrical harness clips (6).
FASTENER TORQUE VALUE
c. Remove terminals from rear stop lamp switch (11).
Banjo bolt to rear caliper 17–19 ft-lbs 23.1–25.8 N·m
Banjo bolt to rear master 17–19 ft-lbs 23.1–25.8 N·m d. Remove fastener (5) securing P-clamp (4).
cylinder e. Release line from retainers (14) securing line to frame.
Brake line, rear, P-clamp 80–100 in-lbs 9–11.3 N·m
f. Free rear brake line hose from brake hose clips (3) on
screw
rear fork.
Engine mount end cap screws, 42–48 ft-lbs 56.9–65 N·m
front g. Remove cable straps. Record locations for assembly.
Hydraulic line multi-clamp 10–15 in-lbs 1.1–1.7 N·m h. Remove rear brake line.
screw
Stop lamp switch, rear 12–15 ft-lbs 16.3–20.3 N·m
Install
Prepare 1. See Figure 3-55. If installing new rear stop lamp switch
(11), apply LOCTITE 565 THREAD SEALANT. Install
1. Remove right saddlebag. See SADDLEBAGS (Page 3-98).
switch into rear brake line. Tighten to 12–15 ft-lbs
2. Remove right side cover. (16.3–20.3 N·m).

94000383 3-49
2. Install brake line. NOTE
Confirm oil switch/sender wires are inboard of rubber mount.
a. Place rear brake line into approximate position along
top of lower right frame tube and top of rear fork. a. Connect terminals onto rear stop lamp switch (11).

b. Install brake line, banjo bolt (2) and new sealing b. Install engine mount end cap. Tighten to 42–48 ft-lbs
washers (1) to caliper. Tighten to 17–19 ft-lbs (56.9–65 N·m).
(23.1–25.8 N·m).
c. Remove support under front of engine.
c. Capture rear brake line hose in two brake hose clips
(3) on rear fork. d. Install cable new straps in previously recorded
positions.
d. Secure P-clamp (4) with screw (5). Tighten to
80–100 in-lbs (9–11.3 N·m). e. Install brake line, banjo bolt (13) and new sealing
washers (12) to master cylinder. Tighten to
e. Secure retainers (14). 17–19 ft-lbs (23.1–25.8 N·m).

f. HDI: Secure active exhaust cable to the brake line

sm08705
at rear brake line retainer (14). 2
3. Secure brake line in clamps.

a. See Figure 3-54. Capture rear brake line in lower

clip of electrical harness retainers and upper passage
of multi-clamp. 1
1
b. Close multi-clamp to secure brake line and clutch
line.

c. Apply LOCTITE 243 (blue) to the threads of used

screw (4).
4 3
d. Install screw (4). Tighten to 10–15 in-lbs
(1.1–1.7 N·m). 1. Rear brake line
2. Front HO2 sensor wire
e. Install front HO2 sensor wire in clip on clamp. 3. Clutch line
4. Screw
4. Install right side front engine mount cap with rider footboard Figure 3-54. Lower Frame Rail Line and Harness Retainers
and master cylinder attached:

3-50 94000383
 sm07609

3 6

4
16
14
5 15
9
11

12
7
8 13
9 10

1. Sealing washers 8. Locknut

2. Banjo bolt 9. O-ring
3. Brake hose clips 10. Fastener
4. P-clamp 11. Rear stop lamp switch
5. Fastener 12. Sealing washers
6. Electrical harness clips 13. Banjo bolt
7. Flat washer 14. Brake line retainers
Figure 3-55. Rear Brake Line Assembly
FASTENER TORQUE VALUE
Complete Banjo bolt to ABS module, 12 28–30 ft-lbs 38–40.6 N·m
1. Bleed brake system. See BLEED BRAKES (Page 3-62). mm
Banjo bolt to front master 17–19 ft-lbs 23.1–25.8 N·m
2. Install right passenger footboard/footpeg. See
cylinder
FOOTBOARDS AND FOOTRESTS (Page 3-155).
Battery tray screws 132–156 in-lbs 14.9–17.6 N·m
3. Install right side cover.
4. Install right saddlebag. See SADDLEBAGS (Page 3-98). Prepare
BRAKE LINE: FRONT MASTER CYLINDER 1. Remove right saddlebag. See SADDLEBAGS (Page 3-98).
TO ABS MODULE 2. Remove right side cover.
3. Remove fuel tank. See FUEL TANK (Page 5-6).
PART NUMBER TOOL NAME
BB200A BASIC VACUUM BRAKE BLEEDER 4. Remove top caddy. See ELECTRICAL CADDIES
(Page 9-9).

94000383 3-51
5. Road King models: Remove right side headlamp nacelle. e. Remove banjo bolt (5). Discard sealing washers.
See HEADLAMP NACELLE: ROAD KING MODELS
f. Remove banjo bolt from master cylinder. Discard sealing
(Page 3-144).
washers.
6. Fairing models, fork-mounted: Remove outer fairing and
g. Remove brake line.
dash panel. See OUTER FAIRING AND WINDSHIELD:
FORK MOUNTED FAIRING MODELS (Page 3-115) and
DASH PANEL: FORK MOUNTED FAIRING MODELS sm07604
(Page 3-117), respectively. 1
7. Fairing models, frame-mounted: Remove instrument
nacelle. See INSTRUMENT NACELLE: FRAME
MOUNTED FAIRING MODELS (Page 3-126).
NOTE 2
For best results, use the BASIC VACUUM BRAKE BLEEDER
(PART NUMBER: BB200A) or equivalent tool to drain the brake
systems.

8. Drain brake line.

a. Remove master cylinder reservoir cover.
b. Attach vacuum brake bleeder to front caliper bleeder
screw. Loosen screw 3/4 turn. 1. Brake line retainer
2. Wheel speed sensor connector
c. Operate vacuum bleeder to evacuate all fluid from
master cylinder and line. Figure 3-56. Steering Head Caddy (right side shown)

d. Wipe out any remaining fluid inside master cylinder

reservoir with a clean, lint-free cloth.
sm07603 7
3
2
4
Remove
1. Cut cable straps to release brake line. 1
2. See Figure 3-56. Release brake line from right steering 5
head caddy retainer.
a. Release upper latch.
b. Rotate top of retainer out and lift from pocket in caddy.
c. Remove line from retainer.
6
NOTE
Loosen and tighten banjo bolts while ABS module is secured. 1. Rear master cylinder, 12 mm
2. ABS module to rear caliper, 10 mm
3. See Figure 3-58. Remove brake line. 3. ABS module to front-right caliper, 10 mm
4. ABS module to front-left caliper, 10 mm
a. Remove retainer (5).
5. Front master cylinder, 12 mm
b. See Figure 3-57. Remove alignment clip (7) from lines 6. Mount locknut (2)
at ABS module. 7. Alignment clip
c. Loosen banjo bolt (5). Figure 3-57. ABS Module Connections
d. Remove two rear battery tray screws to allow battery
Front Line Routing
tray to lower.

3-52 94000383
 sm08578
4 5

1 1
3
3
2

2 4 7
1

3
8

1. Front master cylinder to ABS module 5. Brake line retainer

2. ABS module to front right caliper 6. Retaining features
3. ABS module to front left caliper 7. Fork mounted fairing line orientation
4. Retainer with tab 8. Frame mounted fairing line orientation
Figure 3-58. Front ABS Brake Line Routing

sm08570 Install
NOTE
2 Loosen and tighten banjo bolts while ABS module is secured.

1. Install brake line.

1
a. Route brake line along right side of wire trough with
rear banjo fitting near ABS module.

3 b. Route front of brake line forward along right side of

steering head and up to master cylinder.

c. Start banjo bleeder bolt with new sealing washers

to secure brake line to caliper.

2 d. Start banjo bolt with new sealing washers to secure

brake line to ABS module port marked MF.
1. Harness caddy cover
2. Pockets e. See Figure 3-57. Install alignment clip (7) onto lines
3. Retainer at ABS module.
Figure 3-59. Brake Line Retainer

94000383 3-53
2. Secure brake line.
sm07669

a. Road King models: See Figure 3-60. Secure brake 3

line and clutch line to right riser with new cable strap 2
(2). Secure brake line to clutch line with new cable
strap (1).

b. Fairing models: See Figure 3-60. Secure brake line

and clutch line to right riser with new cable strap (2).
Secure brake line to clutch line with new cable strap
(1).
1
c. Low models: Secure brake line and harnesses near
lower bend on handlebar with new cable strap.

3. See Figure 3-56. Secure brake line right side steering head
caddy.
1. Clutch line to brake line: fork mounted fairing
and Road King models only
a. Install line in retainer (1). 2. Clutch line and brake line to right riser
3. Clutch line to left riser
b. Insert retainer into pocket in caddy.
Figure 3-60. Capture Clutch and Brake Fluid Lines
NOTE
See Figure 3-58. The order in which lines are arranged is
Complete
important. Arrange as the insets show. WARNING
When any hydraulic brake component, line or connection
c. Rotate top of retainer in until latched.
is loosened or replaced on an ABS motorcycle, Digital
Technician II must be used during the brake bleeding
4. Secure brake lines to wire trough including central anchor procedure to verify all air is removed from the system.
block. Failure to properly bleed the brake system could adversely
affect braking, which could result in death or serious injury.
a. Secure lines at rear within retainer (4) and under the (00585c)
tab.
1. Bleed brake system. See BLEED BRAKES (Page 3-62).
b. Secure lines in retaining features (6) at front of wire
trough. 2. Road King models: Install right side headlamp nacelle.
See HEADLAMP NACELLE: ROAD KING MODELS
c. See Figure 3-59. Install retainer (3). (Page 3-144).
3. Fairing models, fork-mounted: Install outer fairing and
5. Tighten master cylinder banjo bolt to 17–19 ft-lbs dash panel. See OUTER FAIRING AND WINDSHIELD:
(23.1–25.8 N·m). FORK MOUNTED FAIRING MODELS (Page 3-115) and
DASH PANEL: FORK MOUNTED FAIRING MODELS
6. Install rear battery tray screws. Tighten to 132–156 in-lbs (Page 3-117), respectively.
(14.9–17.6 N·m).
4. Fairing models, frame-mounted: Install instrument
nacelle See INSTRUMENT NACELLE: FRAME MOUNTED
7. Tighten ABS module banjo bolt to 28–30 ft-lbs FAIRING MODELS (Page 3-126).
(38–40.6 N·m).
5. Install top caddy. See ELECTRICAL CADDIES
(Page 9-9).
6. Install fuel tank. See FUEL TANK (Page 5-6).
7. Install right side cover.
8. Install right saddlebag. See SADDLEBAGS (Page 3-98).
BRAKE LINE: ABS MODULE TO FRONT
CALIPER

PART NUMBER TOOL NAME

BB200A BASIC VACUUM BRAKE BLEEDER

FASTENER TORQUE VALUE

Banjo bleeder bolt to front 17–19 ft-lbs 23.1–25.8 N·m
caliper
Banjo bolt to ABS module, 10 17–19 ft-lbs 23.1–25.8 N·m
mm

3-54 94000383
 FASTENER TORQUE VALUE NOTE
Battery tray screws 132–156 in-lbs 14.9–17.6 N·m Loosen and tighten banjo bolts while ABS module is secured.

NOTE 3. See Figure 3-57. Remove brake line.

This system has separate brake lines to each front caliper.
a. Loosen banjo bolt (3 or 4).
Replacement is similar for both.
b. Remove alignment clip (7) from lines at ABS module.

Prepare c. Remove two rear battery tray screws to allow battery

tray to lower.
1. Remove right saddlebag. See SADDLEBAGS (Page 3-98).
d. Remove banjo bolt securing brake line to ABS module.
2. Remove right side cover. Discard sealing washers.
3. Remove fuel tank. See FUEL TANK (Page 5-6). e. Remove banjo bleeder bolt securing brake line to
4. Remove top caddy. See ELECTRICAL CADDIES caliper. Discard sealing washers.
(Page 9-9). f. Remove brake line.
5. Road King models: Remove headlamp nacelle. See
HEADLAMP NACELLE: ROAD KING MODELS Install
(Page 3-144).
NOTE
6. Fairing models, fork-mounted: Remove outer fairing and
Loosen and tighten banjo bolts while ABS module is secured.
dash panel. See OUTER FAIRING AND WINDSHIELD:
FORK MOUNTED FAIRING MODELS (Page 3-115) and
DASH PANEL: FORK MOUNTED FAIRING MODELS 1. Install brake line.
(Page 3-117), respectively.
7. Fairing models, frame-mounted: Remove instrument a. Route brake line rearward along right side of steering
nacelle. See INSTRUMENT NACELLE: FRAME head and wire trough.
MOUNTED FAIRING MODELS (Page 3-126).
b. Start banjo bleeder bolt with new sealing washers
NOTE to secure brake line to caliper.
For best results, use the BASIC VACUUM BRAKE BLEEDER
(PART NUMBER: BB200A) or equivalent tool to drain the brake c. Secure brake line in lower fork bracket retainer. Latch
systems. retainer closed. Install cable strap.

d. Start banjo bolt with new sealing washers to secure

8. Drain front brake lines.
brake line to ABS module.
a. Remove master cylinder reservoir cover.
NOTE
b. Attach vacuum brake bleeder to caliper bleeder screw.
Loosen screw 3/4 turn. See Figure 3-58. The order in which lines are arranged is
important. Arrange as the insets show.
c. Operate vacuum bleeder to evacuate all fluid from
master cylinder and line. e. See Figure 3-57. Install alignment clip (7) onto lines
d. Wipe out any remaining fluid inside master cylinder at ABS module.
reservoir with a clean, lint-free cloth.
2. Secure brake lines to wire trough including central anchor
block.
Remove
1. See Figure 3-56. Release brake line from right steering a. Secure lines at rear within retainer (4) and under the
head caddy retainer. tab.
a. Release upper latch.
b. Secure lines in retaining features (6) at front of wire
b. Rotate top of retainer out and lift from pocket in caddy. trough.
c. Remove line from retainer.
c. See Figure 3-59. Install retainer (5).
2. See Figure 3-58. Release brake line.
3. See Figure 3-56. Secure brake line to right side steering
a. Remove retainer (5). Release brake line from wire head caddy.
trough.
b. Release brake line from retainer on lower fork bracket. a. Install line in retainer (1).
c. Right line: Release brake line from three conduit clips b. Insert retainer into pocket in caddy.
near front of steering head.
d. Left line: Cut three cable straps securing front wheel c. Rotate top of retainer in until latched.
speed sensor cable and front fender tip lamp wires (if
equipped) to left caliper brake hose. 4. Install rear battery tray screws. Tighten to 132–156 in-lbs
(14.9–17.6 N·m).

94000383 3-55
5. Tighten ABS module banjo bolt to 17–19 ft-lbs FASTENER TORQUE VALUE
(23.1–25.8 N·m). Banjo bolt to rear master 17–19 ft-lbs 23.1–25.8 N·m
cylinder
6. Tighten caliper banjo bleeder bolt to 17–19 ft-lbs Brake line, rear, P-clamp 80–100 in-lbs 9–11.3 N·m
(23.1–25.8 N·m). screw
Engine mount end cap screws, 42–48 ft-lbs 56.9–65 N·m
7. Left line: Secure the WSS cable and fender tip lamp wires front
using three new cable straps:
Hydraulic line multi-clamp 10–15 in-lbs 1.1–1.7 N·m
screw
a. On the brake hose lower crimp capturing cable and
brake hose. Stop lamp switch, rear 12–15 ft-lbs 16.3–20.3 N·m

b. Midway between the upper and lower brake hose Prepare

crimps capturing cable, brake hose and front fender 1. Remove right saddlebag. See SADDLEBAGS (Page 3-98).
tip lamp wires, if equipped.
2. Remove right side cover.
c. On upper crimp capturing sensor cable, brake hose 3. Remove right passenger footboard/footpeg. See
and front fender tip lamp wires, if equipped. FOOTBOARDS AND FOOTRESTS (Page 3-155).

8. Right line: Secure WSS cable to line with three conduit 4. Stand motorcycle upright (not leaning on jiffy stand) on a
clips near front of steering head. level surface.
NOTE
Complete • Clean master cylinder reservoir cover before removal.

WARNING • For best results, use the BASIC VACUUM BRAKE

BLEEDER (PART NUMBER: BB200A) or equivalent tool to
When any hydraulic brake component, line or connection drain the brake systems.
is loosened or replaced on an ABS motorcycle, Digital
Technician II must be used during the brake bleeding 5. Drain rear brake line.
procedure to verify all air is removed from the system.
Failure to properly bleed the brake system could adversely a. Remove master cylinder reservoir cover.
affect braking, which could result in death or serious injury. b. Attach vacuum brake bleeder to rear caliper bleeder
(00585c) screw. Loosen screw 3/4 turn.

1. Bleed brake system. See BLEED BRAKES (Page 3-62). c. Operate vacuum bleeder to evacuate all fluid from
master cylinder and line.
2. Road King models: Install headlamp nacelle. See
HEADLAMP NACELLE: ROAD KING MODELS d. Wipe out any remaining fluid inside master cylinder
(Page 3-144). reservoir with a clean, lint-free cloth.

3. Fairing models, fork-mounted: Install outer fairing and

dash panel. See OUTER FAIRING AND WINDSHIELD: Remove
FORK MOUNTED FAIRING MODELS (Page 3-115) and 1. Remove right footboard/rear brake master cylinder.
DASH PANEL: FORK MOUNTED FAIRING MODELS
(Page 3-117), respectively. a. See Figure 3-62. Remove banjo bolt (13) from master
cylinder reservoir. Discard sealing washers.
4. Fairing models, frame-mounted: Install outer fairing and
dash panel. See INSTRUMENT NACELLE: FRAME b. Support front of engine.
MOUNTED FAIRING MODELS (Page 3-126). c. Remove three screws securing front right engine mount
5. Install top caddy. See ELECTRICAL CADDIES end cap.
(Page 9-9). d. Pull off end cap mount with footboard, master cylinder
6. Install fuel tank. See FUEL TANK (Page 5-6). and brake pedal attached.

7. Install right side cover. 2. See Figure 3-61. Remove brake line from multi-clamp.
8. Install right saddlebag. See SADDLEBAGS (Page 3-98). a. Remove HO2 sensor wires from clip on clamp.
BRAKE LINE: REAR MASTER CYLINDER b. Remove screw (4).
TO ABS MODULE c. Open clamp to release brake line.

PART NUMBER TOOL NAME NOTE

BB200A BASIC VACUUM BRAKE BLEEDER Loosen and tighten banjo bolts while ABS module is secured.

FASTENER TORQUE VALUE 3. Remove brake line.

Banjo bolt to ABS module, 12 28–30 ft-lbs 38–40.6 N·m
mm a. See Figure 3-63. Remove banjo bolt (1) securing brake
line to ABS module. Discard sealing washers.
b. Remove alignment clip (7) from lines at ABS module.

3-56 94000383
 c. See Figure 3-62. Free brake line from electrical harness c. Install line, banjo bolt (1) and new sealing washers
conduit clips (6). to ABS module. Tighten to 28–30 ft-lbs
(38–40.6 N·m).
d. Remove terminals from rear stop lamp switch (11)
e. Remove fastener (5) securing P-clamp (4). d. See Figure 3-62. Secure P-clamp (4) with screw (5).
Tighten to 80–100 in-lbs (9–11.3 N·m).
f. Release line from retainers (14) securing line to frame.
g. Cut cable straps as needed. Record their locations for e. Secure retaining clips (14).
assembly.
f. Install cable new straps in previously recorded
h. Remove brake line. positions.

sm08705 3. Secure brake line in clamps.

2
a. See Figure 3-61. Capture rear brake line in lower
clip of electrical harness retainers and upper passage
of multi-clamp.

1 b. Close multi-clamp to secure brake line and clutch

line.
1
c. Apply LOCTITE 243 (blue) to the threads of used
screw (4).

d. Install screw (4). Tighten to 10–15 in-lbs

4 (1.1–1.7 N·m).
3
1. Rear brake line e. Install front HO2 sensor wire in clip on clamp.
2. Front HO2 sensor wire
3. Clutch line 4. Install right side front engine mount cap with rider footboard
4. Screw and master cylinder attached:
Figure 3-61. Lower Frame Rail Line and Harness Retainers
NOTE
Install Confirm oil switch/sender wires are inboard of rubber mount.
NOTE
a. Connect terminals onto rear stop lamp switch (11).
Loosen and tighten banjo bolts while ABS module is secured.
b. Install engine mount end cap. Tighten to 42–48 ft-lbs
1. If installing new rear stop lamp switch, apply LOCTITE (56.9–65 N·m).
565 THREAD SEALANT. Install switch into rear brake line.
Tighten to 12–15 ft-lbs (16.3–20.3 N·m). c. Remove support under front of engine.

d. Install cable new straps in previously recorded

2. Install brake line.
positions.
a. Place rear brake line into approximate position. e. Install brake line, banjo bolt (13) and new sealing
Route over passenger footboard boss and upward washers (12) to master cylinder. Tighten to
to ABS module. 17–19 ft-lbs (23.1–25.8 N·m).
b. See Figure 3-63. Install alignment clip (7) onto lines
at ABS module.

94000383 3-57
 sm07605

14
5
9
11

7 12
8
13
10
9

1. Sealing washers 8. Locknut

2. Banjo bolt 9. O-ring
3. Brake hose clips 10. Fastener
4. P-clamp 11. Rear stop lamp switch
5. Fastener 12. Sealing washers
6. Electrical harness/brake line clips 13. Banjo bolt
7. Flat washer 14. Brake line retainers
Figure 3-62. Rear ABS Brake Line Assembly
4. Install right saddlebag. See SADDLEBAGS (Page 3-98).
Complete
BRAKE LINE: ABS MODULE TO REAR
WARNING CALIPER
When any hydraulic brake component, line or connection
is loosened or replaced on an ABS motorcycle, Digital PART NUMBER TOOL NAME
Technician II must be used during the brake bleeding BB200A BASIC VACUUM BRAKE BLEEDER
procedure to verify all air is removed from the system.
Failure to properly bleed the brake system could adversely FASTENER TORQUE VALUE
affect braking, which could result in death or serious injury. Banjo bolt to ABS module, 10 17–19 ft-lbs 23.1–25.8 N·m
(00585c) mm
Banjo bolt to rear caliper 17–19 ft-lbs 23.1–25.8 N·m
1. Bleed brake system. See BLEED BRAKES (Page 3-62).
2. Install right passenger footboard/footpeg. See Prepare
FOOTBOARDS AND FOOTRESTS (Page 3-155).
1. Remove right saddlebag. See SADDLEBAGS (Page 3-98).
3. Install right side cover.

3-58 94000383
2. Remove right side cover. Complete
NOTE WARNING
For best results, use the BASIC VACUUM BRAKE BLEEDER
When any hydraulic brake component, line or connection
(PART NUMBER: BB200A) or equivalent tool to drain the brake
is loosened or replaced on an ABS motorcycle, Digital
systems.
Technician II must be used during the brake bleeding
procedure to verify all air is removed from the system.
3. Drain rear brake line.
Failure to properly bleed the brake system could adversely
a. Remove master cylinder reservoir cover. affect braking, which could result in death or serious injury.
(00585c)
b. Attach vacuum brake bleeder to rear caliper bleeder
screw. Loosen screw 3/4 turn.
1. Bleed brake system. See BLEED BRAKES (Page 3-62).
c. Operate vacuum bleeder to evacuate all fluid from
2. Install right side cover.
master cylinder and line.
3. Install right side saddlebag. See SADDLEBAGS
d. Wipe out any remaining fluid inside master cylinder
(Page 3-98).
reservoir with a clean, lint-free cloth.

Remove
1. See Figure 3-62. Remove brake line.
a. Free rear brake hose from brake hose clips (3) on rear
fork.
b. Remove conduit clip securing rear wheel speed sensor
cable to brake hose.
c. See Figure 3-63. Remove banjo bolt (2) to release brake
line from ABS module. Discard sealing washers.
d. Remove alignment clip (7) from lines at ABS module.
e. Remove banjo bolt (2) from rear brake caliper. Discard
sealing washers (1).
f. Release brake line from retainer on right caddy.
g. Remove brake line.

Install
1. Install brake line.

a. Place brake line in approximate position. Secure to

retainer on right caddy.

b. See Figure 3-63. Install alignment clip (7) onto lines

at ABS module.

c. See Figure 3-62. Install line, banjo bolt (2) and new
sealing washers to ABS module. Tighten.
Torque: 17–19 ft-lbs (23.1–25.8 N·m) Banjo bolt to
ABS module, 10 mm
d. Install line, banjo bolt (2) and new sealing washers
to rear caliper. Tighten.
Torque: 17–19 ft-lbs (23.1–25.8 N·m) Banjo bolt to
rear caliper
e. Capture brake hose and wheel speed sensor cable
in two brake hose clips (3) on rear fork.

94000383 3-59
ABS MODULE 3.17
REFLEX™ LINKED BRAKES WITH ABS 3. Drain fluid from system.
OPERATION a. Remove both master cylinder reservoir covers.
b. Attach vacuum brake bleeder to a caliper bleeder screw.
This ABS braking system is an electronically linked brake
Loosen screw 3/4 turn.
system. Front and rear brakes are dynamically linked through
the electronic ABS module. "Linked" means that both front and c. Operate vacuum bleeder to evacuate all fluid from
rear brakes are applied at the same time. Electronic linking master cylinder and line. Repeat with remaining calipers.
provides maximum braking for all riders while allowing the more
d. Wipe out any remaining fluid inside master cylinder
experienced rider flexibility. Braking is more responsive and
reservoir with a clean, lint-free cloth.
allows more balanced braking under a wider range of
conditions.
Remove
• Reflex™ Linked Brakes is designed and tuned to provide a
seamless and predictable braking response. NOTE
Loosen and tighten banjo bolts while ABS module is secured.
• Linking is electronically controlled to achieve an optimized
brake balance based on the amount of brake applied and
vehicle speed. The amount of linking is dynamically adjusted 1. Disconnect ABS module.
to provide maximum benefit in heavier braking and is
reduced or eliminated for light braking and low speed. a. Disconnect ABS module electrical connector.
• Linking can occur in any braking situation above 20–25 mph
(32–40 km/h) whether only the front brake, rear brake, or b. Loosen five banjo bolts (metric). Do not remove.
both brakes are applied. When applying both brakes, the
c. See Figure 3-63. Remove alignment clip (7) from
rider may detect slight feedback in the front brake lever or
lines at ABS module.
rear brake pedal while the dynamic balancing occurs.
• The amount of linking is programmed to provide a good d. Remove two rear battery tray screws to allow battery
balance of stopping and rider feel. tray to lower.
• Front and rear brake systems are still hydraulically
NOTE
independent.
Pry between the bottom of the ABS module and the right caddy
• If an ABS event occurs, the ABS unit will pulse the brakes to release stud on bottom of module from grommet.
to help prevent wheel lockup.
ABS MODULE e. Remove five banjo bolts to release brake lines from
ABS module. Discard sealing washers.
PART NUMBER TOOL NAME
NOTICE
BB200A BASIC VACUUM BRAKE BLEEDER
HD-48650 DIGITAL TECHNICIAN II This device is sensitive to electrostatic discharge (ESD).
To prevent damage to the device, always touch the
FASTENER TORQUE VALUE motorcycle frame or a grounded surface before handling.
(00588c)
ABS module locknuts 53–88 in-lbs 6–10 N·m
Banjo bolt to ABS module, 10 17–19 ft-lbs 23.1–25.8 N·m
mm 2. Remove module.
Banjo bolt to ABS module, 12 28–30 ft-lbs 38–40.6 N·m
a. See Figure 3-63. Loosen two locknuts (6) at rubber
mm
mounts.
Battery tray screws 132–156 in-lbs 14.9–17.6 N·m
b. Separate ABS module from caddy.
NOTE
The ABS module consists of the Hydraulic Control Unit (HCU) 3. Inspect rubber mounts and grommet for damage or
and the Electronic Control Unit (ECU). The two are not serviced deterioration. Replace parts if necessary.
separately.

Prepare
1. Remove right saddlebag. See SADDLEBAGS (Page 3-98).
2. Remove right side cover.
NOTE
For best results, use the BASIC VACUUM BRAKE BLEEDER
(PART NUMBER: BB200A) or equivalent tool to drain the brake
systems.

3-60 94000383
 5. If installing a new ABS module, it must be set up using
sm07603 7 DIGITAL TECHNICIAN II (PART NUMBER: HD-48650):
3
2
4 a. Choose the REFLASH icon.

b. Follow the on-screen prompts.

1
5 Complete
WARNING
When any hydraulic brake component, line or connection
is loosened or replaced on an ABS motorcycle, Digital
Technician II must be used during the brake bleeding
6 procedure to verify all air is removed from the system.
Failure to properly bleed the brake system could adversely
1. Rear master cylinder, 12 mm affect braking, which could result in death or serious injury.
2. ABS module to rear caliper, 10 mm (00585c)
3. ABS module to front-right caliper, 10 mm
4. ABS module to front-left caliper, 10 mm 1. Bleed brake system. See BLEED BRAKES (Page 3-62).
5. Front master cylinder, 12 mm
6. Mount locknut (2) 2. Install right side cover.
7. Alignment clip
Figure 3-63. ABS Module Connections 3. Install right saddlebag. See SADDLEBAGS (Page 3-98).

Install WARNING
NOTICE
After repairing the brake system, test brakes at low speed.
This device is sensitive to electrostatic discharge (ESD). If brakes are not operating properly, testing at high speeds
To prevent damage to the device, always touch the can cause loss of control, which could result in death or
motorcycle frame or a grounded surface before handling. serious injury. (00289a)
(00588c)
4. Operate motorcycle at low speeds to verify that braking
1. Install ABS module. systems operate properly.

a. Apply glass cleaner to ease installation of stud into

grommet. Install ABS module on right caddy.

NOTE
The order in which lines are arranged is important. Arrange as
the insets show in Figure 3-58.

b. See Figure 3-63. Tighten locknuts (6) to 53–88 in-lbs

(6–10 N·m).

2. Connect lines.

a. Route rear caliper line under rear master cylinder

line.

b. Install banjo fittings to their respective ports with

banjo bolts and new sealing washers. Do not tighten.

c. Install alignment clip (7) onto lines at ABS module.

d. Install rear battery tray screws. Tighten to

132–156 in-lbs (14.9–17.6 N·m).

3. Tighten banjo bolts:

a. 10 mm to 17–19 ft-lbs (23.1–25.8 N·m)

b. 12 mm to 28–30 ft-lbs (38–40.6 N·m)

4. Connect ABS module electrical connector.

94000383 3-61
BLEED BRAKES 3.18
FILL AND BLEED b. Install end of clear plastic tubing over bleeder screw.

c. Place opposite end of clear plastic tubing in a clear

PART NUMBER TOOL NAME
container.
BB200A BASIC VACUUM BRAKE BLEEDER
HD-48650 DIGITAL TECHNICIAN II d. Operate the brake lever or pedal to build hydraulic
pressure.
FASTENER TORQUE VALUE
Brake bleeder screw, front 72–108 in-lbs 8.1–12.2 N·m e. Hold pressure with the brake lever or pedal.
Brake bleeder screw, rear 75–102 in-lbs 8.5–11.5 N·m
f. Open bleeder screw three-quarters of a turn.
Brake master cylinder, front, 12–15 in-lbs 1.4–1.7 N·m
reservoir cover screws g. Close bleeder screw as soon as the brake lever or
Brake master cylinder, rear, 12–15 in-lbs 1.4–1.7 N·m pedal has moved full range of travel.
reservoir cover screws
h. Allow brake lever or pedal to return slowly to its
WARNING released position.

A plugged or covered relief port can cause brake drag or
lock-up, which could lead to loss of control, resulting in
death or serious injury. (00288a)
• If DOT 4 brake fluid contacts painted surfaces,
IMMEDIATELY flush area with clear water.
NOTICE
Do not allow dirt or debris to enter the master cylinder
reservoir. Dirt or debris in the reservoir can cause improper
operation and equipment damage. (00205c)
NOTE
• Procedure for filling and bleeding brake fluid is the same for
both the front and the rear brake systems.
• ABS models: Use DIGITAL TECHNICIAN II (PART
NUMBER: HD-48650) to verify that system is bled.
• For best results use BASIC VACUUM BRAKE BLEEDER
(PART NUMBER: BB200A). If a vacuum brake bleeder is
not available, use the following procedure.
1. Verify brake system operation.
a. Verify that the master cylinder is level.
b. Remove cover from master cylinder reservoir.
c. Fill reservoir with DOT 4 BRAKE FLUID. Refer to
Table 3-14.
NOTE
• Monitor the fluid level in the master cylinder reservoir. Add
fluid before it empties to avoid drawing air into the brake
lines.
• Dual caliper front brake system: Bleed both calipers.
d. Verify proper operation of the master cylinder relief
port by actuating the brake pedal or lever. Fluid will
break the fluid surface in the reservoir if internal
components are working properly.
2. Bleed brake system.
a. Remove cap from bleeder screw.
i. Repeat until all air bubbles are purged and a solid
column of fluid is observed in the bleeder tube.
j. Tighten bleeder screw to specification. Refer to Table
3-15. Install bleeder screw cap.
k. Fill reservoir with DOT 4 BRAKE FLUID. Refer to
Table 3-14.
3.
4. Refer to Table 3-15. Install master cylinder reservoir cover:
a. Verify that the master cylinder cover gasket bellows
is not extended.
b. Verify that gasket and sealing surfaces are free of
debris.
c. Front master cylinder reservoir: Install the cover
with the vent holes facing the rear. Install cover
screws. Tighten to specification.
d. Rear master cylinder reservoir: Install cover
screws. Tighten to specification.
WARNING
When any hydraulic brake component, line or connection
is loosened or replaced on an ABS motorcycle, Digital
Technician II must be used during the brake bleeding
procedure to verify all air is removed from the system.
Failure to properly bleed the brake system could adversely
affect braking, which could result in death or serious injury.
(00585c)
5. ABS models: Connect DIGITAL TECHNICIAN II (PART
NUMBER: HD-48650) and perform "ABS Service"
procedure.
WARNING
Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)
6. Check operation of brake lamp.

3-62 94000383
 WARNING
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)

WARNING
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)

7. Test ride motorcycle. Repeat the bleeding procedure if

brakes feel spongy.

Table 3-14. Fluid Level

ITEM SPECIFICATION
Front reservoir Boss or ridge
Rear reservoir Ledge or range window

Table 3-15. Torque Specifications

COMPONENT TORQUE
Bleeder screw, front 72–108 in-lbs (8.1–12.2 N·m)
Bleeder screw, rear 75–102 in-lbs (8.5–11.5 N·m)
Front cover 12–15 in-lbs (1.4–1.7 N·m)
Rear cover 12–15 in-lbs (1.4–1.7 N·m)

94000383 3-63
FRONT FORK 3.19
CHECK FOR OIL LEAK Check Oil Leak
1. Observe oil ring.
Fork Oil Seals
2. Wipe fork clean.
The fork oil seal allows a fine film of oil to lubricate the fork
sliding surface. 3. Ride motorcycle over bumpy road or complete six braking
events.
• The oil film is more visible after continuous high-speed
4. See Figure 3-64. Check fork slider tube for oil.
compression and rebound movement.
a. If a normal oil/dust film (1, 2) is present, there is no leak.
• Due to greater lubrication needs, larger forks have a greater
amount of oil film than smaller forks. b. If an oil run or drip (3) is present, perform procedure
two or three more times to confirm oil leak.

sm07968

1 2
3

1. Normal oil/dust film 3. Drip

2. Normal oil/dust film
Figure 3-64. Front Forks
PREPARE 7. Fairing models, frame-mounted: Remove instrument
bezel. See INSTRUMENT BEZEL: FRAME MOUNTED
FAIRING MODELS (Page 3-125).
NOTICE

When lifting a motorcycle using a jack, be sure jack

REMOVE
contacts both lower frame tubes where down tubes and
lower frame tubes converge. Never lift by jacking on 1. See Figure 3-65. Loosen upper pinch screw (1) but do not
cross-members, oil pan, mounting brackets, components remove.
or housings. Failure to comply can cause serious damage 2. Remove fork.
resulting in the need to perform major repair work. (00586d)
a. Hold fork slider to prevent fork from dropping.
1. Raise the front wheel. b. Loosen lower pinch screws (2).
2. Remove front wheel. See FRONT WHEEL (Page 3-15). c. Slide fork tube down to remove.
3. Remove front fender. See Front Fender (Page 3-146).
3. If necessary, remove screws (3). Remove slider covers.
4. Remove brake caliper. See FRONT BRAKE CALIPER
(Page 3-43).
a. Leave brake hose attached.
b. Support from engine guard.

5. Road King models: Remove headlamp nacelle. See

HEADLAMP NACELLE: ROAD KING MODELS
(Page 3-144).
6. Fairing models, fork-mounted: Remove dash panel. See
DASH PANEL: FORK MOUNTED FAIRING MODELS
(Page 3-117).

3-64 94000383
 5. Tighten upper pinch screw.
sm07545

a. Verify that upper fork bracket is seated against the

upper dust shield.

1 b. Verify that upper fork bracket is evenly positioned

on both fork tubes.

c. Tighten upper pinch screw (1) to 14–18 ft-lbs

(19–24.4 N·m).

sm07957
3 2 3

1. Upper pinch screw

2. Lower pinch screws (2)
3. Screws, slider cover (2) 4
Figure 3-65. Front Fork Attachment
INSTALL 1. Top rear surface
2. Tapered area
FASTENER TORQUE VALUE 3. Upper fork bracket
Fork bracket to fork pinch 14–18 ft-lbs 19–24.4 N·m 4. Upper pinch screw
screws Figure 3-66. Fork Height
Fork slider cover screws 24–48 in-lbs 2.7–5.4 N·m
sm07958

1. See Figure 3-65. If removed, install slider covers.

a. Apply LOCTITE 246 MEDIUM STRENGTH

THREADLOCKER (blue) to the threads of screws
(3).

b. Tighten to 24–48 in-lbs (2.7–5.4 N·m).

A
2. Slide fork tube into place.

3. Set fork height:

a. Visual method: See Figure 3-66. Set fork height so

top rear surface (1) of upper fork bracket is midway
of the tapered area (2) at top of fork.

b. Measurement method: See Figure 3-67. Set top of

fork to a measurement (A) of 8.695 +/- 0.060 in
(220.85 +/- 1.52 mm) from the top rear of the lower
fork bracket. Figure 3-67. Measured Fork Height
COMPLETE
4. See Figure 3-65. Tighten lower fork bracket pinch screws
(2) in sequence: 1. Install front fender. See Front Fender (Page 3-146).
2. Install front wheel. See FRONT WHEEL (Page 3-15).
a. Tighten upper screw to 14–18 ft-lbs (19–24.4 N·m).
3. Install front caliper. See FRONT BRAKE CALIPER
b. Tighten lower screw to 14–18 ft-lbs (19–24.4 N·m). (Page 3-43).
4. Road King models: Install headlamp nacelle. See
c. Repeat previous steps one time.
HEADLAMP NACELLE: ROAD KING MODELS
(Page 3-144).

94000383 3-65
5. Fairing models, fork-mounted: Install dash panel. See b. Allow 10-15 minutes for fork to drain completely.
DASH PANEL: FORK MOUNTED FAIRING MODELS
(Page 3-117). NOTE
6. Fairing models, frame-mounted: Install instrument bezel. If only performing a fork oil change, go to ASSEMBLY, Filling
See INSTRUMENT BEZEL: FRAME MOUNTED FAIRING and Final Assembly.
MODELS (Page 3-125).
6. Remove screw (18).
DISASSEMBLE
a. Position fork horizontal.
PART NUMBER TOOL NAME b. Temporarily install spring, spacer and sleeve.
HD-41177 FORK TUBE HOLDER c. Apply pressure to spring to prevent damper from rotating
and remove screw (18).
NOTE
Always use soft jaws when placing any fork components into d. Remove copper washer (17). Discard washer.
vise. e. Remove sleeve, spacer and spring.

1. See Figure 3-68. If performing complete disassembly, 7. Remove fork tube.

clamp lower end of fork slider in a soft-jawed vise. Loosen
lower screw (18). Do not remove now.
2. Install fork tube in FORK TUBE HOLDER (PART
NUMBER: HD-41177) with fork vertical.
3. Remove fork tube plug (1).
a. Fork tube plug is under spring pressure. Have a firm
grasp on plug as it is removed.
b. Remove and discard O-ring (2).
a. Remove retaining clip (10).
b. Expand fork slider and tube against each other
repeatedly (in a slide-hammer effect) to remove fork
tube.
c. Remove fork tube bushing (14), slider bushing (13),
spacer (12), seal (11) and retaining clip (10) from fork
tube.
d. Remove lower stop (15) from end of fork tube.

4. Remove sleeve (3), spacer (4) and spring (5) from fork 8. Tip fork tube upside down to remove damper tube (7) with
assembly. rebound spring (8).
5. Drain fork oil. 9. Remove rebound spring (8) and wear ring (6) from damper
tube.
a. Slowly pump fork tube and slider at least ten times.

3-66 94000383
 sm07815

1 2
9
3 10

11
4
12
13
5
14
15

16
6

23
8
22
17
21

18 20
19

1. Fork tube plug 13. Slider bushing

2. O-ring 14. Fork tube bushing
3. Sleeve 15. Lower stop
4. Spacer 16. Fork slider
5. Spring 17. Copper washer
6. Wear ring, damper tube 18. Screw (metric)
7. Damper tube 19. Nut (2)
8. Rebound spring 20. Lockwasher (2)
9. Fork tube 21. Flat washer (2)
10. Retaining clip 22. Axle holder
11. Seal 23. Reliefs in wear ring
12. Slider spacer
Figure 3-68. Fork Assembly
CLEAN AND INSPECT 4. Check fork tube and slider for scoring, scratches and
abnormal wear.
1. Clean all parts. 5. Inspect fork tube for nicks from stones and road debris,
2. Inspect parts for wear or damage. Replace parts if especially in area where seal contacts it. Replace if
necessary. necessary.

3. Inspect OD of slider bushing and ID of fork tube bushing. 6. See Figure 3-69. Check runout with a dial indicator.

a. If coating is worn through (metallic substrate showing), a. Set fork tube on V-blocks.
replace bushing. b. Replace fork if runout exceeds 0.008 in (0.2 mm).
b. Inspect for distortion.
c. If deep scratches or scoring are found, replace bushing.
Also inspect mating components for similar wear.
Replace or repair as necessary.

94000383 3-67
 d. Slide damper tube into fork tube, small end first, until
sm02901
it passes through hole at bottom of fork tube. Install
lower stop (15) at end of damper tube.

e. Install fork spring (5) with the tightly wound coils

toward the bottom.

f. Install spacer (4) and sleeve (3).

g. Slide fork slider onto fork tube.

h. Apply LOCTITE 565 THREAD SEALANT to screw

Figure 3-69. Measure Fork Tube Runout (18). Loosely install screw and new copper washer
ASSEMBLE (17).

i. Remove from fork holder.

PART NUMBER TOOL NAME
HD-41177 FORK TUBE HOLDER NOTE
HD-45305 FORK SEAL DRIVER Do not bend or stretch retaining clip (10) when installing.
HD-59000B FORK OIL LEVEL GAUGE
j. While compressing spring, tighten screw (18) to
FASTENER TORQUE VALUE 30–37 ft-lbs (40–50 N·m).
Fork damper tube screw 30–37 ft-lbs 40–50 N·m
(metric) 3. See Figure 3-70. Install fork oil seal.
Fork tube plug 22–59 ft-lbs 30–80 N·m
a. Clamp lower end of fork slider in a soft-jawed vise.
NOTE
Lubricate all seal lips, quad rings and O-rings with b. Using FORK SEAL DRIVER (PART NUMBER:
HARLEY-DAVIDSON SEAL GREASE during assembly. HD-45305) like a slide hammer, drive fork oil seal
down until installer contacts fork slider.
1. See Figure 3-68. Assemble fork tube. c. Remove tool.

a. Coat OD of slider bushing (13) and fork tube bushing d. See Figure 3-68. Install retaining clip (10) in the fork
(14) with clean fork oil. slider groove.

b. Expand slider bushing only enough to slip into groove

sm03227a
of fork tube (9).
4
c. Install fork tube bushing and slider spacer (12) onto 1 2 3
fork tube. Slide down until they contact slider bushing
(13).

d. Wrap masking tape over edge of fork tube to protect

fork oil seal during installation.

e. With the garter spring side toward the fork slider (16),
slide new fork oil seal (11) down fork tube until it
contacts slider spacer (12).

NOTE
Screw (18) can be reused unless damaged.

f. Remove masking tape from fork tube.

1. Slider bushing
2. Install damper tube (7). 2. Spacer
3. Oil seal (lettered side faces upward)
a. Install fork tube horizontally in FORK TUBE HOLDER 4. Fork seal driver
(PART NUMBER: HD-41177).
Figure 3-70. Assembled Fork Seal Driver
b. Install new wear ring (6) in groove of damper tube 4. Loosely install axle holder (22) with flat washers (21),
(7). Install with reliefs (23) down. lockwashers (20) and nuts (19) on right fork slider.

c. Install rebound spring (8) on opposite end. 5. Proceed to Filling and Final Assembly.

3-68 94000383
Filling and Final Assembly sm01639a

1. Clamp fork slider vertically in FORK TUBE HOLDER

(PART NUMBER: HD-41177).
1
2. See Figure 3-68. Remove fork sleeve (3), spacer (4) and
spring (5) from fork tube.

3. Pour slightly more than 24 fl oz (710 ml) TYPE 'E'

HYDRAULIC FORK OIL directly into the fork tube.
3
4. Slowly pump fork tube until some resistance is felt. Then
pump a few more times.
2

WARNING 4

Incorrect amount of fork oil can adversely affect handling

and lead to loss of vehicle control, which could result in
death or serious injury. (00298a)

5. See Figure 3-71. Adjust fork oil level. 1. Fork oil level
2. Tube
a. Adjust collar (3) of FORK OIL LEVEL GAUGE (PART 3. Collar
NUMBER: HD-59000B) to: Standard models: 4. Thumb lock
3.70 in (94 mm). Low models: 3.54 in (90 mm). Figure 3-71. Oil Level Gauge
b. With the fork tube bottomed in the fork slider, insert
tube (2) of gauge until collar (3) rests flat on top of
fork tube.

c. Draw excess oil from fork with plunger. If no oil is

drawn out, add a small amount to the fork tube and
repeat.

6. See Figure 3-68. Extend the fork. Install fork spring (5),
spacer (4) and sleeve (3) into fork tube with the tighter
wound coils at the bottom.

7. Remove fork slider from fork holding tool. Clamp fork tube
into fork holding tool.

8. Install new O-ring (2) onto fork tube plug (1). Install fork
tube plug. Tighten to 22–59 ft-lbs (30–80 N·m).

9. Install fork and assemble motorcycle. See FRONT FORK,

Install (Page 3-65).

94000383 3-69
STEERING HEAD BEARINGS 3.20
PREPARE INSTALL

1. Disassemble motorcycle. FASTENER TORQUE VALUE

a. Road King models: Remove headlamp nacelle. See Upper steering stem, final 63 in-lbs 7.1 N·m
HEADLAMP NACELLE: ROAD KING MODELS torque: Fork mounted fairing
(Page 3-144). models
Upper steering stem, final 192 in-lbs 21.7 N·m
b. Fairing models, fork-mounted: Remove inner fairing torque: Frame mounted fairing
assembly. See INNER FAIRING: FORK MOUNTED models
FAIRING MODELS (Page 3-118).
Upper steering stem, final 108 in-lbs 12.2 N·m
c. Fairing models, frame-mounted: Remove instrument torque: Road King models
nacelle. See INSTRUMENT NACELLE: FRAME Upper steering stem, final 108 in-lbs 12.2 N·m
MOUNTED FAIRING MODELS (Page 3-126). torque: Trike models
Upper steering stem, first 35 ft-lbs 47.5 N·m
2. Remove front forks. See FRONT FORK (Page 3-64).
torque
REMOVE
1. See Figure 3-72. Lubricate upper steering stem threads
1. Release brake lines from lower fork bracket. with SPECIAL PURPOSE GREASE. Apply a coat of
SPECIAL PURPOSE GREASE on bearing rollers and
2. ABS models: Disconnect WSS connector. Remove WSS. cups.
NOTE
Leave hand controls and switches assembled to handlebar. 2. Install lower stem/fork bracket (8) into steering head.

3. Remove upper fork bracket with handlebar attached. 3. Install upper stem.
Secure assembly with elastic cords on a well-padded fuel
tank. See STEERING HEAD BEARINGS, Upper Fork a. Hold lower stem/fork bracket up against lower cup
Bracket (Page 3-71). (5).
4. See Figure 3-72. Remove upper steering stem (1). b. Install upper stem (1) hand-tight.
5. Remove lower steering stem/fork bracket (8).
c. Place wooden block between lower fork bracket and
sm07961 frame.
3
1 d. Tighten upper steering stem (1) to 35 ft-lbs
4 (47.5 N·m).
2
e. Loosen upper steering stem 90-100 degrees. Tighten
to specification. Refer to Table 3-16.

Table 3-16. Steering Stem Torque

5 MODEL TORQUE
Fairing models: fork 63 in-lbs (7.1 N·m)
6 mounted
Fairing models: frame 192 in-lbs (21.7 N·m)
7 mounted
Road King 108 in-lbs (12.2 N·m)
Trike 108 in-lbs (12.2 N·m)
8
COMPLETE
1. Upper steering stem
2. Dust shield, upper 1. Install front forks in lower fork bracket. Use the
3. Upper bearing cone measurement method to adjust height. See FRONT FORK
4. Upper cup (Page 3-64).
5. Lower cup
2. ABS models: Connect WSS cable. Secure to right steering
6. Lower bearing cone
head caddy. See WHEEL SPEED SENSORS, Front Wheel
7. Dust shield, lower
Speed Sensor (WSS) (Page 9-55).
8. Lower steering stem/fork bracket
Figure 3-72. Steering Stem Bearings 3. Install upper fork bracket and handlebar. Do not tighten
fork stem pinch screw. See STEERING HEAD BEARINGS,
Upper Fork Bracket (Page 3-71).

3-70 94000383
4. Assemble motorcycle. 3. See Figure 3-72. Assemble upper steer stem.
a. Road King models: Install headlamp nacelle. See
HEADLAMP NACELLE: ROAD KING MODELS a. Install upper (2) dust shield.
(Page 3-144).
b. Press bearing cone (3) onto upper stem.
b. Fairing models, fork-mounted: Install inner fairing
assembly. See INNER FAIRING: FORK MOUNTED 4. Assemble lower steer stem.
FAIRING MODELS (Page 3-118).
c. Fairing models, frame-mounted: Install the instrument a. Install lower (7) dust shield.
nacelle. See INSTRUMENT NACELLE: FRAME
MOUNTED FAIRING MODELS (Page 3-126). b. Press bearing cone (6) onto lower stem.

5. Adjust swing-back. See STEERING HEAD BEARINGS 5. If removed, install brake line bracket with two screws.
(Page 2-46). Tighten to 12–18 in-lbs (1.4–2 N·m).
DISASSEMBLE
sm04980

NOTE
Removing bearings destroys them. Always install new bearings
upon assembly.

1. See Figure 3-72. Remove bearing cones (3, 6) from upper

stem and lower stems.
NOTE
Internal reliefs in steering head allow punch access to the
bearing cups.

2. Drive both bearing cups (4, 5) out of steering head.

3. If necessary, remove screws securing brake line bracket.
Remove bracket.
ASSEMBLE

PART NUMBER TOOL NAME

HD-51727 STEERING HEAD BEARING
INSTALLER Figure 3-73. Install Steering Head Bearing Cups
UPPER FORK BRACKET
FASTENER TORQUE VALUE
Brake line bracket to lower 12–18 in-lbs 1.4–2 N·m
FASTENER TORQUE VALUE
fork bracket screws
Fork bracket to fork pinch 14–18 ft-lbs 19–24.4 N·m
WARNING screws
Fork bracket to steer stem 22–26 ft-lbs 29.8–35.2 N·m
Properly seat bearing cups in steering head bore. Improper pinch screw
seating can loosen fork stem bearings adversely affecting
stability and handling, which could result in death or Remove
serious injury. (00302a)
1. Disassemble motorcycle:
NOTE
• Always install new bearings. Replace both bearings anytime a. Road King models: Remove headlamp nacelle. See
either requires replacement. HEADLAMP NACELLE: ROAD KING MODELS
(Page 3-144).
• Install both bearing cups at the same time.
b. Fairing models, fork-mounted: Remove inner fairing.
See INNER FAIRING: FORK MOUNTED FAIRING
1. Inspect the bores in the steering head. Remove any paint,
MODELS (Page 3-118).
rust or burrs.
c. Fairing models, frame-mounted: Remove instrument
NOTE nacelle. See INSTRUMENT NACELLE: FRAME
MOUNTED FAIRING MODELS (Page 3-126).
Upper dust shield has a larger OD than the lower dust shield.
2. Disconnect wiring.
2. See Figure 3-73. Install new bearing cups using
STEERING HEAD BEARING INSTALLER (PART a. Disconnect left and right handlebar switch connectors
NUMBER: HD-51727). b. Disconnect ignition switch connector.
c. Disconnect TGS connector.

94000383 3-71
 d. Disconnect upper fork bracket ground connector. 5. Connect wiring.
e. Disconnect heated hand grip connectors if equipped.
a. Connect left and right handlebar switch connectors.
f. Cut cable straps securing hydraulic lines and wiring to
the handlebar risers. b. Connect ignition switch connector.

NOTE c. Connect TGS connector.

Leave hand controls and switches installed on handlebar.
d. Connect upper fork bracket ground connector.
3. If necessary, separate handlebar from upper fork bracket.
e. Connect heated hand grip connectors if equipped.
a. Separate handlebar from handlebar risers. See
HANDLEBAR (Page 3-87). f. See Figure 3-75. Secure lines and wiring to
handlebar risers with new cable straps.
b. Carefully lay on protected fuel tank.

4. See Figure 3-74. Remove upper fork bracket. 6. Assemble motorcycle:

a. Loosen pinch screw (1).
b. Loosen pinch screws (2).
c. Do not loosen pinch screws (4).
d. Lift off upper fork bracket and handlebar as an
assembly. Carefully lay on protected fuel tank.
5. If necessary, disassemble upper fork bracket.
a. Remove handlebar risers and handlebar. See
HANDLEBAR, Handlebar Clamps and Rubber Mounts
(Page 3-92).
b. Remove ignition switch or fork lock. See Ignition Switch
and Fork Lock (Page 9-39).
a. Road King models: Install headlamp nacelle. See
HEADLAMP NACELLE: ROAD KING MODELS
(Page 3-144).
b. Fairing models, fork-mounted: Install inner and
outer fairings. See INNER FAIRING: FORK
MOUNTED FAIRING MODELS (Page 3-118).
c. Fairing models, frame-mounted: Install instrument
nacelle. See INSTRUMENT NACELLE: FRAME
MOUNTED FAIRING MODELS (Page 3-126).
sm05704
1

Install
1. If necessary, assemble upper fork bracket.

a. Install handlebar and risers. See HANDLEBAR,

Handlebar Clamps and Rubber Mounts (Page 3-92).
2 2
b. Install ignition switch or fork lock. See Ignition Switch
and Fork Lock (Page 9-39). 3

2. Check front fork height. Use the measurement method.

See FRONT FORK (Page 3-64).

3. If wheel is installed, raise vehicle to remove weight from

front wheel.

4. See Figure 3-74. Install fork upper bracket.

a. Place upper fork bracket with handlebar over ends 4 4

of forks and onto upper steering stem. If necessary,
use a plastic deadblow hammer to tap the fork
bracket onto the upper steering stem.

b. Hold upper fork bracket down tight against upper

dust shield. Tighten pinch screw (1) to 22–26 ft-lbs 1. Pinch screw, fork stem nut
(29.8–35.2 N·m). 2. Pinch screw, fork bracket, upper
3. Upper steering stem
c. Verify that upper fork bracket is evenly positioned 4. Pinch screw, fork bracket, lower
on both forks. Tighten upper fork pinch screws (2) Figure 3-74. Fork Stem and Brackets
to 14–18 ft-lbs (19–24.4 N·m).

d. If handlebar was removed: Install handlebar. See

HANDLEBAR (Page 3-87).

3-72 94000383
 sm07669

3
2

1. Clutch line to brake line: fork mounted fairing

and Road King models only
2. Clutch line and brake line to right riser
3. Clutch line to left riser
Figure 3-75. Capture Clutch and Brake Fluid Lines

94000383 3-73
REAR SUSPENSION 3.21
REMOVE SHOCK ABSORBER sm08699

Prepare 1
2
NOTE
Remove and install one shock absorber at a time.

1. Raise the rear of the motorcycle until the rear tire is just
touching.
2. Remove saddlebags. See SADDLEBAGS (Page 3-98).

Remove
3
1. Remove upper and lower shock absorber mounting bolts,
lockwashers and flat washers.
2. Remove shock absorber.
CLEAN AND INSPECT
1. Right side
1. Inspect shock absorber for signs of leakage. Replace both 2. Left side
shock absorbers if leak is found. 3. Thicker end toward frame
2. Inspect bushings for cracks and wear. Replace as Figure 3-76. Manual Adjust Shock Absorber
necessary.
MANUAL ADJUST SHOCK ABSORBER
INSTALL SHOCK ABSORBER REPAIR

FASTENER TORQUE VALUE See Figure 3-77. The rear shock absorbers contain no
Shock absorber mounting bolt 63–70 ft-lbs 85.4–95 N·m serviceable parts except an adjustment knob and hardware
kit.
Install 1. Remove the screw and flat washer securing the knob.
NOTE NOTE
• See Figure 3-76. Install right shock absorber (1) with the Do not allow the knob detent ball and spring to release
rod end up. unexpectedly and become lost.
• Install right shock absorber with thicker end (3) of bushings
facing frame. 2. Hold a rag wrapped around the adjuster housing and knob
to prevent loss of the detent ball and spring. Carefully
• Install left shock absorber (2) with the knob topside and
remove the knob.
facing forward.
3. If necessary, remove detent ball and spring.
1. Apply LOCTITE 243 MEDIUM STRENGTH 4. If removed, place spring in bore.
THREADLOCKER AND SEALANT (blue) to each mounting
bolt. 5. Press and hold ball onto end of spring. Install knob on
adjuster housing.
2. Install shock absorber with mounting bolts, lockwashers 6. Install screw. Tighten securely.
and flat washers. Tighten to 63–70 ft-lbs (85.4–95 N·m).
7. Rotate knob to verify that the detent is properly assembled.
Clicks are heard every half rotation.
Complete
1. Install saddlebags. See SADDLEBAGS (Page 3-98).
2. Lower rear wheel.

3-74 94000383
 sm08737

Figure 3-77. Rear Shock Absorber Preload Adjuster Knob

94000383 3-75
REAR FORK 3.22
REMOVE • A 6-point socket is recommended to remove the pivot shaft
screws.
1. Remove rear wheel. See REAR WHEEL (Page 3-18).
7. Remove pivot shaft.
2. Remove debris deflector from bottom of left side fork.
a. Hold left side hex cup (9) and remove right side screw
3. Loosen both lower shock absorber mounting bolts. Do not (10) from pivot shaft (6).
remove now.
b. Remove right hex cup (3).
4. See Figure 3-78. Remove two screws (12) to free left rear
fork bracket (11) with footrest attached. c. Remove pivot shaft, screw (2), left hex cup (9), rubber
mount (8) and outer spacer (7) from the left side as an
5. Release rear brake hose and rear wheel speed sensor assembly.
cable (ABS models) from rear fork.
6. Remove plug (1) from right side. 8. Remove lower shock absorber bolts. Work rear fork free
of transmission mount and rubber mount (4).
NOTE
9. Remove right outer spacer (5) from fork tube.
• For best results, use an air impact wrench to remove the
right side screw. Applying heat to the right side screw also 10. Remove right rubber mount (4).
improves removal.

sm05787b 1
11
10
9
8
7
12
6

5
4
3
2
1

1. Plug 7. Left outer spacer

2. Right side screw 8. Left rubber mount
3. Right hex cup 9. Left hex cup
4. Right rubber mount 10. Left side screw
5. Right outer spacer 11. Fork bracket
6. Pivot shaft 12. Screw (2)
Figure 3-78. Rear Fork Mounting
INSTALL 1. See Figure 3-79. Install right side rubber mount.

FASTENER
Debris deflector screw
Rear fork bracket screws
Rear fork pivot shaft screws
Shock absorber mounting bolt
TORQUE VALUE
65–85 in-lbs 7.3–9.6 N·m
55–65 ft-lbs 74.6–88.1 N·m
55–65 ft-lbs 74.6–88.1 N·m
63–70 ft-lbs 85.4–95 N·m
a. With the slot on the outboard side between the 12
o'clock and 1 o'clock positions, install rubber mount
on inner-right side of frame.
b. Make sure that index tab in mount cavity fully
engages slot in rubber mount.

3-76 94000383
2. Install fork. 10. Capture rear brake line hose in two cable clips at top of
right side fork. Rear cable clip also captures rear wheel
a. Hold outer spacer in right side fork tube and move speed sensor cable on ABS equipped motorcycles.
the fork into position.
11. Install rear wheel. See REAR WHEEL (Page 3-18).
b. Loosely attach shock absorbers.

c. Work the rear fork into final position between the sm05797a

transmission mount and the right rubber mount.

d. Coat pivot shaft with ANTI-SEIZE LUBRICANT.

Avoid getting anti-seize in threads of pivot shaft.

e. See Figure 3-78. Install pivot shaft from left side

through fork and transmission mount. Guide end of
pivot shaft through right rubber mount.

3. Install left side components.

a. Install outer spacer (7) until seated against shoulder

of pivot shaft.
Figure 3-79. Right Side Mount
b. Install left rubber mount (8) with the flat side inboard.
DISASSEMBLE
c. Install hex cup (9).

d. Rotate the left rubber mount (8) so the slot is
between the 11 and 12 o'clock positions.
e. Install left side fork bracket (11) fitting index tab into
slot of rubber mount.
f. Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue) fork
bracket screws (12). Secure left side fork bracket
with footrest. Tighten to 55–65 ft-lbs (74.6–88.1 N·m).
4. Install pivot shaft screws (2, 10).
Remove Bearings
1. See Figure 3-80. Select a driver (1) slightly smaller than
the bearing spacer collar and a rod (2) long enough to
allow pressing through upper bearing.
2. Support the fork (4) in a press with brake anchor weldment
on top. Slide rod through the brake side bearing against
driver. Verify that assembly is square and the bearing bore
is vertical.
3. Press bearing/spacer assembly (3) from rear fork.
4. Turn over fork. Press out brake side bearing in same
manner.

a. Remove plugs (1). 5. If bearings will be replaced with new, press spacers out
and retain for later use.
b. Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue) to pivot sm05792

shaft screws (2, 10).

c. Install screws.

d. Tighten to 55–65 ft-lbs (74.6–88.1 N·m).

5. Verify that rear fork assembly moves freely. 2

6. Install plugs (1). 1 3

4
7. Remove lower shock absorber mounting bolts. Apply a
drop of LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue) to the threads
of each bolt. Install bolts. Tighten to 63–70 ft-lbs
(85.4–95 N·m). 1. Driver
2. Rod
3. Bearing/spacer assembly
8. Install debris deflector. Tighten to 65–85 in-lbs
4. Rear fork
(7.3–9.6 N·m).
Figure 3-80. Remove Rear Fork Bearing
9. Seat caliper bracket on anchor weldment of rear fork.
Disassemble Pivot Shaft/Mount
1. See Figure 3-81. Remove screw (7).

94000383 3-77
2. Remove outer spacer (6), rubber mount (5) and middle
sm03535
spacer (4).

sm05795a
7 8
5 6
4

3 1 2
2
1

1. Drive side driver

2. Brake side driver
1. Rear fork assembly Figure 3-83. Rear Fork Bearing Installer
2. Bearing/spacer assembly
sm05793
3. Pivot shaft
4. Middle spacer
5. Mount
6. Outer spacer
7. Screw 1
8. Fork bracket
Figure 3-81. Pivot Shaft Components
2
ASSEMBLE

PART NUMBER TOOL NAME

HD-45327 REAR SWINGARM BEARING
INSTALLER

Install Bearings
1. Bearing installer
1. Assemble new rear fork bearings and spacers. 2. Fork tube
a. Place bearing on press plate. Figure 3-84. Install Rear Fork Bearing (typical)
b. See Figure 3-82. With the collar topside, start spacer 2. Coat the bearing bores in the rear fork with a light coat of
(1) into bearing (2). SPECIAL PURPOSE GREASE.
c. Press spacer until it bottoms against press plate. 3. See Figure 3-84. Install bearings.
a. Support fork squarely on press bed with the brake
sm02930 anchor weldment on top.
b. Insert bearing into fork assembly with spacer down.
c. Using REAR SWINGARM BEARING INSTALLER
(PART NUMBER: HD-45327) (1) stamped "Brake Side",
press on bearing until shoulder on tool contacts fork
1 tube (2).
d. Turn rear fork over.
e. Repeat process with remaining bearing using tool
stamped "Drive Side". Press bearing until it bottoms.
Shoulder on tool will not contact fork tube.
2
1. Spacer
2. Bearing
Figure 3-82. Press Spacer into Bearing

3-78 94000383
CLUTCH MASTER CYLINDER AND RESERVOIR 3.23
REMOVE NOTE
If DOT 4 brake fluid contacts painted surfaces, IMMEDIATELY
WARNING flush area with clear water.

Be sure no clutch fluid gets on tires, wheels or brakes 1. See Figure 3-85. Loosen cover screws (11).
when draining fluid. Traction can be adversely affected,
which could result in loss of control and death or serious 2. Drain clutch fluid. See BLEED CLUTCH CONTROL
injury. (00295a) SYSTEM (Page 3-85).
3. Remove banjo bolt (7). Discard sealing washers (6).
NOTICE
NOTE
Do not allow dirt or debris to enter the master cylinder
Support the banjo fitting and clutch fluid line.
reservoir. Dirt or debris in the reservoir can cause improper
operation and equipment damage. (00205c)
4. Remove master cylinder clamp screws (9).
5. Remove clutch master cylinder/reservoir assembly.

sm08636
11 12
14
9

10 15
13
16 2

6
3 1

5 4
7
1. Clutch hand lever 9. Clamp screw (2)
2. Bushing 10. Gasket
3. Retaining ring 11. Cover screw (2)
4. Master cylinder 12. Cover
5. Clutch fluid line 13. Pivot pin
6. Sealing washers (2) 14. Rebuild kit
7. Banjo bolt 15. Retaining ring
8. Clamp 16. Anti-bubble button
Figure 3-85. Clutch Master Cylinder Assembly
INSTALL NOTICE

Avoid leakage. Be sure gaskets, banjo bolt(s) and clutch

FASTENER TORQUE VALUE
line are clean and undamaged before assembly. (00329a)
Clutch master cylinder banjo 14–22.8 ft-lbs 19–31 N·m
bolt
4. Install banjo fitting, new sealing washers and banjo bolt.
Clutch master cylinder clamp 60–80 in-lbs 6.8–9 N·m Tighten to specification. Refer to Table 3-17.
screws
Clutch reservoir cover screws 12–15 in-lbs 1.4–1.7 N·m 5. Verify that the line does not touch the handlebar or fairing
when handlebar is turned full lock in both directions.
1. See Figure 3-86. Position clutch lever/master cylinder
reservoir assembly, engaging ear (1) in recess (2).
Table 3-17. Torque Specification
2. Install clamp (4) with screws (3). ITEM TORQUE
Clutch master cylinder banjo bolt 14–22.8 ft-lbs
3. Position for rider comfort. Beginning with the top screw, (19–31 N·m)
tighten to 60–80 in-lbs (6.8–9 N·m).
6. Fill and bleed clutch fluid system. See BLEED CLUTCH
CONTROL SYSTEM (Page 3-85).

94000383 3-79
7. Tighten reservoir cover screws to 12–15 in-lbs WARNING
(1.4–1.7 N·m).
Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
sm07984 safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
3 flow rates. (00061a)
4 2
1. Clean all parts thoroughly.
2. Verify that reservoir is completely free of dust, dirt or
residue.
3. Using a clean air supply, clear piston bore, reservoir and
drilled passages. Do not use a wire or similar instrument.
4. Inspect parts for wear or damage.
a. Inspect banjo seating surface for scratches or nicks.
b. Inspect piston bore.
c. Inspect boot retaining groove.
d. Inspect reservoir cover gasket.
e. Inspect retaining ring for wear or distortion.
1
f. Inspect retaining ring groove for damage.

1. Ear ASSEMBLE
2. Recess
3. Screw (2) 1. Coat piston bore, primary cup and secondary cup with
4. Clamp DOT 4 brake fluid.
Figure 3-86. Hand Control Assembly (typical) 2. See Figure 3-85. Install spring onto piston assembly.
DISASSEMBLE 3. Install piston assembly into bore.
4. Compress piston into bore and install retaining ring (15).
NOTE
Do not scratch or nick banjo sealing surface during handling. 5. Install piston boot.
a. Assemble boot onto pushrod.
1. Remove remaining clutch fluid from reservoir.
b. Work sealing edges of boot until entire circumference
2. Remove clutch hand lever. See HYDRAULIC CLUTCH is seated in cylinder bore groove.
HAND LEVER (Page 3-81).
3. See Figure 3-85. Pry outer edge of piston boot from groove NOTE
in piston bore. Anti-bubble button (16) is a friction fit. Install with convex side
up (see inset).
4. Remove retaining ring (15).
5. Remove piston assembly and spring. Discard both. 6. Install anti-bubble button.
6. If necessary, remove anti-bubble button (16). 7. Loosely install cover and gasket.
CLEANING AND INSPECTION 8. Apply a film of Harley Lube on the end of the pushrod and
hand lever pad.
WARNING 9. Install clutch hand lever. See HYDRAULIC CLUTCH HAND
LEVER (Page 3-81).
Use denatured alcohol to clean brake system components.
Do not use mineral-based solvents (such as gasoline or
paint thinner), which will deteriorate rubber parts even
after assembly. Deterioration of these components can
cause brake failure, which could result in death or serious
injury. (00291a)

• Even residual mineral-based oils and grease can deteriorate

rubber brake components.
• Wash hands before handling brake components.
• Never use oily rags to wipe brake components.

3-80 94000383
HYDRAULIC CLUTCH HAND LEVER 3.24
REMOVE
5. Verify clutch interlock operation. Perform the following
steps in order. Do not skip any steps. If any test fails, stop
WARNING and diagnose the condition before proceeding.
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before a. Remove spark plug cables from spark plugs.
proceeding. (00251b)
b. Straddle vehicle. Press and hold the rear brake
1. Remove main fuse. pedal.

2. See Figure 3-87. Remove retaining ring (1). c. Turn ignition switch ON. Turn the run/stop switch to
3. Remove pivot pin (2). RUN.

4. Remove lever. d. Shift into neutral and release the clutch lever. Briefly
push the start switch. The starter should operate.
sm08670

2 e. Shift into the highest gear. Pull in the clutch lever

and briefly press the start switch. The starter should
3 operate.

f. With the clutch lever released and transmission in

gear, briefly press the start switch. The starter should
not operate.

g. Turn off the ignition and run/stop switches.

1
h. Install spark plug cables.

1. Retaining ring
2. Pivot pin
3. Pivot bushing
Figure 3-87. Clutch Hand Lever
INSTALL

1. See Figure 3-87. Verify that pivot bushing (3) is in place

in clutch hand lever.

2. Apply a film of Harley Lube on pivot pin, the end of the

pushrod and pocket in hand lever.

3. Install clutch hand lever.

a. Engage the pushrod into the pocket on the lever.

b. Hold clutch lever in master cylinder housing

assembly.

c. Insert pivot pin (2) from top.

d. Install new retaining ring (1).

4. Install main fuse.

WARNING
The left hand control switch pack controls the clutch
interlock. A motorcycle with the wrong switch pack
installed can start in gear causing loss of control, which
could result in death or serious injury. Verify clutch
interlock function whenever switch pack is replaced.
(00632b)

94000383 3-81
CLUTCH FLUID LINE 3.25
PREPARE 9. See Figure 3-91. Remove clutch line from multi-clamp.
a. Remove front HO2 sensor wire from clip on clamp.
1. Disassemble motorcycle:
b. Remove screw (4).
a. Fairing models, fork-mounted: Rotate inner fairing.
See INNER FAIRING: FORK MOUNTED FAIRING c. Open clamp to release clutch line.
MODELS (Page 3-118).
10. Remove clutch fluid line.
b. Fairing models, frame-mounted: Remove instrument
bezel. See INSTRUMENT BEZEL: FRAME MOUNTED INSTALL
FAIRING MODELS (Page 3-125).
FASTENER TORQUE VALUE
c. Road King models: Remove headlamp assembly and
handlebar clamp shroud. See HEADLAMP NACELLE: Clutch fluid line flare nut 133–186 in-lbs 15–21 N·m
ROAD KING MODELS (Page 3-144). Clutch master cylinder banjo 14–22.8 ft-lbs 19–31 N·m
bolt
2. Remove transmission outer cover. See TRANSMISSION Hydraulic line multi-clamp 10–15 in-lbs 1.1–1.7 N·m
SIDE COVERS (Page 8-7). screw
REMOVE 1. Loosely secure fluid line to clutch master cylinder with
banjo bolt and new washers.
WARNING
Be sure no clutch fluid gets on tires, wheels or brakes 2. Route fluid line to clutch actuator, retracing original path.
when adding fluid. Traction can be adversely affected,
which could result in loss of control and death or serious a. Route line across and in front of handlebar risers.
injury. (00294a)
b. See Figure 3-92. Route clutch fluid line down right
NOTE side frame tube, behind rear master cylinder and
• If DOT 4 brake fluid contacts painted surfaces, above footboard mounting bracket, to secondary
IMMEDIATELY flush area with clear water. clutch actuator.
• Record routing of clutch fluid line and locations of all cable
c. Loosely install flare nut (1) to secondary clutch
straps.
actuator (2).
• Figure 3-88 shows the handlebar clamp area with
surrounding items removed for clarity. d. Road King: Position line in notch under left
handlebar riser.
1. Drain clutch fluid. See BLEED CLUTCH CONTROL
SYSTEM (Page 3-85). e. See Figure 3-88. Secure lines to both handlebar
clamps with two new cable straps (2, 3).
2. See Figure 3-88. Cut cable straps securing clutch fluid line
to the brake line and handlebar clamp.
NOTE
NOTE See Figure 3-90. It is important to secure the lines and harness
A small amount of fluid drains when fluid line is removed. as shown.

3. See Figure 3-89. Remove clutch fluid line from secondary f. Fork-mounted fairing models and Road King:
clutch actuator. Secure clutch line to brake line with new cable strap
(1).
a. Place a rag under the flare nut.
b. Disconnect flare nut. 3. See Figure 3-91. Install clutch line in multi-clamp.
c. Allow fluid to drain.
a. Close multi-clamp to secure clutch line.
4. Disconnect banjo fitting from clutch reservoir and master
cylinder. Discard washers. b. Apply LOCTITE 243 (blue) to the threads of used
screw (4).
5. Fairing models: Pull banjo bolt end of clutch fluid line out
through inner fairing. c. Install screw (4). Tighten to 10–15 in-lbs
6. Remove hydraulic line retainer from right side of steering (1.1–1.7 N·m).
head.
d. Install front HO2 sensor wire in clip on clamp.
7. See Figure 3-92. Remove two clamps along right frame
downtube. 4. Secure clutch fluid line with new cable straps. Verify that
8. See Figure 3-90. Cut cable straps securing clutch fluid line there is no contact with the exhaust system or any other
to the rear brake line along lower frame. items that cause damage.

3-82 94000383
5. Secure clutch fluid line retainer on right side of steering
sm04001c
head.
2 3
1 4
6. See Figure 3-92. Secure line to downtube with two clamps.

a. Locate the upper clamp just below the upper weld

joint.

b. Align the lower clamp with the bottom of the bow tie
bracket.

7. Tighten banjo bolt to 14–22.8 ft-lbs (19–31 N·m). 1. Rear brake fluid line
2. Front HO2 sensor wire
3. Clutch fluid line in multi-clamp
8. See Figure 3-89. Tighten flare nut (2) to 133–186 in-lbs
4. Cable strap, wiring harness only to the frame
(15–21 N·m).
Figure 3-90. Capture Fluid Lines and Harnesses
9. Bleed clutch control system. See BLEED CLUTCH sm08705
CONTROL SYSTEM (Page 3-85). 2

sm07669

3
2
1
1

1 4 3
1. Rear brake line
2. Front HO2 sensor wire
3. Clutch line
4. Screw
1. Clutch line to brake line: fork mounted fairing Figure 3-91. Lower Frame Rail Line and Harness Retainers
and Road King models only
2. Clutch line and brake line to right riser sm07867

3. Clutch line to left riser

Figure 3-88. Capture Clutch and Brake Fluid Lines

sm08643

2
1

Figure 3-92. Clamp Locations on Right Frame Down Tube

(typical)
COMPLETE
1. Secondary clutch actuator
2. Flare nut 1. Assemble motorcycle:
Figure 3-89. Clutch Fluid Line a. Fairing models, fork mounted: Rotate inner fairing.
See INNER FAIRING: FORK MOUNTED FAIRING
MODELS (Page 3-118).

94000383 3-83
 b. Fairing models, frame mounted: Install instrument
bezel. See INSTRUMENT BEZEL: FRAME MOUNTED
FAIRING MODELS (Page 3-125).
c. Road King models: Install headlamp assembly and
handlebar clamp shroud. See HEADLAMP NACELLE:
ROAD KING MODELS (Page 3-144).

2. Install transmission outer cover. See TRANSMISSION

SIDE COVERS (Page 8-7).

3-84 94000383
BLEED CLUTCH CONTROL SYSTEM 3.26
DRAIN AND FILL b. Remove bleeder cap (9).
c. Attach hose to bleeder screw (8).
PART NUMBER TOOL NAME
d. Place open end of hose in container.
BB200A BASIC VACUUM BRAKE BLEEDER
e. Loosen bleeder screw.
WARNING f. Allow fluid to drain.
Be sure no clutch fluid gets on tires, wheels or brakes
when adding fluid. Traction can be adversely affected, 3. Hand-tighten bleeder screw. Install cap.
which could result in loss of control and death or serious
injury. (00294a) Fill
NOTE
NOTICE
When filling an empty clutch fluid line, a BASIC VACUUM
Do not allow dirt or debris to enter the master cylinder BRAKE BLEEDER (PART NUMBER: BB200A) connected to
reservoir. Dirt or debris in the reservoir can cause improper the bleeder screw can be used for initial bleeding.
operation and equipment damage. (00205c)
1. Position motorcycle and handlebar so that master cylinder
NOTE
is level.
If DOT 4 brake fluid contacts painted surfaces, IMMEDIATELY
flush area with clear water. 2. See Figure 3-93. Fill clutch master cylinder with DOT 4
BRAKE FLUID. Do not exceed FILL LEVEL.

Drain NOTE
The shelf life of an unopened bottle of DOT 4 brake fluid is one
1. See Figure 3-93. Remove transmission outer side cover
year. Discard any opened and uncontaminated bottle after one
(7).
week.
a. If necessary, loosen exhaust system and pull away from
transmission to allow cover removal. See EXHAUST 3. Bleed clutch fluid line and secondary clutch actuator. See
SYSTEM (Page 5-26) BLEED CLUTCH CONTROL SYSTEM, Bleed Hydraulic
Clutch System (Page 3-85).
2. Drain fluid.
a. Remove reservoir cover and gasket.

sm08644

2
1
8 9

7 10
3

6
4
5

1. Cover 6. Secondary clutch actuator

2. Clutch master cylinder 7. Outer side cover
3. Clutch hand lever 8. Bleeder screw
4. Clutch fluid line 9. Bleeder screw cap
5. Clutch line flare fitting 10. Banjo bolt
Figure 3-93. Clutch Hydraulic System
BLEED HYDRAULIC CLUTCH SYSTEM FASTENER TORQUE VALUE
Outer transmission cover 100–120 in-lbs 11.2–13.6 N·m
FASTENER TORQUE VALUE screws
Clutch actuator bleeder screw 56–75 in-lbs 6.3–8.5 N·m
1. Place vehicle on a flat level surface.
Clutch reservoir cover screws 12–15 in-lbs 1.4–1.7 N·m

94000383 3-85
2. Position motorcycle and handlebar so that master cylinder
sm08589
reservoir is level.

3. See Figure 3-94. If necessary, add DOT 4 fluid to clutch

master cylinder/reservoir. Do not exceed FILL level.

4. See Figure 3-93. Remove bleeder cap (9) and run clear
hose from bleeder screw (8) to suitable container.

5. While holding reservoir cover (1) in place:

a. Pump clutch hand lever (3) five times.

b. Hold clutch hand lever against handlebar.

c. Loosen bleeder screw.

Figure 3-94. Clutch Fluid Level
d. Watch hose for air bubbles.

e. Tighten bleeder screw.

NOTE
Fluid level in reservoir increases with clutch wear. Do NOT
overfill clutch reservoir.

f. Release clutch hand lever.

6. Fill reservoir with DOT 4 fluid.

7. Repeat bleed procedure three times or more until only a

steady flow of clutch fluid escapes bleeder valve.

8. Tighten bleeder screw to 56–75 in-lbs (6.3–8.5 N·m).

9. Verify that reservoir is at FILL level.

10. Install reservoir cover. Tighten screws to 12–15 in-lbs

(1.4–1.7 N·m).

11. Measure release plate movement. See HYDRAULIC

CLUTCH RELEASE BEARING AND PUSHROD
(Page 7-16).

12. Install transmission outer side cover. Tighten to

100–120 in-lbs (11.2–13.6 N·m).

13. If loosened, secure exhaust system. See EXHAUST

SYSTEM (Page 5-26).

14. Test ride motorcycle. Incorrect pressure or fluid level can

cause a dragging clutch or difficult shifting.

3-86 94000383
HANDLEBAR 3.27
ADJUST sm03840

FASTENER TORQUE VALUE

Handlebar upper clamp 16–20 ft-lbs 21.7–27.1 N·m
screws

WARNING
To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before
proceeding. (00251b)

1. Remove main fuse.

2. Access upper handlebar clamp:

a. Road King models: See Figure 3-95 and Figure

3-96. Remove decorative plate from handlebar clamp Figure 3-95. Remove Decorative Plate (FLHR/C)
shroud.
sm03838
b. Fairing models, fork-mounted: Remove dash
panel. See DASH PANEL: FORK MOUNTED
FAIRING MODELS (Page 3-117).

c. Fairing models, frame-mounted: Remove

instrument bezel. See INSTRUMENT BEZEL:
FRAME MOUNTED FAIRING MODELS (Page 3-125).

3. Loosen rear screws on the upper handlebar clamp.

4. Position handlebars for rider posture and comfort.

5. Verify that the knurled area on each side handlebar clamp

is equal.

6. Snug upper handlebar clamp screws.

Figure 3-96. Loosen Upper Handlebar Clamp Screws (FL-
7. Slowly turn handlebars to the full right and full left fork HR/C)
stops. Verify that there is no contact with the fuel tank.
REMOVE
Adjust as necessary.
1. Remove main fuse.
8. Tighten the upper handlebar clamp screws to 16–20 ft-lbs
(21.7–27.1 N·m). NOTE
Cover painted surfaces to prevent scratches or other damage.
9. Assemble:
2. Road King models:
a. Road King models: See Figure 3-95. Install
a. See Figure 3-97. Separate left handlebar switch (1) and
decorative plate onto handlebar clamp shroud.
TGS (2) connectors.
b. Fairing models, fork-mounted: Install dash panel. b. See Figure 3-98. Separate right handlebar switch
See DASH PANEL: FORK MOUNTED FAIRING connectors (1).
MODELS (Page 3-117).

c. Fairing models, frame-mounted: Install instrument

bezel. See INSTRUMENT BEZEL: FRAME
MOUNTED FAIRING MODELS (Page 3-125).

10. If necessary, reposition the controls for rider comfort.

11. Install main fuse.

94000383 3-87
 sm07537a sm07967
3
1 5
2 1
5

2
4

1. Left handlebar switch module

2. TGS
3. Right auxiliary/fog/turn signal lamps
4. Left auxiliary/fog/turn signal lamps
5. Caddy retainer
Figure 3-97. Left Side Connectors: Road King Models

1. Right handlebar switch module

2. Front WSS (ABS models)
3. Nacelle switch connector
4. Brake line retainer
5. Caddy retainer
Figure 3-98. Right Side Connectors: Road King

3-88 94000383
 sm07487

16 2
1

7
3 4 5
6
15

14
9 9
12 11
13 10

1. CB module 9. Heated hand grip power, if equipped

2. P&A audio 10. Main-to-fairing harness, left
3. USB cable 11. Run/stop switch
4. AM/FM radio antenna 12. Right handlebar switch harness
5. GPS antenna 13. Main-to-fairing harness, right
6. Left handlebar switch harness 14. TGS
7. CB antenna 15. Radio
8. Front fender tip lamp 16. Accessory power
Figure 3-99. Inner Fairing Harness Connectors: Fork Mounted Fairing

3. Fork-mounted fairing models: sm08382b

a. Remove outer fairing. 2 3 4

1
b. See Figure 3-99. Separate TGS connector (14).
c. Disconnect heated hand grip power connector (9) if
equipped. The hand grip interconnect harness does not
require disconnection.
d. Disconnect handlebar switch connectors (6, 11, 12).
5 5

1. TGS connector
2. Left handlebar switch harness
3. Run/stop switch
4. Right handlebar switch harness
5. Handlebar clamp screws
Figure 3-100. Handlebar Harness Connectors: Frame-
Mounted Fairing Models

94000383 3-89
4. Frame-mounted fairing models: 5. Secure harnesses as necessary with new cable straps.
a. Remove instrument bezel. See INSTRUMENT BEZEL:
FRAME MOUNTED FAIRING MODELS (Page 3-125). 6. Assemble:

b. See Figure 3-100. Separate TGS connector (1).
c. Disconnect heated hand grip power connector if
equipped. The hand grip interconnect harness does not
require disconnection.
d. Disconnect handlebar switch connectors (2, 3, 4).
5. Remove master cylinder/brake lever assembly from
handlebar.
6. Remove clutch hand lever and bracket assembly from
handlebar.
7. Access upper handlebar clamp:
a. Road King models: Remove handlebar clamp shroud.
See HEADLAMP NACELLE: ROAD KING MODELS
(Page 3-144).
b. Fork-mounted fairing models: Rotate inner fairing.
See INNER FAIRING: FORK MOUNTED FAIRING
MODELS (Page 3-118).
a. Road King models: Install handlebar clamp shroud.
See HEADLAMP NACELLE: ROAD KING MODELS
(Page 3-144).
NOTE
Some models use a small hand control bracket clamp while
others use the large one. Make sure to install the correct one
for the model being serviced. The large clamp incorporates an
alignment pin that must engage a slot in the handlebar.
b. Fork-mounted fairing models: Secure inner fairing.
See INNER FAIRING: FORK MOUNTED FAIRING
MODELS (Page 3-118).
7. Install hand brake bracket and clamp:
a. Engage ear in recess. Rotate into position.
b. Install clamp and screws.

8. Remove handlebar assembly. c. Beginning with the upper screw, tighten to

60–80 in-lbs (6.8–9 N·m).
a. Remove upper handlebar clamp screws.
b. Remove upper handlebar clamp 8. Install clutch lever bracket and clamp:
c. Remove handlebar assembly.
a. Engage ear in recess. Rotate into position.
INSTALL
b. Install clamp and screws.

FASTENER TORQUE VALUE c. Beginning with the upper screw, tighten to

Brake master cylinder, front, 60–80 in-lbs 6.8–9 N·m 60–80 in-lbs (6.8–9 N·m).
clamp screws
Clutch lever bracket clamp 60–80 in-lbs 6.8–9 N·m 9. Frame-mounted fairing models:
screws
Handlebar upper clamp 16–20 ft-lbs 21.7–27.1 N·m a. See Figure 3-100. Connect TGS harness (1).
screws
b. Connect handlebar switch harness connectors (2,
1. Install handlebar assembly. 3, 4).

a. Install handlebar and upper clamp. Install screws c. Connect heated hand grip power connector, if
finger-tight. equipped.

b. Center the handlebars. d. Install instrument bezel. See INSTRUMENT BEZEL:

FRAME MOUNTED FAIRING MODELS (Page 3-125).
c. Snug clamp screws.
10. Fork-mounted fairing models:
d. Carefully turn handlebars to the full right and full left
fork stops. Verify that there is no contact with the a. See Figure 3-99. Connect TGS harness (14).
fuel tank. Adjust as necessary.
b. Connect handlebar switch harness connectors (6,
2. Tighten forward clamp screws until upper and lower 11, 12).
handlebar clamps make contact.
c. Connect heated hand grip power connector (9), if
3. Tighten rear screws to 16–20 ft-lbs (21.7–27.1 N·m). equipped.

d. Install outer fairing.

NOTE
A slight gap will exist between the upper and lower clamps at
11. Road King models: See Figure 3-97 and Figure 3-98.
the rear of the handlebars after tightening.
a. Connect left handlebar switch (1) and TGS (2)
4. Tighten forward screws to 16–20 ft-lbs (21.7–27.1 N·m). connectors.

3-90 94000383
 b. Connect right handlebar switch connectors (1).
12. Install main fuse.
WARNING
Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)
13. Test all switches and lights for proper operation.
14. Operate front brake hand lever to verify stop lamp
operation.
15. Operate clutch hand lever to verify start interlock operation.
See HYDRAULIC CLUTCH HAND LEVER (Page 3-81).
INSTALL HARNESSES, FLTR MODELS
Pull Wire Leads
NOTE
• Pull all the harnesses for one end of handlebar at a time.
• Feed harnesses into handlebar as chaser wires are pulled.
1. If installing new handlebar, cut length of chaser wire for
each harness.
a. Feed one chaser wire through hole near left end of
handlebar.
b. Feed one chaser wire through hole near right end of
handlebar and one through right end of handlebar tube.
c. Extract ends of all chaser wires through center hole.

2. Attach chaser wires:

REMOVE HARNESSES, FLTR MODELS
a. Left side: Attach chaser wire extending from hole to
left switch control harness.
NOTE
• Due to room constraints, remove all harnesses for one side b. Right side: Attach chaser wire extending from right
at the same time. end of handlebar tube to TGS harness. Attach chaser
wire extending from hole to right switch control harness.
• Harnesses can be replaced with the handlebar installed or
removed. If only one side requires service, perform the c. Wrap chaser wires and terminals of each harness tightly
appropriate steps. with electrical tape.

1. Remove instrument bezel. See INSTRUMENT BEZEL: 3. Install harnesses.

FRAME MOUNTED FAIRING MODELS (Page 3-125).
a. Lubricate harnesses with glass cleaner.
2. Disconnect TGS connector [204] and all handlebar switch
b. Pull harnesses to the handlebar center hole until TGS
harness connectors [22, 24].
is fully seated. Pull switch harnesses until no slack
3. Disconnect heated grip power connector [189] and exists.
interconnect [206] connector if equipped.
c. Install switch control housings and grip. See
4. Remove cable straps and note location for installation. HANDLEBAR SWITCH PACKS (Page 9-94).

NOTE d. Remove slack in harnesses. Remove tape and chaser

Removal of the handlebar switch module connector terminals wires.
is not required however, doing so makes removal and
installation easier. 4. See Figure 3-101. Secure TGS harness.
a. Fold TGS harness onto itself.
5. Attach chaser wires.
b. Install new cable strap (2).
a. Cut a length of chaser wire for each harness.
5. Connect heated grip power connector and interconnect
b. Attach chaser wire to the end of each harness.
connector if equipped.
c. Wrap end of each wiring harness and chaser wire tightly
6. Connect TGS connector [204] and all handlebar switch
with electrical tape.
harness connectors [22, 24].
6. Remove handlebar switch packs. Do not disconnect switch 7. Install instrument bezel. See INSTRUMENT BEZEL:
pack harnesses unless they require replacement. See FRAME MOUNTED FAIRING MODELS (Page 3-125).
HANDLEBAR SWITCH PACKS (Page 9-94).
7. Remove right grip.
8. Lightly lubricate conduits and tape with glass cleaner.
9. Pull TGS harness out of handlebar, along with the right
switch control harness.
10. Pull left switch control harness out of handlebar.
11. Remove chaser wires from harnesses. Leave the chaser
wire in the handlebar for installation.

94000383 3-91
 1. Remove right handlebar switch housings and front brake
sm03976
control. See HANDLEBAR SWITCH PACKS (Page 9-94).
NOTE
To remove the hand grip, a slight tug may be necessary.

2. Pull hand grip off TGS.

Installation
1. Confirm TGS is completely engaged into the slots in the
handlebar.
2. Position hand grip so cosmetic features are aligned with
left grip. Install the hand grip and rotate to verify that
internal splines are engaged with the twist grip sensor.
3. Install right handlebar switch housings and brake control.
See HANDLEBAR SWITCH PACKS (Page 9-94).
HANDLEBAR CLAMPS AND RUBBER
MOUNTS
Figure 3-101. Wire Leader through Center of Handlebar
LEFT HAND GRIP FASTENER TORQUE VALUE
Handlebar lower clamp bolt 30–40 ft-lbs 40.7–54.2 N·m
Removal • See Figure 3-102. Remove bolts (7) before removing
NOTE handlebar.
The following procedure is for unheated left hand grip. See • When assembling, apply LOCTITE 243 MEDIUM
HANDLEBAR, HEATED HAND GRIPS (Page 3-93) to service STRENGTH THREADLOCKER AND SEALANT (blue) to
heated hand grips. threads of bolts (9).

1. Remove left handlebar switch housings and clutch control. • Temporarily install handlebar. Tighten bolts (9) to
See HANDLEBAR SWITCH PACKS (Page 9-94). 30–40 ft-lbs (40.7–54.2 N·m).

2. Use a sharp blade to cut rubber grip. Peel grip off

handlebar.
3. Thoroughly clean handlebar to remove all residual
adhesive.

Installation
1. Apply a coat of HARLEY-DAVIDSON ADHESIVE (Griplock)
to the inside surface of the new grip to a depth of
approximately 1.0 in (25.4 mm) from the open end. Apply
a coat to the end of the handlebar.
NOTE
Align the cosmetic features with those on the right grip (with
the throttle fully closed).

2. Immediately push grip completely onto end of handlebar

using a twisting motion. Do not hesitate when installing
grip or adhesive may set before installation is complete.
3. Install left handlebar switch housings and clutch control.
See HANDLEBAR SWITCH PACKS (Page 9-94).
4. Allow adhesive to cure for 6-8 hours at 70 °F (21 °C).
RIGHT HAND GRIP

Removal
NOTE
The following procedure is for unheated right hand grip. See
HANDLEBAR, HEATED HAND GRIPS (Page 3-93) to service
heated hand grips.

3-92 94000383
 8. Remove left handlebar switch housing and clutch lever.
sm07529
3 4 Allow to hang. See HANDLEBAR SWITCH PACKS
(Page 9-94).
2 9. Lubricate wire harness conduits with glass cleaner.
1 NOTE
5 When pulling, feed opposite end of harnesses and mechanic's
wire into handlebar.

10. Slide hand grip off end of handlebar. Grasp harnesses and
pull from handlebar. Detach from chaser wire.

sm07525

7
2 3
8
4

8
6 1

1. Right handlebar switch harness

9
2. Run/stop switch
1. Handlebar lower clamp (frame mounted fairing) 3. Left handlebar switch harness
2. Handlebar lower clamp (2) (all except frame 4. Heated hand grip power
mounted fairing) Figure 3-103. Handlebar Harness Connectors
3. Fork bracket ground screw
4. Lower clamp ground screw sm07526

5. Ground jumper wire assembly

6. Cup washer (4) 3 2
1 1
7. Spacer (2)
8. Rubber bushing (4)
9. Bolt (2)
Figure 3-102. Handlebar Mounts
HEATED HAND GRIPS

Remove Left Hand Grip

1. Remove main fuse.
2. Remove outer fairing.
3. Rotate inner fairing. See INNER FAIRING: FORK 1. Cable straps
MOUNTED FAIRING MODELS (Page 3-118). 2. Heated hand grip interconnect harness
4. See Figure 3-103. Disconnect and remove terminals from 3. TGS jumper harness
heated hand grip power connector (4). Figure 3-104. Secure Harness to Handlebar
5. See Figure 3-104. Disconnect and remove terminals from
Install Left Hand Grip
heated hand grip interconnect connector (2).
1. Attach chaser wire to harnesses. Wrap with electrical tape.
NOTE
For connector service, see the electrical diagnostic manual. 2. Lubricate wire harness conduits with glass cleaner.
3. Carefully feed harnesses into handlebar with one hand as
6. Fabricate a chaser wire approximately 3 ft (91.4 cm) long. they are pulled with the other.
Secure to terminals and wire leads of harness. Wrap with
4. Slide hand grip onto end of handlebar. Pull slack from
electrical tape.
wiring harnesses. Remove chaser wire.
7. Bend last few inches of free end of chaser wire into an "L"
shape to prevent pulling it too far into the handlebar.

94000383 3-93
5. Install terminals into connector housing cavities. See the
electrical diagnostic manual.
6. Mate connectors. Secure harnesses with new cable straps.
7. Install left handlebar switch housing and clutch lever. See
HANDLEBAR SWITCH PACKS (Page 9-94). Make sure
rim of hand grip fits into grooves in switch housings.
8. Rotate inner fairing into position and secure. See INNER
FAIRING: FORK MOUNTED FAIRING MODELS
(Page 3-118).
9. Install outer fairing. Install main fuse.

Remove Right Hand Grip

NOTE
This procedure covers only removal and installation of the hand
grip. For service of the TGS, see TWIST GRIP SENSOR (TGS)
(Page 5-14).

1. Remove main fuse.

2. Remove right switch housing and brake control. See
HANDLEBAR SWITCH PACKS (Page 9-94). Suspend out
of the way.
3. Pry end cap from hand grip. Pull connector out through
end of hand grip.
NOTE
To remove the throttle hand grip, a slight tug may be necessary.

4. Pull hand grip off end of handlebar.

Install Right Hand Grip

1. Verify twist grip sensor is properly installed in end of
handlebar.
2. Seat hand grip onto twist grip sensor.
3. Using needle nose pliers, insert prongs of connector into
connector holes located in end of twist grip sensor.
4. Pull hand grip off until it disengages TGS. Rotate hand
grip to allow wires to wrap around connector. Orient hand
grip to match left side and engage hand grip on TGS.
Rotate hand grip to verify proper engagement. Install end
cap.
5. Install right switch control housing and front brake master
cylinder. See HANDLEBAR SWITCH PACKS (Page 9-94).
6. Install main fuse.

3-94 94000383
MIRRORS 3.28
ALL MODELS EXCEPT FLHX, FLHXS Installation
FASTENER TORQUE VALUE NOTE
Mirror stem acorn nut 60–96 in-lbs 6.8–10.8 N·m See Figure 3-106 and Figure 3-107. The letters "L" or "R" are
stamped on the backing plate and inner fairing to identify
Removal location.

1. See Figure 3-105. Remove acorn nut (1) and lockwasher

(2). 1. See Figure 3-107. With the bar and shield logo on mirror
right-side-up, insert threaded stud and align index pin (2)
2. Remove mirror (3). with hole in inner fairing.

Installation 2. Install the backing plate (3) engaging the hole with index
pin (2).
1. Insert threaded stem of mirror into hole in clutch or brake
lever bracket.
3. Install flange nut (4). Tighten to 20–30 in-lbs
(2.3–3.4 N·m).
2. Install lockwasher (2) and acorn nut (1).

4. Install outer fairing. See OUTER FAIRING AND

3. Adjust mirror as necessary and tighten acorn nut to
WINDSHIELD: FORK MOUNTED FAIRING MODELS
60–96 in-lbs (6.8–10.8 N·m).
(Page 3-115).

sm04981
sm07856

1 Figure 3-106. Mirror Location Mark

sm04983a

1
1. Acorn nut
2. Lockwasher
3. Mirror
Figure 3-105. Mirror Assembly (All Models Except FLHX)
FLHX, FLHXS

FASTENER TORQUE VALUE

Mirror flange nut: FLHX/S 20–30 in-lbs 2.3–3.4 N·m

Removal
4 3
1. Remove outer fairing. See OUTER FAIRING AND 2
WINDSHIELD: FORK MOUNTED FAIRING MODELS
(Page 3-115).
2. See Figure 3-107. Remove flange nut (4) and backing 1. Identification
plate (3). Remove mirror. 2. Index pin
3. Backing plate
4. Flange nut
Figure 3-107. Mirror Assembly, typical (FLHX/S)

94000383 3-95
SEAT 3.29
SEAT om01695
2
FASTENER TORQUE VALUE
Seat mounting screw 48–72 in-lbs 5.4–8.1 N·m
Seat strap screw 48–72 in-lbs 5.4–8.1 N·m
Tour-Pak fasteners 60–72 in-lbs 6.8–8.1 N·m

Removal
1. Open either saddlebag.
2. See Figure 3-108. Remove screw to release passenger
seat strap from seat strap bracket.
3. Open Tour-Pak if equipped.
3
NOTE
• Access to seat screw requires compression of the rear of
1
the seat cushion. Use care to not damage the fabric during
removal or installation.
• If the Tour-Pak is located in its forward-most position, the
seat screw is difficult to access. Loosen the Tour-Pak and 1. Seat strap screw
slide fully rearward. 2. Seat strap
3. Seat screw
• APC models: Remove four Tour-Pak mounting screws.
Move Tour-Pak to access seat screw. Figure 3-108. Seat Strap Screw

om01696
4. Remove screw to release seat from top of rear fender.
5. See Figure 3-109 and Figure 3-110. Raise rear of seat.
Push seat rearward to free slot (1) from tongue (2) on rear
fuel tank bracket.
6. Remove seat.

Installation
NOTE
To protect finish of Tour-Pak if equipped, cover rear seat
mounting bracket with palm of hand.

1. See Figure 3-109 and Figure 3-110. Place seat in position.

NOTE
• Access to seat screw requires compression of the rear of
the seat cushion. Use care to not damage the fabric during
removal or installation.
Figure 3-109. Seat Mounting Slot
• If the Tour-Pak was relocated to access the seat screw,
secure it in the original position. Tighten to 60–72 in-lbs
(6.8–8.1 N·m).

2. Hold rear of seat approximately 3 in (76.2 mm) above

fender. Use the other hand to push front of seat downward
and forward until slot engages tongue.

3. Secure seat to fender with screw. Tighten to 48–72 in-lbs

(5.4–8.1 N·m).

4. See Figure 3-108. Tuck end of seat strap into slot. Install
screw and washer. Tighten to 48–72 in-lbs (5.4–8.1 N·m).

5. Pull up on the seat to be sure it is secure.

6. Close saddlebag.

3-96 94000383
 om01158
NOTE
FLHX, FLHXS and FLTRX, FLTRXS models utilize a seat
bumper to minimize seat movement.

1. See Figure 3-112. Install a seat bumper (2) to each upper

frame rail (1), in the orientation shown (arrows forward).

2. Secure with fastener (3). Tighten to 32–36 ft-lbs

(43.4–48.8 N·m).

sm06984
3
1 2

Figure 3-110. Seat Tongue

SEAT RETENTION NUT
1. See Figure 3-111. Remove retention washer (4). Remove
retention nut (2) from fender (1).
2. See inset of Figure 3-111. Slide new retention nut onto a
cable strap as shown. Insert into fender hole and hold with
cable strap. 1. Upper frame rail
2. Seat bumper (2)
3. Align tab (3) on retention nut and hold nut snug against 3. Fastener (2)
underside of rear fender. Orient the retention washer (4).
Figure 3-112. Seat Bumper Installation
Install as shown. Remove cable strap.

sm04964

3 2

1. Rear fender
2. Retention nut
3. Tab
4. Retention washer
Figure 3-111. Install Seat Retention Nut
SEAT BUMPER

FASTENER TORQUE VALUE

Seat bumper fastener: FLHX, 32–36 ft-lbs 43.4–48.8 N·m
FLHXS and FLTRX, FLTRXS

94000383 3-97
SADDLEBAGS 3.30
REMOVE 3. Check that saddlebag is securely fastened.
a. Verify that the saddlebag bottom isolators properly
All Except FLHRC engage the lower support tube.

1. Open saddlebag lid. b. Pull on saddlebag to confirm that it is securely fastened.

2. See Figure 3-114. Turn the mounting screw levers 4. Close saddlebag lid.
counterclockwise to remove.
3. Remove saddlebag. om02297

1 3
FLHRC
1. Open saddlebag lid.
2. See Figure 3-113. Rotate each stud (1) 1/4 turn
counterclockwise. Remove studs and flat washers from
grommets.
3. Remove saddlebag.

om02302
1

2
1. Mounting screw with lever
2. Saddlebag rail
3. Support bracket
Figure 3-114. Saddlebag Removal/Installation

FLHRC
1. Place saddlebag in position on saddlebag rail (2).
2. Install retaining studs and washers.
2
a. Hold groove at end of stud horizontal and insert stud
1. Mounting studs and washers (2) through grommet.
2. Saddlebag rail
b. When groove engages wire form spring in receptacle,
Figure 3-113. Saddlebag Removal/Installation: FLHRC turn stud clockwise one quarter turn until it locks in
INSTALL place.
c. Confirm that stud has been rotated a full 90 degrees
NOTE for complete engagement.
Replace grommets if torn or deteriorated.
3. Check that saddlebag is securely fastened.

All Except FLHRC a. Verify that the saddlebag bottom isolators properly
engage the lower support tube.
1. See Figure 3-114. Place saddlebag in position on
saddlebag rail (2). b. Pull on saddlebag to confirm that it is securely fastened.

NOTE 4. Close saddlebag lid.

The rear mounting screw lever will interfere with the saddlebag
cover unless positioned with lever pointed downward.

2. Install mounting screws through grommets into support

bracket.
a. Tighten the mounting screws until the lever is pointed
downward between the 3 o'clock and 9 o'clock positions
as shown.

3-98 94000383
SADDLEBAG SERVICE 3.31
REPAIR SADDLEBAG sm07923
2
FASTENER TORQUE VALUE
Saddlebag face plate/hinge 40–45 in-lbs 4.5–5.1 N·m 1
screw
3
Saddlebag hinge to latch 30–35 in-lbs 3.4–3.9 N·m
assembly screw
Saddlebag hinge to saddlebag 40–45 in-lbs 4.5–5.1 N·m 4
screw
Saddlebag latch assembly 40–45 in-lbs 4.5–5.1 N·m 5
screws 6
Saddlebag latch handle screw 40–45 in-lbs 4.5–5.1 N·m 1. Face plate
Saddlebag lock lever nut 25–35 in-lbs 2.8–3.9 N·m 2. Screw (3)
Saddlebag lock screw 20–30 in-lbs 2.3–3.4 N·m 3. Nut
Saddlebag strike screw 15–20 in-lbs 1.7–2.3 N·m 4. Screw (2)
5. Lock lever
Saddlebag tether screw 40–45 in-lbs 4.5–5.1 N·m
6. Lock
NOTE Figure 3-115. Saddlebag Lock
• The saddlebag can remain secured to the vehicle when
servicing most of the following components. Strikes
• If tether is removed completely, install with top of logo facing 1. See Figure 3-116. Remove four screws (5).
saddlebag.
2. Remove strike (6).
Lock
3. Install strike. Secure with screws (5). Tighten to
1. See Figure 3-115. Hold face plate (1) while removing 15–20 in-lbs (1.7–2.3 N·m).
screws (2). Remove face plate.
Cover
2. Remove nut (3). Remove lock lever (5).
1. If removed from vehicle, place saddlebag on protected
3. Remove two screws (4). surface with cover open.

4. Remove lock (6). 2. Carefully peel seal away from hinge area.

5. Install lock assembly with tab nearest to cover. 3. See Figure 3-117. Remove screw (6) and latch lever (3).
Do not lose grommet (2).
6. Secure with two screws (4). Tighten to 20–30 in-lbs
(2.3–3.4 N·m). NOTE
Latch assembly remains secured to hinge.
7. Install lock lever. Secure with nut (3). Tighten to
25–35 in-lbs (2.8–3.9 N·m). 4. Optional: To ease access to screws (8), remove screws
securing tether to latch assembly.
8. Secure face plate with screws (2). Tighten to 40–45 in-lbs
(4.5–5.1 N·m). 5. Hold face plate (9) while removing three hinge screws (7).

6. Remove four screws (5). Remove cover from latch

assembly.

7. If installing a new cover, install new seal included. See

procedure later in this section.

8. Inspect condition of foam seal (4).

9. While holding cover in place, loosely install four screws

(5).

10. Hold face plate (9) in place and install screws (7). Tighten
to 40–45 in-lbs (4.5–5.1 N·m).

94000383 3-99
11. Tighten screws (5) to 40–45 in-lbs (4.5–5.1 N·m). 10. Install seal onto hinge. If adhesive does not hold, use
automotive weatherstrip adhesive following manufacturers
12. Install foam seal onto hinge. If adhesive does not hold, directions.
use automotive weatherstrip adhesive following
manufacturer's directions. 11. Align hinge with saddlebag and loosely install screws (4)
without the tether to maintain alignment.
13. Inspect condition of grommet (2) on handle shaft.
12. Install screws (2). Tighten to 40–45 in-lbs (4.5–5.1 N·m).
14. Install latch lever (3). Secure with screw (6). Tighten to
40–45 in-lbs (4.5–5.1 N·m). 13. Remove screws (4), install tether and secure. Tighten to
40–45 in-lbs (4.5–5.1 N·m).
Cover Seal
14. Install lock lever. Secure with nut. Tighten to 25–35 in-lbs
1. Remove old seal. (2.8–3.9 N·m).
2. Remove all residual adhesive using 3M GENERAL
PURPOSE ADHESIVE REMOVER. sm07446

3. Thoroughly clean seal mounting area with isopropyl 2 3

alcohol. Allow to dry completely. 1
NOTE 4
Do not touch the cleaned area with fingers after cleaning.

4. Peel back a few inches of backing and place end of seal

at midpoint of hinge area. Work only a few inches at a
time.
5. Install seal without stretching. 6 5
6. Cut squarely to length so no gap exists. 1. Hinge
7. After the entire seal is initially installed, go back around 2. Screw
the entire seal and press firmly in place to be sure it is 3. Tether
securely adhered. 4. Screw
5. Screw, strike
Hinge 6. Strike (2)
Figure 3-116. Saddlebag Hinge
1. Remove the saddlebag. Place on a protected surface with
cover open. Latch Assembly
2. See Figure 3-116. Remove screws (4) securing tether to NOTE
saddlebag. The latch assembly has no serviceable parts. Replace
assembly upon failure.
3. Remove two remaining screws (2). Separate cover with
latch assembly from saddlebag. 1. Remove screws securing tether to latch assembly.

4. Remove nut and lever from lock. 2. Remove nut and lever from lock.

5. Carefully peel seal away from hinge area.

NOTE
Hinge can remain secured to saddlebag.
6. See Figure 3-117. Remove three screws (7).

7. Remove two screws (8). Remove hinge. 3. Remove cover. See procedure elsewhere in this section.

8. Align hinge. Secure with screws (8). Tighten to NOTE

30–35 in-lbs (3.4–3.9 N·m). Verify foam seal (4) is in place on latch assembly.

9. Hold face plate (9) in place and install screws (7). Tighten 4. See Figure 3-117. Remove two screws (7) securing hinge
to 40–45 in-lbs (4.5–5.1 N·m). to latch assembly. Remove latch assembly.

NOTE 5. Secure hinge to latch assembly with two screws (7).

See Figure 3-116. Screws (2, 4) are easily cross-threaded.
Use extreme care when installing. 6. Install cover and latch lever (3). See procedure elsewhere
in this section.

3-100 94000383
7. Secure tether to latch assembly. Tighten to 40–45 in-lbs 6. Remove screws (1, 8) to release support casting (10).
(4.5–5.1 N·m).
7. Left side: Remove nut securing air valve to support
casting.
8. Install lock lever. Secure with nut. Tighten to 25–35 in-lbs
(2.8–3.9 N·m). 8. Remove saddlebag support assembly with support casting.
9. Disassemble as needed.
sm07445
Installation
2
NOTE
• Refer to Table 3-18 for fastener torque specifications.
• See Figure 3-118. Support tube screw (2) is installed from
1 3 rear to front on all models except FLHX, FLHXS, FLTRX,
FLTRXS.

1. Assemble saddlebag support along with support casting.

9 Refer to Table 3-18 for tightening specifications.
4
2. See Figure 3-119. Verify that rubber cushion is in place
and not damaged.

3. See Figure 3-118. If removed, install saddlebag mounting

7 6 clips (9).
5
8
4. Install saddlebag support assembly with support casting.
1. Latch assembly
2. Grommet 5. Left side: Install nut securing air valve to support casting.
3. Lever Tighten to 40–50 in-lbs (4.5–5.6 N·m).
4. Foam seal
5. Screw, latch-to-cover (4) 6. Secure muffler to lower rail with screws. Tighten to
6. Screw 14–18 ft-lbs (19–24.4 N·m).
7. Screw, face plate-to-cover (3)
8. Screw, hinge-to-latch assembly (2)
7. Install saddlebag. See SADDLEBAGS (Page 3-98). Verify
9. Face plate
that the saddlebag bottom isolators properly engage the
Figure 3-117. Saddlebag Latch Assembly lower support tube. Loosen screws (2, 4) to adjust if
SADDLEBAG SUPPORT necessary.

FASTENER
Muffler to saddlebag support
screws
Saddlebag guard to frame
screw, lower
Saddlebag guard to frame
screw, upper
Saddlebag support casting to
frame screw
Saddlebag support tube screw
Saddlebag support tube to
support casting fastener, large
Saddlebag support tube to
support casting fastener, small
Seat strap bracket screw
Suspension air valve nut
TORQUE VALUE 8. Install seat. After installing seat, pull up on the seat to be
14–18 ft-lbs 19–24.4 N·m sure it is secure.
32–36 ft-lbs 43.4–48.8 N·m
32–36 ft-lbs 43.4–48.8 N·m
15–20 ft-lbs 20.3–27.1 N·m
70–100 in-lbs 7.9–11.3 N·m
30–37 ft-lbs 40.7–50.2 N·m
15–20 ft-lbs 20.3–27.1 N·m
120–144 in-lbs 13.6–16.3 N·m
40–50 in-lbs 4.5–5.6 N·m

Removal
1. Remove saddlebag.
2. Remove seat.
3. Remove fasteners securing muffler to saddlebag support.
4. See Figure 3-118. Remove screw (4) and flange nut.
5. Remove screws (5, 6).

94000383 3-101
 sm07450
3 4
2
10

8 9
5

7 6
1. Screw, support casting
2. Screw, support tube-to-support casting
3. Cushion
4. Screw, support casting/support-to-fender
5. Screw, saddlebag guard, upper
6. Screw, saddlebag guard, lower
7. Screw, saddlebag support tube
8. Screw, seat strap bracket
9. Mounting clip (2)
10. Support casting
Figure 3-118. Saddlebag Supports

Table 3-18. Saddlebag Support Fastener Torque Specific-

ations
ITEM TORQUE
1 15–20 ft-lbs (20.3–27.1 N·m)
2 30–37 ft-lbs (40.7–50.2 N·m)
4 15–20 ft-lbs (20.3–27.1 N·m)
5 32–36 ft-lbs (43.4–48.8 N·m)
6 32–36 ft-lbs (43.4–48.8 N·m)
7 70–100 in-lbs (7.9–11.3 N·m)
8 120–144 in-lbs (13.6–16.3 N·m)

sm08046

Figure 3-119. Saddlebag Supports Cushion

3-102 94000383
TOUR-PAK 3.32
REMOVAL AND INSTALLATION sm07449
1
FASTENER TORQUE VALUE
Tour-Pak adapter mounting 60–72 in-lbs 6.8–8.1 N·m
screws (APC models)
Tour-Pak mounting nuts 60–72 in-lbs 6.8–8.1 N·m 4
Removal
2
NOTE
• Slots in Tour-Pak support allow position adjustment. Record
position before removal.
3
• APC models offer no adjustment. The adapter plate locates
Tour-Pak to meet market regulations.
1. Audio
1. See Figure 3-120. Separate Tour-Pak electrical
2. CB antenna
connectors.
3. Radio antenna
2. Remove four flange nuts securing Tour-Pak to support. 4. Rear lights
3. APC models: See Figure 3-122. Remove four screws and Figure 3-120. Tour-Pak Connectors
flat washers to release adapter from support. Slide forward
pd00563a
to release hooks.
4. Remove Tour-Pak assembly.
5. APC models: Remove four flange nuts to release adapter
from Tour-Pak.

Installation
NOTE
Make sure that connectors do not get trapped between
Tour-Pak and mount.
2
1. APC models: Attach adapter to Tour-Pak with four flange
nuts. Tighten to 60–72 in-lbs (6.8–8.1 N·m). 1

2. Set Tour-Pak in place.

5
3. Install four nuts. Tighten to 60–72 in-lbs (6.8–8.1 N·m).

3
4. APC models: See Figure 3-121.

a. Push forward to engage L-hooks (5) in support.

4
b. Pull back to align rear holes with rear slots in support.

c. See Figure 3-122. Loosely install rear washers and

screws (1).

d. Push forward to align front holes with front slots in 1. Adapter plate
support. 2. Rail tabs
3. Flange nuts (4)
e. Install front washers and screws (2). 4. Support rack
5. L-hooks
f. Tighten to 60–72 in-lbs (6.8–8.1 N·m). Figure 3-121. Tour-Pak Adapter Plate

5. See Figure 3-120. Mate Tour-Pak electrical connectors.

Secure to anchors.

94000383 3-103
 om01748 sm07448
1
2

Figure 3-122. Tour-Pak Bracket Screws (APC Models)

TOUR-PAK SUPPORT
1. Support
FASTENER TORQUE VALUE 2. Cover (2)
Tour-Pak support cover 8–18 in-lbs 0.9–2 N·m 3. Screw (4)
screws 4. Screw (4 each side)
5. Insert (2) (models without Tour-Pak)
Tour-Pak support screws 15–20 ft-lbs 20.3–27.1 N·m
Figure 3-123. Tour-Pak Support
Removal
NOTE
Models without Tour-Pak have spacers in place where the
Tour-Pak support mounts. Removal and installation is similar.

1. See Figure 3-123. Remove harness connectors from

anchors on support.
2. Remove two fasteners (3) from each side. Remove
Tour-Pak support.

Installation
1. See Figure 3-123. Install Tour-Pak support.

2. Install fasteners (3). Tighten to 15–20 ft-lbs

(20.3–27.1 N·m).

3. Secure harness connectors to anchors on support.

4. Install Tour-Pak if removed.

Disassembly/Assembly
1. See Figure 3-123. Remove four screws (4).

2. Remove cover (2).

3. Install cover. Secure with screws (4).

4. Tighten to 8–18 in-lbs (0.9–2 N·m).

3-104 94000383
TOUR-PAK SERVICE 3.33
TOUR-PAK LINER 4. Continue around the opening until the seal returns to the
point of beginning. Use care at the corners to prevent
FASTENER TORQUE VALUE bunching or kinking of the seal.
Tour-Pak tether anchor screws 16–22 in-lbs 1.8–2.5 N·m NOTE
Do not cut seal long. Doing so may cause seal to bunch
NOTE allowing a path of water intrusion.
For service of wrap-around lamp, marker lamps/trim strips and
harness, see TOUR-PAK LIGHTS (Page 9-28). 5. Cut the seal squarely so the ends mate tightly together. A
gap of up to 0.062 in (1.6 mm) is allowed.
Removal 6. After the entire seal is initially installed, go back around
the entire seal and press firmly in place to be sure it is
1. Support lid partly open. securely adhered.
2. Remove screws securing tether anchor. TOUR-PAK LOCK
3. Remove liner.
4. Loosely install tether anchor. FASTENER TORQUE VALUE
Tour-Pak lockset screws 25–35 in-lbs 2.8–3.9 N·m
Installation
Removal
1. Remove tether anchor.
1. See Figure 3-124. Open latch handle (1) completely.
2. Install liner. 2. Remove two screws (2).
3. Remove lock.
3. Secure tether anchor with screws. Tighten to 16–22 in-lbs
(1.8–2.5 N·m). NOTE
Lock contains no service parts. Do not disassemble.
TOUR-PAK SEAL
sm07451
PART NUMBER TOOL NAME
HD-25070 ROBINAIR HEAT GUN 1

Inspection
1. Inspect for accumulation of dirt, grime or debris. Clean
with warm soapy water, if necessary.
2. Inspect parts for wear or damage. Replace if brittle,
cracked, torn or shredded.
3. Verify that seal is adhered securely. Replace if seal is not 2
securely adhered at any point.
1. Latch handle
Replacement
2. Screws
NOTE Figure 3-124. Latch Handle and Lockset Assembly
Use ROBINAIR HEAT GUN (PART NUMBER: HD-25070) to
improve seal removal. Installation
1. Remove old seal and all residual adhesive using 3M 1. See Figure 3-124. Orient lock with key notches toward the
GENERAL PURPOSE ADHESIVE REMOVER or top. Secure with two screws (2).
equivalent.
2. Tighten to 25–35 in-lbs (2.8–3.9 N·m).
NOTE
Do not touch the cleaned area after cleaning.
HINGES
2. Thoroughly clean the seal mounting surface around the
cover using a clean cloth and isopropyl alcohol. FASTENER TORQUE VALUE
Tour-Pak hinge screw 25–35 in-lbs 2.8–3.9 N·m
3. Peel back a few inches of backing material. Beginning at
the front middle, adhere the end of the seal. Work only a
few inches at a time.
Removal
NOTE
NOTE
Carefully compress seal when removing and installing screws
To prevent the possibility of water intrusion, be careful the seal
nearest the edge of the lid.
does not bunch or kink at the corners.

94000383 3-105
1. Remove eight screws securing hinge to Tour-Pak and lid.
sm07453
2. Remove hinge.

Installation 1
NOTE
• The hinges are identified by having the letter "F"ront or
"R"ear cast into them.
• The two screws nearest the edge of the lid are washerless
and shorter than the remaining six. Install the shorter screws 4 2
first.

1. Hold hinge in place.

3
2. Install screws securing hinge to Tour-Pak and lid. Tighten
to 25–35 in-lbs (2.8–3.9 N·m).

LATCH HANDLE AND CATCH 1. Catch

2. Screws (4)
FASTENER TORQUE VALUE 3. Latch handle assembly
Tour-Pak catch screws 25–35 in-lbs 2.8–3.9 N·m 4. Screws (4)
Tour-Pak latch handle 25–35 in-lbs 2.8–3.9 N·m Figure 3-125. Latch Handle and Catch
TETHER
Removal
1. Remove lockset. See TOUR-PAK SERVICE, Tour-Pak FASTENER TORQUE VALUE
Lock (Page 3-105). Tour-Pak tether anchor screws 16–22 in-lbs 1.8–2.5 N·m
2. See Figure 3-125. Remove screws (4). Tour-Pak tether reel screws 16–22 in-lbs 1.8–2.5 N·m
3. Remove latch handle assembly (3) with lock.
Removal
4. Remove screws (2) securing catch (1) to lid. Remove
catch. NOTE
Support the Tour-Pak lid to keep it from opening beyond the
Installation normal travel.

1. See Figure 3-125. Secure catch (1) to lid with screws (2). 1. Remove passenger backrest. See TOUR-PAK BACKREST
Tighten to 25–35 in-lbs (2.8–3.9 N·m). (Page 3-109).
2. See Figure 3-126. Remove screws (2).
2. Hold latch handle assembly (3) in place and secure with
screws (4). Tighten to 25–35 in-lbs (2.8–3.9 N·m). 3. Remove screws (1) securing tether reel.

Installation
1. See Figure 3-126. Secure tether reel with screws (1).

NOTE
Do not allow tether ribbon to twist during installation.

2. Tighten to 16–22 in-lbs (1.8–2.5 N·m).

3. Secure tether anchor with screws (2). Tighten to

16–22 in-lbs (1.8–2.5 N·m).

4. Install passenger backrest. See TOUR-PAK BACKREST

(Page 3-109).

3-106 94000383
 sm07455 sm07456
1

2
2

1. Tether reel screws 3

2. Tether anchor screws
Figure 3-126. Tether Mechanism Screws 4
LUGGAGE RACK

FASTENER TORQUE VALUE

Tour-Pak luggage rack 40–48 in-lbs 4.5–5.4 N·m
fastener

1. See Figure 3-127. Hold the luggage rack while removing 1. Mounting pad (4)
screws (4) and washers (2, 3). 2. Nylon washer (4)
3. Flat washer (4)
4. Screw (4)
2. Remove luggage rack.
Figure 3-127. Luggage Rack
3. Hold the luggage rack in place with mounting pads (1) GROUND PLATE
between luggage rack and lid.
FASTENER TORQUE VALUE
4. Secure with one nylon washer, one flat washer and screw Tour-Pak mounting nuts 60–72 in-lbs 6.8–8.1 N·m
on each stud.
Tour-Pak side marker lamp 20–25 in-lbs 2.3–2.8 N·m
screws
5. Tighten in a crosswise pattern to 40–48 in-lbs
(4.5–5.4 N·m).
Removal
1. Remove Tour-Pak liner. See TOUR-PAK SERVICE,
Tour-Pak Liner (Page 3-105).
2. Disconnect ground wire connectors.
NOTE
See Figure 3-128. Screws (2) secure both the ground plate
and marker lamps/trim strips.

3. Remove screws (2).

NOTE
Slots in Tour-Pak support allow position adjustment. Record
position before removal.

4. Hold Tour-Pak from tipping and remove four flange nuts

(3). Remove ground plate (1).
5. Install a temporary screw and nut to prevent Tour-Pak from
tipping until assembly.

Installation
1. Hold Tour-Pak from tipping while removing temporary
screw and nut.

94000383 3-107
 NOTE
Screws (2) secure both the ground plate and marker lamps/trim
strips.

2. See Figure 3-128. Install ground plate (1). Install four flange
nuts (3). Tighten to 60–72 in-lbs (6.8–8.1 N·m).

3. Install screws (2). While holding lamps in position, tighten

to 20–25 in-lbs (2.3–2.8 N·m).

4. Mate two ground connectors to ground plate.

5. Install Tour-Pak liner. See TOUR-PAK SERVICE, Tour-Pak

Liner (Page 3-105).

sm07969
2

1. Ground plate
2. Screws (4)
3. Flange nut (4)
Figure 3-128. Ground Plate

3-108 94000383
TOUR-PAK BACKREST 3.34
PASSENGER BACKREST sm07458

FASTENER TORQUE VALUE 2 3 3

Passenger backrest flange 108–132 in-lbs 12.2–14.9 N·m 2
nuts

Removal
1. Remove three flange nuts and flat washers.
2. Remove backrest from Tour-Pak lid. 1
5 4
Installation
1. Hold backrest on Tour-Pak lid. 1. Hair pin
2. Washer
2. Secure with flange nuts and flat washers. 3. Rubber isolator
4. Pin
5. Backrest support bracket
3. Tighten to 108–132 in-lbs (12.2–14.9 N·m).
Figure 3-129. Mount and Isolator (typical)
RUBBER ISOLATORS PASSENGER BACKREST FLAP

FASTENER TORQUE VALUE

Removal
Passenger backrest flap 21–24 in-lbs 2.4–2.7 N·m
1. Remove passenger backrest. See TOUR-PAK screws
BACKREST, Passenger Backrest (Page 3-109).
2. See Figure 3-129. Remove hair pin (1). Removal
3. Remove pin (4) and washers (2). 1. Remove molded liner from Tour-Pak. See TOUR-PAK
SERVICE (Page 3-105).
4. Remove backrest support bracket with isolators.
2. Remove two acorn nuts and screws with flat washers.
5. Remove rubber isolators (3) from backrest support bracket
(5). 3. Remove backrest flap.

Installation Installation
NOTE 1. Secure backrest flap with two screws (with flat washers)
The left and right backrest support brackets are identified with and acorn nuts. Tighten to 21–24 in-lbs (2.4–2.7 N·m).
"L" and "R" respectively. The center backrest support bracket
has no identification. 2. Tuck flap between seat and Tour-Pak to hide wires.

1. See Figure 3-129. Place the rubber isolators (3) in the 3. Install molded liner in Tour-Pak. See TOUR-PAK SERVICE
backrest support bracket (5). (Page 3-105).
2. Locate the backrest support bracket assembly in the
backrest. Install washers (2) and pin (4).
NOTE
Washers (2) have a shoulder that fits into the bores of the
backrest mounting area.

3. Secure assembly with hair pin (1).

4. Install passenger backrest. See TOUR-PAK BACKREST,
Passenger Backrest (Page 3-109).

94000383 3-109
FAIRING LOWERS AND ENGINE GUARD 3.35
FAIRING LOWER: AIR-COOLED 3. Install new rubber washer (8), clamp (7), screw (9) and
nut (6). Leave fasteners loose.
FASTENER TORQUE VALUE
4. See Figure 3-131. Align upper clamp to dimension (1).
Fairing lower inner panel 65–75 in-lbs 7.3–8.5 N·m
screws
Lower fairing cap flange nut 30–35 in-lbs 3.4–3.9 N·m NOTE
See Figure 3-131. Verify shift lever and brake pedal do not
Lower fairing glove box screws 12–16.8 in-lbs 1.4–1.9 N·m
contact fairing lower vent. Clearance from the vent openings
Lower fairing glove box tray 12–18 in-lbs 1.4–2 N·m to the shift lever (2) and brake pedal (3) should approximately
screws match the distance shown.
Lower fairing vent knob screw 12–18 in-lbs 1.4–2 N·m
Lower fairing, lower clamp 90–100 in-lbs 10.2–11.3 N·m 5. See Figure 3-130. Tighten flange nuts (4) to 30–35 in-lbs
Lower fairing, upper clamp 30–35 in-lbs 3.4–3.9 N·m (3.4–3.9 N·m).
nuts
6. See Figure 3-130. Verify that fairing lower is aligned.
Remove Tighten lower screw (9) to 90–100 in-lbs (10.2–11.3 N·m).
1. Open glove box door.
7. Place flat washer (10) on stud of fairing cap. Install fairing
2. See Figure 3-130. Remove flange nut (1) securing fairing
cap (3) with flange nut (1). Tighten to 30–35 in-lbs
cap (3). Remove fairing cap and flat washer (10).
(3.4–3.9 N·m).
3. Remove lower fairing clamp screw (9) and nut (6). Discard
rubber washer (8). 8. Close glove box door.
4. Remove flange nuts (4) securing upper clamp (2). Remove
lower fairing assembly. sm07634
1 1
sm07557

2 2
3 3

4
9

1. 10-1/8 in (257.2 mm)

5 2. 5/8 in (16.0 mm)
3. 1-1/4 in (31.8 mm)
8 7 Figure 3-131. Lower Fairing Mounting Dimensions
6
Disassembly
1. Flange nut, fairing cap
2. Upper clamp 1. Grille panel:
3. Lower fairing cap a. See Figure 3-130. Carefully pry on curved edge of grille
4. Flange nuts, upper clamp (2) plate (5) to release retainers.
5. Plate
6. Nut, lower clamp b. Remove from fascia.
7. Lower clamp
8. Rubber washer 2. See Figure 3-132. Remove two screws (9) securing inner
9. Screw, lower clamp panel (8).
10. Flat washer 3. Remove three screws securing glove box frame to fairing
Figure 3-130. Lower Fairing: Air Cooled lower.
4. Pull glove box frame away and pull vent link (4) down to
Install disconnect from vent door lever.
1. Place fairing lower into position. 5. See Figure 3-133. Remove three screws (7) to release
glove box tray (8).
2. See Figure 3-130. Install upper clamp (2) and two flange 6. Remove screw (5) to disassemble knob from link.
nuts (4). Leave fasteners loose.

3-110 94000383
7. Squeeze tabs to release latch (2).
sm07560
8. Glove box door: 2
3
a. Disengage spring (12).
b. Remove push nuts (14) from pins (11). 4 5
c. Remove pins. Remove door. 1
d. If necessary, remove damper (13).
6
9
9. Vent door: 8
a. See Figure 3-132. Rotate lever (5) to position shown.
b. Lift lever assembly to remove. Remove door (6).
c. Push up on lower pivot pin (7) to remove.
7
NOTE
The fascia can be removed and installed without removing the
lower fairing. 1. Knob
2. Screw
3. Slider
10. Fascia:
4. Link
a. See Figure 3-134. The fascia is retained by 5. Lever
double-faced adhesive at the locations shown. 6. Vent door
7. Lower pivot pin
NOTE
8. Inner panel
Do not damage the painted area next to the fascia. 9. Screws, inner panel
Figure 3-132. Lower Fairing Components
b. Starting with the area around the opening, push the
fascia outward to loosen the medium (2) and small (1)
tape strips.
c. Using a ¾ in (19 mm) flexible putty knife, push between
the fascia and fairing housing to cut the large tape strips
(3). A small amount of dish soap or liquid lubricant on
the knife blade eases this process.
d. Separate fascia from fairing lower housing. Remove all
remaining adhesive. Wash thoroughly with isopropyl
alcohol. Allow to dry completely.

94000383 3-111
 sm07558
NOTE
Replacement fascia has adhesive strips installed.

a. See Figure 3-134. Verify that tape locations are clean

and dry.
2
1 3 b. If installing original fascia, place new adhesive strips
4 on fascia in locations shown.

c. Align fascia and press into place. Apply pressure at

each tape location for 10-15 seconds.
5
14 2. Vent door:
6
a. See Figure 3-132. Install lower pivot pin (7) in fairing
13
housing.

b. Rotate lever (5) to position shown.

12
c. Place door on lower pivot pin (7). Hold door (6) at
approximate 45 degree angle as shown and install
10 9 lever (5). Rotate door to verify operation.
11 8 7
3. Glove box door:

1. Door a. See Figure 3-133. If removed, install damper (13).

2. Latch
3. Bumpers b. Fit spring (12) on pin opposite damper. Install pins
4. Frame, glove box to secure door.
5. Screw, link to knob
6. Link c. Install new push nuts (14).
7. Screw, glove box
8. Glove box tray d. Engage spring.
9. Knob, vent
10. Slider 4. Install the latch oriented as shown in inset. Note that latch
11. Hinge pin and latch opening are not symmetrical.
12. Spring
13. Damper 5. Apply a film of ELECTRICAL CONTACT LUBRICANT to
14. Push nut the upper area along the slot where the slider runs.
Figure 3-133. Glove Box
6. Install screw (5) to secure knob to slider. Tighten to
sm07563 12–18 in-lbs (1.4–2 N·m).

7. Install three screws (7) to secure glove box tray to glove

box. Tighten to 12–18 in-lbs (1.4–2 N·m).
1
2 8. Engage linkage to vent door arm.

9. See Figure 3-132. Install inner panel (8) with screws (9).
Tighten to 65–75 in-lbs (7.3–8.5 N·m).
3
10. Secure glove box assembly to fairing lower with three
screws. Tighten to 12–16.8 in-lbs (1.4–1.9 N·m).

11. Install grille plate.

1. Small
2. Medium FAIRING LOWER: TWIN-COOLED
3. Large
Figure 3-134. Fascia Adhesive Locations FASTENER TORQUE VALUE
Lower fairing cap flange nut 30–35 in-lbs 3.4–3.9 N·m
Assembly Lower fairing, lower clamp 90–100 in-lbs 10.2–11.3 N·m
1. Fascia: Lower fairing, upper clamp 30–35 in-lbs 3.4–3.9 N·m
nuts

3-112 94000383
Removal 3. Install new rubber washer (10), clamp (9), screw (11) and
nut (8). Leave fasteners loose.
1. Remove main fuse.
2. Remove fairing lower access panel. Pry the center top and 4. See Figure 3-136. Align upper clamp to dimension (1).
near each lower corner to release retainers.
NOTE NOTE
The fairing lower shell can be replaced without opening the See Figure 3-136. Verify shift lever and brake pedal do not
cooling system. Remove the fan. Allow the radiator to hang by contact fairing lower vent. Clearance from the vent openings
the hoses. See COOLING SYSTEM REPAIR, COOLING FAN to the shift lever (2) and brake pedal (3) should approximately
(Page 6-10). match the distance shown.

3. Drain coolant system. See Coolant (Page 2-19). 5. See Figure 3-135. Tighten flange nuts (5) to 30–35 in-lbs
4. See Figure 3-135. Disconnect upper hose (2) from the (3.4–3.9 N·m).
upper cross tube. Disconnect lower hose (6) from
thermostat. 6. See Figure 3-135. Verify that fairing lower is aligned.
Tighten lower screw (11) to 90–100 in-lbs (10.2–11.3 N·m).
5. Disconnect fan power connector (7) located near pump.
6. Remove flange nut (1) securing fairing cap (4). Remove 7. Place flat washer (12) on stud of fairing cap. Install fairing
fairing cap and flat washer (12). cap (4) with flange nut (1). Tighten to 30–35 in-lbs
(3.4–3.9 N·m).
7. Remove fairing lower clamp screw (11) and nut (8). Discard
rubber washer (10).
8. Verify shift lever and brake pedal do not contact fairing
8. Remove flange nuts (5) securing upper clamp (3). Remove lower vent.
fairing lower assembly.
9. Connect fan power connector (7) located near pump.
sm07571

1 10. Connect upper (2) and lower (6) radiator hoses.

2 11. Install main fuse.

3 12. Fill coolant system. See Coolant (Page 2-19).

4
13. Install fairing lower access panel.

5 14. Install coolant pump cover.

11

sm07634
6 1 1
7
10 9
8

1. Flange nut, fairing cap

2. Upper radiator hose
2
3. Upper clamp 3
4. Lower fairing cap
5. Flange nuts, upper clamp (2)
6. Lower radiator hose
7. Connector
8. Nut, lower clamp
9. Lower clamp
1. 10-1/8 in (257.2 mm)
10. Rubber washer
2. 5/8 in (16.0 mm)
11. Screw, lower clamp
3. 1-1/4 in (31.8 mm)
12. Flat washer
Figure 3-136. Lower Fairing Mounting Dimensions
Figure 3-135. Lower Fairing: Twin-Cooled

Installation Repair
For fairing disassembly and assembly, see FAIRING LOWERS
1. Place fairing lower into position.
AND ENGINE GUARD, Fairing Lower: Air-Cooled (Page 3-110).

2. See Figure 3-135. Install upper clamp (3) and two flange For removal and installation of cooling system components,
nuts (5). Leave fasteners loose. see COOLING SYSTEM REPAIR (Page 6-6).

94000383 3-113
ENGINE GUARD

FASTENER TORQUE VALUE

Engine guard lower screws 15–20 ft-lbs 20.3–27.1 N·m
Engine guard upper screw 22–28 ft-lbs 29.8–37.9 N·m

Removal
1. Remove lower fairings, if present. See FAIRING LOWERS
AND ENGINE GUARD (Page 3-110). Remove lower fairing
clamps from engine guard.
2. See Figure 3-137. Remove two screws (1) to release ends
of engine guard from frame weldments.
3. Remove screw (2) and flat washer (3) and remove engine
guard.

Installation
1. See Figure 3-137. Insert tab at top of engine guard into
slot at base of steering head. Start screw (2) with flat
washer (3).

2. Secure lower ends of engine guard to frame weldments

with screws (1).

3. Tighten lower screws (1) to 15–20 ft-lbs (20.3–27.1 N·m).

4. Tighten upper screw (2) to 22–28 ft-lbs (29.8–37.9 N·m).

5. Install lower fairing clamps on each side of engine guard.

Install lower fairings, if present. See FAIRING LOWERS
AND ENGINE GUARD (Page 3-110).

sm06496

3
2

1. Screw (2)
2. Screws
3. Flat Washer
Figure 3-137. Engine Guard

3-114 94000383
OUTER FAIRING AND WINDSHIELD: FORK MOUNTED FAIRING MODELS3.36
OUTER FAIRING AND WINDSHIELD d. Fit the keyhole on the opposite end of the windshield
over the inner fairing raised boss.
FASTENER TORQUE VALUE
6. Start three screws (1, 2). The center screw is the longest.
Headlamp door screw 9–18 in-lbs 1–2 N·m
Tighten to 25–30 in-lbs (2.8–3.4 N·m).
Headlamp mount to fairing 22–32 in-lbs 2.5–3.6 N·m
Outer fairing screws: fork 20–30 in-lbs 2.3–3.4 N·m 7. Tighten screws (3, 4) to 20–30 in-lbs (2.3–3.4 N·m).
mounted fairing
Windshield screws: 25–30 in-lbs 2.8–3.4 N·m 8. Install the left and right lamp brackets to front forks. See
Fork-mounted fairing models AUXILIARY/FOG LAMPS AND BRACKETS (Page 9-18)
or Turn Signal Lamps (Page 9-31).
Removal
1. Remove main fuse. 9. Install main fuse.
2. Remove the left and right lamp brackets from front forks.
See AUXILIARY/FOG LAMPS AND BRACKETS sm07475
1
(Page 9-18) or Turn Signal Lamps (Page 9-31).
3. See Figure 3-138. Remove three screws (1, 2) securing 2
the windshield.
4. Loosen two screws (3).
5. Spread the inner and outer fairing while removing the
windshield. Loosely install one windshield screw to prevent
fairing from unexpectedly falling.
6. Remove two screws (3).
7. Remove two screws (4).
8. Remove the windshield screw. 3 3
9. Pull the outer fairing forward and separate headlamp
connector [38].
4
10. Remove outer fairing.
1. Windshield screws, short (2)
Installation 2. Windshield screw, long (1)
3. Fairing outer screws, long (2)
1. Verify seals between outer and inner fairing are in good 4. Fairing lower screws, short (2)
shape and in place.
Figure 3-138. Outer Fairing Screws

NOTE Fairing Perimeter Trim

• Confirm that the correct screws are installed in each location.
1. Remove outer fairing.
• See Figure 3-138. Screws (4) are similar to the center screw
2. Remove damaged trim.
that secures the windshield. Use care to avoid mixing them
during installation. Screws (4) have a smooth shank, captive 3. Install new trim. Use masking tape at the ends to hold in
washer and unthreaded tip. place on inner fairing during assembly.
4. Install outer fairing.
2. Mate headlamp connector [38]. Install outer fairing.
Headlamp Mount
3. See Figure 3-138. Start two long screws (3).
NOTE
4. Start two short screws (4). Do not remove adjusting ring unless components will be
replaced.
5. Place the windshield into position:
1. See Figure 3-139. Remove headlamp door (4). If needed,
a. Spread the inner and outer fairings at the windshield remove headlamp from mount (2). See HEADLAMP
opening. (Page 9-16).

b. Fit the keyhole on one end of the windshield over 2. Remove remove screws (3).
the raised boss on the inner fairing.
3. Hold headlamp and mount (2) away from fairing and
c. Fit the center keyhole over the center raised inner disconnect wiring harness.
fairing boss.
4. Remove headlamp trim (1).

94000383 3-115
5. Connect wiring harness to headlamp. Install headlamp
trim and mount with four screws (3). Tighten to
22–32 in-lbs (2.5–3.6 N·m).

6. Install headlamp door (4) with screw (5). Tighten to

9–18 in-lbs (1–2 N·m).

sm08219
1

2
3
4

1. Headlamp trim
2. Headlamp mount
3. Screw (4)
4. Headlamp door
5. Screw
Figure 3-139. Headlamp Mount

Fairing Vent Bezel

1. Remove outer fairing.
2. See Figure 3-140. From inside fairing, use a putty knife to
release adhesive (2).
3. Release latches (1). Remove bezel.
4. Remove all old adhesive from fairing. Clean areas with
rubbing alcohol. Allow to dry completely.
5. Install new bezel. Apply pressure to all adhesive areas for
10 seconds.
6. Install outer fairing.

sm08005
2 1
1

2
1. Latch
2. Adhesive
Figure 3-140. Outer Fairing Vent Bezel

3-116 94000383
DASH PANEL: FORK MOUNTED FAIRING MODELS 3.37
DASH PANEL

FASTENER TORQUE VALUE

Dash panel screws 25–30 in-lbs 2.8–3.4 N·m
Ignition switch housing nut 13–15 ft-lbs 17.5–20.9 N·m

Removal
1. Remove ignition switch knob and spring. Remove nut and
collar from ignition switch. See Ignition Switch and Fork
Lock (Page 9-39).
2. See Figure 3-141. Remove two screws (1) (with flat
washers) to release dash panel.
3. Lift the dash panel and disconnect dash panel switch
connectors (2).
4. Remove dash panel.
5. See ACCESSORY SWITCHES (Page 9-42) for switch
service.

Installation
1. See Figure 3-141. Mate switch connectors (2).
2. Install dash panel over ignition switch housing.

3. Install two screws (1) (with flat washers) to secure dash

panel. Tighten to 25–30 in-lbs (2.8–3.4 N·m).

4. Install collar and nut on ignition switch. Tighten to

13–15 ft-lbs (17.5–20.9 N·m).

sm07912

1 1

2
1. Dash panel screws (2)
2. Dash panel switch connectors (not visible)
Figure 3-141. Dash Panel Screws

94000383 3-117
INNER FAIRING: FORK MOUNTED FAIRING MODELS 3.38
ROTATE INNER FAIRING 6. Install outer fairing and auxiliary/fog lamp brackets or turn
signal brackets. See OUTER FAIRING AND WINDSHIELD:
FASTENER TORQUE VALUE FORK MOUNTED FAIRING MODELS (Page 3-115).
Fairing double studs 120–180 in-lbs 13.6–20.3 N·m
sm07486
NOTE
Rotate the inner fairing to perform repairs such as ignition
switch replacement, handlebar replacement or to access 1
harnesses and lines that are attached to the handlebar. Rotate
only as far as needed to make repair. Over-rotation can result
in cosmetic damage. 2 1

Rotate for Service

1. Remove auxiliary/fog lamp brackets or turn signal brackets.
See AUXILIARY/FOG LAMPS AND BRACKETS
(Page 9-18). 3 2
2. Remove outer fairing. See OUTER FAIRING AND
WINDSHIELD: FORK MOUNTED FAIRING MODELS
(Page 3-115).
1. Screw, dash panel (2)
3. See Figure 3-143. Disconnect TGS connector (14). 2. Double stud (4)
4. Remove dash panel. See DASH PANEL: FORK 3. Chrome skirt
MOUNTED FAIRING MODELS (Page 3-117). Figure 3-142. Inner Fairing Fasteners
NOTE REMOVE AND INSTALL INNER FAIRING
The area below radio opening may contact the ignition switch ASSEMBLY
stem. Use care to avoid cosmetic damage. Place a rag or other
protection between stem and inner fairing. FASTENER TORQUE VALUE
Fairing double studs 120–180 in-lbs 13.6–20.3 N·m
5. See Figure 3-142. Remove double studs (2).
6. Remove chrome skirt (3). Removal
NOTE NOTE
• Disconnection of other electrical components is not Remove the inner fairing as an assembly to perform repairs
necessary. such as handlebar replacement, fork bracket
repair/replacement, steering head bearing
• Over rotation of fairing can result in cosmetic damage. adjustment/replacement and so forth.
Rotate fairing only enough to access the components
needing service. 1. Remove outer fairing. See OUTER FAIRING AND
WINDSHIELD: FORK MOUNTED FAIRING MODELS
7. Lift inner fairing assembly slightly and rotate upper portion (Page 3-115).
forward until it is approximately vertical.
NOTE
8. Perform repairs as necessary.
Vehicles equipped with hydraulic clutch do not require
disconnection.
Rotate Into Place
1. Lift the inner fairing slightly and rotate back into position. 2. See Figure 3-143. Separate connectors (1-15).
3. Release connector anchors on connectors (1, 2, 8, 14).
2. Connect TGS connector.
4. Remove dash panel. See DASH PANEL: FORK
3. Install chrome skirt. MOUNTED FAIRING MODELS (Page 3-117).
NOTE
4. Install double studs. Tighten to 120–180 in-lbs The lower radio bezel may contact the ignition switch stem.
(13.6–20.3 N·m). Use care to avoid cosmetic damage. Place a rag or other
protection between stem and radio bezel.
5. Install dash panel. See DASH PANEL: FORK MOUNTED
FAIRING MODELS (Page 3-117). 5. Pull both auxiliary/fog lamp connectors through the
openings and into the area of the inner fairing.
6. Roll top of fairing assembly forward while lifting to remove.

3-118 94000383
 sm07487

16 2
1

7
3 4 5
6
15

14
9 9
12 11
13 10

1. CB module 9. Heated hand grip power, if equipped

2. P&A audio 10. Main-to-fairing harness, left
3. USB cable 11. Run/stop switch
4. AM/FM radio antenna 12. Right handlebar switch harness
5. GPS antenna 13. Main-to-fairing harness, right
6. Left handlebar switch harness 14. TGS
7. CB antenna 15. Radio
8. Front fender tip lamp 16. Accessory power
Figure 3-143. Inner Fairing Harness Connectors: Fork Mounted Fairing
7. Install outer fairing. See OUTER FAIRING AND
Installation WINDSHIELD: FORK MOUNTED FAIRING MODELS
(Page 3-115).
NOTE
Before installation, confirm that dash panel switch harnesses REPLACE INNER FAIRING SHELL
are routed back between handlebar and upper fork bracket.

FASTENER TORQUE VALUE

1. Slide the lower fairing support brackets over the bosses
Fairing speaker enclosure to 48–60 in-lbs 5.4–6.8 N·m
on the upper fork bracket. Roll top of fairing assembly
fairing screws
rearward while lowering into position.
Fairing speaker grille screws 9–13 in-lbs 1–1.5 N·m
2. Install chrome skirt. Gauges, 2 inch diameter 8–15 in-lbs 0.9–1.7 N·m
gauge screws
3. Install double studs. Tighten to 120–180 in-lbs Gauges, instrument cluster 10–20 in-lbs 1.1–2.3 N·m
(13.6–20.3 N·m). screws
Media compartment screw, 8–12 in-lbs 0.9–1.3 N·m
4. Install dash panel. See DASH PANEL: FORK MOUNTED lower
FAIRING MODELS (Page 3-117). Power outlet, front 13–17 in-lbs 1.5–1.9 N·m
Upper support bracket to inner 10–20 in-lbs 1.1–2.2 N·m
5. See Figure 3-143. Mate connectors (1-15). fairing screws

6. Secure connector anchors on connectors (1, 2, 8, 14). Removal

NOTE
• Cover painted parts to protect finish.

94000383 3-119
• Never lift the fairing assembly by the radio face.
sm07511
2
1. Prepare a protective work surface large enough to lay the 1 1
inner fairing assembly on.
2. Remove air deflectors. See Air Deflectors (Page 3-140). 6
3. Remove outer fairing. See OUTER FAIRING AND
WINDSHIELD: FORK MOUNTED FAIRING MODELS 5
(Page 3-115).
4. Remove inner fairing assembly. See INNER FAIRING: 3 3
4
FORK MOUNTED FAIRING MODELS, Remove and Install
Inner Fairing Assembly (Page 3-118). Lay on protective
surface with gauge faces down.
5. Remove fairing vent. See INNER FAIRING: FORK 1. Screw, speaker enclosure
MOUNTED FAIRING MODELS, Fairing Vent (Page 3-121). 2. Screw, upper support
3. Screw, enclosure, lower
6. Disconnect harness connectors from the gauges and
4. Media cable connector
instrument cluster. Pull harness anchors from the 2-inch
5. Power outlet connector
gauges.
6. Screw, media compartment
7. See Figure 3-144. Remove two upper support screws (2). Figure 3-144. Inner Fairing
8. Remove four enclosure screws (1). Do not remove screws
sm07512
(3) now. 1 2 1
9. Disconnect connectors (4, 5).
3
10. See Figure 3-147. Flip fairing assembly with top near the 3
edge of the protective surface. Lay with protrusions at top
of fairing hanging off edge of surface.
11. Remove two lower enclosure screws (2).
12. See Figure 3-144. Remove media compartment screw (6).
NOTE 5 4
Use caution when lifting fairing from support structure assembly
to prevent speaker damage.
1. 2-Inch Instruments
13. Lift inner fairing shell off support structure assembly. Place 2. Instrument cluster
face-down on protective surface to finalize disassembly. 3. Speaker grill
4. Screw, media compartment
14. See Figure 3-145. Remove screws to release 2-inch
5. Power outlet
gauges (1) and instrument cluster (2).
Figure 3-145. Support Structure Removed
15. Remove screws to release speaker grilles (3).
NOTE Installation
Media compartment door must be open to remove or install
1. Place new inner fairing face-down on a protective surface.
media compartment.
2. FLHX, FLHXS: Install mirrors. See Mirrors, FLHX, FLHXS
16. Remove screw (4) to release media compartment.
(Page 3-95).
17. Remove power outlet (5).
18. Remove left and right edge seals. 3. See Figure 3-145. Install power outlet (5). Tighten to
13–17 in-lbs (1.5–1.9 N·m).
19. FLHX, FLHXS: Remove mirrors. See Mirrors, FLHX,
FLHXS (Page 3-95). 4. Verify that media compartment door is open. Install media
compartment. Tighten screw (4) to 8–12 in-lbs
(0.9–1.3 N·m).

5. Install speaker grilles (3) with arrows aligned with those

on the inner fairing. Tighten to 9–13 in-lbs (1–1.5 N·m).

6. Install 2-inch gauges (1). Tighten to 8–15 in-lbs

(0.9–1.7 N·m).

7. Install instrument cluster (2) using single screw at top.

Tighten to 10–20 in-lbs (1.1–2.3 N·m).

3-120 94000383
8. See Figure 3-146. Place support structure assembly on
sm07514
the work surface with the tops of the speaker enclosures
(2) near the edge of the work surface (1).

2
9. See Figure 3-147. Place inner fairing onto structure 2
assembly. Adjust position so the protrusions at the top of
the fairing hang off the edge of the work surface. Start
lower speaker enclosure screws (2).

10. Flip inner fairing assembly to lay face-down on a protective

surface.

11. See Figure 3-144. Install two screws (2). Tighten to

10–20 in-lbs (1.1–2.2 N·m).
1
12. Install four screws (1). Tighten screws (1, 3) to 1. Protrusions at top of fairing
48–60 in-lbs (5.4–6.8 N·m). 2. Lower speaker enclosure screws (not visible)
Figure 3-147. Inner Fairing Assembly
13. Install media compartment screw (6).
FAIRING VENT
14. Install connectors (4, 5).
FASTENER TORQUE VALUE
15. Install harness connectors to the gauges and instrument Fairing vent to inner fairing: 20–30 in-lbs 2.3–3.4 N·m
cluster. Install harness anchors to the 2-inch gauges. fork mounted fairing

16. Install left and right edge seals. Cleaning

17. Install fairing vent. See INNER FAIRING: FORK
MOUNTED FAIRING MODELS, Fairing Vent (Page 3-121).
18. Install inner fairing assembly. See INNER FAIRING: FORK
MOUNTED FAIRING MODELS, Remove and Install Inner
Fairing Assembly (Page 3-118).
19. Install outer fairing. See OUTER FAIRING AND
WINDSHIELD: FORK MOUNTED FAIRING MODELS
(Page 3-115).
Occasional cleaning of the air duct, vent door and button
provides trouble-free operation.
NOTE
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 forms a white haze on non-painted plastic parts.

20. Install air deflectors. See Air Deflectors (Page 3-140). 1. With button in the UP position (vent door closed), spray
clean water into the area under the button.

sm07513
2. Spray low-pressure air in the same direction.
3. Using mild soapy water and a soft brush, remove dirt and
bugs from vent duct and vent door.
4. Operate vent and repeat cleaning as necessary.
5. If vent door does not operate freely, see Vent Repair which
follows.

Removal
1. Remove outer fairing. See OUTER FAIRING AND
WINDSHIELD: FORK MOUNTED FAIRING MODELS
(Page 3-115).
1 1 2. Remove screws from either end of vent.
2
3. Remove vent.
1. Speaker enclosure
2. Edge of work surface Installation
Figure 3-146. Support Structure Assembly
1. Install vent.

2. Install screws to each end of vent. Tighten to 20–30 in-lbs

(2.3–3.4 N·m).

94000383 3-121
3. Install outer fairing. See OUTER FAIRING AND
sm07895
WINDSHIELD: FORK MOUNTED FAIRING MODELS
(Page 3-115). 3
1
Vent Repair
1. Remove vent assembly from inner fairing. 2 4
2. See Figure 3-148. Using a thin flat tool, carefully pry
between housing (5) and bezel (1) at each of the ten 5
retainer clip (7) locations. Remove bezel.

3. Replace any damaged or missing clips (7). 6

7
4. Disconnect link (4) from vent door. Remove vent door (2).

5. Press catches securing button assembly (3) and push out

of vent housing.

6. Install button assembly.

7. Install vent door. Connect link.

1. Bezel
8. Apply a small amount of ELECTRICAL CONTACT 2. Vent door
LUBRICANT to the vent door pivot journals. 3. Button assembly
4. Link
9. Install bezel. Verify that all ten clips are engaged. 5. Vent housing
6. Foam gasket
10. Install vent assembly to inner fairing. Tighten to 7. Clip (10)
20–30 in-lbs (2.3–3.4 N·m). Figure 3-148. Fairing Vent Assembly
UPPER SUPPORT BRACKET
11. Gasket replacement:
FASTENER TORQUE VALUE
a. Remove all gasket material and adhesive.
Media compartment screw, 25–35 in-lbs 2.8–4 N·m
upper
b. Clean contact area with rubbing alcohol.
Upper support bracket to inner 10–20 in-lbs 1.1–2.2 N·m
c. Install new gasket along raised area of housing. fairing screws
Upper support bracket to radio 25–35 in-lbs 2.8–4 N·m
(storage box) screws
Upper support bracket to 48–60 in-lbs 5.4–6.8 N·m
speaker enclosure screws

Removal
1. Remove outer fairing. See OUTER FAIRING AND
WINDSHIELD: FORK MOUNTED FAIRING MODELS
(Page 3-115).
2. Remove fairing vent. See INNER FAIRING: FORK
MOUNTED FAIRING MODELS, Fairing Vent (Page 3-121).
3. Remove electrical connector anchors from support bracket.
4. If equipped, disconnect GPS antenna connector from radio.
5. See Figure 3-149. Remove four screws (1).
6. Remove two screws (2).
7. Remove four screws (3).
8. Remove screw (6) securing media compartment.
9. Remove upper support bracket (4).
NOTE
Never operate vehicle with the radio or upper support bracket
removed. These components provide important structural

3-122 94000383
support to the fairing. Temporarily install the Police glove box Removal
assembly if the vehicle must be operated while the radio is
1. Remove outer fairing. See OUTER FAIRING AND
removed. Damage to the fairing assembly can result if operated
WINDSHIELD: FORK MOUNTED FAIRING MODELS
without either of these components installed.
(Page 3-115).
2. Remove fairing vent. See INNER FAIRING: FORK
Installation MOUNTED FAIRING MODELS, Fairing Vent (Page 3-121).
1. See Figure 3-149. Place upper support bracket (4) into 3. Remove upper support bracket. See INNER FAIRING:
position. FORK MOUNTED FAIRING MODELS, Upper Support
Bracket (Page 3-122).
2. Loosely install screws (1-3).
NOTE
Never operate vehicle with the radio or upper support bracket
3. Tighten screws in the following sequence for proper
removed. These components provide important structural
alignment:
support to the fairing. Temporarily install the Police glove box
assembly if the vehicle must be operated while the radio is
a. Tighten screws (2) to 10–20 in-lbs (1.1–2.2 N·m). removed. Damage to the fairing assembly can result if operated
without either of these components installed.
b. Tighten screws (1) to 48–60 in-lbs (5.4–6.8 N·m).
4. Separate media cable connector from radio.
c. Install four screws (3). Tighten to 25–35 in-lbs
(2.8–4 N·m). 5. See Figure 3-150. Remove screw (4). Open compartment
door. Remove media compartment.
4. Install screw (6). Tighten to 25–35 in-lbs (2.8–4 N·m).
Installation
5. Secure electrical connector anchors to upper support.
1. See Figure 3-150. Place media compartment into position.

6. Mate GPS antenna connector if removed.

2. Install screw (4). Tighten to 8–12 in-lbs (0.9–1.3 N·m).

7. Install fairing vent. See INNER FAIRING: FORK

3. Mate media cable connector to radio.
MOUNTED FAIRING MODELS, Fairing Vent (Page 3-121).
4. Install upper support bracket. See INNER FAIRING: FORK
8. Install outer fairing. See OUTER FAIRING AND
MOUNTED FAIRING MODELS, Upper Support Bracket
WINDSHIELD: FORK MOUNTED FAIRING MODELS
(Page 3-122).
(Page 3-115).
5. Install fairing vent. See INNER FAIRING: FORK
sm07501 2 MOUNTED FAIRING MODELS, Fairing Vent (Page 3-121).
3
4 6. Install outer fairing. See OUTER FAIRING AND
WINDSHIELD: FORK MOUNTED FAIRING MODELS
1 (Page 3-115).
5
Replace Cable
NOTE
This procedure can be performed with media compartment
6
installed.

1. Remove outer fairing. See OUTER FAIRING AND

WINDSHIELD: FORK MOUNTED FAIRING MODELS
(Page 3-115).
2. Separate media cable connector from radio.
1. Upper support-to-speaker enclosure screw (4)
2. Upper support-to-inner fairing screw (2) 3. Remove cable from retaining feature (3).
3. Upper support-to-radio screw (4)
4. Remove foam insert.
4. Upper support bracket
5. Instrument cluster 5. Push cable grommet (2) into media compartment to
6. Media compartment screw remove.
Figure 3-149. Upper Support Bracket NOTE
MEDIA COMPARTMENT Apply a small amount of window cleaner to aid installation.

FASTENER TORQUE VALUE 6. Route cable through mounting hole from inside
Media compartment screw, 8–12 in-lbs 0.9–1.3 N·m compartment.
lower

94000383 3-123
7. Pull grommet into hole until seated. Secure cable to
retaining feature (3).
8. Install foam insert.
9. Mate media cable connector to radio.
10. Install outer fairing. See OUTER FAIRING AND
WINDSHIELD: FORK MOUNTED FAIRING MODELS
(Page 3-115).

Replace Cover
NOTE
This procedure can be performed with media compartment
installed. Use care to avoid cosmetic damage.

1. Use a thin putty knife between the inner and outer (1)
covers. Carefully pry outer cover off.
2. Align outer cover and apply to inner cover.

Replace Latch
1. Remove media compartment.
2. See Figure 3-150. Release upper and lower catches on
latch (5).
3. Push latch out of housing.
4. See inset. Install new latch. Verify that catches are
securely hooked.
5. Close and open the door to verify operation.
6. Install media compartment.

sm07508

5
4 3

1. Outer cover
2. Grommet
3. Retaining feature
4. Screw
5. Latch
Figure 3-150. Media Compartment

3-124 94000383
INSTRUMENT BEZEL: FRAME MOUNTED FAIRING MODELS 3.39
INSTRUMENT BEZEL

FASTENER TORQUE VALUE

Instrument bezel screws 10–15 in-lbs 1.1–1.7 N·m

Removal
1. Remove ignition switch knob. See Ignition Switch and Fork
Lock (Page 9-39).
2. See Figure 3-151. Remove screws (1) on each side of
bezel (2).
3. Lift the rear of the ignition switch cover (3). Remove cover.
4. Lift bezel to remove.
5. Disconnect instrument connector. Disconnect accessory
switch connectors. Remove bezel assembly.

Installation
1. Mate accessory switch connectors.

2. Mate instrument connector.

3. Lower bezel (2) assembly into place.

4. See Figure 3-151. Install screws (1) on each side of bezel.

Tighten to 10–15 in-lbs (1.1–1.7 N·m).

5. Engage tabs of switch cover (3). Press down on rear to

secure.

6. Install ignition switch knob. See Ignition Switch and Fork

Lock (Page 9-39).

sm08364
2 1
3

1. Screw (2)
2. Bezel
3. Ignition switch cover
Figure 3-151. Remove Instrument Bezel

94000383 3-125
INSTRUMENT NACELLE: FRAME MOUNTED FAIRING MODELS 3.40
INSTRUMENT NACELLE sm08365

1
FASTENER TORQUE VALUE 2
Instrument nacelle to fork 96–115 in-lbs 10.8–13 N·m
bracket screws
6
Removal 3
NOTE
To remove the instrument nacelle with the inner fairing installed,
the handlebars must be able to turn.
5
1. See Figure 3-152. Remove instrument bezel (1). See
INSTRUMENT BEZEL: FRAME MOUNTED FAIRING
MODELS (Page 3-125).
2. Turn the handlebar until screws (2) can be accessed.
Remove screws and flat washers (3). Repeat with opposite 5
4
side.
3. Remove fairing skirt (4).
1. Instrument bezel
4. Pull nacelle halves (5) apart to release two retainers (6). 2. Screw (4)
3. Flat washer (4)
Installation 4. Fairing skirt
5. Nacelle halves
1. See Figure 3-152. Verify that two retainers (6) are in place.
6. Retainers (2)

2. Place nacelle halves into position. Figure 3-152. Instrument Nacelle

3. While holding nacelle halves in approximate position, install

fairing skirt (4).

4. Turn handlebars until screws (2) can be installed.

5. Install screws and flat washers (3). Tighten to

96–115 in-lbs (10.8–13 N·m).

6. Repeat with opposite side.

7. Install instrument bezel (1). See INSTRUMENT BEZEL:

FRAME MOUNTED FAIRING MODELS (Page 3-125).

3-126 94000383
OUTER FAIRING AND WINDSHIELD: FRAME MOUNTED FAIRING
MODELS 3.41
WINDSHIELD sm08363

FASTENER TORQUE VALUE

1
Windshield screws: Frame 8–12 in-lbs 0.9–1.4 N·m
mounted fairing models
2
Removal
Remove four screws securing the windshield. Remove
windshield.

Installation
2
1. Verify that windshield seal is in place on air duct assembly
and not damaged.

2. Install the windshield with four screws. Tighten to

8–12 in-lbs (0.9–1.4 N·m).

TOP AIR DUCT

1. Air duct
2. Retainer slot (2)
FASTENER TORQUE VALUE
Figure 3-153. Top Air Duct
Top duct door mechanism 6–8 in-lbs 0.7–0.9 N·m
Cleaning Air Duct
Removal
Occasional cleaning of the air duct, vent door and button
NOTE
provides trouble-free operation.
The duct housing, vent door and pins are not serviced. Replace
assembly upon failure. NOTE
Never use cleaners containing chlorine or ammonia on plastic
1. Remove windshield. See OUTER FAIRING AND parts.
WINDSHIELD: FRAME MOUNTED FAIRING MODELS,
WINDSHIELD (Page 3-127). • Chlorine causes parts to become distorted and brittle
resulting in cracks.
2. Pull up sharply on front edge of air duct housing to release
two retainers. • Ammonia causes cloudiness and brittleness in windshields
and forms a white haze on unpainted plastic parts.
3. Pull forward to remove air duct.
4. Windshield seal replacement: 1. With button in the UP position (vent door closed), spray
clean water into the area under the button.
a. Remove old windshield seal.
2. Spray low-pressure air in the same direction.
b. Install new windshield seal, pulling each retaining tab
through duct housing until each snap engages. 3. Using mild soapy water and a soft brush, remove dirt and
bugs from air duct and vent door.

Installation 4. Operate vent and repeat cleaning as necessary.

1. See Figure 3-154. Replace damaged or missing retainers Repair Button Mechanism
(2).
1. Remove duct assembly.
2. Check that windshield seal is in place on duct assembly
and not damaged.
2. See Figure 3-154. With latch released, remove screws (4).
3. Verify that foam strip is in place on upper flange of outer Remove button mechanism (6) as an assembly.
fairing.
4. Install duct assembly by engaging tabs in inner fairing. 3. Inspect spring (3) and other components for damage.
Align retainers and push down to secure. Clean residue from the gear teeth.
5. Install windshield. See OUTER FAIRING AND
WINDSHIELD: FRAME MOUNTED FAIRING MODELS, 4. Latch replacement:
WINDSHIELD (Page 3-127).
a. Release catches on latch (5).

94000383 3-127
 NOTE b. See inset. With latch released, align the first tooth
Latch (5) is not symmetrical. A raised feature (arrow) on the of the button gear between the first two teeth of the
housing prevents improper installation. vent door gear while lowering the button mechanism
into place.
b. Push latch out of housing.
c. Install screws (4) to hold mechanism in place
c. See inset. Install new latch. Verify that catches are
d. Connect spring (3).
securely hooked.

6. Tighten six screws (4) to 6–8 in-lbs (0.7–0.9 N·m). Verify

5. Install mechanism:
that mechanism operates correctly.

a. Disconnect spring (3).

7. Install duct assembly.

sm08360

6
3

1. Duct housing assembly 4. Screw (6)

2. Retainer (2) 5. Latch
3. Spring 6. Button mechanism
Figure 3-154. Top Air Duct Assembly
OUTER FAIRING Removal
1. Remove main fuse.
FASTENER TORQUE VALUE
2. Remove windshield.
Outer fairing lower screws 8–15 in-lbs 0.9–1.7 N·m
(also air deflector): frame 3. Remove air duct. Loosely install two windshield screws to
mounted fairing keep fairing from falling in later steps.
Outer fairing upper screws 20–30 in-lbs 2.3–3.4 N·m 4. Remove left and right speaker grilles. See Boom! Box
(near speakers): frame Infotainment System, Front Fairing Speaker and Enclosure:
mounted fairing Frame-Mounted Fairing (Page 9-72).
Turn signal lamp mounting 48–60 in-lbs 5.4–6.8 N·m
screw, front: frame mounted 5. See Figure 3-155. Separate lamp connectors (2, 3).
fairing 6. Remove two upper screws (1).
Windshield screws: 8–12 in-lbs 0.9–1.4 N·m
7. Remove two lamp screws (4).
Frame-mounted fairing models

3-128 94000383
8. Remove two lower screws (5). 10. Pull the outer fairing forward to remove.
9. Remove windshield screws loosely installed earlier.

sm08362
2

4
1

1. Upper screws, short (2) 4. Lamp screws, long (2)

2. Left lamp connector 5. Lower screws (2)
3. Right lamp connector
Figure 3-155. Outer Fairing Screws
NOTE
Installation See Figure 3-156. Do not allow any wiring or connectors to
encroach in the darkened area. Interference of the top air duct
1. If damaged, replace the foam strip on upper flange of outer
latch mechanism results.
fairing:

a. Remove existing foam strip. Remove all residual 8. Tighten lamp screws (4) to 48–60 in-lbs (5.4–6.8 N·m).
adhesive.
9. Mate left (2) and right (3) lamp connectors. Verify that left
b. Clean mounting area with rubbing alcohol. Allow to connector and harness are positioned so they do not
dry completely. interfere with the top air duct latch mechanism.

c. Install new foam strip centered within ½ in (13 mm). 10. Install the speaker grilles.

2. Engage alignment features while sliding outer fairing back
into position. Loosely install two windshield screws to
prevent fairing from falling.
3. See Figure 3-155. Start two lamp screws (4).
11. Check that windshield seal is in place on air duct assembly
and not damaged.
12. Verify that foam strip is in place on upper flange of outer
fairing.

4. Start two screws (5). 13. Install the air duct.

5. Start two screws (1). 14. Install the windshield with four screws. Tighten to
8–12 in-lbs (0.9–1.4 N·m).
6. Tighten upper screws (1) to 20–30 in-lbs (2.3–3.4 N·m).
15. Install main fuse.
7. Tighten lower screws (5) to 8–15 in-lbs (0.9–1.7 N·m).

94000383 3-129
 sm08487

Figure 3-156. Inner Fairing No-Harness Area

3-130 94000383
INNER FAIRING: FRAME MOUNTED FAIRING MODELS 3.42
REMOVAL 3. Remove headlamp. See HEADLAMP (Page 9-16).
4. See Figure 3-157. Separate radio harness connector (1)
Inner Fairing Assembly and antenna cable connector (2) from radio.

1. Place protective material on top of front fender to protect 5. Release left (3) and right (4) main harness connector
paint. anchors. Separate connectors. Release antenna lead
retainer located near left main harness retainer.
2. Remove outer fairing. See OUTER FAIRING AND
WINDSHIELD: FRAME MOUNTED FAIRING MODELS 6. Draw branches of main harness to front of inner fairing
(Page 3-127). through openings in fairing bracket.

sm08368

1 2

5 5

1. Radio 4. Main-to-fairing harness, right

2. AM/FM radio antenna 5. Screws (4)
3. Main-to-fairing harness, left
Figure 3-157. Inner Fairing Harness Connectors

7. See Figure 3-158. Remove screws (1) securing left and NOTE
right fairing support brackets (4) to engine guard (6). Tabs on inner fairing are engaged in slots (5) on fairing mount.

8. Remove screws (7) and washers securing fairing support 10. Lift inner fairing from fairing mount and move to bench
brackets to inner fairing. Remove support brackets. area.
9. Remove four screws (3).

94000383 3-131
 sm08369

7
3

5
1. Screws 5. Slots in inner fairing mount
2. Cap 6. Engine guard
3. Screw (4) 7. Screw (2)
4. Support bracket
Figure 3-158. Inner Fairing Mounting
INSTALLATION
Fairing Mounting Bracket
1. Remove the inner fairing assembly. FASTENER TORQUE VALUE
2. Remove the instrument nacelle. See INSTRUMENT Fairing mount to steering head 20–30 ft-lbs 27.1–40.7 N·m
NACELLE: FRAME MOUNTED FAIRING MODELS locknuts: Frame-mounted
(Page 3-126). fairing
Fairing support 40–50 in-lbs 4.5–5.7 N·m
3. See Figure 3-159. Remove locknuts (3) and screws (1). bracket-to-engine guard
4. Remove fairing mounting bracket. screws
Fairing support 48–60 in-lbs 5.4–6.8 N·m
sm08370 bracket-to-inner fairing screws:
4 Frame-mounted fairing
3 Inner fairing-to-mount screws: 96–144 in-lbs 10.9–16.3 N·m
Frame-mounted fairing

Fairing Mounting Bracket

2 NOTE
3 • Pull main harness branches through center of fairing
mounting bracket as it is moved into place.
1
• Route WSS cable between the upper and lower legs of inner
fairing mounting bracket to the right steering head caddy.
5
1. See Figure 3-159. Position fairing mounting bracket (5).

2. Position left (4) and right (2) main harness guides. Install
1. Screw (2) screws (1) from the right side. Install flange locknuts (3).
2. Right main harness guide Tighten to 20–30 ft-lbs (27.1–40.7 N·m).
3. Flange locknut (2)
4. Left main harness guide 3. Install the instrument nacelle. See INSTRUMENT
5. Fairing mounting bracket NACELLE: FRAME MOUNTED FAIRING MODELS
Figure 3-159. Fairing Mounting Bracket (Page 3-126).

3-132 94000383
4. Install inner fairing. 3. See Figure 3-160. Release main harness connector anchor
from hole (1) in radio mount bracket.
Inner Fairing Assembly 4. Remove two screws (3).

1. Place protective material on top of front fender to protect 5. Remove air duct assembly (2).
paint. Rest inner fairing on front fender.
Installation
2. See Figure 3-158. Move inner fairing into place while NOTE
feeding end of harnesses through opening. Engage tabs See Figure 3-160. Hole in tab must engage pin on inner fairing
on bottom of inner fairing with slots (5) in fairing mount. (see arrow).

3. Install fairing support brackets (4) to fairing with screws

1. Install air duct assembly (2). Secure with two screws (3).
(7) and washers. Do not tighten.
Tighten to 8–15 in-lbs (0.9–1.7 N·m).
4. Start four screws (3). Adjust inner fairing until level. Tighten
2. Secure main harness connector to hole (1) in radio mount
to 96–144 in-lbs (10.9–16.3 N·m).
bracket.
5. Secure fairing support brackets:
3. Install headlamp. See HEADLAMP (Page 9-16).
a. Apply LOCTITE 243 (blue) to the threads of screws
4. Install outer fairing. See OUTER FAIRING AND
(1). Start screws.
WINDSHIELD: FRAME MOUNTED FAIRING MODELS
b. Locate support brackets on engine guard (Page 3-127).
approximately 6.125 in (155.6 mm) from center of
engine guard. Tighten to 40–50 in-lbs (4.5–5.7 N·m). sm08374
1
2
6. Tighten fairing support bracket screws to 48–60 in-lbs
(5.4–6.8 N·m).

7. See Figure 3-157. Locate the branch of the main harness

with the radio connector.

a. Route it through the opening on the right side of the 3

fairing mount.

b. Mate connectors (1, 4). Secure connector (4) to the

anchor.

8. Route the remaining main harness through the left opening

of the fairing mount. 1. Main harness connector anchor hole
2. Duct assembly
a. Mate connectors (2, 3). 3. Screw
Figure 3-160. Air Duct Assembly (right side shown)
b. Secure connector (3) to the anchor.
Repair Air Duct
9. Install the headlamp. See HEADLAMP (Page 9-16).
1. Remove air duct assembly from inner fairing.
10. Install outer fairing. See OUTER FAIRING AND
WINDSHIELD: FRAME MOUNTED FAIRING MODELS 2. See Figure 3-161. Disconnect linkage (3).
(Page 3-127).
3. Remove screws (1). Remove button assembly (2).
FAIRING AIR DUCT
4. Remove retaining ring (6). Remove shaft (4).
FASTENER TORQUE VALUE
5. Install shaft with new retaining ring. Connect link.
Fairing air duct latch screws 9–13 in-lbs 1–1.5 N·m
Fairing air duct to inner fairing: 8–15 in-lbs 0.9–1.7 N·m
6. Install button assembly with three screws. Tighten to
Frame-mounted fairing
9–13 in-lbs (1–1.5 N·m).

Removal 7. Apply a small amount of ELECTRICAL CONTACT

1. Remove outer fairing. See OUTER FAIRING AND LUBRICANT to the pivot journals.
WINDSHIELD: FRAME MOUNTED FAIRING MODELS
(Page 3-127). 8. Install linkage.
2. Remove headlamp. See HEADLAMP (Page 9-16).

94000383 3-133
9. Install air duct assembly to inner fairing. 2. Remove air deflectors. See Air Deflectors (Page 3-140).

3. Remove outer fairing. See OUTER FAIRING AND

sm08428
2 3 WINDSHIELD: FRAME MOUNTED FAIRING MODELS
(Page 3-127).

1 NOTE
4 The graphic shows only the right side screws. Remove the
same screws from the left side.

5 4. Remove inner fairing assembly. See INNER FAIRING:

FRAME MOUNTED FAIRING MODELS, Removal
(Page 3-131). Lay on protective surface with gauge faces
down.
6
5. Separate gauge jumper connectors (5, 6) from the fairing
harness.
1. Screw (3)
2. Button assembly
6. See Figure 3-162. Remove radio support bracket upper
3. Linkage
screws (4).
4. Shaft
5. Duct housing
6. Retaining ring 7. Remove speaker enclosure screws (2, 9).

Figure 3-161. Air Duct Repair (right side shown)

8. Remove radio support bracket lower screws (7).
INNER FAIRING SHELL REPLACEMENT
NOTE
FASTENER TORQUE VALUE Use caution when lifting fairing from support structure assembly
Fairing air duct to inner fairing: 8–15 in-lbs 0.9–1.7 N·m to prevent speaker damage.
frame mounted fairing
Fairing speaker enclosure to 48–60 in-lbs 5.4–6.8 N·m 9. Remove fairing air duct screws (8).
fairing screws
Gauges, 2 inch diameter 8–15 in-lbs 0.9–1.7 N·m 10. Lift inner fairing support structure assembly off from the
gauge screws fairing shell. Carefully set aside.
Power outlet, front 13–17 in-lbs 1.5–1.9 N·m
Radio support bracket to inner 48–60 in-lbs 5.4–6.8 N·m 11. Remove storage compartment screws (3). Remove storage
fairing screws: FLTR compartments.
Storage compartment screws 48–60 in-lbs 5.4–6.8 N·m
12. Transfer fairing power outlet to new fairing shell. Tighten
Removal to 13–17 in-lbs (1.5–1.9 N·m).

NOTE
• To avoid scratches or other damage, place protective
material over front fender and fuel tank.
• Never lift the fairing assembly by the radio face.
1. Prepare a protective work surface large enough to lay the
inner fairing assembly on.
13. Transfer 2-inch gauges to new fairing shell. Tighten to
8–15 in-lbs (0.9–1.7 N·m).
14. Transfer storage compartment doors and hinges to new
fairing shell. See STORAGE COMPARTMENTS: FRAME
MOUNTED FAIRING MODELS (Page 3-138).

3-134 94000383
 sm08384
4

5
6

3
2

8
1
9

1. Air deflector upper screw 6. Voltmeter jumper connector

2. Speaker enclosure screw (socket head) 7. Radio support bracket lower screw (Torx head)
3. Storage compartment screw (socket head) 8. Fairing air duct screw
4. Radio support bracket upper screw (Torx head) 9. Speaker enclosure screw (socket head)
5. Fuel gauge jumper connector
Figure 3-162. Inner Fairing Shell Fasteners (right side shown)
9. Install inner fairing assembly. See INNER FAIRING:
Installation FRAME MOUNTED FAIRING MODELS, Installation
(Page 3-132).
1. Place new inner fairing shell face-down on a protective
surface.
10. Install outer fairing. See OUTER FAIRING AND
WINDSHIELD: FRAME MOUNTED FAIRING MODELS
2. Install storage compartments with screws (3). Tighten to (Page 3-127).
48–60 in-lbs (5.4–6.8 N·m).
11. Install air deflectors. See Air Deflectors (Page 3-140).
3. Place support structure onto fairing shell. Engage pins on
fairing vents into fairing shell.
RADIO SUPPORT BRACKET
4. See Figure 3-162. Install radio support bracket upper
screws (4). Tighten to 48–60 in-lbs (5.4–6.8 N·m). FASTENER TORQUE VALUE
Inner fairing to mount screws: 96–144 in-lbs 10.9–16.3 N·m
5. Install speaker enclosure screws (2, 9). Tighten to frame-mounted fairing
48–60 in-lbs (5.4–6.8 N·m). Radio support bracket to inner 48–60 in-lbs 5.4–6.8 N·m
fairing screws: FLTR
6. Install radio support bracket lower screws (5). Tighten to
48–60 in-lbs (5.4–6.8 N·m). Removal
1. Place protective material on front fender.
7. Install fairing air duct screws (8). Tighten to 8–15 in-lbs
(0.9–1.7 N·m). 2. Remove outer fairing. See OUTER FAIRING AND
WINDSHIELD: FRAME MOUNTED FAIRING MODELS
(Page 3-127).
8. Mate gauge jumper connectors (5, 6).
3. Remove headlamp. See HEADLAMP (Page 9-16).

94000383 3-135
4. Remove radio. See Boom! Box Infotainment System 5. Install fairing air ducts. See INNER FAIRING: FRAME
(Page 9-68). MOUNTED FAIRING MODELS (Page 3-131).
5. Remove speaker enclosures. See Boom! Box Infotainment
System (Page 9-68). 6. Install speaker enclosures. See Boom! Box Infotainment
System (Page 9-68).
6. Remove fairing air ducts. See INNER FAIRING: FRAME
MOUNTED FAIRING MODELS (Page 3-131). 7. Install radio. See Boom! Box Infotainment System
7. Release connector retainers and wire retainers from top (Page 9-68).
of radio support bracket. Move harnesses out of the way.
8. Secure connector anchors and wire anchors to top of radio
8. Release left and right main harness connector anchors.
support bracket. See FAIRING HARNESS, Harness
Separate connectors.
Service: Frame Mounted Fairing (Page 9-92).
9. Draw branches of main harness to front of inner fairing
through openings in fairing bracket. 9. See Figure 3-157. Locate the branch of the main harness
10. See Figure 3-163. Remove four screws (1). with the radio connector.

11. Remove four screws (3).

a. Route it through the opening on the right side of the
12. Lift bracket (2) following the angle of the fairing mount. fairing mount.
Remove radio support bracket while feeding harnesses
through center opening. b. Mate connectors (1, 4). Secure connector (4) to the
anchor.
Installation
10. Route the remaining main harness through the left opening
1. Set the radio support bracket in place on the inner fairing. of the fairing mount.
Verify the two tabs on the bottom of the bracket engage
the slots in the fairing mount.
a. Mate connectors (2, 3).

2. See Figure 3-163. Install four screws (3) finger-tight. b. Secure connector (3) to the anchor.

3. Install four screws (1). Tighten to 48–60 in-lbs 11. Install headlamp. See HEADLAMP (Page 9-16).
(5.4–6.8 N·m).
12. Install outer fairing. See OUTER FAIRING AND
4. Tighten screws (3) to 96–144 in-lbs (10.9–16.3 N·m). WINDSHIELD: FRAME MOUNTED FAIRING MODELS
(Page 3-127).

3-136 94000383
 sm08385

2
1

1. Radio support bracket upper screws (4) 3. Fairing mounting screws (4)
2. Radio support bracket
Figure 3-163. Radio Support Bracket

94000383 3-137
STORAGE COMPARTMENTS: FRAME MOUNTED FAIRING MODELS 3.43
STORAGE COMPARTMENT, DOOR AND 4. Tighten screws (1) to 48–60 in-lbs (5.4–6.8 N·m).
HINGE
5. Secure and connect harness.
FASTENER TORQUE VALUE
Fairing air deflector screws: 8–15 in-lbs 0.9–1.7 N·m 6. Install fairing support bracket:
Frame-mounted fairing
Fairing support 40–50 in-lbs 4.5–5.7 N·m a. Secure fairing support bracket to inner fairing with
bracket-to-engine guard screw (3) and washer. Tighten to 48–60 in-lbs
screws (5.4–6.8 N·m).
Fairing support 48–60 in-lbs 5.4–6.8 N·m b. Tighten fairing support bracket screws (4) to
bracket-to-inner fairing screws: 40–50 in-lbs (4.5–5.7 N·m).
Frame-mounted fairing
Storage compartment door 8–15 in-lbs 0.9–1.7 N·m 7. Install outer fairing. See OUTER FAIRING AND
hinge screws WINDSHIELD: FRAME MOUNTED FAIRING MODELS
Storage compartment door 8–15 in-lbs 0.9–1.7 N·m (Page 3-127).
screws
Storage compartment screws 48–60 in-lbs 5.4–6.8 N·m
sm08371
1
Replace Storage Compartment Door 5
1. See Figure 3-165. Hold door (1) open. Remove four screws
(4). 1 2

2. Apply LOCTITE 243 (blue) to the threads of screws (4). 1

3. Install new door with four screws (4).

1
3
4. Align door. Tighten to 8–15 in-lbs (0.9–1.7 N·m).

4
Remove Media Storage Compartment
1. Remove outer fairing. See OUTER FAIRING AND
1. Socket head screws (4)
WINDSHIELD: FRAME MOUNTED FAIRING MODELS
2. Glove box
(Page 3-127).
3. Screw, support bracket
2. Release harness: 4. Screw, support bracket clamp (2)
5. Air deflector upper screw
a. Left side: Release accessory power connector harness
from features on storage compartment. Figure 3-164. Media Storage Compartment

b. Right side: Release media cable retainer from upper Remove Storage Compartment Door/Hinge
speaker enclosure. Disconnect from radio.
1. Remove storage compartment.
3. See Figure 3-164. Remove fairing support bracket: 2. See Figure 3-165. Remove screws (4) and door (1).
a. Loosen two screws (4) securing fairing support bracket 3. Remove screws (3). Remove hinge assembly (2).
to engine guard.
NOTE
b. Remove screw (3) and washer securing fairing support
Hinge cannot be repaired. Replace assembly upon failure.
bracket to inner fairing.

4. Remove air deflector upper screw (5). Install Storage Compartment Door/Hinge
5. Remove four screws (1). Remove media storage NOTE
compartment.
See Figure 3-165. If removed, install new storage compartment
door bumpers (5) in door.
Install Media Storage Compartment
1. See Figure 3-164. Route harness into position as storage 1. Install hinge with four screws (3). Tighten to 8–15 in-lbs
compartment is moved into place. (0.9–1.7 N·m).

2. Position storage compartment. Start four screws (1). 2. Apply LOCTITE 243 (blue) to the threads of screws (4).

3. Install air deflector with air deflector upper screw (5). 3. Place storage compartment door into position. Secure with
Tighten to 8–15 in-lbs (0.9–1.7 N·m). four screws (4). Tighten to 8–15 in-lbs (0.9–1.7 N·m).

3-138 94000383
4. Install storage compartment.

Storage Compartment Media Cable

1. Release media cable retainer from upper speaker
enclosure. Disconnect from radio.
2. Remove right storage compartment.
3. Compress rubber grommet and push into storage
compartment.
4. Install storage compartment.
5. Route media cable to radio. Secure to upper speaker
enclosure with anchored cable strap.

sm08372

5 2

4
3
1. Door
2. Hinge assembly
3. Hinge screws (4)
4. Door screws (4)
5. Bumper (2)
Figure 3-165. Glove Box Door and Hinge

94000383 3-139
AIR DEFLECTORS 3.44
FAIRING AIR DEFLECTORS sm08380

FASTENER TORQUE VALUE

Fairing air deflector screws: 8–15 in-lbs 0.9–1.7 N·m
Frame-mounted fairing
Fairing air deflector screws: 15–25 in-lbs 1.7–2.8 N·m
fork mounted fairing

Removal: Fork-mounted fairing models

1. See Figure 3-166. Remove three screws to release air
deflector at side of inner fairing.
2. Repeat previous step on opposite side.

Installation: Fork-mounted fairing models

Figure 3-167. Air Deflector (right side shown)
1. See Figure 3-166. Install three screws to fasten air MID-FRAME AIR DEFLECTORS
deflector at side of inner fairing. Alternately tighten screws
to 15–25 in-lbs (1.7–2.8 N·m).
FASTENER TORQUE VALUE
Mid-frame air deflector screws 25–35 in-lbs 2.8–4 N·m
2. Repeat previous step on opposite side.

Removal
sm07499
1. See Figure 3-168. Release rear spark plug wire from
retainer (3).
2. Remove screws (5) and washers (4).
3. Remove deflector from frame.

Installation
1. See Figure 3-168. Install air deflector (1 or 6) with washers
(4) and screws (5). Tighten to 25–35 in-lbs (2.8–4 N·m).

a. Install upper-right screw through hole (2).

2. Secure rear spark plug wire in retainer (3).

Figure 3-166. Air Deflector (Adjustable)

Removal: Frame-mounted fairing models

1. See Figure 3-167. Remove two screws.
2. Repeat previous step on opposite side.

Installation: Frame-mounted fairing models

1. See Figure 3-167. Install two screws to fasten air deflector
at side of inner fairing. Alternately tighten screws to
8–15 in-lbs (0.9–1.7 N·m).

2. Repeat previous step on opposite side.

3-140 94000383
 sm08768

3
4

2 5
1
7
6
3 4
5

1. Right air deflector

2. Upper-right mount hole
3. Spark plug cable retainer
4. Washer (4)
5. Screw (4)
6. Left air deflector
7. Clinch nut (2)
Figure 3-168. Mid-Frame Air Deflector

94000383 3-141
WINDSHIELD: ROAD KING MODELS 3.45
WINDSHIELD WINDSHIELD WINDOW

Remove PART NUMBER TOOL NAME

HD-25070 ROBINAIR HEAT GUN
1. Raise both wireform latch springs.
2. Move the top of the windshield forward to disengage from FASTENER TORQUE VALUE
the upper grommets. Windshield window screws: 20–25 in-lbs 2.3–2.8 N·m
3. Raise the windshield to disengage from the lower Road King models
grommets.
Removal
Install 1. Remove windshield. See WINDSHIELD: ROAD KING
1. Firmly seat the bottom of the windshield bracket to engage MODELS (Page 3-142).
the lower grommets. 2. Place windshield front side up on clean padded surface.
2. Push the top of the windshield rearward to engage the top 3. See Figure 3-169. Remove acorn nuts (3) and screws (1,
grommets. 2) from each vertical brace to release mounting bracket.
3. Push down on the wireform latch springs so that they 4. Remove three remaining screws from horizontal brace.
overhang the rubber grommets.

sm03565

3 9

8
1
6

5 2

8
1
4

1. Screws, short (7) 6. Horizontal brace (front)

2. Screws, long (2) 7. Horizontal brace (rear)
3. Acorn nuts (9) 8. Two-sided adhesive strip
4. Vertical brace (right side) 9. Windshield
5. Mounting bracket (right side)
Figure 3-169. Windshield Assembly
WARNING
5. Carefully pry braces (4, 6, 7) from windshield. Discard
windshield. Be sure to follow manufacturer's instructions when using
the Robinair Heat Gun or any other radiant heating device.
6. Remove adhesive strip from braces: Failure to follow manufacturer's instructions can cause a
fire, which could result in death or serious injury. (00379a)
a. Liberally apply 3M GENERAL PURPOSE ADHESIVE
REMOVER. Allow to soak. b. Apply heat with ROBINAIR HEAT GUN (PART
NUMBER: HD-25070).

3-142 94000383
 c. Peel adhesive strip from braces.
sm02882
9
d. Remove any remaining adhesive with 3M GENERAL
PURPOSE ADHESIVE REMOVER. 3

Installation
1
1. See Figure 3-169. Remove paper backing from one side
of each adhesive strip (8) and apply to windshield side of
5
each brace (4, 6, 7).
2
2. Place new windshield with front side down on clean
padded surface. 8
3. Remove paper backing from adhesive strip on thicker
horizontal brace (7). Align holes in brace with holes in
windshield and press brace into position.
4 7
4. Turn windshield over (front side up).
5. Remove paper backing from adhesive strip on thinner
horizontal brace (6). Align holes in brace with holes in
windshield. Edges of inner and outer braces must be even.
Press into position.
6
6. Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue) to three short
screws (1). Install screws through the middle and outer
holes of the horizontal braces. Loosely install acorn nuts Figure 3-170. Windshield Torque Sequence
(3) on rear side.

7. Remove paper backing from adhesive strip on vertical

brace . With the stepped end overlapping the horizontal
brace (6) and the slight bend angled outward, align holes
in brace with holes in windshield. Press into position.

8. Position mounting bracket (5) on rear side of windshield

with the wireform facing inboard.

9. Secure vertical brace:

a. Apply LOCTITE 243 MEDIUM STRENGTH

THREADLOCKER AND SEALANT (blue) to two short
screws (1) and one long screw (2).

b. Install the longer screw at the stepped end where

the vertical brace overlaps the horizontal brace.

c. Install short screws in the remaining holes.

d. Loosely install acorn nuts.

10. Install second vertical brace and mounting bracket in a

similar manner.

11. See Figure 3-170. Following the sequence shown, tighten

all screws to 20–25 in-lbs (2.3–2.8 N·m).

12. Install windshield. See WINDSHIELD: ROAD KING

MODELS (Page 3-142).

94000383 3-143
HEADLAMP NACELLE: ROAD KING MODELS 3.46
REMOVAL 9. Loosen screw (3) until nut (5) and flat washer are near the
end of screw.
1. Remove windshield. See WINDSHIELD: ROAD KING 10. Lift the handlebar clamp shroud (4). Pull rearward through
MODELS (Page 3-142). the gap to remove shroud.
2. Loosen acorn nuts. Do not remove acorn nuts now. 11. Remove acorn nuts, grommets and clutch cable P-clamp
Remove the auxiliary/fog lamp bracket. See from the fork bracket studs.
AUXILIARY/FOG LAMPS AND BRACKETS (Page 9-18).
12. See Figure 3-172. Disconnect accessory switch (1) and
3. FLHP: auxiliary/fog lamp switch (2) connectors.
a. Remove acorn nuts securing speedometer bracket. 13. Remove the headlamp nacelle (8) housings.
Remove speedometer and hang over handlebar.
NOTE
b. Remove nut securing audio jack (left side). See ACCESSORY SWITCHES (Page 9-42) for nacelle switch
replacement.
4. Remove screw securing the headlamp door (chrome ring).
Remove the headlamp door.
sm07973
5. See Figure 3-171. Remove eight screws (10) to free the
headlamp assembly (9).
1
sm07536
2 3
1 4
6

2
5 7

12
8

1. Accessory switch connector

2. Auxiliary/fog lamp switch connector
Figure 3-172. Nacelle Switch Connectors

9 INSTALLATION

FASTENER TORQUE VALUE

Handlebar clamp shroud 10–20 in-lbs 1.1–2.3 N·m
screws
11 Headlamp door screw 9–18 in-lbs 1–2 N·m
10
Headlamp mount to nacelle 9–18 in-lbs 1–2 N·m
screws
Headlamp nacelle acorn nuts: 96–132 in-lbs 10.8–14.9 N·m
1. Fork lock plate FLHR/C
2. Screw (2) Headlamp nacelle chrome 15–20 in-lbs 1.7–2.3 N·m
3. Screw strip flange nut
4. Handlebar clamp shroud Speedometer bracket acorn 72–108 in-lbs 8.1–12.2 N·m
5. Nut nuts: FLHP
6. Chrome strip
7. Flange nut NOTE
8. Nacelle
See Figure 3-171. Verify that trim strips (12) are installed to
9. Headlamp assembly
prevent chafing of the brake hose and/or handlebar switch
10. Screw (8)
wires.
11. Well nut (8)
12. Trim strip
1. Install headlamp nacelle (8) housings on fork brackets.
Figure 3-171. Headlamp Nacelle Assembly
Install grommets. Start acorn nuts. Also secure clutch cable
6. Disconnect headlamp connectors. Remove the headlamp P-clamp on upper-left stud. If studs were removed:
assembly.
7. Remove flange nut (7). Remove chrome strip (6). a. Install acorn nut on the stud end without locking
agent. Install until stud is bottomed in nut.
8. Carefully pry off the fork lock plate (1). Remove two screws
(2). b. Install grommet on stud.

3-144 94000383
 c. Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue) to the
threads of stud.

d. While holding nacelle housing in place, start

stud/nut/grommet assembly in each hole.

e. Install auxiliary/fog lamp bracket.

f. Tighten to 96–132 in-lbs (10.8–14.9 N·m).

NOTE
See Figure 3-171. If disassembled, install screw (3), flat washer
and nut (5) on the handlebar clamp shroud (4).

2. Connect accessory switch and auxiliary/fog lamp switch

connectors.

3. See Figure 3-171. Install the handlebar clamp shroud (4):

a. Slide the handlebar clamp shroud screw forward into

the gap.

b. Position the shroud over the flange at the top of the

nacelle.

c. Install screws (2).

4. Tighten screws (2, 3) to 10–20 in-lbs (1.1–2.3 N·m). Install

fork lock plate (1).

5. Install chrome strip (6). Secure with flange nut (7). Tighten
to 15–20 in-lbs (1.7–2.3 N·m).

6. Tighten acorn nuts to 96–132 in-lbs (10.8–14.9 N·m).

7. Connect headlamp connector.

8. Install headlamp assembly. Secure with eight screws (10).

Tighten to 9–18 in-lbs (1–2 N·m).

9. Install headlamp door. Secure with screw. Tighten to

9–18 in-lbs (1–2 N·m).

10. FLHP:

a. Install speedometer and bracket with acorn nuts.

Tighten to 72–108 in-lbs (8.1–12.2 N·m).

b. Install audio jack. Tighten securely.

11. Install the auxiliary/fog lamp bracket. Capture the clutch

cable P-clamp on the upper left stud. See AUXILIARY/FOG
LAMPS AND BRACKETS (Page 9-18).

12. Install windshield. See WINDSHIELD: ROAD KING

MODELS (Page 3-142).

94000383 3-145
FRONT FENDER 3.47
REMOVAL sm07480

FASTENER TORQUE VALUE

Fender, front, fender tip lamp 20–25 in-lbs 2.3–2.8 N·m
nuts
Fender, front, fender tip 20–25 in-lbs 2.3–2.8 N·m
screws
Fender, front, mounting 16–20 ft-lbs 21.7–27.1 N·m 2
screws 3
Fender, front, trim skirt 10–15 in-lbs 1.1–1.7 N·m 1
screws/nuts
Fender, front, trim strip T-bolt 10–15 in-lbs 1.1–1.7 N·m
nut

1. See Figure 3-173. If equipped with fender tip lamp, remove 1. Screws
outer fairing and disconnect fender tip lamp connector. 2. Fork
2. Remove cable straps as necessary. 3. Fender

3. Draw connector housing down to fender area. Figure 3-174. Front Fender Fasteners

4. See Figure 3-174. Remove screws (1). Remove fender. Repair

sm07479 Refer to Figure 3-175 and Table 3-19 for fender disassembly
and assembly.

NOTE
Fender tip lamp wires route under the left trim strip, through
rear oval hole into the fender cavity, then exit through grommet
toward the rear of the fender. Tuck fender tip lamp wires
between the fender mounting bracket and fender body. See
FENDER TIP LAMPS (Page 9-26).

Figure 3-173. Front Fender Tip Lamp Connector

3-146 94000383
 sm07616

4
1

Figure 3-175. Front Fender

NOTE
Table 3-19. Front Fender Faster Torque Values If fender appears twisted or misaligned, loosen screws and
ITEM TORQUE retighten.
1 10–15 in-lbs (1.1–1.7 N·m)
1. Install fender on fork sliders and start screws. Tighten to
2 16–20 ft-lbs (21.7–27.1 N·m)
16–20 ft-lbs (21.7–27.1 N·m).
3 20–25 in-lbs (2.3–2.8 N·m)
4 20–25 in-lbs (2.3–2.8 N·m) 2. See Figure 3-176. If equipped with fender tip lamp:
5 10–15 in-lbs (1.1–1.7 N·m)
a. Mate connector. Secure harness with two new cable
straps (1). See FENDER TIP LAMPS (Page 9-26).
INSTALLATION
b. Install outer fairing.
FASTENER TORQUE VALUE
Fender, front, mounting 16–20 ft-lbs 21.7–27.1 N·m
screws

NOTE
• The contact area of the fork and fender mounting surfaces
must be free from any paint or foreign substance. It must
be metal-to-metal contact. Paint or debris in this area can
result in loosening of fastener torque.
• If reusing the screws, apply LOCTITE 243 MEDIUM
STRENGTH THREADLOCKER AND SEALANT (blue) to
properly cleaned screws.
• If fender is being installed as part of a fork or wheel
installation, tighten fender screws after all other components
are installed.
94000383 3-147
 sm07482

1. WSS cable, fender tip lamp cable, brake hose

2. WSS cable, brake hose
Figure 3-176. Secure Cables and Brake Hose

3-148 94000383
REAR FENDER 3.48
REMOVAL sm06606

1. Remove seat. See SEAT (Page 3-96).

2. Remove saddlebags.
3. All except FLHX, FLHXS, FLTRX, FLTRXS: See Figure
3-177. Disconnect rear lighting connector from front of
fender. Release connector from fender.
4. FLHX, FLHXS, FLTRX, FLTRXS: See Figure 3-178 and
Figure 3-179. Remove shield and disconnect lights harness
from rear fascia lamp. Release lights harness from
retainers on left fascia and left saddlebag support casting.
5. If equipped, remove Tour-Pak and Tour-Pak support. See
TOUR-PAK (Page 3-103).
6. Remove saddlebag supports and support castings. See
SADDLEBAG SERVICE (Page 3-99).
Figure 3-178. Rear Fender Lights Connector: FLHX, FLHXS,
7. See Figure 3-180. Remove fender mounting screws (7)
FLTRX, FLTRXS
from both sides. Fender will drop when screws are
removed. sm06617

8. Carefully roll the fender back and out of the frame. 1

sm04825

2
3

1. Upper clips (3)

2. Molded clip (2)
3. Antenna mount
Figure 3-179. Rear Fender Lamps Harness and Antenna
Cable: FLHX, FLHXS, FLTRX, FLTRXS

Figure 3-177. Rear Fender Lights Connector (models with

under fender wiring)

94000383 3-149
 sm07483
3 4

2 5

7
6

1. Nut (4) 6. Stud plate

2. Washer (4) 7. Screw, fender to rear frame (4)
3. Retaining ring 8. Seat retention nut
4. Flange nut 9. Mounting boss (4)
5. Nylon washer
Figure 3-180. Rear Fender
FENDER REPAIR INSTALLATION

FASTENER TORQUE VALUE FASTENER TORQUE VALUE

Fender, rear, mounting boss 15–20 ft-lbs 20.3–27.1 N·m Fender, rear, mounting screws 15–20 ft-lbs 20.3–27.1 N·m
Fender, rear, stud plate 60–96 in-lbs 6.8–10.8 N·m
1. Verify that rubber cushion adhered to inside of each
saddlebag support bracket is in place.
Mounting Hardware
1. See Figure 3-180. Remove nut (1), washer (2) and 2. Carefully roll the fender into position.
mounting boss (9).
3. FLHX, FLHXS, FLTRX, FLTRXS: Verify that the rear
2. Install new components as necessary. Tighten nut (1) to fender lights harness is routed below the front left fender
15–20 ft-lbs (20.3–27.1 N·m). screw location.

Stud Plate 4. See Figure 3-180. Install four fasteners (7). Tighten to
15–20 ft-lbs (20.3–27.1 N·m).
1. See Figure 3-180. Remove flange nuts (4).
5. Install saddlebag supports and support castings. See
2. Remove nylon washers (5) and stud plate (6). SADDLEBAG SERVICE (Page 3-99).

3. Install new components as necessary. Tighten nuts (4) to 6. If equipped, install Tour-Pak support and Tour-Pak. See
60–96 in-lbs (6.8–10.8 N·m). TOUR-PAK (Page 3-103).

Lights and Harnesses 7. All except FLHX, FLHXS, FLTRX, FLTRXS: See Figure
3-177. Connect rear fender lights connector. Secure anchor
All except FLHX, FLHXS, FLTRX, FLTRXS: For service of in rear fender hole.
the tail lamps or harness, see Rear Lighting (Page 9-21).

FLHX, FLHXS, FLTRX, FLTRXS: For service of the rear fascia 8. FLHX, FLHXS, FLTRX, FLTRXS: See Figure 3-178 and
or fascia lamp, see REAR FASCIA (Page 3-152). For service Figure 3-179. Secure harness in retainers on left fascia
of the tail lamps or harness, see Rear Lighting (Page 9-21). and left saddlebag support casting. Connect rear fender
lights connector. Install shield.

3-150 94000383
9. Install seat. After installing seat, pull up on the seat to be
sure it is secure.

10. Install saddlebags.

WARNING
Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)

11. Verify rear lamp operation.

94000383 3-151
REAR FASCIA 3.49
REMOVAL NOTE
Stud plates installed in production use adhesive strips as an
1. Remove saddlebags. assembly aid. Carefully work stud plate free using a small putty
knife or gasket scraper.
2. See Figure 3-181. Remove six flange nuts (1).
3. Remove radio antenna mast. 4. Carefully pry stud plate (3) away from rear fender.
4. Release rear lamps harness from molded clips on left side
sm05882a
of fascia (2). 3
5. Remove shield (7). Disconnect rear lamps harness and 2
tail lamp jumper from fascia lamp (8).
6. Loosen nut (5). 4
7. Spread top of fascia (2) and pull downward to release
fascia from fender. Remove fascia lamp (8) if necessary.
8
INSTALLATION
1
FASTENER TORQUE VALUE 6 5
7
Fender, rear, support to fender 45–85 in-lbs 5.1–9.6 N·m
nut
Rear fascia flange nuts 30–45 in-lbs 3.4–5.1 N·m 1. Flange nut (6)
Rear fascia lamp screws 18–22 in-lbs 2–2.5 N·m 2. Fascia
3. Stud plate (2)
1. See Figure 3-181. If removed, install fascia lamp (8). 4. Fender support
Tighten screws to 18–22 in-lbs (2–2.5 N·m). 5. Nut
6. P-clip
2. Insert flange at top of fascia (2) between support (4) and 7. Shield
fender. Tighten nut (5) to 45–85 in-lbs (5.1–9.6 N·m). 8. Fascia lamp
Spread top of fascia to engage top studs. Figure 3-181. Rear Fascia

3. Apply a drop of LOCTITE 243 MEDIUM STRENGTH Installation

THREADLOCKER AND SEALANT (blue) to threads of
each stud. Install flange nuts (1). Tighten to 30–45 in-lbs 1. See Figure 3-181. Install new stud plate (3).
(3.4–5.1 N·m).
2. Install fender support (4).
4. Secure rear lamps harness in molded clips of left fascia.
Connect harness to fascia lamp. Connect tail lamp jumper a. Install P-clamp (6), washer and nut (5). Tighten to
to fascia lamp. Install shield (7). 45–85 in-lbs (5.1–9.6 N·m).

5. Install radio antenna mast. b. Secure lower fender support to saddlebag support
with screws and nuts. Tighten to 15–20 ft-lbs
(20.3–27.1 N·m).
6. Install saddlebags.

3. Install rear fascia (2). See REAR FASCIA (Page 3-152).

STUD PLATE
4. If removed, install rear wheel. See REAR WHEEL
FASTENER TORQUE VALUE (Page 3-18).
Fender, rear, support to fender 45–85 in-lbs 5.1–9.6 N·m
nut
REAR FASCIA LAMP
Saddlebag support to lower 15–20 ft-lbs 20.3–27.1 N·m
fender support screw
See Rear Lighting (Page 9-21) for fascia lamp service.

Removal
1. Remove rear wheel as necessary to gain access to fender
well. See REAR WHEEL (Page 3-18).
2. See Figure 3-181. Remove rear fascia (2).
3. Remove screws and nuts securing fender support (4) to
saddlebag support on both sides. Remove nut (5), flat
washer and P-clamp (6). Remove support.

3-152 94000383
REAR FRAME 3.50
REAR FRAME sm07546

FASTENER TORQUE VALUE

1
Battery tray screws 132–156 in-lbs 14.9–17.6 N·m
Left electrical caddy fastener 72–96 in-lbs 8.1–10.8 N·m
Rear frame to main frame 40–45 ft-lbs 54.2–61 N·m
fastener
Top caddy screws 72–96 in-lbs 8.1–10.8 N·m

Removal 2
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)

1. Raise the motorcycle.

2. Remove the seat, top caddy and battery. See Battery
Maintenance (Page 2-51). 1. Top caddy fasteners
3. Cut cable straps securing harnesses to rear frame. Move 2. Rear battery tray fasteners
harnesses aside. Record cable strap locations for Figure 3-182. Upper Caddy Fasteners
assembly.
sm05867
4. Remove Tour-Pak if equipped. See TOUR-PAK
(Page 3-103).
1
5. Remove luggage rack, Tour-Pak support or spacers as
equipped. See TOUR-PAK, Tour-Pak Support (Page 3-104).
6. Remove saddlebags, saddlebag supports and rear fender.
See REAR FENDER (Page 3-149). 2
7. Remove shock absorbers. See Rear Suspension
(Page 3-74).
8. See Figure 3-182. Remove two rear battery tray fasteners
(2). 3
9. Remove fastener securing left electrical caddy to rear 1. Rear frame
frame. 2. Fasteners (6)
10. See Figure 3-183. Remove six fasteners (2) and washers 3. Hardened washer (6)
(3) securing the rear frame (1). Figure 3-183. Subframe
11. Remove rear frame.

94000383 3-153
 sm05877

3 2
1 4

5 6

Figure 3-184. Rear Frame Torque Sequence

13. Install the saddlebags.
Installation
1. See Figure 3-183. Hold the rear frame in place. Start two Thread Repair
lower fasteners (2) and hardened washers (3). Install four NOTE
remaining upper fasteners and hardened washers. • Never re-tap the threaded holes in the rear frame to repair
damaged threads. Always use the following procedure to
2. See Figure 3-184. Tighten rear frame fasteners in provide repair.
sequence shown to 40–45 ft-lbs (54.2–61 N·m).
• If more than one threaded hole is damaged on a given side,
or if a thread repair has previously been done, replace the
3. Secure left electrical caddy to rear frame. Tighten to
rear frame. Never repair more than one hole per side.
72–96 in-lbs (8.1–10.8 N·m).
1. Remove the damaged fastener.
4. See Figure 3-182. Secure upper battery tray to rear frame.
Tighten to 132–156 in-lbs (14.9–17.6 N·m). 2. Drill out damaged threads. Install the appropriate size
thread repair insert.
5. Install shock absorbers. See Rear Suspension 3. Install new fastener with hardened washer. Tighten to the
(Page 3-74). specified torque.

6. Install rear fender and saddlebag supports. See REAR

FENDER (Page 3-149).

7. Install luggage rack, Tour-Pak support or spacers as

equipped. See TOUR-PAK, Tour-Pak Support (Page 3-104).

8. Install Tour-Pak if equipped. See TOUR-PAK (Page 3-103).

9. Install battery. See Battery Maintenance (Page 2-51).

10. See Figure 3-182. Install top caddy. Tighten to

72–96 in-lbs (8.1–10.8 N·m).

11. Secure harnesses to rear frame with cable straps. Locate

straps as noted during disassembly.

12. Install seat. After installing seat, pull up on the seat to be

sure it is secure.

3-154 94000383
FOOTBOARDS AND FOOTRESTS 3.51
RIDER FOOTBOARDS NOTE
Left side footboard fasteners also secure the jiffy stand bracket.
FASTENER TORQUE VALUE
Footboard bracket screws, 36–42 ft-lbs 48.8–56.9 N·m 1. If removing left side footboard, support the motorcycle to
rider remove weight from jiffy stand.
Footboard feeler screws 96–108 in-lbs 10.8–12.2 N·m 2. See Figure 3-185. Remove screw (5) and lockwasher (6).
Footboard pivot bolt nut, rider 60–80 in-lbs 6.8–9 N·m 3. Remove screw (8), lockwasher (9) and flange nut (11).

Removal 4. Remove footboard and bracket assembly.

NOTICE Installation
When lifting a motorcycle using a jack, be sure jack 1. See Figure 3-185. Install footboard and bracket assembly
contacts both lower frame tubes where down tubes and and secure with screws (5, 8), lockwashers (6, 9), and
lower frame tubes converge. Never lift by jacking on flange nut (11).
cross-members, oil pan, mounting brackets, components
or housings. Failure to comply can cause serious damage 2. Tighten to 36–42 ft-lbs (48.8–56.9 N·m).
resulting in the need to perform major repair work. (00586d)

sm05850
1 3 4
5
7 3
4
5
6

11 12
10
9
2 8 6 8

15 9
14
16
13

1. Rubber pad 9. Lockwasher

2. Footboard 10. Right forward bracket
3. Pivot screw nut (2) 11. Flange nut
4. Pivot screw (2) 12. Left rear bracket
5. Socket head screw, short 13. Jiffy stand bracket
6. Lockwasher 14. Left forward bracket
7. Right rear bracket 15. Footboard feeler
8. Socket head screw, long 16. Screw (2)
Figure 3-185. Rider Footboards (Typical) (Quantities shown are for each footboard)
2. See Figure 3-185. Low models: Remove screws (16).
Disassembly Remove feeler (15).
NOTE 3. See Figure 3-185. Remove nuts (3) and pivot screws (4)
If only replacing the rubber pad, refer to step 1, then see steps from underside of footboard.
3-4 under ASSEMBLY. 4. Remove footboard from brackets.

1. Tilt footboard upward. From bottom of footboard, use a

large flat blade screwdriver to push four rubber anchors
on pad up through holes in footboard.

94000383 3-155
Assembly sm02925a
2 3
NOTE
1
The bottoms of FLHX/FLTRX footboards are stamped L(eft)
or R(ight) to aid proper installation. 4

1. See Figure 3-185. Hold footboard into position between 9 5

brackets. Install pivot screws (4) with the nuts (3) on the 6
inboard side.

2. Install nuts (3) onto pivot screws. Tighten to 60–80 in-lbs

(6.8–9 N·m).

3. Low models: Install feeler (15) with screws (16). Tighten 8 7

to 96–108 in-lbs (10.8–12.2 N·m).

4. Moisten four rubber anchors on bottom of new pad (1)

with soapy water. 1. Rubber pad
2. Upper screw
5. Place pad into position on footboard. From bottom of 3. Lockwasher
footboard, use pliers to pull rubber anchors through holes 4. Steel ball
in footboard. 5. Spring
6. Footboard bracket
7. Lower screw
PASSENGER FOOTBOARD 8. Footboard
9. Pivot pin (2)
FASTENER TORQUE VALUE
Figure 3-186. Passenger Footboard
Footboard/footrest lower 48–72 in-lbs 5.4–8.1 N·m
fastener, passenger 3. Moisten rubber beads on pad with soapy water. Use needle
nose pliers to pull rubber beads through holes in footboard.
Footboard/footrest upper 36–42 ft-lbs 48.8–56.9 N·m
fastener, passenger 4. Engage nubs on inboard corners of pad with holes in
footboard.
Removal
Installation
See Figure 3-186. Remove screw (2), lockwasher (3), screw
(7) and footboard/bracket assembly from frame. NOTE
Passenger footboards can be installed to one of three positions.
Disassembly To install footboards in a new position, remove plastic plugs
from holes in frame.
1. See Figure 3-186. Use a small flat blade screwdriver to
push rubber beads on pad bottom through holes in
footboard. Remove pad. 1. If reusing screws, apply a drop of LOCTITE 243 MEDIUM
STRENGTH THREADLOCKER AND SEALANT (blue) to
2. Using a brass drift and mallet, tap two pivot pins (9) toward
the threads of each screw.
center of footboard and remove.
3. Remove footboard from footboard bracket. 2. See Figure 3-186. Secure bracket (6) with screw (2),
4. Remove steel ball (4) and spring (5). lockwasher (3) and screw (7).

Assembly a. Tighten upper screw (2) to 36–42 ft-lbs

(48.8–56.9 N·m).
1. See Figure 3-186. Place spring (5) and ball (4) into hole
in footboard bracket. b. Tighten lower screw (7) to 48–72 in-lbs
2. Place footboard into position on bracket and install pivot (5.4–8.1 N·m).
pins (9) from the outboard side. Using a brass drift and
mallet, tap pins until centered in lugs of bracket. PASSENGER FOOTREST: FLHX, FLHXS,
FLTRX, FLTRXS

FASTENER TORQUE VALUE

Footboard/footrest lower 48–72 in-lbs 5.4–8.1 N·m
fastener, passenger: FLHX,
FLHXS, FLTRX, FLTRXS
Footboard/footrest upper 36–42 ft-lbs 48.8–56.9 N·m
fastener, passenger: FLHX,
FLHXS, FLTRX, FLTRXS

3-156 94000383
 FASTENER TORQUE VALUE Installation
Footrest pad screw: FLHX, 15–20 ft-lbs 20.3–27.1 N·m NOTE
FLHXS, FLTRX, FLTRXS
Passenger footrests can be installed to one of three positions.
To install footboards in a new position, remove plastic plugs
Removal from holes in frame.
See Figure 3-187. Remove screw (9), lockwasher (10) and
shoulder screw (11) to remove footrest bracket (8) from frame. 1. Locate pin on footrest bracket into hole in frame.

Disassembly 2. Install shoulder screw (11). Tighten to 48–72 in-lbs

1. See Figure 3-187. Remove screw (1). Remove rubber pad (5.4–8.1 N·m).
(2) from footrest.
3. See Figure 3-187. Install screw (9) and lockwasher (10).
2. Remove footrest (3) from footrest mount.
Tighten to 36–42 ft-lbs (48.8–56.9 N·m).
3. Remove retaining ring (4) and pivot pin (5).
4. Remove footrest mount (6) and wave spring (7). PASSENGER FOOTREST: LOW MODELS

Assembly FASTENER TORQUE VALUE

Footboard/footrest lower 48–72 in-lbs 5.4–8.1 N·m
1. See Figure 3-187. Holding wave spring (7) in place with
fastener, passenger
concave side against bracket (8), install footrest (3) with
the rounded side of the pivot end up. Footboard/footrest upper 36–42 ft-lbs 48.8–56.9 N·m
fastener, passenger
2. Install pivot pin (5). Secure with new retaining ring (4). Footrest pad screw (FLHX, 15–20 ft-lbs 20.3–27.1 N·m
FLHXS, FLTRX, FLTRXS)
3. Install footrest onto footrest mount (6). Install rubber pad
(2) into footrest. Rotate footrest so that the rubber pad is Removal
topside. 1. See Figure 3-188. Remove screw (11).
2. Remove screw (9) and lockwasher (10). Remove footrest
4. Apply a drop of LOCTITE 243 MEDIUM STRENGTH
assembly.
THREADLOCKER AND SEALANT (blue) to threads of
screw (1) and install. Tighten to 15–20 ft-lbs
(20.3–27.1 N·m).
Disassembly
1. See Figure 3-188. Remove screw (1).

sm02926a 2. Remove footrest (3) with pad from footrest mount (6).
10 9 3. Remove rubber pad (2) from footrest.
8 4. Remove retaining ring (4) and pivot pin (5).
4
5. Remove footrest mount (6) and wave spring (7).

6 2 Assembly
1. See Figure 3-188. Holding wave spring (7) in place with
concave side against bracket (8), install footrest (3) with
the rounded side of the pivot end up.
3
5 NOTE
7 1
Certain orientations of the footrest/pad assembly cause contact
11 to the side cover when rotated up.

1. Socket screw 2. Install pivot pin (5). Secure with new retaining ring (4).
2. Rubber pad
3. Footrest 3. Install pad (2) onto footrest (3). Slide assembly onto
4. Retaining ring footrest mount (6) while aligning on spline.
5. Pivot pin
6. Footrest mount 4. Rotate footrest up to verify that there is no contact with
7. Wave spring the side cover.
8. Footrest bracket
9. Socket screw 5. Apply a drop of LOCTITE 243 MEDIUM STRENGTH
10. Lockwasher THREADLOCKER AND SEALANT (blue) to threads of
11. Shoulder screw screw (1) and install. Tighten to 15–20 ft-lbs
Figure 3-187. Passenger Footrest: FLHX, FLHXS and (20.3–27.1 N·m).
FLTRX, FLTRXS models

94000383 3-157
Installation sm08424
10 8
NOTE 9
Passenger footrests can be installed to one of three positions.
To install footboards in a new position, remove plastic plugs 2
from holes in frame. 4 5

1. See Figure 3-188. Install screw (11). Tighten to

48–72 in-lbs (5.4–8.1 N·m).
3
2. See Figure 3-188. Adjust to appropriate position. Install 6 7
screw (9) and lockwasher (10). Tighten to 36–42 ft-lbs
(48.8–56.9 N·m).

11
Replace Pad and Adjust Footrest 1
1. See Figure 3-188. Remove screw (1). 1. Socket screw
2. Rubber pad
2. Remove footrest (3) with pad from footrest mount. 3. Footrest
4. Retaining ring
NOTE 5. Pivot pin
6. Footrest mount
Certain orientations of the footrest/pad assembly cause contact
7. Wave spring
to the side cover when rotated up.
8. Footrest bracket
9. Socket screw
3. Remove rubber pad (2) from footrest. 10. Lockwasher
11. Shoulder screw
4. Install pad (2) onto footrest (3). Slide assembly onto Figure 3-188. Passenger Footrest: Low models
footrest mount (6) while aligning on spline.

5. Rotate footrest up to verify that there is no contact with

the side cover.

6. Apply a drop of LOCTITE 243 MEDIUM STRENGTH

THREADLOCKER AND SEALANT (blue) to threads of
screw (1) and install. Tighten to 15–20 ft-lbs
(20.3–27.1 N·m).

3-158 94000383
JIFFY STAND 3.52
REMOVE LEG sm05949

1. Support motorcycle upright. 1

2. See Figure 3-191. Extend jiffy stand to the down position.
Remove hex bolt (4), lockwasher (3), flat washer (2) and
leg stop (5).
3. Hold leg (8) forward beyond the normal down position and
remove end of spring (9) from leg. Remove leg from
bracket. Remove other end of spring from frame weldment.
4. Inspect parts for wear or damage. Replace if necessary. 3 2
INSTALL LEG

FASTENER TORQUE VALUE

Jiffy stand leg stop hex screw 15–20 ft-lbs 20.3–27.1 N·m

NOTE 1. Leg stop (longer side faces rear)

See Figure 3-190. Verify that end of spring enters hole from 2. Hex screw, lockwasher and flat washer
front of leg weldment. If end of spring enters hole from rear of 3. Bracket
weldment, spring coil will rub on leg when exercised. Figure 3-189. Leg Stop Orientation in Full Forward (Down)
Position
1. Apply ANTI-SEIZE LUBRICANT to area of leg that rotates
sm04761
within the bracket.

2. Install end of spring into hole in frame weldment. Insert

leg up through bracket. Hold leg forward beyond the normal
down position and install other end of spring into hole in
leg weldment.

WARNING
If leg stop is incorrectly installed, excessive wear can allow
vehicle to fall when rested on jiffy stand, which could result
in death or serious injury. (00479b)

3. See Figure 3-189. Holding leg at the normal forward (down)
position, install stop (1) with the stamped side down. Verify
5.
that the longer side of the stop faces the rear.
Figure 3-190. Rubber Stop and Spring Orientation
Verify that jiffy stand swings freely to the fully extended
and fully retracted positions.

4. Install flat washer, lockwasher and hex screw (2). Tighten
to 15–20 ft-lbs (20.3–27.1 N·m).
6. Remove support. Park motorcycle on a level surface on
jiffy stand.
NOTE
See Figure 3-190. Verify that rubber stop is installed in hole of
jiffy stand weldment to prevent damage to the painted finish.

JIFFY STAND BRACKET

FASTENER TORQUE VALUE

Jiffy stand bracket fasteners 36–42 ft-lbs 48.8–57 N·m

Removal
1. Support motorcycle upright.
2. Remove left rider footboard and support brackets. See
FOOTBOARDS AND FOOTRESTS (Page 3-155).
3. See Figure 3-191. Remove jiffy stand leg (8). See Jiffy
Stand, Remove Leg (Page 3-159).
4. Remove two fasteners (6) and lockwashers (7) to release
jiffy stand bracket from frame weldment.

94000383 3-159
 sm05856 sm05859a
3 1
4
2 2
5
1
6
7 3
10

8
9

1. Bracket
2. Flat washer
3. Lockwasher
4. Bolt
5. Stop 1. Connector location
6. Fastener (2) 2. Cable strap
7. Lockwasher (2) 3. Sensor fastener
8. Leg Figure 3-192. Jiffy Stand Interlock Sensor
9. Spring
10. Rubber stop Installation
Figure 3-191. Jiffy Stand Assembly
1. Move jiffy stand to full forward (down) position.
Installation
2. See Figure 3-192. Install sensor into bore of jiffy stand
1. See Figure 3-191. Install two fasteners (6) and lockwashers bracket.
(7) to secure front of bracket (1) to frame weldment.
3. If reusing fastener (3), apply a small dab of LOCTITE 243
2. Temporarily install footboard rear fastener to align rear of MEDIUM STRENGTH THREADLOCKER AND SEALANT
jiffy stand bracket but do not tighten. (blue) to threads before installation. Install fastener. Tighten
to 96–120 in-lbs (10.8–13.6 N·m).
3. Tighten front fasteners (6) to 36–42 ft-lbs (48.8–57 N·m).
4. Route connector and cable over top of frame weldment,
4. Install footrest. See FOOTBOARDS AND FOOTRESTS staying rear of front frame down tube, and to area below
(Page 3-155). voltage regulator.

5. Install jiffy stand leg. See Jiffy Stand, Install Leg 5. Connect jiffy stand interlock sensor connector and push
(Page 3-159). anchor into hole in front frame cross member.

6. Install new cable strap (2) to capture cable. Trim cable

JIFFY STAND INTERLOCK SENSOR strap.

FASTENER TORQUE VALUE

Jiffy stand interlock sensor 96–120 in-lbs 10.8–13.6 N·m
fastener

Removal
NOTE
See Figure 3-192. The sensor connector (1) is located below
the voltage regulator.

1. Push anchor on sensor connector from hole in front frame

cross member. Disconnect connector.
2. See Figure 3-192. Cut cable strap (2) to release cable.
3. Move jiffy stand to full forward (down) position.
4. Remove fastener (3). Pull sensor from jiffy stand bracket.

3-160 94000383
FRONT ENGINE MOUNT 3.53
PREPARE d. Verify the notches and tabs of engine mounts are
aligned.
1. Remove right side rider footboard. See FOOTBOARDS
AND FOOTRESTS (Page 3-155). e. Start screws (1).

2. Remove rear brake master cylinder and pedal. f. Install flange nut (5). Tighten to 50–60 ft-lbs
(67.8–81.3 N·m).
a. Remove screws securing master cylinder.
b. Remove locknut and flat washer securing brake pedal. 3. Tighten end cap fasteners (1) to 42–48 ft-lbs
c. Pull brake pedal/master cylinder assembly from pedal (56.9–65 N·m).
shaft.
4. Connect upper stabilizer link. Tighten to 30–35 ft-lbs
d. Allow assembly to hang from brake line.
(40.7–47.5 N·m).
e. Discard O-rings from each side of brake pedal lever
bore.
sm08585
5
REMOVE
1. Support the engine with a jack under the crankcase. Use
a wooden block to distribute pressure.
2. See Figure 3-193. Remove engine mounts.
a. Remove end cap fasteners (1). 4
b. Remove flange nut (5).
4
c. Remove engine mount bolt (2) with end cap (3).

3. Remove right engine mount (4).

4. Remove left mount (4). 3
a. Disconnect upper stabilizer link. 2
b. Hold engine toward right side of frame.
c. Remove left engine mount.

INSTALLATION
1
FASTENER TORQUE VALUE
1. End cap fastener
Engine mount end cap screws, 42–48 ft-lbs 56.9–65 N·m 2. Engine mount bolt
front 3. End cap
Engine mount flange nut 50–60 ft-lbs 67.8–81.3 N·m 4. Engine mount (2)
Engine stabilizer link screws 30–35 ft-lbs 40.7–47.5 N·m 5. Flange nut
Figure 3-193. Front Engine Mount
1. See Figure 3-193. Install left mount (4).
COMPLETE
a. Disconnect upper stabilizer link.
FASTENER TORQUE VALUE
b. Hold engine toward right side of frame. Brake master cylinder, rear, 126–150 in-lbs 14.2–17 N·m
mounting screws
c. Install left engine mount. Brake pedal shaft locknut 15–20 ft-lbs 20.3–27.1 N·m
d. Align notch in engine mount with tab on frame. 1. Install brake pedal/master cylinder assembly.

2. Install right engine mount (4). a. Apply a light coat of WHEEL BEARING GREASE to
the brake pedal shaft and bore.
a. Assemble engine mount bolt (2), end cap (3) and
engine mount (4). b. Install new O-ring on each side of pedal bore.

b. Align notch in engine mount with tab on end cap. c. Install brake pedal/master cylinder assembly on the
pedal shaft.
c. Install assembly until mount bolt exits the left side.
d. Install flat washer and new locknut.

94000383 3-161
 e. Install screws securing master cylinder. Tighten to
sm08586
126–150 in-lbs (14.2–17 N·m). 2

f. Tighten brake pedal shaft locknut to 15–20 ft-lbs

1 3
(20.3–27.1 N·m).

2. Install right side rider footboard. See FOOTBOARDS AND

FOOTRESTS (Page 3-155).
6
STABILIZER LINK
4
FASTENER TORQUE VALUE
Engine stabilizer bracket 50–60 ft-lbs 67.8–81.3 N·m
screws
Engine stabilizer link screws 30–35 ft-lbs 40.7–47.5 N·m

Remove
1. See Figure 3-194. Remove screws (1, 2) from each end
of stabilizer link (3).
2. Remove link.
5
3. Check each end of the stabilizer link for excessive wear.
The spherical ball end may rotate freely, but should not
have any lateral movement. Replace the link if lateral 1. Screw, link to bracket
movement exists. 2. Screw, link to frame
3. Stabilizer link
Install 4. Bracket
5. Screw (2)
1. Place washer (6) between stabilizer link (3) and bracket 6. Washer
(4). Figure 3-194. Engine Stabilizer

2. See Figure 3-194. Secure stabilizer link with screws (1,

2).

3. Tighten to 30–35 ft-lbs (40.7–47.5 N·m).

Stabilizer Link Bracket

1. See Figure 3-194. Disconnect stabilizer link from bracket
(4).

2. Remove two screws (5). Remove bracket from cylinder

head.

3. Attach bracket to cylinder head with screw (5). Tighten to

50–60 ft-lbs (67.8–81.3 N·m).

4. Attach stabilizer link to bracket with screw (1) and washer

(6).

5. Tighten to 30–35 ft-lbs (40.7–47.5 N·m).

3-162 94000383
MEDALLIONS, BADGES AND TANK EMBLEMS 3.54
REMOVAL INSTALLATION
1. Mark location of emblem with masking tape. NOTE
NOTE • Apply in ambient temperatures between 70–100 °F
(21–38 °C).
Wear protective gloves.
• Do not remove protective film from adhesive until ready to
2. Saw behind emblem with mono-filament fishing line or apply.
waxed dental floss to remove emblem. • Do not bend emblem to fit contour of mounting surface.
3. Use 3M GENERAL PURPOSE ADHESIVE REMOVER to
remove remaining foam backing tape and adhesive from 1. Test fit medallion in intended location.
mounting surface. a. Check medallion against curve of mounting surface.
NOTE b. Match left and right sides of fuel tank.
For maximum bond, surface must be clean and dry.
NOTE
4. Clean with a mixture of 50 percent isopropyl alcohol and • Protect adhesive from grease, oil, dust, dirt and fingerprints.
50 percent distilled water.
• Once applied, do not shift medallion.
NOTE
• The adhesive bonds in 72 hours at room temperature.
Apply medallion within minutes of cleaning.
2. Remove protective film from back of medallion.
5. Allow to dry completely.
3. Apply even pressure across entire surface with palms and
fingers of both hands. Hold in place for 15 seconds.
4. Wait 20 minutes before touching medallion.
5. Wait 24 hours before washing.

94000383 3-163
NOTES
SUBJECT PAGE NO.
4.1 FASTENER TORQUE VALUES ............................................................................................ 4-1
4.2 SPECIFICATIONS ................................................................................................................ 4-3
4.3 SERVICE WEAR LIMITS ...................................................................................................... 4-5
4.4 ENGINE OIL FLOW .............................................................................................................. 4-7
4.5 OIL PUMP OPERATION ..................................................................................................... 4-10
4.6 BREATHER OPERATION ................................................................................................... 4-12
4.7 OIL PRESSURE .................................................................................................................. 4-13
4.8 TROUBLESHOOTING ........................................................................................................ 4-14
4.9 OIL COOLER AND DOWNTUBE ........................................................................................ 4-16
4.10 OIL COOLANT LINES ....................................................................................................... 4-19
4.11 HOW TO USE THIS SECTION ......................................................................................... 4-21
4.12 PREPARE MOTORCYCLE FOR SERVICE ..................................................................... 4-22
4.13 ASSEMBLE MOTORCYCLE AFTER SERVICE ............................................................... 4-23
4.14 TOP END SERVICE ......................................................................................................... 4-24
4.15 CAM COMPARTMENT SERVICE ..................................................................................... 4-26
4.16 BOTTOM END SERVICE ................................................................................................. 4-27
4.17 REMOVE ENGINE ............................................................................................................ 4-28
4.18 INSTALL ENGINE ............................................................................................................. 4-29
4.19 UPPER ROCKER COVERS ............................................................................................. 4-30
4.20 LOWER ROCKER COVERS ............................................................................................ 4-32
4.21 BREATHERS .................................................................................................................... 4-33
4.22 ROCKER ARMS ............................................................................................................... 4-34
4.23 PUSHRODS, LIFTERS AND COVERS ............................................................................ 4-35
4.24 CYLINDER HEAD ............................................................................................................. 4-38

ENGINE
4.25 CYLINDERS ...................................................................................................................... 4-43
4.26 PISTONS .......................................................................................................................... 4-46
4.27 CAM COMPARTMENT AND COMPONENTS .................................................................. 4-51
4.28 OIL PUMP ......................................................................................................................... 4-56
4.29 CRANKCASE .................................................................................................................... 4-58
4.30 FLYWHEEL AND CONNECTING RODS .......................................................................... 4-66
4.31 OIL PAN ............................................................................................................................ 4-69
NOTES
FASTENER TORQUE VALUES 4.1
FASTENER TORQUE VALUES IN THIS
CHAPTER

The table below lists torque values for all fasteners presented
in this chapter.

FASTENER TORQUE VALUE NOTES

Breather screw 90–120 in-lbs 10.2–13.6 N·m 4.21 BREATHERS, Install
Cam chain tensioner fasteners 90–120 in-lbs 10.2–13.6 N·m 4.27 CAM COMPARTMENT AND COMPONENTS,
Install
Cam cover screws 90–120 in-lbs 10.2–13.6 N·m 4.27 CAM COMPARTMENT AND COMPONENTS,
Complete
Cam needle bearing installation maxim- 25 ft-lbs 33.9 N·m 4.27 CAM COMPARTMENT AND COMPONENTS,
um torque Camshaft Needle Bearings
Cam sprocket screw, final torque 34 ft-lbs 46.1 N·m 4.27 CAM COMPARTMENT AND COMPONENTS,
Install
Apply LOCTITE 262 HIGH STRENGTH THREAD-
LOCKER AND SEALANT (red)
Cam sprocket screw, first torque 15 ft-lbs 20.3 N·m 4.27 CAM COMPARTMENT AND COMPONENTS,
Install
Cam support plate screws 90–120 in-lbs 10.2–13.6 N·m 4.27 CAM COMPARTMENT AND COMPONENTS,
Install
Coolant downtube lower screws 20–22 ft-lbs 27.1–29.8 N·m 4.9 OIL COOLER AND DOWNTUBE, Install
Coolant downtube upper screws 90–110 in-lbs 10.2–12.4 N·m 4.9 OIL COOLER AND DOWNTUBE, Install
Crankcase oil check valve or plug with 120–168 in-lbs 13.6–19 N·m 4.29 Crankcase, Plugs and Oil Fittings
O-ring
Crankcase screws, first torque 120 in-lbs 13.6 N·m 4.29 Crankcase, Assemble
final tighten
Crankcase screws, last torque 15–19 ft-lbs 20.3–25.8 N·m 4.29 Crankcase, Assemble
Crankcase tapered plugs 120–144 in-lbs 13.6–16.3 N·m 4.29 Crankcase, Plugs and Oil Fittings
Crankshaft sprocket screw, final torque 24 ft-lbs 32.5 N·m 4.27 CAM COMPARTMENT AND COMPONENTS,
Install
Crankshaft sprocket screw, first torque 15 ft-lbs 20.3 N·m 4.27 CAM COMPARTMENT AND COMPONENTS,
Install
Apply LOCTITE 262 HIGH STRENGTH THREAD-
LOCKER AND SEALANT (red)
Cylinder head bolt first torque 20–30 ft-lbs 27.1–40.7 N·m 4.24 CYLINDER HEAD, Install
Apply ENGINE OIL to cylinder head bolt washers
and threaded portion of the cylinder head bolts.
See procedure for torque sequence.
Cylinder head bolt second torque 9–11 ft-lbs 12.2–14.9 N·m 4.24 CYLINDER HEAD, Install
Cylinder head bolt third torque 25–27 ft-lbs 33.9–36.6 N·m 4.24 CYLINDER HEAD, Install
Cylinder stud 120–240 in-lbs 13.6–27.1 N·m 4.29 Crankcase, Cylinder Studs
Cylinder temperature sensor 120–180 in-lbs 13.6–20.3 N·m 4.24 CYLINDER HEAD, Assemble
Engine oil drain plug 14–21 ft-lbs 19–28.5 N·m 4.31 OIL PAN, Install
Clean plug before installation
Exhaust crossover pipe hanger bracket 100–120 in-lbs 11.3–13.6 N·m 4.31 OIL PAN, Complete
Knock sensor screw 13–17 ft-lbs 17.6–23 N·m 4.24 CYLINDER HEAD, Assemble
Lifter anti-rotation device screw 90–120 in-lbs 10.2–13.6 N·m 4.23 Pushrods, Lifters and Covers, Install
Lifter cover screws 132–156 in-lbs 14.9–17.6 N·m 4.23 Pushrods, Lifters and Covers, Install
Lower rocker cover screws 90–120 in-lbs 10.2–13.6 N·m 4.19 UPPER ROCKER COVERS, Install
Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue) to
screws.

94000383 4-1
FASTENER TORQUE VALUE NOTES
Lower rocker cover screws 90–120 in-lbs 10.2–13.6 N·m 4.20 LOWER ROCKER COVERS, Install
Oil cooler screws 96–120 in-lbs 10.8–13.6 N·m 4.9 OIL COOLER AND DOWNTUBE, Install
Oil cooler screws 96–120 in-lbs 10.8–13.6 N·m 4.9 OIL COOLER AND DOWNTUBE, Install
Oil line manifold screws 90–120 in-lbs 10.2–13.6 N·m 4.10 OIL COOLANT LINES, Install
Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (BLUE)
Oil pan fasteners 132–156 in-lbs 14.9–17.6 N·m 4.31 OIL PAN, Install
Torque sequence; LOCTITE 243 MEDIUM
STRENGTH THREADLOCKER AND SEALANT
(blue) with used fasteners
Oil pan tapered plug 30–36 ft-lbs 40.7–48.8 N·m 4.31 OIL PAN, Install
Apply LOCTITE 565 THREAD SEALANT
Oil pump screws, final torque 90–120 in-lbs 10.2–13.6 N·m 4.27 CAM COMPARTMENT AND COMPONENTS,
Install
Oil pump screws, first torque 12–60 in-lbs 1.4–6.8 N·m 4.27 CAM COMPARTMENT AND COMPONENTS,
Install
Piston jet screws 25–35 in-lbs 2.8–3.9 N·m 4.29 Crankcase, Repair Right Crankcase Half
Rocker shaft screw 23–27 ft-lbs 31.2–36.6 N·m 4.22 Rocker Arms, Install
Spark plug 89–133 in-lbs 10–15 N·m 4.8 Troubleshooting, Compression Test
Spark plug 89–133 in-lb 10–15 N·m 4.23 Pushrods, Lifters and Covers, Complete
Timer cover screws 25–35 in-lbs 2.8–4 N·m 4.27 CAM COMPARTMENT AND COMPONENTS,
Complete
Transmission drain plug 14–21 ft-lbs 19–28.5 N·m 4.31 OIL PAN, Install
Clean plug before installation
Upper rocker cover screws 120–140 in-lbs 13.6–15.8 N·m 4.19 UPPER ROCKER COVERS, Install
Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue) to
screws.
Voltage regulator screws 96–120 in-lbs 10.8–13.6 N·m 4.9 OIL COOLER AND DOWNTUBE, Install

4-2 94000383
SPECIFICATIONS 4.2
SPECIFICATIONS Table 4-4. Oiling System
ITEM SPECIFICATION
Table 4-1. Engine: Milwaukee-Eight™ 107 Engine Recommended oil Genuine Harley-Davidson H-D 360
ITEM SPECIFICATION Motorcycle Oil
Number of cylinders 2 Pump Twin gerotor, dual scavenge, crank
mounted and driven, internal oil pump,
Type 4-cycle, 45 degree
dry sump
V-Type, air-cooled
Single camshaft Pressure 30–40 psi (207–275 kPa) at 2000 RPM
Single balance shaft and normal operating temperature of
230 °F (110 °C)
Compression ratio 10.0:1
Filtration 5 micron media, filtered between pump
Bore 3.937 in 100 mm
and engine
Stroke 4.375 in 111.1 mm
Cooling Oil cooler
Displacement 107 in3 1753 cm3 (Air-cooled models only)
Fuel requirement Premium unleaded Certain models also have a cooler-
mounted fan.
Lubrication system Pressurized, dry sump
with oil cooler* Table 4-5. Rocker Arms Specifications
* Fan cooled on some models.
ROCKER ARMS IN MM

Table 4-2. Engine: Twin-Cooled™ Milwaukee-Eight™ 107 Shaft fit in bushing (loose) 0.0005-0.0022 0.013-0.056
Engine End clearance 0.004-0.015 0.10-0.38
ITEM SPECIFICATION
Table 4-6. Rocker Arm Shaft Specifications
Number of cylinders 2
ROCKER ARM SHAFTS IN MM
Type 4-cycle, 45 degree
V-Type, Twin-Cooled Diameter 0.5538-0.5543 14.067-14.079
Single camshaft
Single balance shaft Table 4-7. Hydraulic Lifter Specifications
Compression ratio 10.0:1 HYDRAULIC LIFT- IN MM
Bore 3.937 in 100 mm ERS

Stroke 4.375 in 111.1 mm Fit in crankcase 0.0009-0.0026 0.023-0.066

(loose)
Displacement 107 in3 1753 cm3
Fuel requirement Premium unleaded Table 4-8. Cylinder Head Specifications
Lubrication system Pressurized, dry sump CYLINDER HEAD IN MM
Cooling system Liquid-cooled cylinder heads Head gasket surface (flatness) 0-0.003 0-0.08
with lower fairing-mounted radiators and
electric pump Table 4-9. Valve Specifications
VALVES IN MM
Table 4-3. Engine Idle Characteristics
Exhaust: fit in guide 0.001-0.003 0.0254-0.0762
CONDITION DOM * ALL OTHERS *
Intake: fit in guide 0.001-0.003 0.0254-0.0762
Cold start 1450 rpm 1700 rpm
Seat width 0.040-0.080 1.02-2.03
Hot idle 850 rpm 850 rpm
Stem protrusion from cylinder 1.714-1.721 43.54-43.71
Hot idle; EITMS en- 950 rpm 950 rpm head boss
gaged
Valve lash * 0.000-0.003 0.00-0.08
Low voltage 200 rpm increase from normal
* Variation between valve pairs operated by a common rocker
Trike in reverse 1100 rpm 1100 rpm arm.
* All values are approximate
Table 4-10. Valve Spring Specifications
Table 4-4. Oiling System
VALVE IN MM
ITEM SPECIFICATION SPRINGS
Capacity with filter Twin-Cooled (new system): 5.0 qt (4.5 L) Closed 63 lbs @ 1.535 in. 280 N @ 39.0 mm
Air-Cooled (new system): 5.2 qt (4.5 L) Open 165 lbs @ 1.154 in. 735 N @ 29.3 mm
Service oil change (all): 4.75 qt (4.5 L) Free length 1.838 in. 46.69 mm

94000383 4-3
 Table 4-11. Piston
PISTON IN MM
Fit in cylinder 0.0025-0.0036 0.064-0.091
Piston pin fit (loose) 0.0002-0.0005 0.005-0.013
Ring end Top compression 0.010-0.016 0.25-0.40
gap 2nd compression 0.016-0.024 0.40-0.60
Oil control ring 0.008-0.028 0.20-0.70
Ring side Top compression 0.0012-0.0027 0.030-0.068
clear- 2nd compression 0.0012-0.0027 0.030-0.068
ance
Oil control rails 0.001-0.007 0.025-0.178

Table 4-12. Connecting Rod Specifications

CONNECTING ROD IN MM
Piston pin fit (loose) 0.0007-0.0012 0.018-0.030
Side play between fly- greater than greater than 0.13
wheels 0.005
Connecting rod to crank- 0.0004-0.0017 0.0102-0.0432
pin (loose)

Table 4-13. Flywheel Specifications

FLYWHEELS IN MM
Runout (shaft measured 0.000-0.010 0.0-0.254
in case)
Runout (measured in tru- 0.000-0.004 0.0-0.102
ing stand)
End play 0.003-0.013 0.076-0.330

Table 4-14. Crankshaft/Sprocket Shaft Bearing Specifica-

tions
CRANKSHAFT/SPROCK- IN MM
ET SHAFT BEARINGS
Roller bearing fit (loose) 0.0002-0.0015 0.005-0.038
Bearing fit in crankcase 0.0038-0.0054 0.097-0.137
(tight)
Bearing inner race on 0.0004-0.0014 0.010-0.036
crankshaft (tight)

4-4 94000383
SERVICE WEAR LIMITS 4.3
SPECIFICATIONS Table 4-20. Valve Stem to Guide
VALVE STEM TO GUIDE REPLACE IF WEAR EXCEEDS
Wear limits are given here as a guideline for measuring used
engine components. Replace components when they exceed IN MM
these values. Intake 0.0038 0.0965
Exhaust 0.0038 0.0965
Table 4-15. Rocker Arm/Rocker Arm Shaft
ROCKER ARM/ROCKER REPLACE IF WEAR EXCEEDS Table 4-21. Valve Springs
ARM SHAFT IN MM VALVE IN MM
Shaft fit in bushing 0.006 0.152 SPRINGS
End clearance 0.025 0.635 Closed 56.8-66.1 lbs 253-294 N
@ 1.154 in @ 29.3 mm
Table 4-16. Hydraulic Lifter Open 150.0-172.7 lbs 667-768 N
@ 1.091 in @ 27.70 mm
HYDRAULIC LIFTER REPLACE IF WEAR EXCEEDS
Free length 1.838 in 46.70 mm
IN MM
Fit in crankcase 0.006 0.152 Table 4-22. Cylinder
Roller fit 0.0015 0.038 CYLINDER REPLACE IF WEAR EXCEEDS
Roller end clearance 0.022 0.559 IN MM

Table 4-17. Cam Support Plate Taper 0.003 0.102

Out of round 0.003 0.102
ITEM REPLACE IF WEAR EXCEEDS
Warpage of gasket sur- 0.006 0.152
IN MM
face: top
Cam chain tensioner shoe 0.060 min. 1.52 min.
thickness Warpage of gasket sur- 0.004 0.102
face: base
Crankshaft bore maxim- 0.8545 21.704
um ID Table 4-23. Piston
Camshaft bore 1.1023 27.998 PISTON REPLACE IF WEAR EX-
Flatness 0.010 0.25 CEEDS
IN MM
Table 4-18. Oil Pump
Fit in cylinder (loose) 0.0041 0.104
OIL PUMP REPLACE IF WEAR
Piston pin fit (loose) 0.0008 0.020
EXCEEDS
Ring end Top compression 0.020 0.508
IN MM
gap
Rotor tip clearance 0.004 0.10 Second compres- 0.030 0.762
sion
Rotor thickness variation 0.001 0.025
Oil control rails 0.050 1.27
Table 4-19. Cylinder Head Ring side Top compression 0.004 0.102
clearance
CYLINDER HEAD REPLACE IF Second compres- 0.004 0.102
sion
IN MM
Oil control rails 0.010 0.254
Valve seat width (max) 0.080 2.03
Valve margin (min) 0.031 0.80 Table 4-24. Connecting Rod
Valve stem protrusion (max) 1.752 44.50 CONNECTING ROD REPLACE IF WEAR
Cylinder head warpage (max) 0.006 0.152 EXCEEDS
Valve lash (max) * 0.008 0.20 IN MM
* Variation between valve pairs operated by a common rocker Piston pin fit (loose) 0.002 0.051
arm. Fit on crankpin (loose) 0.002 0.051

94000383 4-5
 Table 4-25. Flywheel
FLYWHEEL REPLACE IF WEAR EXCEEDS
IN MM
Runout (shaft measured 0.012 0.305
in case)
Runout (measured in tru- 0.005 0.127
ing stand)
End play 0.013 0.330

Table 4-26. Crankshaft Roller Bearing

CRANKSHAFT ROLLER REPLACE IF
BEARING IN MM
Roller bearing fit (loose) More than More than 0.038
0.0015
Bearing fit in crankcase Less than Less than 0.097
(tight) 0.0038
Inner race on crankshaft Less than Less than 0.010
(tight) 0.0004

4-6 94000383
 ENGINE OIL FLOW 4.4
OIL FLOW same for Twin-Cooled and air cooled engines. Air cooled
engines also have an oil cooler and circulate oil between the
ENGINE exhaust ports
INTERNAL
Milwaukee-Eight engines are dry sump engines meaning that OILfor additional heat control.
FLOW
they have external oil reservoirs. Internal engine oil flow is the

sm08728

12

13

kout

10

9 11
7

8
3
14

5
11 4
6

1. Oil in from oil pan 8. Cam plain bearing

2. Oil pump feed rotors 9. Oil to camshaft, lifters and piston jets
3. Oil pump scavenge rotors 10. Piston jets
4. Scavenge oil in from cam chest 11. Oil through crankshaft to crankpin and rod
bearings
5. Oil pressure switch 12. Oil through pushrods to rocker arms
6. Oil out to oil cooler (oil cooled only) 13. Oil spillover to lubricate valve stems
7. Oil filter 14. Hydraulic chain tensioner
Figure 4-1. Internal Engine Oil Flow

94000383 4-7
Internal Oil Distribution: All
1. See Figure 4-1.
a. Oil from the oil pan (1) is pulled through ports in the oil
pan (not shown), the transmission housing and
crankcase.
b. Oil enters the oil pump feed gerotors.
c. Oil exits the pump and passes oil pressure switch (5)
and oil cooler port (6) headed to oil filter (7). Oil cooler
port is plugged on Twin-Cooled engines.
d. Oil exits filter and is directed back into cam support
plate where its split between crankshaft, hydraulic chain
tensioner (14), and lifters (9).
e. Crankshaft oil travels through crankshaft to the crankpin
and rod bearings (11).
4-8
f. Flow toward lifters splits to cam plain bearing (8), lifters
and on to piston jets (10).
g. Oil flows from lifters up through pushrods to rocker arms
(12).
h. Oil exits rocker arms to lubricate valve stems via
spillover (13).
i. Oil drains through passages in the heads and cylinders
back to the camchest cavity. Residual oil in the
camchest cavity and the crankcase cavity is picked up
by the scavenge port (4) in the pump. Return oil is fed
through the scavenge gerotors and case passages back
to the oil pan.
j. Main bearings, balancer bearing and left cam bearing
are lubricated by oil splash.
94000383
 ENGINE EXTERNAL OIL FLOW

sm08729

10
6

7 9

11
8

12 5
7

1. Oil out check valve 7. Manifold

2. Hose, engine to oil cooler 8. Passages around exhaust ports
3. Oil cooler 9. Return oil line
4. Hose, oil cooler to downtube 10. Rear oil hose
5. Downtube 11. Passage through transmission
6. Supply oil line 12. Return oil to oil pan
Figure 4-2. External Engine Oil Flow: Air Cooled
f. Rear hose connects to a passage (11) in transmission
External Oil Distribution: Air Cooled Only where it returns to the oil pan (12).
1. See Figure 4-2.
a. Pressurized oil exits crankcase and flows through check
valve (1), hose (2) to oil cooler (3).
b. Oil flows through oil cooler, hose (4) to downtube (5).
c. Oil flow splits at oil supply line (6) and flows to manifolds
(7).
d. Oil flows through passages between the exhaust ports
(8) in cylinder heads and back to manifolds.
e. Oil flows through return line (9) to rear hose (10).

94000383 4-9
OIL PUMP OPERATION 4.5
GENERAL sm02317

See Figure 4-3. The oil pump has two gerotor gear sets driven 2 3
by the crankshaft.

• The feed gerotor set distributes oil to the engine. 1 4

• The scavenge gerotor set draws oil from the cam and
flywheel compartments and returns it to the oil pan.

PLACEHOLDER
Each gerotor gear set has an inner and outer gerotor. The inner
and outer gerotors have fixed centers that are slightly offset to
one another. Also, the inner gerotor has one less tooth.

sm08550
6

4 5

3
1. Oil in
2 2. Seal
3. Outer gerotor
4. Inner gerotor
1 Figure 4-4. Inlet Side Oil Flow

sm02319

1. Feed gerotor
2. Housing
3. Scavenge gerotor
4. Inner cover
5. Scavenge port O-ring
6. Feed port O-ring
Figure 4-3. Oil Pump 2
OPERATION
1
The oil pump is driven by the crankshaft. The inlet and outlet
sides of the pump are sealed by the tips and lobes of the inner
and outer gerotors. This prevents oil on the outlet side (high
pressure) from being transferred to the inlet side.

3
1. Seal
2. Oil out
3. Continuous flow
Figure 4-5. Outlet Side Oil Flow

See Figure 4-4. As the gerotors rotate, the cavity volume

increases between the inner and outer gerotors on the inlet
side of the pump. This creates a vacuum causing oil to be

4-10 94000383
drawn in. The cavity increases until the volume is equivalent
to that of the missing tooth on the inner gerotor.

See Figure 4-5. As the oil moves to the outlet side of the pump,
the cavity decreases in volume. This forces pressurized oil out
the discharge port. In operation, the gerotors provide a
continuous flow of oil.

94000383 4-11
BREATHER OPERATION 4.6
CRANKCASE VENTILATION

A breather assembly is mounted to each cylinder head to

prevent a buildup of pressure caused by the downward force
of the pistons. Burning crankcase vapor eliminates the
pollutants normally discharged from the crankcase.

See Figure 4-6. As pistons push downward, displaced air in

the crankcase is vented through the crankshaft roller bearing
into the cam compartment. The air flows up the pushrod covers
(1) into the rocker housing. The moving air absorbs a small
amount of oil vapor as it travels through the engine.

The oil/air vapor passes through an opening in the breather

assembly (3).

In the breather assembly, the flow of air passes downward

through a labyrinth where most of the oil is separated from the
air. It then moves upward through the breather element (4)
where the remaining oil is removed. Two small holes in the
bottom of the breather housing allow the separated oil to drain
back into the crankcase.

Passing through the breather element, the vapor passes

through the umbrella valve (2). Vapor passes down into the
cylinder head passageway and through the breather bolt (5).
It passes through a breather tube (6) into the air filter element
where it combines with the intake air stream and is burned
during normal combustion.

sm08572 2
3

1
6

1. Pushrod cover
2. Umbrella valve
3. Breather assembly
4. Breather element
5. Breather bolt
6. Breather tube
Figure 4-6. Breather Air Flow

4-12 94000383
OIL PRESSURE 4.7
OIL PRESSURE INDICATOR LAMP b. Assemble banjo bolt (3), washer (4), oil pressure gauge
(1), banjo fitting and second washer onto adapter.
See Figure 4-7. The red OIL PRESSURE indicator lamp Hand-tighten.
illuminates to indicate improper pressure of the engine oil. The
5. Check oil pressure.
lamp illuminates when the ignition is initially turned on (before
the engine is started), but should extinguish once the engine a. Operate engine at various speeds.
is running.
b. Record results.
NOTICE c. Stop engine.
If the oil pressure indicator lamp remains lit, always check
6. Remove oil pressure gauge assembly.
the oil supply first. If the oil supply is normal and the lamp
is still lit, stop the engine at once and do not ride further 7. Install oil pressure switch. See Oil Pressure Switch
until the trouble is located and the necessary repairs are (Page 9-58).
made. Failure to do so may result in engine damage.
8. Verify that oil pressure is within specifications. Refer to
(00157a)
Table 4-27.
If the indicator lamp does not extinguish, it may be caused by Table 4-27. Oil Pressure
low oil level or diluted oil supply. In freezing weather, the oil
feed and return lines can clog with ice or sludge. Other SPECIFICATION *
CHECK
conditions that may cause the lamp to remain lit are: SAE METRIC
• Faulty lamp wiring Oil pressure - min at idle 5 psi 34.5 kPa
• Faulty oil pressure sending unit Oil pressure - normal at 30-38 psi 207-262 kPa
2000 rpm
• Damaged oil pump
Oil pressure - max 50 psi 345 kPa
• Plugged oil filter element
* With oil at normal operating temperature of 230 °F (110 °C)
• Incorrect oil viscosity for the operating temperature
• Fractured or weak spring in the oil pressure relief valve sm02322

• Incorrectly installed O-rings in the engine

To troubleshoot the problem, always check the engine oil level

first. If the oil level is OK, determine if oil returns to the oil pan.
If oil does not return, shut off the engine until the problem is
located and corrected. 1
sm02321

3 2

1. Gauge
Figure 4-7. Oil Pressure Indicator Lamp 2. Adapter
OIL PRESSURE CHECK 3. Banjo bolt
4. Washer (2)
PART NUMBER TOOL NAME Figure 4-8. Oil Pressure Gauge Set
HD-96921-52D OIL PRESSURE TEST GAUGE KIT

1. Verify that engine oil is at the proper level. See ENGINE

OIL AND FILTER (Page 2-15).
2. Run motorcycle until engine oil reaches at least 200 °F
(93 °C). Stop engine.
3. Remove oil pressure switch from crankcase. See Oil
Pressure Switch (Page 9-58).
4. See Figure 4-8. Install OIL PRESSURE TEST GAUGE
KIT (PART NUMBER: HD-96921-52D).
a. Hand-tighten adapter (2) in oil pressure switch mounting
hole.

94000383 4-13
TROUBLESHOOTING 4.8
COMPRESSION TEST 6. Remove dowel from induction module.

PART NUMBER TOOL NAME 7. Connect TCA connector.

HD-33223-1 CYLINDER COMPRESSION GAUGE
8. Assemble the air cleaner. See AIR CLEANER ELEMENT
FASTENER TORQUE VALUE (Page 2-17).
Spark plug 89–133 in-lbs 10–15 N·m
9. Install the spark plugs. Tighten to 89–133 in-lbs
Check for cylinder leakage with a compression test. Use (10–15 N·m). Connect spark plug wires.
CYLINDER COMPRESSION GAUGE (PART NUMBER:
HD-33223-1) with a screw-in type adapter. Table 4-28. Compression Specifications
1. Remove all spark plug cables. ACR STATUS PSI kPa
ACR connected 110 (min) 758 (min)
NOTE
ACR disconnected 175 (min) 1207 (min)
Never use a metal object to hold the throttle plate open.
Table 4-29. Compression Test Results
2. Remove one spark plug from each cylinder.
TEST RESULTS DIAGNOSIS
3. Open throttle plate. • Compression low on first stroke. - Ring trouble
• Compression builds on the following
a. Remove air cleaner cover and filter. See AIR strokes, but does not reach normal.
CLEANER ELEMENT (Page 2-17).
• Improves considerably when oil is
b. Disconnect TCA connector [211] from the induction added to cylinder.
module.
• Compression low on first stroke. - Head gasket leak
c. Insert a 0.75 in (19 mm) diameter by 12 in (305 mm) - Incorrect valve
• Compression does not build much on
long wooden or nylon dowel to hold the throttle valve lash
following strokes.
open. - Valve trouble
• Does not improve considerably with
the addition of oil.
4. Test compression.

a. Connect compression tester to front cylinder following CYLINDER LEAKDOWN TEST

manufacturer's instructions.
PART NUMBER TOOL NAME
b. Crank engine continuously through 5-7 full
HD-35667-A CYLINDER LEAKDOWN TESTER
compression strokes.
HD-52252 CRANKSHAFT LOCKING TOOL
c. Note gauge readings at the end of the first and last
compression strokes. Record test results. 1. Verify that the CYLINDER LEAKDOWN TESTER (PART
NUMBER: HD-35667-A) is free from leakage.
d. Disconnect ACR and repeat test.
a. Apply a soap/water solution around all tester fittings.
e. Connect ACR.
b. Connect cylinder leakdown tester to compressed air
f. Repeat steps (a-e) on rear cylinder. source.

5. Compare with specifications. Refer to Table 4-28 c. Bubbles indicate leakage.

a. If compression is within specifications and the NOTE

variance between cylinders is less than 10%, Perform the test with the ignition switch turned OFF.
compression is normal.
2. Remove one spark plug per cylinder.
b. If readings do not meet specifications, inject 0.5 oz.
(15 ml) engine oil into each cylinder and repeat the
3. Set piston in the cylinder being tested at top dead center
compression tests on both cylinders. Readings that
(TDC) of compression stroke (both valves closed).
are considerably higher during the second test
indicate worn piston rings.
NOTE
c. Refer to Table 4-29 for possible causes of low Never use CRANKSHAFT LOCKING TOOL (PART NUMBER:
compression. HD-52252) for procedures such as servicing the compensator,

4-14 94000383
servicing the clutch or servicing the camshaft. Crankcase 6. Check top end components.
damage will result.
a. Check for excess rocker arm end play or binding.
b. Inspect valve stems for scuffing. Check stem to guide
4. Lock the crankshaft.
clearance.
a. Remove CKP. See CRANKSHAFT POSITION c. Check for loose valve seats or signs of shifting.
SENSOR (CKP) (Page 9-44).
7. Grind valves and valve seats. See CYLINDER HEAD,
b. Install CRANKSHAFT LOCKING TOOL (PART Valve and Seat Repair (Page 4-42).
NUMBER: HD-52252).
DIAGNOSING SMOKING ENGINE OR HIGH
5. Follow the manufacturer's instructions to perform the
OIL CONSUMPTION
leakdown test.
Perform both a compression test and a cylinder leakage test.
See Troubleshooting, Compression Test (Page 4-14) and
a. Record the percent of leakage.
Troubleshooting, Cylinder Leakdown Test (Page 4-14). If further
b. Listen for air leaks at throttle body, exhaust pipe, oil testing is needed, inspect for the following:
fill spout and head gasket.
Check Before Cylinder Head Removal:
6. Verify that the piston is still at TDC. Repeat the test if it 1. Oil level too high
moved.
2. Oil carryover

7. Results: 3. Restricted breather hose

4. Restricted oil filter
a. Leakage greater than 25 percent indicates that
further diagnosis is warranted. Check After Cylinder Head Removal:
b. Air escaping through the throttle body indicates 1. Clogged oil return passages
leaking past intake valves. 2. Valve guide seals

c. Air escaping through the exhaust pipe indicates 3. Valve guide to valve stem clearance
leaking past exhaust valves. 4. Gasket surfaces of head and cylinder

d. Air sound from the oil fill spout indicates leaking past 5. Cylinder head casting porosity allowing oil to drain into
piston rings. combustion chamber
6. O-ring damaged or missing from oil pump/crankcase
8. Remove crankshaft locking tool. junction
7. If the above checks do not reveal the cause:
DIAGNOSE VALVE TRAIN NOISE
a. Remove the cylinder.
NOTE b. Verify that the piston ring gaps are properly staggered.
Some valve train noise at start-up is normal until lifters fill with c. Inspect for excess piston ring wear.
oil. Continuous noise requires diagnosis.

1. With engine and oil at normal operating temperature, check

oil pressure at 2000 rpm.
2. If oil pressure is above 50 psi (345 kPa) or below 5 psi
(34 kPa), inspect the following:
a. Oil pump wear
b. Crankcase passages for blockages
c. Oil hoses for blockages

3. If oil-starved hydraulic lifters are suspected, remove lifters

and inspect. See Pushrods, Lifters and Covers, Inspect
Lifters (Page 4-37).
a. Clean lifter bore of all foreign material.

4. Inspect pushrod, lifter and lifter bore for proper fit and
unusual wear.
5. Visually inspect camshaft lobes for abnormal wear.

94000383 4-15
OIL COOLER AND DOWNTUBE 4.9
PREPARE b. Remove lower electrical cover (6) from frame.
c. Disconnect fan electrical connector.
1. Cover the front fender to protect finish.
2. Place a drain pan under motorcycle. 3. Remove screws (2).

3. Remove oil cooler cover. 4. Slide oil cooler assembly up to disengage retainer (5) from
slot (3). Remove the oil cooler/fan assembly.
a. Pull forward at bottom to free posts from grommets.
5. Inspect for dirt, debris and damage.
b. Rotate up and lift off upper retainer.
Remove Downtube Components
REMOVE
1. Remove voltage regulator. See VOLTAGE REGULATOR
(Page 9-50).
PART NUMBER TOOL NAME
HD-52004 24 INCH HOSE CLAMP TOOL 2. Remove oil cooler assembly. See OIL COOLER AND
DOWNTUBE, Disassemble Fan from Oil Cooler
(Page 4-18).
Downtube Assembly with Components
NOTE sm08615

Use 24 INCH HOSE CLAMP TOOL (PART NUMBER:

HD-52004) to reach rotated or difficult to reach spring clamps.

1. See Figure 4-9. Disconnect hoses from oil cooler (4) and 1
upper end of downtube (1).
NOTE
Not all models have an oil cooler fan. 2

2. Fan equipped:
a. Remove push-in clips (5).
b. Remove lower electrical cover (6) from frame.
3
c. Disconnect fan electrical connector. 6

3. Remove screws (2, 3).

4. Pull assembly away from frame and disconnect voltage 5 4
regulator connectors.
1. Downtube
5. Remove downtube assembly with components.
2. Screw (2)
3. Lower screw (2)
Oil Cooler Only 4. Oil cooler
1. See Figure 4-10. Disconnect hoses (1, 6) from the oil 5. Push-in clip (2)
cooler (8). 6. Lower electrical cover
2. Fan equipped: Figure 4-9. Oil Downtube Assembly

a. Remove two push-in clips (5).

4-16 94000383
 sm08614
4
3

5
8
2
7

5 9

1. Hose, engine to oil cooler 6. Hose, oil cooler to downtube

2. Screw (2) 7. Fan (some models)
3. Slot 8. Oil cooler, fan cooled
4. Downtube 9. Oil cooler, non-fan cooled
5. Retainer
Figure 4-10. Oil Cooling Components
INSTALL b. Connect voltage regulator connectors as regulator
is moved into place.
FASTENER TORQUE VALUE
3. Install hose (6).
Coolant downtube lower 20–22 ft-lbs 27.1–29.8 N·m
screws
a. Install hose between oil cooler and downtube (4).
Coolant downtube upper 90–110 in-lbs 10.2–12.4 N·m
screws
b. Secure with hose clamps.
Oil cooler screws 96–120 in-lbs 10.8–13.6 N·m
Voltage regulator screws 96–120 in-lbs 10.8–13.6 N·m
Install Downtube Assembly with Components
Install Components to Downtube Assembly 1. See Figure 4-9. Install downtube assembly with screws
(2, 3).
1. See Figure 4-10. Install oil cooler to downtube.
a. Apply silicone-based dielectric grease to both voltage
a. Engage tab (5) into T-slot (3). regulator connectors.
b. Install two screws (2). b. Connect voltage regulator connectors as downtube
assembly is moved into place.
c. Tighten to 96–120 in-lbs (10.8–13.6 N·m).
c. Apply Apply LOCTITE 243 (blue) to the threads of
2. Install voltage regulator with four screws. Tighten to screws (2).
96–120 in-lbs (10.8–13.6 N·m).
d. Tighten screws (2) to 90–110 in-lbs (10.2–12.4 N·m).
a. Apply silicone-based dielectric grease to both voltage
regulator connectors. e. Install screws (3). Tighten to 20–22 ft-lbs
(27.1–29.8 N·m).

94000383 4-17
2. Fan equipped: ASSEMBLE FAN TO OIL COOLER
a. Connect fan electrical connector. 1. Install grommets in fan housing with larger flange toward
oil cooler.
b. Install lower electrical cover (6) to frame with new
push-in clips (5). 2. See Figure 4-10. Install fan (7) to oil cooler (8).
a. Place oil cooler on smooth surface with fittings facing
3. Connect hoses to fittings (1, 4). up.
b. Position fan on oil cooler with retainer (5) opposite from
a. Secure with hose clamps.
oil cooler fittings.
c. Hook clip on end of fan over oil cooler tank with the
Oil Cooler Only smaller hose fitting.
NOTE d. Push on center of fan to install remaining clip over oil
• See Crankcase, Plugs and Oil Fittings (Page 4-64) to install cooler tank.
oil check valve in crankcase.
• See Figure 4-10. If removed, install hose (6) with arrow up.

1. See Figure 4-10. Install the oil cooler assembly.

a. Engage tab (5) into T-slot (3).

b. Install two screws (2).

NOTE
Not all models have an oil cooler fan.

c. Tighten to 96–120 in-lbs (10.8–13.6 N·m).

2. Fan equipped:

a. Connect fan electrical connector.

b. Install protective cover to frame with new retainers.

3. Connect hoses to the oil cooler (8).

COMPLETE
1. Install oil cooler cover.
a. Engage upper retainer.
b. Rotate down and back to engage posts to grommets.

2. Check engine oil level. See ENGINE OIL AND FILTER

(Page 2-15).
DISASSEMBLE FAN FROM OIL COOLER

NOTE
Remove fan only with oil cooler removed from vehicle.

1. Remove oil cooler assembly.

2. See Figure 4-10. Remove fan (7) from oil cooler (8). Use
a rigid putty knife for best results.
a. Pry between wrap-around clip and oil cooler tank with
larger hose fitting.
b. As clip expands, work clip off tank. Separate fan from
oil cooler.

3. Remove grommets from fan housing.

4-18 94000383
OIL COOLANT LINES 4.10
PREPARE
1. Clean components.
1. Remove main fuse. See System Fuses and Relays
a. Remove all residual thread locking material from
(Page 9-6).
screws and manifolds.
2. Remove seat. See SEAT (Page 3-96).
b. Clean all debris from mating surfaces and threaded
3. Remove fuel tank. See FUEL TANK (Page 5-6).
holes.
4. Remove stabilizer link and bracket. See FRONT ENGINE
MOUNT (Page 3-161). c. Clean all debris from coolant ports in heads and
manifolds.
REMOVE
2. See Figure 4-11. If removed, install hose (2) to line
PART NUMBER TOOL NAME assembly. Secure with spring clamp (4).
HD-52004 24 INCH HOSE CLAMP TOOL
3. Install new O-rings on the ports of each manifold (3).
1. Disconnect:
a. Fuel injector connectors. See ELECTRICAL CADDIES, 4. Install line assembly (5) with screws (7).
Lower Backbone Caddy (Page 9-12).
b. Knock sensor connectors. See ELECTRICAL CADDIES, a. Apply LOCTITE 243 MEDIUM STRENGTH
Lower Backbone Caddy (Page 9-12). THREADLOCKER AND SEALANT (BLUE) to threads
of screws.
c. ACR connectors. See ELECTRICAL CADDIES, Lower
Backbone Caddy (Page 9-12). b. Tighten to 90–120 in-lbs (10.2–13.6 N·m).
d. Left spark plug cables.
5. Install hose (2) to transmission with spring clamp (4).
e. Horn connectors. Release harness from clamp and
cable strap.
6. Install hose (6) to downtube with spring clamp.

NOTE
7. Connect:
Use 24 INCH HOSE CLAMP TOOL (PART NUMBER:
HD-52004) to reach rotated or difficult to reach spring clamps.
a. Fuel injector connectors. See ELECTRICAL
CADDIES, Lower Backbone Caddy (Page 9-12).
2. See Figure 4-11. Disconnect hose (6) from downtube.
3. Use low-pressure compressed air to blow oil out of line b. Knock sensor connectors. See ELECTRICAL
assembly. CADDIES, Lower Backbone Caddy (Page 9-12).
a. Remove engine oil filler cap. c. ACR connectors. See ELECTRICAL CADDIES,
b. Blow into the hose (6) where disconnected from Lower Backbone Caddy (Page 9-12).
downtube.
d. Left spark plug cables.
4. Disconnect hose from transmission fitting (1).
e. Horn connectors. Secure harness in clamp and new
5. Remove screws (7) from each manifold port (3). cable strap.
6. Remove line assembly (5).
7. If necessary, remove rear oil hose (2) from line assembly
(5).
INSTALL

FASTENER TORQUE VALUE

Oil line manifold screws 90–120 in-lbs 10.2–13.6 N·m

PART NUMBER CONSUMABLE

11100005 LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT
(BLUE)

NOTE
Verify that all components and mating surfaces are free of all
debris before assembling.

94000383 4-19
 sm8612

4 5

6
2 3

3
7
1. Transmission fitting
2. Rear oil hose
3. Manifold
4. Spring clamp (2)
5. Line assembly
6. Forward oil hose
7. Screw (4)
Figure 4-11. Oil Coolant Lines
COMPLETE

1. Install stabilizer link and bracket. See FRONT ENGINE

MOUNT (Page 3-161).
2. Install fuel tank. See FUEL TANK (Page 5-6).
3. Install seat. See SEAT (Page 3-96).
4. Install main fuse. See System Fuses and Relays
(Page 9-6).
5. Check engine oil level. See ENGINE OIL AND FILTER
(Page 2-15).

4-20 94000383
HOW TO USE THIS SECTION 4.11
TOP END REPAIR

NOTE
During top end disassembly, the engine may be left in the
chassis for service.

If servicing only cylinder head components, pistons or cylinders,

two options are available depending on engine status.

• TOP END SERVICE, Engine in Chassis (Page 4-24).

• TOP END SERVICE, Engine Removed from Chassis
(Page 4-24).
BOTTOM END REPAIR

NOTE
Servicing components in the cam compartment requires only
partial disassembly. This can be done with the engine left in
the chassis.

After disassembling to the cylinder heads, it might become

evident that bottom end repair is necessary. Bottom end service
requires either partial or complete disassembly of the engine.

• To service the cam compartment, see CAM

COMPARTMENT AND COMPONENTS (Page 4-51).
• To service components in the flywheel compartment, the
engine must be removed and the crankcase halves
separated. See BOTTOM END SERVICE, Engine Removed
from Chassis (Page 4-27).
TYPICAL SYMPTOMS

Symptoms indicating a need for engine repair are often

misleading. If more than one symptom is present, possible
causes can be narrowed to make at least a partial diagnosis.

For example, an above normal consumption of oil could be

caused by several mechanical faults. However when
accompanied by blue-gray smoke from the exhaust and low
compression, it indicates the rings need replacing. Low
compression by itself is more likely to be caused by improperly
seated or burned valves, not worn rings.

Certain knocking noises may occur because of loose bearings,

others by piston slap. Piston slap is a condition where piston
or cylinder or both are out of tolerance. This excessive
clearance allows the piston to slap the cylinder as it moves up
and down.

Most frequently, valves, rings, pins, bushings and bearings

need attention at about the same time. If the symptoms indicate
that any one of the above components is worn, service all
related parts.

94000383 4-21
PREPARE MOTORCYCLE FOR SERVICE 4.12
ENGINE IN CHASSIS
Table 4-30. Disassemble
STEP NO. COMPONENT INSTRUCTIONS
Cam Compartment Service Only
1 Remove seat. SEAT (Page 3-96)
2 Disconnect negative battery cable. Battery Maintenance (Page 2-51)
3 Remove saddlebags. SADDLEBAGS (Page 3-98)
4 Remove fuel tank. FUEL TANK (Page 5-6)
5 Remove air cleaner and backplate. AIR CLEANER ASSEMBLY (Page 5-5)
6 Remove spark plugs. Spark Plugs (Page 2-44)
7 Remove right rider floorboard and bracket. FOOTBOARDS AND FOOTRESTS (Page 3-155)
8 Remove exhaust system. EXHAUST SYSTEM (Page 5-26)
9 Remove engine stabilizer bracket and link. FRONT ENGINE MOUNT (Page 3-161)
10 Remove upper cooling lines. COOLING SYSTEM REPAIR (Page 6-6) or OIL COOLANT LINES
(Page 4-19)
11 Disconnect purge solenoid hose, if EVAPORATIVE EMISSIONS CONTROL SYSTEM (Page 5-29)
equipped, from induction module.
Top End Service
12 Complete previous steps.
13 Remove induction module. INDUCTION MODULE (Page 5-17)
14 Secure disconnected harness connectors
out of the way.

4-22 94000383
ASSEMBLE MOTORCYCLE AFTER SERVICE 4.13
ENGINE IN CHASSIS
Table 4-31. Assemble
STEP NO. COMPONENT INSTRUCTIONS
Top End Service
1 Install induction module. INDUCTION MODULE (Page 5-17)
2 Release disconnected harness connectors.
Cam Compartment Service Only
3 Connect purge solenoid hose, if equipped, EVAPORATIVE EMISSIONS CONTROL SYSTEM (Page 5-29)
to induction module.
4 Install upper cooling lines. COOLING SYSTEM REPAIR (Page 6-6) or OIL COOLANT LINES
(Page 4-19)
5 Install engine stabilizer bracket and link. FRONT ENGINE MOUNT (Page 3-161)
6 Fill and purge cooling system. Coolant (Page 2-19)
7 Install spark plugs. Spark Plugs (Page 2-44)
8 Install air cleaner and backplate. AIR CLEANER ASSEMBLY (Page 5-5)
9 Install exhaust system. FOOTBOARDS AND FOOTRESTS (Page 3-155)
10 Install right rider footboard. FOOTBOARDS AND FOOTRESTS (Page 3-155)
11 Install fuel tank. FUEL TANK (Page 5-6)
12 Connect negative battery cable. Battery Maintenance (Page 2-51)
13 Install seat. SEAT (Page 3-96)
14 Install saddlebags. SADDLEBAGS (Page 3-98)

94000383 4-23
TOP END SERVICE 4.14
ENGINE IN CHASSIS
Table 4-32. Engine In Chassis
STEP NO. COMPONENT INSTRUCTIONS
Disassemble
1 Remove parts to gain access to all compon- PREPARE MOTORCYCLE FOR SERVICE (Page 4-22)
ents above cylinder deck.
2 Remove upper rocker cover. UPPER ROCKER COVERS (Page 4-30)
3 Remove rocker arms. Rocker Arms (Page 4-34)
4 Remove breather. BREATHERS (Page 4-33)
5 Remove lower rocker cover. LOWER ROCKER COVERS (Page 4-32)
6 Remove push rods and push rod covers. Pushrods, Lifters and Covers (Page 4-35)
7 Remove cylinder head. CYLINDER HEAD (Page 4-38)
8 Remove cylinder. CYLINDERS (Page 4-43)
9 Remove piston. PISTONS (Page 4-46)
Assemble
1 Install piston. PISTONS (Page 4-46)
2 Install cylinder. CYLINDERS (Page 4-43)
3 Install cylinder head. CYLINDER HEAD (Page 4-38)
4 Install push rods and push rod covers. Pushrods, Lifters and Covers (Page 4-35)
5 Install lower rocker cover. LOWER ROCKER COVERS (Page 4-32)
6 Install breather. BREATHERS (Page 4-33)
7 Install rocker arms. Rocker Arms (Page 4-34)
8 Install upper rocker cover. UPPER ROCKER COVERS (Page 4-30)
9 Assemble motorcycle. ASSEMBLE MOTORCYCLE AFTER SERVICE (Page 4-23)

ENGINE REMOVED FROM CHASSIS

Table 4-33. Engine Removed From Chassis
STEP NO. COMPONENT INSTRUCTIONS
1 Remove engine from motorcycle. REMOVE ENGINE (Page 4-28)
Disassemble
2 Remove upper rocker cover. UPPER ROCKER COVERS (Page 4-30)
3 Remove rocker arms. Rocker Arms (Page 4-34)
4 Remove breather. BREATHERS (Page 4-33)
5 Remove lower rocker cover. LOWER ROCKER COVERS (Page 4-32)
6 Remove push rods and push rod covers. Pushrods, Lifters and Covers (Page 4-35)
7 Remove cylinder head. CYLINDER HEAD (Page 4-38)
8 Remove cylinder. CYLINDERS (Page 4-43)
9 Remove piston. PISTONS (Page 4-46)
Assemble
1 Install piston. PISTONS (Page 4-46)
2 Install cylinder. CYLINDERS (Page 4-43)
3 Install cylinder head. CYLINDER HEAD (Page 4-38)
4 Install push rods and push rod covers. Pushrods, Lifters and Covers (Page 4-35)
5 Install lower rocker cover. LOWER ROCKER COVERS (Page 4-32)
6 Install breather. BREATHERS (Page 4-33)
7 Install rocker arms. Rocker Arms (Page 4-34)

4-24 94000383
 Table 4-33. Engine Removed From Chassis
STEP NO. COMPONENT INSTRUCTIONS
8 Install upper rocker cover. UPPER ROCKER COVERS (Page 4-30)
9 Install engine in motorcycle. INSTALL ENGINE (Page 4-29)

94000383 4-25
CAM COMPARTMENT SERVICE
REPLACE CAMSHAFT
Table 4-34. Engine In Chassis: Cam Compartment Service
STEP NO. COMPONENT
Disassemble
1 Remove parts to gain access to all compon- PREPARE MOTORCYCLE FOR SERVICE (Page 4-22)
ents above cylinder deck.
2 Remove upper rocker covers.
3 Remove rocker arms.
4 Remove push rods and push rod covers.
5 Hold up lifters.
6 Remove timing chain and sprockets.
7 Remove cam support plate.
8 Remove camshaft.
9 Remove oil pump.
Assemble
1 Install oil pump.
2 Install camshaft.
3 Install cam support plate.
4 Install timing chain and sprockets.
5 Remove lifter holding device.
6 Install push rods and push rod covers.
7 Install rocker arms.
8 Install upper rocker covers.
9 Complete motorcycle assembly.
4-26
4.15
INSTRUCTIONS
UPPER ROCKER COVERS (Page 4-30)
Rocker Arms (Page 4-34)
Pushrods, Lifters and Covers (Page 4-35)
CAM COMPARTMENT AND COMPONENTS (Page 4-51)
CAM COMPARTMENT AND COMPONENTS (Page 4-51)
CAM COMPARTMENT AND COMPONENTS (Page 4-51)
CAM COMPARTMENT AND COMPONENTS (Page 4-51)
Oil Pump (Page 4-56)
Oil Pump (Page 4-56)
CAM COMPARTMENT AND COMPONENTS (Page 4-51)
CAM COMPARTMENT AND COMPONENTS (Page 4-51)
CAM COMPARTMENT AND COMPONENTS (Page 4-51)
CAM COMPARTMENT AND COMPONENTS (Page 4-51)
Pushrods, Lifters and Covers (Page 4-35)
Rocker Arms (Page 4-34)
UPPER ROCKER COVERS (Page 4-30)
ASSEMBLE MOTORCYCLE AFTER SERVICE (Page 4-23)
94000383
BOTTOM END SERVICE 4.16
ENGINE REMOVED FROM CHASSIS
Table 4-35. Engine Removed: Flywheel Compartment Service or Complete Engine Overhaul
STEP NO. COMPONENT INSTRUCTIONS
Prepare
1 Remove engine from motorcycle. REMOVE ENGINE (Page 4-28)
2 Disassemble top end. TOP END SERVICE (Page 4-24)
3 Remove camshaft and lifters. CAM COMPARTMENT AND COMPONENTS (Page 4-51)
4 Remove oil pump. Oil Pump (Page 4-56)
Disassemble
5 Separate crankcase halves. Crankcase (Page 4-58)
6 Remove balancer shaft. Crankcase (Page 4-58)
7 Remove flywheel assembly. Crankcase (Page 4-58)
8 Inspect flywheel/connecting rod assembly. FLYWHEEL AND CONNECTING RODS (Page 4-66)
Assemble
1 Install flywheel assembly. Crankcase (Page 4-58)
2 Install balancer shaft. Crankcase (Page 4-58)
3 Mate crankcase halves. Crankcase (Page 4-58)
Complete
4 Install oil pump. Oil Pump (Page 4-56)
4 Install camshaft, lifters. CAM COMPARTMENT AND COMPONENTS (Page 4-51).
5 Assemble top end. TOP END SERVICE (Page 4-24)
6 Install engine. INSTALL ENGINE (Page 4-29)

94000383 4-27
REMOVE ENGINE 4.17
REMOVE Follow all steps listed to remove engine from frame. Refer to
Table 4-36.
PART NUMBER TOOL NAME
HD-45968 FAT JACK
Table 4-36. Remove Engine
STEP NO. COMPONENT INSTRUCTIONS
1 Secure motorcycle on lift. General, Secure the Motorcycle for Service (Page 2-3)
2 Remove seat. SEAT (Page 3-96)
3 Remove fuel tank. FUEL TANK (Page 5-6)
4 Disconnect negative battery cable. Battery Maintenance (Page 2-51)
5 Remove exhaust system. EXHAUST SYSTEM (Page 5-26)
6 Remove air cleaner assembly. AIR CLEANER ASSEMBLY (Page 5-5)
7 Remove induction module assembly. INDUCTION MODULE (Page 5-17)
8 Twin-Cooled: Drain coolant. Coolant (Page 2-19)
9 Disconnect upper cooling lines. COOLING SYSTEM REPAIR (Page 6-6) or OIL COOLANT LINES
(Page 4-19)
10 Drain engine oil. Discard filter. ENGINE OIL AND FILTER (Page 2-15)
11 Disconnect CKP sensor connector. CRANKSHAFT POSITION SENSOR (CKP) (Page 9-44)
12 Remove voltage regulator. VOLTAGE REGULATOR (Page 9-50)
13 Disconnect oil pressure sender connector. Oil Pressure Switch (Page 9-58)
14 Remove primary chaincase housing. PRIMARY CHAINCASE HOUSING (Page 7-9)
15 Remove alternator rotor and stator. ALTERNATOR (Page 9-52)
16 Release main harness and brake line from MAIN WIRING HARNESS (Page 9-82)
lower frame rail. Allow to hang below frame.
17 Disconnect ACRs. Automatic Compression Release (ACR) (Page 9-48)
18 Disconnect knock sensors. KNOCK SENSOR (KS) (Page 9-45)
19 Disconnect cylinder temperature sensor. ENGINE TEMPERATURE SENSOR (ET) (Page 9-46)
20 Disconnect spark plug cables.
21 Remove horn and bracket. HORN (Page 9-60)
22 Wrap rear master cylinder with protective
padding.
23 Wrap rocker covers and lower frame rails
with protective padding.
24 Support transmission. Support transmission using FAT JACK (PART NUMBER: HD-45968)
or similar.
25 Remove four transmission to engine bolts.
26 Remove front stabilizer link and bracket. FRONT ENGINE MOUNT (Page 3-161)
27 Remove lower front engine mount. FRONT ENGINE MOUNT (Page 3-161)
28 Remove engine from chassis. Move engine forward to clear dowels.
Remove engine from right side.

4-28 94000383
INSTALL ENGINE 4.18
INSTALL

Follow all steps listed to install engine in frame. Refer to Table

4-37.
Table 4-37. Install Engine
STEP NO. COMPONENT INSTRUCTIONS
1 Secure motorcycle on lift. General, Secure the Motorcycle for Service (Page 2-3)
2 Install engine. Install engine from right side. Position in chassis. Move rearward into
transmission.
3 Install lower front engine mount. FRONT ENGINE MOUNT (Page 3-161)
4 Install four transmission to engine bolts. TRANSMISSION CASE (Page 8-24)
5 Remove transmission support.
6 Install front stabilizer link and bracket. FRONT ENGINE MOUNT (Page 3-161)
7 Remove protective padding from rear mas-
ter cylinder, rocker covers and lower frame
rails.
8 Install horn and bracket. HORN (Page 9-60)
9 Connect spark plug cables.
10 Connect cylinder temperature sensor. ENGINE TEMPERATURE SENSOR (ET) (Page 9-46)
11 Connect knock sensors. KNOCK SENSOR (KS) (Page 9-45)
12 Connect ACRs. Automatic Compression Release (ACR) (Page 9-48)
13 Secure main harness and brake line to lower MAIN WIRING HARNESS (Page 9-82)
frame rail.
14 Install alternator rotor and stator. ALTERNATOR (Page 9-52)
15 Install primary chaincase housing. PRIMARY CHAINCASE HOUSING (Page 7-9)
16 Connect oil pressure sender connector. Oil Pressure Switch (Page 9-58)
17 Install voltage regulator. VOLTAGE REGULATOR (Page 9-50)
18 Connect CKP sensor connector. CRANKSHAFT POSITION SENSOR (CKP) (Page 9-44)
19 Fill engine oil. Install new filter. ENGINE OIL AND FILTER (Page 2-15)
20 Connect upper cooling lines. COOLING SYSTEM REPAIR (Page 6-6) or OIL COOLANT LINES
(Page 4-19)
21 Twin-Cooled: Fill coolant. Coolant (Page 2-19)
22 Install induction module. INDUCTION MODULE (Page 5-17)
23 Install air cleaner assembly. AIR CLEANER ASSEMBLY (Page 5-5)
24 Install exhaust system. EXHAUST SYSTEM (Page 5-26)
25 Connect negative battery cable. Battery Maintenance (Page 2-51)
26 Install fuel tank. FUEL TANK (Page 5-6)
27 Install seat. SEAT (Page 3-96)
28 Run motorcycle until engine is at normal ENGINE OIL AND FILTER (Page 2-15)
operating temperature. Perform engine oil
level hot check.

94000383 4-29
UPPER ROCKER COVERS 4.19
PREPARE d. Hold hex on stud (4) when tightening center screw
(3).
NOTE
e. See Figure 4-13. Tighten in sequence shown to
Abrasive particles can damage machined surfaces or plug oil 120–140 in-lbs (13.6–15.8 N·m).
passageways. Clean parts before disassembly to prevent
component damage.
3. Install spark plug cables.
1. Use low-pressure compressed air to clean exterior surfaces
of engine. 4. Connect ACR connector.

2. Remove seat. See SEAT (Page 3-96). COMPLETE

3. Remove fuel tank. See FUEL TANK (Page 5-6).
4. Remove upper cooling lines. See COOLING SYSTEM 1. Install upper cooling lines. See COOLING SYSTEM
REPAIR (Page 6-6) or OIL COOLANT LINES REPAIR (Page 6-6) or OIL COOLANT LINES
(Page 4-19). (Page 4-19).
2. Install fuel tank. See FUEL TANK (Page 5-6).
REMOVE
3. Install seat. See SEAT (Page 3-96).
1. Disconnect ACR harness.
sm08559
NOTE 3
Use HD-52006 (Adjustable Spark Plug Wire Puller) to remove
2
stubborn spark plug boots.

2. Disconnect both spark plug cables from spark plugs.

3. See Figure 4-12. Remove the rocker cover screws. 1
a. Hold hex on stud (4).
b. Remove center screw (3).
c. Remove remaining screws.

4. Remove the rocker cover (2) and gasket (1). Discard

gasket.
5. Clean threadlocker from all screws and threaded holes. 4
See Cleaning Fastener Threads in General, Shop
Practices (Page 2-3).
a. Cover exposed internal engine area to prevent
contamination from loosened threadlocker.
b. Verify that no foreign material in the threaded hole.

INSTALL

FASTENER TORQUE VALUE

Lower rocker cover screws 90–120 in-lbs 10.2–13.6 N·m
Upper rocker cover screws 120–140 in-lbs 13.6–15.8 N·m 1. Gasket
2. Rocker cover
1. Verify that all threaded holes are free from oil and 3. Center screw
threadlocking residue. 4. Stud
Figure 4-12. Rocker Cover Screws
2. Install rocker cover and new gasket.

a. Verify that torque of stud (4) is 90–120 in-lbs

(10.2–13.6 N·m).

b. Apply LOCTITE 243 MEDIUM STRENGTH

THREADLOCKER AND SEALANT (blue) to 5-7
screw threads.

c. Start all screws.

4-30 94000383
 sm08560

5 7

3 2

10

8 9

1 4
6

Figure 4-13. Rocker Cover Tightening Sequence

94000383 4-31
LOWER ROCKER COVERS 4.20
PREPARE sm08561

1. Remove seat. See SEAT (Page 3-96).

2. Remove fuel tank. See FUEL TANK (Page 5-6).
3. Remove upper cooling lines. See COOLING SYSTEM
REPAIR (Page 6-6) or OIL COOLANT LINES
(Page 4-19). 3 2
4. Remove upper rocker cover. See UPPER ROCKER
COVERS (Page 4-30).
5. Remove breather. See BREATHERS (Page 4-33). 5
6. Engine in chassis: Remove rocker arms. See Rocker
Arms (Page 4-34).
REMOVE 1 4

1. See Figure 4-14. Remove lower rocker cover.

a. Remove five screws. Figure 4-14. Lower Rocker Cover

b. Lift off from cylinder head.

COMPLETE
c. Engine in chassis: Remove from left side. 1. Engine in chassis: Install rocker arms. See Rocker Arms
(Page 4-34).
2. Discard gasket.
2. Install breather. See BREATHERS (Page 4-33).
3. Clean threadlocker from all screws and threaded holes.
See Cleaning Fastener Threads in General, Shop 3. Install upper rocker cover. See UPPER ROCKER COVERS
Practices (Page 2-3). (Page 4-30).

a. Cover exposed internal engine area to prevent 4. Install upper cooling lines. See COOLING SYSTEM
contamination from loosened threadlocker. REPAIR (Page 6-6) or OIL COOLANT LINES
(Page 4-19).
INSTALL 5. Install fuel tank. See FUEL TANK (Page 5-6).
6. Install seat. See SEAT (Page 3-96).
FASTENER TORQUE VALUE
Lower rocker cover screws 90–120 in-lbs 10.2–13.6 N·m

1. Install new gasket.

2. See Figure 4-14. Install lower rocker cover.

a. Engine in chassis: Install from left side.

b. Apply LOCTITE 243 MEDIUM STRENGTH

THREADLOCKER AND SEALANT (blue) to 5-7
screw threads.

c. Start four screws and the stud.

d. Tighten in sequence shown to 90–120 in-lbs

(10.2–13.6 N·m).

4-32 94000383
BREATHERS 4.21
PREPARE

1. Remove seat. See SEAT (Page 3-96).

2. Remove fuel tank. See FUEL TANK (Page 5-6).
3. Remove cooling lines. See COOLING SYSTEM REPAIR
(Page 6-6) or OIL COOLANT LINES (Page 4-19).
4. Remove upper rocker cover. See UPPER ROCKER
COVERS (Page 4-30).
REMOVE
1. See Figure 4-15. Remove screw (1).
2. Remove breather assembly (2).
NOTE
Breather assembly contains no service parts. Replace as an
assembly.

INSTALL

FASTENER TORQUE VALUE

Breather screw 90–120 in-lbs 10.2–13.6 N·m

1. See Figure 4-15. Lubricate O-ring (3).

2. Install breather with screw (1). Tighten to 90–120 in-lbs

(10.2–13.6 N·m).

sm08567
1

1. Screw
2. Breather assembly
3. O-ring
Figure 4-15. Breather
COMPLETE

1. Install upper rocker cover. See UPPER ROCKER COVERS

(Page 4-30).
2. Install cooling lines. See COOLING SYSTEM REPAIR
(Page 6-6) or OIL COOLANT LINES (Page 4-19).
3. Install fuel tank. See FUEL TANK (Page 5-6).
4. Install seat. See SEAT (Page 3-96).

94000383 4-33
ROCKER ARMS 4.22
PREPARE f. Tighten to 23–27 ft-lbs (31.2–36.6 N·m).

g. Repeat with remaining rocker arms.

1. Remove seat. See SEAT (Page 3-96).
2. Remove fuel tank. See FUEL TANK (Page 5-6). NOTE
3. Remove cooling lines. See COOLING SYSTEM REPAIR Do not rotate crankshaft until lifters have bled down. Rotating
(Page 6-6) or OIL COOLANT LINES (Page 4-19). crankshaft sooner could result in valve-to-piston contact
resulting in damage.
4. Remove upper rocker cover. See UPPER ROCKER
COVERS (Page 4-30).
3. Allow lifters to bleed down. When lifters have bled down,
REMOVE pushrods can be rotated by hand.

1. Remove rocker arms. 4. Check valve lash after lifters have bled down.
a. Set piston at TDC on the compression stroke.
a. Position crankshaft at TDC of compression stroke.
b. See Figure 4-16. Remove screws (3). All valves will be closed.
c. Remove rocker shaft (1) and rocker arm (4).
b. While holding rocker arm against valves, attempt to
d. Repeat with remaining rocker arm. slide a feeler gauge between each valve stem tip
and the rocker arm.
sm08562
4 c. The maximum allowable lash on a common rocker
arm is 0.008 in (0.2 mm). A measurement in excess
requires disassembly and repair of cylinder head
3 assembly.
2
COMPLETE
1 1. Install upper rocker cover. See UPPER ROCKER COVERS
(Page 4-30).
2. Install cooling lines. See COOLING SYSTEM REPAIR
(Page 6-6) or OIL COOLANT LINES (Page 4-19).
3. Install fuel tank. See FUEL TANK (Page 5-6).
4. Install seat. See SEAT (Page 3-96).
1. Shaft
2. Head casting CLEAN AND INSPECT
3. Screw
4. Rocker arm 1. Clean all parts.
Figure 4-16. Remove Rocker Arms 2. Inspect for wear. Replace or repair as necessary.
INSTALL a. Measure rocker arm bore.
b. Measure rocker arm shaft for excessive wear.
FASTENER TORQUE VALUE
Rocker shaft screw 23–27 ft-lbs 31.2–36.6 N·m c. Inspect valve contact areas for excessive wear.
d. Inspect pushrod pocket for excessive wear.
1. Set piston at approximate BDC on the power stroke.
e. Verify that oil holes in rocker arms are clean and open.
2. Install rocker arms.

a. Verify that lifters are on the base circle of the

camshaft lobe.

b. See Figure 4-16. Install rocker arm (4) and rocker

shaft (1).

c. Verify that rocker shaft is seated in both towers.

d. Install screws (3).

e. Alternately tighten screws to pull rocker shaft down

evenly.

4-34 94000383
PUSHRODS, LIFTERS AND COVERS 4.23
PREPARE sm02329

1. Remove seat. See SEAT (Page 3-96).

2. Remove fuel tank. See FUEL TANK (Page 5-6).
1
3. Remove spark plugs.
4. Remove upper cooling lines. See COOLING SYSTEM
REPAIR (Page 6-6) or OIL COOLANT LINES
(Page 4-19).
5. Remove upper rocker cover. See UPPER ROCKER 2
COVERS (Page 4-30).
6. Remove rocker arms. See Rocker Arms (Page 4-34).
7. Remove intake manifold and induction module. See
INDUCTION MODULE (Page 5-17)
REMOVE
1. Tab
2. Spring cap
NOTE
Mark parts for location and orientation during removal. Figure 4-17. Removing Spring Cap Retainer

sm08563
1. Remove pushrods. 2
2. Remove pushrod covers using 94086-09 (PUSHROD 1
COVER RETAINER INSTALLATION AND REMOVAL 3
TOOL).
a. See Figure 4-17. Alternately, insert the blade of a 4
screwdriver in tab (1) of spring cap retainer.
b. While pushing down on spring cap (2), rotate bottom of 5
retainer outboard.

3. Remove pushrod covers.

a. Collapse upper and lower pushrod covers. 6

4. Disassemble pushrod cover assemblies.

a. Discard three O-rings.

5. See Figure 4-18. Remove lifter covers. 1. Screw (4)

2. Lifter cover
a. Remove four screws (1). 3. Gasket
b. Remove the lifter cover (2) and gasket (3). Discard 4. Screw
gasket. 5. Anti-rotation device
6. Lifter (2)
6. Remove lifters. Figure 4-18. Lifter Cover
a. Remove screw (4) securing anti-rotation device (5). ASSEMBLE PUSHROD COVER
b. Remove anti-rotation device.
1. See Figure 4-19 . Apply a film of clean engine oil to new
c. Remove the lifters (6) and place in clean plastic bags O-rings (1, 7 and 9).
to prevent contamination.
2. Install upper O-ring (1) on the upper pushrod cover (2).
3. Slide the spring cap (4), spring (5), flat washer (6) and
middle O-ring (7) onto the body of the upper pushrod cover.
Move parts up until spring cap contacts upper O-ring seat.
4. Fit the straight end of the upper pushrod cover into the
flared end of the lower pushrod cover (8).
5. Install lower O-ring (9) on lower pushrod cover.

94000383 4-35
 d. See Figure 4-18. Install the anti-rotation device.
sm02493
1
3 e. Install screw (4). Tighten to 90–120 in-lbs
2 (10.2–13.6 N·m).

4 2. Install the lifter cover (2), new gasket (3) and screws (1).
Tighten to 132–156 in-lbs (14.9–17.6 N·m) in a cross-wise
pattern.
5
3. Install pushrod covers.
6
7
a. Assemble pushrod covers with new O-rings.

b. Install new O-rings on each end of the pushrod

cover.

c. Compress the pushrod cover assembly and fit into

10
the lifter cover bore.

d. Extend the assembly into the cylinder head bore.

e. Verify that the ends of the pushrod covers fit snugly

8 into the cylinder head and lifter cover bores.

4. Install spring cap retainers using 94086-09 (PUSHROD

COVER RETAINER INSTALLATION AND REMOVAL
TOOL).

a. Insert the upper edge of spring cap retainer into the

cylinder head bore.
9
b. See Figure 4-20. Alternately, insert blade of small
1. Upper O-ring (small) screwdriver between bottom edge of spring cap
2. Upper pushrod cover retainer and top of spring cap.
3. Spring cap retainer
4. Spring cap c. Press spring cap down and slide bottom edge of
5. Spring retainer toward tip of screwdriver.
6. Flat washer
d. Verify that spring cap retainer seats tightly against
7. Middle O-ring (intermediate)
upper pushrod cover.
8. Lower pushrod cover
9. Lower O-ring (large)
10. Flared end of lower pushrod cover 5. Apply a small amount of SCREAMIN' EAGLE ASSEMBLY
LUBE to the ends of each pushrod.
Figure 4-19. Assembled Pushrod Cover
INSTALL 6. Install the pushrods. If installing original parts, install them
in their original locations and orientation.
FASTENER TORQUE VALUE
Lifter anti-rotation device 90–120 in-lbs 10.2–13.6 N·m
screw
Lifter cover screws 132–156 in-lbs 14.9–17.6 N·m

NOTE
Anti-rotation devices are marked "F" (front) and "R" (rear).

1. Install lifters.

a. Apply SCREAMIN' EAGLE ASSEMBLY LUBE to

outer surface of each lifter. Pour a small amount onto
each cam lobe.

b. Rotate crankshaft until both cam lobes are visible in

lifter bores.

c. Carefully install lifters in the lifter bores. Do not drop

lifters onto cam lobes.

4-36 94000383
 5. Examine lifter rollers. If damaged, examine the associated
sm02347
cam lobe.

a. Verify that the hydraulic lifter rollers turn freely.

b. Check for flat spots, scuff marks and pitting.

c. See Figure 4-21. A dull lifter roller surface is called

frosting (2). Frosting is a cosmetic condition and does
not affect function.

6. Inspect the lifter for signs of wear.

a. Verify that the plunger is fully extended against the

C-clip.

b. Pump plunger to verify operation.

7. Examine the pushrods. Replace any pushrods that are

bent, dented, damaged, discolored or if the ball ends show
signs of excessive wear or damage.

Figure 4-20. Install Spring Cap Retainers 8. Cover all parts to protect them from dust and dirt.
COMPLETE
sm08482
FASTENER TORQUE VALUE
1 2
1
Spark plug 89–133 in-lb 10–15 N·m

1. Install rocker arms. See Rocker Arms (Page 4-34).

2. Install rocker cover. See UPPER ROCKER COVERS
(Page 4-30).
3. Install manifold and induction module. See INDUCTION
MODULE (Page 5-17)
4. Install upper cooling lines. See COOLING SYSTEM
REPAIR (Page 6-6) or OIL COOLANT LINES
(Page 4-19).
5. Install spark plugs. Tighten to 89–133 in-lb (10–15 N·m).
6. Install fuel tank. See FUEL TANK (Page 5-6). 1. Normal roller
2. Frosted roller
7. Install seat. See SEAT (Page 3-96)
Figure 4-21. Roller Inspection
CLEAN AND INSPECT
INSPECT LIFTERS
1. Except for the hydraulic lifters, clean all parts in a
1. Measure the lifter outer diameter. Record the
non-volatile cleaning solution or solvent.
measurement.

WARNING 2. Measure lifter bore. Subtract this measurement from the

lifter measurement to determine clearance.
Compressed air can pierce the skin and flying debris from
a. Clearance when new is 0.0008 –0.002 in
compressed air could cause serious eye injury. Wear
(0.0203–0.0508 mm).
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air b. Install new lifters and/or replace crankcases if clearance
flow rates. (00061a) exceeds service wear limit of 0.007 in (0.076 mm).

2. Dry parts with low-pressure, compressed air. 3. Check lifter roller end clearance.
a. Allowable end clearance is within 0.008 –0.022 in
3. Verify that the O-ring seats and contact surfaces of the (0.203–0.559 mm).
pushrod covers are completely clean.
b. Replace lifters if end clearance exceeds service wear
limit of 0.022 in (0.559 mm).
4. Verify that all oil holes are clean and open.
4. Soak lifters in clean engine oil. Keep covered until
assembly.

94000383 4-37
CYLINDER HEAD 4.24
PREPARE
1. Remove old gasket material from cylinder head. Do not
cause scratches or nicks.
1. Disconnect negative battery cable. See Battery
Maintenance (Page 2-51).
NOTICE
2. Remove fuel tank. See FUEL TANK (Page 5-6).
Do not use glass or sand to bead blast surfaces exposed
3. Remove exhaust system. See EXHAUST SYSTEM
to engine oil. Blasting materials can lodge in pores of the
(Page 5-26).
casting. Heat expansion releases this material which can
4. Remove air cleaner assembly. See AIR CLEANER contaminate oil resulting in engine damage. (00534b)
ASSEMBLY (Page 5-5).
5. Remove upper cooling lines. See COOLING SYSTEM 2. Remove all carbon deposits from combustion chamber
REPAIR (Page 6-6) or OIL COOLANT LINES and machined surfaces of cylinder head. Do not remove
(Page 4-19). any metal material.

6. Remove induction module and manifold. See INDUCTION

MODULE (Page 5-17). NOTE
Keep all parts grouped by location so they can be installed in
7. Remove rocker covers. See UPPER ROCKER COVERS the original location.
(Page 4-30) and LOWER ROCKER COVERS (Page 4-32).
8. Remove rocker arms. See Rocker Arms (Page 4-34). 3. To soften stubborn deposits, soak the cylinder head in a
9. Remove pushrods and pushrod covers. See Pushrods, chemical solution, such as GUNK HYDRO-SEAL or other
Lifters and Covers (Page 4-35). carbon and gum dissolving agent. Repeat previous step
as necessary.
REMOVE
4. Thoroughly clean the cylinder head, spring retainers,
1. Disconnect knock sensor connector. tapered keepers, valves and valve springs in a non-volatile
2. See Figure 4-22. Remove cylinder head bolts. cleaning solution or solvent. Follow up with a thorough
wash in hot soapy water.
a. Loosen each cylinder head bolt in sequence shown.
b. Remove head bolts. 5. Thoroughly flush all coolant and oil passages to remove
loose debris.
3. Remove cylinder head.
a. Lift cylinder head from dowel pins. WARNING

b. Discard gasket. 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
sm08564
use your hand to check for air leaks or to determine air
flow rates. (00061a)

1 3 3 1 6. Dry parts with low-pressure, compressed air.

7. Clean threadlocker from all screws and threaded holes.

See Cleaning Fastener Threads in General, Shop
Practices (Page 2-3).
4 2 2 4
a. Cover exposed internal engine area to prevent
contamination from loosened threadlocker.

INSTALL

Figure 4-22. Head Bolt Tightening Sequence FASTENER TORQUE VALUE

Cylinder head bolt first torque 20–30 ft-lbs 27.1–40.7 N·m
CLEANING
Cylinder head bolt second 9–11 ft-lbs 12.2–14.9 N·m
torque
NOTE
Cylinder head bolt third torque 25–27 ft-lbs 33.9–36.6 N·m
Avoid getting debris in coolant and oil passages during gasket
removal and cleaning.
1. Clean all gasket surfaces.
NOTE
Bead blasting materials could enter threaded holes. This would 2. Thoroughly flush all coolant and oil passages to remove
adversely affect fastener engagement and torque indication. loose debris.
Cover all threaded holes before bead blasting.

4-38 94000383
3. See Figure 4-23. Install cylinder head. 3. Check valve lash variation. See Rocker Arms (Page 4-34).
4. Install rocker covers. See LOWER ROCKER COVERS
a. Install new gasket with the part number facing up. (Page 4-32) and UPPER ROCKER COVERS (Page 4-30).
b. Install cylinder head on dowel pins. 5. Install induction module and manifold. See INDUCTION
MODULE (Page 5-17).
4. Install cylinder head bolts. 6. Install upper cooling lines. See COOLING SYSTEM
REPAIR (Page 6-6) or OIL COOLANT LINES
a. Apply new engine oil to flanges and threaded portion (Page 4-19).
of the cylinder head bolts.
7. Install air cleaner assembly. See AIR CLEANER
ASSEMBLY (Page 5-5).
b. Install cylinder head bolts.
8. Install exhaust system. See EXHAUST SYSTEM
5. See Figure 4-22.Tighten head bolts in five stages following (Page 5-26).
sequence shown. 9. Install fuel tank. See FUEL TANK (Page 5-6).

a. Tighten to 20–30 ft-lbs (27.1–40.7 N·m). 10. Connect negative battery cable. See Battery Maintenance
(Page 2-51).
b. Loosen one full rotation. DISASSEMBLE
c. Tighten to 9–11 ft-lbs (12.2–14.9 N·m).
PART NUMBER TOOL NAME
d. Tighten to 25–27 ft-lbs (33.9–36.6 N·m). B-49312 CYLINDER HEAD HOLDING FIXTURE
HD-34736-B VALVE SPRING COMPRESSOR
e. Final tighten an Cylinder head bolt final
torqueadditional 90 degrees-. 1. Secure cylinder head for service.
a. Remove spark plugs.
6. Connect knock sensor.
b. Turn 12 mm end of CYLINDER HEAD HOLDING
FIXTURE (PART NUMBER: B-49312) (1) into cylinder
sm08565
head (2) spark plug hole.

1 c. Clamp tool in vise at a comfortable working position.

2. Remove ACR. See Automatic Compression Release (ACR)

(Page 9-48).
3. See Figure 4-24. Remove screw (2) and knock sensor (1).

2 4. Remove cylinder head temperature sensor (3).

5. See Figure 4-26. Remove valves.
a. See Figure 4-25. Use VALVE SPRING COMPRESSOR
(PART NUMBER: HD-34736-B) to compress valve
spring.
b. Remove tapered keepers (1).
c. Slowly release valve spring compression.
d. Remove the spring retainer (2) and valve spring (3).
e. Remove the valve (11).

6. Remove and discard valve stem seal assembly (4).

3 7. Identify components.
a. Mark the valve head for identification.

1. Head bolt (4) b. Place tapered keepers, valve spring and spring retainer
2. Cylinder head in a plastic bag with identification.
3. Head gasket
8. Remove the remaining valves and components.
Figure 4-23. Cylinder Head
COMPLETE
1. Install pushrods and pushrod covers. See Pushrods, Lifters
and Covers (Page 4-35).
2. Install rocker arms. See Rocker Arms (Page 4-34).

94000383 4-39
 sm08568 sm08569 1
2
1
2 3

1. Knock sensor
2. Screw
3. Head temperature sensor (rear head only)
Figure 4-24. Cylinder Head Sensors

sm02495
5

1. Keepers (2)
2. Retainer
3. Spring
4. Stem seal assembly
5. Valve
1
Figure 4-26. Valve Components
2
INSPECT

PART NUMBER TOOL NAME

B-45525 VALVE GUIDE HONE
HD-34751 CLEANING BRUSH

See SERVICE WEAR LIMITS (Page 4-5) for specifications

not shown here.

Cylinder Head
1. Holding fixture 1. Check all gasket sealing surfaces for scratches and nicks.
2. Compressor 2. Check head flatness with feeler gauge.
Figure 4-25. Valve Spring Compressor
a. Using a straightedge, check gasket surface for warpage.
b. Replace the head if warpage is 0.006 in (0.152 mm)
or greater.

3. Verify that all oil holes are clean and open.

Valve Guides
1. Inspect external surfaces for cracks.
2. Prepare valve guides for inspection.
a. Lightly hone bore using the VALVE GUIDE HONE
(PART NUMBER: B-45525).
b. Scrub bore with the CLEANING BRUSH (PART
NUMBER: HD-34751).
c. Polish valve stem with fine emery cloth or steel wool to
remove carbon buildup.

4-40 94000383
3. Check valve stem to guide clearance. FASTENER TORQUE VALUE
a. Measure the inside diameter of the valve guide. Knock sensor screw 13–17 ft-lbs 17.6–23 N·m

b. Measure the outside diameter of the valve stem. 1. Secure cylinder head for service.
c. If stem to guide clearance exceeds service limits, repeat
measurements with a new valve to determine worn a. Turn 10 mm end of CYLINDER HEAD HOLDING
components. FIXTURE (PART NUMBER: B-49312) into spark
plug hole.
d. If stem to guide clearance exceeds service limits with
a new valve, replace cylinder head.
NOTE
Install all parts in their original location and position.
Valves and Valve Seats
1. With valves removed, inspect the sealing surface of the b. Clamp tool in vise at a comfortable working position.
valve face and valve seat.
2. Install valve.
a. The sealing surfaces must be smooth and even around
entire contact area.
a. Clean valve guide with CLEANING BRUSH (PART
b. If the sealing contact area is uneven or shows evidence NUMBER: HD-34751).
of pitting, carbon tracking, or other indications of
combustion gas leakage, recondition the valve and seat, b. Apply a liberal amount of SCREAMIN' EAGLE
or replace cylinder head assembly. See CYLINDER ASSEMBLY LUBE to valve stem.
HEAD, Valve and Seat Repair (Page 4-42).
c. Install the valve into the cylinder head.
2. Inspect the valve for burning, cracking, carbon tracking,
or other indications of combustion gas leakage. d. Spin the valve as it is installed to distribute the
lubricant evenly.
3. Inspect the end of the valve stem for pitting or uneven
wear. e. Remove the valve and apply a second coat of
4. Remove burrs around the valve stem keeper groove with SCREAMIN' EAGLE ASSEMBLY LUBE to the valve
a fine tooth file. stem. Install the valve.

5. To determine if the valve stem is excessively worn, see

NOTICE
valve guide inspection.
Failure to install plastic capsule can cause the valve stem
Valve Springs seal to catch the edge of the valve stem keeper groove.
The resulting damage can cause leakage around the valve
1. Inspect springs for cracked or discolored coils.
stem, excessive oil consumption and valve sticking.
2. Check for squareness. (00535b)
3. Check free length.
3. Install valve stem seal.
4. Load test using a commercially available valve spring
tester.
a. Slide plastic capsule supplied with new valve stem
seal over valve stem tip.
Tapered Keepers
Install new keepers any time valves are installed. b. Apply SCREAMIN' EAGLE ASSEMBLY LUBE to
capsule.
Valve Seats
c. See Figure 4-27. Slide new valve stem seal
1. Inspect seats for cracking, chipping or burning, carbon assembly over capsule and down valve stem until
tracking, or other indications of combustion gas leakage. seated against cylinder head casting.
2. Check seat wear by measuring valve stem protrusion. See
d. Remove capsule from valve stem tip.
CYLINDER HEAD, Valve and Seat Repair (Page 4-42).
3. Replace cylinder head if seats are damaged or worn sm02528a
excessively.
ASSEMBLE

PART NUMBER TOOL NAME

B-49312 CYLINDER HEAD HOLDING FIXTURE
HD-34736-B VALVE SPRING COMPRESSOR
HD-34751 CLEANING BRUSH

FASTENER TORQUE VALUE Figure 4-27. Valve Stem Seal Assembly

Cylinder temperature sensor 120–180 in-lbs 13.6–20.3 N·m

94000383 4-41
4. See Figure 4-26. Install valve spring.
sm00148

a. Apply a liberal amount of SCREAMIN' EAGLE

ASSEMBLY LUBE to valve stem tip and keeper
groove.

b. Install the valve spring (3) with the smaller diameter

coils topside. 1 2
c. Place the spring retainer (2) on top of the valve
spring.

5. Install new keepers.

5
a. compress valve spring with VALVE SPRING 3 4
COMPRESSOR (PART NUMBER: HD-34736-B).
1. 0.040-0.080 in (1.02-2.03 mm)
b. Install the keepers. 2. 60 degrees
3. 31 degrees
c. Slowly release valve spring compression. 4. 46 degrees
5. Margin: 0.031 in (0.79 mm) minimum
d. Tap the end of the valve stem once or twice with a Figure 4-28. Valve and Seat Dimensions
soft mallet to make sure that tapered keepers are
tightly seated. Table 4-38. Valve Stem to Guide Clearance
VALVE IN MM
6. Install remaining valves.
Intake 0.001-0.003 0.0254-0.0762
7. Install ACR. See Automatic Compression Release (ACR) Exhaust 0.001-0.003 0.0254-0.0762
(Page 9-48).

8. See Figure 4-24. Install knock sensor with screw (2).

a. Rotate sensor housing up against head casting.

b. Tighten to 13–17 ft-lbs (17.6–23 N·m).

9. Install temperature sensor (3). Tighten to 120–180 in-lbs

(13.6–20.3 N·m).

VALVE AND SEAT REPAIR

NOTE
• Verify correct valve stem to valve guide clearance before
refacing. Refer to Table 4-38.
• The correct finished angles are 45 degree valve face and
46 degree valve seat eliminating the need to lap.
• Finish valve seat to an even width of 0.040 –0.062 in
(1.016–1.575 mm).
• See Figure 4-28. Replace the valve if margin (5) is less than
0.0313 in (0.795 mm).
• Refurbish valves and seats in pairs. Valve stem protrusion
of a pair operated by the same rocker arm must be equal.
Verify that valve lash is within specification. See Rocker
Arms, Install (Page 4-34).
• If valve stem protrusion exceeds 1.752 in (44.5 mm),
replace the valve or cylinder head as necessary.

4-42 94000383
CYLINDERS 4.25
PREPARE sm08734
2
1. Disconnect negative battery cable. See Battery
1
Maintenance (Page 2-51).
2. Remove fuel tank. See FUEL TANK (Page 5-6).
3. Remove exhaust system. See EXHAUST SYSTEM
3
(Page 5-26).
4. Remove air cleaner assembly. See AIR CLEANER
ASSEMBLY (Page 5-5).
5. Remove upper cooling lines. See COOLING SYSTEM 4
REPAIR (Page 6-6) or OIL COOLANT LINES
(Page 4-19).
6. Remove induction module and manifold. See INDUCTION
MODULE (Page 5-17). 1. Head gasket
2. Dowel pin
7. Remove rocker covers. See UPPER ROCKER COVERS
3. Cylinder
(Page 4-30) and LOWER ROCKER COVERS (Page 4-32).
4. Gasket
8. Remove rocker arms. See Rocker Arms (Page 4-34). Figure 4-29. Cylinder Assembly
9. Remove pushrods and pushrod covers. See Pushrods, CLEAN AND INSPECT
Lifters and Covers (Page 4-35).
10. Remove cylinder head. See CYLINDER HEAD, Prepare 1. Clean all gasket material from the cylinder.
(Page 4-38).
2. Clean parts in a non-volatile cleaning solution. Dry parts
REMOVE with low-pressure, compressed air.
3. Deglaze cylinders. See CYLINDERS, Deglaze Cylinder
NOTE (Page 4-43).
Do not bend the cylinder studs.
4. Verify that all oil holes are clean and open.

1. Remove the cylinder. 5. Inspect the cylinder bore for defects or damage in the ring
travel area.
a. Raise the cylinder and place clean shop towels under
the piston. 6. Carefully remove any nicks or burrs from the machined
gasket surfaces.
b. Hold the piston to prevent touching the studs as it exits
the cylinder. 7. Check the gasket surfaces for flatness. Measure with a
straightedge and feeler gauge.
c. Lift cylinder clear of piston.
a. Check head gasket surface of the cylinder. Record
2. Slide plastic tubing, rubber hose or conduit over each measurements.
cylinder stud to protect cylinder studs and piston from b. Check lower gasket surface of the cylinder. Record
damage. measurements.
3. See Figure 4-29. Discard gasket (4). c. Discard cylinder if either gasket surface flatness is not
within wear limits. See SERVICE WEAR LIMITS
(Page 4-5)

8. Measure cylinder bore for out-of round and taper. Measure

parallel to and perpendicular to the crankshaft centerline.
a. Measure the cylinder diameter at the top of the piston
ring travel zone, below the combustion zone. Record
the measurements.
b. Repeat the measurements at the center of the piston
ring travel zone.
c. If the measurements are not within wear limits, replace
the cylinder. See SERVICE WEAR LIMITS (Page 4-5).

DEGLAZE CYLINDER

NOTE
A precise 60 degree crosshatch pattern in the piston travel
area is important.

94000383 4-43
1. Lightly swab the cylinder bore with a cloth dipped in clean
sm02343
engine oil.

NOTICE

The angular crosshatch pattern ensures an even flow of 1

oil onto the cylinder walls and promotes longer cylinder, 3
piston and ring life. An incorrect cross hatch pattern will
2
result in insufficient oil retention and possible piston
seizure and/or high oil consumption. (00536c)

2. Deglaze cylinder with a 240 grit flexible ball-type deglazing

tool. Create a 60 degree crosshatch.

NOTICE

Failure to remove all abrasive particles may result in

premature cylinder, piston and ring wear and engine
failure. (00537c)

3. Thoroughly wash the cylinder bore with liquid dishwashing

soap and hot water. Continue cleaning until a clean cloth
shows no evidence of dirt or debris.

a. Hot rinse the cylinder and dry with moisture free

compressed air. 1. Support plate
2. Knobs
b. Immediately apply a thin film of clean engine oil to a 3. Screw
clean white paper towel and thoroughly wipe the
inside of the cylinder. Figure 4-30. Piston Support Plate
5. See Figure 4-31. Install cylinder using PISTON RING
c. Repeat wiping process until a new towel remains COMPRESSOR (PART NUMBER: HD-96333-51F).
white.
a. Align tool with the top of the band positioned between
INSTALL the top compression ring and the piston crown.
b. Compress piston rings.
PART NUMBER TOOL NAME c. Align the indent in the cooling fins to the right side of
HD-96333-51F PISTON RING COMPRESSOR the engine. Slide cylinder over the cylinder studs and
piston until it rests on the top of the ring compressor.
NOTE
d. Push down on the cylinder with a sharp, quick motion
Front and rear cylinders are unique. Install them in the correct
using the palms of both hands.
locations.
e. Remove pliers and piston support plate.
1. Prepare for cylinder installation. f. Remove shop towels from around the crankcase bore.
a. Install new base gasket to the crankcase. g. Push down on the cylinder until it is fully seated in the
b. See Figure 4-42. Verify piston ring alignment. crankcase bore.

c. Apply clean engine oil to piston, piston rings and h. See Figure 4-32. Install HD-52020 (CYLINDER
cylinder bore. HOLD-DOWN NUTS) onto cylinder studs.

d. Rotate crankshaft until piston is at top dead center.

2. Remove protective covers from cylinder studs.

3. See Figure 4-30. Install the HD-52185 (PISTON SUPPORT
PLATE) under piston.
4. Rotate crankshaft until piston skirt is centered and firmly
seated on top of support plate.

4-44 94000383
 9. Install exhaust system. See EXHAUST SYSTEM
sm02344
(Page 5-26).
10. Install fuel tank. See FUEL TANK (Page 5-6).
11. Connect negative battery cable. See Battery Maintenance
1
2 (Page 2-51).

1. Pliers
2. Compressor band
Figure 4-31. Piston Ring Compressor

sm08735

Figure 4-32. Install Threaded Cylinders to Studs

COMPLETE
1. Install cylinder head. See CYLINDER HEAD, Install
(Page 4-38).
2. Install pushrods and pushrod covers. See Pushrods, Lifters
and Covers (Page 4-35).
3. Install rocker arms. See Rocker Arms (Page 4-34).
4. Adjust valve clearance. See Rocker Arms (Page 4-34).
5. Install rocker covers. See LOWER ROCKER COVERS
(Page 4-32) and UPPER ROCKER COVERS (Page 4-30).
6. Install induction module and manifold. See INDUCTION
MODULE (Page 5-17).
7. Install upper cooling lines. See COOLING SYSTEM
REPAIR (Page 6-6) or OIL COOLANT LINES
(Page 4-19).
8. Install air cleaner assembly. See AIR CLEANER
ASSEMBLY (Page 5-5).

94000383 4-45
PISTONS 4.26
PREPARE sm08617
2
1. Disconnect negative battery cable. See Battery 3
Maintenance (Page 2-51). 1
2. Remove fuel tank. See FUEL TANK (Page 5-6).
3. Remove exhaust system. See EXHAUST SYSTEM
(Page 5-26).
4. Remove air cleaner assembly. See AIR CLEANER
ASSEMBLY (Page 5-5).
5. Remove upper cooling lines. See COOLING SYSTEM
REPAIR (Page 6-6) or OIL COOLANT LINES
(Page 4-19).
6. Remove induction module and manifold. See INDUCTION
MODULE (Page 5-17).
7. Remove rocker covers. See UPPER ROCKER COVERS
(Page 4-30) and LOWER ROCKER COVERS (Page 4-32). 1. Piston pin retaining ring installer
2. Piston
8. Remove rocker arms. See Rocker Arms (Page 4-34). 3. Protective material over cylinder studs
9. Remove pushrods and pushrod covers. See Pushrods, Figure 4-33. Piston Pin Retaining Ring Removal
Lifters and Covers (Page 4-35).
3. See Figure 4-34. Remove piston.
10. Remove cylinder head. See CYLINDER HEAD
(Page 4-38). a. Remove the piston pin using HD-42320-8 (PISTON PIN
EXTRACTOR) with HD-42320-D (PISTON PIN
11. Remove cylinder. See CYLINDERS (Page 4-43). REMOVER).
REMOVE b. Hold the connecting rod to prevent it from striking the
crankcase. Remove the piston.
NOTE c. Place a piece of foam-type water pipe insulation around
It is not necessary to remove both piston pin retaining rings for connecting rod to prevent damage.
piston removal.
4. Identify piston location by marking piston pin boss
1. Place clean shop towels over crankcase bore to prevent underneath.
the piston pin retaining ring from falling into the crankcase.
sm08618
2. See Figure 4-33. Using HD-51069-2 (PISTON PIN
RETAINING RING INSTALLER) with HD-51069-17 (NOSE
ADAPTER), remove and discard one piston pin retaining
ring.
a. Insert tool (1) into piston pin bore with claw on tool in
slot of piston (2) (directly under retaining ring).
b. Squeeze handles of tool together.
c. Pull retaining ring from bore. Discard retaining ring.

Figure 4-34. Remove Piston Pin

INSTALL

NOTE
Do not reuse piston pin retaining rings.

1. Install one new piston pin retaining ring using HD-51069-2

(PISTON PIN RETAINING RING INSTALLER) with
HD-51069-17 (NOSE ADAPTER).
a. See Figure 4-35. Slide retaining ring down nose of tool
until it contacts claw.
b. Center retaining ring at top of tool. Lightly squeeze
handles of tool to capture retaining ring in claw.

4-46 94000383
 c. Tilt the retaining ring forward until the end gap contacts
sm02380a
nose of tool.
d. See Figure 4-37. Insert the tool (2) into the piston pin
bore until claw is aligned with slot (3) in piston.
e. Firmly push the tool into the piston pin bore until it 3
bottoms.
1
f. Release handles, Remove tool.
g. See Figure 4-36. Verify that retaining ring end gap (3)
2
is opposite from opening (2).
h. Inspect the retaining ring to verify that it is fully seated
in the groove.

2. Install piston.
a. Verify that one retaining ring is installed in piston pin
bore.
1. Piston pin
b. Apply SCREAMIN' EAGLE ASSEMBLY LUBE to piston 2. Retaining ring opening
pin, piston pin bores and upper connecting rod bore. 3. End gap location
c. Remove water pipe insulation from connecting rod Figure 4-36. Pre-Installed Retaining Ring
shank.
sm08619
d. See Figure 4-37. Place piston over rod end with the 1
arrow (1) pointing toward the front of the engine.
e. Insert piston pin through pin bore and upper connecting
2
rod until it contacts retaining ring installed in opposite
pin boss.
f. Place clean shop towels over the cylinder and lifter
bores.

3. Install new retaining ring using HD-51069-2 (PISTON PIN 3

RETAINING RING INSTALLER) with HD-51069-17 (NOSE
ADAPTER) (2).

sm02339

1. Arrow
2. Piston pin retaining ring installer
3. Slot
Figure 4-37. Install Pin Retaining Ring
COMPLETE
1. Install cylinder. See CYLINDERS (Page 4-43).
2. Install cylinder head. See CYLINDER HEAD (Page 4-38).
3. Install pushrods and pushrod covers. See Pushrods, Lifters
and Covers (Page 4-35).

Figure 4-35. Aligning Retaining Ring 4. Install rocker arms. See Rocker Arms (Page 4-34).
5. Install rocker covers. See LOWER ROCKER COVERS
(Page 4-32) and UPPER ROCKER COVERS (Page 4-30).
6. Install induction module and manifold. See INDUCTION
MODULE (Page 5-17).
7. Install upper cooling lines. See COOLING SYSTEM
REPAIR (Page 6-6) or OIL COOLANT LINES
(Page 4-19).
8. Install air cleaner assembly. See AIR CLEANER
ASSEMBLY (Page 5-5).
9. Install exhaust system. See EXHAUST SYSTEM
(Page 5-26).
10. Install fuel tank. See FUEL TANK (Page 5-6).

94000383 4-47
11. Connect negative battery cable. See Battery Maintenance
(Page 2-51).
DISASSEMBLE
1. Remove piston rings.
CLEANING
WARNING
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)
NOTE
• Do not sandblast or glass bead blast pistons. Bead blasting
rounds off ring lands.
• Do not damage or enlarge the holes.
• Do not use a wire brush to clean oil holes.
• Avoid scratching the sides of the piston ring grooves.
1. Remove all combustion deposits.
a. Soak the pistons in hot water with dishwashing liquid
or a cleaner designed to remove carbon and which does
not corrode aluminum.
b. Follow the manufacturer's instructions.
c. Thoroughly rinse the pistons.
d. Clean the oil drain holes in the oil control ring groove
with a small bristle brush.
e. Dry parts with low-pressure, compressed air.
2. Verify that all oil holes are clean and open.
NOTE
A portion of a compression ring properly ground to a sharp
chisel-like edge works well to clean piston ring grooves.
3. Thoroughly clean the three piston ring grooves of all carbon
deposits.
INSPECT
1. Check piston running clearance.
a. Insert a lightly oiled good piston pin into the piston pin
bore to feel for the proper fit. The pin should slide in
and out without binding, pivoting or rocking.
b. Measure pin and pin bore diameters to determine
running clearance. Replace piston and/or pin if
clearance exceeds 0.0008 in (0.02 mm).
NOTE
Pistons with superficial wear marks, minor scratching or mild
scoring are acceptable for use.
4-48
2. Carefully inspect the pistons for damage or excessive
wear. Discard if any of the following conditions are found:
a. Using dye penetrant, inspect the piston for surface
cracks. Particularly examine the area around the pin
bores, ring lands and oil drain holes beneath the piston
crown. If no cracks are found, thoroughly wash piston
to remove traces of dye.
b. Cracked, worn or bent ring lands
c. Cracks, gouges, deep scratches or heavy scoring
d. Evidence of burning, etching or melting
e. Marks or imprints caused by contact with valves
3. Lightly file to remove any dings, nicks or burrs around the
edge of the piston crown.
4. See Figure 4-38. Measure piston ring side clearance.
a. Insert the edge of a new ring into the piston ring groove.
b. Insert a feeler gauge between the upper surface of the
ring and the ring land.
c. Repeat this check at several locations around the piston
groove.
d. Discard the piston if the side clearance of either
compression ring exceeds 0.0045 in (0.11 mm).
e. Discard the piston if the oil control ring side clearance
exceeds 0.010 in (0.25 mm).
NOTE
• Check the piston clearance in the cylinder in which the piston
will run. The cylinder must be deglazed and have torque
plates installed when measuring bore.
• This inspection is very heat-sensitive. Both the piston and
cylinder must be at room temperature before proceeding.
Do not check piston running clearance immediately after
honing or deglazing cylinder. Even holding the piston for
too long can cause measurements to vary by as much as
0.0002 in (0.0051 mm).
• See upper frame of Figure 4-39. The coating has an
oval-shaped opening (1) on each side of the piston for
proper micrometer placement.
• See lower frame of Figure 4-39. Use a blade or ball anvil
style micrometer to measure piston.
5. See Figure 4-39. Measure running clearance of pistons:
a. Measure the piston skirt at the bare aluminum openings
(1) in the coating.
b. Transfer that measurement to dial bore gauge.
c. Measure at the top, middle and bottom of the piston
ring travel zone. Measure parallel and perpendicular to
crankshaft.
d. Replace piston and/or cylinder if running clearance
exceeds 0.003 in (0.076 mm).
94000383
 1. See Figure 4-40. Check ring end gap of each ring before
sm1556a
installing on piston.
a. Insert piston upside down into cylinder. Apply even
downward force to align piston ring.
b. Measure the ring end gap with a feeler gauge. Refer to
Table 4-11.

sm08265

Figure 4-38. Measure Ring Clearance

sm08620

Figure 4-40. Measuring Ring Gap

ASSEMBLE

NOTE
Piston ring position is identical for both pistons.
1
1. See Figure 4-41. Install three-piece oil control ring.
a. Install expander ring (1) with ends facing up (see inset).
b. Install bottom oil rail (2).
c. Install top oil rail (3).
2
NOTE
• Position the "N" marking on the compression rings to the
top of the piston.
• The top ring has chamfered corners on the ring face. The
second ring has a sharp upper corner and a groove cut
around the lower edge.

3 2. Install second compression ring (4).

1. Bare aluminum opening 3. Install top compression ring (5).

2. Micrometer 4. Verify that all piston rings rotate freely.
3. Spherical anvil adapters
5. See Figure 4-42. Arrange gaps as shown.
Figure 4-39. Measure Piston Running Clearance
CHECK PISTON RING GAP

NOTE
• Always install new piston rings.
• Always deglaze (or hone) the cylinder before installing new
rings.
• Insufficient ring gap may cause the ends to touch at
operating temperatures. This causes ring breakage, cylinder
scuffing and/or piston seizure.
• Excessive ring gap causes high oil consumption and blow-by
of exhaust gases resulting in contaminated oil and reduced
engine efficiency.

94000383 4-49
 sm08698

3
4

1
2
1. Expander ring
2. Bottom oil rail
3. Top oil rail
4. Second compression ring
5. Top compression ring
Figure 4-41. Piston Rings

sm08622

3 1

5 4
21900037

1. Expander ring
2. Bottom oil rail
3. Top oil rail
4. Second compression ring
5. Top compression ring
Figure 4-42. Piston Ring Order of Assembly and Gap
Alignment

4-50 94000383
CAM COMPARTMENT AND COMPONENTS 4.27
PREPARE d. Remove cam sprocket screw (4) and washer (3).
e. Remove crank sprocket screw (5) and washer (6).
1. Remove main fuse.
f. Remove camshaft locking tool.
2. Remove seat. See SEAT (Page 3-96).
g. Remove both sprockets and chain.
3. Remove fuel tank. See FUEL TANK (Page 5-6).
h. Remove spacer (10).
4. Remove front exhaust pipe. See EXHAUST SYSTEM
(Page 5-26).
sm08544
5. Remove upper cooling lines. See COOLING SYSTEM
REPAIR (Page 6-6) or OIL COOLANT LINES 1
(Page 4-19).
6. Remove both upper rocker covers. See UPPER ROCKER 2
COVERS (Page 4-30).
7. Remove rocker arms. See Rocker Arms (Page 4-34). 3
8. Remove pushrods and pushrod covers. See Pushrods, 10
Lifters and Covers (Page 4-35). 4 9
9. See Figure 4-43. Remove camshaft cover. 8
7
a. Remove screws (3).
6
b. Remove cam cover (4). 5
c. Discard gasket (5). 1. Cam chain tensioner
2. Screw (2)
3. Washer
sm08546
4. Screw, cam sprocket
5 5. Screw, crank sprocket
4 6. Washer
7. Chain
3 8. Crank sprocket
9. Cam sprocket
2 10. Spacer
Figure 4-44. Camshaft Drive
1 2. Remove camshaft.
a. See Figure 4-45. Support lifters using SCREAMIN'
EAGLE MAGNETIC LIFTER HOLDERS (PART
NUMBER: 93979-10).
b. See Figure 4-46. Remove four screws (5).
1. Screw (5)
c. Remove screws (1).
2. Timer cover
3. Screw (9) d. Remove cam support plate (2).
4. Camshaft cover
e. Remove camshaft (3).
5. Gasket
Figure 4-43. Camshaft Cover f. Remove O-ring (4).

REMOVE

PART NUMBER TOOL NAME

93979-10 SCREAMIN' EAGLE MAGNETIC LIFTER
HOLDERS
HD-47941 CRANKSHAFT/CAMSHAFT SPROCKET
LOCKING TOOL

1. See Figure 4-44. Remove chain and sprockets.

a. Mark one of the chain links with a colored marker.
b. Remove cam chain tensioner fasteners (2). Remove
cam chain tensioner (1).
c. Install CRANKSHAFT/CAMSHAFT SPROCKET
LOCKING TOOL (PART NUMBER: HD-47941) between
cam sprocket (9) and crank sprocket (8).

94000383 4-51
 2. Measure flatness of support plate.
sm08757
3. Inspect gerotor area for excessive wear or deep grooves.
4. Verify that all oil passages are clean and open.

Cam Drive Components

1. Inspect sprockets and chain for wear.
INSTALL

PART NUMBER TOOL NAME

HD-47941 CRANKSHAFT/CAMSHAFT SPROCKET
LOCKING TOOL

FASTENER TORQUE VALUE

Cam chain tensioner fasteners 90–120 in-lbs 10.2–13.6 N·m
Cam sprocket screw, final 34 ft-lbs 46.1 N·m
Figure 4-45. SCREAMIN' EAGLE Magnetic Lifter Holder torque
sm08545
Cam sprocket screw, first 15 ft-lbs 20.3 N·m
torque
Cam support plate screws 90–120 in-lbs 10.2–13.6 N·m
3
Crankshaft sprocket screw, 24 ft-lbs 32.5 N·m
2
final torque
Crankshaft sprocket screw, 15 ft-lbs 20.3 N·m
1 first torque
4 Oil pump screws, final torque 90–120 in-lbs 10.2–13.6 N·m
Oil pump screws, first torque 12–60 in-lbs 1.4–6.8 N·m

1. Apply SCREAMIN' EAGLE ASSEMBLY LUBE to all

bearing surfaces and bearings.
5
2. See Figure 4-46. Install cam and cam support plate.
1. Support plate screw (6)
2. Cam support plate a. Install camshaft in crankcase.
3. Camshaft
4. O-ring b. Install new O-ring (4) into the feed oil port of the
5. Oil pump screws (4) crankcase.
Figure 4-46. Cam Support Plate c. Apply a thin film of SCREAMIN' EAGLE ASSEMBLY
CAM COMPONENT INSPECTION LUBE to the feed port spigot of cam support plate.

d. Slide cam support plate over shafts and onto two

NOTE
ring dowels in crankcase.
See Specifications, Specifications (Page 4-3) for
specifications. e. Verify that cam support plate is fully seated.

Camshaft f. Start all screws.

1. Inspect lobes for abnormal wear or discoloration. 3. See Figure 4-47. Tighten screws in sequence.
2. Inspect bearing surfaces for scoring or discoloration.
a. Tighten screws (1, 2) to 12–60 in-lbs (1.4–6.8 N·m).
3. Measure bearing journals.
4. If desired, remove and inspect lifters. b. Rotate crankshaft one full revolution (360 degrees).
a. Mark lifters so they can be installed in the same location c. Tighten screws (3-8) in the sequence shown to
and orientation as original. 90–120 in-lbs (10.2–13.6 N·m) in the sequence
b. Remove lifters through camshaft cavity. shown.
c. Measure lifters. d. Final tighten four oil pump screws (1-2, 9-10) to
90–120 in-lbs (10.2–13.6 N·m) the same sequence.
Cam Support Plate
1. Measure the diameters of the camshaft and crankshaft
bores.

4-52 94000383
 Table 4-39. Cam Sprocket Spacers
sm08548 5
PART NO. IN MM
25734-06 0.120 3.05
3 25736-06 0.130 3.30
7 25737-06 0.140 3.56
25738-06 0.150 3.81
2
10 5. Install camshaft drive.
8 a. Apply a light film of SCREAMIN' EAGLE ASSEMBLY
9 LUBE to camshaft and crankshaft.

4 1 b. Install cam sprocket spacer (10).

6
c. See Figure 4-48. Assemble sprockets and chain with
Figure 4-47. Cam Support Plate Tightening Sequence timing marks aligned. Verify that the marked chain link
is on the same side as the timing marks.
NOTE
Check sprocket alignment if any of the following parts are new: d. Rotate camshaft until keyed spline is up.
e. Rotate crankshaft until flat is up.
• Cam support plate
f. Install sprockets and chain.
• Camshaft
g. Verify that timing marks on the sprockets are aligned.
• Cam sprocket
h. Apply LOCTITE 262 HIGH STRENGTH
• Crankshaft sprocket
THREADLOCKER AND SEALANT (red) to screws.
• Flywheel assembly
i. Apply a film of oil to bottom of both sprocket screw
heads and washers.
4. Check sprocket alignment.
j. Loosely install screws and washers.
a. See Figure 4-46. Install original cam sprocket spacer
(10). sm08549

b. Install cam sprocket without chain using screw (4)

and washer (3).

c. Install crankshaft sprocket without chain using screw

(5) and a smaller diameter flat washer from bulk
inventory.

d. Position the CRANKSHAFT/CAMSHAFT

SPROCKET LOCKING TOOL (PART NUMBER:
HD-47941) between the sprockets. Tighten both
sprocket screws to 15 ft-lbs (20.3 N·m). Remove the
sprocket locking tool.

e. Push on crankshaft and camshaft to eliminate end

play. Figure 4-48. Timing Marks

f. Place a straightedge across the sprocket faces. 6. Tighten sprocket screws.

Alignment offset must be 0.009 in (0.23 mm) or less.
a. Position the CRANKSHAFT/CAMSHAFT
g. Remove cam sprocket. SPROCKET LOCKING TOOL (PART NUMBER:
HD-47941) between the sprockets.
h. Install the appropriate spacer (10) using Table 4-39
as a guide. b. Tighten both sprocket screws to 15 ft-lbs (20.3 N·m).

i. Check alignment with the new spacer installed. c. Loosen both screws one revolution (360 degrees).

j. Remove both sprockets. d. Final tighten the cam sprocket screw to 34 ft-lbs
(46.1 N·m).
Table 4-39. Cam Sprocket Spacers
e. Final tighten the crank sprocket screw to 24 ft-lbs
PART NO. IN MM (32.5 N·m).
25729-06 0.100 2.54
f. Remove the sprocket locking tool.
25731-06 0.110 2.79

94000383 4-53
7. Install primary cam chain tensioner. Tighten to CAMSHAFT NEEDLE BEARINGS
90–120 in-lbs (10.2–13.6 N·m).
FASTENER TORQUE VALUE
8. Apply SCREAMIN' EAGLE ASSEMBLY LUBE to chain
Cam needle bearing 25 ft-lbs 33.9 N·m
and sprockets.
installation maximum torque

COMPLETE Remove
1. See Figure 4-50. Remove camshaft bearing using
FASTENER TORQUE VALUE
components of HD-42325-C (CAMSHAFT NEEDLE
Cam cover screws 90–120 in-lbs 10.2–13.6 N·m BEARING REMOVER/INSTALLER TOOL).
Timer cover screws 25–35 in-lbs 2.8–4 N·m
2. Hold the flat on the HD-42325-12A (COLLET). Turn hex
1. See Figure 4-43. Install cam cover and new gasket. at end to expand collet.
3. Turn hex nut to remove bearing.
a. Install screws.
sm08659
b. See Figure 4-49. Following the sequence shown,
tighten to 90–120 in-lbs (10.2–13.6 N·m).

c. If removed, install timer cover with five screws.

Tighten to 25–35 in-lbs (2.8–4 N·m).

2. Install pushrods and pushrod covers. See Pushrods, Lifters

and Covers (Page 4-35).

3. Install rocker arms. See Rocker Arms (Page 4-34).

4. Install upper rocker covers. See UPPER ROCKER

COVERS (Page 4-30).

5. Install upper cooling lines. See COOLING SYSTEM

REPAIR (Page 6-6) or OIL COOLANT LINES
(Page 4-19).

6. Install front exhaust pipe. See EXHAUST SYSTEM Figure 4-50. Remove Camshaft Needle Bearing
(Page 5-26).
Install
7. Install fuel tank. See FUEL TANK (Page 5-6).
1. Calculate bearing installed depth.
8. Install seat. See SEAT (Page 3-96).
a. Measure thickness of HD-42325-4 (SUPPORT
9. Install main fuse. PLATE).

NOTE
sm08547
8 Do not exceed 25 ft-lbs (33.9 N·m) during needle bearing
installation or damage to crankcase will occur.
6 1
b. Add support plate thickness to 2.250 in (57.15 mm).
Record this value.
4
3 2. See Figure 4-50. Install bearing using HD-42325-7A
(CAMSHAFT NEEDLE BEARING INSTALLER).

2 a. Place new needle bearing on installer with letters

5 facing cam compartment.

b. Install support plate.

9 7
c. See Figure 4-51. Turn forcing screw to press needle
Figure 4-49. Cam Cover Tightening Sequence bearing to depth calculated earlier ± 0.020 in
(0.51 mm).

4-54 94000383
 sm08660

Figure 4-51. Measure from Top of Support Plate to Edge

of Needle Bearing

94000383 4-55
OIL PUMP 4.28
PREPARE 4. Dry parts using low-pressure compressed air.
5. Inspect housing.
1. Remove main fuse.
a. Verify that all oil holes are clean and open.
2. Remove seat. See SEAT (Page 3-96).
b. Inspect relief valve piston and seat for damage.
3. Remove fuel tank. See FUEL TANK (Page 5-6).
c. Inspect oil pump housing bores for scoring, gouging or
4. Remove front exhaust pipe. See EXHAUST SYSTEM cracking.
(Page 5-26).
d. See Figure 4-52. Inspect for grooves or scratches on
5. Remove upper cooling lines. See COOLING SYSTEM the cam support plate and back housing (4).
REPAIR (Page 6-6) or OIL COOLANT LINES
(Page 4-19). 6. See Figure 4-54. Check gerotor wear.
6. Remove both upper rocker covers. See UPPER ROCKER a. Check for damage on lobes of gerotors.
COVERS (Page 4-30).
b. Mesh rotors of one gerotor set together.
7. Remove rocker arms. See Rocker Arms (Page 4-34).
c. Measure clearance between tips of lobes on inner and
8. Remove pushrods and pushrod covers. See Pushrods, outer gerotors.
Lifters and Covers (Page 4-35).
d. Maximum clearance is 0.004 in (0.1 mm). Inspect
9. Remove cam support plate. See CAM COMPARTMENT second gerotor set in the same manner.
AND COMPONENTS (Page 4-51).
e. Measure and compare thickness of each rotor in a
REMOVE gerotor set. Maximum difference is 0.001 in
(0.025 mm). Inspect second gerotor set in the same
1. Remove oil pump assembly from crankshaft. manner.
2. See Figure 4-52. Discard O-rings (5, 6).
7. See Figure 4-52. Assemble the oil pump.
3. Disassemble and inspect oil pump components.
sm08551
sm08550

6
5
4
3
2 2
1 1
3

1. Spring
1. Feed gerotor set 2. Piston
2. Oil pump housing 3. Roll pin
3. Scavenge gerotor set Figure 4-53. Oil Pressure Relief Valve
4. Back housing
5. Scavenge port O-ring
6. Feed port O-ring
Figure 4-52. Oil Pump
DISASSEMBLE AND INSPECT
1. See Figure 4-52. Remove gerotors.
2. See Figure 4-53. Remove pressure relief valve.
a. Hold spring (1) compressed.
b. Drive out roll pin (3).
c. Carefully release spring pressure.
d. Remove spring and piston (2).

3. Clean parts in a non-volatile cleaning solution.

4-56 94000383
 6. Install front exhaust pipe. See EXHAUST SYSTEM
sm02521
1 (Page 5-26).
7. Install fuel tank. See FUEL TANK (Page 5-6).
2 8. Install seat. See SEAT (Page 3-96).
9. Install main fuse.

1. Outer gerotor
2. Inner gerotor
3. Wear limit
Figure 4-54. Measure Gerotor Sets for Wear
ASSEMBLE

1. Install pressure relief valve.

a. See Figure 4-53. Apply a film of SCREAMIN' EAGLE
ASSEMBLY LUBE to piston (2) and bore.
b. Install piston and spring (1).
c. Hold spring compressed and install roll pin (3).

INSTALL

1. Lubricate all parts with SCREAMIN' EAGLE ASSEMBLY

LUBE during assembly.
2. See Figure 4-52. Install back housing (4) and scavenge
gerotor set (3) on crankshaft.
3. Install new O-ring (5) in scavenge port of crankcase.
4. Apply a film of SCREAMIN' EAGLE ASSEMBLY LUBE to
scavenge port spigot.
5. Slide oil pump housing (4) onto crankshaft while fitting
scavenge port into O-ring.
a. Firmly push on oil pump housing to verify that it is snug
in bore.

6. Install the feed gerotor set (1).

7. Install new O-ring (6) in the feed port of crankcase.
COMPLETE

1. Install cam support plate. See CAM COMPARTMENT AND

COMPONENTS (Page 4-51).
2. Install pushrods and pushrod covers. See Pushrods, Lifters
and Covers (Page 4-35).
3. Install rocker arms. See Rocker Arms (Page 4-34).
4. Install upper rocker covers. See UPPER ROCKER
COVERS (Page 4-30).
5. Install upper cooling lines. See COOLING SYSTEM
REPAIR (Page 6-6) or OIL COOLANT LINES
(Page 4-19).

94000383 4-57
CRANKCASE 4.29
PREPARE sm08552
1
1. Remove engine. See REMOVE ENGINE (Page 4-28).
3 11
2. Remove cylinder heads. See CYLINDER HEAD
(Page 4-38). 4
3. Remove cylinders. See CYLINDERS (Page 4-43). 10
5
4. Remove pistons. See PISTONS (Page 4-46).
5. Remove camshaft, lifters and oil pump. See CAM
COMPARTMENT AND COMPONENTS (Page 4-51). 9
6
DISASSEMBLE
7
2 12 8
1. Remove oil pump from crankshaft.

Figure 4-55. Crankcase Torque Sequence

CAUTION
sm08553
Do not rotate crankcase half in engine stand when flywheel
is installed. The flywheel assembly can fall out, resulting
in parts damage or moderate injury. (00552c) 1
NOTE
Never move or lift the crankcase by grasping the cylinder studs.

2. Position crankcase with cam compartment facing down.

3. Separate crankcase halves.

a. See Figure 4-55. Remove 12 crankcase screws in 2

the sequence shown.

b. Separate case halves.

c. See Figure 4-56. Lift left crankcase half (2) off end
of crankshaft. 3

NOTE
HD-52065 (Balancer Gear Alignment Tool) must be installed 4
before removing balancer.

4. Remove two dowel pins in split line face of right case half.

5. Remove balancer (4). 1. Screw (12)

2. Left crankcase
a. Rotate gear teeth slightly with a screwdriver to allow 3. Flywheel assembly
tool installation. 4. Balancer
Figure 4-56. Separate Crankcase Halves
b. Install HD-52065 (Balancer Gear Alignment Tool).
CLEANING AND INSPECTION
c. Lift balancer from crankcase.
1. Remove all gasket material from the crankcase flanges.
6. Remove flywheel assembly (3).
2. Clean all parts in a non-volatile cleaning solution or solvent.

WARNING
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)

4-58 94000383
3. Dry parts with moisture-free compressed air. NOTE
The balancer shaft may splay away from the crankshaft. Wiggle
4. Verify that all oil holes are clean and open. crankcase during installation to help fully seat balancer shaft
in bearing.
5. Check ring dowels for looseness, wear or damage.
Replace if necessary. 5. Mate crankcase halves.
a. Verify that both dowel pins are installed in split line face
6. Use a file to carefully remove any nicks or burrs from of right case half.
machined surfaces.
b. See Figure 4-58. Apply a bead of CRANKCASE
7. Clean out tapped holes and clean up damaged threads. SEALANT (Part No. 11100202) approximately 0.060 in
(1.52 mm) wide to the split line face of right crankcase
half.
8. Check the top of the crankcase for flatness with a
straightedge and feeler gauge. Replace if warped. c. Place CRANKSHAFT GUIDE (PART NUMBER:
HD-42326-B) over end of crankshaft until it contacts
9. Spray all machined surfaces with clean engine oil. shoulder on shaft.
d. Mate case halves. Keep crankcase splitline parallel as
10. Inspect crankshaft/flywheel assembly. See FLYWHEEL left crankcase is lowered into place.
AND CONNECTING RODS (Page 4-66).
e. Wiggle crankcase during installation to help fully seat
balancer shaft in bearing.
ASSEMBLE
f. Remove crankshaft guide.
PART NUMBER TOOL NAME
HD-42326-B CRANKSHAFT GUIDE sm08554

HD-97225-55C SPROCKET SHAFT BEARING

INSTALLER

FASTENER TORQUE VALUE 1 3

2
Crankcase screws, first torque 120 in-lbs 13.6 N·m
Crankcase screws, last torque 15–19 ft-lbs 20.3–25.8 N·m

1. Position right crankcase with cam compartment facing

down.
2. Install flywheel assembly.
a. Work a liberal amount of SCREAMIN' EAGLE
ASSEMBLY LUBE into both main bearings and balancer
bearings.
1. Balancer gear
b. Slide CRANKSHAFT GUIDE (PART NUMBER: 2. Timing marks
HD-42326-B) onto flywheel sprocket shaft. 3. Flywheel gear
c. Slide flywheel assembly into right crankcase half. Figure 4-57. Balancer Timing Marks

d. Remove crankshaft guide tool. sm08555

NOTE
• If timing gears have more than one timing mark symbol,
align similar symbols.
• Timing marks may not align exactly. Align to the closest
tooth.

3. See Figure 4-57. Install balancer.

a. Rotate flywheel so crankpin is at BDC.
b. Install balancer while aligning timing marks (2).

4. Remove alignment tool.

a. Rotate gear teeth slightly with a screwdriver to unload
pressure on tool.
b. Remove tool.
Figure 4-58. Sealant

94000383 4-59
6. See Figure 4-55. Install 12 crankcase screws.
sm02348

a. Finger-tighten each screw.

b. Tighten screws in sequence shown to 120 in-lbs

(13.6 N·m).

c. Loosen, then following the same sequence, tighten

to 15–19 ft-lbs (20.3–25.8 N·m).

7. Rotate crankcase assembly so sprocket shaft is pointing

straight up.

8. Install thrust washer on sprocket shaft with "THIS SIDE

OUT" facing out (and the chamfer inboard). If using original
part without markings, position to preserve existing wear
pattern.

9. See Figure 4-59. Install new sprocket shaft oil seal.

a. Verify that lip garter spring is in place on both sides

of oil seal.

b. Install sprocket shaft spacer in oil seal bore.

c. Install sprocket shaft spacer.

d. Install oil seal using components from SPROCKET

SHAFT BEARING INSTALLER (PART NUMBER:
Figure 4-59. Sprocket Shaft Oil Seal Installer
HD-97225-55C) with HD-52064 (LEFT MAIN
BEARING OIL SEAL INSTALLER). COMPLETE

10. Rotate crankcase so that cam compartment is facing up. 1. Install camshaft and oil pump. See CAM COMPARTMENT
AND COMPONENTS (Page 4-51).
11. Apply a liberal amount of SCREAMIN' EAGLE ASSEMBLY 2. Install pistons. See PISTONS (Page 4-46).
LUBE to the main bearing. Rotate flywheel assembly to
distribute lube. 3. Install cylinders. See CYLINDERS (Page 4-43).
4. Install cylinder heads. See CYLINDER HEAD (Page 4-38).
5. Install engine. See INSTALL ENGINE (Page 4-29).
REPAIR RIGHT CRANKCASE HALF

PART NUMBER TOOL NAME

HD-42720-2 CRANKCASE BEARING
REMOVER/INSTALLER BASE

FASTENER TORQUE VALUE

Piston jet screws 25–35 in-lbs 2.8–3.9 N·m

Remove Main Bearing

NOTE
Never move or lift the crankcase by grasping the cylinder studs.

1. See Figure 4-60. Remove bearing using HD-52071-3

(MAIN BEARING INSTALLER) and CRANKCASE
BEARING REMOVER/INSTALLER BASE (PART
NUMBER: HD-42720-2).
a. Press bearing from the cam side into the flywheel side
of the crankcase.

2. Discard bearing.

4-60 94000383
 sm08663 sm08664

1 2 3
1 2

4
3 1 6
1 2

1. Pilot/driver
2. Base
3. Press ram
Figure 4-60. Remove Right Main Bearing
1. Main bearing installer
Install Main Bearing 2. Bearing depth arbor
3. Main bearing pilot
1. See Figure 4-61. Install bearing using HD-52071-3 (MAIN
4. Press ram
BEARING INSTALLER), HD-52071-2 (MAIN BEARING
5. Main bearing
ARBOR) and HD-52071-4 (BEARING SUPPORT).
Figure 4-61. Right Main Bearing Installation
a. Place crankcase on main bearing pilot with flywheel
Table 4-40. Right Crankcase Bearing Installed Depth
side facing up.
BEARING LOCATION DEPTH from SPLIT
b. Spread a film of clean engine oil on OD of new LINE
bearing (5).
Right side main 2.160 –2.18 in
c. Place bearing on bearing bore with the lettering (54.86–55.37 mm)
facing up. Right side balancer 2.070 –2.09 in
(52.58–53.09 mm)
d. Place bearing depth arbor with side marked RIGHT
against the bearing. Remove Piston Jets
e. Press until bearing depth arbor contacts machined 1. See Figure 4-62. Remove two screws (1) to free piston jet
surface. (2) from crankcase.
2. Discard gasket (1).
f. Check installed depth. Refer to Table 4-40.

94000383 4-61
 b. See Figure 4-64. Press the bearing from the stator side
sm08631
into the flywheel side of the crankcase.

4. Discard bearing.
1
2
sm02523a

1. Gasket (2)
2. Piston jet (2)
3. Screw (2 each jet)
Figure 4-62. Piston Jets

Install Piston Jets Figure 4-63. Remove Retaining Ring

NOTE
sm02524a
If piston jet is being reused, apply LOCTITE 222 LOW
STRENGTH THREADLOCKER AND SEALANT (purple) to
screws.
1
1. See Figure 4-62. Install new gasket (1).
2 3
2. With jet pointed up, secure piston jet (2) with two screws
(1). Tighten to 25–35 in-lbs (2.8–3.9 N·m).

REPAIR LEFT CRANKCASE HALF

PART NUMBER TOOL NAME

HD-42720-5 CRANKCASE BEARING
REMOVER/INSTALLER BASE

Remove Main Bearing 3

CAUTION 1. Ram
2. Pilot/driver
Do not rotate crankcase half in engine stand when flywheel
3. Support tube ("A" end up)
is installed. The flywheel assembly can fall out, resulting
in parts damage or moderate injury. (00552c) Figure 4-64. Remove Left Main Bearing

NOTE Install Main Bearing

• Never move or lift the crankcase by grasping the cylinder
studs. 1. See Figure 4-65. Install bearing using HD-52071-3 (MAIN
BEARING INSTALLER), HD-52071-2 (MAIN BEARING
• Always replace sprocket shaft bearing inner race whenever ARBOR) and HD-52071-4 (BEARING SUPPORT).
left main bearing is replaced. See Crankcase, Sprocket
Shaft Bearing Inner Race (Page 4-63). a. Place crankcase on support tube with flywheel side side
facing up.
1. Remove thrust washer from outboard side of crankcase b. Spread a thin film of clean engine oil on OD of new
half by pulling it past oil seal. Set thrust washer aside for bearing (5).
inspection or reuse.
c. Place bearing on bearing bore with the lettering facing
2. Remove oil seal. up.
3. Remove bearing using HD-52071-3 (MAIN BEARING d. Place bearing depth arbor with side marked LEFT
INSTALLER) and CRANKCASE BEARING against the bearing.
REMOVER/INSTALLER BASE (PART NUMBER:
HD-42720-5). e. Press until bearing bottoms in bore or depth arbor
contacts machined surface.
a. See Figure 4-63. Remove bearing retaining ring.
2. Install new retaining ring in bearing bore groove. Make
sure that retaining ring is fully seated in groove.

4-62 94000383
 sm02525a sm03852
2

1
3

2
4
3 1

1. Locating pin
2. Hold-down clamp
1. Ram
2. Remover/installer Figure 4-66. Flywheel Holding Fixture
3. Support tube ("A" end up) NOTICE
4. Main bearing
Install wedge attachment only so far as necessary to
Figure 4-65. Install Left Main Bearing ensure positive contact with bearing inner race. Installing
SPROCKET SHAFT BEARING INNER RACE tool with more contact than necessary will result in damage
to the flywheel (00500b)
PART NUMBER TOOL NAME
HD-25070 ROBINAIR HEAT GUN 2. See Figure 4-67. Install pulling tool.
HD-34902-B BIG-TWIN MAINSHAFT PRIMARY
BEARING RACE REMOVER AND a. Position WEDGE ATTACHMENT (PART NUMBER:
INSTALLER HD-95637-46B) (5) on inboard side of thrust washer.
HD-44358 FLYWHEEL SUPPORT FIXTURE
b. Draw wedge halves together evenly.
HD-95637-46B WEDGE ATTACHMENT
HD-97225-55C SPROCKET SHAFT BEARING c. Secure the bridge and forcing screw from BIG-TWIN
INSTALLER MAINSHAFT PRIMARY BEARING RACE
REMOVER AND INSTALLER (PART NUMBER:
Remove HD-34902-B) to the wedge attachment with flat
washers and two 3/8-16 x 7-1/2 in bolts.
NOTE
For proper clamping force, hold-down clamp must not be tilted. d. Place hardened washer between end of sprocket
Rotate hex on outboard stud until clamp is level. shaft and the end of the forcing screw.

1. See Figure 4-66. Secure flywheel assembly in FLYWHEEL NOTE

SUPPORT FIXTURE (PART NUMBER: HD-44358).
a. Secure fixture in soft-jawed vise with the round hole
topside.
b. Insert crankshaft end through hole, resting flywheel
assembly on fixture.
c. Engage knurled locating pin in crank pin hole.
d. Hand-tighten locating pin.
To assist removal without heat, apply a light penetrating oil to
shaft and leading edge of bearing inner race.
3. Uniformly heat the bearing inner race for about 30 seconds
using the ROBINAIR HEAT GUN (PART NUMBER:
HD-25070).
WARNING

e. Secure flywheel with hold-down clamps (2). Do not use heating devices with penetrating oil.
Penetrating oil is flammable which could result in death
or serious injury. (00375a)

4. See Figure 4-67. Remove bearing race.

a. Turn forcing screw until thrust washer and bearing

inner race move approximately 0.125 in (3.2 mm).

b. Reposition WEDGE ATTACHMENT (PART

NUMBER: HD-95637-46B) to pull on bearing inner
race only.

c. Verify that the tool assembly is square.

94000383 4-63
 d. Heat the bearing inner race for about 30 seconds.
sm03857

e. Turn forcing screw until bearing inner race is free of

sprocket shaft.

f. Remove thrust washer from sprocket shaft.

sm03853

1 2

3
4
7

6 5
Figure 4-68. Press Inner Race onto Sprocket Shaft: Opera-
tion
CYLINDER STUDS

FASTENER TORQUE VALUE

Cylinder stud 120–240 in-lbs 13.6–27.1 N·m

Remove
1. Tighten two nuts together on threads of stud.
2. Place wrench on lower nut. Turn to remove stud.
1. Forcing screw
2. 3/8-16 bolt with flat washer Install
3. Bridge
4. Hardened washer 1. Place a steel ball inside a cylinder head screw.
5. Wedge attachment
6. Bearing inner race 2. Put the head screw on the long end of the cylinder stud.
7. Sprocket shaft
Figure 4-67. Remove Inner Race from Sprocket Shaft 3. Install stud using air gun until collar reaches crankcase.

Install 4. Tighten to 120–240 in-lbs (13.6–27.1 N·m).

1. Place new thrust washer over sprocket shaft.
PLUGS AND OIL FITTINGS
2. Uniformly heat new bearing for about 60 seconds using
the ROBINAIR HEAT GUN (PART NUMBER: HD-25070). FASTENER TORQUE VALUE
Crankcase oil check valve or 120–168 in-lbs 13.6–19 N·m
NOTE plug with O-ring
To assist installation without heat, apply a light penetrating oil Crankcase tapered plugs 120–144 in-lbs 13.6–16.3 N·m
to shaft and leading edge of bearing inner race.
Remove
3. Drop heated bearing inner race over sprocket shaft. See Figure 4-69. Turn pipe plug counterclockwise until free.

WARNING Install
Do not use heating devices with penetrating oil. 1. See Figure 4-69. Install tapered plug (1).
Penetrating oil is flammable which could result in death
or serious injury. (00375a) a. Apply LOCTITE 565 THREAD SEALANT to threads.

4. See Figure 4-68. Seat the bearing race using SPROCKET b. Tighten to 120–144 in-lbs (13.6–16.3 N·m).
SHAFT BEARING INSTALLER (PART NUMBER:
HD-97225-55C). Follow instructions supplied with tool. 2. Install oil check valve (2) or plug with O-ring (3).

5. Verify that thrust washer cannot be rotated by hand. a. Install new O-ring.

b. Tighten to 120–168 in-lbs (13.6–19 N·m)

4-64 94000383
 sm08632

1 1
2 3
1. Tapered plug (5)
2. Oil check valve
3. Plug with O-ring
Figure 4-69. Crankcase Pipe Plugs

94000383 4-65
FLYWHEEL AND CONNECTING RODS
SYMPTOMS
Overview
Flywheels that shift out of true at the crank pin generally exhibit
one of two symptoms: no oil pressure or vibration. This
condition is also known as scissored flywheels.
No Oil Pressure
When the crankshaft shifts more than 0.015 in (0.381 mm), it
can break the oil pump gerotors. This causes a loss of oil
pressure.
If a low or no oil pressure condition is confirmed, inspect the
oil pump and cam support plate. If the oil pump gerotors are
bound or damaged, the cause is likely from a contaminant
running through the pump or a shifted crankshaft. If this type
of damage is found, always replace the oil lines and clean all
debris from the entire lubrication system. See Troubleshooting
(Page 2-60) for general diagnostics of low oil pressure.
Vibration
Generally, left crankshaft runout must exceed 0.020 in
(0.508 mm) to be noticeable to the rider. It is much more likely
that vibration issues are resolved by following the checklist in
Troubleshooting (Page 2-60).
If correct chassis set-up has been verified and other items in
Troubleshooting (Page 2-60) have been eliminated, checking
left crankshaft runout is appropriate.
4.30
NOTE
Bluing on connecting rods is part of the hardening process and
is considered a normal condition.
NOTE
In some cases the connecting rods will not fall under their own
weight due to as-designed bearing preload. flywheels should
NOT be replaced if the rods can be rotated with light finger
pressure.
2. Check connecting rod bearing clearance. Place the
assembly as shown in Figure 4-70 .
a. Rotate each connecting rod around crankpin feeling for
smooth operation.
b. Holding the shank of each rod just above the bearing
bore, pull up and down on the connecting rods.
c. Any up and down movement indicates excessive lower
bearing clearance. Replace the flywheel/connecting rod
assembly.
3. Measure crankshaft runout if the crankshaft is suspected
of being out-of-true.
NOTE
If the flywheel, connecting rods or right side bearing inner race
require replacement, replace the entire flywheel assembly.
sm02310

INSPECTION

NOTE
Do not attempt to straighten connecting rods. Straightening
rods damage both the upper bushing and lower bearing.
Connecting rod bearing failures generally exhibit noise and
secondary damage in the form of steel debris circulating
throughout the engine. Closely scrutinize the connecting
rod bearing if any of the following are evident:
• Rod knock noise
• Steel debris in oil filter
• Piston skirt scoring / scuffing
• Wear of the oil pump scavenge rotor and housing
• Piston to valve contact
• Damage to the flywheel pinion journal Figure 4-70. Connecting Rod Bearing Clearance
MEASURING CRANKSHAFT RUNOUT
1. Replace the flywheel/connecting rod assembly if any of
the following conditions are noted:
Crankshaft Installed
a. Bent or twisted connecting rods
b. Sprocket teeth are worn in an irregular pattern or NOTE
chipped • Perform the following checks during engine disassembly as
a method to determine condition of crankshaft and whether
c. The crankshaft (roller) bearing inner races are brinelled, crankshaft is suitable for reuse. The checks can be done
burnt, scored, blued or damaged with the engine either installed in the frame or removed.
d. Crankshaft runout exceeds specification • Dial indicators must be set up and zeroed perpendicular
to the shaft in both directions. The indicator must be 90
degrees when viewed from the end and from the side.

4-66 94000383
• For a reliable reading, only measure on the cam support
plate bushing machined surface of the crankshaft, never on
a shaft adapter or the bolt holes.
• Never secure the dial indicator base to the vehicle frame.
Movement within the engine mounts will result in a false
reading.
• While rotating the crankshaft, the indicator needle may move
to both the minus and plus sides of zero. The total indicator
reading is the value to record.
1. Right Side
a. Remove spark plugs.
b. Remove the cam support plate. See CAM
COMPARTMENT AND COMPONENTS (Page 4-51).
c. Secure a dial indicator base to a stable location
(crankcase, engine stand, etc.).
Crankshaft Removed
NOTE
• The following procedure should be performed if the
crankshaft/flywheel assembly is suspected of being
out-of-true.
• The crankshaft must be supported by the bearing races
during inspection. Never use centers as the holes may not
be perfectly centered.
• Verify that the bearing races are in good condition and
suitable for performing this inspection.
1. See Figure 4-71. Mount crankshaft in truing stand so it is
supported on the bearing races (1) by the roller supports
(2).
2. Secure a dial indicator mount near each end of the
crankshaft.

NOTE NOTE
To obtain an accurate measurement, the dial indicator Dial indicators must be perpendicular to the shaft in both
must be set up perpendicular in both directions to the shaft directions.
being measured.
3. Set up each indicator (3) to measure the machined surface
d. Attach a dial indicator and set it up to measure runout (4) on one end and splines (5) on the other.
at the cam plate bearing contact area of the crankshaft. 4. Adjust both indicators to zero.
Adjust the indicator to zero.
5. Slowly rotate the crankshaft assembly while observing the
e. Slowly rotate the crankshaft one complete revolution total indicator reading.
and record the total needle movement.
NOTE
f. Compare results of measurements. If the total indicator
reading exceeds service wear limit, the Twin Cam crankshaft/flywheel assemblies are not serviceable.
crankshaft/flywheel assembly should be removed and Replace parts not within specifications.
checked on a truing stand. Refer to Table 4-41.
6. Compare results of measurements. If the total indicator
2. Left Side reading exceeds service wear limit, replace the
crankshaft/flywheel assembly. Refer to Table 4-41.
a. Remove spark plugs.
sm06879
b. Remove the primary cover and compensating sprocket.
See DRIVE COMPONENTS (Page 7-5). 3
3
c. Secure a dial indicator base to a stable location
(crankcase, engine stand, etc.).
1 1
NOTE
To obtain an accurate measurement, the dial indicator
must be set up perpendicular in both directions to the shaft
being measured.

d. Attach a dial indicator set up to measure runout near

the end of the splined area of the crankshaft. Adjust the 5 2 2 4
indicator to zero on the "high" part of one spline.
e. Mark the crankshaft and crankcase to use as reference
for the amount of rotation.
NOTE
Pay attention to only the values from the "high" part of the
splines. 1. Bearing race
2. Roller support
f. Slowly rotate the crankshaft one complete revolution 3. Dial indicator
and record the total needle movement. 4. Machined surface
5. Spline
g. Compare results to Table 4-41. If the total indicator
Figure 4-71. Checking Crankshaft Runout
reading exceeds service wear limit, remove the
crankshaft/flywheel assembly and check on a truing
stand.

94000383 4-67
 Table 4-41. Flywheel
FLYWHEEL REPLACE IF WEAR EXCEEDS
IN MM
Runout (shaft measured 0.012 0.305
in case)
Runout (measured in tru- 0.005 0.127
ing stand)
End play 0.013 0.330

4-68 94000383
OIL PAN 4.31
PREPARE 2. Clean engine oil and transmission lubricant drain plugs.

1. Position motorcycle on a lift. a. Replace O-rings as required.

2. Drain engine oil. See ENGINE OIL AND FILTER
3. Install transmission drain plug and O-ring. Tighten to
(Page 2-15).
14–21 ft-lbs (19–28.5 N·m).
3. Drain transmission lubricant. See Transmission Lubricant
(Page 2-28). 4. Install engine oil drain plug and O-ring. Tighten to
4. Remove rear wheel. See REAR WHEEL (Page 3-18). 14–21 ft-lbs (19–28.5 N·m).

5. Remove the left muffler, exhaust cross-over pipe and

5. See Figure 4-72. If removed, install tapered plug (4).
cross-over pipe clamp bracket from the transmission. See
EXHAUST SYSTEM (Page 5-26).
a. Apply LOCTITE 565 THREAD SEALANT.
REMOVE
NOTE
1. Remove the engine oil fill plug/dipstick. If oil pan fasteners are original, apply LOCTITE 243 MEDIUM
STRENGTH THREADLOCKER AND SEALANT (blue). New
2. See Figure 4-72. Remove oil pan.
fasteners have a lock patch applied.
a. Remove 12 screws (4).
b. Slide oil pan (2) rearward to remove. b. Tighten to 30–36 ft-lbs (40.7–48.8 N·m).

c. Discard oil pan gasket (1). 6. Install oil pan.

d. If necessary, remove tapered plug (3).
a. Apply a thin coat of HYLOMAR GASKET AND
NOTE THREAD SEALANT to oil pan flange.
Debris that remains in the pan can cause a repeat failure. Install
a new oil pan if necessary. b. Place new gasket (1) on oil pan flange. Allow sealer
to dry until tacky.
3. Thoroughly inspect and clean the oil pan.
c. Position oil pan with gasket on bottom of
sm08556
transmission.

d. Loosely install fasteners (4).

1
e. See Figure 4-73. Verify that the gasket is properly
positioned. Tighten to 132–156 in-lbs
(14.9–17.6 N·m) following sequence shown
2
sm08557

3
12 8 6
10 4
4

11
1. Gasket 2
2. Oil pan
3. Tapered plug
4. Screws (12) 1
Figure 4-72. Oil Pan Assembly
9 7 5 3
INSTALL

FASTENER TORQUE VALUE Figure 4-73. Oil Pan Tightening Sequence

Engine oil drain plug 14–21 ft-lbs 19–28.5 N·m COMPLETE
Oil pan fasteners 132–156 in-lbs 14.9–17.6 N·m
Oil pan tapered plug 30–36 ft-lbs 40.7–48.8 N·m FASTENER TORQUE VALUE
Transmission drain plug 14–21 ft-lbs 19–28.5 N·m Exhaust crossover pipe 100–120 in-lbs 11.3–13.6 N·m
hanger bracket
1. Clean and examine all flange surfaces.
1. Install exhaust crossover pipe hanger bracket. Tighten to
100–120 in-lbs (11.3–13.6 N·m).

94000383 4-69
2. Install exhaust cross-over pipe and left muffler. See 4. Add fluids.
EXHAUST SYSTEM (Page 5-26).
a. Add transmission lubricant. See Transmission
3. Install rear wheel. See REAR WHEEL (Page 3-18). Lubricant (Page 2-28).

b. Install new engine oil filter.

c. Fill engine oil. See ENGINE OIL AND FILTER

(Page 2-15).

4-70 94000383
SUBJECT PAGE NO.
5.1 FASTENER TORQUE VALUES ............................................................................................ 5-1
5.2 SPECIFICATIONS: FUEL SYSTEM ..................................................................................... 5-2
5.3 FUEL PRESSURE TEST ...................................................................................................... 5-3
5.4 INTAKE LEAK TEST ............................................................................................................. 5-4
5.5 AIR CLEANER ASSEMBLY .................................................................................................. 5-5
5.6 FUEL TANK ........................................................................................................................... 5-6
5.7 FUEL TANK TOP PLATE ...................................................................................................... 5-9
5.8 FUEL FILTER ...................................................................................................................... 5-11
5.9 FUEL PRESSURE REGULATOR ....................................................................................... 5-12
5.10 FUEL LEVEL SENDER ..................................................................................................... 5-13
5.11 TWIST GRIP SENSOR (TGS) .......................................................................................... 5-14
5.12 INDUCTION MODULE ...................................................................................................... 5-17
5.13 TEMPERATURE MANIFOLD ABSOLUTE PRESSURE SENSOR (TMAP) ..................... 5-20
5.14 FUEL INJECTORS ............................................................................................................ 5-21
5.15 HEATED OXYGEN SENSORS (HO2) .............................................................................. 5-22
5.16 FUEL PUMP ...................................................................................................................... 5-24
5.17 EXHAUST SYSTEM ......................................................................................................... 5-26
5.18 EVAPORATIVE EMISSIONS CONTROL SYSTEM .......................................................... 5-29

FUEL SYSTEM
NOTES
FASTENER TORQUE VALUES 5.1
FASTENER TORQUE VALUES IN THIS
CHAPTER

The table below lists torque values for all fasteners presented
in this chapter.

FASTENER TORQUE VALUE NOTES

Breather bolts 22–24 ft-lbs 29.8–32.5 N·m 5.5 AIR CLEANER ASSEMBLY, Install
metric
Charcoal canister screws 15–20 in-lbs 1.7–2.3 N·m 5.18 EVAPORATIVE EMISSIONS CONTROL
SYSTEM, Charcoal Canister
metric
Console fastener, front 20–30 in-lbs 2.3–3.4 N·m 5.6 FUEL TANK, Console
Console fastener, rear 36–60 in-lbs 4.1–6.8 N·m 5.6 FUEL TANK, Console
Exhaust crossover pipe clamp 38–43 ft-lbs 51.5–58.3 N·m 5.17 EXHAUST SYSTEM, Install Exhaust System
Always use a new clamp
Exhaust crossover pipe hanger bracket 100–120 in-lbs 11.3–13.6 N·m 5.17 EXHAUST SYSTEM, Install Exhaust System
Exhaust crossover pipe hanger to trans- 14–18 ft-lbs 19–24.4 N·m 5.17 EXHAUST SYSTEM, Install Exhaust System
mission bracket fastener
Exhaust flange adapter nuts, final torque 100–120 in-lbs 11.3–13.6 N·m 5.17 EXHAUST SYSTEM, Install Exhaust System
Exhaust flange adapter nuts, first torque 9–18 in-lbs 1–2 N·m 5.17 EXHAUST SYSTEM, Install Exhaust System
Exhaust shield clamps 20–40 in-lbs 2.3–4.5 N·m 5.17 EXHAUST SYSTEM, Install Exhaust System
Exhaust side bracket flange locknut 15–20 ft-lbs 20.3–27.1 N·m 5.17 EXHAUST SYSTEM, Install Exhaust System
Fuel door lock 30–40 in-lbs 3.4–4.5 N·m 5.6 FUEL TANK, Fuel Door
Fuel door screws 30–35 in-lbs 3.4–4 N·m 5.6 FUEL TANK, Fuel Door
Fuel rail screws 31–49 in-lbs 3.5–5.5 N·m 5.14 Fuel Injectors, Install
Fuel supply line quick-connect fitting 22–26 ft-lbs 29.8–35.3 N·m 5.6 FUEL TANK, Fuel Supply Check Valve/Tube
metric
Fuel tank front screws 15–20 ft-lbs 20.3–27.1 N·m 5.6 FUEL TANK, Installation
Fuel tank rear bracket screws 15–20 ft-lbs 20.3–27.1 N·m 5.6 FUEL TANK, Installation
HO2 sensor 14 ft-lbs 19 N·m 5.15 HEATED OXYGEN SENSORS (HO2), Install
metric
Ignition coil screws 32–40 in-lbs 3.6–4.5 N·m 5.18 EVAPORATIVE EMISSIONS CONTROL
SYSTEM, Charcoal Canister
Induction module bracket 66–84 in-lbs 7.5–9.5 N·m 5.12 INDUCTION MODULE, Assemble
Induction module flange adapter screws 96–156 in-lbs 10.9–17.6 N·m 5.12 INDUCTION MODULE, Install
metric
Left electrical caddy fastener 72–96 in-lbs 8.1–10.9 N·m 5.18 EVAPORATIVE EMISSIONS CONTROL
SYSTEM, Charcoal Canister
metric
Muffler clamp 38–43 ft-lbs 51.5–58.3 N·m 5.17 EXHAUST SYSTEM, Mufflers
Muffler to saddlebag support screws 14–18 ft-lbs 19–24.4 N·m 5.17 EXHAUST SYSTEM, Mufflers
Temperature manifold absolute pressure 23–39 in-lbs 2.5–4.5 N·m 5.13 TEMPERATURE MANIFOLD ABSOLUTE
sensor (TMAP) screw PRESSURE SENSOR (TMAP), Install
Throttle body to manifold screws 35–53 in-lbs 4–6 N·m 5.12 INDUCTION MODULE, Assemble

94000383 5-1
SPECIFICATIONS: FUEL SYSTEM 5.2
SPECIFICATIONS

Table 5-1. Fuel Capacity

FUEL TANK CAPACITY GALLONS LITERS
Total 6.0 22.7
Reserve (warning light 1.0 3.79
on)

5-2 94000383
FUEL PRESSURE TEST 5.3
PREPARE sm02626a
4
3
WARNING
Gasoline is extremely flammable and highly explosive.
Keep gasoline away from ignition sources which could 2
result in death or serious injury. See the Safety chapter.
(00635c)

WARNING
To prevent spray of fuel, purge system of high-pressure 1
fuel before supply line is disconnected. Gasoline is 5
extremely flammable and highly explosive, which could
result in death or serious injury. (00275a)

1. Purge and disconnect fuel line. See FUEL TANK 1. Fuel supply line
(Page 5-6). 2. Adapter to fuel line
3. Fuel tank fitting
TEST 4. Pressure adapter Schroeder valve union
5. Fuel valve (closed position)
PART NUMBER TOOL NAME
Figure 5-1. Fuel Pressure Test Connections
HD-41182 FUEL PRESSURE GAUGE
HD-44061 FUEL PRESSURE GAUGE ADAPTER
COMPLETE

NOTE 1. Connect fuel supply line. See FUEL TANK (Page 5-6).
Use two fuel pressure gauge adapters to prevent twisting of
the fuel supply line. Verify that all connections are secure.

1. See Figure 5-1. Attach FUEL PRESSURE GAUGE (PART

NUMBER: HD-41182) and FUEL PRESSURE GAUGE
ADAPTER (PART NUMBER: HD-44061) to fuel tank fitting
(3) and fuel supply line (1).
2. Close fuel valve (5).
3. Insert clear tube of fuel pressure gauge into a suitable
container.
4. Start engine.
5. Open fuel valve.
6. Open clear tube bleeder valve.
7. Close clear tube bleeder valve.
8. Check pressure.
a. Operate engine at various speeds.
b. Note pressure gauge reading.
c. Compare readings to specifications. Refer to Table 5-2.

9. Turn off engine.

10. Open clear tube bleeder to remove pressure.
11. Remove fuel pressure tester.

Table 5-2. Fuel Pressure

SPECIFICATION KPA PSI
Fuel pressure 55-62 380-425

94000383 5-3
INTAKE LEAK TEST 5.4
LEAK TESTER sm02629b

PART NUMBER TOOL NAME 9 8

HD-41417 PROPANE ENRICHMENT KIT

WARNING
Do not allow open flame or sparks near propane. Propane
is extremely flammable, which could cause death or 7
serious injury. (00521b)

WARNING
Read and follow warnings and directions on propane 6
bottle. Failure to follow warnings and directions can result
in death or serious injury. (00471b)
5
Parts List
• Small propane cylinder.
• PROPANE ENRICHMENT KIT (PART NUMBER:
HD-41417).
4
Tester Assembly
1. See Figure 5-2. Make sure valve knob (6) is closed (fully 1
clockwise).
2. Install valve assembly (5) onto propane bottle (1).
2
Tester Adjustment 3
1. See Figure 5-2. Press and hold trigger button (8).
2. Slowly open valve knob (6) until pellet in flow gauge (7)
1. Propane bottle
rises 5-10 SCFH on gauge.
2. Nozzle
3. Release trigger button. 3. Copper tube
4. Hose
PROCEDURE 5. Valve assembly
6. Valve knob
NOTE 7. Flow gauge
Propane injected into air cleaner causes false readings. Keep 8. Trigger button
air cleaner cover installed. 9. Hanger
Figure 5-2. Leak Tester
1. Run motorcycle until engine is at normal operating
temperature.
2. Aim nozzle toward possible sources of leak.
NOTE
The tone of the engine changes when propane enters source
of leak.

3. Press and release trigger button to dispense propane.

4. Repeat as necessary to detect leak.
5. When test is finished, close valve.

5-4 94000383
AIR CLEANER ASSEMBLY 5.5
REMOVE 3. Remove two breather bolts (6).
4. Remove backplate (7).
1. Remove air cleaner cover and filter. See AIR CLEANER
ELEMENT (Page 2-17). 5. Remove seal ring (8) from backplate. Discard seal ring.

2. See Figure 5-3. Remove breather tube (5) from fittings on 6. Clean and inspect filter element. See AIR CLEANER
breather bolts. ELEMENT (Page 2-17). Replace if necessary.
7. Verify that passages in breather bolts (6) are clear.

sm08575
7

2 3

10

1. Cover screw 6. Breather bolt (2)

2. Air cleaner cover 7. Backplate
3. Screw (3) 8. Seal ring
4. Filter element 9. Rubber seal
5. Breather tube assembly
Figure 5-3. Air Cleaner Assembly
INSTALL
4. Install breather tubes (5) onto breather bolts.
FASTENER TORQUE VALUE
5. Install air cleaner filter and cover. See AIR CLEANER
Breather bolts 22–24 ft-lbs 29.8–32.5 N·m ELEMENT (Page 2-17).
1. See Figure 5-3. Install seal ring (8) on backplate (7).

2. Apply LOCTITE 565 THREAD SEALANT to threads of

breather bolts (6).

3. Install backplate with breather bolts. Tighten to 22–24 ft-lbs

(29.8–32.5 N·m).

NOTE
Failure to connect the breather tubes allows crankcase vapors
to be vented into the atmosphere in violation of legal emissions
standards.

94000383 5-5
FUEL TANK 5.6
REMOVAL sm07592
1
NOTE
The fuel tank can be removed without draining. However, 7
draining is necessary whenever the fuel tank or internal
components are serviced.

Purge and Disconnect Fuel Supply Line 6 2

WARNING
To prevent spray of fuel, purge system of high-pressure
fuel before supply line is disconnected. Gasoline is 5
extremely flammable and highly explosive, which could
result in death or serious injury. (00275a) 3
4
NOTE
The gasoline in the fuel supply line is under high pressure:
58 psi (400 kPa). To avoid an uncontrolled discharge or spray 1. Top caddy
of gasoline, always purge the line before disconnecting. 2. Screw (2)
3. ECM
1. Remove seat. See SEAT (Page 3-96). 4. Connector, grey
5. Connector, black
2. See Figure 5-4. Disconnect fuel pump connector (gray) 6. HFSM antenna
(4). 7. Purge valve solenoid
3. Run the engine until it stalls. Operate starter an additional Figure 5-4. Top Caddy
3 seconds after engine stalls to remove remaining fuel
from fuel supply line. sm04502

4. Remove main fuse.

5. Connect fuel pump connector (gray).
6. See Figure 5-5. Pull up on chrome sleeve of quick-connect
fitting (1) and pull down on fuel supply line (2) fitting to 1
disconnect.

Remove Tank 2

1. Remove console. See FUEL TANK, Console (Page 5-7).

2. Carefully remove fuel vapor vent tube from vapor valve

fitting on top plate.

3. Remove fuel level sender/fuel pump connector [141] from

top plate. 1. Quick connect fitting (chrome sleeve)
2. Fuel supply line fitting
4. Road King Models: Draw fuel gauge connector out of Figure 5-5. Fuel Tank (Left Side View)
tunnel under fuel tank. Separate connector. INSTALLATION
WARNING FASTENER TORQUE VALUE
Gasoline can drain from the fuel line when disconnected Fuel tank front screws 15–20 ft-lbs 20.3–27.1 N·m
from fuel tank. Gasoline is extremely flammable and highly Fuel tank rear bracket screws 15–20 ft-lbs 20.3–27.1 N·m
explosive, which could result in death or serious injury.
Wipe up spilled fuel immediately and dispose of rags in a 1. Place fuel tank onto frame backbone and start front fuel
suitable manner. (00260a) tank fasteners.

5. Remove rubber caps from front fuel tank screws. Remove 2. Secure rear fuel tank bracket to frame backbone with two
screws. screws. Tighten to 15–20 ft-lbs (20.3–27.1 N·m). If
removed, install plastic trim cover over bracket.
6. Remove two screws to release rear tank bracket from
frame backbone. 3. Tighten front fuel tank screws to 15–20 ft-lbs
(20.3–27.1 N·m). Install rubber caps over screws. Left and
7. Remove fuel tank. right caps are not interchangeable.

5-6 94000383
 WARNING 4. Install screws to fasten front and rear of console to fuel
tank.
To prevent spray of fuel, be sure quick-connect fittings
are properly mated. Gasoline is extremely flammable and a. Tighten front fastener to 20–30 in-lbs (2.3–3.4 N·m).
highly explosive, which could result in death or serious
injury. (00268a) b. Tighten rear fastener to 36–60 in-lbs (4.1–6.8 N·m).

4. Connect quick-connect fitting to fuel tank. While pushing 5. Connect connectors (4, 5).
up on bottom of fitting, pull down on chrome sleeve. After
completing installation, tug on fuel line fitting to verify that
it is locked in position.
FUEL DOOR

5. Road King Models: Mate fuel gauge connector. Feed FASTENER TORQUE VALUE
connector into tunnel at front of fuel tank. Fuel door lock 30–40 in-lbs 3.4–4.5 N·m
Fuel door screws 30–35 in-lbs 3.4–4 N·m
6. See Figure 5-6. Connect fuel vapor vent tube to vapor
valve fitting (1) on top plate. Replace Door
1. Remove screws securing hinge.
7. If equipped, connect overflow hose (2) to top plate and
route along inner downtube as shown. Secure to brake
line with cable strap (3). Do not over-tighten cable strap. 2. Separate door from hinge. Remove door.

8. Install fuel level sender/fuel pump connector [141], 4-place 3. Apply a drop of LOCTITE 243 MEDIUM STRENGTH
Delphi. For best clearance with cam ring, tilt connector at THREADLOCKER AND SEALANT (blue) to the threads
35 degree angle before installation. of each screw.

9. Install console. See FUEL TANK, Console (Page 5-7). 4. Secure door to hinge with screws. Tighten to 30–35 in-lbs
(3.4–4 N·m).
10. Install seat. See SEAT (Page 3-96).
Replace Lock
NOTE
1. Remove nut securing lock assembly.
The low fuel lamp will not turn off until there is sufficient fuel in
the tank, the ignition switch has been turned off and back on,
2. Remove lock assembly.
and the vehicle has begun forward movement.
3. Secure lock assembly with nut. Tighten to 30–40 in-lbs
11. Install main fuse, left side cover and saddlebag. (3.4–4.5 N·m).

CONSOLE VENT TUBE: MODELS WITHOUT EVAP

SYSTEM
FASTENER TORQUE VALUE
Console fastener, front 20–30 in-lbs 2.3–3.4 N·m
Removal
Console fastener, rear 36–60 in-lbs 4.1–6.8 N·m
1. Remove seat. See SEAT (Page 3-96).
Removal 2. Remove console. See FUEL TANK, Console (Page 5-7).
1. See Figure 5-4. Separate fuel pump connector (4). 3. See Figure 5-6. Remove vapor tube from fitting (1) on fuel
Separate rider headset harness connector (5) if equipped. tank top plate.
2. Remove screws to release front and rear of console from 4. Remove two cable straps (4) securing tube to rear frame
fuel tank. downtube.
3. Road King Models: Remove console. 5. Remove tube.
4. All but Road King Models: Remove filler cap. Remove 6. Inspect parts for wear or damage. Replace if necessary.
console.

Installation
1. Road King Models: Position console on fuel tank.

2. All but Road King Models: Remove filler cap and position
console on fuel tank. Install filler cap.

3. Verify that harnesses and vent tube are not pinched.

94000383 5-7
 sm05938a
WARNING
Gasoline can drain from the fuel line when disconnected
1
2 from fuel tank. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
Wipe up spilled fuel immediately and dispose of rags in a
suitable manner. (00260a)

3. See Figure 5-7. Remove the quick-connect fitting and fuel

supply tube from fuel tank.

Install
1. Inspect fuel supply tube for damage. Replace if necessary.
3
2. See Figure 5-7. Install lightly oiled new O-ring into groove
of quick-connect fitting.

3. Feeding fuel supply tube through hole at bottom of fuel

tank, turn quick-connect fitting into bore.
4
4. Tighten fitting to 22–26 ft-lbs (29.8–35.3 N·m).

5. Install top plate. See FUEL TANK TOP PLATE

(Page 5-9).
1. Fuel vapor vent valve fitting
2. Overflow hose
3. Cable strap WARNING
4. Cable strap
To prevent spray of fuel, be sure quick-connect fittings
Figure 5-6. Vent Tube are properly mated. Gasoline is extremely flammable and
highly explosive, which could result in death or serious
Installation injury. (00268a)
1. See Figure 5-6. Route tube down along inner side of rear
left downtube. Install two cable straps (4) to secure to 6. Connect quick-connect fitting to fuel tank.
frame.
2. Route line along center of fuel tank and connect to fitting a. While pushing up on bottom of fitting, pull down on
(1) on fuel tank top plate. chrome sleeve.

3. Install console. See FUEL TANK, Console (Page 5-7). b. Pull on fuel line fitting to verify that it is locked in
4. Install seat. See SEAT (Page 3-96). position.

FUEL SUPPLY CHECK VALVE/TUBE sm04504

FASTENER TORQUE VALUE

Fuel supply line quick-connect 22–26 ft-lbs 29.8–35.3 N·m
fitting

Remove
NOTE
The in-tank check valve is housed in the quick-connect fitting.
The check valve prevents the fuel tank from draining when the
external supply line is disconnected.

1. Purge and disconnect fuel supply line. See FUEL TANK,

Removal (Page 5-6). Leave the fuel pump connector
separated.
Figure 5-7. Fuel Quick-Connect Fitting
2. Remove top plate. See FUEL TANK TOP PLATE
(Page 5-9).

5-8 94000383
FUEL TANK TOP PLATE 5.7
REMOVAL sm04098

PART NUMBER TOOL NAME

HD-48646 CAM RING REMOVER/INSTALLER

WARNING
Gasoline is extremely flammable and highly explosive.
Keep gasoline away from ignition sources which could
result in death or serious injury. See the Safety chapter.
(00635c)
NOTE
The gasoline in the fuel supply line is under high pressure
(58 psi (400 kPa). To avoid an uncontrolled discharge or spray
of gasoline, always purge the line before disconnecting.

1. Relieve pressure from fuel system. See FUEL TANK, Figure 5-9. Hold Both Tool and Ratchet During Handling
Removal (Page 5-6).
sm04068a
2. Drain fuel from tank.
3. Remove console. See FUEL TANK, Console (Page 5-7).
4. See Figure 5-8. Remove cam ring using CAM RING
REMOVER/INSTALLER (PART NUMBER: HD-48646)
and raise top plate.
NOTE
See Figure 5-9. Always hold on to both the Cam Ring
Remover/Installer and ratchet to prevent unexpected separation
resulting in possible damage to the fuel tank.

5. Remove connector at bottom of top plate using a small

screwdriver.
Figure 5-10. Remove Ground Wire Spade Terminal From
6. See Figure 5-10. Disconnect ground wire spade terminal Top Plate
from slot of top plate.
7. See Figure 5-11. Press tabs on fuel line retainers (3) to
remove lines from fittings on fuel filter shell.
8. If top plate replacement is necessary, remove fuel filter
shell. See Fuel Filter (Page 5-11).

sm04067

Figure 5-8. Cam Ring Remover/Installer (HD-48646)

94000383 5-9
 7. Install fuel tank top plate engaging index tab in slot at front
sm04187a
of fuel tank collar.
3
8. See Figure 5-12. Install cam ring over fuel tank top plate
with the TOP stamp up.

9. Engage CAM RING REMOVER/INSTALLER (PART

NUMBER: HD-48646) in top plate. Push down on tool and
rotate clockwise until each of four index tabs begin to
engage slots in fuel tank collar.

NOTE
See Figure 5-9. Always hold on to both the Cam Ring
1 Remover/Installer and ratchet to prevent unexpected separation
resulting in possible damage to the fuel tank.

10. Install ratchet and rotate until cam ring is fully installed.

11. Install console. See FUEL TANK, Console (Page 5-7).

12. Install seat. See SEAT (Page 3-96).

WARNING
Wipe up spilled fuel and dispose of rags in a suitable
manner. An open spark around gasoline could cause a
fire or explosion, resulting in death or serious injury.
(00518b)

13. Fill fuel tank. Carefully inspect for leaks. Start engine and
2 repeat inspection.

sm04196
1. With Fuel Filter Shell
2. Without Fuel Filter Shell
3. Fuel line retainers
Figure 5-11. Top Plate Assembly
INSTALLATION

PART NUMBER TOOL NAME

HD-48646 CAM RING REMOVER/INSTALLER

1. If installing a new top plate, first install fuel filter shell. See
Fuel Filter (Page 5-11).

2. Inspect seal ring at bottom of top plate for damage. If

necessary, install new seal ring with the nubs contacting Figure 5-12. Cam Ring Stamp
the ring groove walls.

3. See Figure 5-11. Verify retainers (3) are secure on fuel

filter fittings, and that they are not damaged. Note that
retainers are of different sizes to prevent improper
assembly.

4. Aligning latches and push tubes onto fittings of fuel filter

shell until an audible click is heard. Pull on tubes to verify
they are attached securely.

5. Install connector at bottom of top plate.

6. Route ground wire (from top plate connector) along inboard

side of vapor valve and install spade terminal into slot in
top plate.

5-10 94000383
FUEL FILTER 5.8
REMOVAL sm04035a
1
WARNING
Gasoline is extremely flammable and highly explosive.
Keep gasoline away from ignition sources which could
result in death or serious injury. See the Safety chapter.
(00635c)

WARNING
Do not use solvents or other products that contain chlorine
on plastic fuel system components. Chlorine can degrade
plastic fuel system components, which can cause a loss
of fuel system pressure or engine stalling and could result
in death or serious injury. (00621b) 2 3
4
1. Remove top plate. See FUEL TANK TOP PLATE
(Page 5-9). 1. Filter shell
2. Locate ground wire spade terminal in slot of fuel filter shell. 2. U-clip
Insert tip of small flat blade screwdriver through window 3. O-ring
to press tang, and then pull terminal from slot. See Figure 4. Filter
5-13. Figure 5-14. Fuel Filter Assembly
3. See Figure 5-14. Gently raise locking arm and pull U-clip INSTALLATION
(2) from holes in fuel filter shell.
4. Remove fuel filter shell (1) from end cap. 1. See Figure 5-14. Install new filter (4) in fuel filter shell (1).

5. Remove O-ring (3) and filter (4) from fuel filter shell. 2. Seat O-ring (3) on counterbore at top of filter.
3. Install fuel filter shell over end cap with slot in fuel filter
sm04033a shell engaged index pin on end cap.
4. Holding parts together, slide U-clip (2) through holes on
locking arm side of fuel filter shell. Push U-clip until ends
exit holes on opposite side. Retract U-clip until contact is
made with step in locking arm.
5. Route ground wire from top plate screw around index pin
side of end cap. Install spade terminal into slot in fuel filter
shell. Gently tug on wire to verify that terminal is locked.
NOTE
If terminal does not lock, use a thin blade to bend tang slightly
away from terminal body.

6. Inspect strainer. Replace if damaged.

Figure 5-13. Remove Ground Wire Spade Terminal From 7. Install top plate. See FUEL TANK TOP PLATE
Fuel Filter Shell (Page 5-9).

94000383 5-11
FUEL PRESSURE REGULATOR 5.9
REMOVAL INSTALLATION

WARNING 1. See Figure 5-16. Insert small O-ring (6) at top of pressure
port bore.
Gasoline is extremely flammable and highly explosive.
Keep gasoline away from ignition sources which could 2. Install screen (5) at top of pressure regulator bore, with
result in death or serious injury. See the Safety chapter. sleeve on ID facing small O-ring. Install regulator seat (3)
(00635c) to evenly press screen into bore. Remove regulator seat.
3. Install large O-ring (4) at top of screen.
1. Remove top plate. See FUEL TANK TOP PLATE
(Page 5-9). 4. Install regulator seat and fuel pressure regulator.

2. See Figure 5-15. Remove ground wire spade terminal from 5. Install spring clip (1), with indented sides engaging top of
slot of fuel filter shell. center rib on fuel pressure regulator. Rounded sides
engage bottom of tabs on housing.
3. See Figure 5-16. Remove spring clip (1) securing fuel
pressure regulator. 6. Route ground wire around index pin side of end cap. Install
spade terminal into slot in fuel filter shell.
4. Remove fuel pressure regulator (2), regulator seat (3),
large O-ring (4), screen (5) and small O-ring (6). 7. Install top plate. See FUEL TANK TOP PLATE
(Page 5-9).
sm04033a

Figure 5-15. Remove Ground Wire Spade Terminal From

Fuel Filter Shell

sm04032a
1

6
5

3
4
1. Spring clip
2. Fuel pressure regulator
3. Regulator seat
4. Large O-ring
5. Screen
6. Small O-ring
Figure 5-16. Fuel Pressure Regulator Assembly

5-12 94000383
FUEL LEVEL SENDER 5.10
REMOVAL sm04194

WARNING
Gasoline is extremely flammable and highly explosive.
Keep gasoline away from ignition sources which could
result in death or serious injury. See the Safety chapter.
(00635c)

1. Remove top plate. See FUEL TANK TOP PLATE

(Page 5-9).
2. Disconnect 2-place connector to release fuel level sender
from wire harness.
NOTE
See Figure 5-17. Look into fuel tank at bracketry. Note that
finger (1) on front bracket points forward, while finger on rear
bracket points rearward.

3. Pull up on front finger (1) and slide fuel level sender

bracket rearward until four ears on bracket are free of Figure 5-18. Fuel Level Sender
catches at top of tunnel.
INSTALLATION
4. Remove fuel level sender from left side of fuel tank. See
Figure 5-18. 1. See Figure 5-17. With the finger on the fuel level sender
bracket (1) pointing forward, install fuel level sender into
sm04400a
left side of fuel tank.
2. Engage four ears on fuel level sender bracket with front
3 set of catches at top of tunnel. Push fuel level sender
bracket forward until ears are fully engaged.
1
3. Connect fuel level sender connector (2) to wire harness.
4. Install top plate. See FUEL TANK TOP PLATE
2 (Page 5-9).
NOTE
The low fuel lamp will not turn off until there is sufficient fuel in
the tank, the ignition switch has been turned off and back on,
and the vehicle has begun forward movement.

1. Fuel level sender bracket (front finger)

2. Fuel level sender connector
3. Top plate connector
Figure 5-17. Front Finger (Fuel Level Sender Bracket)

94000383 5-13
TWIST GRIP SENSOR (TGS) 5.11
REMOVE sm08036

1. Remove main fuse.

2. Remove right switch housing and front brake control from
the handlebar. See HANDLEBAR SWITCH PACKS
(Page 9-94).
3. Models with heated hand grips: Pry end cap from hand
grip. Pull connector out through end of hand grip. See
HANDLEBAR, HEATED HAND GRIPS (Page 3-93). Do
not disconnect the heated hand grip power or interconnect
connectors.
4. Remove the right hand grip.
5. Road King models: See Figure 5-19. Figure 5-20. TGS Connector: Fork-Mounted Fairing Models

a. Remove harness retainers from right side of handlebar. sm08382b

b. Remove headlamp and handlebar clamp shroud. See 2 3 4

HEADLAMP NACELLE: ROAD KING MODELS 1
(Page 3-144).
c. Disconnect TGS connector (2). Cut cable strap securing
harness to right riser.
d. Remove cable strap gathering TGS harness.

6. Fork-mounted fairing models: 5 5

a. Remove outer fairing.
b. See Figure 5-20. Disconnect TGS connector.
c. Rotate inner fairing. See INNER FAIRING: FORK
MOUNTED FAIRING MODELS, Rotate Inner Fairing
(Page 3-118). 1. TGS connector
d. Cut cable straps securing TGS harness. 2. Left handlebar switch harness
3. Run/stop switch
7. Frame-mounted fairing models: 4. Right handlebar switch harness
5. Handlebar clamp screws
a. Remove instrument bezel. See INSTRUMENT BEZEL:
Figure 5-21. Handlebar Harness Connectors: Frame-
FRAME MOUNTED FAIRING MODELS (Page 3-125).
Mounted Fairing Models
b. See Figure 5-21. Disconnect TGS connector (1).
8. Models with heated hand grips: Disconnect the heated
c. Remove cable strap gathering TGS harness. hand grip jumper harness connector.
9. Attach a chaser wire to the TGS connector.
sm07537a
10. Pull TGS and harness out of handlebar.
1 5
11. Remove TGS.
2 INSTALL

NOTE
3 See Figure 5-22. The seal cap protects the TGS terminals from
dirt and moisture. It also serves as a retention device for the
throttle grip.
4
1. Install seal cap at end of TGS. If seal cap is not present,
remove from inside throttle grip.
a. Check condition of O-ring on seal cap. O-ring is
1. Left handlebar switch module available only as part of the seal cap assembly.
2. TGS
3. Right auxiliary/fog/turn signal lamps b. See Figure 5-22. Install seal cap engaging legs in slots
4. Left auxiliary/fog/turn signal lamps at end of TGS.
5. Caddy retainer
Figure 5-19. Left Side Connectors: Road King Models

5-14 94000383
2. See Figure 5-23. Install TGS.
a. Draw harness into handlebar while guiding TGS into
end of handlebar.
b. Align index tabs on TGS into slots in handlebar.
c. Verify that the TGS is completely engaged into the slots
in the handlebar.
3. Connect TGS connector.
4. Install hand grip.
a. Install hand grip with cosmetic features properly
positioned.
b. Rotate to verify that internal splines are engaged with
the twist grip sensor.
c. Models with heated hand grips:Connect heated hand
grip interconnect harness connector. See HANDLEBAR,
HEATED HAND GRIPS (Page 3-93). Install end cap.
NOTE
Always follow the procedure in HANDLEBAR SWITCH PACKS
(Page 9-94) when installing right switch housing to make sure
that the twist grip operates correctly.
5. Install switch housing and brake master cylinder assembly.
See HANDLEBAR SWITCH PACKS (Page 9-94).
sm04169
Figure 5-22. Install Seal Cap (Models without heated grips)
sm04172a
Figure 5-23. Install Twist Grip Sensor
94000383
6. Road King models:
a. Install handlebar clamp shroud and headlamp. See
HEADLAMP NACELLE: ROAD KING MODELS
(Page 3-144).
b. Install cable clips on harnesses into holes in handlebar.
c. Secure TGS harness and brake line to right handlebar
riser with a new cable strap.
d. See Figure 5-19. Connect TGS connector.
e. See Figure 5-25. Loop TGS harness onto itself.
f. Install new cable strap (2).
7. Fork-mounted fairing models:
a. Rotate inner fairing. See INNER FAIRING: FORK
MOUNTED FAIRING MODELS, Rotate Inner Fairing
(Page 3-118).
b. See Figure 5-20. Connect TGS connector.
c. Install outer fairing.
d. See Figure 5-24. Fold TGS harness (3) across
handlebar. Secure with new cable straps (2).
8. Frame-mounted fairing models:
a. See Figure 5-21. Connect TGS connector (1).
b. See Figure 5-25. Loop TGS harness onto itself.
c. Install new cable strap (2).
d. Install instrument bezel. See INSTRUMENT BEZEL:
FRAME MOUNTED FAIRING MODELS (Page 3-125).
9. Install main fuse.
NOTE
Whenever a new TGS (or ECM) is installed, idle speed must
be reset. The ECM uses the first four ignition cycles to establish
the optimum idle speed. If the procedure is not performed,
initial performance problems may result.
10. Reset idle speed.
a. Place the engine run/stop switch in the RUN position.
b. Turn the ignition/light keyswitch to IGNITION and then
back to OFF four times without starting engine. Allow
at least three seconds to elapse between ignition cycles.
c. Start engine to verify installation.
5-15
 sm07526

3 2
1 1

1. Cable straps
2. Heated hand grip interconnect harness
3. TGS jumper harness
Figure 5-24. Secure Harness to Handlebar

sm08523
1

1. Green tape
2. Cable strap
3. White tape
Figure 5-25. Secure TGS Harness: FLHR, FLTR, FLHX/S,
FLHTCU, FLHTK

5-16 94000383
INDUCTION MODULE 5.12
PREPARE d. Remove TCA connector (11). Release harness from
anchor point (12)
1. Remove fuel tank. See FUEL TANK (Page 5-6).
NOTE
2. Remove air cleaner and backplate. See AIR CLEANER See Figure 5-27. For best results, use the HD-35801 (INTAKE
ASSEMBLY (Page 5-5). MANIFOLD WRENCH).
REMOVE
3. See Figure 5-26. Remove right side screws (3).
1. See Figure 5-26. California models: Pull purge tube from 4. Loosen left side screws (3).
fitting (13).
5. Remove induction module from right side.
2. Remove connections:
6. Discard seals (1). Remove flange adapters (2, 9).
a. Remove TMAP sensor connector (10).
7. Disconnect fuel line from induction module.
b. Remove front fuel injector connector (8).
a. Push fuel line toward fuel rail.
c. Remove rear fuel injector connector (5).
b. Pull and hold retainer sleeve (7) in direction of arrow.
c. Pull fuel line from fuel rail inlet fitting.

sm08581

2 5
1 3
4
7

9
13

10

12

11

1. Seal (2) 8. Front fuel injector connector [84]

2. Rear flange adapter 9. Front flange adapter
3. Right side screw (2) 10. TMAP sensor connector [80]
4. Left side screw (2) 11. TCA connector [211]
5. Rear fuel injector connector [85] 12. TCA harness anchor point
6. Fuel rail and inlet fitting 13. Purge tube fitting/cap
7. Retainer sleeve
Figure 5-26. Induction Module Assembly

94000383 5-17
 d. Install TCA connector (11).
sm08590

e. Capture TCA harness to anchor point (12) with new

anchored cable strap.

f. California models: Connect purge tube to fitting

(13).

g. Non-California models: Inspect rubber cap for

damage.

COMPLETE
1. Install fuel tank. See FUEL TANK (Page 5-6).
Figure 5-27. Intake Manifold Wrench
2. Install air cleaner assembly. See AIR CLEANER
INSTALL ASSEMBLY (Page 5-5).

FASTENER TORQUE VALUE

DISASSEMBLE
Induction module flange 96–156 in-lbs 10.9–17.6 N·m
adapter screws 1. See Figure 5-28. Remove TMAP sensor (7). See
TEMPERATURE MANIFOLD ABSOLUTE PRESSURE
1. Connect fuel line to induction module. SENSOR (TMAP) (Page 5-20).
2. Remove fuel injectors (8, 10) and fuel rail (9). See Fuel
a. Push fuel line firmly onto fuel rail inlet fitting (6) until Injectors (Page 5-21).
a click is heard.
3. Remove bracket (1).
b. Pull hose to verify secure attachment. a. Remove screws (2).
b. Remove bracket.
2. See Figure 5-26. With the counterbore facing outward,
install flange adapters (2, 9) onto the induction module. 4. Remove throttle body (4).

NOTE a. Remove screws (3).

For best results, use the HD-35801 (INTAKE MANIFOLD b. Remove throttle body.
WRENCH).
c. Remove rubber cap (5).
d. Discard gasket (6).
3. Place a new seal (1) in each flange adapter with the
beveled side against the counterbore.
ASSEMBLE
4. Install induction module.
FASTENER TORQUE VALUE
a. Slide induction module into position until slots engage Induction module bracket 66–84 in-lbs 7.5–9.5 N·m
left side screws (4). Throttle body to manifold 35–53 in-lbs 4–6 N·m
screws
b. Start right side screws (3).
1. See Figure 5-28. Install throttle body (4).
c. Temporarily fasten mounting bracket to cylinder
heads with breather bolts. a. Install new gasket (6).

5. Tighten right side screws (3) until snug. b. Install throttle body.

6. Tighten left side screws (4) to 96–156 in-lbs c. Install screws (3). Tighten to 35–53 in-lbs (4–6 N·m).
(10.9–17.6 N·m).
d. Install new rubber cap (5).
7. Tighten right side screws (3) to same torque.
2. Install bracket (1) with screws (2). Tighten to 66–84 in-lbs
(7.5–9.5 N·m).
8. Install connections:

3. Install TMAP sensor (7). See TEMPERATURE MANIFOLD

a. Install rear fuel injector connector (5) (black).
ABSOLUTE PRESSURE SENSOR (TMAP) (Page 5-20).
b. Install front fuel injector connector (8) (grey).
4. Install fuel injectors (8, 10) and fuel rail (9). See Fuel
c. Install TMAP sensor connector (10). Injectors (Page 5-21).

5-18 94000383
 sm08584
9
8

10
1 7

5 6
2
4 11

1. Bracket 7. TMAP sensor

2. Screw (2) 8. Rear fuel injector
3. Screw (3) 9. Fuel rail
4. Throttle body 10. Front fuel injector
5. Rubber cap 11. Intake manifold
6. Gasket
Figure 5-28. Induction Module Assembly

94000383 5-19
TEMPERATURE MANIFOLD ABSOLUTE PRESSURE SENSOR (TMAP) 5.13
PREPARE sm08583
2
WARNING
Gasoline is extremely flammable and highly explosive. 1
Keep gasoline away from ignition sources which could
result in death or serious injury. See the Safety chapter.
(00635c)

WARNING
To prevent spray of fuel, purge system of high-pressure
fuel before supply line is disconnected. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00275a)

1. Remove seat. See SEAT (Page 3-96).

2. Remove fuel tank. See FUEL TANK (Page 5-6).
3. Remove main fuse. See System Fuses and Relays
(Page 9-6).
REMOVE
1. Disconnect TMAP sensor connector.
1. TMAP sensor
2. See Figure 5-29. Remove TMAP sensor. 2. Screw
a. Remove screw (2). Figure 5-29. TMAP Sensor
b. Remove TMAP sensor (1). COMPLETE

INSTALL 1. Install fuel tank. See FUEL TANK (Page 5-6).

2. Install seat. See SEAT (Page 3-96).
FASTENER TORQUE VALUE
3. Install main fuse. See System Fuses and Relays
Temperature manifold 23–39 in-lbs 2.5–4.5 N·m
(Page 9-6).
absolute pressure sensor
(TMAP) screw

1. See Figure 5-29. Install TMAP sensor.

a. Install TMAP sensor (1).

b. Install screw (2). Tighten to 23–39 in-lbs

(2.5–4.5 N·m).

2. Connect TMAP sensor connector.

5-20 94000383
FUEL INJECTORS 5.14
PREPARE sm08582
3
2
WARNING
Gasoline is extremely flammable and highly explosive.
Keep gasoline away from ignition sources which could 1 4
result in death or serious injury. See the Safety chapter.
(00635c)

WARNING
To prevent spray of fuel, purge system of high-pressure
fuel before supply line is disconnected. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00275a)

1. Remove seat. See SEAT (Page 3-96).

2. Remove fuel tank. See FUEL TANK (Page 5-6).
3. Remove main fuse. See System Fuses and Relays
(Page 9-6).
REMOVE
1. Disconnect fuel injector connectors.
1. Screw (2)
2. See Figure 5-30. Remove fuel rail and fuel injectors. 2. Rear fuel injector
a. Remove screws (1). 3. Fuel rail
4. Front fuel injector
b. Remove fuel rail (3).
Figure 5-30. Fuel Injectors
c. Remove fuel injectors (2, 4). COMPLETE
3. Remove O-rings from intake manifold. Discard O-rings.
1. Install fuel tank. See FUEL TANK (Page 5-6).
INSTALL 2. Install seat. See SEAT (Page 3-96).

FASTENER TORQUE VALUE 3. Install main fuse. See System Fuses and Relays
(Page 9-6).
Fuel rail screws 31–49 in-lbs 3.5–5.5 N·m

1. See Figure 5-30. Install fuel injectors to intake manifold.

2. Install fuel rail.

a. Install fuel rail (3).

b. Install screws (1). Tighten to 31–49 in-lbs

(3.5–5.5 N·m).

3. Connect fuel injector connectors.

a. Grey connector to front injector.

b. Blsck connector to rear injector.

94000383 5-21
HEATED OXYGEN SENSORS (HO2) 5.15
REMOVE 2. See Figure 5-31. Cut cable straps (8, 9).
3. Disconnect oxygen sensor connector (1 or 2).
PART NUMBER TOOL NAME
4. Front HO2 sensor: Remove anchored cable strap (7)
HD-50017 OXYGEN SENSOR WRENCH from oil pressure harness. Remove wire from clips on
multi-clamp (5) and harness retainers (4).
1. Remove main fuse. See System Fuses and Relays
(Page 9-6). 5. Using OXYGEN SENSOR WRENCH (PART NUMBER:
HD-50017), remove oxygen sensor (6).

sm06656c
1 2

9 10

8 3

7
5

1. Front oxygen sensor connector (grey) 6. Front oxygen sensor

2. Rear oxygen sensor connector (black) 7. Anchored cable strap: oxygen sensor to oil
pressure harness
3. Rear oxygen sensor 8. Cable strap: oxygen sensor, brake line, vent hose
4. Main harness clips 9. Cable strap: both oxygen sensors to frame
5. Multi-clamp 10. Cable strap: rear oxygen sensor to frame
Figure 5-31. Oxygen Sensors (typical)
INSTALL • Replacement sensor assemblies have threads coated with
anti-seize lubricant and a new gasket.
PART NUMBER TOOL NAME • The electrical connector must be clean and free of any
HD-50017 OXYGEN SENSOR WRENCH dielectric grease.

FASTENER TORQUE VALUE 1. If reusing HO2 sensor:

HO2 sensor 14 ft-lbs 19 N·m
a. Use high-quality professional grade sidecutters to
NOTE remove used seal. Install a new one.
• Do not install sensors that have been dropped or impacted
by other components. The sensing element may be b. Apply a light coating of ANTI-SEIZE LUBRICANT to
damaged. threads.

5-22 94000383
2. Using OXYGEN SENSOR WRENCH (PART NUMBER:
HD-50017), install oxygen sensor. Tighten to 14 ft-lbs
(19 N·m).

3. Front HO2 sensor: See Figure 5-31.

a. Route harness along lower frame and above the rear

engine mount.

b. Secure anchored cable strap to anchor on oil

pressure harness (7).

c. Install HO2 sensor harness in clips on multi-clamp

(5) and harness retainers (4).

4. Rear HO2 sensor:

a. Route harness along top of transmission to neutral

switch area.

NOTE
Verify connector halves are clean and free of grease or other
contaminants. NEVER apply dielectric grease, cleaning agents
or any other lubricants, sealants or fluids to HO2 sensor
connectors. Any such application will result in corrupted signals
and sensor failure.

b. Follow neutral switch wires to frame area. Secure

with cable strap (10).

5. Connect sensor connector (1 or 2).

6. Secure sensor harnesses with new cable straps (7, 8, 9).

7. Install main fuse. See System Fuses and Relays

(Page 9-6).

94000383 5-23
FUEL PUMP 5.16
GENERAL sm04402a

WARNING
Gasoline is extremely flammable and highly explosive. 3
Keep gasoline away from ignition sources which could
result in death or serious injury. See the Safety chapter. 1
(00635c)

WARNING
Do not use solvents or other products that contain chlorine
on plastic fuel system components. Chlorine can degrade
plastic fuel system components, which can cause a loss
of fuel system pressure or engine stalling and could result
2
in death or serious injury. (00621b)

Carefully inspect tubes for damage. Even a small hole can

cause a reduction in fuel pressure. Replace fuel pump as 1. Fuel pump bracket (rear finger)
necessary. 2. Transfer tube/bracket
3. Fuel pump to fuel filter fitting
See the electrical diagnostic manual for information on the
Figure 5-32. Rear Finger (Fuel Pump Bracket)
function and testing of the fuel pump.
sm04404
REMOVAL
1. Remove top plate. See FUEL TANK TOP PLATE
(Page 5-9).
2. Remove fuel level sender. See FUEL LEVEL SENDER
(Page 5-13).
3. See Figure 5-32. Pull up on transfer tube bracket (2) to
release two tabs at bottom from slots at top of fuel pump
bracket.
4. Press collar on each side of fitting to disconnect transfer
tube from transfer tube bracket.
5. Pull up on rear finger (1) and slide fuel pump bracket
forward until four ears on bracket are free of catches at
top of tunnel. Figure 5-33. Fuel Pump Assembly
6. See Figure 5-33. Remove fuel pump from left side of fuel INSTALLATION
tank. Rotate fuel pump assembly 90 degrees clockwise
until transfer tube connection is pointing rearward. Remove 1. If removed, assemble fuel pump assembly:
from fuel tank.
a. Reaching into fuel tank, capture transfer tube in weld
7. If necessary, further disassemble fuel pump assembly:
clip on right side of tunnel.
a. Reaching into fuel tank, release transfer tube from weld b. Install fuel inlet strainer to bottom of fuel pump.
clip on right side of tunnel. Remove transfer tube from
fuel tank. 2. Hold fuel pump assembly with transfer tube connection
b. Press arms on fuel inlet strainer and remove from slots pointing rearward and insert into fuel tank. Rotate assembly
in fuel pump housing. 90 degrees counterclockwise.
c. Inspect the condition of the fuel pump wiring. If the 3. Look into fuel tank to verify that fuel inlet strainer lies flat
wiring requires replacement, see FUEL PUMP, Fuel and that ends are not folded under fuel pump. Also verify
Pump and Fuel Level Sender Wire Harness that wire harness is still captured in molded clip at front of
(Page 5-25). fuel pump bracket.
4. With the finger on the fuel pump bracket pointing rearward,
engage four ears on bracket with rear set of catches at
top of tunnel. Push fuel pump bracket rearward until ears
are fully engaged.

5-24 94000383
5. Install transfer tube onto transfer tube bracket. Fit two tabs
sm04406a
at bottom of transfer tube bracket into slots at top of fuel
pump bracket. Verify that transfer tube is still captured in
weld clip on right side of tunnel. Verify that free end is in
contact with bottom of fuel tank.
6. Install fuel level sender. See FUEL LEVEL SENDER
(Page 5-13).
7. Install top plate. See FUEL TANK TOP PLATE
(Page 5-9).
NOTE
The low fuel lamp will not turn off until there is sufficient fuel in
the tank, the ignition switch has been turned off and back on,
and the vehicle has begun forward movement.

FUEL PUMP AND FUEL LEVEL SENDER

WIRE HARNESS
Figure 5-35. Capture Wires in Molded Clip

Removal
NOTE
Damaged wiring, terminals and/or connectors requires
replacement of the wire harness. Do not replace the special
Teflon coated wiring with ordinary bulk wire. Ordinary insulation
materials deteriorate when in contact with gasoline.

1. Remove fuel pump. See FUEL PUMP (Page 5-24).

2. Cut cable strap to release wire harness and both fuel pump
and transfer tubes from arm of fuel pump bracket.
3. Release wire harness from molded clip at front of fuel
pump bracket.
4. Remove connector at top of fuel pump.

Installation
1. Install connector at top of fuel pump.
2. See Figure 5-34. Route wire harness rearward and then
forward under arm of fuel pump bracket. Install new cable
strap at elbow capturing fuel pump and transfer tubes at
top of arm and wire harness at bottom.
3. See Figure 5-35. Route wire harness through molded clip
at front of fuel pump bracket.
4. Install fuel pump. See FUEL PUMP (Page 5-24).

sm04405a

Figure 5-34. Capture Wires in Cable Strap

94000383 5-25
EXHAUST SYSTEM 5.17
MUFFLERS 2. Remove mufflers. See EXHAUST SYSTEM, Mufflers
(Page 5-26).
FASTENER TORQUE VALUE 3. Remove seat. See SEAT (Page 3-96).
Muffler clamp 38–43 ft-lbs 51.5–58.3 N·m 4. Remove right side rider footboard and brackets from frame.
Muffler to saddlebag support 14–18 ft-lbs 19–24.4 N·m See FOOTBOARDS AND FOOTRESTS, Rider Footboards
screws (Page 3-155).
5. Disconnect front and rear HO2 sensor connectors.
Removal
1. Remove saddlebags. See SADDLEBAGS (Page 3-98). REMOVE EXHAUST SYSTEM
2. See Figure 5-36. Remove two fasteners (2) and 1. See Figure 5-36. Remove exhaust shields (8, 18, 21) from
lockwashers. pipes.
3. Loosen clamp (22). 2. Loosen clamp (4).
4. Pull and twist muffler to remove. 3. Remove flange bolt (5) and crossover pipe support clamp
5. Inspect rubber mount (1) for deterioration or damage. (6).
Replace as necessary. 4. Remove cross-over pipe (7).

Installation 5. Remove two flange nuts (15) from front cylinder head.
Slide exhaust flange down header pipe to improve
1. Slide new muffler clamp onto muffler. Push muffler clearance around exhaust port.
squarely onto exhaust pipe.
6. Remove two flange nuts (15) from studs of rear cylinder
head.
2. Secure muffler to bracket (3) with fasteners (2) and
lockwashers. Tighten to 14–18 ft-lbs (19–24.4 N·m). 7. Remove flange locknut (20) from stud (16).
8. Remove exhaust header pipe.
3. Tighten clamp (22) to 38–43 ft-lbs (51.5–58.3 N·m).
9. Discard gaskets (13).
4. Install saddlebags. See SADDLEBAGS (Page 3-98). 10. Inspect retaining rings (14) and exhaust flanges (12).
Replace if necessary.
PREPARE
1. Remove saddlebags. See SADDLEBAGS (Page 3-98).

5-26 94000383
 sm08647

8
1 2

5 6
9
4 10 13
12 14
23 11

22 15
16

21 17
20

19 18

1. Rubber mount 13. Gasket (2)

2. Screw (4) 14. Retaining ring (2)
3. Bracket (2) 15. Flange nut (4)
4. Clamp 16. Stud
5. Flange bolt 17. Exhaust side bracket
6. Crossover pipe support clamp 18. Exhaust shields, header pipes
7. Crossover pipe 19. Worm clamp (8)
8. Exhaust shield, crossover pipe 20. Flange locknut
9. Screw (2) 21. Exhaust shield, collector
10. Transmission exhaust bracket 22. Muffler clamp (2)
11. O2 Sensor (2) 23. Muffler (2)
12. Exhaust flange (2)
Figure 5-36. Exhaust System
INSTALL EXHAUST SYSTEM FASTENER TORQUE VALUE
Exhaust crossover pipe 14–18 ft-lbs 19–24.4 N·m
FASTENER TORQUE VALUE hanger to transmission bracket
Exhaust crossover pipe clamp 38–43 ft-lbs 51.5–58.3 N·m fastener
Exhaust crossover pipe 100–120 in-lbs 11.3–13.6 N·m Exhaust flange adapter nuts, 100–120 in-lbs 11.3–13.6 N·m
hanger bracket final torque

94000383 5-27
 FASTENER TORQUE VALUE b. Tighten crossover pipe clamp (4) to 38–43 ft-lbs
Exhaust flange adapter nuts, 9–18 in-lbs 1–2 N·m (51.5–58.3 N·m).
first torque
NOTE
Exhaust shield clamps 20–40 in-lbs 2.3–4.5 N·m
• Verify that the exhaust shields do not contact the motorcycle
Exhaust side bracket flange 15–20 ft-lbs 20.3–27.1 N·m
frame or any mounted components.
locknut
• Install cross-over pipe heat shield with the longer straight
1. See Figure 5-36. If removed, install transmission exhaust portion toward the muffler.
bracket (10). Tighten screws (9) to 100–120 in-lbs
(11.3–13.6 N·m). c. Tighten flange bolt (5) to 14–18 ft-lbs (19–24.4 N·m).

2. Install new gaskets (13) in both cylinder head exhaust
ports with the tapered side out.
3. Place exhaust header pipe into position. Start two flange
nuts (15) to secure front header pipe to cylinder head.
4. Roll pipe into position at rear cylinder.
5. Start two flange nuts to secure rear header pipe to rear
cylinder head.
6. Secure header pipe to stud (16) with exhaust side bracket
(17) and flange locknut (20). Do not tighten.
7. Slide new clamp (4) onto cross-over pipe.
13. Install exhaust shields. Position each clamp so that screw
is on the outboard side in the most accessible position.
Tighten to 20–40 in-lbs (2.3–4.5 N·m).
COMPLETE
1. Connect O2 sensor connectors. Secure leads to rear frame
with new cable strap. Secure in harness retainer on lower
frame.
2. Install right side rider footboard and brackets. See
FOOTBOARDS AND FOOTRESTS, Rider Footboards
(Page 3-155).
3. Install seat. See SEAT (Page 3-96).
4. Install saddlebags. See SADDLEBAGS (Page 3-98).

8. Install cross-over pipe (8) and new clamp (4). Do not

tighten.

9. Install crossover support clamp (6). Secure with flange

bolt (5). Do not tighten.

NOTE
• Verify that the exhaust components do not contact the
motorcycle frame or any mounted components.
• Verify that no components are in a bind before and during
tightening to reduce the chance of unwanted noise or
vibration.

10. Install mufflers (24). See EXHAUST SYSTEM, Mufflers

(Page 5-26).

11. Tighten the exhaust flange nuts.

a. Rear: Tighten the bottom nut to first torque. Tighten

the top nut to final torque. Tighten the bottom nut to
final torque. Refer to Table 5-3.

b. Front: Tighten the bottom nut to first torque. Tighten

the top nut to final torque. Tighten the bottom nut to
final torque. Refer to Table 5-3.

Table 5-3. Exhaust Flange Nut Torque

ITEM TORQUE
First torque 9–18 in-lbs (1–2 N·m)
Final torque 100–120 in-lbs (11.3–13.6 N·m)

12. Tighten the remaining exhaust system fasteners.

a. Tighten flange locknut (20) to 15–20 ft-lbs

(20.3–27.1 N·m).

5-28 94000383
EVAPORATIVE EMISSIONS CONTROL SYSTEM
GENERAL
Motorcycles sold in some markets are equipped with an
evaporative (EVAP) emissions control system. See Figure
5-37. The EVAP system functions as follows:
• The fuel vapor vent tube (6) connects to the vent tube on
the fuel tank top plate (7). It allows fuel vapors in the fuel
tank to be vented to the charcoal canister (9).
• Under certain engine conditions, the ECM (working with the
EFI system relay) opens the purge solenoid (2). Negative
pressure (vacuum) draws the fuel vapors in the charcoal
canister through the purge tube to the induction module.
They are then burned as part of the normal combustion
process.
5.18
WARNING
Keep evaporative emissions vent lines away from exhaust
and engine. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
(00266a)
NOTE
The EVAP system has been designed to operate with a
minimum of maintenance. Check that all tubes are correctly
routed and properly connected. Also, verify that the tubes are
not pinched or kinked. Verify that there is no contact between
the tubes and engine parts.

sm08601
3 5
1 6

9
8

1. Top caddy 6. Fuel vapor vent tube

2. Purge solenoid 7. Fuel tank top plate
3. Purge solenoid-to-induction module tube 8. Fastener (2)
4. Canister-to solenoid tube 9. Charcoal canister
5. Retainer (2)
Figure 5-37. Evaporative Emissions Control System (EVAP)
VAPOR VALVE

NOTE
See Figure 5-38. The vapor valve is not serviceable. Damage
or failure of the vapor valve requires replacement of the fuel
tank top plate. See FUEL TANK TOP PLATE (Page 5-9).

94000383 5-29
 2. Remove fuel tank. See FUEL TANK (Page 5-6).
sm04094a
3. See Figure 5-39. Remove purge tube (4) from purge
solenoid.
4. Remove line from retainer (6).
5. Remove purge tube retainer from frame backbone.
6. Disconnect tube from fitting on induction module.
7. Remove purge tube.

Installation
NOTE
See Figure 5-39. Purge tube (4) must be routed under main
wire harness (5), then up to purge solenoid (2).

Figure 5-38. Fuel Tank Top Plate With Vapor Valve 1. See Figure 5-39. Place purge tube (4) in approximate
position.
FUEL VAPOR VENT TUBE
2. Connect to fitting on induction module.

Removal 3. Install on upper fitting of purge solenoid (2).

4. Secure purge tube to bottom of frame backbone with new
1. Remove seat. See SEAT (Page 3-96).
retainer.
2. Remove console. See FUEL TANK, Console (Page 5-7).
5. Install fuel tank. See FUEL TANK (Page 5-6).
3. See Figure 5-37. Remove fuel vapor vent tube (6) from
6. Install seat. See SEAT (Page 3-96).
vapor valve fitting on fuel tank top plate (7).
4. Disconnect vent tube from fitting on canister (9). sm08710
2
5. Remove vapor vent tube from motorcycle.

Installation 1 3
1. See Figure 5-37. Connect fuel vapor vent tube (6) onto
vapor valve fitting of fuel tank top plate (7).
2. Connect vent tube to fitting on charcoal canister (9) marked 4
"TANK".
3. Install console. See FUEL TANK, Console (Page 5-7). 5
4. Install seat. See SEAT (Page 3-96).
CANISTER-TO-SOLENOID TUBE
6
Removal
1. Remove seat. See SEAT (Page 3-96).
1. Fuel vapor vent tube
2. See Figure 5-39. Remove purge tube (3) from fittings of 2. Purge solenoid
purge solenoid and canister. 3. Canister-to-solenoid purge tube
4. Solenoid-to-induction module purge tube
Installation 5. Main wire harness
6. Retainer
NOTE
See Figure 5-39. This line is routed above the main wire Figure 5-39. Purge Tube Connections and Routing
harness (5). PURGE SOLENOID
1. Install end of purge tube with curved hose onto lower fitting
of canister. Removal
2. Install opposite end onto purge solenoid lower fitting. 1. Remove seat. See SEAT (Page 3-96).

3. Install seat. See SEAT (Page 3-96). 2. Remove top electrical caddy and remove purge solenoid
from caddy. Lay caddy aside. See ELECTRICAL CADDIES
SOLENOID-TO-INDUCTION MODULE TUBE (Page 9-9).
3. See Figure 5-40. Remove purge solenoid connector (1).
Removal 4. Remove purge tubes (2, 3) from purge solenoid.
1. Remove seat. See SEAT (Page 3-96). 5. Remove purge solenoid from motorcycle.

5-30 94000383
 11. Remove two screws to release charcoal canister from
sm05933a
frame crossmember.
12. Guide canister down into battery tray, right end first, and
1
3 remove.

Installation
1. Slide the charcoal canister under electrical harnesses,
fitting end first, and work into place.

2. Secure canister with two screws. Tighten to 15–20 in-lbs

(1.7–2.3 N·m).
2
3. See Figure 5-43. Install three ground ring terminals on left
1. Purge solenoid connector ground stud (1).
2. Canister-to-solenoid purge tube
3. Solenoid-to-induction module purge tube 4. Install two ground ring terminals on right ground stud (2).
Figure 5-40. Purge Solenoid Place battery chassis ground terminal on stud first.

Installation 5. See Figure 5-42. Connect purge tube (2) (charcoal canister
to purge solenoid) to lower canister fitting marked
1. See Figure 5-40. Install purge tube to induction module "PURGE."
(3) onto fitting of purge solenoid closest to the connector
cavity.
6. Connect fuel vapor vent tube (1) (vapor valve to charcoal
2. Install purge tube from charcoal canister (2) onto purge canister) to upper canister fitting marked "TANK."
solenoid.
3. Install purge solenoid connector (1). 7. See Figure 5-41. Install left electrical caddy with two
screws. Tighten to 72–96 in-lbs (8.1–10.9 N·m).
4. Secure solenoid to top caddy and install top caddy. See
ELECTRICAL CADDIES (Page 9-9).
sm05929
5. Check all routing to be sure that tubes are not pinched or
kinked, and that there is no contact with hot exhaust or
engine parts.
6. Install seat. See SEAT (Page 3-96).
CHARCOAL CANISTER

FASTENER TORQUE VALUE

Charcoal canister screws 15–20 in-lbs 1.7–2.3 N·m
Ignition coil screws 32–40 in-lbs 3.6–4.5 N·m
Left electrical caddy fastener 72–96 in-lbs 8.1–10.9 N·m

Removal
1. Remove seat. See SEAT (Page 3-96). Figure 5-41. Left Electrical Caddy Screws

2. Remove saddlebags. See SADDLEBAGS (Page 3-98). sm05930a

3. Remove side covers. 1

4. Remove battery. See Battery Maintenance (Page 2-51).
5. Remove two screws securing battery hold-down bracket
and ignition coil.
6. See Figure 5-41. Remove screws securing left side caddy.
2
7. See Figure 5-42. Disconnect fuel vapor vent tube (1) from
canister fitting marked "TANK."
8. Disconnect purge tube (2) from canister fitting marked
"PURGE."
9. See Figure 5-43. Remove three ground ring terminals from
left ground stud (1). 1. Fuel vapor vent tube
2. Purge tube
10. Remove two ground ring terminals from right ground stud
(2). Figure 5-42. Purge Tube Connections

94000383 5-31
 8. Check all routings to be sure that tubes are not pinched
sm05931a
or kinked, and that there is no contact with hot exhaust or
engine parts.
2
9. Secure battery hold-down bracket and coil with two screws.
Tighten to 32–40 in-lbs (3.6–4.5 N·m).

1 10. Install battery. See Battery Maintenance (Page 2-51).

11. Install side covers.

12. Install saddlebags. See SADDLEBAGS (Page 3-98).

13. Install seat. See SEAT (Page 3-96).

1. Left ground stud
2. Right ground stud
Figure 5-43. Chassis Ground Studs

5-32 94000383
SUBJECT PAGE NO.
6.1 FASTENER TORQUE VALUES ............................................................................................ 6-1
6.2 SPECIFICATIONS: COOLING SYSTEM .............................................................................. 6-2
6.3 COOLING SYSTEM OPERATION ........................................................................................ 6-3
6.4 TESTING AND DIAGNOSTICS ............................................................................................ 6-4
6.5 COOLING SYSTEM REPAIR ................................................................................................ 6-6

COOLING SYSTEM
NOTES
FASTENER TORQUE VALUES 6.1
FASTENER TORQUE VALUES IN THIS
CHAPTER

The table below lists torque values for all fasteners presented
in this chapter.

FASTENER TORQUE VALUE NOTES

Air duct nut, lower fairing 65–75 in-lbs 7.3–8.4 N·m 6.5 COOLING SYSTEM REPAIR, COOLING FAN
Air duct screws, lower fairing 65–75 in-lbs 7.3–8.4 N·m 6.5 COOLING SYSTEM REPAIR, COOLING FAN
Coolant bottle nut 65–75 in-lbs 7.3–8.4 N·m 6.5 COOLING SYSTEM REPAIR, Coolant Bottle
Coolant bottle nut 65–75 in-lbs 7.3–8.4 N·m 6.5 COOLING SYSTEM REPAIR, COOLING FAN
Coolant downtube lower screws 20–22 ft-lbs 27.1–29.8 N·m 6.5 COOLING SYSTEM REPAIR, Coolant Down-
tubes
Coolant downtube upper screws 90–110 in-lbs 10.2–12.4 N·m 6.5 COOLING SYSTEM REPAIR, Coolant Down-
tubes
Coolant line manifold screws 90–120 in-lbs 10.2–13.6 N·m 6.5 COOLING SYSTEM REPAIR, Install Upper
Coolant Lines
Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (BLUE)
Glove box screws, lower fairing 12–16 in-lbs 1.4–1.8 N·m 6.5 COOLING SYSTEM REPAIR, COOLING FAN
Lower fairing cap flange nut 30–35 in-lbs 3.4–3.9 N·m 6.5 COOLING SYSTEM REPAIR, COOLING FAN

94000383 6-1
SPECIFICATIONS: COOLING SYSTEM 6.2
GENERAL

Table 6-1. Capacities

ITEM QUARTS LITERS
Engine coolant * 0.8 0.8
* Excludes overflow bottle

Table 6-2. Coolant Pressure

ITEM PSI KPA
Cap lower limit 18 124
Rated cap pressure 20 138
Cap upper limit 22 152

Table 6-3. Coolant Temperatures

ITEM °F °C
Engine temperature lamp 266 130
Antifreeze protection -34 -36.7

Table 6-4. Fan Operation *

STATUS Coolant Temperature
°F °C
On (below 15 mph) 194 90
Off (below 15 mph) 181 83
On (above 15 mph) 230 110
Off (above 15 mph) 216 102
Fans and pump will run after vehicle shutdown until 189 °F
(87 °C) is reached or three minutes, whichever occurs first.

6-2 94000383
COOLING SYSTEM OPERATION
OPERATION
An electric pump (4) mounted near the voltage regulator
circulates the coolant through the system.
Coolant flows from the pump (4) up through the left downtube
to a manifold (8) between the cylinder heads. Coolant flows
through passages around the exhaust valve seats in each
cylinder head. Coolant then exits both cylinder heads to a
collection manifold (9) which combines the flow and returns
coolant to the left radiator (6). Coolant then flows to the right
radiator (2) before returning to the pump through hose (3).
A fan (7) is mounted behind each radiator to boost air flow at
low road speeds and at engine idle. The fans are controlled
6.3
by the ECM based on coolant temperature and vehicle speed.
Temperature switch (5) mounted in the left radiator reports
coolant temperature to the ECM.
The coolant bottle (1) stores extra coolant to control coolant
expansion and contraction during operation.
The pump will not run until the engine is started, then runs
continually while the engine is running. The fans will cycle on
and off while the engine is running, depending on vehicle speed
and coolant temperature. If the fans are running when the
engine is stopped, the fans and pump will continue to run until
coolant is at a certain temperature or for a predetermined length
of time, whichever occurs first. If the fans are not running when
the engine is stopped, they will not start again with the ignition
OFF.

sm08607
1
9
8

7
2
3

4 6

1. Coolant bottle 6. Left radiator

2. Right radiator 7. Fan (2)
3. Coolant return to pump 8. Inlet manifold
4. Pump 9. Outlet manifold
5. Coolant temperature switch
Figure 6-1. Coolant Flow

94000383 6-3
TESTING AND DIAGNOSTICS 6.4
TROUBLESHOOTING b. Opens above high limit, 22 psi (152 kPa)
c. Pressure falls rapidly when pressurized within range
WARNING
7. Remove adapter and cap.
The Troubleshooting section of this manual is a guide to
diagnose problems. Read the appropriate sections of this sm08167
manual before performing any work. Improper repair and/or
maintenance could result in death or serious injury.
(00528b)

High Engine Temperature

1. Blocked hoses, pipes or passages.
2. Restricted air flow through radiator.
3. Defective cooling fan.
4. Faulty coolant pump.
5. Low coolant level.
6. Air in system.
7. Defective pressure cap.
8. Defective engine coolant sensor.

Coolant Leaks
1. Pressure cap not properly installed.
2. Damaged pressure cap gasket. Figure 6-2. Pressure Cap Test
3. Deteriorated O-rings on coolant pump or manifolds. SYSTEM PRESSURE TEST
4. Leaking hose or hose connection.
PART NUMBER TOOL NAME
PRESSURE CAP TEST
HD-45335 COOLANT SYSTEM PRESSURE
TESTER
PART NUMBER TOOL NAME
HD-45335 COOLANT SYSTEM PRESSURE 1. See Figure 6-3. Before troubleshooting cooling system,
TESTER make sure that engine coolant level is at or slightly above
COLD full mark on coolant bottle (3).
Test pressure cap for the correct operating range every time
the coolant is changed or any cooling system maintenance
WARNING
performed.
Do not loosen or remove pressure cap when engine is hot.
WARNING The cooling system is under pressure and hot coolant and
Do not loosen or remove pressure cap when engine is hot. steam can escape from pressure cap, which could cause
The cooling system is under pressure and hot coolant and severe burns. Allow engine to cool before servicing the
steam can escape from pressure cap, which could cause cooling system. (00091b)
severe burns. Allow engine to cool before servicing the NOTE
cooling system. (00091b)
Damaged filler neck cams, safety stops and sealing surfaces
can cause cap to leak or affect the pressure limiting valve.
1. Remove pressure cap.
Replace the filler neck if damaged. Damaged cap stop can
2. Inspect cap for gasket deterioration and inoperative also cause a coolant leak. Replace cap if damaged.
springs.
3. New cap: Wet the upper sealing gasket before turning 2. Pull filler neck (2) from retainer on coolant bottle. Remove
onto adapter. cap.
4. See Figure 6-2. Connect COOLANT SYSTEM PRESSURE
TESTER (PART NUMBER: HD-45335) to pressure cap. NOTE
Wet the upper sealing surfaces before turning adapter onto
5. Pump handle to pressurize cap. Stop pumping when tester head.
pressure limiting valve in cap opens.
6. Replace pressure cap if: 3. Clean and inspect filler neck, upper and lower sealing
a. Opens below low limit, 18 psi (124 kPa) seats, overflow tube and coolant bottle.

6-4 94000383
 NOTE WARNING
When performing the coolant system pressure test, never
Do not loosen or remove pressure cap when engine is hot.
exceed the upper limit rating of the pressure cap. Excessive
The cooling system is under pressure and hot coolant and
pressure can rupture cooling pipes, hoses and radiator.
steam can escape from pressure cap, which could cause
severe burns. Allow engine to cool before servicing the
4. Connect COOLANT SYSTEM PRESSURE TESTER cooling system. (00091b)
(PART NUMBER: HD-45335) to the filler neck.
2. Remove filler cap.
5. Pump tester until pressure reaches 20 psi (138 kPa).
3. If filler neck is full of coolant, remove an amount of coolant
6. Observe pressure gauge and proceed as indicated in Table equal to the amount of dye.
6-5.
4. See Figure 6-4. Pour COOLANT FLUORESCENT LEAK
7. Release system pressure. Remove tester from filler neck. DETECTION DYE (PART NUMBER: HD-29545-6A) into
filler neck.
Table 6-5. System Pressure Test
NEEDLE MOVEMENT LEAK ACTION sm00614

Holds steady for 2 minutes None None

Drops slowly Small Perform dye
test
Drops quickly Major Perform visual
inspection

sm07566a
1

Figure 6-4. Pouring Dye into Filler Neck

5. Install pressure cap. Run engine for 10 minutes.
3 2 6. Use BLACK LIGHT LEAK DETECTOR (PART NUMBER:
HD-35457) to illuminate entire cooling system. A yellow
fluorescence indicates a leak.
7. Inspect engine oil for yellow dye.
NOTE
Dye in the oil may indicate a damaged engine head gasket.
Draining and replacing coolant contaminated oil is necessary
as part of engine service.
1. Tester adapter
2. Filler neck
3. Bottle
Figure 6-3. System Pressure Test
LEAK DETECTION DYE TEST

PART NUMBER TOOL NAME

HD-29545-6A COOLANT FLUORESCENT LEAK
DETECTION DYE
HD-35457 BLACK LIGHT LEAK DETECTOR

NOTE
If the coolant bottle is empty when the engine is cold, air has
possibly been drawn into the coolant system. Fill system with
coolant and purge any trapped air.

1. Before troubleshooting cooling system, make sure that

engine coolant level is at COLD FULL mark on coolant
bottle.

94000383 6-5
COOLING SYSTEM REPAIR 6.5
CRIMP CLAMPS 7. Empty coolant bottle into a suitable container.
8. Note orientation of overflow hose to bottle. Remove
PART NUMBER TOOL NAME overflow hose from lower barb.
HD-41137 HOSE CLAMP PLIERS
sm08138

Removal
2
NOTE 1
Pry overlap to release crimp clamps. If clamps must be cut,
use a sharp high-quality wire cutter. To prevent breaking plastic
fittings, do not twist clamp while cutting.
4
1. See Figure 6-5. Push the tip of a small screwdriver under 3
end of tang (2).
NOTE
Plastic fittings are fragile. Use care when removing clamp.

2. Pry until tang is free of tab (1).

3. Remove clamp.

sm07937 1
1. Nut
2. Clamp
3. Overflow hose
4. Vent hose
2
Figure 6-6. Remove Coolant Bottle

Installation
NOTE
If HARLEY-DAVIDSON HYLOMAR SEALANT (Part. No
1. Tab 99653-85) is not available, obtain an equivalent such as
2. Tang PermaShield Gasket Dressing and Flange Sealant 85420.

Figure 6-5. Removing Crimp Clamp

1. Thoroughly clean hose barb with clean towels. Clean inside
Installation of overflow hose end.

1. Install new clamp. 2. Apply a small amount of HARLEY-DAVIDSON HYLOMAR

2. Tighten clamp using HOSE CLAMP PLIERS (PART SEALANT to hose barb. Apply sealant completely around
NUMBER: HD-41137). the flare of the barb using an applicator. Do not get sealant
in the opening of the barb.
COOLANT BOTTLE
NOTE
FASTENER TORQUE VALUE • Sealant requires no cure time or special handling.
Coolant bottle nut 65–75 in-lbs 7.3–8.4 N·m
• If hose clamp is damaged, replace with new part.
Removal
3. See Figure 6-6. Install overflow hose (3) on barb at bottom
1. Remove access panel from right fairing lower. of coolant bottle until fully seated. Rotate 90 degrees to
distribute sealant.
a. Pry the center top.
b. Pull out to release retainers. 4. Position hose as noted during removal.

2. See Figure 6-6. Remove overflow hose (3) from filler neck.
5. Install hose clamp.
3. Remove nut (1).
4. Maneuver coolant bottle out of fairing lower. Use care to 6. Remove excess sealant from connection area.
not spill coolant from bottle.
7. Connect vent hose (4). Secure with clamp.
5. Disconnect vent hose (4). Record vent hose routing for
reference during installation.
6. Remove coolant bottle.

6-6 94000383
8. Install bottle into fairing lower.
sm08608

a. Verify that vent hose is routed as noted during

removal

b. Verify that mounting post on bottle is firmly installed

in grommet. 1
2
9. Secure bottle with nut (1). Tighten to 65–75 in-lbs
(7.3–8.4 N·m).
3
10. Connect overflow hose (3) to filler neck. Secure with hose 1
clamp (2).

11. Fill coolant bottle. See Coolant (Page 2-19).

1. Manifold port
12. Clean any spilled or leaked coolant from fairing lower. 2. Upper hoses
3. Screw (2)
13. Install access panel. Figure 6-7. Upper Coolant Lines
INSTALL UPPER COOLANT LINES
REMOVE UPPER COOLANT LINES
FASTENER TORQUE VALUE
PART NUMBER TOOL NAME Coolant line manifold screws 90–120 in-lbs 10.2–13.6 N·m
HD-52004 24 INCH HOSE CLAMP TOOL
PART NUMBER CONSUMABLE
1. Remove fuel tank. See FUEL TANK (Page 5-6).
11100005 LOCTITE 243 MEDIUM STRENGTH
2. Disconnect: THREADLOCKER AND SEALANT
(BLUE)
a. Fuel injector connectors.
b. Knock sensor connectors. Hose and Manifold Installation
c. Left spark plug cables. 1. Clean components.
d. ACR connectors.
a. Remove all residual thread locking material from
e. Horn connectors. Release harness from clamp and
screws and manifolds.
cable strap.
b. Clean all debris from mating surfaces and threaded
3. Remove stabilizer link and bracket. See FRONT ENGINE
holes.
MOUNT (Page 3-161).
4. See Figure 6-7. Remove screw (3) from each cylinder c. Clean all debris from coolant ports in heads and
head. manifolds.

NOTE
2. See Figure 6-7. Install new O-rings on each manifold port
Use 24 INCH HOSE CLAMP TOOL (PART NUMBER: (1).
HD-52004) to reach rotated or difficult to reach spring clamps.
3. Set coolant line assembly in position.
5. Remove hose clamps at top of coolant downtubes.
Separate hoses (2) from downtubes.
4. Install screw (3) in each cylinder head.
6. Remove coolant line assembly.
7. Discard O-rings from each manifold port (1). a. Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (BLUE) to threads
of screws.

b. Tighten to 90–120 in-lbs (10.2–13.6 N·m).

5. Install hoses (2) to coolant downtubes. Secure with hose

clamps.

6. Connect:

a. Fuel injector connectors.

b. Knock sensor connectors.

94000383 6-7
 c. Left spark plug cables. 3. Install voltage regulator. See VOLTAGE REGULATOR
(Page 9-50).
d. ACR connectors.
a. Apply silicone-based dielectric grease to both voltage
e. Horn connectors. Secure harness in clamp and new regulator connectors.
cable strap.
b. Connect voltage regulator connectors as downtube
7. Fill and bleed cooling system. See Coolant (Page 2-19). assembly is moved into place.

8. Install stabilizer link and bracket. See FRONT ENGINE 4. See Figure 6-8. Install downtube assembly with screws
MOUNT (Page 3-161). (3, 5).

9. Install fuel tank. See FUEL TANK (Page 5-6). a. Apply Apply LOCTITE 243 (blue) to the threads of
screws (3).
10. Run motorcycle until engine is at normal operating
temperature. Check coolant level. Check for coolant leaks. b. Tighten screws (3) to 90–110 in-lbs (10.2–12.4 N·m).

c. Install screws (5). Tighten to 20–22 ft-lbs

COOLANT DOWNTUBES (27.1–29.8 N·m).

PART NUMBER TOOL NAME 5. Install hoses to upper connections (2).

HD-52004 24 INCH HOSE CLAMP TOOL
a. Secure with new crimp clamps.
FASTENER TORQUE VALUE
Coolant downtube lower 20–22 ft-lbs 27.1–29.8 N·m 6. Install hoses to lower connections (4).
screws
Coolant downtube upper 90–110 in-lbs 10.2–12.4 N·m a. Secure with spring clamps.
screws
7. Connect pump electrical connector.
Remove
1. Remove main fuse. 8. Install pump cover.
2. Remove pump cover.
9. Fill and bleed cooling system. See Coolant (Page 2-19).
3. Drain coolant. See Coolant (Page 2-19).
4. Disconnect pump electrical connector. 10. Install fuel tank. See FUEL TANK (Page 5-6).
5. See Figure 6-8. Remove upper hose connections (2) from
11. Run motorcycle until engine is at normal operating
downtubes.
temperature. Check coolant level. Check for coolant leaks.
NOTE
Use 24 INCH HOSE CLAMP TOOL (PART NUMBER:
HD-52004) to reach rotated or difficult to reach spring clamps.

6. Disconnect hoses from lower connections (4).

7. Remove screws (3, 5).
8. Pull assembly away from frame and disconnect voltage
regulator connectors.
9. Remove downtube assembly.
10. Remove voltage regulator. See VOLTAGE REGULATOR
(Page 9-50).
11. Remove coolant pump. See COOLING SYSTEM REPAIR
(Page 6-6).

Install
1. Verify that all tubes and hoses are free from debris
internally.

2. Install coolant pump. See COOLING SYSTEM REPAIR

(Page 6-6).

6-8 94000383
 sm08609 sm07935
1
2

1 3
1
2

4
5

1. Frame cross member 1. Hose (2)

2. Upper connections 2. Hose clamp (2)
3. Screw (2) 3. Horizontal tube
4. Lower connections 4. Retainer (2)
5. Lower screw (2) Figure 6-9. Coolant Horizontal Line
Figure 6-8. Coolant Downtubes RADIATOR
HORIZONTAL COOLANT TUBE
PART NUMBER TOOL NAME
PART NUMBER TOOL NAME HD-41137 HOSE CLAMP PLIERS
HD-52004 24 INCH HOSE CLAMP TOOL
Removal
Removal
1. Remove main fuse.
1. Drain coolant. See Coolant, Drain and Fill Cooling System
2. Remove fan. See COOLING SYSTEM REPAIR, COOLING
(Page 2-20).
FAN (Page 6-10).
2. See Figure 6-9. Release retainers (4).
3. Drain coolant. See Coolant, Drain and Fill Cooling System
NOTE (Page 2-20).
Use 24 INCH HOSE CLAMP TOOL (PART NUMBER: 4. See Figure 6-10. Remove clamps (1). See COOLING
HD-52004) to reach rotated or difficult to reach spring clamps. SYSTEM REPAIR, Crimp Clamps (Page 6-6).

3. Remove clamps (2). 5. Disconnect upper and lower hoses from radiator.

4. Disconnect hoses (1). Remove horizontal tube (3). 6. Remove radiator.

7. Right side: Remove clamp (3). Remove filler assembly
Installation (2).
1. See Figure 6-9. Place horizontal tube (3) in position. 8. If necessary, remove gasket (4).
Connect hoses (1).
2. Install retainers (4). Installation
3. Install clamps (2). 1. See Figure 6-10. If removed, install new gasket (4).

4. Fill and bleed coolant system. See Coolant, Drain and Fill a. Carefully align to bosses.
Cooling System (Page 2-20). b. Place gap (5) at bottom center.

2. Right side: Install filler assembly (2) using new clamp (3).
3. Connect hoses to radiator using new clamps (1).
4. Tighten crimp clamps using HOSE CLAMP PLIERS (PART
NUMBER: HD-41137).

94000383 6-9
5. Install fan and assemble lower fairing. See COOLING 4. See Figure 6-11. Remove hoses (1, 6) from pump.
SYSTEM REPAIR, COOLING FAN (Page 6-10).
5. Disconnect pump power connector. Pull pump off mounting
6. Install main fuse. tabs (7).
7. Fill and bleed coolant system. See Coolant, Drain and Fill
Cooling System (Page 2-20).
Install Coolant Pump
1. See Figure 6-11. Install pump on mounting tabs (7). Apply
sm07553 window cleaner or rubbing alcohol to ease installation.
NOTE
Verify that clamps are not installed on the barbed area of the
fitting.

2 2. Install hoses (1, 6).

a. Install spring clamps (2).
1
3 b. Verify that hoses are installed completely on each fitting.

3. Mate power connector to pump.

4
4. Install pump cover.
5. Fill and bleed coolant system. See Coolant, Drain and Fill
Cooling System (Page 2-20).

sm08610
4
3
2

1 5
7
4 5
1. Hose clamp, upper and lower (2)
2. Filler assembly
2
1
3. Hose clamp, filler
4. Gasket 6
5. Gap
Figure 6-10. Radiator
2
COOLANT PUMP 1. Hose, right radiator to pump
2. Hose clamps, spring type (3)
PART NUMBER TOOL NAME 3. Hose, left radiator to right downtube
4. Hose clamps, crimp type (3)
HD-52004 24 INCH HOSE CLAMP TOOL
5. Coolant pump
6. Hose, pump to left downtube
Remove Coolant Pump 7. Pump mount tabs
CAUTION Figure 6-11. Coolant Pump and Hoses

Cooling fans operate automatically, even when the ignition COOLING FAN
switch is off. Keep hands away from fan blades. Contact
with a rotating fan blade can result in minor or moderate FASTENER TORQUE VALUE
injury. (00093a) Air duct nut, lower fairing 65–75 in-lbs 7.3–8.4 N·m
NOTE Air duct screws, lower fairing 65–75 in-lbs 7.3–8.4 N·m
• Removing the front fender increases working room and Coolant bottle nut 65–75 in-lbs 7.3–8.4 N·m
helps prevent cosmetic damage. Add cosmetic protection Glove box screws, lower 12–16 in-lbs 1.4–1.8 N·m
or remove the fender. fairing
• The pump assembly contains no service parts. Lower fairing cap flange nut 30–35 in-lbs 3.4–3.9 N·m

1. Remove main fuse. Removal

2. Remove pump cover. CAUTION
3. Drain coolant. See Coolant (Page 2-19). Cooling fans operate automatically, even when the ignition
NOTE switch is off. Keep hands away from fan blades. Contact
with a rotating fan blade can result in minor or moderate
Use 24 INCH HOSE CLAMP TOOL (PART NUMBER:
injury. (00093a)
HD-52004) to reach rotated or difficult to reach spring clamps.

6-10 94000383
 NOTE 3. See Figure 6-12. Mate connector (10). Install anchor in
Always remove the main fuse when servicing cooling fans. fan housing.

1. Remove main fuse. 4. Install air duct (12).

2. Remove access panel from fairing lower.

a. Verify that lower radiator mounts are aligned with
a. Pry the center top. bosses.
b. Pull out to release retainers. b. Tighten screws (13) to 65–75 in-lbs (7.3–8.4 N·m).
3. Remove nut securing lower fairing cap. Remove fairing c. Tighten nut (2) to 65–75 in-lbs (7.3–8.4 N·m).
cap.
4. See Figure 6-12. Remove lower fairing clamp screw and 5. Right side:
nut (8).
5. Remove nuts (7) securing upper clamp (5). Move lower a. Install coolant bottle (4) into rubber grommet and
fairing away from engine guard to access screws (6). onto stud.

6. Remove three screws (6) securing glove box frame (1). b. Capture filler neck in retainer.
Loosely install upper clamp.
c. Install nut (3). Tighten to 65–75 in-lbs (7.3–8.4 N·m).
7. Pull glove box frame away releasing two clips (14).
8. Disconnect vent linkage from vent door lever. 6. Left side: Connect temperature sensor.
9. Right side: Remove nut (3) securing coolant bottle (4).
Release bottle from stud and lower grommet. 7. Move glove box frame (10) into position. Connect vent
linkage.
10. Left side: Disconnect temperature sensor.
11. Remove screws (13). NOTE
12. Remove nut (2). Remove air duct (12). Lower fairing must be aligned to make sure shift lever and
brake pedal do not contact fairing lower vent.
13. Disconnect fan power connector (10). Remove connector
anchor.
8. Secure glove box frame with screws (6). Tighten to
14. Pull radiator/fan assembly away from lower fairing. 12–16 in-lbs (1.4–1.8 N·m).
15. Release latches securing fan to radiator. Remove fan.
9. Secure lower fairing to engine guard. See FAIRING
Installation LOWERS AND ENGINE GUARD (Page 3-110).

1. If removed, install upper clamp (5). The left upper clamp

10. Install lower fairing cap with flange nut. Tighten to
has only one stud facing the inside. Install it with the single
30–35 in-lbs (3.4–3.9 N·m).
stud at the bottom.
11. Install access panel.
2. Latch fan onto radiator.
12. Install main fuse.
NOTE
Route overflow vent hose through notch (11) when installing
air duct.

94000383 6-11
 sm07552

2 3
4

14
5

13
11
12 9

10

1. Frame, glove box 8. Nut, lower clamp

2. Nut, inner air deflector 9. Fan
3. Nut, coolant bottle 10. Connector
4. Coolant bottle 11. Notch
5. Upper clamp 12. Air duct
6. Glove box screws (3) 13. Screws, lower, air deflector and fan (2)
7. Nut, upper clamp (2) 14. Clips (2)
Figure 6-12. Lower Fairing: Twin-Cooled

6-12 94000383
SUBJECT PAGE NO.
7.1 FASTENER TORQUE VALUES ............................................................................................ 7-1
7.2 SPECIFICATIONS: DRIVE ................................................................................................... 7-2
7.3 PRIMARY CHAINCASE COVER .......................................................................................... 7-3
7.4 DRIVE COMPONENTS ........................................................................................................ 7-5
7.5 PRIMARY CHAINCASE HOUSING ...................................................................................... 7-9
7.6 CLUTCH: ASSIST AND SLIP ............................................................................................. 7-12
7.7 HYDRAULIC CLUTCH RELEASE BEARING AND PUSHROD ......................................... 7-16
7.8 TRANSMISSION SPROCKET ............................................................................................ 7-18
7.9 DRIVE BELT ....................................................................................................................... 7-20

DRIVE
NOTES
FASTENER TORQUE VALUES 7.1
FASTENER TORQUE VALUES IN THIS
CHAPTER

The table below lists torque values for all fasteners presented
in this chapter.

FASTENER TORQUE VALUE NOTES

Clutch hub mainshaft nut 70–80 ft-lbs 94.9–108.5 N·m 7.4 DRIVE COMPONENTS, Install
Clutch inspection cover screws 84–108 in-lbs 9.5–12.2 N·m 7.7 HYDRAULIC CLUTCH RELEASE BEARING
AND PUSHROD, Install
Clutch stopper plate bolts 70–100 in-lbs 7.9–11.3 N·m 7.6 CLUTCH: ASSIST AND SLIP, Clutch Pack Only
Compensating sprocket bolt, final torque 175 ft-lbs 237.3 N·m 7.4 DRIVE COMPONENTS, Install
Compensating sprocket bolt, first torque 100 ft-lbs 135.6 N·m 7.4 DRIVE COMPONENTS, Install
Loosen then final tighten
Mass damper screw 90–120 in-lbs 10.2–13.6 N·m 7.3 PRIMARY CHAINCASE COVER, Install
Primary chaincase sealing screws 26–28 ft-lbs 35.3–38 N·m 7.5 PRIMARY CHAINCASE HOUSING, Install
Primary chain tensioner fasteners 21–24 ft-lbs 28.5–32.6 N·m 7.4 DRIVE COMPONENTS, Install
Primary cover fasteners 12–13 ft-lbs 16.3–17.6 N·m 7.3 PRIMARY CHAINCASE COVER, Install
See sequence in the procedure
Shift lever pinch screw, heel and toe 18–22 ft-lbs 24.4–29.8 N·m 7.3 PRIMARY CHAINCASE COVER, Install
levers
Transmission sprocket lockplate screws 90–120 in-lbs 10.2–13.6 N·m 7.8 TRANSMISSION SPROCKET, Install
Lock patch, use 3-5 times
Transmission sprocket nut, final torque 35–40 ° 35–40 ° 7.8 TRANSMISSION SPROCKET, Install
Do not loosen to align lockplate screws.
Transmission sprocket nut, first torque 100 ft-lbs 135.6 N·m 7.8 TRANSMISSION SPROCKET, Install
Apply LOCTITE 271 HIGH STRENGTH THREAD-
LOCKER (red) to last few threads. Loosen one full
turn after first torque.
Transmission sprocket nut, second 35 ft-lbs 47.5 N·m 7.8 TRANSMISSION SPROCKET, Install
torque plus 35-40 degrees

94000383 7-1
SPECIFICATIONS: DRIVE 7.2
SPECIFICATIONS

FORMULA+ TRANSMISSION AND PRIMARY CHAINCASE

LUBRICANT and SCREAMIN' EAGLE SYN3 FULL
SYNTHETIC MOTORCYCLE LUBRICANT 20W50 are both
acceptable lubricants.

Table 7-1. Primary Chaincase Lubricant

ITEM DRY FILL** WET FILL***
Oz L L Oz
Amount* 34 1.0 30 0.9
* Amount is approximate. Fill to bottom of pressure plate OD
with vehicle upright.
** Cover was removed and installed.
*** Lubricant was drained through the drain plug only.

Table 7-2. Sprocket Teeth

DRIVE ITEM NUMBER OF
TEETH
Primary Engine 34
Clutch 46
Final Transmission 32
Rear wheel 68

Table 7-3. Overall Drive Ratios

GEAR RATIO
First 9.593
Second 6.650
Third 4.938
Fourth 4.000
Fifth 3.407
Sixth 2.875

NOTE
Overall gear ratios indicate number of engine revolutions
required to drive rear wheel one revolution.

7-2 94000383
PRIMARY CHAINCASE COVER 7.3
PREPARE 2. Verify that all debris is washed from the inside ribs of the
cover.
WARNING
3. Install new cover gasket (1).
To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (-) battery 4. See Figure 7-1. Install cover.
cable before proceeding. (00048a)
a. Apply a drop of LOCTITE 243 MEDIUM STRENGTH
1. Disconnect negative battery cable.
THREADLOCKER AND SEALANT (blue) to the
2. Remove left passenger footboard and bracket as an threads of each screw.
assembly. See FOOTBOARDS AND FOOTRESTS
(Page 3-155). b. Install cover with screws (1, 2) in positions shown.
3. Remove screw securing jiffy stand interlock sensor, if c. See Figure 7-3. Tighten in sequence to 12–13 ft-lbs
equipped. See Jiffy Stand, Jiffy Stand Interlock Sensor (16.3–17.6 N·m).
(Page 3-160).
4. Remove left rider footboard and brackets as an assembly. sm08641
See FOOTBOARDS AND FOOTRESTS (Page 3-155). 1
REMOVE
1. Drain primary chaincase. See Primary Chaincase
Lubricant, Change Primary Chaincase Lubricant
(Page 2-26).
2. Remove heel shift lever.
a. Mark position of heel shift lever in relation to shaft.
b. Remove heel shift lever pinch screw.
c. Remove heel shift lever.

3. See Figure 7-1. Remove cover screws (1, 2). Remove

cover.

sm003716
2
1
1
1 3
1
2
1 1. Cover gasket
2 2. Primary chaincase cover
3. Mass damper and screw
Figure 7-2. Primary Chaincase Cover Gasket

1 sm003718
9
11
2
1 4
2 2 6
1 1 13
8
1. Short screws (9)
2. Long screws (4)
Figure 7-1. Primary Chaincase Cover Screws
12
INSTALL
7 10
FASTENER TORQUE VALUE 5 3 1
Mass damper screw 90–120 in-lbs 10.2–13.6 N·m
Primary cover fasteners 12–13 ft-lbs 16.3–17.6 N·m
Shift lever pinch screw, heel 18–22 ft-lbs 24.4–29.8 N·m Figure 7-3. Primary Chaincase Cover Tightening Sequence
and toe levers
5. Fill primary chaincase. See Primary Chaincase Lubricant,
Change Primary Chaincase Lubricant (Page 2-26).
1. See Figure 7-2. If removed, install mass damper and screw
(3). Tighten to 90–120 in-lbs (10.2–13.6 N·m).

94000383 7-3
6. Install heel shift lever.

a. Align marks made during disassembly.

b. Install pinch screw.

c. Tighten to 18–22 ft-lbs (24.4–29.8 N·m).

COMPLETE
1. Install jiffy stand, rider footboard and interlock sensor if
equipped. See Jiffy Stand, Jiffy Stand Bracket (Page 3-159)
and FOOTBOARDS AND FOOTRESTS (Page 3-155).
2. Install passenger left footboard. See FOOTBOARDS AND
FOOTRESTS (Page 3-155).
3. Verify shift lever operation.
4. Connect negative battery cable.

7-4 94000383
DRIVE COMPONENTS 7.4
PREPARE sm07270

1
WARNING
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.

2
2. Remove secondary clutch actuator and pushrod. See
SECONDARY CLUTCH ACTUATOR (Page 8-9).
3. Remove primary chaincase cover. See PRIMARY 1. Chain tensioner shoe
CHAINCASE COVER, Remove (Page 7-3). 2. Cable strap
REMOVE Figure 7-4. Securing Chain Tensioner

sm08592
PART NUMBER TOOL NAME
HD-48219 PRIMARY DRIVE LOCKING TOOL

1. See Figure 7-4. Remove chain tensioner.

1
a. Install cable strap (2) as shown. Exposed portion below
cover indicates need for removal before cover 2
installation.
b. See Figure 7-5. Remove chain tensioner fasteners (2).
c. Remove chain tensioner (1).
3
NOTE
1. Chain tensioner
Remove compensating sprocket, clutch assembly and primary
2. Chain tensioner fasteners
chain as an assembly.
3. Cable strap
2. Mark one of the links of the primary chain for reference Figure 7-5. Chain Tensioner
during installation.
sm08598
3. Remove clutch release plate and bearing. See
HYDRAULIC CLUTCH RELEASE BEARING AND
1 3
PUSHROD (Page 7-16).
NOTE 2
The mainshaft nut has left-hand threads.

4. See Figure 7-6. Remove mainshaft nut.

a. Place the PRIMARY DRIVE LOCKING TOOL (PART
NUMBER: HD-48219) between the sprockets as shown. 4
b. Rotate clutch hub mainshaft nut (4) clockwise to
remove.
1. Engine compensating sprocket
5. See Figure 7-7. Remove compensating sprocket bolt. 2. Primary drive locking tool
a. Place the primary drive locking tool between the 3. Clutch sprocket
sprockets as shown. 4. Clutch hub mainshaft nut
Figure 7-6. Removing Clutch Hub Mainshaft Nut
b. Rotate compensating sprocket bolt (1) counterclockwise
to loosen.
c. See Figure 7-8. Remove bolt (9), retainer (8) and thrust
washer (7).

6. Inspect thrust bearing and thrust washers for damage.

7. Clean sprocket retainer (9). Verify that oil holes are clear.
8. Remove clutch assembly, primary chain and compensating
sprocket assembly as a single unit.

94000383 7-5
 1. See Figure 7-12. Install spring washers.
sm08595

a. Apply a thin layer of primary chaincase oil to the inner

diameter of the compensating sprocket (6) and the
2 splines of shaft extension (1).
1
b. Install shaft extension.

c. Install large spring washers (2) and medium spring

washers (3). Outer diameter of spring washers must
contact each other.

d. Install small spring washer (4) so outer diameter

contacts sliding cam (5).
1. Bolt
2. Install primary chain, compensating sprocket and clutch
2. Primary drive locking tool
as an assembly.
Figure 7-7. Removing Engine Compensating Sprocket Bolt
NOTE
sm04526e 1 2 Clutch hub mainshaft nut has left-hand threads.
3
4 3. Lightly lubricate thrust bearing (8). Install components (7,
5 6 8) and new bolt (9). Hand tighten.

4. Install mainshaft nut.

a. Clean and prime threads of clutch hub mainshaft

nut.
7
b. Apply two drops of LOCTITE 262 HIGH STRENGTH
8 THREADLOCKER AND SEALANT (red) to the
9 threads.
1. Shaft extension
2. Large spring washer (2) c. Install nut onto mainshaft. Hand-tighten.
3. Medium spring washer (2)
4. Small spring washer 5. See Figure 7-10. Tighten compensating sprocket bolt.
5. Sliding cam
6. Compensating sprocket a. Place the PRIMARY DRIVE LOCKING TOOL (PART
7. Thrust washer NUMBER: HD-48219) between the sprockets as
8. Sprocket retainer shown.
9. Bolt
Figure 7-8. Engine Compensating Sprocket Assembly b. Tighten compensating sprocket bolt (1) to 100 ft-lbs
(135.6 N·m).
INSTALL
c. Loosen one-half turn.
PART NUMBER TOOL NAME
d. Final tighten to 175 ft-lbs (237.3 N·m).
HD-48219 PRIMARY DRIVE LOCKING TOOL

FASTENER TORQUE VALUE 6. See Figure 7-11. Tighten mainshaft nut.

Clutch hub mainshaft nut 70–80 ft-lbs 94.9–108.5N·m
a. Install the PRIMARY DRIVE LOCKING TOOL (PART
Compensating sprocket bolt, 175 ft-lbs 237.3 N·m
NUMBER: HD-48219) between the sprockets as
final torque
shown.
Compensating sprocket bolt, 100 ft-lbs 135.6 N·m
first torque b. Tighten clutch hub mainshaft nut (2) to 70–80 ft-lbs
Primary chain tensioner 21–24 ft-lbs 28.5–32.6 N·m (94.9–108.5 N·m).
fasteners
NOTE
NOTE • Primary chain tensioner is non-repairable. If tensioner is
The O-ring inside the shaft extension is for manufacturing worn or damaged, replace assembly.
assembly only and has no replacement part number.
• Chain tensioner is not interchangable with previous model
year parts. Shoe color is black.

7-6 94000383
7. Install clutch release plate and bearing. See HYDRAULIC
sm05990b
CLUTCH RELEASE BEARING AND PUSHROD
(Page 7-16).

8. If primary chain tensioner becomes disassembled, 2

assemble in order shown.

a. See Figure 7-12. Locate end of spring rod (2) on roll

pin (3).
1
b. See Figure 7-13. Slide wedge (2) of primary chain
tensioner in direction of arrow until all travel is
removed.

c. See Figure 7-14. Push shoe (1) down until it contacts 1. Large spring washer (2)
wedge. Keep tension on shoe so wedge stays in 2. Medium spring washer (2)
place. Figure 7-9. Spring Washer Orientation

d. Insert cable strap (2) as shown to hold wedge in sm08596

place. Verify that end of cable strap hangs below
primary chain tensioner. Cable strap serves as a
reminder to remove before installing primary cover.
1 2
9. See Figure 7-15. Install primary chain tensioner.

a. Install primary chain tensioner (1) with fasteners (2).

b. Tighten to 21–24 ft-lbs (28.5–32.6 N·m).

c. Remove cable strap.

10. Set preliminary chain tension.

1. Bolt
2. Primary drive locking tool
a. Check tension at the top span while pulling down on
chain midway between sprockets. Correct tension Figure 7-10. Installing Engine Compensating Sprocket Bolt
is 0.500 –0.625 in (13–14 mm)
sm08597

b. If chain is loose, move chain adjuster one notch. 2

1
Check tension.

NOTE
Primary chain tensioner will not complete chain adjustment
until vehicle is ridden.

c. Repeat steps until tension is within specification.

11. Test ride vehicle after tensioner removal/installation to

provide proper adjustment.

1. Primary drive locking tool

2. Clutch hub mainshaft nut
Figure 7-11. Installing Clutch Hub Mainshaft Nut

94000383 7-7
 sm02411a
COMPLETE
1
1. Verify that all debris is washed from the inside ribs.
2. Install primary chaincase cover and new gasket. See
PRIMARY CHAINCASE COVER (Page 7-3).
2 3. Fill primary chaincase.
4. Install secondary clutch actuator and pushrod. See
SECONDARY CLUTCH ACTUATOR (Page 8-9).
5. Connect negative battery cable.

1. Shoe
2. Spring rod
3. Roll pin
Figure 7-12. Spring Rod Location

sm02412
1

1. Shoe
2. Wedge
Figure 7-13. Primary Chain Tensioner

sm07270

1. Chain tensioner shoe

2. Cable strap
Figure 7-14. Securing Chain Tensioner

sm08592

1
2

3
1. Chain tensioner
2. Chain tensioner fasteners
3. Cable strap
Figure 7-15. Chain Tensioner

7-8 94000383
PRIMARY CHAINCASE HOUSING 7.5
PREPARE INSTALL

WARNING FASTENER TORQUE VALUE

Primary chaincase sealing 26–28 ft-lbs 35.3–38 N·m
To prevent accidental vehicle start-up, which could cause
screws
death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)
NOTE
1. Disconnect negative battery cable. Cover mainshaft clutch hub splines with tape to prevent the
splines from damaging the primary housing inner oil seal.
2. Remove primary chaincase cover. See PRIMARY
CHAINCASE COVER (Page 7-3).
1. Verify pivot shaft torque. See REAR FORK (Page 3-76).
3. Remove starter. See STARTER (Page 9-15).
4. Remove primary chain, clutch and compensating sprocket. 2. See Figure 7-18. Install gasket on surface (2). Verify
See DRIVE COMPONENTS (Page 7-5). dowels in gasket engage dowel holes (3).

REMOVE 3. Spread a film of oil on mainshaft oil seal lip and rubber
portion of crankcase gasket.
1. See Figure 7-16. Remove five sealing screws (5).
2. Remove primary chaincase housing (6). 4. Install primary chaincase housing.
3. Discard the crankcase gasket (7) and sealing screws.
5. See Figure 7-19. Install new sealing screws.
sm08602
1 2 6. See Figure 7-20. Tighten in sequence shown to
4
3 26–28 ft-lbs (35.3–38 N·m).

sm08604

7 1 1
6 2

4
1. Dowel
2. Crankcase gasket
1. Seal
Figure 7-17. Crankcase Gasket
2. Retaining ring
3. Bearing
4. Hollow dowel (4)
5. Sealing screw (5)
6. Primary chaincase housing
7. Crankcase gasket
Figure 7-16. Primary Chaincase Housing
INSPECT
1. Inspect primary chaincase for cracks or damaged gasket
surface.
2. Check the mainshaft bearing. Replace if bearing does not
rotate freely. See PRIMARY CHAINCASE HOUSING,
Mainshaft Bearing and Seal (Page 7-10).
3. Replace the oil seal. See PRIMARY CHAINCASE
HOUSING, Mainshaft Bearing and Seal (Page 7-10).
4. Inspect shifter shaft bushing. Replace if necessary. See
PRIMARY CHAINCASE HOUSING, Shifter Shaft Bushing
(Page 7-11).

94000383 7-9
 sm08639
MAINSHAFT BEARING AND SEAL

2 Remove
1. Remove seal with a seal remover or rolling head pry bar
for best results.

WARNING
3
Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip from the
pliers and could be propelled with enough force to cause
1 3 serious eye injury. (00312a)
NOTE
Support the bearing support area on the transmission side of
the primary chaincase while pressing out bearing.

1. Crankcase 2. See Figure 7-21. Remove retaining ring (1).

2. Gasket surface
3. Dowel holes 3. Place inner primary chaincase in a press with clutch side
Figure 7-18. Crankcase up.

sm02383
4. Press out bearing from clutch side.

Install
1. Verify that the bearing bore is clean and smooth.
NOTE
Support the bearing support area on the clutch side of the
primary chaincase while pressing bearing.

2. Place primary chaincase in a press with the transmission

side up.
3. Install new bearing with letter side up.
Figure 7-19. Primary Chaincase Sealing Screw a. Apply a thin film of oil to outer diameter of bearing.
sm05039 b. Press outer race until it makes solid contact with the
bearing support area.
2
4. See Figure 7-21. Install retaining ring.
5 a. Retaining ring (1) must not block oil passage (2).
3
b. Verify that the ring is fully seated in the groove.

5. Install mainshaft oil seal.

a. Lubricate the OD of the new seal with SCREAMIN'
4 EAGLE ASSEMBLY LUBE.
1
b. Place over bore with the lip garter spring side (stamped
"OIL SIDE") facing toward the bearing.
Figure 7-20. Sealing Screw Tightening Sequence c. Press against the outer rim of oil seal the seal until seal
is flush with machined surface of inner primary housing.
COMPLETE
6. Lubricate the bearing and seal lip with multi-purpose
1. Install the primary chain, clutch, compensating sprocket grease or SCREAMIN' EAGLE ASSEMBLY LUBE.
and chain tensioner. See DRIVE COMPONENTS
(Page 7-5).
2. Install starter. See STARTER (Page 9-15).
3. Install primary chaincase cover and new gasket. Fill
primary chaincase. See PRIMARY CHAINCASE COVER
(Page 7-3).
4. Connect negative battery cable.

7-10 94000383
 sm02385a sm03455

1 2

1
2

1. Retaining ring
2. Oil passage
Figure 7-21. Retaining Ring Orientation
MAINSHAFT BEARING INNER RACE

PART NUMBER TOOL NAME

HD-34902-C BEARING RACE REMOVER AND 5
INSTALLER KIT

Remove
4
NOTE
Use only BEARING RACE REMOVER AND INSTALLER KIT
(PART NUMBER: HD-34902-C). 6
1. Bearing inner race
1. See Figure 7-22. Remove bearing inner race using 2. Extension shaft
BEARING RACE REMOVER AND INSTALLER KIT (PART 3. Wrench flat
NUMBER: HD-34902-C). 4. Installer sleeve
5. Washer (2)
sm05961a
6. Nut
Figure 7-23. Installing Bearing Race

4 1 SHIFTER SHAFT BUSHING

2
1. See Figure 7-24. Press out old bushing (1). Inspect the
bushing bore to verify that it is clean and smooth.
2. Press new bushing until it is flush to 0.030 in (0.76 mm)
below edge of bore.

sm08603

3 2

1. Bearing inner race

2. End cap
3. Puller
4. Forcing screw
Figure 7-22. Pulling Mainshaft Inner Bearing Race

Install 1
1. See Figure 7-23. Install bearing inner race (1) onto
mainshaft using BEARING RACE REMOVER AND
INSTALLER KIT (PART NUMBER: HD-34902-C). 1. Shifter shaft bushing
2. Primary chaincase
2. Lubricate race with SCREAMIN' EAGLE ASSEMBLY
LUBE. Figure 7-24. Shifter Shaft Bushings

94000383 7-11
CLUTCH: ASSIST AND SLIP 7.6
REMOVAL AND INSTALLATION c. Replace any steel plate that is warped more than
0.006 in (0.15 mm).
To remove the clutch without disassembly or for installation
4. Check hub to shell bearing for smooth operation. Replace
instructions, see DRIVE COMPONENTS, Remove (Page 7-5).
the bearing if it runs rough, binds or has any end play. See
CLUTCH PACK ONLY CLUTCH: ASSIST AND SLIP, Complete Clutch
Disassembly (Page 7-14).
FASTENER TORQUE VALUE 5. Replace clutch shell if primary chain sprocket or starter
Clutch stopper plate bolts 70–100 in-lbs 7.9–11.3 N·m ring gear are worn or damaged.
6. Replace clutch hub and shell if slots for clutch plates are
Prepare worn or damaged.
NOTE 7. Replace coil springs and stopper plate if either are cracked
This procedure can be performed without removing the clutch or bent.
shell or hub. For replacement of the shell or hub, see CLUTCH:
ASSIST AND SLIP, Complete Clutch Disassembly (Page 7-14). Assemble
1. Soak all friction plates in primary chaincase lubricant for
1. Remove primary chaincase cover. See PRIMARY
at least five minutes.
CHAINCASE COVER, Prepare (Page 7-3).

Disassemble NOTE
Never mix plates and discs between 9-plate and 10-plate
1. See Figure 7-25. Remove three bolts (1) to release stopper
clutches. Trike and CVO models use a 10-plate clutch.
plate (2). Alternately loosen each bolt 1-2 turns.
NOTE 2. Install the three spring seats (5) in the clutch pressure
Do not lose the coil spring seats (5). plate (6).

2. Remove stopper plate, coil springs (4) and pressure plate 3. See Figure 7-25. Install narrow plates on pressure plate
(6) from clutch hub. (6). (See inset.)
3. Remove the spring seats (5) from pressure plate (6).
a. Install a narrow friction plate (7).
4. Remove all friction plates and steel plates from clutch hub.
b. Install a narrow steel plate (8).
Clean and Inspect
1. Wash all parts in cleaning solvent, except for friction plates c. Install a narrow friction plate (7).
and bearing. Dry parts with low-pressure, compressed air.
4. Assemble remaining plates on clutch hub (13).
NOTE
Replace any damaged spring seats. a. Install damper spring seat (12). (See inset.)

2. Check friction plates: b. Install damper spring (11) with concave side toward
a. Use compressed air to remove all lubricant from the steel plate (9).
friction plates. Do not wipe off with a cloth or wash in
c. Install a narrow friction plate (7).
solvent.
b. Measure the thickness of each plate. d. Install a wide steel plate (9).
c. If the thickness of any plate is less than 0.143 in
NOTE
(3.62 mm), replace with a complete new set.
• Alternately tighten the stopper plate bolts 1-2 turns to
d. Look for worn or damaged fiber surface material (both prevent damage to the stopper plate.
sides).
• Verify that the pressure plate splines are aligned with the
splines on the hub.
NOTE
• Discard any plate that is grooved or bluish in color.
e. Alternately install remaining wide steel plates and
• Friction plates and steel plates are sold only as a kit. wide friction plates. The last plate installed is steel.

3. Check the steel plates: 5. Install pressure plate/plate assembly to the clutch hub.
a. Lay the plate on a precision flat surface.
a. Align pressure plate holes with threaded bosses on
b. Insert a feeler gauge between the plate and the flat hub.
surface in several places.
b. Install three coil springs (4) in pressure plate.

7-12 94000383
 c. Install stopper plate (2). 1. Install primary chaincase cover. Fill primary chaincase.
See PRIMARY CHAINCASE COVER, Prepare
d. Install three bolts (1) (metric) to secure stopper plate (Page 7-3).
and coil springs to clutch hub. Alternately tighten to
2. Check and adjust hydraulic fluid level. See BLEED
70–100 in-lbs (7.9–11.3 N·m).
CLUTCH CONTROL SYSTEM, Drain and Fill (Page 3-85).

Complete
NOTE
Always install a new gasket between primary cover and
housing.

sm08648
11

12 13
13 12
11
14

4
5

6
7
8
7
9
10
9
7

1. Bolt (3) 8. Narrow steel plate (1)

2. Stopper plate 9. Wide steel plate (7)
3. Mainshaft nut 10. Wide friction plate (6)
4. Coil spring (3) 11. Damper spring
5. Seat (3) 12. Damper spring seat
6. Pressure plate 13. Clutch hub
7. Narrow friction plate (3) 14. Clutch shell
Figure 7-25. Clutch Shell Assembly, 9-plate

94000383 7-13
COMPLETE CLUTCH DISASSEMBLY sm02421a

Prepare
1. Remove primary chaincase cover. See PRIMARY
CHAINCASE COVER, Prepare (Page 7-3).
2. Remove clutch assembly. See DRIVE COMPONENTS,
Remove (Page 7-5).
3. Disassemble clutch pack. See CLUTCH: ASSIST AND
SLIP, Clutch Pack Only (Page 7-12).

Disassemble
WARNING
Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip from the
pliers and could be propelled with enough force to cause Figure 7-27. Pressing Clutch Hub From Bearing
serious eye injury. (00312a)
sm02424a

NOTE
Do not disassemble the clutch shell and hub assembly unless
the bearing, hub or shell require replacement. Replace the
bearing if disassembled.

1. Press out clutch hub.

a. See Figure 7-26. Remove clutch hub retaining ring (2).
b. See Figure 7-27. Support clutch shell in press with ring
gear side up.
c. Press hub from bearing in clutch shell.

2. Remove bearing.
a. See Figure 7-26. Remove bearing retaining ring (1)
from groove in clutch shell bore.
b. See Figure 7-28. Support clutch shell in press with ring
gear side is down.
c. Use a suitable press plug to remove bearing. Figure 7-28. Pressing Bearing From Clutch Shell

3. Clean and inspect components. See CLUTCH: ASSIST Assemble

AND SLIP, Clutch Pack Only (Page 7-12).
1. Install new bearing.
sm02419b
a. Place clutch shell in press with ring gear side up.

b. Support clutch shell bore on sprocket side to avoid

damage to ears on clutch basket.

c. Using a suitable press plug, press against outer race

3 until bearing contacts shoulder in clutch shell bore.

1 2
WARNING
Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip from the
pliers and could be propelled with enough force to cause
serious eye injury. (00312a)

d. See Figure 7-26. Install bearing retaining ring (1)

with flat side toward bearing.

1. Clutch hub retaining ring 2. Install clutch hub.

2. Bearing retaining ring
3. Bearing
a. Place clutch shell in press with sprocket side up.
Figure 7-26. Clutch Retaining Rings

7-14 94000383
 b. Center the hub in bearing.

c. Support bearing inner race with a sleeve on

transmission side.

d. Press hub into bearing until shoulder contacts

bearing inner race.

e. See Figure 7-26. Install clutch hub retaining ring (2)

in groove of clutch hub.

Complete
1. Assemble clutch components. See CLUTCH: ASSIST AND
SLIP, Clutch Pack Only (Page 7-12).
2. Install clutch. See DRIVE COMPONENTS, Complete
(Page 7-8).
NOTE
Avoid leaks. Always install a new gasket between primary
cover and housing.

3. Install primary chaincase cover and new gasket. Fill

primary chaincase. See PRIMARY CHAINCASE COVER,
Install (Page 7-3).

94000383 7-15
HYDRAULIC CLUTCH RELEASE BEARING AND PUSHROD 7.7
PREPARE sm04072a

1. Remove seat.
2. Disconnect negative battery cable.
REMOVE

1. Close master cylinder fluid port. 6

a. See Figure 7-29. Compress clutch lever slightly. 2
5
b. Place the eyelet of a cable strap between the lever and 4
housing.

2. See Figure 7-31. Remove clutch inspection cover.

3
3. See Figure 7-30. Remove bearing plate retaining ring (1).
4. Remove release bearing plate (3) with release bearing (4)
and release rod (5). Remove pushrod if necessary.
1
sm08634
1. Bearing plate retaining ring
2. Release rod retainer
3. Release bearing plate
4. Release bearing
5. Release rod
6. Pushrod
Figure 7-30. Release Bearing and Pushrod

Measure Release Plate Movement

1. Attach a dial indicator to measure pushrod axial movement.

WARNING
Insufficient clutch-release plate movement can lead to
Figure 7-29. Insert Eyelet
difficulty or inability to shift, causing loss of control, which
INSTALL could result in death or serious injury. (00345a)

FASTENER TORQUE VALUE 2. Actuate the clutch lever to measure the axial movement
Clutch inspection cover 84–108 in-lbs 9.5–12.2 N·m of the pushrod and the clutch-release plate assembly. The
screws minimum axial movement must be as specified. Refer to
Table 7-4.
1. Install pushrod if removed.
NOTE NOTE
If cable strap at hand lever becomes dislodged, the piston of Proper bleeding of the system typically yields plate movement
the secondary actuator will move toward the released position. greater than specification. If clutch release plate movement is
Apply steady inward pressure when installing bearing plate less than specification, bleed system and measure plate
until retaining ring can be installed. movement again.

2. See Figure 7-30. Seat the bearing plate in the clutch. Table 7-4. Minimum Release Plate Movement Specification
3. Install bearing plate retaining ring (1). IN MM
4. Measure release plate movement. 0.086 2.18

Install Clutch Inspection Cover

1. Thoroughly clean oil from clutch inspection cover and
mating surface on primary cover.

2. See Figure 7-31. Install clutch inspection cover and new

gasket.

7-16 94000383
3. Tighten to 84–108 in-lbs (9.5–12.2 N·m) in sequence
shown.

om02155

4 3

2 5

Figure 7-31. Clutch Cover Tightening Sequence

COMPLETE
1. Connect negative battery cable.
2. Install seat.
DISASSEMBLE

1. See Figure 7-30. Remove release rod retainer (2).

2. Press release rod (5) from bearing (4).
3. Press release bearing (4) from bearing plate (3).
ASSEMBLE

1. See Figure 7-30. Press on the outer race to install a new

release bearing (4) into bearing plate (3).
2. Assemble release rod (5) to bearing.
3. Install new retainer (2).

94000383 7-17
TRANSMISSION SPROCKET 7.8
PREPARE sm05983a

1. Remove drive components. See DRIVE COMPONENTS 1

(Page 7-5).
2. Remove primary chaincase housing. See PRIMARY
CHAINCASE HOUSING (Page 7-9).
3. Loosen drive belt. See DRIVE BELT AND SPROCKETS
(Page 2-37).
REMOVE 3

PART NUMBER TOOL NAME 2

HD-46282A FINAL DRIVE SPROCKET LOCKING
TOOL
HD-47910 MAINSHAFT LOCKNUT WRENCH 1. Rear fork pivot
HD-94660-2 PILOT 2. Final drive sprocket locking tool
3. Sprocket nut
NOTE Figure 7-33. Sprocket Nut Removal
• Loosen sprocket nut only while transmission is installed in
frame. Otherwise damage to transmission or transmission
CLEAN AND INSPECT
stand results.
1. Using a non-volatile cleaning solvent, clean sprocket of all
• Sprocket nut has a right-hand thread. grease and dirt.

1. See Figure 7-32. Remove sprocket nut. 2. Inspect belt and sprocket. See DRIVE BELT AND
SPROCKETS, Inspect (Page 2-37).
a. Remove two screws (1) and lockplate (2).
3. Inspect main drive gear and mainshaft seals. Replace if
b. See Figure 7-33. Install FINAL DRIVE SPROCKET damaged.
LOCKING TOOL (PART NUMBER: HD-46282A) (2)
with arm of tool against bottom of rear fork pivot (1). INSTALL
c. Install PILOT (PART NUMBER: HD-94660-2) on
PART NUMBER TOOL NAME
mainshaft.
HD-46282A FINAL DRIVE SPROCKET LOCKING
d. Remove the sprocket nut (3) using MAINSHAFT TOOL
LOCKNUT WRENCH (PART NUMBER: HD-47910)
HD-47910 MAINSHAFT LOCKNUT WRENCH
(1).
HD-94660-2 PILOT
2. Remove sprocket, allowing belt to slip from sprocket as TA360 TORQUE ANGLE GAUGE
sprocket is removed.
FASTENER TORQUE VALUE
sm02428 Transmission sprocket 90–120 in-lbs 10.2–13.6 N·m
5 4 lockplate screws
Transmission sprocket nut, 35–40 ° 35–40 °
final torque
3 2 Transmission sprocket nut, 100 ft-lbs 135.6 N·m
first torque
Transmission sprocket nut, 35 ft-lbs 47.5 N·m
1 second torque

NOTE
• Tighten sprocket nut only while transmission is installed in
frame. Otherwise damage to transmission or transmission
stand results.
1. Screw (2) • Never get oil on the threads of the sprocket nut.
2. Lockplate
3. Sprocket nut • The transmission sprocket nut has right-hand threads.
4. Sprocket
5. Main drive gear 1. Place transmission sprocket in position. Install the belt as
Figure 7-32. Transmission Sprocket the sprocket is installed.

7-18 94000383
2. Install sprocket nut.
sm05984a 2
a. See Figure 7-32. Apply a film of clean engine oil to
the mating surfaces of the sprocket nut (3) and the
sprocket (4).

b. If reusing the sprocket nut, apply LOCTITE 271 HIGH

STRENGTH THREADLOCKER (red) to the threads
of the sprocket nut.
3
c. Install the sprocket nut finger-tight.
1
d. See Figure 7-34. Install FINAL DRIVE SPROCKET
LOCKING TOOL (PART NUMBER: HD-46282A) (2)
resting against the rear fork pivot (3).

e. Install PILOT (PART NUMBER: HD-94660-2) on 1. Sprocket nut

mainshaft. 2. Final drive sprocket locking tool
3. Rear fork pivot
f. Using MAINSHAFT LOCKNUT WRENCH (PART Figure 7-34. Sprocket Nut Installation
NUMBER: HD-47910), tighten sprocket nut to
100 ft-lbs (135.6 N·m) initial torque.
35° 45°
sm05068a
2
3. Loosen sprocket nut one full turn.
3
NOTE 1
See Figure 7-35. Scribe lines (3) or use TORQUE ANGLE
GAUGE (PART NUMBER: TA360) for final torque.

4. Tighten to 35 ft-lbs (47.5 N·m).

NOTE
• The lockplate can be installed either side out.
• Never LOOSEN nut to align screw holes.
• If necessary, tighten the nut slightly to align lockplate.
1. Transmission sprocket nut
• Do not exceed a final torque of 45 degrees. 2. Transmission sprocket
3. Scribed lines
5. Turn sprocket nut an additional 35–40 ° (35–40 °). Figure 7-35. Transmission Sprocket Nut Final Tightening
COMPLETE
6. Install lockplate.
1. Install drive components. See DRIVE COMPONENTS
a. Align lockplate holes with tapped holes in sprocket.
(Page 7-5).
b. See Figure 7-32. Install two new screws (1). 2. Install primary chaincase housing. See PRIMARY
CHAINCASE HOUSING (Page 7-9).
c. Tighten to 90–120 in-lbs (10.2–13.6 N·m).
3. Verify pivot shaft torque. See REAR FORK (Page 3-76).
4. Adjust drive belt deflection. See DRIVE BELT AND
SPROCKETS (Page 2-37).

94000383 7-19
DRIVE BELT 7.9
REMOVE INSTALL

NOTE WARNING
See DRIVE BELT AND SPROCKETS, Adjust Belt Deflection
Never bend belt forward into a loop smaller than the drive
(Page 2-39).
sprocket diameter. Never bend belt into a reverse loop.
Over bending can damage belt resulting in premature
1. Remove rear wheel and rear fork. See REAR FORK failure, which could cause loss of control and death or
(Page 3-76). serious injury. (00339a)
2. Remove primary chain, clutch, engine compensating
sprocket and chain adjuster. See DRIVE COMPONENTS 1. Install belt over transmission sprocket.
(Page 7-5).
2. Install primary chaincase housing. See PRIMARY
3. Remove primary chaincase housing. See PRIMARY CHAINCASE HOUSING, Install (Page 7-9).
CHAINCASE HOUSING, Remove (Page 7-9).
3. Install drive components. See DRIVE COMPONENTS
4. Remove belt from transmission sprocket. (Page 7-5).
4. Install primary chaincase cover. Fill primary chaincase.
See PRIMARY CHAINCASE COVER (Page 7-3).
5. Install rear fork and rear wheel. See REAR FORK
(Page 3-76).
6. Adjust drive belt deflection. See DRIVE BELT AND
SPROCKETS (Page 2-37).

7-20 94000383
SUBJECT PAGE NO.
8.1 FASTENER TORQUE VALUES ............................................................................................ 8-1
8.2 SPECIFICATIONS: TRANSMISSION ................................................................................... 8-2
8.3 TRANSMISSION OPERATION ............................................................................................. 8-3
8.4 SHIFTER LINKAGE .............................................................................................................. 8-5
8.5 TRANSMISSION SIDE COVERS ......................................................................................... 8-7
8.6 SECONDARY CLUTCH ACTUATOR ................................................................................... 8-9
8.7 TRANSMISSION ................................................................................................................. 8-10
8.8 MAIN DRIVE GEAR AND BEARING .................................................................................. 8-19
8.9 TRANSMISSION CASE ...................................................................................................... 8-24

TRANSMISSION
NOTES
FASTENER TORQUE VALUES 8.1
FASTENER TORQUE VALUES IN THIS
CHAPTER

The table below lists torque values for all fasteners presented
in this chapter.

FASTENER TORQUE VALUE NOTES

Battery ground cable to transmission 66–114 in-lbs 7.5–12.9 N·m 8.9 TRANSMISSION CASE, Install
Clutch actuator screws 100–120 in-lbs 11.2–13.6 N·m 8.6 SECONDARY CLUTCH ACTUATOR, Install
Clutch fluid line flare nut 133–186 in-lbs 15–21 N·m 8.6 SECONDARY CLUTCH ACTUATOR, Install
Oil return tube/cover screw 100–120 in-lbs 11.3–13.6 N·m 8.9 TRANSMISSION CASE, Assemble
Shift drum detent screw 120–150 in-lbs 13.6–17 N·m 8.7 Transmission, Assemble
Shift drum lock plate screws 57–63 in-lbs 6.4–7.1 N·m 8.7 Transmission, Assemble
Shifter pawl centering screw 18–23 ft-lbs 24.4–31.2 N·m 8.9 TRANSMISSION CASE, Assemble
Shifter peg screw 96–144 in-lbs 10.9–16.3 N·m 8.4 SHIFTER LINKAGE, Heel-Toe Shift Levers
Shifter rod jamnut 80–120 in-lbs 9–13.6 N·m 8.4 SHIFTER LINKAGE, Shifter Rod
Shifter rod lever pinch screw, front lever 132–156 in-lbs 14.9–17.6 N·m 8.4 SHIFTER LINKAGE, Shifter Rod Lever, Front
Shifter rod lever pinch screw, transmis- 18–22 ft-lbs 24.4–29.8 N·m 8.9 TRANSMISSION CASE, Complete
sion lever
Shifter rod lever pinch screw, transmis- 18–22 ft-lbs 24.4–29.8 N·m 8.9 TRANSMISSION CASE, Assemble
sion lever
Shifter rod to front lever nut 70–90 in-lbs 7.9–10.2 N·m 8.4 SHIFTER LINKAGE, Shifter Rod Lever, Front
Shifter rod to shift lever 70–90 in-lbs 7.9–10.2 N·m 8.4 SHIFTER LINKAGE, Shifter Rod
Shifter rod to shift lever nut 70–90 in-lbs 7.9–10.2 N·m 8.4 SHIFTER LINKAGE, Shifter Rod
Shift lever pinch screw, heel and toe 18–22 ft-lbs 24.4–29.8 N·m 8.4 SHIFTER LINKAGE, Heel-Toe Shift Levers
levers
Transmission bearing housing screws 22–25 ft-lbs 29.8–33.9 N·m 8.7 Transmission, Install
Transmission drain plug 14–21 ft-lbs 19–28.5 N·m 8.7 Transmission, Complete
Transmission drain plug 14–21 ft-lbs 19–28.5 N·m 8.9 TRANSMISSION CASE, Complete
Transmission inner side cover screws 132–156 in-lbs 14.9–17.6 N·m 8.5 TRANSMISSION SIDE COVERS, Install
Transmission mainshaft/countershaft 85–95 ft-lbs 115.3–128.8 N·m 8.7 Transmission, Assemble
locknuts
Transmission mounting bolts, final torque 34–39 ft-lbs 46.1–52.9 N·m 8.9 TRANSMISSION CASE, Install
Transmission mounting bolts, initial 15 ft-lbs 20.3 N·m 8.9 TRANSMISSION CASE, Install
torque
Transmission outer side cover screws 100–120 in-lbs 11.2–13.6 N·m 8.5 TRANSMISSION SIDE COVERS, Install
Transmission top cover 132–156 in-lbs 14.9–17.6 N·m 8.7 Transmission, Install

94000383 8-1
SPECIFICATIONS: TRANSMISSION 8.2
SPECIFICATIONS Table 8-5. Countershaft Tolerance Specifications
COUNTERSHAFT IN MM
Table 8-1. Transmission Specifications TOLERANCE
TRANSMISSION DATA Second gear end play 0.001-0.40 0.03-1.02
(axial)
Type 6-speed forward constant
mesh Second gear clearance 0.0004-0.0020 0.010-0.052
(radial)
FORMULA+ TRANSMISSION Part No. 99851-05 (qt)
AND PRIMARY CHAINCASE Third gear end play (axial) 0.001-0.042 0.03-1.07
LUBRICANT Third gear clearance (radi- 0.0004-0.0020 0.010-0.052
SYN3 20W50 Oil Part No. 99824-03/00QT (qt) al)
Capacity (dry; approximate) 32 oz. (946.4 ml) Fourth gear end play (axi- 0.001-0.028 0.03-0.71
al)
Table 8-2. Transmission Gear Ratios Fourth gear clearance 0.0004-0.0020 0.010-0.052
GEAR GEAR RATIO (radial)

First (low) 3.34 Table 8-6. Shifter Dog Clearance Specifications

Second 2.31
SHIFTER DOG IN MM
Third 1.72
First 0.013-0.121 0.33-3.07
Fourth 1.39
Second 0.016-0.138 0.41-3.51
Fifth 1.19
Third 0.010-0.125 0.25-3.17
Sixth (high) 1.00
Fourth 0.018-0.129 0.46-3.28

NOTE Fifth 0.007-0.117 0.18-2.97

Final gear ratios indicate the number of mainshaft revolutions Sixth 0.022-0.131 0.56-3.33
required to drive the output sprocket one revolution.
Table 8-7. Bearing Housing Bearing Specifications
SERVICE WEAR LIMITS
BEARING HOUSING BEAR- IN MM
ING
Table 8-3. Main Drive Gear Specifications
Fit in bearing housing (tight) 0.0001-0.0014 0.0025-0.0356
MAIN DRIVE GEAR (sixth) IN MM
Fit on countershaft (tight) -0.0004 -0.010
Bearing fit in transmission 0.0003-0.0017 0.0076-0.043
case (loose) Fit on countershaft (loose) +0.0012 +0.030

Fit in bearing (press-fit) 0.001-0.003 0.025-0.076 Fit on mainshaft (tight) -0.0004 -0.010

End play none none Fit on mainshaft (loose) +0.0012 +0.030

Table 8-4. Mainshaft Tolerance Specifications Table 8-8. Shifter Fork Specifications

MAINSHAFT TOLERANCE IN MM SHIFTER FORKS IN MM

Mainshaft runout 0.000-0.003 0.00-0.08 Shifter fork to cam groove end 0.004-0.012 0.102-0.305
play
Mainshaft end play none none
Shifter fork to dog ring end 0.004-0.016 0.102-0.4060
Fifth gear end play (axial) 0.002-0.026 0.05-0.66 play
Fifth gear clearance (radial) 0.0004-0.0020 0.009-0.052 First and second gear shift 0.258 6.55
Main drive gear (sixth) fit 0.0009-0.0022 0.023-0.056 fork pad thickness wear limit
Third and fourth gear shift fork 0.198 5.03
Table 8-5. Countershaft Tolerance Specifications pad thickness wear limit
COUNTERSHAFT IN MM Fifth and sixth gear shift fork 0.258 6.55
TOLERANCE pad thickness wear limit
Countershaft runout 0.000-0.003 0.00-0.08
Countershaft end play 0.001-0.003 0.025-0.08
First gear end play (axial) 0.001-0.023 0.03-0.58
First gear clearance (radi- 0.0004-0.0020 0.010-0.052
al)

8-2 94000383
TRANSMISSION OPERATION
POWER FLOW
See Figure 8-1. The 6-speed transmission consists of two
parallel shafts supporting six gears each. The longer, or
mainshaft (7), also supports the clutch and serves as the input
shaft. The shorter shaft is called the countershaft (8).
Each gear on the mainshaft is in constant mesh with a
corresponding gear on the countershaft. Each of these six pairs
of gears makes up a different speed in the transmission.
The transmission gears are divided into two types, gears that
rotate with the shaft, and gears that spin freely on the shaft. A
gear that rotates with the shaft always meshes with a
freewheeling gear. Also, three dog rings are able to slide
sideways on the shaft. These dog rings are used to change
transmission speeds. The dogs on the sides of dog rings
engage dogs on adjacent freewheeling gears, transmitting
power through the transmission.
Gear shifting is accomplished by three forks which fit into
grooves machined into the dog rings that slide on the guide
hubs. The position of the shifter forks is controlled by a
drum-shaped shifter cam located in the transmission bearing
housing.
Neutral
Power is introduced to the transmission through the clutch. In
neutral, with the clutch engaged, the mainshaft first, second,
third and fourth gears are rotating. No power is transferred to
the countershaft since countershaft first, second, third and
fourth gears are freewheeling gears.
First Gear
When the transmission is shifted into first gear, the dog ring
between countershaft first and second, which rotates with the
countershaft, engages countershaft first, which has been
spinning freely on the countershaft driven by mainshaft first.
Now countershaft first is no longer freewheeling, but locked to
the countershaft causing the countershaft and countershaft
94000383
8.3
sixth to turn. Countershaft sixth transmits the power to the main
drive gear and the sprocket as shown (1).
Second Gear
Second gear is engaged when the dog ring between
countershaft first and second is shifted out of countershaft first
and engages countershaft second. This locks countershaft
second to the countershaft to complete the power flow as
shown (2).
Third Gear
Two shifter forks are used to make the shift from second to
third. One fork moves the dog ring between countershaft first
and second to its neutral position. At the same time another
fork engages the dog ring between countershaft third and fourth
with countershaft third. This locks countershaft third to the
countershaft to complete the power flow as shown (3).
Fourth Gear
Fourth gear is engaged when the dog ring between
countershaft third and fourth is shifted out of countershaft third
and engages countershaft fourth. This locks countershaft fourth
to the countershaft to complete the power flow as shown (4).
Fifth Gear
Two shifter forks are used to make the shift from fourth to fifth.
One fork moves the dog ring between countershaft third and
fourth to its neutral position. At the same time another fork
engages the dog ring between mainshaft fifth and sixth with
mainshaft fifth. This locks mainshaft fifth to the mainshaft to
complete the power flow as shown (5).
Sixth Gear
The shift from fifth to sixth gear occurs when the dog ring
between mainshaft fifth and sixth is shifted out of mainshaft
fifth. It is shifted directly into the main drive gear (sixth gear).
The main drive gear is locked to the mainshaft. this results in
a direct one-to-one drive ratio from the clutch to the sprocket
as shown (6).
8-3
 sm00068a

1 7 2

3 4

5 6

1. First gear 5. Fifth gear

2. Second gear 6. Sixth gear
3. Third gear 7. Mainshaft
4. Fourth gear 8. Countershaft
Figure 8-1. Transmission Power Flow

8-4 94000383
SHIFTER LINKAGE 8.4
SHIFTER ROD sm07547
9 10
8
FASTENER TORQUE VALUE
Shifter rod jamnut 80–120 in-lbs 9–13.6 N·m 7 11
Shifter rod to shift lever 70–90 in-lbs 7.9–10.2 N·m
6
Shifter rod to shift lever nut 70–90 in-lbs 7.9–10.2 N·m 5
1
Replace 4
1. See Figure 8-2. Remove nut (10), lockwasher (9) and flat
washer (7) from front shift arm.

3 2
2. Remove ball stud from rear shift arm. Remove shifter rod.

3. Install shifter rod to each shift arm. Tighten to 70–90 in-lbs

1. Jamnut (2)
(7.9–10.2 N·m).
2. Shifter rod
3. Pinch screw, shift lever
Adjust 4. Screw, peg
5. Peg
NOTE
6. Rubber spacer
• The shifter rod should not require adjustment under normal 7. Transmission shift lever
circumstances. However, if full gear engagement or full lever 8. Pinch screw, shifter rod lever
travel is not achieved, adjust the shifter rod. 9. Lockwasher
• Do not allow shift levers to contact footboard when shifting. 10. Nut
This prevents proper gear engagement. Contact may also 11. Shifter rod lever
damage the transmission. Figure 8-2. Shifter Linkage
HEEL-TOE SHIFT LEVERS
1. See Figure 8-2. Remove nut (10), lockwasher (9) and flat
washer (7) to free forward end of shifter rod from inner
FASTENER TORQUE VALUE
shift arm.
Shift lever pinch screw, heel 18–22 ft-lbs 24.4–29.8 N·m
and toe levers
2. Loosen jamnuts (1). Adjust rod (2) as necessary.
Shifter peg screw 96–144 in-lbs 10.9–16.3 N·m
3. Secure shift rod to inner shift arm with flat washer,
lockwasher and locknut (10). Tighten to 70–90 in-lbs Removal
(7.9–10.2 N·m). 1. See Figure 8-2. Mark position of levers in relation to shaft.

4. Tighten jamnuts (1) to 80–120 in-lbs (9–13.6 N·m). 2. Remove pinch screws securing heel and toe shift levers.
3. Remove levers from shaft.
4. Remove rubber spacer (6).

Repair
1. Remove screw securing rubber peg to lever. Separate
screw from peg.

2. Assemble peg to lever with screw. Tighten to 96–144 in-lbs

(10.9–16.3 N·m).

Installation
NOTE
Shift lever peg height is a customer preference. During
installation, check operation of both shift levers. To achieve
proper gear engagement and to avoid damage to transmission,
the pegs must not contact the footboard when shifting.

1. Install rubber spacer.

2. Install heel and toe levers. Align to marks made during

removal.

94000383 8-5
3. Install pinch screws. Tighten to 18–22 ft-lbs
(24.4–29.8 N·m).

4. Verify shift lever operation.

SHIFTER ROD LEVER, FRONT

FASTENER TORQUE VALUE

Shifter rod lever pinch screw, 132–156 in-lbs 14.9–17.6 N·m
front lever
Shifter rod to front lever nut 70–90 in-lbs 7.9–10.2 N·m

Removal
1. See Figure 8-2. Remove nut (10) and lockwasher (9) to
free linkage.
2. Mark position of shifter rod lever in relation to shaft.
3. Remove pinch screw. Remove shifter rod lever.

Installation
1. Install shifter rod lever. Align to marks made during
removal.

2. See Figure 8-2. Install pinch screw (8). Tighten to

132–156 in-lbs (14.9–17.6 N·m).

3. Install flat washer (7) on shift linkage stud.

4. Secure linkage to shifter rod lever with flat washer (7),

lockwasher (9) and nut (10). Tighten to 70–90 in-lbs
(7.9–10.2 N·m).

5. Verify shift lever operation.

8-6 94000383
TRANSMISSION SIDE COVERS 8.5
PREPARE sm08645
1
6 2
1. Remove seat.
5
WARNING
To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)

2. Disconnect negative battery cable.

3. Loosen exhaust system and pull away from side covers.

See Figure 5-36 in EXHAUST SYSTEM (Page 5-26). 3

a. Remove rear muffler hanger screws (2) and 4

lockwashers.
1. Inner side cover
b. Remove transmission crossover pipe clamp (6). 2. Gasket
3. Secondary clutch actuator
c. Remove exhaust side bracket flange locknut (20). 4. Outer side cover screw (2)
5. Outer side cover
REMOVE 6. Inner side cover screw (4)
Figure 8-3. Transmission Side Covers
Outer Cover INSTALL
1. See Figure 8-3. Remove screws (4).
FASTENER TORQUE VALUE
2. Remove outer side cover (5).
Transmission inner side cover 132–156 in-lbs 14.9–17.6 N·m
screws
Inner Cover
Transmission outer side cover 100–120 in-lbs 11.2–13.6 N·m
1. Remove rear exhaust header shield and rear cylinder pipe screws
shield. See EXHAUST SYSTEM (Page 5-26).
2. Drain transmission. Inner Cover
3. If necessary, remove secondary clutch actuator (3). See 1. See Figure 8-3. Install inner side cover and new gasket
SECONDARY CLUTCH ACTUATOR (Page 8-9). (2) with screws (6).
4. Remove screws (6) and inner side cover (1).
2. Tighten to 132–156 in-lbs (14.9–17.6 N·m).
5. Discard gasket (2).
6. Clean and inspect inner side cover. Clean with denatured 3. If removed, install secondary clutch actuator (3). See
alcohol only. SECONDARY CLUTCH ACTUATOR (Page 8-9).

4. Fill transmission lubricant. See Transmission Lubricant

(Page 2-28).

5. Install exhaust shields. See EXHAUST SYSTEM

(Page 5-26).

Outer Cover
1. See Figure 8-3. Install outer transmission side cover.

a. Install screws (4).

b. Tighten to 100–120 in-lbs (11.2–13.6 N·m).

COMPLETE
1. Secure exhaust system. See EXHAUST SYSTEM
(Page 5-26).
2. Install seat. See SEAT (Page 3-96).

94000383 8-7
3. Connect negative battery cable. See Battery Maintenance
(Page 2-51).

8-8 94000383
SECONDARY CLUTCH ACTUATOR 8.6
PREPARE sm08640

1. Remove main fuse.

4
2. Remove outer side cover. See TRANSMISSION SIDE
COVERS (Page 8-7).
REMOVE
5
NOTE
• A small amount of transmission lubricant drains when
secondary clutch actuator is removed.
• Do not allow DOT 4 fluid to contact diaphragm. 1
3 2
• If DOT 4 fluid contacts painted surfaces, IMMEDIATELY
flush area with clear water.
• A small amount of fluid drains when fluid line is removed.

1. If replacing actuator: 1. Bleeder screw and cap

2. Clutch fluid line
a. Drain clutch fluid. See BLEED CLUTCH CONTROL 3. Screw (3)
SYSTEM (Page 3-85). 4. Secondary clutch actuator
b. Disconnect clutch fluid line (2). Figure 8-5. Secondary Clutch Actuator
c. Place a rag under the flare nut. INSTALL
d. Disconnect flare nut.
FASTENER TORQUE VALUE
e. Allow fluid to drain. Clutch actuator screws 100–120 in-lbs 11.2–13.6 N·m
Clutch fluid line flare nut 133–186 in-lbs 15–21 N·m
2. If removing to service other components, close master
cylinder fluid port.
NOTE
a. See Figure 8-4. Compress clutch lever slightly. When not installed, the piston of the secondary actuator will
b. Place the eyelet of a cable strap between the lever and move toward the released position. Apply steady inward
housing. pressure when installing actuator until fully seated.

3. See Figure 8-5. Remove three screws (3) and secondary 1. See Figure 8-5. Install secondary clutch actuator.
clutch actuator (4).
a. Lubricate mounting bore in side cover with a film of
sm08634
transmission lubricant.

b. Install secondary clutch actuator (4) and screws (3).

c. Evenly tighten to 100–120 in-lbs (11.2–13.6 N·m).

2. Connect fluid line (2).

a. Install flare nut.

b. Tighten to 133–186 in-lbs (15–21 N·m).

3. Fill and bleed clutch control system. See BLEED CLUTCH

CONTROL SYSTEM (Page 3-85).

Figure 8-4. Insert Eyelet COMPLETE

1. Install transmission side cover. See TRANSMISSION SIDE

COVERS (Page 8-7).
2. Install main fuse.
3. Verify proper clutch operation.

94000383 8-9
TRANSMISSION 8.7
PREPARE sm05040a

1. Remove exhaust system. See EXHAUST SYSTEM

(Page 5-26).
2. Loosen drive belt. See DRIVE BELT AND SPROCKETS
(Page 2-37).
3. Remove primary chaincase housing. See PRIMARY
CHAINCASE HOUSING (Page 7-9).
4. Remove the transmission mainshaft bearing inner race.
See PRIMARY CHAINCASE HOUSING (Page 7-9).
5. Remove the clutch release cover, inner side cover and
clutch pushrod. See TRANSMISSION SIDE COVERS
(Page 8-7).
Figure 8-7. Bearing Housing Pry Point
REMOVE
sm03669

NOTE
Do not remove the transmission case unless the case requires
replacement. See TRANSMISSION CASE (Page 8-24).
2
1. Remove transmission top cover. Do not remove gasket.
2. See Figure 8-6. Set shifter cam pawl on cover gasket.
2
3. Cover mainshaft clutch hub splines with tape to prevent 2
damaging the main drive gear bearings and oil seal. 1
NOTE
See Figure 8-7. Always pry bearing housing loose. Never tap
on shafts to remove transmission assembly. The bearing
housing bearings will be damaged.

4. See Figure 8-8. Remove the transmission and bearing 1. Long screw (2)
housing assembly: 2. Short screw (6)
a. Remove the transmission bearing housing screws (1, Figure 8-8. Bearing Housing Screws
2). INSTALL
b. Remove exhaust bracket, if equipped.
FASTENER TORQUE VALUE
c. See Figure 8-7. Pry the bearing housing loose.
Transmission bearing housing 22–25 ft-lbs 29.8–33.9 N·m
d. Remove bearing housing and transmission components screws
from transmission case as an assembly. Transmission top cover 132–156 in-lbs 14.9–17.6 N·m
e. Discard gasket.
1. Cover mainshaft clutch hub splines with tape to prevent
damaging the main drive gear bearings and oil seal.
sm03011a

2. Install a new gasket on the ring dowels.

1
NOTE
Verify that transmission filler plug/dipstick is removed.

3. Apply clean transmission lubricant to the main drive gear

bearings.

4. Install the transmission assembly in the transmission case.

2 5. See Figure 8-8. Install transmission bearing housing.

1. Shifter pawl a. Install exhaust bracket using long screws (1).

2. Top cover gasket
Figure 8-6. Set Shifter Pawl on Gasket b. Install short screws (2).

8-10 94000383
 c. See Figure 8-9. Tighten in sequence to 22–25 ft-lbs DISASSEMBLE
(29.8–33.9 N·m).

Remove Shift Cam and Shifter Forks

sm05044a
1. See Figure 8-10. Remove shift fork shafts:
5 7
a. Set bearing housing on bench with shafts pointing up.
NOTE
Shafts have slight interference fit.
3 2
b. Remove shift fork shafts using spiral-flute screw
extractor (14) or vise grips.
c. Mark end of shaft to aid assembly.
1 4
2. Remove shift forks from dog rings.
8 6 3. See Figure 8-11. Remove lock plate (2). Discard screws
(3).
4. Hold detent arm back and remove shift cam (4).
Figure 8-9. Transmission Bearing Housing Tightening Se-
5. See Figure 8-12. If needed, remove detent assembly.
quence
a. Remove detent screw (1), detent arm (2), sleeve (3)
6. Install top cover. and detent spring (4).
b. Discard detent screw.
a. Set shifter cam pawl on shift cam.

b. Install new transmission top cover gasket. NOTE

Mark parts so they can be installed in same direction as
c. Install transmission top cover and screws. removed.

7. Tighten to 132–156 in-lbs (14.9–17.6 N·m). 6. See Figure 8-13. Remove mainshaft and countershaft
locknuts.
8. Install vent hose to top cover fitting, if removed. a. Lock two gears in place using dog rings.
b. Temporarily put transmission assembly into
COMPLETE transmission case.

FASTENER TORQUE VALUE c. Remove locknuts.

Transmission drain plug 14–21 ft-lbs 19–28.5 N·m d. Remove transmission assembly from transmission case.

1. Install mainshaft bearing inner race. See TRANSMISSION

SPROCKET (Page 7-18).

2. Install pushrod, inner side cover with new gasket and

clutch release cover. See PRIMARY CHAINCASE
HOUSING (Page 7-9).

3. Install primary chaincase housing. See PRIMARY

CHAINCASE COVER, Install (Page 7-3).

4. Install drain plug with new O-ring. Tighten to 14–21 ft-lbs

(19–28.5 N·m).

5. Fill transmission. See Transmission Lubricant (Page 2-28).

6. Adjust drive belt deflection. See DRIVE BELT AND

SPROCKETS (Page 2-37).

7. Install exhaust system. See EXHAUST SYSTEM

(Page 5-26).

94000383 8-11
 sm05070b sm03600b
4
1 2

13
7
14 1
12

11
6
10
5
9
4

3
3 8 3
2
1. Bearing housing
2. Lock plate
3. Lock plate screw (2)
4. Shift cam
1. Mainshaft Figure 8-11. Shift Drum
2. Countershaft
3. Mainshaft first gear sm03018a

4. Mainshaft second gear

5. Mainshaft third gear 1
6. Mainshaft fourth gear
7. Mainshaft fifth gear
8. Countershaft first gear 2
9. Countershaft second gear
10. Countershaft third gear
11. Countershaft fourth gear
12. Countershaft fifth gear
13. Countershaft sixth gear 3
14. Screw extractor 4
Figure 8-10. Gear Set

1. Detent screw
2. Detent arm
3. Sleeve
4. Detent spring
Figure 8-12. Detent Assembly

8-12 94000383
 sm03670a sm03599b

3
4
2
2 1

2 3

4
1 1

1. Retaining ring (2)

2. Bearing (2)
3. Mainshaft locknut
4. Countershaft locknut
Figure 8-13. Bearing Housing Locknuts

Remove Mainshaft
NOTE 1. Retaining ring pliers
• The mainshaft fourth gear, third gear, second gear and first 2. Guiding hub
gear are integral parts of the shaft. Damage to any gear 3. Dog ring
requires mainshaft replacement. 4. Mainshaft fifth gear
• Always replace bearing housing bearings. Figure 8-14. Mainshaft Fifth Gear

1. See Figure 8-14. Using 714 (OTC HORSESHOE LOCK Remove Countershaft
RING PLIERS,), remove retaining ring.
NOTE
2. Remove dog ring (3), guiding hub (2), mainshaft fifth gear Do not press directly on the end of the countershaft. Place a
(4) and bearing. spacer between the end of the countershaft and the press ram.
NOTE
1. If mainshaft is not removed, hold countershaft third and
Do not press directly on the end of the mainshaft. Use a spacer
fourth gear shift dog up while removing countershaft.
between the end of the mainshaft and the press ram.
2. Press countershaft out of bearing housing bearing.
3. Press mainshaft out of bearing housing bearing.
3. See Figure 8-15. Remove washer (1), countershaft first
4. Replace bearing housing bearing. See procedure later in gear (2) and bearing.
this section.
4. Remove countershaft second, third and forth gears.
a. See Figure 8-16. Remove dog ring (5).
b. Remove lock ring (1).
c. Remove securing segments (2).
d. Remove guiding hub (3), countershaft second gear (4)
and bearing.
e. See Figure 8-17 and Figure 8-18. Repeat steps with
third and fourth gears.

NOTE
The countershaft fifth gear and sixth gear are integral parts of
the shaft. Damage to either gear requires countershaft
replacement.

5. Replace bearing housing bearing. See procedure later in

this section.

94000383 8-13
 sm08774 sm03024a

1
2 1

2
3

1. Lock ring
2. Securing segment (2)
3. Internal spline washer
4. Countershaft third gear
Figure 8-17. Countershaft Third Gear
1. Washer
2. Countershaft scissor first gear sm03025b

Figure 8-15. Countershaft First Gear

sm03022a

1
2
1 5

2 2 3
3

4 4

5 1. Lock ring
2. Securing segment (2) (not visible)
3. Guiding hub
4. Countershaft fourth gear
1. Lock ring 5. Dog ring
2. Securing segment (2)
3. Guiding hub Figure 8-18. Countershaft Fourth Gear
4. Countershaft second gear
5. Dog ring Remove Bearing Housing Bearings
Figure 8-16. Countershaft Second Gear NOTE
Always replace bearing housing bearing if the shaft is pressed
out.

1. See Figure 8-19. Remove the retaining rings (2). Discard

retaining rings.
2. Press the bearings out of the bearing housing.

8-14 94000383
 sm05071 sm03006

3
1 2

1. Retaining ring (2)

2. Bearing (2)
3. Bearing housing
Figure 8-19. Bearing Housing Bearings
CLEANING AND INSPECTION

WARNING
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 Figure 8-20. Checking Fork
flow rates. (00061a)
ASSEMBLE
1. Clean parts in a non-volatile cleaning solution. Dry parts
with low-pressure, compressed air. FASTENER TORQUE VALUE
2. Replace gears that are worn or damaged. Shift drum detent screw 120–150 in-lbs 13.6–17 N·m
Shift drum lock plate screws 57–63 in-lbs 6.4–7.1 N·m
3. Replace the dog rings if dogs and/or pockets are rounded,
battered or chipped. Transmission 85–95 ft-lbs 115.3–128.8N·m
mainshaft/countershaft
4. Replace guiding hubs if splines are rounded, battered or locknuts
chipped.
5. Replace shift fork shafts if bent or damaged. Install Bearing Housing Bearings
6. Replace a shift fork if it is excessively worn or shows signs NOTE
of overheating. • Always replace bearing housing bearing if the shaft was
removed.
7. See Figure 8-20. Using a small square, verify that the shift
forks are square. Replace shift fork if not square. • Always support the bearing housing with a plate when
pressing bearings.
8. Replace shift drum assembly if drum or bearing are
damaged. • Press on the bearing outer race.
9. Clean shift cam lock plate mounting holes in transmission
bearing housing. 1. Install bearings.

a. Support the bearing housing at the bearing bores

with a flat plate.

b. Position new bearing over bore with number side

up.

c. Press the bearing until seated in the bore.

WARNING
Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip from the
pliers and could be propelled with enough force to cause
serious eye injury. (00312a)

2. See Figure 8-19. Install new beveled retaining ring (1) with
the flat side against the bearing.

94000383 8-15
 Install Countershaft sm03027b

1. Install fourth, third and second gears on countershaft.

a. See Figure 8-18. Install countershaft fourth gear (4).
b. Lubricate needle bearings and races with SCREAMIN'
EAGLE ASSEMBLY LUBE.
c. Install new needle bearing.
d. Install guiding hub (3).
e. Install dog ring (5).
f. Install securing segments (2) with the rounded edge
facing up. Verify that segments fully engage grooves
in countershaft.
g. Install lock ring (1) with waved, stepped face toward the
securing segments.
h. See Figure 8-17. Install countershaft third gear (4).
NOTE
Install the second gear guiding hub with the deeper
counterbore facing countershaft second gear.
Figure 8-22. Installing Countershaft
i. See Figure 8-16. Install countershaft second gear (4).

2. See Figure 8-21. Preload scissor first gear.

Install Mainshaft
NOTE
a. While holding thick gear, rotate thin gear until holes
align. Failure to press on bearing inner race damages the bearing.

b. Install HD-52235 (SCISSOR FIRST GEAR TOOL).

3. See Figure 8-15. Install new needle bearing, countershaft
first gear (2) and washer (1).
NOTE
• If installing countershaft with mainshaft installed, raise and
hold countershaft third and fourth gear shift dog up while
pressing bearing housing bearing on to countershaft.
• Failure to press on bearing inner race damages the bearing.
4. See Figure 8-23. If mainshaft is not removed, raise and
hold countershaft third and fourth gear shift dog while
installing countershaft.
5. See Figure 8-22. Install countershaft to bearing housing.
1. Support mainshaft fourth gear in press.
2. See Figure 8-23. Raise and hold dog ring engaged with
countershaft third gear during the press procedure.
3. Using a suitable sleeve, press on bearing inner race until
bearing contacts mainshaft first gear.
4. See Figure 8-14. With bearing housing on end (shafts
pointing up), install new bearing and mainshaft fifth gear
(4).
5. With guiding hub counterbore facing mainshaft fifth gear,
install guiding hub (2) and dog ring (3).

a. Support countershaft sixth gear in press. 6. Install new retaining ring using 714 (OTC HORSESHOE
b. Using a suitable sleeve, press on bearing inner race LOCK RING PLIERS,) (1).
until bearing contacts countershaft first gear washer.
7. Remove holding tool from scissor first gear.
sm08772
8. Install new mainshaft and countershaft locknuts.
FA
-
01
17

a. Using dog rings, lock two gears in place.

0

out
b. Temporarily install transmission assembly in
transmission case.

c. Install locknuts. Tighten to 85–95 ft-lbs

(115.3–128.8 N·m).

d. Remove transmission assembly from transmission

case.

Figure 8-21. Preload Scissor First Gear

8-16 94000383
 c. Slide shift shaft through shifter forks.
sm02860b

d. Install shaft in bearing housing.

sm03018a

3
Figure 8-23. Raise and Hold Dog Ring 4

Install Shifter Cam/Shifter Forks

1. Set bearing housing on bench with shafts pointing up. 1. Detent screw
2. Detent arm
2. Install detent arm assembly, if removed. 3. Sleeve
4. Detent spring
a. See Figure 8-24. Clean detent screw mounting hole Figure 8-24. Detent Assembly
in transmission bearing housing.
sm03600b

b. Assemble new detent screw (1), detent arm (2), 4

sleeve (3) and detent spring (4).

c. Align spring and detent arm as shown.

d. Install detent assembly in bearing housing with screw

(1). 1

e. Tighten to 120–150 in-lbs (13.6–17 N·m).

3. See Figure 8-25. Hold detent arm back and install shift
cam assembly (4).

NOTE
See Figure 8-26. The shifter forks are unique and identified as
shown.
3
4. Install lock plate (2) and new lock plate screws (3). Tighten 3
to 57–63 in-lbs (6.4–7.1 N·m). 2
5. Remove any burrs created on shift shafts (1, 3) during 1. Bearing housing
removal. 2. Lock plate
3. Lock plate screw (2)
6. See Figure 8-27. Install long shift shaft (1): 4. Shift cam
Figure 8-25. Shift Drum
a. Insert shifter fork (2) into the dog ring between
mainshaft fifth and sixth gear.

b. Slide shift shaft through shifter fork.

c. Install shaft in hole in bearing housing.

7. Install short shift shaft (4):

a. Insert shifter fork (6) into the dog ring between

countershaft third and fourth gear.

b. Insert shifter fork (9) into the dog ring between

countershaft first and second gear.

94000383 8-17
 sm03028 sm03029b

1
1
4
2

5
3
3 6
2

4 7

9
5

1. Long shift shaft 10

2. Fifth and sixth gear shifter fork
3. Short shift shaft
1. Long shift shaft
4. Third and fourth gear shifter fork
2. Fifth and sixth gear shifter fork
5. First and second gear shifter fork
3. Mainshaft fifth gear
Figure 8-26. Shifter Forks and Shafts 4. Short shift shaft
5. Countershaft fifth gear
6. Third and fourth gear shifter fork
7. Third gear
8. Second gear
9. First and second gear shifter fork
10. First gear
Figure 8-27. Transmission Gears and Shifter Forks

8-18 94000383
MAIN DRIVE GEAR AND BEARING 8.8
PREPARE sm03033

5 1
NOTE
Leave transmission case in the frame unless the case must 7
be replaced. Some illustrations show the case removed for 3
clarity.

1. Remove exhaust system. See EXHAUST SYSTEM

(Page 5-26).
2. Remove primary chaincase housing. See PRIMARY
CHAINCASE HOUSING (Page 7-9).
3. Remove bearing inner race from the transmission 6
mainshaft. See PRIMARY CHAINCASE HOUSING, 4
Mainshaft Bearing Inner Race (Page 7-11). 2
4
4. Remove transmission bearing housing and gear assembly.
See Transmission (Page 8-10).
REMOVE

PART NUMBER TOOL NAME

HD-35316-D MAIN DRIVE GEAR REMOVER AND
INSTALLER SET

NOTICE 1. Cross plate

2. Screw (2)
Failure to use Main Drive Gear Remover and Installer can 3. 12-in bolt
cause premature failure of bearing and related parts. 4. Main drive gear
(00540b) 5. Washer
NOTE 6. Bearing
Main drive gear and bearing can be removed with the 7. Nut
transmission case in the frame after removing bearing housing. Figure 8-28. Removing Main Drive Gear

sm03034
1. Remove retaining ring securing gear to bearing.
4
2. See Figure 8-28. Remove gear using MAIN DRIVE GEAR
REMOVER AND INSTALLER SET (PART NUMBER: 2
HD-35316-D).
3. Remove tool. Remove gear from gearcase.
4. See Figure 8-29. Remove inner race from main drive gear.
5. Remove large main drive gear oil seal.
6. Remove retaining ring from bearing bore.
7. See Figure 8-30. Remove main drive gear bearing from 3
transmission case. 1
8. Discard main drive gear bearing.

1. Main drive gear

2. Long bolt (2)
3. Wedge attachment
4. Press ram
Figure 8-29. Removing Inner Bearing Race From Main Drive
Gear

94000383 8-19
 sm03035 sm03051
5 4
5 2 7 2 1

7 6 4 3 1 6
3

1. 8-in bolt
2. Bearing driver 1. 12-in bolt
3. Pilot 2. Cross plate
4. Main drive gear bearing 3. Screw (2)
5. Receiver cup 4. Main drive gear bearing
6. Bearing 5. Bearing driver
7. Nut 6. Bearing
7. Nut
Figure 8-30. Removing Main Drive Gear Bearing
Figure 8-31. Installing Main Drive Gear Bearing (Typical)
CLEAN AND INSPECT
2. See Figure 8-32. Install new O-ring (4) onto main drive
NOTE gear (3). Lubricate O-ring with clean engine oil.
Never wash the transmission case and needle bearings with 3. Install main drive gear using MAIN DRIVE GEAR
solvent unless replacing the needle bearings. Normal cleaning REMOVER AND INSTALLER SET (PART NUMBER:
methods wash dirt or other contaminants into the bearing case HD-35316-D).
(behind the needles) and leads to bearing failure.
NOTE
See Figure 8-33. Install retaining ring with the flat side facing
1. Clean all parts in solvent except the transmission case
the bearing and the opening within the range shown.
and needle bearings. Dry parts with low-pressure,
compressed air.
4. Install new retaining ring.
2. Inspect the main drive gear for pitting and wear.
3. Inspect the needle bearings inside the main drive gear.
4. Inspect mainshaft race. Replace the needle bearings if the
mainshaft race is damaged.
INSTALL

PART NUMBER TOOL NAME

HD-35316-D MAIN DRIVE GEAR REMOVER AND
INSTALLER SET
HD-47856 MAIN DRIVE GEAR SEAL INSTALLER
KIT

NOTICE

Improper tightening of sprocket nut can cause drive

component damage. (00541b)

1. See Figure 8-31. Install main drive gear bearing using

MAIN DRIVE GEAR REMOVER AND INSTALLER SET
(PART NUMBER: HD-35316-D).

8-20 94000383
 sm03052 sm03062a
6 3
1

7 4 1
5 2

1. Crow's foot wrench

2. Breaker bar
3. Adjustable wrench
Figure 8-34. Press Seal into Crankcase
1. 8-in bolt
2. Washer COMPLETE
3. Main drive gear
4. O-ring 1. Install bearing housing and transmission components. See
5. Installer cup Transmission (Page 8-10).
6. Bearing
2. Install sprocket and drive belt. See TRANSMISSION
7. Nut
SPROCKET (Page 7-18). Do not adjust belt deflection
Figure 8-32. Installing Main Drive Gear (Typical) now.
sm03053 3. Install the bearing inner race on the transmission
mainshaft. See TRANSMISSION CASE (Page 8-24).
4. Install primary chaincase housing. See PRIMARY
CHAINCASE HOUSING (Page 7-9).
5. Install primary chain, compensating sprocket and clutch
as an assembly. See DRIVE COMPONENTS (Page 7-5).
6. Install primary chaincase cover. See PRIMARY
CHAINCASE COVER (Page 7-3).
7. Adjust drive belt deflection. See DRIVE BELT AND
SPROCKETS (Page 2-37).
8. Install exhaust system. See EXHAUST SYSTEM
Figure 8-33. Retaining Ring Opening (Page 5-26).
5. See Figure 8-34. Install new main drive gear large seal REPLACE NEEDLE BEARINGS
using MAIN DRIVE GEAR SEAL INSTALLER KIT (PART
NUMBER: HD-47856).
PART NUMBER TOOL NAME
HD-47932 MAIN DRIVE GEAR BEARING AND
SEAL INSTALLATION TOOL

NOTE
See Figure 8-36. When replacing needle bearings, replace
retaining rings (1) with new retaining rings (2).

1. See Figure 8-35. Remove mainshaft seal (7).

2. Remove retaining rings (1), needle bearings (2, 6) and
spacer (5) from main drive gear (3). Discard retaining rings.
3. Discard O-ring (4).

94000383 8-21
 sm03036
NOTE
1 2 The mainshaft seal can also be installed after the main drive
3 gear is installed. See MAIN DRIVE GEAR AND BEARING,
4 Replace Mainshaft Seal (Page 8-22).

5 5. See Figure 8-38. Install mainshaft seal with garter spring

2 side down.
1 a. Use the 0.090-in step of MAIN DRIVE GEAR BEARING
AND SEAL INSTALLATION TOOL (PART NUMBER:
6 HD-47932).
b. Press until tool contacts gear.

1. Retaining ring (2) 6. See Figure 8-35. Turn over the main drive gear. Install
2. Inner needle bearing spacer (5).
3. Main drive gear
7. See Figure 8-39. Use MAIN DRIVE GEAR BEARING AND
4. O-ring
SEAL INSTALLATION TOOL (PART NUMBER: HD-47932)
5. Spacer
to press inner needle bearing until tool contacts gear.
6. Outer needle bearing
7. Mainshaft seal 8. See Figure 8-35. Install new retaining rings (1).
Figure 8-35. Main Drive Gear Assembly 9. Install new O-ring (4).
sm03038
1 2 sm03044

1. Original retaining ring

2. Replacement retaining ring
Figure 8-36. Main Drive Gear Retaining Rings
4. See Figure 8-37. Use MAIN DRIVE GEAR BEARING AND
SEAL INSTALLATION TOOL (PART NUMBER: HD-47932) Figure 8-38. Pressing in Seal
to install outer needle bearing. Press until tool contacts
sm02302
gear.

sm03040

Figure 8-39. Installing Inner Needle Bearing in Main Drive

Gear

Figure 8-37. Installing Outer Needle Bearing in Main Drive

REPLACE MAINSHAFT SEAL
Gear
PART NUMBER TOOL NAME
HD-47933 MAIN DRIVE GEAR SEAL INSTALLER

8-22 94000383
See Figure 8-40. Use the MAIN DRIVE GEAR SEAL
sm03049
INSTALLER (PART NUMBER: HD-47933) to replace the
mainshaft seal while the main drive gear is installed.

sm03045
2

1. Driver
2. Seal protector sleeve Figure 8-42. Seal Driver
Figure 8-40. Main Drive Gear Seal Installer
1. Remove the seal using a seal remover or rolling head pry
bar.
2. Verify that bore is clean and smooth.
3. See Figure 8-41. Place the seal protector sleeve (1) of
MAIN DRIVE GEAR SEAL INSTALLER (PART NUMBER:
HD-47933) over the end of the mainshaft.
4. Lightly lubricate the protector sleeve and seal ID with clean
transmission oil.
5. Slide the seal (2) on the seal protector sleeve with the
garter spring facing the bearing.
6. See Figure 8-42. Hand press seal onto place until seal
driver contacts end of main drive gear using MAIN DRIVE
GEAR SEAL INSTALLER (PART NUMBER: HD-47933).
Lightly tap with a rubber mallet if necessary.

sm03048

2
1

1. Seal protector sleeve

2. Seal
Figure 8-41. Seal Protector Sleeve

94000383 8-23
TRANSMISSION CASE 8.9
PREPARE 4. In a cross-wise pattern, remove four bolts securing
transmission to engine.
WARNING NOTE
See Figure 8-43. Do not use a hammer to remove transmission.
Disconnect negative (-) battery cable first. If positive (+)
If the transmission sticks or binds on the ring dowels, gently
cable should contact ground with negative (-) cable
pry away from crankcase using the pry point.
connected, the resulting sparks can cause a battery
explosion, which could result in death or serious injury.
(00049a) 5. Move transmission rearward until two ring dowels in lower
flange are free of crankcase.
1. Disconnect battery cables. See Battery Maintenance 6. Remove transmission case from left side of the motorcycle.
(Page 2-51).
sm03566a

2. Drain engine oil. See ENGINE OIL AND FILTER

(Page 2-15).

3. Drain transmission. See Transmission Lubricant

(Page 2-28).

4. Remove starter. See STARTER (Page 9-15).

5. Remove transmission assembly. See TRANSMISSION

OPERATION (Page 8-3).

6. Remove oil pan. See OIL PAN (Page 4-69).

Figure 8-43. Transmission Case Pry Point

NOTICE
INSTALL
When lifting a motorcycle using a jack, be sure jack
contacts both lower frame tubes where down tubes and FASTENER TORQUE VALUE
lower frame tubes converge. Never lift by jacking on
Battery ground cable to 66–114 in-lbs 7.5–12.9 N·m
cross-members, oil pan, mounting brackets, components
transmission
or housings. Failure to comply can cause serious damage
resulting in the need to perform major repair work. (00586d) Transmission mounting bolts, 34–39 ft-lbs 46.1–52.9 N·m
final torque
7. Position jack across lower frame to support rear of Transmission mounting bolts, 15 ft-lbs 20.3 N·m
motorcycle. Slide wooden blocks beneath the crankcase initial torque
to support the weight of the engine and transmission
assembly. NOTE
A new transmission case has the shifter shaft sleeve and seal,
8. Remove rear fork. See REAR FORK (Page 3-76). centering screw, countershaft needle bearing and main drive
gear bearing and seal installed.
9. Disconnect vehicle speed sensor (VSS). See Vehicle
Speed Sensor (VSS) (Page 9-54). 1. Install new ground post at top of transmission case.
Tighten ground post until snug.
10. Disconnect neutral switch. See NEUTRAL SWITCH
(Page 9-57). 2. Wipe all engine oil from pockets in crankcase flange.

REMOVE 3. Install new engine-to-transmission gasket.

1. Remove battery negative cable from ground post at top of 4. Verify that transmission dowels are seated. Place
transmission case. transmission case into position.

2. Move aside the harness that terminates at the O2 sensor,

5. Secure transmission.
starter solenoid, neutral switch and VSS.
3. Remove transmission shift lever. a. Install shorter bolts at the top, longer bolts at the
a. Mark splines on transmission shift lever and shift shaft bottom. Hand-tighten bolts.
to help with assembly.
b. See Figure 8-44. Tighten bolts in the sequence
b. Remove pinch screw. shown to 15 ft-lbs (20.3 N·m).
c. Pull lever from shaft.

8-24 94000383
 c. Final tighten to 34–39 ft-lbs (46.1–52.9 N·m) in the 11. Install starter. See STARTER (Page 9-15).
same sequence.
12. Connect VSS, O2 sensors, starter solenoid and neutral
6. Secure battery ground cable to ground post at top of switch connectors.
transmission case. Tighten to 66–114 in-lbs
(7.5–12.9 N·m). 13. Install exhaust system. See EXHAUST SYSTEM
(Page 5-26).
sm08605
4 2 14. Install transmission drain plug. Tighten to 14–21 ft-lbs
(19–28.5 N·m). Fill transmission. See Transmission
Lubricant (Page 2-28).

15. Fill primary chaincase. See Primary Chaincase Lubricant

(Page 2-26).

16. Fill engine oil. See ENGINE OIL AND FILTER (Page 2-15).
1
WARNING
Connect positive (+) battery cable first. If positive (+) cable
should contact ground with negative (-) cable connected,
the resulting sparks can cause a battery explosion, which
3
could result in death or serious injury. (00068a)

Figure 8-44. Transmission Housing to Crankcase Tighten-

17. Connect battery cables. See Battery Maintenance
ing Sequence
(Page 2-51).
COMPLETE
DISASSEMBLE
FASTENER TORQUE VALUE
Shifter rod lever pinch screw, 18–22 ft-lbs 24.4–29.8 N·m
transmission lever Remove Shifter Pawl Lever
Transmission drain plug 14–21 ft-lbs 19–28.5 N·m 1. See Figure 8-46. Remove shifter rod lever.

1. Install oil pan. See OIL PAN (Page 4-69). a. Remove pinch screw (8).
b. Remove shifter rod lever (9) from the shifter pawl lever
2. Install rear fork. See REAR FORK (Page 3-76). assembly (1).

3. Install transmission shift lever. 2. Remove shifter pawl assembly.

a. Remove retaining ring (7), washer (6) and seal (5).
a. Align marks made during disassembly.
b. Discard retaining ring and seal.
b. Install pinch screw. c. Remove shifter pawl lever assembly.

c. Tighten to 18–22 ft-lbs (24.4–29.8 N·m). 3. Inspect sleeve (3) in transmission case.

4. Install transmission and bearing housing assembly. See Remove Oil Return Tube/Cover
TRANSMISSION OPERATION (Page 8-3).
1. If transmission case is installed in vehicle, disconnect
battery.
5. Install neutral switch. See NEUTRAL SWITCH
(Page 9-57). 2. See Figure 8-45. Remove screw (1).
3. Remove oil return tube (2) or cover (3).
6. Install VSS. See Vehicle Speed Sensor (VSS) (Page 9-54).

7. Adjust drive belt deflection. See DRIVE BELT AND

SPROCKETS (Page 2-37).

8. Install primary chaincase housing. See PRIMARY

CHAINCASE HOUSING (Page 7-9).

9. Install drive components. See DRIVE COMPONENTS

(Page 7-5).

10. Install primary chaincase cover and new gasket. See

PRIMARY CHAINCASE COVER (Page 7-3).

94000383 8-25
 sm08777 sm03066
8
1
10
11
2 9
3
4

4 7
6
5
3
2
1. Screw 1
2. Oil return tube
3. Cover
1. Shifter pawl lever assembly
4. O-ring
2. Shift lever centering spring
Figure 8-45. Oil Return Tube/Cover 3. Sleeve (inside transmission case)
CLEAN AND INSPECT 4. Shifter shaft lever spring
5. Seal
6. Washer
WARNING
7. Retaining ring
Compressed air can pierce the skin and flying debris from 8. Screw
compressed air could cause serious eye injury. Wear 9. Shifter rod lever
safety glasses when working with compressed air. Never 10. Screw
use your hand to check for air leaks or to determine air Figure 8-46. Shifter Arm Assembly
flow rates. (00061a)
ASSEMBLE
NOTE
Never wash the transmission case and needle bearings with PART NUMBER TOOL NAME
solvent. Normal cleaning methods wash dirt or other HD-51337 SHIFTER SHAFT SEAL INSTALLATION
contaminants into the bearing case (behind the needles) TOOL
leading to bearing failure.
FASTENER TORQUE VALUE
1. Clean all parts in solvent except the case and main drive Oil return tube/cover screw 100–120 in-lbs 11.3–13.6 N·m
gear needle bearings. Dry parts with low-pressure,
compressed air. Shifter pawl centering screw 18–23 ft-lbs 24.4–31.2 N·m
Shifter rod lever pinch screw, 18–22 ft-lbs 24.4–29.8 N·m
2. See Figure 8-46. Inspect the shifter pawl lever assembly transmission lever
(1) for wear. Replace assembly if pawl ends are damaged.
Replace centering spring (3) if elongated.
Install Oil Return Tube/Cover
3. Inspect the shifter shaft lever spring (4). Replace if the
spring fails to hold the pawl on the cam pins. 1. See Figure 8-45. Install new O-ring (4).

4. Thoroughly clean the oil pan. 2. Remove oil return tube (2) or cover (3).
5. Inspect transmission top cover vent hose for damage.
Verify that hose and fitting are unobstructed. 3. Install screw (1).

a. Tighten to 100–120 in-lbs (11.3–13.6 N·m).

4. Connect battery.

Replace Countershaft Needle Bearing

1. Press or drive out bearing using a bearing driver 1.25 in
(31.75 mm) in diameter.
2. Install new bearing.
a. From the outside of the transmission case, place the
bearing on the bearing bore.
b. Install the bearing flush or to a maximum depth of
0.030 in (0.76 mm) with the outside surface of the case.

8-26 94000383
3. Lubricate the bearing with SCREAMIN' EAGLE
sm03067a
ASSEMBLY LUBE.

Install Shifter Pawl Lever

4
1. See Figure 8-46. Verify that sleeve (3) is in transmission
case bore.
1
2. Install screw (10) into side of transmission case. Tighten
to 18–23 ft-lbs (24.4–31.2 N·m). 2
3. See Figure 8-47. Assemble shifter arm.
3
a. Slide shifter lever centering spring (2) over shaft of
shifter pawl lever assembly (3).

b. Align opening on spring with tab on lever. 1. Pawl (part of shifter pawl lever assembly)
2. Shifter pawl lever assembly
c. Place shifter shaft lever spring (4) on shifter pawl 3. Shifter lever centering spring
lever assembly. Flex spring only enough to 4. Shifter shaft lever spring
assemble. Figure 8-47. Shifter Pawl Lever Assembly

4. See Figure 8-48. Insert the shifter arm assembly into the sm03068a
4
transmission case.

5. See Figure 8-49. Verify that pin of screw sits inside shifter 1
shaft lever spring.

6. Install new seal with garter spring facing the transmission.

a. Drive the seal until the tool bottoms on the

transmission case using SHIFTER SHAFT SEAL 2
INSTALLATION TOOL (PART NUMBER: HD-51337).
3
NOTE
Install shifter rod lever one spline from vertical toward front of
vehicle.
1. Washer (with seal behind)
2. Retaining ring
7. See Figure 8-48. Install washer (1) and new retaining ring 3. Shifter shaft lever
(2). 4. Pin
Figure 8-48. Shifter Shaft Lever, Exterior View
8. See Figure 8-46. Install shifter rod lever (9).
sm03069a
a. Install pinch screw (8).

b. Tighten to 18–22 ft-lbs (24.4–29.8 N·m).

Figure 8-49. Shifter Shaft Lever Spring

94000383 8-27
NOTES
SUBJECT PAGE NO.
9.1 FASTENER TORQUE VALUES ............................................................................................ 9-1
9.2 SPECIFICATIONS: ELECTRICAL ........................................................................................ 9-5
9.3 SYSTEM FUSES AND RELAYS ........................................................................................... 9-6
9.4 ELECTRONIC CONTROL MODULE (ECM) ........................................................................ 9-7
9.5 BODY CONTROL MODULE (BCM) ...................................................................................... 9-8
9.6 ELECTRICAL CADDIES ....................................................................................................... 9-9
9.7 IGNITION COIL AND SPARK PLUG CABLES ................................................................... 9-13
9.8 STARTER ............................................................................................................................ 9-15
9.9 HEADLAMP ........................................................................................................................ 9-16
9.10 AUXILIARY/FOG LAMPS AND BRACKETS .................................................................... 9-18
9.11 REAR LIGHTING .............................................................................................................. 9-21
9.12 FENDER TIP LAMPS ........................................................................................................ 9-26
9.13 TOUR-PAK LIGHTS .......................................................................................................... 9-28
9.14 TURN SIGNAL LAMPS ..................................................................................................... 9-31
9.15 IGNITION SWITCH AND FORK LOCK ............................................................................. 9-39
9.16 ACCESSORY SWITCHES ................................................................................................ 9-42
9.17 CRANKSHAFT POSITION SENSOR (CKP) .................................................................... 9-44
9.18 KNOCK SENSOR (KS) ..................................................................................................... 9-45
9.19 ENGINE TEMPERATURE SENSOR (ET) ........................................................................ 9-46
9.20 ENGINE COOLANT TEMPERATURE SENSOR (ECT) ................................................... 9-47
9.21 AUTOMATIC COMPRESSION RELEASE (ACR) ............................................................. 9-48
9.22 VOLTAGE REGULATOR ................................................................................................... 9-50

ELECTRICAL
9.23 ALTERNATOR ................................................................................................................... 9-52
9.24 VEHICLE SPEED SENSOR (VSS) ................................................................................... 9-54
9.25 WHEEL SPEED SENSORS .............................................................................................. 9-55
9.26 NEUTRAL SWITCH .......................................................................................................... 9-57
9.27 OIL PRESSURE SWITCH ................................................................................................ 9-58
9.28 STOP LAMP SWITCHES .................................................................................................. 9-59
9.29 HORN ................................................................................................................................ 9-60
9.30 FAIRING POWER OUTLET .............................................................................................. 9-62
9.31 GAUGES AND INSTRUMENTS: FAIRING MODELS ...................................................... 9-63
9.32 GAUGES AND INSTRUMENTS: ROAD KING MODELS ................................................. 9-65
9.33 INDICATOR LAMPS: ROAD KING MODELS ................................................................... 9-67
9.34 BOOM! BOX INFOTAINMENT SYSTEM .......................................................................... 9-68
9.35 ANTENNA CABLES .......................................................................................................... 9-77
9.36 WIRE TROUGH ................................................................................................................ 9-80
9.37 MAIN WIRING HARNESS ................................................................................................ 9-82
9.38 FAIRING HARNESS ......................................................................................................... 9-91
9.39 HANDLEBAR SWITCH PACKS ........................................................................................ 9-94
9.40 SECURITY SYSTEM MAINTENANCE ............................................................................. 9-99
9.41 PERSONAL IDENTIFICATION NUMBER (PIN) ............................................................. 9-101
9.42 SECURITY SYSTEM ACTUATION ................................................................................. 9-102
9.43 SECURITY SIREN .......................................................................................................... 9-103
NOTES
FASTENER TORQUE VALUES 9.1
FASTENER TORQUE VALUES IN THIS
CHAPTER

The table below lists torque values for all fasteners presented
in this chapter.

FASTENER TORQUE VALUE NOTES

ABS module locknuts 53–88 in-lbs 6–10 N·m 9.6 ELECTRICAL CADDIES, Right Side Caddy
Accessory switch module screws 12–17 in-lbs 1.4–1.9 N·m 9.16 ACCESSORY SWITCHES, Fork-Mounted
Fairing Models
Accessory switch module screws 12–17 in-lbs 1.4–1.9 N·m 9.16 ACCESSORY SWITCHES, Frame-Mounted
Fairing Models
ACR 16–19.5 ft-lbs 23–26.4 N·m 9.21 Automatic Compression Release (ACR), Install
Apply three equally spaced dots of LOCTITE 246
MEDIUM STRENGTH/HIGH TEMPERATURE
THREADLOCKER (blue) around lower third of
threads
Auxiliary/fog lamp bracket acorn nuts: 120–180 in-lbs 13.6–20.3 N·m 9.10 AUXILIARY/FOG LAMPS AND BRACKETS,
Fairing models Turn Signal/Auxiliary/Fog Lamp Bracket
Auxiliary/fog lamp bracket acorn nuts: 72–108 in-lbs 8.1–12.2 N·m 9.10 AUXILIARY/FOG LAMPS AND BRACKETS,
Road King models Turn Signal/Auxiliary/Fog Lamp Bracket
Auxiliary/fog lamp door screw 6–10 in-lbs 0.7–1.1 N·m 9.10 AUXILIARY/FOG LAMPS AND BRACKETS,
Replace Auxiliary/Fog Lamp Bulb
Auxiliary/fog lamp stud locknut 20–24 ft-lbs 27.1–32.5 N·m 9.10 AUXILIARY/FOG LAMPS AND BRACKETS,
Auxiliary/Fog Lamp Housing
Battery terminal bolt 60–70 in-lbs 6.8–7.9 N·m 9.8 STARTER, Install
Battery terminal bolt 60–70 in-lbs 6.8–7.9 N·m 9.23 ALTERNATOR, Complete
Battery tray screws 132–156 in-lbs 14.9–17.6 N·m 9.6 ELECTRICAL CADDIES, Right Side Caddy
Battery tray screws 132–156 in-lbs 14.9–17.6 N·m 9.6 ELECTRICAL CADDIES, Battery Tray
Brake master cylinder, front, clamp 60–80 in-lbs 6.8–9 N·m 9.39 HANDLEBAR SWITCH PACKS, Install
screws
CB antenna base set screw 14–16 in-lbs 1.6–1.8 N·m 9.13 TOUR-PAK LIGHTS, Wrap-Around Lamp (if
equipped)
CB antenna stud nut 14–16 in-lbs 1.6–1.8 N·m 9.13 TOUR-PAK LIGHTS, Tour-Pak Lights Harness
CB antenna stud nut 14–16 in-lbs 1.6–1.8 N·m 9.13 TOUR-PAK LIGHTS, Wrap-Around Lamp (if
equipped)
CB module bracket to speaker enclosure 25–35 in-lbs 2.8–4 N·m 9.34 Boom! Box Infotainment System, CB Module:
screw Fork Mounted Fairing
CB module to speaker enclosure screw 25–35 in-lbs 2.8–4 N·m 9.34 Boom! Box Infotainment System, CB Module:
Fork Mounted Fairing
CKP mount screw 90–120 in-lbs 10.2–13.6 N·m 9.17 CRANKSHAFT POSITION SENSOR (CKP),
Installation
Clutch lever bracket clamp screws 60–80 in-lbs 6.8–9 N·m 9.39 HANDLEBAR SWITCH PACKS, Install
Coolant downtube lower screws 90–110 in-lbs 10.2–12.4 N·m 9.22 VOLTAGE REGULATOR, Install
Coolant downtube upper screws 20–22 ft-lbs 27.1–29.8 N·m 9.22 VOLTAGE REGULATOR, Install
Dash panel screws 25–30 in-lbs 2.8–3.4 N·m 9.38 FAIRING HARNESS, Harness Service: Fork-
Mounted Fairing
Engine temperature sensor 132–188 in-lbs 14.9–21.2 N·m 9.19 ENGINE TEMPERATURE SENSOR (ET),
Install
Fairing double studs 120–180 in-lbs 13.6–20.3 N·m 9.38 FAIRING HARNESS, Harness Service: Fork-
Mounted Fairing
Fairing speaker enclosure to fairing 48–60 in-lbs 5.4–6.8 N·m 9.34 Boom! Box Infotainment System, Front Fairing
screws Speakers: Fork Mounted Fairing

94000383 9-1
FASTENER TORQUE VALUE NOTES
Fairing speaker enclosure to fairing 48–60 in-lbs 5.4–6.8 N·m 9.34 Boom! Box Infotainment System, Front Fairing
screws Speaker and Enclosure: Frame-Mounted Fairing
Fairing speaker enclosure to fairing 48–60 in-lbs 5.4–6.8 N·m 9.34 Boom! Box Infotainment System, Front Fairing
support screws Speakers: Fork Mounted Fairing
Fairing speaker enclosure to radio sup- 48–60 in-lbs 5.4–6.8 N·m 9.34 Boom! Box Infotainment System, Front Fairing
port bracket screws: FLTR Speaker and Enclosure: Frame-Mounted Fairing
Fairing speaker grille screws 9–13 in-lbs 1–1.4 N·m 9.34 Boom! Box Infotainment System, Front Fairing
Speakers: Fork Mounted Fairing
Fairing speaker screw 9–13 in-lbs 1–1.5 N·m 9.34 Boom! Box Infotainment System, Front Fairing
Speakers: Fork Mounted Fairing
Fairing speaker screw 9–13 in-lbs 1–1.5 N·m 9.34 Boom! Box Infotainment System, Front Fairing
Speaker and Enclosure: Frame-Mounted Fairing
Fairing speaker screw 9–13 in-lbs 1–1.5 N·m 9.34 Boom! Box Infotainment System, Front Fairing
Speaker and Enclosure: Frame-Mounted Fairing
Fender, rear, lights harness stud plate 60–96 in-lbs 6.8–10.9 N·m 9.11 Rear Lighting, Rear Fender Lights Harness:
flange nuts all except FLHX, FLHXS, FLTRX, FLTRXS
Fender tip lamp, front 20–25 in-lbs 2.3–2.8 N·m 9.12 FENDER TIP LAMPS, Front Fender Tip Lamp
Fender tip lamp, rear, harness P-clamp 45–85 in-lbs 5.1–9.6 N·m 9.12 FENDER TIP LAMPS, Rear Fender Tip Lamp
locknut
Fender tip lamp, rear, screws 12–18 in-lbs 1.4–2 N·m 9.12 FENDER TIP LAMPS, Rear Fender Tip Lamp
Fender trim strips, front 10–15 in-lbs 1.1–1.7 N·m 9.12 FENDER TIP LAMPS, Front Fender Tip Lamp
Fork lock screws: Road King 36–60 in-lbs 4.1–6.8 N·m 9.15 Ignition Switch and Fork Lock, Road King
Models
Gauges, 2 inch diameter gauge screws 8–15 in-lbs 0.9–1.7 N·m 9.31 GAUGES AND INSTRUMENTS: FAIRING
MODELS, 2-Inch Diameter Gauges
Gauges, instrument cluster screws 10–20 in-lbs 1.1–2.3 N·m 9.31 GAUGES AND INSTRUMENTS: FAIRING
MODELS, Speedometer/Tachometer Instrument
Cluster: Fork-Mounted Fairing
Gauges, instrument cluster screws: 12–17 in-lbs 1.4–1.9 N·m 9.31 GAUGES AND INSTRUMENTS: FAIRING
frame mounted fairing models MODELS, Speedometer/Tachometer Instrument
Cluster: Frame Mounted Fairing
Handlebar switch housing screws 35–45 in-lbs 4–5 N·m 9.39 HANDLEBAR SWITCH PACKS, Install
Handlebar switch housing screws 35–45 in-lbs 4–5 N·m 9.39 HANDLEBAR SWITCH PACKS, Install
Harness ground stud flange nuts 50–90 in-lbs 5.7–10.2 N·m 9.7 IGNITION COIL AND SPARK PLUG CABLES,
Install
Harness ground stud flange nuts 50–90 in-lbs 5.7–10.2 N·m 9.37 MAIN WIRING HARNESS, Installation: All
Models (Part 1)
(10 mm)
Headlamp bezel: FLTR 8–15 in-lbs 0.9–1.7 N·m 9.9 HEADLAMP, Headlamp: FLTR Models
Headlamp door screw 9–18 in-lbs 1–2 N·m 9.9 HEADLAMP, Headlamp: All But FLTR Models
Headlamp retaining ring screws: All ex- 23–26 in-lbs 2.6–2.9 N·m 9.9 HEADLAMP, Headlamp: All But FLTR Models
cept FLTR
Headlamp screws: FLTR models 48–60 in-lbs 5.4–6.8 N·m 9.9 HEADLAMP, Headlamp: FLTR Models
Headset DIN connector 7–9 in-lbs 0.8–1 N·m 9.34 Boom! Box Infotainment System, Rear
Speaker Enclosures
Headset DIN connector 7–9 in-lbs 0.8–1 N·m 9.34 Boom! Box Infotainment System, Rider
Headset Connector
Horn bracket acorn nut 80–120 in-lbs 9–13.6 N·m 9.29 HORN, Installation
Horn bracket to cylinder head screws 35–40 ft-lbs 47.5–54.2 N·m 9.29 HORN, Installation
Horn cover to bracket 35–55 in-lbs 3.9–6.2 N·m 9.29 HORN, Installation
Horn rubber mount 120–180 in-lbs 13.6–20.3 N·m 9.29 HORN, Installation
Apply LOCTITE 271 HIGH STRENGTH THREAD-
LOCKER (red)

9-2 94000383
FASTENER TORQUE VALUE NOTES
Horn stud flange nut 80–100 in-lbs 9–11.3 N·m 9.29 HORN, Installation
Ignition coil screws 71–106 in-lbs 8–12 N·m 9.6 ELECTRICAL CADDIES, Right Side Caddy
Ignition coil screws 71–106 in-lbs 8–12 N·m 9.6 ELECTRICAL CADDIES, Battery Tray
Ignition coil screws 71–106 in-lbs 8–12 N·m 9.7 IGNITION COIL AND SPARK PLUG CABLES,
Install
Ignition switch housing nut: Fairing 13–15 ft-lbs 17.5–20.9 N·m 9.15 Ignition Switch and Fork Lock, Fairing Models
models
Ignition switch housing screws: Fairing 85–115 in-lbs 9.6–13 N·m 9.15 Ignition Switch and Fork Lock, Fairing Models
models
Ignition switch screws: Road King 25–35 in-lbs 2.8–3.9 N·m 9.15 Ignition Switch and Fork Lock, Road King
Models
Knock sensor screw 13–17 ft-lbs 17.6–23 N·m 9.18 KNOCK SENSOR (KS), Install
Left electrical caddy fastener 72–96 in-lbs 8.1–10.9 N·m 9.6 ELECTRICAL CADDIES, Battery Tray
Left electrical caddy fasteners 72–96 in-lbs 8.1–10.9 N·m 9.6 ELECTRICAL CADDIES, Left Side Caddy
License plate bracket screws 60–90 in-lbs 6.8–10.2 N·m 9.14 Turn Signal Lamps, Rear Turn Signal Lamps
Bracket
License plate bracket screws 60–90 in-lbs 6.8–10.2 N·m 9.14 Turn Signal Lamps, Rear Turn Signal Lamps
Bracket
Nacelle switch hex nut 9–15 in-lbs 1–1.7 N·m 9.16 ACCESSORY SWITCHES, Nacelle Switches
Neutral switch 120–180 in-lbs 13.6–20.3 N·m 9.26 NEUTRAL SWITCH, Installation
Oil pressure sender 13–17 ft-lbs 17.6–23 N·m 9.27 Oil Pressure Switch, Install
Passenger audio switch screws 25–30 in-lbs 2.8–3.4 N·m 9.34 Boom! Box Infotainment System, Rear
Speaker Enclosures
Radio (or storage box) to fairing support 60–84 in-lbs 6.8–9.5 N·m 9.34 Boom! Box Infotainment System, Radio: Fork-
bracket screws Mounted Fairing
Radio antenna inner set screw 14–16 in-lbs 1.6–1.8 N·m 9.13 TOUR-PAK LIGHTS, Wrap-Around Lamp (if
equipped)
Radio antenna stud nut 16–19 in-lbs 1.8–2.1 N·m 9.13 TOUR-PAK LIGHTS, Wrap-Around Lamp (if
equipped)
Radio to fairing support bracket screws 60–84 in-lbs 6.8–9.5 N·m 9.34 Boom! Box Infotainment System, Radio:
Frame Mounted Fairing
Rear fascia lamp screws 18–22 in-lbs 2–2.5 N·m 9.11 Rear Lighting, Rear Fascia Lamp
Rear speaker enclosure to Tour-Pak 20–25 in-lbs 2.3–2.8 N·m 9.34 Boom! Box Infotainment System, Rear
screws Speaker Enclosures
Right caddy to battery tray screw 36–40 in-lbs 4.1–4.5 N·m 9.6 ELECTRICAL CADDIES, Right Side Caddy
Right caddy to battery tray screw 36–40 in-lbs 4.1–4.5 N·m 9.6 ELECTRICAL CADDIES, Battery Tray
Solenoid terminal post nut 70–104 in-lbs 7.9–11.8 N·m 9.8 STARTER, Install
Spark plug 89–133 in-lbs 10–15 N·m 9.2 SPECIFICATIONS: ELECTRICAL, Specifica-
tions
Starter mounting screws 22–24 ft-lbs 29.8–32.5 N·m 9.8 STARTER, Install
Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue).
Stator mounting screws 55–75 in-lbs 6.2–8.5 N·m 9.23 ALTERNATOR, Install
Always use new screws
Stop lamp switch, rear 12–15 ft-lbs 16.3–20.3 N·m 9.28 STOP LAMP SWITCHES, Rear Stop Lamp
Switch
Use LOCTITE 565 THREAD SEALANT
Tail lamp base screw 40–48 in-lbs 4.5–5.4 N·m 9.11 Rear Lighting, Tail Lamp Base
Tail lamp screws 20–24 in-lbs 2.3–2.7 N·m 9.11 Rear Lighting, Replace Tail Lamp Bulb
Tail lamp screws 20–24 in-lbs 2.3–2.7 N·m 9.11 Rear Lighting, Tail Lamp Base
Tail lamp screws 20–24 in-lbs 2.3–2.7 N·m 9.11 Rear Lighting, Rear Fender Lights Harness:
all except FLHX, FLHXS, FLTRX, FLTRXS

94000383 9-3
FASTENER TORQUE VALUE NOTES
Tail lamp screws 20–24 in-lbs 2.3–2.7 N·m 9.11 Rear Lighting, Rear Fender Lights Harness:
FLHX, FLHXS, FLTRX, FLTRXS
Tail lamp screws 20–24 in-lbs 2.3–2.7 N·m 9.12 FENDER TIP LAMPS, Rear Fender Tip Lamp
Tail lamp screws 20–24 in-lbs 2.3–2.7 N·m 9.14 Turn Signal Lamps, Rear Turn Signal Lamp
Temperature sensor, radiator 17.7–19.2 ft-lbs 24–26 N·m 9.20 ENGINE COOLANT TEMPERATURE
SENSOR (ECT), Coolant Temperature Sensor
Top caddy screws 72–96 in-lbs 8.1–10.9 N·m 9.6 ELECTRICAL CADDIES, Top Caddy
Tour-Pak ground plate screws 20–25 in-lbs 2.3–2.8 N·m 9.13 TOUR-PAK LIGHTS, Tour-Pak Lights Harness
Tour-Pak side marker lamp screws 20–25 in-lbs 2.3–2.8 N·m 9.13 TOUR-PAK LIGHTS, Tour-Pak Side
Lamps/Trim Strips
Tour-Pak wrap-around lamp screws 20–25 in-lbs 2.3–2.8 N·m 9.13 TOUR-PAK LIGHTS, Wrap-Around Lamp (if
equipped)
Turn signal, front, lamp to bracket screw: 96–120 in-lbs 10.9–13.5 N·m 9.14 Turn Signal Lamps, Front Turn Signal Lamp
Bullet Style, auxiliary/fog lamp equipped
Turn signal, front, lamp to bracket screw: 15–20 ft-lbs 20.3–27.1 N·m 9.14 Turn Signal Lamps, Front Turn Signal Lamp
Bullet Style, without auxiliary/fog lamps
Turn signal lamp, front, mounting bracket 30–60 in-lbs 4.1–6.8 N·m 9.14 Turn Signal Lamps, Front Turn Signal Lamp
screws: Flat lens style
Turn signal lamps bracket, rear, screws 84–144 in-lbs 9.5–16.3 N·m 9.14 Turn Signal Lamps, Rear Turn Signal Lamps
Bracket
Use LOCTITE 271 HIGH STRENGTH THREAD-
LOCKER (red)
Turn signal lamps bracket, rear, screws 84–144 in-lbs 9.5–16.3 N·m 9.14 Turn Signal Lamps, Rear Turn Signal Lamps
Bracket
Use LOCTITE 271 HIGH STRENGTH THREAD-
LOCKER (red)
Turn signal lamp to auxiliary/fog lamp 96–120 in-lbs 10.9–13.5 N·m 9.10 AUXILIARY/FOG LAMPS AND BRACKETS,
bracket screw: Bullet style turn signal Auxiliary/Fog Lamp Housing
lamps
Turn signal lamp to fairing screws: 60–120 in-lbs 6.8–13.6 N·m 9.14 Turn Signal Lamps, Front Turn Signal Lamp
FLTRU, FLTRX, FLTRXS
Turn signal lamp to rear turn signal 30–50 in-lbs 3.4–5.6 N·m 9.14 Turn Signal Lamps, Rear Turn Signal Lamp
lamps bracket screws
Upper support bracket to speaker enclos- 48–60 in-lbs 5.4–6.8 N·m 9.34 Boom! Box Infotainment System, Front Fairing
ure screws Speakers: Fork Mounted Fairing
Voltage regulator screws 96–120 in-lbs 10.8–13.6 N·m 9.22 VOLTAGE REGULATOR, Install
VSS fastener 100–120 in-lbs 11.3–13.6 N·m 9.24 Vehicle Speed Sensor (VSS), VSS

9-4 94000383
SPECIFICATIONS: ELECTRICAL 9.2
SPECIFICATIONS

FASTENER TORQUE VALUE

Spark plug 89–133 in-lbs 10–15 N·m

Table 9-1. Ignition

IGNITION DATA
Spark plug size 10 mm
Spark plug gap 0.031-0.035 in
0.80-0.90 mm
Spark plug torque 89–133 in-lbs
(10–15 N·m)
Spark plug cable resistance Front Left: 94,500-
256,000 ohms
Front Right: 88,500-
240,000 ohms
Rear: 45,750-126,000
ohms
Ignition coil primary resistance 0.3-1.5 ohms
Ignition coil secondary resistance 8000-12,000 ohms

Table 9-2. Fuses

FUSE AMPS
Main fuse 50
System power 7.5
P&A 20
Radio power 20
Cooling 15
Battery 5

Table 9-3. Charging System

CHARGING SYSTEM DATA
Battery 28 amp hour/405 CCA
Alternator AC voltage output 40-55 VAC at 2000 RPM
Alternator stator coil resistance 0.1-0.3 ohms
Maxumum output 46-50 amps

Table 9-4. Starter Specifications

STARTER DATA
Free current 90 A (max) @ 11.5 V
Cranking current 250 A (max) @ 68 °F (20 °C)

94000383 9-5
SYSTEM FUSES AND RELAYS 9.3
MAIN FUSE
Removal
Removal 1. Remove left saddlebag.

1. Remove left side saddlebag. See SADDLEBAGS 2. Remove left side cover.
(Page 3-98). 3. Press in tabs on the left and right sides of fuse block cover.
2. Remove left side cover. Remove the cover.

3. Siren equipped models: With security fob present, turn 4. See Figure 9-1. Remove system fuse or relay from fuse
ignition switch ON. block. Replace fuse if the element is burned. Automotive
type ATO fuses are used.
4. See Figure 9-1. Pull main fuse (11) from main fuse holder.
Installation
Installation
1. See Figure 9-1. Install system fuse or relay in fuse block.
1. See Figure 9-1. Insert main fuse (11) into main fuse holder.
2. Install fuse block cover.
2. Install left side cover.
3. Install left side cover.
3. Install left side saddlebag. See SADDLEBAGS
(Page 3-98). 4. Install left saddlebag.

SYSTEM FUSES AND RELAYS

NOTE
All Touring model motorcycles use a common fuse block. Actual
fuse assignment may vary based on model and options.

sm07593

1 2 3

4 5 6 11

7 8 9

10
50

1. Radio power (20 A) 7. P&A relay

2. System power (7.5 A) 8. Cooling relay
3. Battery (5 A) 9. Spare (7.5 A)
4. P&A (20 A) 10. Spare (20 A)
5. Cooling (15 A) 11. Main fuse (50 A)
6. Spare (5 A)
Figure 9-1. Fuses and Relays
FUSE BLOCKS System Fuse Block
See ELECTRICAL CADDIES (Page 9-9) for removal and
Main Fuse Holder installation of the system fuse block. See the electrical
See ELECTRICAL CADDIES (Page 9-9) for removal and diagnostic manual for terminal removal and installation.
installation of the main fuse holder. See the electrical diagnostic
manual for terminal removal and installation.

9-6 94000383
ELECTRONIC CONTROL MODULE (ECM) 9.4
ECM sm07624

1
PART NUMBER TOOL NAME
HD-48650 DIGITAL TECHNICIAN II

Removal
1. Remove seat. See SEAT (Page 3-96).
2. Free ECM from top caddy.
2
2
3. Disconnect three ECM connectors. See the electrical
diagnostic manual.

Installation
1. Connect ECM connectors. 3
NOTE
Connectors are keyed to install only in the correct location.
The color of each connector is also imprinted on the ECM next 1. Connectors
to each connector. 2. Latch
3. ECM
2. Secure ECM in top caddy. Figure 9-2. ECM
3. Install seat. After installing seat, pull up on the seat to be
sure it is secure.
4. If installing a new ECM, it must be set up using DIGITAL
TECHNICIAN II (PART NUMBER: HD-48650):
a. Choose the REFLASH icon.
b. Follow the on-screen prompts.

NOTE
• Whenever a new TGS or ECM is installed, perform the idle
speed procedure. The ECM uses the first four ignition cycles
to establish the optimum idle speed. Failure to perform these
steps can result in initial performance problems.
• After installing new ECM, always perform password learn
procedure using Digital Technician II. See the electrical
diagnostic manual.

5. If a new ECM was installed, reset idle speed.

a. Place the engine run/stop switch in the RUN position.
b. Turn the ignition switch to IGNITION and then OFF four
times without starting engine. Allow at least three
seconds to elapse between ignition cycles.

94000383 9-7
BODY CONTROL MODULE (BCM) 9.5
REMOVAL
1. Remove left saddlebag. See SADDLEBAGS (Page 3-98).
2. Remove left side cover.
3. Siren equipped models: With security fob present, turn
ignition switch ON.
4. Remove main fuse.
5. Lift retaining tab and pull BCM from left caddy.
6. See Figure 9-3. Remove BCM power wire connector (4).
7. Push lock latch and rotate lock (2) until a click is heard.
Remove BCM connector (1).
INSTALLATION

PART NUMBER TOOL NAME

HD-48650 DIGITAL TECHNICIAN II

1. See Figure 9-3. Install BCM connector (1). Rotate lock (2)
to secure.
2. Connect BCM power wire (4).
3. Install BCM in left caddy. Install main fuse.
4. Install side cover.
5. Install left saddlebag. See SADDLEBAGS (Page 3-98).
6. If installing a new BCM, it must be set up using DIGITAL
TECHNICIAN II (PART NUMBER: HD-48650):
a. Choose the VEHICLE SETUP icon.
b. Follow the on-screen prompts.

sm07588

3 4

1. BCM connector
2. Lock
3. BCM
4. BCM power wire connector
Figure 9-3. BCM

9-8 94000383
ELECTRICAL CADDIES 9.6
FAIRING AND STEERING HEAD CADDIES sm07592
1
For service of the fairing harness caddy, see FAIRING
HARNESS (Page 9-91). 7
For service of the steering head caddies, see MAIN WIRING
HARNESS (Page 9-82).

TOP CADDY 6 2

FASTENER TORQUE VALUE

Top caddy screws 72–96 in-lbs 8.1–10.9 N·m
5
Removal
1. Remove seat. See SEAT (Page 3-96). 4 3
2. See Figure 9-4. Remove HFSM antenna (6), if present.
3. Lift up on ECM (3) until free of caddy (1). 1. Top caddy
4. Remove connectors (4, 5) from retaining devices. 2. Screw (2)
3. ECM
5. Remove screws (2). 4. Connector, grey
6. Lift caddy and slide purge valve solenoid (7) from caddy, 5. Connector, black
if present. Remove caddy. 6. HFSM antenna
7. Purge valve solenoid
Installation Figure 9-4. Top Caddy

1. See Figure 9-4. Install purge valve solenoid (7) on caddy LEFT SIDE CADDY
(1). Place caddy into position over battery.
FASTENER TORQUE VALUE
2. Install screws (2). Tighten to 72–96 in-lbs (8.1–10.9 N·m). Left electrical caddy fasteners 72–96 in-lbs 8.1–10.9 N·m

3. Install ECM (3). Removal

1. Remove left saddlebag. See SADDLEBAGS (Page 3-98).
4. Install HFSM antenna (6) onto caddy, if present.
2. Remove left side cover.
5. Secure connectors (4, 5) to retaining devices. 3. Remove seat. See SEAT (Page 3-96).
4. Siren Equipped Models: With security fob present, turn
6. Install seat. See SEAT (Page 3-96). ignition switch ON.
5. Remove main fuse.
6. Disconnect rear fender lights harness connector. Remove
connector from retaining device.
7. See Figure 9-5. Remove BCM (1). See BODY CONTROL
MODULE (BCM) (Page 9-8).
8. Remove siren (3), if equipped. If not equipped, remove
connector from storage location (4) on caddy.
9. Release data link connector (8), auxiliary device connector
(7) and battery tender connector (6) from caddy.
10. Remove fuse block cover.
11. Remove two screws securing caddy.

94000383 9-9
 9. Route rear fender lights connector through opening in
sm07591
2 3 4 battery tray and up through opening in frame. Secure
1 caddy with two screws. Tighten to 72–96 in-lbs
(8.1–10.9 N·m).

10. Secure auxiliary device connector (7), data link connector

10 5 (8), and battery tender connector (6) to caddy.

11. Install fuse block cover.

9
12. Install siren (3) and attach electrical connector, if equipped.
8 If not equipped, attach connector to storage location (4).
6
7 13. Connect and install BCM (1). See BODY CONTROL
MODULE (BCM) (Page 9-8).
1. BCM
2. Fuse block latch locations (lower two are not
14. Connect rear fender lights harness connector. Secure to
visible)
retaining device.
3. Siren (if equipped)
4. Siren connector storage
5. Cable strap, rear 15. Install main fuse.
6. Battery tender connector
7. Auxiliary device connector 16. Install seat. See SEAT (Page 3-96).
8. Data link connector
9. Cable strap, BCM harness 17. Install left side cover.
10. Cable strap, main harness
Figure 9-5. Caddy Components WARNING
12. Remove cable straps (5, 9, 10). Be sure that all lights and switches operate properly before
13. Pull harnesses back through openings in caddy. operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)
14. Use a thin tool to release four latches (2) securing fuse
block. Push fuse block back through opening in caddy.
18. Install left saddlebag. See SADDLEBAGS (Page 3-98).
15. From back side of caddy, squeeze tabs of main fuse holder
and pull away from caddy. RIGHT SIDE CADDY
Installation
FASTENER TORQUE VALUE
1. See Figure 9-5. Route harnesses through openings. ABS module locknuts 53–88 in-lbs 6–10 N·m
Battery tray screws 132–156 in-lbs 14.9–17.6 N·m
2. Loosely install a new cable strap (9) on the BCM harness. Ignition coil screws 71–106 in-lbs 8–12 N·m
Right caddy to battery tray 36–40 in-lbs 4.1–4.5 N·m
3. Loosely secure main harness to anchor on back side of screw
caddy with cable strap (10).
Removal
4. Install main fuse holder into caddy. Confirm that the latches
on the fuse holder are secured to the caddy. 1. Remove right saddlebag.
2. Remove right side cover.
5. Insert fuse block from back side of caddy. Confirm the
latches (2) are secured to the fuse block. 3. Remove battery. See Battery Maintenance (Page 2-51).
4. Remove O2 sensor connector anchors.
6. Loosely secure BCM harness to tab with previously
5. See Figure 9-6. Remove CAN termination resistor
installed cable strap (9).
connector (3).

NOTE 6. Remove P&A connector (2).

Tighten cable straps only enough to secure harnesses but still 7. Remove wheel speed sensor connector anchor, if
allow movement. equipped.
8. Remove ignition coil screws and battery hold-down bracket.
7. Loosely secure harnesses to tab at rear opening with a
cable strap (5). 9. Remove screw (1) securing right side caddy to battery
tray.
8. Tighten the main harness, BCM harness then rear harness 10. Remove four screws securing battery tray to frame.
cable straps until snug. 11. Disengage latch on bottom of caddy. Release caddy from
dovetails while lowering battery tray into frame.

9-10 94000383
 NOTE
sm07596
Stud on bottom of ABS module is a tight fit in grommet. 1
Considerable effort may be needed to remove module.

12. ABS models: Loosen nuts securing ABS module assembly

(3). Remove ABS module from caddy.
13. Remove caddy. 4
2
Installation
1. ABS models: Install ABS module to caddy. Apply glass
cleaner to grommets to aid installation. Tighten to
53–88 in-lbs (6–10 N·m).
3
2. Engage right side caddy onto dovetails while lifting battery
tray up into position. Verify latch on bottom of caddy is 1. Screw
engaged. 2. P&A connector
3. CAN termination resistor connector
3. See Figure 9-6. Install screw (1). Tighten to 36–40 in-lbs 4. ABS module
(4.1–4.5 N·m). Figure 9-6. Right Side Caddy

4. Install four screws securing battery tray to frame. Tighten

BATTERY TRAY
to 132–156 in-lbs (14.9–17.6 N·m).
FASTENER TORQUE VALUE
5. Install battery hold-down bracket and screws to secure Battery tray screws 132–156 in-lbs 14.9–17.6 N·m
ignition coil. Tighten to 71–106 in-lbs (8–12 N·m). Ignition coil screws 71–106 in-lbs 8–12 N·m
Left electrical caddy fastener 72–96 in-lbs 8.1–10.9 N·m
6. Secure O2 sensor connector anchors. Locate the gray Right caddy to battery tray 36–40 in-lbs 4.1–4.5 N·m
connector in the outboard position. screw

7. Secure the wheel speed sensor connector anchor, if Removal

equipped.
1. Remove seat. See SEAT (Page 3-96).
8. Install CAN termination resistor connector (3). 2. Remove battery. See Battery Maintenance (Page 2-51).
3. Remove screws securing left side caddy. Pull caddy away
9. Install P&A connector (2). from frame while pulling rear fender lights harness out
through battery tray.
10. Install battery and top caddy. See Battery Maintenance
(Page 2-51). 4. Remove ignition coil screws and battery hold-down bracket.
See IGNITION COIL AND SPARK PLUG CABLES
(Page 9-13).
11. Install seat. See SEAT (Page 3-96).
5. Remove screw securing right side caddy, if equipped.
12. Install side cover and saddlebag. 6. Models without right side caddy: Release connectors
from retaining devices.
7. Remove four screws securing battery tray to frame.
8. Models with right side caddy: Disengage latch on bottom
of caddy. Release caddy from dovetails while lowering
battery tray into frame.
9. Roll front of battery tray up and out of frame.

Installation
1. Roll rear of battery tray down into frame.

2. Models with right side caddy: Engage right side caddy

onto dovetails while lifting battery tray up into position.
Verify latch on bottom of caddy is engaged.

3. Install screw to retain caddy to battery tray. Tighten to

36–40 in-lbs (4.1–4.5 N·m).

94000383 9-11
4. Install four screws securing battery tray to frame. Tighten 12. Install side covers and saddlebags.
to 132–156 in-lbs (14.9–17.6 N·m).
LOWER BACKBONE CADDY
5. Models without right side caddy: Secure connectors to
retaining devices.
Remove
6. Install battery hold-down bracket and screws to secure 1. Remove main fuse.
ignition coil. Tighten to 71–106 in-lbs (8–12 N·m).
2. Remove fuel tank.
7. Route rear fender lights connector through opening in 3. See Figure 9-7. Release electrical connectors(2, 3, 4, 5,
battery tray and up through opening in frame. Secure left 7) from retaining features on caddy.
side caddy with screws. Tighten to 72–96 in-lbs
4. Remove two plastic rivets (1).
(8.1–10.9 N·m).
5. Slide caddy forward and down to remove.
8. Mate rear fender lights connector. Secure to retaining 6. Cut cable straps (8).
device.
Install
9. Secure main harness to left top frame with two cable
straps. 1. See Figure 9-7. Install electrical connectors to retaining
features on caddy.
10. Install battery and top caddy. See Battery Maintenance 2. Install new cable straps (8).
(Page 2-51).
3. Slide caddy up and rearward to engage latches.

11. Install seat. See SEAT (Page 3-96). 4. Install two plastic rivets (1).
5. Install fuel tank.
WARNING 6. Install main fuse.
Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)

sm08637

5 6
3 4
2 7

1 9
8

1. Plastic rivet (2) 6. Hook

2. Rear ACR connector 7. ET sensor connector
3. Rear KS connector 8. Cable straps (3)
4. Front KS connector 9. Horn wires
5. Front ACR connector
Figure 9-7. Lower Backbone Caddy

9-12 94000383
IGNITION COIL AND SPARK PLUG CABLES 9.7
REMOVAL sm06037
1
1. Remove battery. See Battery Maintenance (Page 2-51).
2. See Figure 9-8. Remove spark plug wires (1-4) from 4
ignition coil towers.
3. Remove ignition coil connector (5).
4. See Figure 9-9. Remove screws (2) and battery hold-down
bracket (3).
5. Loosen ground terminal nut (4). While holding ground 2
terminal wires out of the way, remove ignition coil (1). 2
3
INSTALL

FASTENER TORQUE VALUE

Harness ground stud flange 50–90 in-lbs 5.7–10.2 N·m 1. Ignition coil
nuts 2. Screw (2)
Ignition coil screws 71–106 in-lbs 8–12 N·m 3. Battery hold-down bracket
4. Ground terminal nut
1. See Figure 9-9. While holding ground terminal wires out Figure 9-9. Ignition Coil
of the way, place ignition coil (1) into position.
SPARK PLUG CABLES
2. Install battery hold-down bracket (3) and screws (2).
Tighten to 71–106 in-lbs (8–12 N·m). Prepare
1. Remove fuel tank. See FUEL TANK (Page 5-6).
3. Tighten ground terminal nut (4) to 50–90 in-lbs
(5.7–10.2 N·m).
Remove
4. See Figure 9-8. Install ignition coil connector (5). 1. Remove cables from ignition coil.
2. Release cables retainers.
5. Connect spark plug wires (1-4) to ignition coil towers.
3. Remove boots from spark plugs using HD-52006
(Adjustable Spark Plug Wire Puller).
6. Install battery. See Battery Maintenance (Page 2-51).
Install
sm08638 1 2 1. See Figure 9-10. Connect long cables to front spark plugs.
2. Connect short cables to rear spark plugs.
5 3. Adjust spark plug boots to avoid contact with fuel tank.
4. Right cables: Secure cable straps (1). Route front cable
through caddy retainers (3).
5. Left cables: Secure left side anchored cable straps (2) to
frame backbone.
6. See Figure 9-8. Connect cables to ignition coil.
3 Complete
4
1. Install fuel tank. See FUEL TANK (Page 5-6).

1. Front right
2. Front left
3. Rear left
4. Rear right
5. Ignition coil connector
Figure 9-8. Ignition Coil Connections

94000383 9-13
 sm08713 sm02659a
1 4
2 1 3

1
2

1. Ohmmeter positive lead

1. Anchored cable straps 2. Ohmmeter negative lead
2. Left side anchored cable straps 3. Spark plug cable
3. Caddy retainers 4. Ohmmeter
Figure 9-10. Spark Plug Cable Routing Figure 9-11. Testing Resistance
INSPECT SPARK PLUG CABLES

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.

2. Check cable boots and caps for cracks or tears. Replace

cable if boots or caps are worn or damaged.
3. See Figure 9-11. Check spark plug cable resistance with
an ohmmeter. Replace cables not meeting resistance
specifications. Refer to Table 9-5.

Table 9-5. Spark Plug Cables

LOCA- LENGTH RESISTANCE
TION
Left rear 15.25 –15.75 in 3,800-11,000 ohms
length (387–400 mm)
Left front 31.5 –32 in 7,800-21,500 ohms
length (800–812 mm)
Right front 29.50 –30 in 7,300-20,000 ohms
length (749–762 mm)
Right rear 15.25 –15.75 in 3,800-11,000 ohms
length (387–400 mm)

9-14 94000383
STARTER 9.8
REMOVAL NOTICE

Do not over-tighten bolts on battery terminals. Use

1. Remove seat. See SEAT (Page 3-96). recommended torque values. Over-tightening battery
terminal bolts could result in damage to battery terminals.
WARNING (00216a)

Disconnect negative (-) battery cable first. If positive (+)

cable should contact ground with negative (-) cable 8. Connect battery negative cable to battery. Tighten to
connected, the resulting sparks can cause a battery 60–70 in-lbs (6.8–7.9 N·m).
explosion, which could result in death or serious injury.
(00049a) 9. Install seat. See SEAT (Page 3-96).

NOTE
The battery positive cable and power wire for the main fuse
are crimped together at the starter ring terminal.

2. Remove negative cable from battery.

3. Remove battery positive and main fuse power cable ring

terminal from starter solenoid stud.

4. Remove starter solenoid connector [128] at front of starter.

5. Remove engine oil filler cap/dipstick. Cover fill spout with

clean shop cloth to keep out dirt and debris.

6. Remove starter mounting screws.

7. Remove starter. Avoid losing the ring dowels.

INSTALL

FASTENER TORQUE VALUE

Battery terminal bolt 60–70 in-lbs 6.8–7.9 N·m
Solenoid terminal post nut 70–104 in-lbs 7.9–11.8 N·m
Starter mounting screws 22–24 ft-lbs 29.8–32.5 N·m

1. Verify that two ring dowels are installed in the primary

chaincase or starter flange.

2. Lubricate O-ring on starter and bore of primary chaincase

with light film of clean primary chaincase lubricant.

3. Apply a drop of LOCTITE 243 MEDIUM STRENGTH

THREADLOCKER AND SEALANT (blue) to the starter
mounting screws.

4. Install starter and start both mounting screws. Tighten to

22–24 ft-lbs (29.8–32.5 N·m).

5. Install engine oil filler cap/dipstick.

6. Install battery positive cable on stud of solenoid. Tighten

to 70–104 in-lbs (7.9–11.8 N·m). Pull down rubber boot
over terminal connections.

7. Install starter solenoid connector [128] at front of starter.

94000383 9-15
HEADLAMP
HEADLAMP: ALL BUT FLTR MODELS
FASTENER
Headlamp door screw
Headlamp retaining ring
screws: All except FLTR
9.9
Bulb Replacement: Halogen Type
TORQUE VALUE WARNING
9–18 in-lbs 1–2 N·m Handle bulb carefully and wear eye protection. Bulb
23–26 in-lbs 2.6–2.9 N·m contains gas under pressure, which, if not handled
carefully, could cause serious eye injury. (00062b)

NOTICE
Removal
1. Remove screw at bottom of headlamp door (chrome ring). When replacement is required, use only the specified
sealed beam unit or bulb, available from a Harley-Davidson
2. Rotate door counterclockwise a few degrees. Pull dealer. An improper wattage sealed beam or bulb, can
headlamp door straight forward to remove. cause charging system problems. (00209a)
3. See Figure 9-12. Remove screws (1) securing retaining NOTE
ring.
This headlamp assembly uses separate quartz halogen bulbs
4. Remove headlamp. Disconnect headlamp connectors. for the low beam and the high beam. HDI models also contain
a position lamp bulb.
om00991c

1 2 1. Remove headlamp assembly.

2. Disconnect wire harness connectors from the bulbs.

2 3. Rotate bulb assembly 1/4 turn counterclockwise to remove

2 from the reflector/lens.

NOTICE

Never touch the quartz bulb. Fingerprints will etch the

glass and decrease bulb life. Handle the bulb with paper
1 or a clean, dry cloth. Failure to do so could result in bulb
damage. (00210b)
1
4. Insert new bulb into reflector/lens and rotate 1/4 turn
clockwise.

1. Retaining ring screw (3)

5. HDI models: Rotate position lamp bulb retainer 1/4 turn
2. Headlamp adjusting screw (3)
counterclockwise to remove. Replace bulb and install bulb
Figure 9-12. Headlamp Retaining Ring retainer in lamp housing.

Installation 6. Connect the wiring harness connectors to the bulbs.

1. Attach headlamp connectors.
7. Secure the headlamp assembly and headlamp door.
2. See Figure 9-12. Secure headlamp assembly with retaining
ring and screws (1). Tighten to 23–26 in-lbs (2.6–2.9 N·m). Bulb Replacement: LED Type
LED headlamp contains no service parts including bulbs.
3. Install the headlamp door (chrome ring):
Replace the entire assembly if failure occurs.

a. Verify that rubber seal is in place on headlamp door. HEADLAMP: FLTR MODELS
Apply glass cleaner to seal to ease installation.
FASTENER TORQUE VALUE
b. With the headlamp door rotated a few degrees
counterclockwise, push headlamp door straight onto Headlamp bezel: FLTR 8–15 in-lbs 0.9–1.7 N·m
headlamp. Headlamp screws: FLTR 48–60 in-lbs 5.4–6.8 N·m
models
c. Rotate clockwise until screw can be installed. Tighten
to 9–18 in-lbs (1–2 N·m). Removal
NOTE
This headlamp assembly contains no service parts including
bulbs and rubber boots. Replace assembly upon failure.

9-16 94000383
1. Remove outer fairing. See OUTER FAIRING AND
WINDSHIELD: FRAME MOUNTED FAIRING MODELS
(Page 3-127).
2. See Figure 9-13. Remove four screws (2).
3. Remove headlamp assembly. Disconnect headlamp
connector.
4. If necessary, remove screws (3) to remove bezel (4) from
each side of headlamp assembly.

Installation
1. If removed, secure bezel (4) with screws (3) to each side
of headlamp assembly. Tighten to 8–15 in-lbs
(0.9–1.7 N·m).

NOTE
Verify that pins engage hole in vent housings (arrows) during
headlamp installation.

2. Attach headlamp connector.

3. Secure headlamp assembly with four screws (2). Tighten

to 48–60 in-lbs (5.4–6.8 N·m).

4. Install outer fairing. See OUTER FAIRING AND

WINDSHIELD: FRAME MOUNTED FAIRING MODELS
(Page 3-127).

sm08381

4 3 2

1. Headlamp assembly
2. Screw (4)
3. Screw (2 each side)
4. Bezel
Figure 9-13. Headlamp: FLTR

94000383 9-17
AUXILIARY/FOG LAMPS AND BRACKETS 9.10
REPLACE AUXILIARY/FOG LAMP BULB sm07931

1
FASTENER TORQUE VALUE 2
Auxiliary/fog lamp door screw 6–10 in-lbs 0.7–1.1 N·m 3
4
WARNING
Handle bulb carefully and wear eye protection. Bulb
contains gas under pressure, which, if not handled
carefully, could cause serious eye injury. (00062b)

NOTICE

Never touch the quartz bulb. Fingerprints will etch the 6

glass and decrease bulb life. Handle the bulb with paper
or a clean, dry cloth. Failure to do so could result in bulb
damage. (00210b)
5
NOTE
Some models have LED auxiliary lamps. LED lamps contain 1. Auxiliary/fog lamp housing
no service parts including bulbs. Replace the lamp assembly 2. Nesting ring
if it fails. 3. Lamp
4. Door
5. Door screw
Removal 6. Nesting ring index tab
1. See Figure 9-14. Loosen screw (5). Pull door (4) from lip Figure 9-14. Auxiliary/Fog Lamp
of lamp housing (1).
AUXILIARY/FOG LAMP HOUSING
2. Disconnect auxiliary/fog lamp connector. Remove lamp
(3). PART NUMBER TOOL NAME
3. Remove nesting ring (2). FRX181 FLARE NUT SOCKET
4. Quartz halogen models: Rotate bulb housing 1/4 turn
FASTENER TORQUE VALUE
counterclockwise to remove from lamp.
Auxiliary/fog lamp stud locknut 20–24 ft-lbs 27.1–32.5 N·m
Installation Turn signal lamp to 96–120 in-lbs 10.9–13.5 N·m
auxiliary/fog lamp bracket
1. Quartz halogen models: Install new bulb/housing screw: Bullet style turn signal
assembly. Rotate 1/4 turn clockwise. lamps

2. See Figure 9-14. Place nesting ring (2) on back of lamp Removal
(3) with tab facing away from lamp.
1. Disassemble auxiliary/fog lamp. See AUXILIARY/FOG
LAMPS AND BRACKETS, Replace Auxiliary/Fog Lamp
3. Mate connector. Bulb (Page 9-18).

4. Engage nesting ring index tab (6) in slot at bottom of lamp
housing.
5. Hold nesting ring in place and rotate lamp so that index
tabs engage slots in nesting ring.
6. Install lamp door (4) on lamp housing (1) with screw (5)
centered at bottom. Tighten to 6–10 in-lbs (0.7–1.1 N·m).
2. Remove lamp and bracket:
a. Road King models: See Figure 9-16. Disconnect
auxiliary/fog lamps connector (2 or 3).
b. Fairing models: Remove auxiliary/fog lamp/bracket
assembly. See AUXILIARY/FOG LAMPS AND
BRACKETS, Turn Signal/Auxiliary/Fog Lamp Bracket
(Page 9-19).
3. Remove appropriate terminals from connector housing.
See the electrical diagnostic manual.

Table 9-6. FLHTC/U, FLHTK Auxiliary/Fog Lamps [31L/R]

LEFT SIDE [31L] RIGHT SIDE [31R]
WIRE COLOR CHAMBER WIRE COLOR CHAMBER
GY/BK 4 GY/BK 4
Note: Terminals 1, 2 and 3 are reserved for the turn signal
lamp.

9-18 94000383
 Table 9-7. FLHR/C Auxiliary/Fog Lamps [73]
sm07476
LEFT SIDE RIGHT SIDE
WIRE COLOR CHAMBER WIRE COLOR CHAMBER 1 2
GY/BK 1 GY/BK 2 3

4. See Figure 9-15. Remove screw (1) and washer to release 4

turn signal lamp (11) from bracket.
5
5. Use FLARE NUT SOCKET (PART NUMBER: FRX181) to
remove locknut (10), lockwasher (9) and clamp block (8).
6. Remove auxiliary/fog lamp housing (2) from bracket.
7
7. Remove rubber washer (7).
8
Installation
9
1. Lay old auxiliary/fog lamp next to new auxiliary/fog lamp 6
11 10
and cut wire to length.

2. Strip 3/16 in (4.8 mm) of insulation off wire and crimp on

new socket terminal. See the electrical diagnostic manual.
1. Screw, turn signal
3. See Figure 9-15. Install rubber washer (7) on stud. 2. Auxiliary/fog lamp housing
3. Nesting ring
4. Position auxiliary/fog lamp housing on bracket. Install 4. Lamp
clamp block (8), lockwasher (9) and locknut (10). 5. Door
6. Screw and nut
5. Using FLARE NUT SOCKET (PART NUMBER: FRX181), 7. Rubber washer
tighten locknut to 20–24 ft-lbs (27.1–32.5 N·m). 8. Clamp block
9. Lockwasher
6. Route wire through passage in bracket and protective 10. Locknut
conduit. 11. Turn signal lamp and standoff
Figure 9-15. Auxiliary/Fog Lamp Assembly
7. Install terminals into connector housing. See the electrical TURN SIGNAL/AUXILIARY/FOG LAMP
diagnostic manual. Refer to Table 9-6 or Table 9-7 for BRACKET
terminal location.

FASTENER TORQUE VALUE

8. Install turn signal lamp. Secure with screw (1). Tighten to
96–120 in-lbs (10.9–13.5 N·m). Auxiliary/fog lamp bracket 120–180 in-lbs 13.6–20.3 N·m
acorn nuts: Fairing models
9. Install lamp/bracket assembly: Auxiliary/fog lamp bracket 72–108 in-lbs 8.1–12.2 N·m
acorn nuts: Road King models
a. Road King models: Route harness up through lower
fork bracket and mate connector. Secure harness to Removal
lower fork bracket with cable strap. NOTE
On models not equipped with auxiliary/fog lamps, removal of
b. Fairing models: Mate connector. Install lamp
lamp bracket is similar.
bracket. See AUXILIARY/FOG LAMPS AND
BRACKETS, Turn Signal/Auxiliary/Fog Lamp Bracket
(Page 9-19). 1. Road King Models:
a. See Figure 9-16. Disconnect both lamp connectors (3,
10. Assemble auxiliary/fog lamp. See AUXILIARY/FOG LAMPS 4) located on left steering head.
AND BRACKETS, Replace Auxiliary/Fog Lamp Bulb
b. Cut cable straps securing harnesses to lower fork
(Page 9-18).
bracket.

11. Check for proper operation and alignment. Adjust if c. Pull harnesses down through openings in lower fork
necessary. bracket.
d. Loosen acorn nuts securing lamp bracket.

2. Fairing Models:
a. Remove acorn nuts securing lamp brackets.
b. Pull lamp bracket away from fork and separate electrical
connector.

94000383 9-19
3. Remove auxiliary/fog lamp bracket.

Installation
1. Fairing Models:

a. Mate electrical connector.

b. Install auxiliary/fog lamp bracket.

c. Install acorn nuts. Tighten to 120–180 in-lbs

(13.6–20.3 N·m).

2. Road King Models:

a. Install auxiliary/fog lamp bracket with bushings

outside bracket.

b. Tighten acorn nuts to 72–108 in-lbs (8.1–12.2 N·m).

c. See Figure 9-16. Pull harnesses up through openings

in lower fork bracket.

d. Connect both lamp connectors (3, 4).

e. Install cable straps securing harnesses to lower fork

bracket.

sm07537a

1 5
2

1. Left handlebar switch module

2. TGS
3. Right auxiliary/fog/turn signal lamps
4. Left auxiliary/fog/turn signal lamps
5. Caddy retainer
Figure 9-16. Left Side Connectors: Road King Models
ADJUSTMENT

See Headlamp Alignment (Page 2-56) for alignment

procedures.

9-20 94000383
REAR LIGHTING 9.11
REPLACE TAIL LAMP BULB TAIL LAMP BASE

FASTENER TORQUE VALUE FASTENER TORQUE VALUE

Tail lamp screws 20–24 in-lbs 2.3–2.7 N·m Tail lamp base screw 40–48 in-lbs 4.5–5.4 N·m
Tail lamp screws 20–24 in-lbs 2.3–2.7 N·m
Removal
1. Remove two screws to release tail lamp assembly from Removal
chrome base. 1. Remove two screws to release tail lamp assembly from
2. See Figure 9-17. Disconnect tail lamp connector (3). chrome base.

3. Rotate bulb socket (4) a quarter turn counterclockwise and 2. See Figure 9-18 and Figure 9-19. Disconnect all
remove from tail lamp assembly. Remove bulb. connectors.
NOTE
Installation See Figure 9-19. To release turn signal lamp connectors, use
1. Coat base of new bulb with ELECTRICAL CONTACT a pick or small screwdriver to press latch.
LUBRICANT. Install new bulb.
3. Remove screw at center of chrome base. Push chrome
2. See Figure 9-17. Insert socket (4) into tail lamp assembly. base upward until it is free of fender. Pull out of fender
Rotate a quarter turn clockwise. hole.
4. Remove chrome base.
3. Attach tail lamp connector (3).
5. Remove pin housing/circuit board from chrome base.

NOTE sm03624
Do not over-tighten screws. 3 1 2 5

4. Place tail lamp into position against chrome base.

4

5. Install two screws. Tighten to 20–24 in-lbs (2.3–2.7 N·m).

WARNING
Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)

6. Check operation of all lamps.

om01003
4 3
6
1. Left turn signal lamp [18]
2. Right turn signal lamp [19]
3. Rear fender tip lamp [45]
4. Tail lamp [93]
5. Rear fender lights harness [94]
68140-98
6. Opening
Figure 9-18. Rear Fender Lights Connectors

1 2

1. Lens
2. Base
3. Tail lamp connector
4. Bulb socket
Figure 9-17. Tail Lamp Assembly

94000383 9-21
 sm03625 sm03626

H-D
USA

68830-98

Figure 9-20. Place Pin Housing Over Circuit Board

REAR FENDER LIGHTS HARNESS: ALL
Figure 9-19. Use Pick Tool to Release Left Turn Signal EXCEPT FLHX, FLHXS, FLTRX, FLTRXS
Lamp Socket

Installation FASTENER TORQUE VALUE

Fender, rear, lights harness 60–96 in-lbs 6.8–10.9 N·m
1. See Figure 9-18. Feed connectors through openings in stud plate flange nuts
chrome base. For best results, feed the larger socket Tail lamp screws 20–24 in-lbs 2.3–2.7 N·m
housings first.
Removal
2. Fit bottom of chrome base into fender hole and push down.
NOTE
3. See Figure 9-20. Install pin housing/circuit board with FLHTC models use a jumper harness between the fender
screw. Tighten to 40–48 in-lbs (4.5–5.4 N·m). harness connector and the main harness connector located in
the left electrical caddy. That harness can be removed and
4. Install connectors into circuit board. installed independent of the fender harness.

5. See Figure 9-17. To avoid stressing wires, verify that tail 1. Remove rear fender. See REAR FENDER (Page 3-149).
lamp harness is positioned on the outboard side of the 2. Remove and disconnect tail lamp assembly from chrome
rear fender tip lamp and left turn signal lamp harness. base.
3. See Figure 9-18. Disconnect connector (5). Feed through
6. Install tail lamp with two screws. Tighten to 20–24 in-lbs opening to inboard side of fender.
(2.3–2.7 N·m).
4. See Figure 9-21. Release turn signal lamp wires from cable
clips (3). On FLHTCU, FLHTK models, release wire from
WARNING
stamped fender clip (4).
Be sure that all lights and switches operate properly before
5. FLHTCU, FLHTK models: Release wire from stamped
operating motorcycle. Low visibility of rider can result in
fender clip (4).
death or serious injury. (00316a)
6. Release harness from channel in stud plate (2). Loosen
7. Test tail lamp operation. flange nuts if necessary.
7. Remove adhesive conduit (1) with wire harness from
fender well.
8. If replacing only conduit (1):
a. Carefully cut adhesive conduit. Remove wire harness.
b. Remove rear connector from harness. See
CONNECTORS (Page A-1).

9-22 94000383
 e. Swab area with isopropyl alcohol. Allow to dry
sm03627
completely.

2. If replacing only the adhesive conduit:

2 a. See Figure 9-22. Verify cable strap (3) is installed as

shown to prevent rearward movement of the harness.
b. Draw harness through new conduit until progress is
halted by installed cable strap (3).

3. Install connector housing on harness. See CONNECTORS

5 (Page A-1). Refer to Table 9-8.
4. See Figure 9-21. Remove paper backing and lightly press
1 conduit in location shown in graphic.
5. Use a wallpaper seam roller to press conduit securely in
place.
7 6. Allow the adhesive 72 hours to fully cure. Installation of
the fender may proceed, but exercise caution to avoid
pulling or repositioning adhesive conduit.
7. Feed forward connector housing of harness through hole
in front of fender.

8. Capture harness in channel of stud plate (2). If loosened,

tighten flange nuts to 60–96 in-lbs (6.8–10.9 N·m).

9. Feed rear harness connectors through openings in fender

6 and capture turn signal lamp wires in cable clips (3).

10. FLHTCU, FLHTK models: Capture rear fender tip lamp

wire in stamped fender clip (4).

11. See Figure 9-18. Mate tail lamp connectors (3, 4) to tail
3 3 lamp base.

12. Verify that tail lamp harnesses are routed as shown in

Figure 9-17.
4
13. Install tail lamp. Tighten to 20–24 in-lbs (2.3–2.7 N·m).
1. Adhesive conduit
2. Stud plate
3. T-stud cable clips (2) 14. Install rear fender. See REAR FENDER (Page 3-149).
4. Stamped fender clip
5. Cable strap WARNING
6. 0.88 in. (22.4 mm) between conduit and chrome
base hole Be sure that all lights and switches operate properly before
7. 1.43 in. (36.3 mm) between conduit and fender operating motorcycle. Low visibility of rider can result in
seat screw centerline death or serious injury. (00316a)
Figure 9-21. Rear Fender Well
15. Check operation of all lamps.
Installation
Table 9-8. Rear Fender Lights [94]
1. Clean fender:
WIRE CHAMBER WIRE CHAMBER
a. Thoroughly clean fender well with soap and water. Do
COLOR NUMBER COLOR NUMBER
not use solvents or harsh chemicals that may damage
painted surfaces. O/W 1 R/Y 4
b. Remove all residual adhesive using 3M GENERAL BN 2 V 5
PURPOSE ADHESIVE REMOVER. BE 3 BK 6
c. See Figure 9-21. Using a soapy non-abrasive scouring
pad, thoroughly clean fender well in area of adhesive
conduit.
d. Rinse with clear water and thoroughly dry with a clean
white cloth. Repeat until clean cloth shows no evidence
of dirt.

94000383 9-23
 sm04757 sm05882a
3
5 2

1 4
4
2 3

6 1
6 5
7

1. Connector [7B]
2. Conduit 1. Flange nut (6)
3. Cable strap 2. Fascia
4. Adhesive conduit 3. Stud plate (2)
5. 0.25 in (6.35 mm) 4. Fender support
6. 8.75 in (222.25 mm) 5. Nut
6. P-clip
Figure 9-22. Install Cable Strap on Conduit
7. Shield
REAR FASCIA LAMP 8. Fascia lamp
Figure 9-23. Rear Fascia
FASTENER TORQUE VALUE
REAR FENDER LIGHTS HARNESS: FLHX,
Rear fascia lamp screws 18–22 in-lbs 2–2.5 N·m
FLHXS, FLTRX, FLTRXS
Removal
FASTENER TORQUE VALUE
1. See Figure 9-23. Remove shield (7) and disconnect rear Tail lamp screws 20–24 in-lbs 2.3–2.7 N·m
lights harness and tail light jumper harness from fascia
lamp.
Removal
2. Remove screws securing lamp (8).
1. Remove left saddlebag and left side cover.
Installation 2. See Figure 9-24. Cut cable strap (3).

1. See Figure 9-23. Secure lamp (8) with two screws. Tighten 3. Separate connector (2).
to 18–22 in-lbs (2–2.5 N·m). 4. See Figure 9-25. Release harness from upper clips (1).
5. Release harness from molded clips (2) on fascia.
2. Connect rear lights harness and tail lamp jumper harness
to fascia lamp. 6. Disconnect harness from fender tip lamp.
7. Note harness routing. Remove harness.
3. Install shield (7).
NOTE
Canadian models have both a turn signal light bar and tail lamp,
and include an extra jumper harness.

8. Canadian models: See Figure 9-26.

a. Remove rear fender. See REAR FENDER (Page 3-149).
b. Remove tail lamp lens.
c. Disconnect jumper harness (2) from the rear fascia lamp
and the tail lamp.
d. Release jumper harness from clamps (1, 3). Remove
from fender.

Installation
1. Canadian models: See Figure 9-26.

NOTE
Do not over-tighten screws.

a. Route jumper harness (2) from tail lamp to the fascia

lamp and connect to each lamp.

9-24 94000383
 b. Install tail lamp lens with screws. Tighten to
sm06617
20–24 in-lbs (2.3–2.7 N·m).
1
c. Secure jumper harness with clamps (1, 3). Install
fender. See REAR FENDER (Page 3-149).

2. See Figure 9-24 and Figure 9-25. Route harness in

approximate position, passing back under frame cross
member and through opening in left caddy.
2
3
3. See Figure 9-25. Secure harness:

a. Pass harness over antenna mount (3).

b. Secure harness in molded clips (2) on inside of

fascia. 1. Upper clips (3)
2. Molded clip (2)
c. Connect to fender tip lamp. 3. Antenna mount

d. Pull harness up to remove slack near fender tip lamp. Figure 9-25. Rear Fender Lamps Harness and Antenna
Cable: FLHX, FLHXS, FLTRX, FLTRXS
4. Secure harness in three upper clips (1). sm06624

5. See Figure 9-24. Pull slack from harness. Secure rear 3

lighting harness and antenna cable to left upper frame with
new cable strap (3).

6. Mate connector (2). Secure connector housing to upper 2

caddy. 4
7. Install side cover and saddlebag.
1
WARNING
Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)
1. P-clamp
8. Check operation of all lamps. 2. Jumper harness
3. Clamp, tee-stud
4. Turn signal lamps harnesses
sm06616 Figure 9-26. Tail Lamp Jumper Harness (models with tail
1 2 lamp)

1. Antenna cable connector

2. Rear lighting connector
3. Cable strap (2)
Figure 9-24. Rear Fender Lamps Harness and Antenna
Cable Routing: FLHX, FLHXS, FLTRX, FLTRXS

94000383 9-25
FENDER TIP LAMPS 9.12
FRONT FENDER TIP LAMP sm07481

FASTENER TORQUE VALUE

Fender tip lamp, front 20–25 in-lbs 2.3–2.8 N·m
Fender trim strips, front 10–15 in-lbs 1.1–1.7 N·m 3
2
Removal 1
1. Remove outer fairing and front fender. See Front Fender
(Page 3-146).
2. See Figure 9-27. Remove nuts (2) securing left fender trim
strip. Remove trim strip.
3. Remove nuts (3) securing fender tip lamp. Remove lamp
and harness assembly.
1. Fender mounting bracket
Installation 2. Nuts, trim strip
NOTE 3. Nuts, fender tip lamp
Over-tightening screws can crack the bracket or scratch the Figure 9-27. Front Fender Underside
fender paint.
sm03630
1
1. See Figure 9-27. Mount fender tip lamp. Secure with nuts 5
(3). Tighten to 20–25 in-lbs (2.3–2.8 N·m).

2. See Figure 9-28. Route harness through trim strip and into
oblong hole (5). Confirm harness routes between trim strip
and tee bolt.

3. Secure trim strip with two nuts. Tighten to 10–15 in-lbs

(1.1–1.7 N·m).

4. See Figure 9-27. Route harness between fender and

fender mounting bracket (1). 2

5. Route harness out through grommet and install connector

3
housing.
4
6. Install fender and outer fairing. See Front Fender 1. Fender tip lamp bracket
(Page 3-146). 2. Tee bolt
3. Wire conduit
4. Trim strip
WARNING
5. Oblong hole
Be sure that all lights and switches operate properly before Figure 9-28. Install Conduit in Trim Strip
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a) REAR FENDER TIP LAMP

7. Test lamp for proper operation. FASTENER TORQUE VALUE

Fender tip lamp, rear, harness 45–85 in-lbs 5.1–9.6 N·m
P-clamp locknut
Fender tip lamp, rear, screws 12–18 in-lbs 1.4–2 N·m
Tail lamp screws 20–24 in-lbs 2.3–2.7 N·m

Removal
1. Remove and disconnect tail lamp assembly from chrome
base.
2. See Figure 9-29. Disconnect rear fender tip lamp connector
[45] (2).
3. Remove harness from upper clip on inner side of fender.
4. Remove locknut, washer and P-clamp securing harness
near lamp.

9-26 94000383
5. See Figure 9-30. Remove two screws (2).
sm03634a
6. Remove fender tip lamp. 1

sm03633
2 1

2
1. Fender tip lamp
2. Screw (2)
Figure 9-30. Rear Fender Tip Lamp
WARNING
Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)
3
7. Test lamp operation.
1. Tail lamp connector [93]
2. Rear fender tip lamp connector [45]
3. Opening
Figure 9-29. Depress Button to Release Socket from Pin
Housing

Installation
1. See Figure 9-29. Route rear fender tip lamp harness
through hole at bottom of fender and back through opening
(3). Attach rear fender tip lamp connector [45] (2).

2. Secure lamp harness to upper clip on inner side of fender.

3. Secure lower portion of harness with P-clamp, washer and

locknut. Tighten to 45–85 in-lbs (5.1–9.6 N·m).

4. See Figure 9-30. Place fender tip lamp into position.

Secure with two screws (2). Tighten to 12–18 in-lbs
(1.4–2 N·m).

5. See Figure 9-29. Attach tail lamp connector [93] (1).

6. Install tail lamp with two screws. Tighten to 20–24 in-lbs

(2.3–2.7 N·m).

94000383 9-27
TOUR-PAK LIGHTS 9.13
TOUR-PAK SIDE LAMPS/TRIM STRIPS 5. Install Tour-Pak liner. See TOUR-PAK SERVICE, Tour-Pak
Liner (Page 3-105).
FASTENER TORQUE VALUE
Tour-Pak side marker lamp 20–25 in-lbs 2.3–2.8 N·m TOUR-PAK LIGHTS HARNESS
screws
FASTENER TORQUE VALUE
Removal CB antenna stud nut 14–16 in-lbs 1.6–1.8 N·m
NOTE Tour-Pak ground plate screws 20–25 in-lbs 2.3–2.8 N·m
The Tour-Pak may be equipped with either side marker lamps
or trim strips depending on model. Removal and installation Removal
are similar. 1. Remove Tour-Pak liner. See TOUR-PAK SERVICE,
Tour-Pak Liner (Page 3-105).
1. Remove Tour-Pak liner. See TOUR-PAK SERVICE,
2. Remove Tour-Pak. See TOUR-PAK (Page 3-103).
Tour-Pak Liner (Page 3-105).
3. See Figure 9-31. Remove radio antenna cable (7).
2. Remove Tour-Pak. See TOUR-PAK (Page 3-103).
4. Remove nut and ring terminal securing CB antenna cable
NOTE (8).
See Figure 9-31. Screws (3) secure both the ground plate and
marker lamp/trim strip. 5. Remove four screws (3) securing ground plate. Disconnect
two ground connectors. Remove ground plate.
3. See Figure 9-31. Remove four screws (3) securing ground 6. Disconnect side marker lamp connectors (4, 6).
plate. Disconnect two ground connectors. Remove ground
plate. 7. Disconnect power outlet connector (2).

4. Lamp equipped: 8. Push grommet with harness out toward front. Remove
Tour-Pak lights harness.
a. Disconnect side marker lamp connector (4 or 6).
b. Remove split bushing. Pull harness and connector Installation
through hole. 1. See Figure 9-31. Install rubber grommet on harness with
the split down. Position next to cable strap (1).
Installation
2. Route Tour-Pak lights harness through hole into Tour-Pak.
1. Lamp equipped: Install grommet.

a. See Figure 9-31. Feed connector through hole in 3. Place harness at bottom of Tour-Pak.
Tour-Pak and place side marker lamp into position.
4. Mate marker lamp (4, 6) and power outlet (1) connectors.
b. Install split bushing.

c. Connect side marker lamp connector (4 or 6). 5. Install ground plate with four screws (3). Tighten to
20–25 in-lbs (2.3–2.8 N·m).
2. Install ground plate with four screws (3). While holding
lamps or trim strips in position, tighten to 20–25 in-lbs 6. Connect audio radio antenna cable (7).
(2.3–2.8 N·m).
7. Install CB antenna cable (8), flat washer and nut onto stud.
3. Mate two ground connectors to ground plate. Tighten to 14–16 in-lbs (1.6–1.8 N·m).

4. Install Tour-Pak. See TOUR-PAK (Page 3-103). 8. Install Tour-Pak. See TOUR-PAK (Page 3-103).

9. Install Tour-Pak liner. See TOUR-PAK SERVICE, Tour-Pak

Liner (Page 3-105).

9-28 94000383
 sm07459

1
2

6 5 4 3
3

7 8

1. Cable strap 5. Tape

2. Power outlet connector 6. Left marker lamp connector
3. Ground plate/marker lamp screws 7. Radio antenna cable
4. Right marker lamp connector 8. CB antenna cable
Figure 9-31. Tour-Pak Harness
WRAP-AROUND LAMP (IF EQUIPPED) 4. Disconnect electrical connector (4).
5. Disconnect CB antenna cable connector if equipped.
FASTENER TORQUE VALUE
6. Remove nut (5), washer and ring terminal from CB antenna
CB antenna base set screw 14–16 in-lbs 1.6–1.8 N·m stud.
CB antenna stud nut 14–16 in-lbs 1.6–1.8 N·m
7. Remove nut (2), ring terminal and large flat washer from
Radio antenna inner set screw 14–16 in-lbs 1.6–1.8 N·m
AM/FM radio antenna stud.
Radio antenna stud nut 16–19 in-lbs 1.8–2.1 N·m
Tour-Pak wrap-around lamp 20–25 in-lbs 2.3–2.8 N·m
screws

Removal
1. Remove Tour-Pak liner. See TOUR-PAK SERVICE,
Tour-Pak Liner (Page 3-105).
2. Remove both antenna masts from lamp housing.
3. See Figure 9-32. Disconnect radio antenna cable
connector (3).

94000383 9-29
 sm07457
6. Install both antenna masts.
2
1 7. Install Tour-Pak liner. See TOUR-PAK SERVICE, Tour-Pak
3 Liner (Page 3-105).

1. Screws (8)
2. Nut, audio radio stud
3. Radio antenna cable connector
4. Electrical connector
5. Nut, CB antenna stud
Figure 9-32. Wrap-around Lamp
8. Remove eight screws (1) to free lamp assembly from
Tour-Pak.

Repair
1. Remove CB antenna stud and remove antenna base from
lamp housing.

2. Using the original nut and a 1/2 in.-20 UNF nut as a jamnut,
remove connector stud from radio antenna base.

3. Remove inner stud. Remove antenna base from lamp

housing.

4. Install radio antenna base with inner set screw. Tighten to

14–16 in-lbs (1.6–1.8 N·m).

5. Install radio antenna connector stud. Tighten securely.

Remove nuts.

6. If equipped, install CB antenna base into lamp housing

and secure with set screw. Tighten to 14–16 in-lbs
(1.6–1.8 N·m).

Installation
1. See Figure 9-32. Install lamp and secure with eight screws
(1). Tighten to 20–25 in-lbs (2.3–2.8 N·m).

2. Install electrical connector (4).

3. Install large flat washer, ring terminal and nut (2) onto
AM/FM radio antenna stud. Tighten to 16–19 in-lbs
(1.8–2.1 N·m).

4. Connect AM/FM radio antenna cable connector (3).

5. Install ring terminal, flat washer and nut (5) onto CB

antenna stud. Tighten to 14–16 in-lbs (1.6–1.8 N·m).
Connect CB antenna cable if equipped.

9-30 94000383
TURN SIGNAL LAMPS 9.14
TURN SIGNAL BULB REPLACEMENT: 3. Inspect condition of electrical contacts in socket. If
BULLET STYLE necessary, clean with a small wire brush and electrical
contact cleaner.
NOTE
4. Apply ELECTRICAL CONTACT LUBRICANT to contacts
Models with LED lamps do not contain replacement bulbs.
in socket and at bottom of new bulb.
Replace the LED assembly.

5. Align pins on new bulb with guides in bulb socket. Push

1. See Figure 9-33. Insert a coin or the blade of a small and rotate new bulb clockwise into socket.
screwdriver into the notch at the bottom of the lens cap.
Carefully twist until the lens cap pops out of the lamp
6. Secure lens (2) to lamp housing (4) with two screws (1).
housing.

2. Push bulb in and rotate counterclockwise. Pull bulb from WARNING

socket. Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
3. Inspect condition of electrical contacts in socket. If death or serious injury. (00316a)
necessary, clean with a small wire brush and electrical
contact cleaner. 7. Check operation of all lamps.

4. Apply ELECTRICAL CONTACT LUBRICANT to contacts

in socket and at bottom of new bulb. om01101
4
5. Align pins on new bulb with pin guides in bulb socket. Push
bulb in and turn clockwise to lock in place.

6. Snap lens cap onto the lamp housing with notch at bottom.

WARNING
Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in 3
death or serious injury. (00316a)

7. Check operation of all lamps. 2

1
om00343c

1. Screws (2)
2. Lens
3. Bulb
4. Lamp housing
Figure 9-34. Turn Signal Lamp Assembly: Flat Lens Style
FRONT TURN SIGNAL LAMP

FASTENER TORQUE VALUE

Turn signal lamp to fairing 60–120 in-lbs 6.8–13.6 N·m
screws: FLTRU, FLTRX,
FLTRXS
Turn signal lamp, front, 30–60 in-lbs 4.1–6.8 N·m
mounting bracket screws: Flat
Figure 9-33. Remove Lens
lens style
TURN SIGNAL BULB REPLACEMENT: FLAT Turn signal, front, lamp to 96–120 in-lbs 10.9–13.5 N·m
LENS STYLE bracket screw: Bullet Style,
auxiliary/fog lamp equipped
1. See Figure 9-34. Remove two screws (1) to release lens Turn signal, front, lamp to 15–20 ft-lbs 20.3–27.1 N·m
(2) from lamp housing (4). bracket screw: Bullet Style,
without auxiliary/fog lamps
2. While pushing bulb (3) in, rotate counterclockwise to
remove.

94000383 9-31
Removal: Flat Lens Style 7. Connect front turn signal/auxiliary/fog lamp connector.
1. See Figure 9-35. Remove headlamp assembly. See
HEADLAMP (Page 9-16). Disconnect front turn signal 8. See Figure 9-35. Secure anchor to fork stem nut lockplate.
lamps connector. Install headlamp assembly. See HEADLAMP (Page 9-16).

2. Remove terminals from connector housing. See the

WARNING
electrical diagnostic manual.
3. See Figure 9-34. Remove two screws to release turn signal Be sure that all lights and switches operate properly before
lamp from mounting bracket. operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)
NOTE
Make sure that chaser wire is of sufficient strength to pull 9. Check operation of all lamps.
terminals through conduit without breaking. Wire lengths must
also be long enough that free ends are not lost in conduit when
pulled. sm03621

4. See Figure 9-36. Obtain three equal lengths of strong

flexible wire for use as chaser wires. Securely attach a
chaser wire to terminal of each wire.
5. Carefully pull wires to draw terminals through both sections
of conduit. For best results, pull one wire at a time.
6. Remove chaser wire from terminals.

sm07537a

1 5
2

3 Figure 9-36. Fix Chaser Wire to Socket Terminal

Removal: Bullet Style, Fork-Mounted

1. Remove turn signal/auxiliary/fog lamp bracket. See
4
AUXILIARY/FOG LAMPS AND BRACKETS (Page 9-18).
2. See Figure 9-37. Remove terminals from connector
housing (4). See the electrical diagnostic manual.
1. Left handlebar switch module
2. TGS 3. Remove screw (1 or 5). Remove lamp assembly from
3. Right auxiliary/fog/turn signal lamps bracket.
4. Left auxiliary/fog/turn signal lamps
5. Caddy retainer
Figure 9-35. Left Side Connectors: Road King Models

Installation: Flat Lens Style

1. Lay old turn signal lamp next to new turn signal lamp and
cut wires to length.

2. Strip 3/16 in (4.8 mm) of insulation off wires and crimp on

new terminals. See the electrical diagnostic manual.

3. Secure chaser wires to terminals. Carefully draw terminals

back through conduit.

4. Remove chaser wires.

5. Install terminals into connector housing. See the electrical

diagnostic manual.

6. See Figure 9-34. 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
30–60 in-lbs (4.1–6.8 N·m).

9-32 94000383
 2. See Figure 9-38. Cut cable strap (6). Remove wire
sm07519
retainers (1). Release wires from hook (7).
3. Remove screw (2) and mounting plate (3). Remove gasket
1 2 3 (4) and lamp assembly (5).
4. If necessary, separate lamp from mounting bracket:
a. Remove terminals from connector housing. See the
electrical diagnostic manual.
b. Separate lamp assembly from mounting bracket.
PLACEHOLDER

sm08388
7 4

6 6

5 1

2
1. Screw 3
2. Washer 7
3. Turn signal lamp assembly, models without 4
auxiliary/fog lamps
5
4. Connector housing
5. Screw
6. Turn signal lamp assembly, models with
auxiliary/fog lamps
7. Standoff
Figure 9-37. Front Turn Signal Lamp: Fork-Mounted Fairing 1. Wire retainer (3 per side)
Models 2. Screw
3. Mounting plate
Installation: Bullet Style, Fork-Mounted 4. Gasket
5. Turn signal lamp
1. See Figure 9-37. Install lamp on mounting bracket. Tighten 6. Cable strap
to: 7. Hook on mounting plate
Figure 9-38. Front Turn Signal Lamp: Frame-Mounted
a. Models without auxiliary/fog lamps: 15–20 ft-lbs Fairing Models
(20.3–27.1 N·m).
Installation: Bullet Style, Fairing Mounted
b. Models with auxiliary/fog lamps: 96–120 in-lbs
(10.9–13.5 N·m). 1. If separated, assemble lamp to mounting bracket:

2. Install terminals into connector housing. See the electrical a. Install lamp onto mounting bracket.
diagnostic manual.
b. Install terminals into connector housing. See the
3. Install turn signal/auxiliary/fog lamp bracket. See electrical diagnostic manual.
AUXILIARY/FOG LAMPS AND BRACKETS (Page 9-18).
2. See Figure 9-38. Install mounting plate (3), gasket (4) and
lamp (5). Secure with screw (2). Tighten to 60–120 in-lbs
WARNING
(6.8–13.6 N·m).
Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in 3. Secure harness in hook (7) and route upwards.
death or serious injury. (00316a)
NOTE
4. Check operation of all lamps. Place retainers (1) within bosses molded into the inside of the
fairing.
Removal: Bullet Style, Fairing Mounted
1. Remove outer fairing. See OUTER FAIRING AND 4. Clean all residual adhesive from retainer mounting areas.
WINDSHIELD: FRAME MOUNTED FAIRING MODELS
(Page 3-127). 5. Secure with three new wire retainers (1) and cable strap
(6).

94000383 9-33
6. Install outer fairing. See OUTER FAIRING AND
sm06184
WINDSHIELD: FRAME MOUNTED FAIRING MODELS
(Page 3-127).
1
WARNING
Be sure that all lights and switches operate properly before 2
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)
3
7. Check operation of all lamps.

Lamp Repair: Bullet Style

NOTE
Models with LED lamps contain no service parts and cannot
be disassembled. 4

1. Remove reflector assembly:

a. Remove terminals from connector housing. See the
electrical diagnostic manual.
b. Separate lamp from mounting bracket.
1. Lamp terminal base
c. Remove lens and bulb.
2. Spring
d. See Figure 9-39. Use a right angle pick or a small hex 3. Rubber isolator
key through hole (4) to pull reflector from lamp. 4. Hole
e. Remove isolator (3) from lamp if still installed. Figure 9-39. Reflector Assembly
REAR TURN SIGNAL LAMP
2. Install reflector assembly:
a. See Figure 9-39. Seat reflector assembly in rubber PART NUMBER TOOL NAME
isolator (3), aligning tab on reflector with slot in isolator. FABL5 LONG SHANK BALL END SOCKET
b. Feed wires through lens opening and out through
non-threaded hole. FASTENER TORQUE VALUE
Tail lamp screws 20–24 in-lbs 2.3–2.7 N·m
c. Aligning tab on reflector with slot inside lamp, apply
even pressure around outer edge of reflector assembly Turn signal lamp to rear turn 30–50 in-lbs 3.4–5.6 N·m
until fully seated. signal lamps bracket screws

d. Liberally apply dielectric grease to contacts in socket Removal: All but FLHX, FLHXS, FLTRX, FLTRXS
and at bottom of bulb. Install bulb and lens with slot at
bottom of lamp. 1. Remove saddlebag as necessary. See SADDLEBAGS
(Page 3-98).
e. Install lamp onto mounting bracket.
2. See Figure 9-40. Remove and disconnect tail lamp
f. Install terminals into connector housing. See the assembly from chrome base.
electrical diagnostic manual.

9-34 94000383
 9. Remove terminals from connector. See the electrical
sm03653
diagnostic manual.
1 2
3
Installation: All but FLHX, FLHXS, FLTRX,
FLTRXS
1. Place new turn signal lamp assembly next to discarded
unit and cut wires to proper length.
2. Crimp new terminals onto turn signal lamp wires. Install
terminals into connector housing. See the electrical
diagnostic manual.

3. Install turn signal lamp assembly. Tighten to 30–50 in-lbs

(3.4–5.6 N·m).

4. See Figure 9-41. Route connector through channel in

bracket, then through fender hole (2).

5. Capture harness in cable clip under fender.

1. Left turn signal lamp [18] 6. Feed connector through opening (1) in chrome base.
2. Right turn signal lamp [19]
3. Tail lamp [93] 7. See Figure 9-40. Connect turn signal harness connector
Figure 9-40. Release Tail Lamp Connector (1 or 2).

sm03655
8. Connect tail lamp connector (3). Verify that tail lamp
harness is positioned outboard of the rear fender tip lamp
and left turn signal lamp harnesses.

9. Install tail lamp. Tighten to 20–24 in-lbs (2.3–2.7 N·m).

WARNING
Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)

10. Check operation of all lamps.

11. Install saddlebag.

Removal: FLHX, FLHXS, FLTRX, FLTRXS

NOTE
2 1 • This procedure covers replacement of the rear turn signal
lamp reflector/ isolator assembly only.
1. Opening • Individual LEDs cannot be replaced. Replace assembly
2. Fender hole upon failure. See Turn Signal Lamps, Rear Turn Signal
Figure 9-41. Release Turn Signal Lamp Connector Lamps Bracket (Page 9-36).
3. See Figure 9-41. Disconnect turn signal lamp connector
1. Models with tail lamp:
(2-place Multilock). Use a pick or small screwdriver to press
latch. a. Remove circuit board and chrome base. See Rear
Lighting (Page 9-21).
4. Feed connector to inboard side of rear fender.
b. Remove terminals from turn signal lamp connector
5. Release harness from cable clip inside fender.
housing. See the electrical diagnostic manual.
6. Draw out harness and connector through fender hole (2).
c. Release harness from cable clip inside fender.
7. Draw connector through channel on inboard side of rear
d. Draw harness and terminals through hole to outboard
turn signal lamp bracket, so that length of conduit hangs
side of fender. Proceed with reflector/isolator removal.
below turn signal lamp.
8. Remove two screws to release turn signal lamp assembly. 2. Models without tail lamp:
Use a LONG SHANK BALL END SOCKET (PART
a. Remove turn signal lamps bracket. See Turn Signal
NUMBER: FABL5) or equivalent through the channel in
Lamps, Rear Turn Signal Lamps Bracket (Page 9-36).
the bracket.

94000383 9-35
 b. Remove grommet from harness. 6. Place new reflector assembly next to discarded unit and
cut wires to proper length.
c. Remove license plate bracket.
7. Seat reflector assembly in rubber isolator, aligning tab on
d. Remove screws securing license plate lamp.
reflector with slot in isolator.
e. Remove terminals from connector housing. See the
8. Feed wires through lens opening and out through hole in
electrical diagnostic manual.
lamp housing.
f. Pull wires through main conduit.
9. Install grommet in lamp housing. Lubricate parts with glass
cleaner or isopropyl alcohol.
Installation: FLHX, FLHXS, FLTRX, FLTRXS 10. Align tab on reflector with slot inside lamp. Use thumbs of
1. Models with tail lamp: both hands to apply even pressure around outer edge of
reflector assembly until fully seated.
a. Install new terminals onto wires. See the electrical 11. Liberally apply dielectric grease to contacts in socket and
diagnostic manual. at bottom of bulb. Install bulb and lens with slot at bottom
of lamp.
b. Feed terminals through hole to inboard side of
fender. sm06184

c. Install terminals into connector housing. See the

1
electrical diagnostic manual.

d. Capture harness in cable clip inside fender. 2

e. Install chrome base and circuit board assembly. See
Rear Lighting (Page 9-21).
3
2. Models without tail lamp:

a. Feed wires through main conduit. Install new

terminals and install in connector housing. See the
electrical diagnostic manual.

b. Route both turn signal lamp harnesses under license 4

plate lamp area. Install license plate lamp and license
plate bracket. See Turn Signal Lamps, Rear Turn
Signal Lamps Bracket (Page 9-36).

c. Install turn signal lamps bracket. See Turn Signal

Lamps, Rear Turn Signal Lamps Bracket
(Page 9-36). 1. Lamp terminal base
2. Spring
WARNING 3. Rubber isolator
4. Hole
Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in Figure 9-42. Reflector Assembly
death or serious injury. (00316a) REAR TURN SIGNAL LAMPS BRACKET
3. Check operation of all lamps. FASTENER TORQUE VALUE
License plate bracket screws 60–90 in-lbs 6.8–10.2 N·m
Lamp Repair Turn signal lamps bracket, 84–144 in-lbs 9.5–16.3 N·m
NOTE rear, screws
LED type lamps are not serviced separately. Replace the light
bar assembly. Removal: All but FLHX, FLHXS, FLTRX, FLTRXS
1. Remove circuit board and chrome base. See Rear Lighting
1. Remove lens and bulb. (Page 9-21).
2. Push grommet into lamp housing. Lubricate parts with 2. Remove rear turn signal lamps from bracket. See Turn
glass cleaner or isopropyl alcohol. Signal Lamps, Rear Turn Signal Lamp (Page 9-34).
3. See Figure 9-42. Insert a right angle pick or a small hex 3. If equipped with license plate lamp on turn signal bracket,
key from inside the bulb socket through hole (4). Pull remove terminals from license plate lamp connector. See
reflector from lamp. in the electrical diagnostic manual.
4. Remove rubber isolator (3). 4. Remove two screws to free rear turn signal lamps bracket
from rear fender.
5. Install rubber isolator.

9-36 94000383
5. Remove two screws to free license plate bracket and lamp,
sm06624
if equipped.
3
Installation: All but FLHX, FLHXS, FLTRX,
FLTRXS
1. Install license plate bracket and lamp, if equipped, onto
turn signal bracket. Tighten to 60–90 in-lbs (6.8–10.2 N·m). 2
4
2. Apply one drop of LOCTITE 271 HIGH STRENGTH
THREADLOCKER (red) to screws.
1
3. Install rear turn signal lamps bracket. Tighten to
84–144 in-lbs (9.5–16.3 N·m).

4. If equipped with license plate lamp on turn signal bracket,

route wires through hole in fender. Install terminals into 1. P-clamp
license plate lamp connector. See the electrical diagnostic 2. Jumper harness
manual. 3. Clamp, tee-stud
4. Turn signal lamps harnesses
5. Install rear turn signal lamps in bracket. See Turn Signal
Figure 9-43. Tail Lamp Jumper Harness (models with tail
Lamps, Rear Turn Signal Lamp (Page 9-34).
lamp)

6. Install chrome base and circuit board assembly. See Rear sm06606a
Lighting (Page 9-21). 1
2
Removal: FLHX, FLHXS, FLTRX, FLTRXS
1. Models with tail lamp:
a. Remove circuit board and chrome base. See Rear
Lighting (Page 9-21).
b. See Figure 9-43. Release turn signal lamp harnesses
(4) from cable clips.
c. Remove terminals from license plate lamp connector.
See the electrical diagnostic manual.
3
2. Models without tail lamp:
a. See Figure 9-44. Disconnect turn signal connector (3)
from rear fascia lamp. 1. Grommet
2. J-clamp
b. Release harness from J-clamp (2) located above fascia
3. Connector
lamp.
Figure 9-44. Rear Turn Signal Lights Connector (models
c. Push grommet (1) rearward out of hole in fender. without tail lamp)

3. Remove two screws to release rear turn signal lamps

bracket. Remove bracket and harnesses.
4. Remove screws to release license plate bracket and lamp
from turn signal bracket.

94000383 9-37
 sm06724a

1. Grommet
2. License plate bracket screws
Figure 9-45. Rear Turn Signal Lamps and Harness (models
without tail lamp)
1
Installation: FLHX, FLHXS, FLTRX, FLTRXS
1. Install license plate lamp and bracket onto turn signal
bracket. Tighten to 60–90 in-lbs (6.8–10.2 N·m).

2. Models with tail lamp: Feed socket housings of left and

right rear turn signal lamps and license plate wire terminals
through respective holes to inboard side of fender.
2
3. Models without tail lamp:

a. See Figure 9-45. Install grommet (1) and orient as

shown. 2nd option
b. Route harness through hole in fender and seat
grommet in hole.

4. Apply one drop of LOCTITE 271 HIGH STRENGTH

THREADLOCKER (red) to screws.

5. Install rear turn signal lamps bracket. Tighten to

84–144 in-lbs (9.5–16.3 N·m).

6. Models with tail lamp:

a. Install terminals into license plate lamp connector.

See the electrical diagnostic manual.

b. Install chrome base and circuit board assembly. See

Rear Lighting (Page 9-21).

7. Models without tail lamp:

a. See Figure 9-44. Install connector (3).

b. Secure harness in J-clamp (2) and under tab on end

of fascia lamp.

9-38 94000383
IGNITION SWITCH AND FORK LOCK 9.15
FAIRING MODELS sm03679

PART NUMBER TOOL NAME

HD-51198 IGNITION SWITCH ALIGNMENT TOOL

FASTENER TORQUE VALUE

Ignition switch housing nut: 13–15 ft-lbs 17.5–20.9 N·m
Fairing models
Ignition switch housing 85–115 in-lbs 9.6–13 N·m
screws: Fairing models

Removal
1. Remove main fuse. See System Fuses and Relays
(Page 9-6).
2. Remove the ignition switch knob: Figure 9-47. Ignition Switch Alignment Tool
a. Insert the ignition switch key and turn to the UNLOCK
sm07500
position. Leave the key installed.
b. See Figure 9-46. Rotate the knob to FORK LOCK.
c. Press and hold the release button at bottom (left side)
of the knob, and turn key 60 degrees counterclockwise.
d. Lift knob to remove. Spring will drop out of bore at
underside of knob when removed.

NOTE
See Figure 9-48. Use IGNITION SWITCH ALIGNMENT TOOL
(PART NUMBER: HD-51198) to move the switch to other
positions as required. Insert tool until bottom of handle contacts
top of ignition switch. Rotate handle to the selected position.

sm03678a
Figure 9-48. Bottom Alignment Tool in Threaded Post and
Rotate to Desired Position
3. Fork mounted fairing models:
a. Remove nut and collar from ignition switch.
b. Remove dash panel. See DASH PANEL: FORK
MOUNTED FAIRING MODELS (Page 3-117).

4. Frame mounted fairing models: Remove instrument

60° bezel. See INSTRUMENT BEZEL: FRAME MOUNTED
FAIRING MODELS (Page 3-125).
5. Disconnect ignition switch connector [33].
6. Remove two screws and flat washers securing ignition
switch assembly.
7. Remove ignition switch.

Figure 9-46. Ignition Switch Knob Release Button (Top and Installation
Bottom Views)
1. Place ignition switch into position.

2. Install two screws and flat washers. Tighten to

85–115 in-lbs (9.6–13 N·m).

3. Install ignition switch connector.

94000383 9-39
4. Fork mounted fairing models:
sm03684

a. Install dash panel. See DASH PANEL: FORK

MOUNTED FAIRING MODELS (Page 3-117).

b. Install collar and nut. Tighten to 13–15 ft-lbs

(17.5–20.9 N·m).

5. Frame mounted fairing models: Install instrument bezel.

See INSTRUMENT BEZEL: FRAME MOUNTED FAIRING
MODELS (Page 3-125).

6. Place spring into bore at underside of knob.

7. Install ignition switch knob:

Figure 9-49. Rotate Alignment Tool Without Bottoming
a. See Figure 9-46. Verify that button at bottom of knob
is pressed and key is turned 60 degrees ROAD KING MODELS
counterclockwise of the UNLOCK position.
FASTENER TORQUE VALUE
b. With the knob pointing toward the FORK LOCK Fork lock screws: Road King 36–60 in-lbs 4.1–6.8 N·m
position, insert shaft into ignition switch. Ignition switch screws: Road 25–35 in-lbs 2.8–3.9 N·m
King
c. Hold the knob down and the turn key clockwise to
the UNLOCK position. An audible "click" is heard
when knob and switch are properly engaged. Remove Ignition/Light Key Switch
1. Remove main fuse. See System Fuses and Relays
d. Release the knob. Rotate through all four switch (Page 9-6).
positions to verify proper operation. If knob does not
install properly, proceed to next step. 2. Remove seat. See SEAT (Page 3-96).
3. Remove console. See FUEL TANK, Console (Page 5-7).
8. Knob was removed in the ACCESS position or switch
4. See Figure 9-50. Disconnect ignition switch connector (1).
was moved out of the FORK LOCK position:
Release ignition switch conduit from plastic clip (3), if
necessary.
a. See Figure 9-48. Insert alignment tool until bottom
of handle contacts top of ignition switch. While 5. Remove four screws (2) to release ignition switch from
holding front forks at the left fork stop, rotate handle console.
of tool counterclockwise until fork locks.
Install Ignition/Light Key Switch
b. Remove tool. Install knob.
1. See Figure 9-50. Install ignition switch with screws (2).
c. If knob does not install properly, proceed to next Tighten to 25–35 in-lbs (2.8–3.9 N·m) in a cross-wise
step. pattern.

9. Detent and switch position lugs are misaligned:
a. Insert knob into ignition switch and rotate until it
drops into the partially installed position. Take note
whether it is pointing toward the rear, or to ACCESS,
IGNITION or OFF.
2. Connect ignition connector (1). Capture ignition switch
conduit in plastic clip (3), if removed.
3. Using caution to avoid pinching wire harness and vent
tube, install console. See FUEL TANK, Console
(Page 5-7).

b. See Figure 9-49. Remove knob. Insert and hold

alignment tool so that the bottom of the handle is
approximately 0.50 –0.75 in (12.7–19.1 mm) from
the top of the ignition switch.

c. Rotate alignment tool counterclockwise the number

of positions needed to get to FORK LOCK.

d. Install knob.

10. Install main fuse. See System Fuses and Relays

(Page 9-6).

9-40 94000383
 sm03685
1

1. Ignition switch connector [33]

2. Screw (4)
3. Plastic clip
Figure 9-50. Instrument Console (Road King)
4. Install seat. See SEAT (Page 3-96).
5. Install main fuse. See System Fuses and Relays
(Page 9-6).

Remove Fork Lock

1. Remove handlebar clamp shroud. See HEADLAMP
NACELLE: ROAD KING MODELS (Page 3-144).
2. Start acorn nuts on both the left and right side fork bracket
studs to keep halves of headlamp nacelle on motorcycle.
3. See Figure 9-51. Remove two screws (with flat washers).
4. Remove fork lock assembly from upper fork bracket bore.

Install Fork Lock

1. See Figure 9-51. Position fork lock assembly into bore of
upper fork bracket.

2. Install two screws (with flat washers). Tighten to

36–60 in-lbs (4.1–6.8 N·m).

sm03686

Figure 9-51. Fork Lock (Road King)

3. Install handlebar clamp shroud. See HEADLAMP
NACELLE: ROAD KING MODELS (Page 3-144).

94000383 9-41
ACCESSORY SWITCHES 9.16
FORK-MOUNTED FAIRING MODELS sm07496

FASTENER TORQUE VALUE

2
Accessory switch module 12–17 in-lbs 1.4–1.9 N·m
screws

Removal
NOTE 1
Maximum current rating for each switch is 2A.

1. Remove dash panel. See DASH PANEL: FORK 3

MOUNTED FAIRING MODELS (Page 3-117).
1. Switch hole plug
2. See Figure 9-52. Remove two screws (3). Remove switch 2. Switch module
module (2) or hole plug (1). 3. Screws
NOTE Figure 9-52. Dash Panel Switches
• Record positions of switches and plunger types for
sm07497
assembly. 1
• The switch module assembly can house either active switch
plungers or static plungers depending on equipment. Active
plungers can be push-push type or momentary. All are
removed and installed in the same manner. 2
• See Figure 9-53. Lock (3) extracts approximately ⅛ in
(3.2 mm) and does not come free from housing.

3. Gently pry lock (3) outward to release switch plunger (2).

4. Remove switch plunger from switch module (1).

Installation 3
NOTE
Verify that switches are located as recorded during 1. Switch module
disassembly. 2. Switch plunger
3. Lock
Figure 9-53. Switch Module Components
1. See Figure 9-53. Push plunger (2) into switch module (1).
Push lock (3) into place. FRAME-MOUNTED FAIRING MODELS

2. See Figure 9-52. Secure switch module (2) to dash panel FASTENER TORQUE VALUE
with two screws (3). Tighten to 12–17 in-lbs (1.4–1.9 N·m). Accessory switch module 12–17 in-lbs 1.4–1.9 N·m
screws
3. Install dash panel. See DASH PANEL: FORK MOUNTED
FAIRING MODELS (Page 3-117). Removal

4. Operate all switches to verify repair. NOTE

Maximum current rating for each switch is 2A.

1. Remove instrument bezel. See INSTRUMENT BEZEL:

FRAME MOUNTED FAIRING MODELS (Page 3-125).
2. See Figure 9-54. Remove two screws (3). Remove switch
module or hole plug (1).
NOTE
• Record positions of switches and plunger types for
assembly.
• The switch module assembly can house either active switch
plungers or static plungers depending on equipment. Active
plungers can be push-push type or momentary. All are
removed and installed in the same manner.
• See Figure 9-53. Lock (3) extracts approximately ⅛ in
(3.2 mm) and does not come free from housing.
9-42 94000383
3. Gently pry lock (3) outward to release switch plunger (2). 2. Turn hex nut (4) against the inside of the nacelle. Tighten
to 9–15 in-lbs (1–1.7 N·m).
4. Remove switch plunger from switch module (1).

Installation 3. Install the nacelle half. See HEADLAMP NACELLE: ROAD

KING MODELS (Page 3-144).
NOTE
Verify that switches are located as recorded during 4. Operate switch to verify repair.
disassembly.
sm08220
1. See Figure 9-53. Push plunger (2) into switch module (1).
Push lock (3) into place.
1
2. See Figure 9-54. Secure switch module (1) with two screws
(3). Tighten to 12–17 in-lbs (1.4–1.9 N·m). 2

3. Install instrument bezel. See INSTRUMENT BEZEL:

FRAME MOUNTED FAIRING MODELS (Page 3-125). 4
4. Operate all switches to verify repair.

sm08375 3
2
1. Dress nut
2. Label
3. Switch
4. Hex nut
Figure 9-55. Nacelle Switch

3
1. Switch module or hole plug
2. Instrument bezel
3. Screws
Figure 9-54. Accessory Switches
NACELLE SWITCHES

FASTENER TORQUE VALUE

Nacelle switch hex nut 9–15 in-lbs 1–1.7 N·m

Removal
1. Remove the nacelle half containing the switch to be
replaced. See HEADLAMP NACELLE: ROAD KING
MODELS (Page 3-144).
2. See Figure 9-55. Remove dress nut (1).
3. Remove switch (3).

Installation
1. See Figure 9-55. Install the switch:

a. Turn hex nut (4) down against switch body.

b. Verify label (2) is in place.

c. Put the switch (3) in place.

d. Install the dress nut (1) 1.5-2.5 turns.

94000383 9-43
CRANKSHAFT POSITION SENSOR (CKP) 9.17
REMOVE sm08615

1. Remove main fuse. See System Fuses and Relays

(Page 9-6).
2. Fan equipped: See Figure 9-57. Remove lower electrical 1
cover.
a. Remove two push-in clips (1).
b. Release cover (2) from hook on frame. 2

NOTE
CKP sensor connector is fixed to front caddy at bottom of lower
frame crossmember.
3
3. Detach connector from caddy. 6
4. Separate connector.
5. See Figure 9-56. Remove screw to free CKP sensor. Pull
sensor from bore. 5 4
INSTALLATION 1. Downtube
2. Screw (2)
FASTENER TORQUE VALUE 3. Lower screw (2)
4. Oil cooler
CKP mount screw 90–120 in-lbs 10.2–13.6 N·m
5. Push-in clip (2)
6. Lower electrical cover
1. Install new O-ring on sensor if damaged. Apply a thin film
of clean engine oil to O-ring before installation. Figure 9-57. Oil Downtube Assembly

2. See Figure 9-56. Install sensor with screw.

Torque: 90–120 in-lbs (10.2–13.6 N·m) CKP mount screw

3. Route connector to front caddy at bottom of lower frame

crossmember.

4. Mate connector. Secure to caddy.

5. Mount connector to caddy T-stud.

6. Fan equipped: See Figure 9-57. Install lower electrical

cover (6) with new push-in clips (5).

7. Install main fuse. See System Fuses and Relays

(Page 9-6).

sm08579

Figure 9-56. CKP Sensor Screw

9-44 94000383
KNOCK SENSOR (KS) 9.18
PREPARE

1. Remove seat. See SEAT (Page 3-96).

2. Remove fuel tank. See FUEL TANK (Page 5-6).
REMOVE

1. See Figure 9-58. Remove screw (2).

2. Disconnect connector. Remove sensor (1).
INSTALL

FASTENER TORQUE VALUE

Knock sensor screw 13–17 ft-lbs 17.6–23 N·m

1. See Figure 9-58. Install sensor (1) with screw (2).

a. Rotate sensor housing up against head casting.

b. Tighten to 13–17 ft-lbs (17.6–23 N·m).

2. Connect connector.

sm08568

1
2

1. Knock sensor
2. Screw
3. Head temperature sensor (rear head only)
Figure 9-58. Cylinder Head Sensors
COMPLETE

1. Install fuel tank. See FUEL TANK (Page 5-6).

2. Install seat. See SEAT (Page 3-96).

94000383 9-45
ENGINE TEMPERATURE SENSOR (ET) 9.19
PREPARE

1. Remove seat. See SEAT (Page 3-96).

2. Remove fuel tank. See FUEL TANK (Page 5-6).
3. Remove induction module. See INDUCTION MODULE
(Page 5-17).
REMOVE

1. See Figure 9-59. Disconnect connector.

2. Remove sensor (3) from rear cylinder head.
INSTALL

FASTENER TORQUE VALUE

Engine temperature sensor 132–188 in-lbs 14.9–21.2 N·m

1. See Figure 9-59. Install sensor (3). Tighten to

132–188 in-lbs (14.9–21.2 N·m).

2. Connect connector.

sm08568

1
2

1. Knock sensor
2. Screw
3. Head temperature sensor (rear head only)
Figure 9-59. Cylinder Head Sensors
COMPLETE

1. Install induction module. See INDUCTION MODULE

(Page 5-17).
2. Install fuel tank. See FUEL TANK (Page 5-6).
3. Install seat. See SEAT (Page 3-96).

9-46 94000383
ENGINE COOLANT TEMPERATURE SENSOR (ECT) 9.20
COOLANT TEMPERATURE SENSOR

FASTENER TORQUE VALUE

Temperature sensor, radiator 17.7–19.2 ft-lbs 24–26 N·m

Remove
1. Drain coolant. See Coolant, Drain and Fill Cooling System
(Page 2-20).
2. Disassemble left lower fairing. See COOLING SYSTEM
REPAIR, COOLING FAN (Page 6-10).
NOTE
Hold hex on radiator while removing and installing sensor.

3. See Figure 9-60. Remove sensor from bottom of left

radiator.

Install
1. Used sensor: Apply LOCTITE 565 THREAD SEALANT
to sensor. Avoid getting sealant on sensor probe.

2. Install sensor. Tighten to 17.7–19.2 ft-lbs (24–26 N·m).

3. Assemble left lower fairing. See COOLING SYSTEM

REPAIR, COOLING FAN (Page 6-10).

4. Install main fuse.

5. Fill and bleed coolant system. See Coolant, Drain and Fill
Cooling System (Page 2-20).

sm08627

Figure 9-60. ECT Sensor

94000383 9-47
AUTOMATIC COMPRESSION RELEASE (ACR) 9.21
PREPARE 6. Connect the ACR connector.

1. Remove fuel tank. See FUEL TANK (Page 5-6). ed01626

2. Remove upper rocker cover. See UPPER ROCKER

COVERS (Page 4-30).
REMOVE
1. Separate the ACR connector from the main wiring harness.
2. See Figure 9-64. Remove the ACR using HD-48498-B
(ACR SOLENOID SOCKET).

sm08625

Figure 9-62. Bottom Third

ed01627

Figure 9-61. ACR and Cylinder Head

INSTALL

FASTENER TORQUE VALUE Figure 9-63. Three Dots of LOCTITE 246 MEDIUM
ACR 16–19.5 ft-lbs 23–26.4 N·m STRENGTH/HIGH TEMPERATURE THREADLOCKER (blue)

1. If installing a new ACR, verify that the old copper seal sm06232

washer has been removed from the cylinder head.

2. Verify that the copper seal washer is in place on the ACR.

3. See Figure 9-62. Apply threadlocker.

a. Identify a location around the threads of the ACR

approximately one-third of distance from end.

b. See Figure 9-63. Apply three equally spaced dots of

LOCTITE 246 MEDIUM STRENGTH/HIGH
TEMPERATURE THREADLOCKER (blue) on
threads.

4. Install by hand and tighten finger-tight. Figure 9-64. ACR Solenoid Socket and ACR
COMPLETE
5. See Figure 9-64. Using HD-48498-B (ACR SOLENOID
SOCKET), tighten to 16–19.5 ft-lbs (23–26.4 N·m). 1. Install upper rocker cover. See UPPER ROCKER COVERS
(Page 4-30).

9-48 94000383
2. Install fuel tank. See FUEL TANK (Page 5-6).

94000383 9-49
VOLTAGE REGULATOR 9.22
PREPARE FASTENER TORQUE VALUE
Voltage regulator screws 96–120 in-lbs 10.8–13.6 N·m
1. Remove main fuse. See System Fuses and Relays
(Page 9-6). 1. See Figure 9-65. Install voltage regulator.

REMOVE a. Apply silicone-based dielectric grease to voltage

regulator connector.
1. Release downtube assembly.
a. Remove lower cover. b. Pull downtube assembly away from frame to access
screws securing voltage regulator.
b. Release locking latch. Disconnect stator connector from
regulator. c. Install voltage regulator with screws (1). Tighten to
c. See Figure 9-65. Remove screws (2, 3) securing coolant 96–120 in-lbs (10.8–13.6 N·m).
downtubes.
d. Install voltage regulator connector. Secure connector
d. Disconnect upper hoses from downtubes. with locking latch.
e. Pull top of downtube assembly away from frame to gain
e. Secure voltage regulator cable with anchored cable
access to screws and connector.
clip (4).
2. Remove regulator.
2. Secure downtube assembly.
a. Release voltage regulator cable from anchored cable
clip (4).
a. Install upper screws (2). Tighten to 20–22 ft-lbs
b. Release locking latch. Disconnect voltage regulator (27.1–29.8 N·m).
connector.
b. Install lower screws (3). Tighten to 90–110 in-lbs
c. Remove screws (1). (10.2–12.4 N·m).
d. Remove regulator from downtube assembly.
c. Apply silicone-based dielectric grease to stator
INSTALL connector.

d. Connect stator connector. Secure connector with

FASTENER TORQUE VALUE locking latch.
Coolant downtube lower 90–110 in-lbs 10.2–12.4 N·m
screws e. Install lower cover.
Coolant downtube upper 20–22 ft-lbs 27.1–29.8 N·m
screws

sm08626
1 1

2 2

4 4

3 3

1. Voltage regulator screws (4) 3. Lower screw (2)

2. Upper screw (2) 4. Anchored cable clip
Figure 9-65. Voltage Regulator (Typical)

9-50 94000383
COMPLETE
1. Install main fuse. See System Fuses and Relays
(Page 9-6).
2. Air-Cooled: Perform hot oil check. See ENGINE OIL AND
FILTER (Page 2-15).
3. Twin-Cooled: Check coolant level after first heat and cool
cycle. See Coolant (Page 2-19).
4. Verify charging system operation.

94000383 9-51
ALTERNATOR 9.23
PREPARE sm08599 5
3
1. Remove seat. See SEAT (Page 3-96).

WARNING 1
To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (-) battery 4 2
cable before proceeding. (00048a)

2. Disconnect negative battery cable from battery. See Battery

Maintenance (Page 2-51).

3. Remove primary chaincase housing. See PRIMARY

CHAINCASE HOUSING (Page 7-9).
1. Stator
2. Screw (3)
REMOVE 3. Grommet
4. Rotor
1. See Figure 9-66. Disconnect stator connector (5) from 5. Connector [47B]
voltage regulator. Figure 9-66. Rotor and Stator

CAUTION sm03469

The high-output rotor contains powerful magnets. Exercise 4

caution to prevent possible hand injury during removal 2
and installation. (00558b)

2. Remove alternator rotor (4) using HD-52073 (Alternator

Rotor Remover and Installer).

NOTE
The rubber molded stator connector (5) is not serviceable. 3
1
3. Cut anchored cable strap securing stator wiring to frame.

4. Remove screws (2) to free stator (1) from crankcase.

Discard screws.

5. See Figure 9-67. Remove grommet (2).

1. Awl
a. Use the end of an awl (1) or small screwdriver to 2. Grommet
move grommet (2) away from crankcase. 3. Stator
Figure 9-67. Remove Grommet From Crankcase (Typical)
b. Squirt isopropyl alcohol or glass cleaner into opening.
CLEANING AND INSPECTION
c. Repeat this step at one or two other locations around
grommet. 1. Check inside of rotor and remove any metal fragments
captured by magnets.
d. Push on the grommet from outside of crankcase
while pulling through the bore with needle nose 2. Clean the rotor using a petroleum solvent. Clean the stator
pliers. Do not pull on the wires unless the stator will and grommet by wiping it with a clean cloth.
be replaced. INSTALL
6. Draw harness and connector through crankcase bore as
FASTENER TORQUE VALUE
stator is removed.
Stator mounting screws 55–75 in-lbs 6.2–8.5 N·m

1. Install grommet.

a. Feed connector and harness through hole from inside

crankcase.

9-52 94000383
 b. Lubricate parts with glass cleaner or isopropyl 1. Install primary chaincase housing. See PRIMARY
alcohol. Ribs of grommet must be clean and free of CHAINCASE HOUSING (Page 7-9).
dirt and oily residue.
2. Connect negative battery cable. Tighten bolt to
c. Push grommet into crankcase bore while carefully 60–70 in-lbs (6.8–7.9 N·m).
pulling on outside cable.
3. Install seat. See SEAT (Page 3-96).
NOTE
Do not reuse stator mounting screws.

d. Installation is complete when cable stop contacts

casting and capped rib of grommet exits crankcase
bore.

2. Secure stator to crankcase using new screws. Tighten to

55–75 in-lbs (6.2–8.5 N·m).

3. See Figure 9-68. Secure stator wiring (2) to frame with

new anchored cable strap (1). Verify that stator wire does
not contact the engine.

4. Apply silicone based dielectric grease to connector.

NOTE
Install rotor slowly to prevent damaging rotor magnets.
Damaged magnet fragments can damage the stator.

5. Install connector to voltage regulator. Engage locking latch.

CAUTION
The high-output rotor contains powerful magnets. Exercise
caution to prevent possible hand injury during removal
and installation. (00558b)

6. Install rotor HD-52073 (Alternator Rotor Remover and

Installer).

sm06181a

2
1

1. Anchored cable strap

2. Stator wiring
Figure 9-68. Stator Wiring
COMPLETE

FASTENER TORQUE VALUE

Battery terminal bolt 60–70 in-lbs 6.8–7.9 N·m

94000383 9-53
VEHICLE SPEED SENSOR (VSS) 9.24
VSS

FASTENER TORQUE VALUE

VSS fastener 100–120 in-lbs 11.3–13.6 N·m

Removal
1. Remove starter. See STARTER (Page 9-15).
2. See Figure 9-69. Disconnect VSS connector.
3. Remove screw and pull sensor from transmission case.

Installation
1. Inspect VSS O-ring damage. Replace as necessary.

2. Insert sensor into transmission case with screw. Tighten

to 100–120 in-lbs (11.3–13.6 N·m).

3. Connect VSS connector.

4. Install starter. See STARTER (Page 9-15).

sm08708

Figure 9-69. VSS

9-54 94000383
WHEEL SPEED SENSORS 9.25
FRONT WHEEL SPEED SENSOR (WSS) sm04204a

Removal
NOTE
• Always keep the wheel speed sensor (WSS) and ABS
encoder bearing away from magnetic fields. Items such as 2
magnetic parts trays, magnetic base dial indicators,
alternator rotors, etc. will damage sensor. 1
• Never pull WSS cable taut or use to retain wheel, axle or
other components.

1. Fairing models: Remove outer fairing. See OUTER

FAIRING AND WINDSHIELD: FORK MOUNTED FAIRING
MODELS (Page 3-115).
2. See Figure 9-70. Separate sensor connector (2).
a. FLH models: Remove sensor cable from retainer (1)
on caddy.
b. FLT models: Cut cable strap (2) securing sensor cable 1. Push lip to disengage
to brake line. 2. Push tab to engage
Figure 9-71. Front Wheel Speed Sensor Cable Clip
3. Release sensor cable from retainers and cut cable straps
securing cable to brake hoses.
Installation
4. See Figure 9-71. Release sensor cable from clip at caliper:
NOTE
a. Push on lip (1) at rear of clip to disengage from bracket. Install WSS with index pin on the outboard side.
Rotate tab (2) (stamped ABS) rearward until clip is
perpendicular to bracket and remove cable. 1. Push axle through new front WSS and left fork slider.
b. Rotate tab (2) forward until clip is aligned with bracket 2. Secure front wheel. See FRONT WHEEL (Page 3-15).
and apply pressure to tab until lip (1) engages. Rotate WSS until it makes contact with fork slider. Back
off just enough to maintain clearance between the WSS
5. Retract axle until front WSS is free. See FRONT WHEEL wire stem and fork slider.
(Page 3-15).
3. Route sensor cable up to lower fork bracket following brake
NOTE hose.
The WSS works in conjunction with the ABS encoder bearing
installed in the wheel hub. If necessary, see SEALED WHEEL 4. Route connector up through opening in lower fork bracket.
BEARINGS (Page 3-33) for bearing removal and installation 5. FLT models: Route cable between the upper and lower
instructions. legs of inner fairing mounting bracket to the right steering
head caddy.
sm08504 6. See Figure 9-70. Continue to right steering head caddy.
1 Mate connector.
a. FLH models: Secure connector on retainer (1) on
caddy.
b. FLT models: Secure sensor cable to brake line just
below the caddy with new cable strap (2).

7. Secure the sensor cable and fender tip lamp wires using
three new cable straps:
2
a. On the brake hose lower crimp capturing WSS cable
and brake hose.
b. Midway between the upper and lower brake hose crimps
capturing WSS cable, brake hose and front fender tip
1. Retainer, FLH models lamp wires, if equipped.
2. Cable strap, FLT models c. On upper crimp capturing WSS cable, brake hose and
Figure 9-70. Front WSS Connector front fender tip lamp wires, if equipped.

94000383 9-55
8. See Figure 9-71. Install WSS cable in retaining clip: 7. Install right saddlebag. See SADDLEBAGS (Page 3-98).
a. Push on lip (1) at rear of retaining clip to disengage
sm04028
from bracket. Rotate tab (2) (stamped ABS) rearward
until retaining clip is perpendicular to bracket. Install
cable.
b. Rotate tab (2) forward and apply pressure until lip (1)
engages. Gently tug on cable to verify that retaining clip
is properly installed.

9. Fairing models: Capture WSS cable to three retainers

on brake hoses near steering head. Install outer fairing.
See OUTER FAIRING AND WINDSHIELD: FORK
MOUNTED FAIRING MODELS (Page 3-115).
REAR WHEEL SPEED SENSOR

Removal
NOTE Figure 9-72. Rear Wheel Speed Sensor Index Pin
• Always keep the wheel speed sensor (WSS) and ABS
encoder bearing away from magnetic fields. Items such as
magnetic parts trays, magnetic base dial indicators,
alternator rotors, etc. will damage sensor.
• Never pull WSS cable taut or use to retain wheel, axle or
other components.

1. Remove right saddlebag. See SADDLEBAGS (Page 3-98).

2. Remove right side cover.
3. Release rear WSS connector from anchor on right side
caddy. Disconnect connector.
4. Release rear WSS cable from two cable retainers and
conduit clip secured to the brake hose.
5. Retract axle until rear WSS is free. See REAR WHEEL
(Page 3-18).
NOTE
The WSS works in conjunction with the ABS encoder bearing
installed in the wheel hub. If necessary, see SEALED WHEEL
BEARINGS (Page 3-33) for bearing removal and installation
instructions.

Installation
NOTE
Install WSS with index pin on the outboard side.

1. See Figure 9-72. Hold new rear WSS in place with index
pin outboard toward rear fork, and push axle through
sensor, caliper bracket and right side of rear fork.
2. Secure rear wheel. See REAR WHEEL (Page 3-18).
Rotate rear WSS until index pin makes contact with caliper
bracket at point shown in Figure 9-72.
3. Route rear WSS cable forward along top of rear fork.
4. Capture rear WSS cable and brake hose in cable retainers
on top of rear fork. Secure cable to brake hose with conduit
clip placed 1.25 in (31.8 mm) ahead of the rear brake
hose crimp.
5. Route cable to outboard side of right side caddy. Mate
connectors and secure to anchor.
6. Install right side cover.

9-56 94000383
NEUTRAL SWITCH 9.26
REMOVAL
1. Place transmission in NEUTRAL.
2. See Figure 9-73. Remove two elbow connectors from
neutral switch posts.
3. Remove neutral switch from transmission case.
INSTALLATION

FASTENER TORQUE VALUE

Neutral switch 120–180 in-lbs 13.6–20.3 N·m

1. See Figure 9-73. Inspect O-ring for damage. Replace as

necessary. Lightly lubricate new O-ring with clean
transmission oil before installation.

2. Verify that transmission is in NEUTRAL.

NOTE
The neutral switch is not polarity sensitive. Install connectors
on either post.

3. Install neutral switch in transmission case. Tighten to

120–180 in-lbs (13.6–20.3 N·m).

4. Install both connectors onto neutral switch posts.

5. Verify proper operation of neutral switch.

a. Turn ignition/light key switch to IGNITION.

b. Verify that neutral indicator light illuminates.

sm08709

Figure 9-73. Neutral Switch

94000383 9-57
OIL PRESSURE SWITCH 9.27
REMOVAL

1. See Figure 9-74. Remove connector from oil pressure

sender (2).
2. Remove sender from crankcase.
INSTALL

FASTENER TORQUE VALUE

Oil pressure sender 13–17 ft-lbs 17.6–23 N·m

NOTE
If reusing oil pressure sender, apply LOCTITE 565 THREAD
SEALANT to threads.

NOTE
Make sure that harness is routed inside front downtube.

1. See Figure 9-74. Start oil pressure sender (2) into

crankcase bore. Tighten to 13–17 ft-lbs (17.6–23 N·m).

2. Connect harness.

3. Test oil pressure sender for proper operation. Check for

leaks.

sm06058a

1. Rear master cylinder

2. Oil pressure sender
Figure 9-74. Oil Pressure Sender

9-58 94000383
STOP LAMP SWITCHES 9.28
FRONT STOP LAMP SWITCH sm08600

Removal/Installation 2
1 3
See HANDLEBAR SWITCH PACKS (Page 9-94).

REAR STOP LAMP SWITCH

FASTENER TORQUE VALUE

Stop lamp switch, rear 12–15 ft-lbs 16.3–20.3 N·m

Remove
• If DOT 4 brake fluid contacts painted surfaces,
IMMEDIATELY flush area with clear water.
1. See Figure 9-75. Remove rear brake master cylinder from
frame. Do not disconnect brake line. See REAR BRAKE 1. Wire terminals
MASTER CYLINDER (Page 3-44). 2. Stop lamp switch
3. Brake line fitting
2. Disconnect stop lamp switch connectors from terminals
Figure 9-75. Rear Stop Lamp Switch
(1).
NOTE
Wrap banjo fittings with pieces of lint-free shop towel to absorb
any loss of brake fluid.

3. Hold brake line fitting (3) and remove rear stop lamp switch
(2).

Install
1. Apply LOCTITE 565 THREAD SEALANT to rear stop lamp
switch.

2. See Figure 9-75. Install rear stop lamp switch (2) into rear
brake line fitting (3).

3. Hold brake line fitting and tighten to 12–15 ft-lbs

(16.3–20.3 N·m).

4. Install rear brake master cylinder. See REAR BRAKE

MASTER CYLINDER (Page 3-44).

a. Connect stop lamp switch connectors to terminals

(1).

b. Confirm oil switch/sender wires are inboard of rubber

mount.

5. Bleed brake system. See REAR BRAKE MASTER

CYLINDER (Page 3-44).

WARNING
Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)

6. Verify tail lamp and stop lamp operation.

94000383 9-59
HORN 9.29
REMOVAL b. Install in bracket (9). Tighten to 120–180 in-lbs
(13.6–20.3 N·m).
1. See Figure 9-76. Remove acorn nut (4) and flat washer
(5) to free horn assembly from rubber mount (7) stud. 3. Install bracket (6). Tighten to 35–55 in-lbs (3.9–6.2 N·m).

2. Remove terminal contacts and release harness from

J-clamp (11).
NOTE
Over-tightening the flange nut can cause permanent horn
3. Remove flange nut (12) (metric) from back of horn bracket. damage resulting in reduced volume and tone quality.
Remove horn (1) from chrome horn cover (2).
4. If necessary, remove two screws and washers (8) securing 4. Fit horn (1) into chrome cover (2). Apply two drops of
horn bracket (9) to cylinder heads. LOCTITE 222 LOW STRENGTH THREADLOCKER AND
SEALANT (purple) to horn stud.
INSTALLATION
NOTE
FASTENER TORQUE VALUE
The horn is not polarity sensitive. Attach terminals to either
Horn bracket acorn nut 80–120 in-lbs 9–13.6 N·m
spade contact.
Horn bracket to cylinder head 35–40 ft-lbs 47.5–54.2 N·m
screws
5. Install flange nut (12). Tighten to 80–100 in-lbs
Horn cover to bracket 35–55 in-lbs 3.9–6.2 N·m
(9–11.3 N·m).
Horn rubber mount 120–180 in-lbs 13.6–20.3 N·m
Horn stud flange nut 80–100 in-lbs 9–11.3 N·m 6. Attach terminals.

1. See Figure 9-76. If removed, install horn bracket to cylinder

7. Install horn bracket (6) onto rubber mount with flat washer
heads with two screws (8) and washers. Tighten to
(5) and acorn nut (4). Tighten to 80–120 in-lbs
35–40 ft-lbs (47.5–54.2 N·m).
(9–13.6 N·m).

2. Install mount (7) if removed:

a. Apply LOCTITE 271 HIGH STRENGTH

THREADLOCKER (red) to mount stud.

9-60 94000383
 sm07598

8
9

7
6
5
4
3

2
10

11
1

12

1. Horn 7. Rubber mount

2. Cover 8. Screw (2)
3. Push nut (2) 9. Mounting bracket
4. Acorn nut 10. Screw (2)
5. Washer 11. J-clamp
6. Bracket 12. Flange nut
Figure 9-76. Horn

94000383 9-61
FAIRING POWER OUTLET 9.30
REMOVAL

NOTE
Do not use the power outlet as a cigarette lighter. Damage to
the socket may occur.

1. Remove outer fairing. See OUTER FAIRING AND

WINDSHIELD: FORK MOUNTED FAIRING MODELS
(Page 3-115).
2. Disconnect power outlet connector.
3. Hold socket and loosen outer shell. Remove socket and
outer shell from inner fairing.
INSTALLATION
1. Slide socket of power outlet through bore in fairing. Install
outer shell and tighten securely.
2. Install power connector.
3. Install outer fairing. See OUTER FAIRING AND
WINDSHIELD: FORK MOUNTED FAIRING MODELS
(Page 3-115).

9-62 94000383
GAUGES AND INSTRUMENTS: FAIRING MODELS 9.31
AMBIENT AIR TEMPERATURE SENSOR 2. Install gauge in inner fairing. Secure with screws (1).
Tighten to 8–15 in-lbs (0.9–1.7 N·m).
NOTE
3. Attach electrical connector.
See Figure 9-77. The sensor is located at the left steering head
caddy on all radio-equipped models.
4. Fork mounted fairing: Install upper fairing support. See
INNER FAIRING: FORK MOUNTED FAIRING MODELS,
1. Separate the connector.
Upper Support Bracket (Page 3-122).
2. Release the sensor pins from the caddy to remove the
sensor. 5. Install fairing vent. See INNER FAIRING: FORK
3. Install the new sensor. Mate the connector. MOUNTED FAIRING MODELS, Fairing Vent (Page 3-121)
or INNER FAIRING: FRAME MOUNTED FAIRING
sm08387
MODELS, Removal (Page 3-131).

6. Install outer fairing. See OUTER FAIRING AND

WINDSHIELD: FORK MOUNTED FAIRING MODELS
(Page 3-115) or OUTER FAIRING AND WINDSHIELD:
FRAME MOUNTED FAIRING MODELS (Page 3-127).

sm07506
5
4
3
2
1
Figure 9-77. Ambient Air Temperature Sensor (FLHTK
shown)
2-INCH DIAMETER GAUGES

FASTENER TORQUE VALUE 1. Screw (3)

Gauges, 2 inch diameter 8–15 in-lbs 0.9–1.7 N·m 2. Icon
gauge screws 3. Back clamp
4. 2-inch gauge
Removal 5. Bezel
Figure 9-78. 2-Inch Gauge
1. Remove outer fairing. See OUTER FAIRING AND
WINDSHIELD: FORK MOUNTED FAIRING MODELS SPEEDOMETER/TACHOMETER
(Page 3-115) or OUTER FAIRING AND WINDSHIELD: INSTRUMENT CLUSTER: FORK-MOUNTED
FRAME MOUNTED FAIRING MODELS (Page 3-127). FAIRING
2. Remove fairing vent. See INNER FAIRING: FORK
MOUNTED FAIRING MODELS, Fairing Vent (Page 3-121) FASTENER TORQUE VALUE
or INNER FAIRING: FRAME MOUNTED FAIRING Gauges, instrument cluster 10–20 in-lbs 1.1–2.3 N·m
MODELS, Removal (Page 3-131). screws
3. Fork mounted fairing: Remove upper fairing support.
See INNER FAIRING: FORK MOUNTED FAIRING Removal
MODELS, Upper Support Bracket (Page 3-122). 1. Remove outer fairing. See OUTER FAIRING AND
4. Disconnect electrical connector. WINDSHIELD: FORK MOUNTED FAIRING MODELS
(Page 3-115).
5. See Figure 9-78. Remove screws (1). Remove back clamp
(3), gauge (4) and bezel (5). 2. Remove fairing vent. See INNER FAIRING: FORK
MOUNTED FAIRING MODELS, Fairing Vent (Page 3-121).
Installation 3. Remove upper fairing support. See INNER FAIRING:
NOTE FORK MOUNTED FAIRING MODELS, Upper Support
Bracket (Page 3-122).
See Figure 9-78. Fuel and battery icons (2) are cast into the
back clamp and inner fairing near each gauge opening to 4. Disconnect electrical connector.
identify correct location. The voltmeter is always mounted on
5. See Figure 9-79. Remove screws (1). Remove instrument
the right side and uses the tan back clamp. The fuel gauge is
cluster (2) and bezels (3).
always mounted on the left side and uses the black back clamp.

1. Assemble gauge (4), back clamp (3) and bezel (5).

94000383 9-63
Installation 3. Install instrument bezel assembly. See INSTRUMENT
BEZEL: FRAME MOUNTED FAIRING MODELS
1. See Figure 9-79. Carefully align bezels (3) in openings. (Page 3-125).

2. Install instrument cluster (2) in inner fairing. Secure with

sm08376
screws (1). Tighten to 10–20 in-lbs (1.1–2.3 N·m). 1
2
3. Attach electrical connector.

4. Install upper fairing support. See INNER FAIRING: FORK

MOUNTED FAIRING MODELS, Upper Support Bracket
(Page 3-122).

5. Install outer fairing. See OUTER FAIRING AND

WINDSHIELD: FORK MOUNTED FAIRING MODELS
(Page 3-115).

3
sm07507
2
3 1. Gauge bezel (2)
2. Instrument cluster
3. Screws (3)
Figure 9-80. Instrument Cluster

1. Screw (2)
2. Instrument cluster
3. Bezel
Figure 9-79. Instrument Cluster
SPEEDOMETER/TACHOMETER
INSTRUMENT CLUSTER: FRAME MOUNTED
FAIRING

FASTENER TORQUE VALUE

Gauges, instrument cluster 12–17 in-lbs 1.4–1.9 N·m
screws: frame mounted fairing
models

Removal
1. Remove instrument bezel assembly. See INSTRUMENT
BEZEL: FRAME MOUNTED FAIRING MODELS
(Page 3-125).
2. See Figure 9-80. Remove screws (3). Remove instrument
cluster (2) and bezels (1).

Installation
1. See Figure 9-80. Carefully align instrument bezels (1) in
openings.

2. Install instrument cluster (2). Secure with screws (3).

Tighten to 12–17 in-lbs (1.4–1.9 N·m).

9-64 94000383
GAUGES AND INSTRUMENTS: ROAD KING MODELS 9.32
FUEL GAUGE 6. Route connector forward and then inboard between front
of crossover hose fitting and bottom of fuel tank. Mate fuel
gauge connector and push into tunnel of fuel tank.
Removal
7. Install main fuse. See System Fuses and Relays
1. Remove main fuse. See System Fuses and Relays (Page 9-6).
(Page 9-6).
sm02975
2. Draw fuel gauge connector out of tunnel under left side of
fuel tank and disconnect.
3. Remove terminals from connector housing. See the
electrical diagnostic manual.
4. Remove convoluted tubing from wires.
5. Remove the gauge from the fuel tank. Do not twist during
removal. Pull upward just far enough to free the gauge
from the fuel tank.
6. Remove fuel gauge from motorcycle while feeding wires
and terminals up through tube.
7. If reusing gauge, inspect rubber gasket for damage.
Replace gasket if necessary. Install new seal with flat side
contacting edge of gauge.

Installation
1. Place new fuel gauge assembly next to discarded unit and
cut wires to proper length. Figure 9-81. Fuel Gauge (FLHR/C)

2. Crimp new pin terminals onto wires. See the electrical

SPEEDOMETER
diagnostic manual.
3. Install gauge: Removal
a. Feed wires down into tube while lowering gauge into 1. Remove main fuse. See System Fuses and Relays
position. (Page 9-6).

b. When terminals exit bottom of fuel tank, gently pull wires 2. Remove seat. See SEAT (Page 3-96).
while lowering the fuel gauge. 3. Remove console. See FUEL TANK, Console (Page 5-7).
NOTE 4. See Figure 9-82. Remove speedometer connector (7).
Do not twist the gauge during installation.
5. Remove anchored cable strap (4) from speedometer.

c. Hold the gauge firmly and press downward until it snaps 6. Gently pry three latches (5) upward to release lock ring
in place. (6) from back of speedometer.
7. Remove speedometer (8) from top side of console.
4. Install convoluted tubing on wires.
8. Remove rubber gasket from speedometer bore.
5. See Figure 9-81. Install terminals into connector housing.
See the electrical diagnostic manual.

94000383 9-65
 sm02977

7 6 5 4
3 2 1

1
8

1. Metal clip (3) 5. Latch (1 of 3)

2. Ignition switch connector [33] 6. Lock ring
3. Indicator lamp assembly 7. Speedometer connector [39]
4. Anchored cable strap 8. Speedometer
Figure 9-82. Instrument Console Assembly (FLHR/C)

Installation
1. Lubricate groove in rubber gasket with isopropyl alcohol
or glass cleaner. Place the gasket into position around the
console speedometer bore.
2. Install speedometer into rubber gasket. Lubricate gasket
with isopropyl alcohol or glass cleaner, if necessary. The
speedometer should fit snugly against the gasket without
movement.
3. See Figure 9-82. Place lock ring (6) over back of
speedometer aligning two slots with console bosses. Press
latches (5) down until they lock into position.
4. Connect speedometer connector (7).
5. Insert anchored cable strap (4).
NOTE
Avoid pinching wire harness and vent tube while installing
console.

6. Install console. See FUEL TANK, Console (Page 5-7).

7. Install seat. See SEAT (Page 3-96).
8. Install main fuse. See System Fuses and Relays
(Page 9-6).

9-66 94000383
INDICATOR LAMPS: ROAD KING MODELS 9.33
INDICATOR LAMPS NOTE
Avoid pinching wire harness and vent tube while installing
console.
Removal
NOTE 3. Install console. See FUEL TANK, Console (Page 5-7).
• Indicator lamps are Light Emitting Diodes (LEDs). Replace 4. Install seat. See SEAT (Page 3-96).
the entire assembly if an LED fails.
5. Install main fuse. See System Fuses and Relays
• Indicator lamp assembly is part of the console harness (Page 9-6).
assembly and not serviced separately.

1. Remove main fuse. See System Fuses and Relays

(Page 9-6).
2. Remove seat. See SEAT (Page 3-96).
3. Remove console. See FUEL TANK, Console (Page 5-7).
4. See Figure 9-83. Disconnect ignition switch connector (3)
and speedometer connector (1).
5. Free harness from metal clips.
6. Remove indicator lamp assembly from console:
a. Insert the blade of a large screwdriver under rear corner
of indicator lamp assembly.
b. Squeeze front and rear paddles (2) on same side of
assembly while rotating screwdriver.
c. When one side of assembly becomes free, repeat
procedure on opposite side to release unit from console.

Installation
1. See Figure 9-83. Install indicator lamp assembly into
console:
a. Place assembly into position in console. Engage four
paddles (2) in slots of indicator lamp assembly.
b. While pushing down on assembly, push up on lens on
outboard side of console until assembly fits snugly.

sm02978
1 2
3

1. Speedometer connector
2. Paddles
3. Ignition switch connector
Figure 9-83. Release Paddles to Free Indicator Lamp As-
sembly (FLHR/C)
2. Mate speedometer connector (1) and ignition switch
connector (3). Secure harness under metal clips to capture
harness.

94000383 9-67
BOOM! BOX INFOTAINMENT SYSTEM 9.34
RADIO FACE PROTECTIVE FILM 8. XM equipped:
a. Remove screws securing XM module in radio frame.
Replacement b. Transfer XM module into new radio immediately. If new
The touch screen on the radio is covered by a protective film. radio is not available, place XM module in a static proof
The film can wear in time and require replacement. bag and store in a safe place.
Replacement instructions are included in the film replacement c. Tighten screw securely.
kit. Screen damage due to using the radio without a protector
is not a warrantable condition.
Installation
RADIO: FORK-MOUNTED FAIRING NOTE
Confirm that foam tape is in place on inner fairing near radio
PART NUMBER TOOL NAME opening.
HD-48650 DIGITAL TECHNICIAN II
1. Position radio on fairing support brackets and push toward
FASTENER TORQUE VALUE
opening in inner fairing.
Radio (or storage box) to 60–84 in-lbs 6.8–9.5 N·m
fairing support bracket screws
2. See Figure 9-86. Install four screws (1). Leave fasteners
loose.
Removal
NOTE 3. Install instrument cluster. See GAUGES AND
Never operate vehicle with the radio or upper support bracket INSTRUMENTS: FAIRING MODELS (Page 9-63).
removed. These components provide important structural
support to the fairing. Temporarily install a Police glove box 4. See Figure 9-85. Install upper support bracket (3). Tighten
assembly if the vehicle must be operated while the radio is upper bracket screws in the sequence shown in INNER
removed. Damage to the fairing assembly can result if operated FAIRING: FORK MOUNTED FAIRING MODELS, Upper
without either of these components installed. Support Bracket (Page 3-122).

1. Remove main fuse. See System Fuses and Relays NOTE

(Page 9-6). Some connectors are not used on all models.
2. Remove outer fairing. See OUTER FAIRING AND
WINDSHIELD: FORK MOUNTED FAIRING MODELS 5. See Figure 9-86. Tighten screws (1) to 60–84 in-lbs
(Page 3-115). (6.8–9.5 N·m).
3. Remove fairing vent and upper support bracket. See
INNER FAIRING: FORK MOUNTED FAIRING MODELS, 6. See Figure 9-84. Mate connectors:
Upper Support Bracket (Page 3-122).
a. Radio harness connector (6).
4. Remove instrument cluster. See GAUGES AND
INSTRUMENTS: FAIRING MODELS (Page 9-63).
b. USB connector (5).
NOTE
Some connectors are not used on all models. c. AM/FM antenna cable connector (4).

d. GPS connector (3).

5. See Figure 9-84. Disconnect:
a. Radio harness connector (6). e. SiriusXM connector (2) (if equipped)

b. USB connector (5).

7. Install fairing vent and outer fairing. See INNER FAIRING:
c. AM/FM antenna cable connector (4). FORK MOUNTED FAIRING MODELS, Fairing Vent
(Page 3-121).
d. GPS connector (3).
e. SiriusXM connector (2) (if equipped) 8. Install main fuse. See System Fuses and Relays
(Page 9-6).
6. See Figure 9-86. Remove four screws (1) to release radio
(2) from fairing support brackets.
9. If installing a new radio, it must be set up using DIGITAL
7. Pull radio up and forward to remove. TECHNICIAN II (PART NUMBER: HD-48650):

NOTE
a. Choose the REFLASH icon.
The XM module is very fragile and is sensitive to static
discharge.

9-68 94000383
 NOTE
Instructions to check, download and install software are
sm07501 2 3
available in PDF format at 4
www.harley-davidson.com/softwaredownloads.
1
b. Follow the on-screen prompts. If the vehicle has an
5
amplifier, it must also be configured after configuring
the radio.

10. Check software version:

6
a. V i s i t
www.harley-davidson.com/softwaredownloads.

b. Compare the software version number to the online

version number.
1. Upper support-to-speaker enclosure screw (4)
c. If the online version number is higher than the 2. Upper support-to-inner fairing screw (2)
displayed version number, download and install the 3. Upper support-to-radio screw (4)
latest version. 4. Upper support bracket
5. Instrument cluster
sm08377 6. Media compartment screw
1
Figure 9-85. Upper Support Bracket

sm07502
2

6 2
5 4 3
1. Screws, radio mounting (4)
2. SiriusXM connector
3. GPS connector
4. AM/FM antenna connector
5. USB connector 1. Screw, radio-to-fairing support bracket (4)
6. Radio harness connector 2. Radio
Figure 9-84. Radio: Frame Mounted Fairing Models Figure 9-86. Remove Radio from Fairing Brackets
CB MODULE: FORK MOUNTED FAIRING

FASTENER TORQUE VALUE

CB module bracket to speaker 25–35 in-lbs 2.8–4 N·m
enclosure screw
CB module to speaker 25–35 in-lbs 2.8–4 N·m
enclosure screw

Removal
1. Remove main fuse. See System Fuses and Relays
(Page 9-6).
2. Remove outer fairing. See OUTER FAIRING AND
WINDSHIELD: FORK MOUNTED FAIRING MODELS
(Page 3-115).
3. See Figure 9-87. Disconnect:
a. CB antenna cable connector (2).
b. CB module connector (1).

4. Remove screw (3). Remove CB module.

94000383 9-69
Installation Remove
1. Slide CB module into place. Verify the alignment pins 1. See Figure 9-88. Cut cable strap (1).
engage the holes in the enclosure. 2. Disconnect antenna connector (3).
3. Gently pry the antenna (2) from the upper support bracket.
2. Install screw (3). Tighten to 25–35 in-lbs (2.8–4 N·m).
Install
3. See Figure 9-87. Mate connectors:
1. See Figure 9-88. Install antenna:
a. CB antenna cable connector (2). a. Clean the top of the upper support bracket with isopropyl
alcohol. Allow to dry completely.
b. CB module connector (1).
b. Remove adhesive backing from the antenna.
4. Install outer fairing. See OUTER FAIRING AND c. With the wire lead toward the right, press and hold
WINDSHIELD: FORK MOUNTED FAIRING MODELS antenna (2) for 60 seconds.
(Page 3-115).
NOTE
5. Install main fuse. See System Fuses and Relays After installing the antenna, avoid contact with or movement
(Page 9-6). of the antenna for 20 minutes.

sm08425
2. Install antenna connector (3) to the radio.
3. Secure antenna lead to harness with cable strap (1).
1 4. Install outer fairing. See the service manual.
3 5. Install main fuse.

Complete
1. Install outer fairing. See OUTER FAIRING AND
WINDSHIELD: FORK MOUNTED FAIRING MODELS
(Page 3-115).

2 2. Install main fuse.

sm08724

1. CB module connector 2
2. CB antenna cable connector
3. Screw (not visible)
1
Figure 9-87. CB Connectors
3
CB Module Bracket
1. Remove upper fairing support. See INNER FAIRING:
FORK MOUNTED FAIRING MODELS, Upper Support
Bracket (Page 3-122).

2. Remove screw securing bracket to speaker enclosure.

3. Install bracket to speaker enclosure. Tighten to 1. Cable strap

25–35 in-lbs (2.8–4 N·m). 2. GPS antenna
3. Connector
4. Install upper fairing support. See INNER FAIRING: FORK Figure 9-88. GPS Antenna
MOUNTED FAIRING MODELS, Upper Support Bracket FRONT FAIRING SPEAKERS: FORK
(Page 3-122). MOUNTED FAIRING
GPS ANTENNA FASTENER TORQUE VALUE
Fairing speaker enclosure to 48–60 in-lbs 5.4–6.8 N·m
Prepare fairing screws
Fairing speaker enclosure to 48–60 in-lbs 5.4–6.8 N·m
1. Remove main fuse.
fairing support screws
2. Remove outer fairing. See OUTER FAIRING AND Fairing speaker grille screws 9–13 in-lbs 1–1.4 N·m
WINDSHIELD: FORK MOUNTED FAIRING MODELS Fairing speaker screw 9–13 in-lbs 1–1.5 N·m
(Page 3-115).

9-70 94000383
 FASTENER TORQUE VALUE 6. Secure enclosure to upper support bracket with two screws
Upper support bracket to 48–60 in-lbs 5.4–6.8 N·m (2). Tighten to 48–60 in-lbs (5.4–6.8 N·m).
speaker enclosure screws
7. Mate speaker and power outlet connectors. Secure
Removal harness anchors to speaker enclosure.

NOTE 8. Install CB module if equipped. See Boom! Box Infotainment

Never operate vehicle with the speaker enclosures removed. System, CB Module: Fork Mounted Fairing (Page 9-69).
These components provide important structural support to the
fairing. Operating without these components can result in 9. Install outer fairing. See OUTER FAIRING AND
damage to fairing assembly. WINDSHIELD: FORK MOUNTED FAIRING MODELS
(Page 3-115).
1. Remove outer fairing. See OUTER FAIRING AND
WINDSHIELD: FORK MOUNTED FAIRING MODELS
(Page 3-115). Speaker Grille
2. Remove harness anchors from speaker enclosure. 1. Remove speaker enclosure. See Boom! Box Infotainment
System, Front Fairing Speakers: Fork Mounted Fairing
3. See Figure 9-89. Disconnect speaker connector (7).
(Page 9-70).
4. Right side: Disconnect power outlet connector.
5. Left side: Remove CB module if equipped. See Boom! Box 2. See Figure 9-89. Remove three screws (4).
Infotainment System, CB Module: Fork Mounted Fairing
(Page 9-69). 3. Remove speaker grille (5).

6. Remove three screws (1) securing enclosure to fairing

4. Install speaker grille and secure with screws (4). Tighten
support (6).
to 9–13 in-lbs (1–1.4 N·m).
7. Remove two screws (2) securing enclosure to upper
support bracket. 5. Install speaker enclosure.
8. Remove three screws (8). Remove speaker enclosure
from fairing.
sm07503

NOTE
Do not remove screws securing speaker enclosure halves
together. 5
4
2 3
9. Remove four screws to free speaker from enclosure.
10. Disconnect wires and remove speaker from enclosure.
1 6
11. If necessary, remove grommet and harness.

Installation
NOTE
7
Verify that harness grommet is correctly installed. An incorrectly
8
installed grommet can result in poor audio, whistling or a rattle.

1. If removed, install harness and grommet. 1. Enclosure-to-fairing support screw (3)

2. Upper bracket-to-enclosure screw (2)
3. Speaker enclosure
NOTE
4. Speaker grill screw (3)
Verify hole in speaker frame mates with alignment pin on 5. Speaker grill
enclosure. 6. Fairing support
7. Speaker connector
2. Attach speaker wire connectors. 8. Enclosure-to-fairing screw (3)
Figure 9-89. Speaker Enclosure
3. Install speaker and secure with four screws. Tighten to
RADIO: FRAME MOUNTED FAIRING
9–13 in-lbs (1–1.5 N·m).

PART NUMBER TOOL NAME

4. See Figure 9-89. Install speaker enclosure to inner fairing.
Secure with three screws (8). Tighten to 48–60 in-lbs HD-48650 DIGITAL TECHNICIAN II
(5.4–6.8 N·m).
FASTENER TORQUE VALUE
5. Secure enclosure to fairing support (6) with three screws Radio to fairing support 60–84 in-lbs 6.8–9.5 N·m
(1). Tighten to 48–60 in-lbs (5.4–6.8 N·m). bracket screws

94000383 9-71
Removal Installation
NOTE 1. Position radio on fairing support bracket and push toward
Never operate vehicle with the radio or upper support bracket opening in inner fairing.
removed. These components provide important structural
support to the fairing. Damage to the fairing assembly can NOTE
result if operated without these components installed.
Some connectors are not used on all models.

1. Remove main fuse. See System Fuses and Relays

(Page 9-6). 2. See Figure 9-90. Install four screws (1). Tighten to
60–84 in-lbs (6.8–9.5 N·m).
2. Remove outer fairing. See OUTER FAIRING AND
WINDSHIELD: FRAME MOUNTED FAIRING MODELS 3. Mate connectors:
(Page 3-127).
NOTE a. Radio harness connector (6).
Some connectors are not used on all models.
b. USB connector (5).
3. See Figure 9-90. Disconnect:
c. AM/FM antenna cable connector (4).
a. Radio harness connector (6).
d. GPS connector (3).
b. USB connector (5).
c. AM/FM antenna cable connector (4). e. SiriusXM connector (2) (if equipped).
d. GPS connector (3).
4. Install fairing vent and outer fairing. See OUTER FAIRING
e. SiriusXM connector (2) (if equipped) AND WINDSHIELD: FRAME MOUNTED FAIRING
MODELS (Page 3-127).
4. Remove four screws (1) to release radio from fairing
support bracket. 5. Install main fuse. See System Fuses and Relays
5. Pull radio up and forward to remove. (Page 9-6).

NOTE 6. If installing a new radio, it must be set up using DIGITAL

The XM module is very fragile and is sensitive to static TECHNICIAN II (PART NUMBER: HD-48650):
discharge.
a. Choose the REFLASH icon.
6. XM equipped:
a. Remove screws securing XM module in radio frame. NOTE
Instructions to check, download and install software are
b. Transfer XM module into new radio immediately. If new
available in PDF format at
radio is not available, place XM module in a static proof
www.harley-davidson.com/softwaredownloads.
bag and store in a safe place.
c. Tighten screw securely. b. Follow the on-screen prompts. If the vehicle has an
amplifier, it must also be configured after configuring
sm08377
the radio.
1
7. Check software version:

a. V i s i t
www.harley-davidson.com/softwaredownloads.

b. Compare the software version number to the online

version number.

c. If the online version number is higher than the

displayed version number, download and install the
latest version.
6 2
5 4 3
FRONT FAIRING SPEAKER AND
1. Screws, radio mounting (4) ENCLOSURE: FRAME-MOUNTED FAIRING
2. SiriusXM connector
3. GPS connector FASTENER TORQUE VALUE
4. AM/FM antenna connector Fairing speaker enclosure to 48–60 in-lbs 5.4–6.8 N·m
5. USB connector fairing screws
6. Radio harness connector
Figure 9-90. Radio: Frame Mounted Fairing Models

9-72 94000383
 FASTENER TORQUE VALUE sm08379
Fairing speaker enclosure to 48–60 in-lbs 5.4–6.8 N·m
radio support bracket screws: 1
FLTR
Fairing speaker screw 9–13 in-lbs 1–1.5 N·m

NOTE
• Repair of the left and right sides are similar. 2
• Speaker enclosure removal and installation does not require
speaker removal.

Speaker Grille
NOTE
Do not damage speaker when inserting right angle tool. 1. Retainer
2. Tab
1. See Figure 9-91. Remove speaker grille. Method A:
Figure 9-92. Speaker Grille
a. Carefully insert a right angle tool (3) through a hole in
the grille next to one retainer (1). Speaker Only
b. Pull to release retainer. 1. Remove speaker grille.
c. Repeat with remaining retainer.
2. Remove screws securing speaker to enclosure.
d. Remove speaker grille.

2. Method B: NOTE
Verify that hole in speaker frame mates with alignment pin on
a. Remove top air duct. enclosure.
b. From above, reach down into speaker area. Push on
tab to disengage upper retainer (1). 3. Hold speaker away from enclosure and disconnect wires.
c. Carefully pull near lower retainer (1) to disengage. Remove speaker.
Remove grille.
4. Connect wires to speaker terminals. Set speaker in place.
3. See Figure 9-92. Install speaker grille:
a. Verify that rubber gasket is in place on perimeter of 5. Secure with four screws. Tighten to 9–13 in-lbs
grille. (1–1.5 N·m).

b. Engage tab (2) into grille opening. 6. Install speaker grille.

c. Engage retainers (1) in slots.
d. Push on grille in retainer areas until an audible click is Remove Speaker Enclosure
heard.
NOTE
Never operate vehicle with the speaker enclosures removed.
sm08426 These components provide important structural support to the
inner fairing. Operating without these components can result
in damage to fairing assembly.
3
1 1. See Figure 9-93. Disconnect speaker connector (2).
2
2. Left side: Remove power port cable from features on
enclosure.
3. Right side: Separate USB cable anchor (6) from tab (5)
at upper corner of enclosure.
NOTE
Do not remove the Torx head screws securing the speaker
1 enclosure halves together.

1. Retainer (2) 4. Remove three socket head screws (3) securing lower
2. Tab enclosure.
3. Right angle tool 5. Remove two socket head screws (1) securing enclosure
Figure 9-91. Remove Speaker Grille to support bracket.
6. Remove speaker enclosure (4) from fairing.

94000383 9-73
 NOTE REAR SPEAKER ENCLOSURES
Do not disassemble speaker enclosure.
PART NUMBER TOOL NAME
7. Remove four screws to free speaker from enclosure. HD-51656 DIN CONNECTOR TOOL
8. Disconnect wires. Remove speaker from enclosure.
FASTENER TORQUE VALUE
9. If necessary, remove grommet and harness.
Headset DIN connector 7–9 in-lbs 0.8–1 N·m
Install Speaker Enclosure Passenger audio switch 25–30 in-lbs 2.8–3.4 N·m
screws
NOTE Rear speaker enclosure to 20–25 in-lbs 2.3–2.8 N·m
Verify that the harness grommet is correctly installed. An Tour-Pak screws
incorrectly installed grommet can result in poor audio, whistling
or a rattle. Removal
NOTE
1. If removed, install harness and grommet.
It is not necessary to remove the enclosure to service the
internal components.
NOTE
Align hole in speaker frame with alignment pin on enclosure. 1. Remove Tour-Pak liner. See TOUR-PAK SERVICE,
Tour-Pak Liner (Page 3-105).
2. Attach speaker wire connectors. 2. See Figure 9-94. Separate speaker pod jumper (2)
connector from main harness.
3. Install speaker. Secure with four screws. Tighten to
9–13 in-lbs (1–1.5 N·m). NOTE
If both speaker enclosures are removed, connector disassembly
4. See Figure 9-93. Install speaker enclosure (4) to inner is not required.
fairing. Start all screws (1, 3).
3. Remove appropriate terminals from housing. See the
5. Tighten two screws (1) to 48–60 in-lbs (5.4–6.8 N·m). electrical diagnostics manual.
NOTE
6. Tighten screws (3) to 48–60 in-lbs (5.4–6.8 N·m) ending See Figure 9-95. Screws securing right speaker enclosure also
with the screw nearest the rear. secure power outlet (4).

7. Secure harness to speaker enclosure. 4. Remove three screws (6) with flat washers (5) to free
speaker enclosure from Tour-Pak.
8. Install outer fairing. See OUTER FAIRING AND
5. Remove gasket (2) and sound port (3).
WINDSHIELD: FRAME MOUNTED FAIRING MODELS
(Page 3-127).
Installation

sm08378
1. See Figure 9-95. Install sound port (3) and new gasket
5 6 1 (2).

2. Install three screws (6) with flat washers (5) to secure

4 speaker enclosure (1), sound port (3) and power outlet (4)
(right side only) to Tour-Pak. Tighten to 20–25 in-lbs
(2.3–2.8 N·m).

3. Install terminals in connector housing. See the electrical

2 diagnostics manual.

4. Mate rear audio connector to main harness.

3 5. Install Tour-Pak liner. See TOUR-PAK SERVICE, Tour-Pak

Liner (Page 3-105).
1. Upper screws (2)
2. Speaker connector
3. Screws (3)
4. Speaker enclosure
5. Tab
6. USB cable anchor
Figure 9-93. Speaker Enclosure (right side shown)

9-74 94000383
 4. Left speaker:
sm07928
3
a. Using DIN CONNECTOR TOOL (PART NUMBER:
2 HD-51656), remove nut and weather cap from
passenger headset connector.
1 4 b. Remove passenger headset connector and harness
assembly.

5. See Figure 9-95. To separate left and right harnesses,

5 remove terminals from connector (7).
6. Remove harness grommet.

Assembly
1. Install harness grommet. The left enclosure grommet has
the larger hole.
1. Tour-Pak lights
2. Speaker pod jumper
3. Cable strap 2. See Figure 9-95. If separated, assemble left and right
4. Radio antenna harnesses to connector (7). See the electrical diagnostics
5. CB antenna manual.
Figure 9-94. Tour-Pak Harness Connectors
3. See Figure 9-96. Right speaker:
sm07460
6 3
a. Install switch bezel (8).

4 b. Install harness and switch (7) assembly with wires

5 1 nearest to wall of speaker enclosure.

2 c. Install screws (1) securing switch. Tighten to

25–30 in-lbs (2.8–3.4 N·m).

d. Install well nut (2) removed to access screw.

e. Route harness through grommet (6).

4. Left speaker:
7
a. Install passenger headset connector and harness
1. Speaker enclosure
assembly.
2. Gasket
3. Sound port b. Install weather cap and nut to secure passenger
4. Power outlet headset connector. Using DIN CONNECTOR TOOL
5. Washers (3) (PART NUMBER: HD-51656), tighten to 7–9 in-lbs
6. Screws (3) (0.8–1 N·m).
7. Connector
Figure 9-95. Speaker Enclosures c. Route harness under boss and through grommet.

Disassembly 5. Install cable strap on harness next to inside of grommet

1. See Figure 9-96. Remove four screws (4). (6) to act as strain relief.

2. Remove speaker (3) and grille (5) from enclosure.

NOTE
Disconnect terminals.
Over-tightening screws (4) can cause well nuts to pull through
3. Right speaker: mounting holes.
a. Remove well nut (2) to access switch screw (1).
6. Connect terminals to speaker.
b. Remove screws securing switch (7).
c. Remove harness and switch assembly. 7. Secure speaker and grille with four screws (4). Tighten
d. Remove switch bezel (8). carefully.

NOTE
It is not necessary to remove the enclosure to service the rear
speaker components.

94000383 9-75
 5. Install console on fuel tank capturing wire harness and
sm07461
4 front headset connector harnesses in metal clips. See
3 FUEL TANK, Console (Page 5-7).
2
6. Test operation of headset connector.
1

5
6
7
8
1. Screw (2)
2. Well nut (4)
3. Speaker
4. Screw (4)
5. Grill
6. Grommet
7. Switch
8. Bezel
Figure 9-96. Rear Speaker (typical)
PASSENGER AUDIO CONTROLS

NOTE
It is not necessary to remove the enclosure to service the rear
speaker components.

Perform disassembly and assembly procedures for left rear

speaker enclosure. See Boom! Box Infotainment System, Rear
Speaker Enclosures (Page 9-74).

RIDER HEADSET CONNECTOR

PART NUMBER TOOL NAME

HD-51656 DIN CONNECTOR TOOL

FASTENER TORQUE VALUE

Headset DIN connector 7–9 in-lbs 0.8–1 N·m

Removal
1. Remove console. See FUEL TANK, Console (Page 5-7).
2. Using DIN CONNECTOR TOOL (PART NUMBER:
HD-51656), rotate lock ring counterclockwise to loosen.
3. Remove lock ring and cap.
4. Remove headset connector and harness assembly.

Installation
1. Insert headset connector through hole in console.

2. Slide weather cap over headset connector.

3. With the notches on the outboard side, thread lock ring

onto headset connector.

4. Using DIN CONNECTOR TOOL (PART NUMBER:

HD-51656), tighten to 7–9 in-lbs (0.8–1 N·m).

9-76 94000383
ANTENNA CABLES 9.35
REMOVAL sm07928
3
2
Main Cable
NOTE 1 4
• Replacement of the radio and CB antenna cables is basically
the same.
• Most of the original cable remains within the main harness
conduit. 5

1. Remove seat and fuel tank. See FUEL TANK (Page 5-6).
2. Remove outer fairing. See OUTER FAIRING AND
WINDSHIELD: FORK MOUNTED FAIRING MODELS
(Page 3-115).
3. See Figure 9-97. Disconnect antenna cable (1) from radio. 1. Tour-Pak lights
Cut cable where it exits front and rear of the main harness. 2. Speaker pod jumper
3. Cable strap
4. Remove wire trough cover. 4. Radio antenna
5. See Figure 9-98. Disconnect antenna cable connector (4) 5. CB antenna
at rear fender. Figure 9-98. Tour-Pak Harness Connectors
6. Cut cable strap (3). Remove antenna cable.
Cable Extension: FLHX, FLHXS, FLTRX, FLTRXS
sm07927 1. Remove left saddlebag.
2. See Figure 9-99. Release antenna cable from three upper
2
clips (1).
1
3. Disconnect antenna cable from antenna.
4. See Figure 9-101. Disconnect antenna cable connector
(1). Remove cable.

sm06617

1. AM/FM radio antenna

2
2. CB radio antenna 3
Figure 9-97. Radio Antenna Cable Connectors

Cable Extension: Models with Tour-Pak

1. Remove Tour-Pak harness. See TOUR-PAK LIGHTS,
Tour-Pak Lights Harness (Page 9-28). 1. Upper clips (3)
2. See Figure 9-100. Cut cable strap (2). Peel away the 2. Molded clip (2)
forward wrap (3). 3. Antenna mount
Figure 9-99. Rear Fender Lamps Harness and Antenna
3. CB antenna cable (6):
Cable: FLHX, FLHXS, FLTRX, FLTRXS
a. Remove tape (5) securing cable to harness.
INSTALLATION
b. Remove antenna cable.

4. Radio antenna cable (7): Main Cable

a. Cut antenna cable extension where it exits each end of 1. See Figure 9-97. Connect new radio antenna cable
harness wrap. connector to radio.

b. Remove antenna cable. 2. Route free end of radio antenna cable rearward along left
side of steering head and rearward through left side of
wire trough. Continue along inboard side of left upper frame
tube and rearward to top of rear fender.

94000383 9-77
3. See Figure 9-98. Mate antenna cable connectors at top Cable Extension: Models with Tour-Pak
of rear fender. Install cable strap (3).
1. See Figure 9-100. Lay new antenna cable along harness
4. Capture antenna cable and main harness in steering head with front connector approximately even with the other
retainer. antenna cable connector (8).
5. Install two new cable straps to secure antenna cable and 2. Secure cable to harness with tape (5).
main harness to left upper frame tube.
3. Install new forward wrap (3) next to rear wrap (4) remaining
6. Install wire trough cover. Verify that all latches are fully on harness.
engaged.
4. Install new cable strap (2) 2 in (51 mm) (1) from end of
7. Install fuel tank and seat. See FUEL TANK (Page 5-6). forward wrap.
8. Install outer fairing. See OUTER FAIRING AND 5. Install Tour-Pak harness. See TOUR-PAK LIGHTS,
WINDSHIELD: FORK MOUNTED FAIRING MODELS Tour-Pak Lights Harness (Page 9-28).
(Page 3-115).

sm07938

8 3

4
7

1. Dimension to cable strap 5. Electrical tape

2. Cable strap 6. CB antenna cable
3. Forward wrap 7. Radio antenna cable
4. Rear wrap 8. Antenna cable ends
Figure 9-100. Antenna Leads
4. See Figure 9-101. Pull cable snug. Capture antenna cable
Cable Extension: FLHX, FLHXS, FLTRX, FLTRXS and rear lighting harness with new cable straps (3).
1. See Figure 9-101. Route antenna cable back along upper 5. Mate to connector (1)
left frame, passing back under frame cross member and
6. Install left saddlebag.
through opening in left caddy. Continue along saddlebag
support to antenna.
2. See Figure 9-99. Pass connector through grommet and
connect to bottom of antenna.
3. Capture cable in three upper clips (1).

9-78 94000383
 sm06616

1 2

1. Antenna cable connector

2. Rear lighting connector
3. Cable strap (2)
Figure 9-101. Rear Fender Lamps Harness and Antenna
Cable Routing: FLHX, FLHXS, FLTRX, FLTRXS

94000383 9-79
WIRE TROUGH 9.36
REMOVE sm05143a

1. Remove main fuse. See System Fuses and Relays

(Page 9-6).
2. Remove fuel tank. See FUEL TANK (Page 5-6).
3. Remove air cleaner and backplate. See AIR CLEANER
ASSEMBLY (Page 5-5).
4. Remove TMAP sensor connector [80].
a. Pull back yellow lock.
b. Push down firmly on latch.
c. Disconnect connector.

5. Disconnect fuel injector connectors.

6. Disconnect TCA connector [211]. Release anchored cable Figure 9-103. Mark Location of Cable Straps
strap securing harness to induction module.
sm05146a
7. Disconnect ACR connectors and release connector
housings from induction module support.
8. Disconnect knock sensor connectors. 1
9. Disconnect terminals from horn and release harness from
J-clamp. Release cable straps securing harness to horn
bracket.
10. Disconnect ET sensor connector [90].
11. Draw connectors to right side of motorcycle.
12. ABS models: Release brake lines from wire trough.
13. See Figure 9-102. Cut two cable straps to release breakout
harnesses from right side of wire trough.
14. Remove wire trough cover.
15. See Figure 9-103. Using a paint pen, draw a line on both 2
sides of each cable strap securing wire bundles.

sm07580a

1. Reusable (tail removed)

1 2
2. Not reusable (eyelet removed)
Figure 9-104. Cut Cable Straps
NOTE
See Figure 9-104. When removing cable straps, cut off the tail,
not the eyelet. The cable strap can then be reused to gather
wires when removing harness from wire trough.

16. Cut cable straps. Temporarily use them to bundle wires.

a. Cut tails of cable straps as close to the eyelet as
possible.

1. Rear injector, rear ACR, TCA, horn, rear KS b. Remove each cable strap from slots in wire trough.
2. Front injector, front ACR, TMAP, ET sensor, Remove the tail remnant from the eyelet.
front KS c. Install the cable strap back on the harness near the
Figure 9-102. Breakout Harnesses painted lines to gather the bunch of wires. Verify that
all wires are captured.

17. Pull breakout harnesses out through slot in breakout

compartment. If ABS equipped, move harnesses outboard
of brake lines.

9-80 94000383
18. FLHR/C: Remove fuel gauge harness from slot in front of 18. Connect TCA connector. Secure harness to induction
wire trough. module with new anchored cable strap.
19. Pry anchor pins at rear of wire trough from holes in frame 19. Connect ACR connectors.
backbone.
20. Secure knock sensor connectors, ACR connectors and
20. Remove wire trough. ET sensor connector to lower backbone caddy.
INSTALL 21. Install fuel tank. See FUEL TANK (Page 5-6).
22. Install air cleaner. See AIR CLEANER ASSEMBLY
1. Thread six new cable straps through slots inside wire (Page 5-5).
trough.
23. Install main fuse. See System Fuses and Relays
2. Slide wire trough into position. (Page 9-6).
3. Route forward branches through channels in trough.
4. FLHR/C: Route the fuel gauge harness through slot in
front-left of wire trough.
5. See Figure 9-102. Secure breakout harnesses in the rear
of the breakout compartment with a new cable strap. Do
not tighten.
a. Rear fuel injector
b. Rear ACR
c. TCA
d. Rear knock sensor
e. Horn

6. Secure breakout harnesses in the front of the breakout

compartment with a new cable strap. Do not tighten.
a. Front fuel injector
b. Front ACR
c. ET sensor
d. Front knock sensor
e. TMAP

7. ABS models: Pull breakout harnesses inboard of brake

lines.
8. Adjust harness wires inside wire trough so they are
positioned within the cable straps. Install each cable strap
but do not tighten.
9. Remove the cable straps used to gather the wire bunches.
10. Secure rear of wire trough into holes in frame backbone.
11. Align the painted lines with the cable straps. Tighten and
trim cable straps.
12. Align the painted lines on branches exiting the breakout
compartment with cable straps. Tighten and trim cable
straps.
13. Secure cover to wire trough starting at the rear and working
forward. Verify that all latches are fully engaged.
14. ABS models: Secure brake lines as shown in Figure
9-115.
15. Connect TMAP sensor connector. Engage yellow lock.
16. Connect rear fuel injector connector, front fuel injector
connector, ET sensor connector and knock sensor
connectors.
17. Install terminals onto horn contacts. Capture horn harness
in J-clamp. Secure harness to horn bracket with cable
straps.

94000383 9-81
MAIN WIRING HARNESS 9.37
REMOVAL: ALL MODELS (PART 1) sm07967
3
1. Remove fuel tank. See FUEL TANK (Page 5-6).
2. Remove battery. See Battery Maintenance (Page 2-51). 1
5
3. Remove saddlebags. See SADDLEBAGS (Page 3-98).
4. Remove left and right side covers.
5. Depending upon model, continue procedure at MAIN
WIRING HARNESS, Removal: Road King Models (Part
2) (Page 9-82), MAIN WIRING HARNESS, Removal: Fork 2
Mounted Fairing Models (Part 2) (Page 9-82) or MAIN
WIRING HARNESS, Removal: Frame Mounted Fairing
Models (Part 2) (Page 9-83). 4
REMOVAL: ROAD KING MODELS (PART 2)
1. Remove headlamp assembly. See HEADLAMP
(Page 9-16).
2. See Figure 9-105. Separate connectors (1-4) at left
steering head caddy. Leave main harness connectors
secured to caddy.
3. Separate ground wire leading to left upper fork bracket. 1. Right handlebar switch module
2. Front WSS (ABS models)
4. See Figure 9-106. Separate connectors (1, 2) at right 3. Nacelle switch connector
steering head caddy. Leave main harness connectors 4. Brake line retainer
secured to caddy. 5. Caddy retainer
5. Remove brake line retainer (4). Leave lines captured in Figure 9-106. Right Side Connectors: Road King
retainer. REMOVAL: FORK MOUNTED FAIRING
6. Loosen caddy retainer screw (5). Remove retainer securing MODELS (PART 2)
each steering head caddy.
7. Remove both caddies from steering head. 1. Remove outer fairing. See OUTER FAIRING AND
WINDSHIELD: FORK MOUNTED FAIRING MODELS
8. Disconnect nacelle switch connectors (3). (Page 3-115).
NOTE 2. See Figure 9-109. Separate connectors (1-9). Remove
Continue procedure at MAIN WIRING HARNESS, Removal: from retaining devices if present.
All Models (Part 3) (Page 9-84).
3. Remove dash panel. Disconnect switches. See DASH
PANEL: FORK MOUNTED FAIRING MODELS
sm07537a (Page 3-117).
1 5 4. Disconnect ignition switch connector. See Ignition Switch
and Fork Lock (Page 9-39).
2 5. Pull dash panel switch and ignition switch harnesses
forward into fairing area.

3 6. ABS equipped: See Figure 9-108. Separate wheel speed

sensor connector (2).
7. Release brake line retainer (1) from steering head caddy.

4 8. See Figure 9-107. Loosen retainer screw. Pull retainer

securing each steering head caddy.
9. Remove both caddies from steering head.

1. Left handlebar switch module 10. Pull main harnesses rearward and allow to hang.
2. TGS NOTE
3. Right auxiliary/fog/turn signal lamps
Continue procedure at MAIN WIRING HARNESS, Removal:
4. Left auxiliary/fog/turn signal lamps
All Models (Part 3) (Page 9-84).
5. Caddy retainer
Figure 9-105. Left Side Connectors: Road King Models

9-82 94000383
 sm07582 sm07604
1

1. Brake line retainer

Figure 9-107. Steering Head Caddy (right side shown) 2. Wheel speed sensor connector
Figure 9-108. Steering Head Caddy (right side shown)

sm07487b

2
1 3

8
5
7
6

1. CB module 6. Ground wire, fork bracket

2. P&A audio 7. Main-to-fairing harness, right
3. AM/FM radio antenna 8. TGS
4. CB radio antenna 9. Radio
5. Main-to-fairing harness, left
Figure 9-109. Main Harness Fairing Connectors (typical)
REMOVAL: FRAME MOUNTED FAIRING 2. Remove inner fairing. See INNER FAIRING: FRAME
MODELS (PART 2) MOUNTED FAIRING MODELS (Page 3-131).
3. Remove instrument nacelle. See INSTRUMENT NACELLE:
1. Remove outer fairing. See OUTER FAIRING AND FRAME MOUNTED FAIRING MODELS (Page 3-126).
WINDSHIELD: FRAME MOUNTED FAIRING MODELS
(Page 3-127). 4. Remove fairing mounting bracket. See INNER FAIRING:
FRAME MOUNTED FAIRING MODELS (Page 3-131).

94000383 9-83
5. See Figure 9-110. Separate connectors (1-4, 6-10).
sm08580
Remove the retainer securing the left branch from the 4
nacelle caddy. 1
6. Pull main harness branches rearward and allow to hang. 3
NOTE
Continue procedure at MAIN WIRING HARNESS, Removal:
All Models (Part 3) (Page 9-84).

sm08386
2 3
4
1

10 5

9
6
8 2
1. Front fuel injector [84]
7 2. TCA [211]
3. TMAP sensor [80]
1. Ground 4. Rear fuel injector [85]
2. TGS Figure 9-111. Induction Module Connectors
3. Left hand controls
4. Disconnect terminals from horn and release harness
4. Right hand controls
conduit from J-clamp. Release anchored cable strap
5. Nacelle caddy
securing harness to horn bracket.
6. Right accessory switch module
7. WSS (ABS models) 5. Disconnect ET sensor connector [90].
8. Ambient air temperature sensor
6. Disconnect knock sensor connectors.
9. Ignition switch
10. Left accessory switch module 7. Release lower backbone caddy from backbone.
Figure 9-110. Nacelle Connectors: FLTRX, FLTRXS a. Remove right front spark plug cable anchor from caddy.
REMOVAL: ALL MODELS (PART 3) b. Remove two anchor pins.

1. Remove air cleaner cover and backplate. See AIR
CLEANER ASSEMBLY (Page 5-5).
2. Disconnect ACR connectors.
3. See Figure 9-111. Remove connectors from induction
module:
a. Disconnect TMAP sensor connector (3).
b. Disconnect fuel injector connectors (1, 4).
c. Disconnect TCA connector (2). Release anchored cable
strap securing harness to induction module.
c. Push caddy forward to release caddy latches.
8. Draw harnesses to right side of motorcycle.
9. ABS equipped: Release brake lines from wire trough.
10. Cut cable straps securing harnesses to left upper frame
rails.
11. Disconnect purge solenoid connector [95], if equipped.
12. Disconnect ECM connectors.
13. Disconnect ignition coil connector [83].
NOTE
Record harness ground ring terminal orientation when
removing.

14. Remove main harness ground ring terminals from left and
right frame ground studs (metric) located ahead of battery
tray.
15. Pry anchor pins at rear of wire trough from holes in frame
backbone.
16. Disconnect siren if equipped. Remove siren from left side
caddy.
17. Remove BCM. See BODY CONTROL MODULE (BCM)
(Page 9-8).

9-84 94000383
18. Remove screws securing left side caddy. See
ELECTRICAL CADDIES (Page 9-9).
19. FLHR, FLHRC Only:
a. Pull anchor on ignition switch jumper harness connector
[222], 4-place Packard, from hole in left caddy.
Disconnect connector.
b. Disconnect instrument console connector [20], 16-place
Molex, inboard of left upper frame tube. Remove
instrument console.
20. FLHX, FLHXS, FLTRX, FLTRXS:
a. See Figure 9-112. Disconnect radio antenna cable
connector (1).
b. Disconnect rear lighting connector (2).
sm06616
1 2
3
1. Antenna cable connector
2. Rear lighting connector
3. Cable strap (2)
Figure 9-112. Rear Fender Lamps Harness and Antenna
Cable Routing: FLHX, FLHXS, FLTRX, FLTRXS
21. Models with Tour-Pak: Disconnect rear audio harness,
antenna and Tour-Pak lighting connectors located near
Tour-Pak. Release audio connector from anchor.
22. Disconnect oxygen sensor connectors. Remove from
anchors.
23. Disconnect connector [179] from active exhaust valve
actuator or from mock pin housing on right side of battery
tray, as equipped.
24. ABS models:
a. Disconnect ABS module connector [166].
b. Disconnect rear wheel speed sensor connector [168].
25. Draw harness branch into battery tray.
26. Remove main power cable ring terminal from starter
solenoid post. Draw out cable through opening at rear of
left side caddy.
27. Remove starter and disconnect VSS connector. See
Vehicle Speed Sensor (VSS) (Page 9-54).
28. Remove connectors from neutral switch.
94000383
29. Draw harness branch into battery tray.
30. Disconnect voltage regulator. See VOLTAGE
REGULATOR (Page 9-50).
31. Remove CKP sensor connector from front lower caddy.
See CRANKSHAFT POSITION SENSOR (CKP)
(Page 9-44).
32. Air-Cooled: Remove protective cover from frame.
33. Disconnect jiffy stand interlock sensor connector [133].
34. Disconnect oil pressure switch/sender at front right side
of crankcase.
35. Disconnect rear stop lamp switch connectors.
36. Twin-Cooled: Disconnect pump, left fan and right fan
connectors.
37. Air-Cooled: Disconnect fan connector.
38. Cut anchored cable strap at front frame crossmember.
39. Free main harness from two conduit clips anchored to
lower-right frame tube.
40. Cut cable straps to release harness from middle frame
downtube.
41. Pull up harness branch through battery tray.
42. While pulling left side caddy away from motorcycle, feed
wire trough and harnesses out through opening.
INSTALLATION: ALL MODELS (PART 1)
FASTENER TORQUE VALUE
Harness ground stud flange 50–90 in-lbs 5.7–10.2 N·m
nuts
1. Feed front end of wire trough in through opening between
left frame downtubes. Then pull up and out through
opening at top of battery tray. Lay wire trough on top of
frame backbone.
2. Push anchor pins at rear of wire trough into holes in frame
backbone.
3. Locate the lower front branch terminating at the voltage
regulator, stop lamp switch, oil pressure switch, and so
forth. Route down inside of the mid downtube and to the
front following the lower frame tube.
4. Locate branch terminating in the VSS, neutral switch and
starter solenoid connectors. Route down through opening
right of ignition coil to top of transmission.
5. Locate branch terminating in the oxygen sensor, ABS
module (if equipped) and rear wheel speed sensor
connectors. Route down to area of right caddy.
6. Models with Tour-Pak: Locate branch terminating in the
Tour-Pak lights and audio harness connectors. Route along
left upper frame tube to area near Tour-Pak. Mate
connectors. Secure audio connector to anchor.
7. Route starter power cable and ignition coil connector down
through opening left of ignition coil.
9-85
8. Route rear fender lights connector through opening at rear
of battery tray and up through frame crossmember. Install
left side electrical caddy. See ELECTRICAL CADDIES
(Page 9-9).
9. All except FLHX, FLHXS, FLTRX, FLTRXS: Mate rear
fender lights connector. Secure to top of fender.
10. FLHX, FLHXS, FLTRX, FLTRXS: Mate rear fender lights
connector. Secure to top caddy.
11. Install BCM. See BODY CONTROL MODULE (BCM)
(Page 9-8).
22. Connect CKP sensor connector [79]. Push anchor on
connector into hole in front caddy.
23. Connect jiffy stand interlock sensor connector [133].
Secure to T-stud on front caddy.
24. See Figure 9-113. Secure the regulator harness and jiffy
stand sensor harness to the frame with a new cable strap.
25. Air-Cooled: Install protective cover to frame with new
retainers.
sm08629

12. Connect VSS and neutral switch.

13. Install ignition coil connector [83].

14. Install starter. See STARTER (Page 9-15).

15. Install purge solenoid connector [95] if equipped.

16. Install main harness ground ring terminals:

a. Install two main harness ground ring terminals onto

left frame ground stud. Secure with nut.

b. Install remaining ground ring terminal on right frame Figure 9-113. Capture Main, Regulator and Jiffy Stand
ground stud under starter ground cable ring terminal. Sensor Harnesses
Secure with nut.
26. Connect oil pressure switch/sender connector.
NOTE 27. Connect rear stop lamp switch connectors.
Replace conduit clips if damaged, deteriorated or missing. With
28. See Figure 9-117. Secure lower front branch to mid-frame
the slotted side up, push hole in conduit clip over T-stud to
downtube with new cable strap (3).
install.
29. Secure horizontal portion along lower frame in conduit
c. Tighten both nuts (metric) to 50–90 in-lbs clips (2).
(5.7–10.2 N·m). a. See Figure 9-114. Verify that rear brake line (1) and
HO2 sensor wire (2) are secured in retainers on conduit
17. Route lower front branch inboard of front engine mounting clips.
bracket.
30. Install connector [179] to the active exhaust valve actuator
18. Twin-Cooled: or to mock connector housing on right side of battery tray,
as equipped.
a. Route pump and fan connectors under the front 31. ABS equipped: Connect ABS module connector [166]
engine mount. and rear wheel speed sensor connector [168].
b. Mate pump, left fan and right fan connectors. 32. Connect oxygen sensor front (gray) and rear (black)
connectors. Secure connectors to anchors on right caddy.
c. Secure to anchors.

19. Air-Cooled:

a. Route fan connector under the front engine mount.

b. Mate fan connector.

c. Secure to anchor.

20. Secure harness to frame crossmember with new anchored

cable strap.

21. Install voltage regulator. See VOLTAGE REGULATOR

(Page 9-50).

9-86 94000383
 34. FLHR, FLHRC Only:
sm08705
2 a. Lay a clean shop towel on forward part of rear fender.
Lay console upside down on shop towel.
b. Connect instrument console connector [20].
c. Connect ignition switch jumper harness connector [222].
1 Secure connector in hole in left side of battery tray.

1 35. Connect ECM connectors.

NOTE
ABS equipped: The order in which lines are arranged is
important. Arrange as the insets show.
4 3 36. See Figure 9-115. Secure brake lines to wire trough
1. Rear brake line including the central anchor block.
2. Front HO2 sensor wire a. Secure lines at rear within retainer (4) and under the
3. Clutch line tab.
4. Screw
b. Route lines under retainer tab (5).
Figure 9-114. Lower Frame Rail Line and Harness Retainers
c. Secure lines in retaining features (6) at front of wire
33. Secure harnesses to left upper frame tube with two new trough.
cable straps.
d. See Figure 9-116. Route lines under retainer (3). Secure
retainers tabs under pockets (2) on harness caddy cover
(1).

94000383 9-87
 sm08578
4 5

1 1
3
3
2

2 4 7
1

3
8

1. Front master cylinder to ABS module 5. Brake line retainer

2. ABS module to front right caliper 6. Retaining features
3. ABS module to front left caliper 7. Fork mounted fairing line orientation
4. Retainer with tab 8. Frame mounted fairing line orientation
Figure 9-115. Front ABS Brake Line Routing
37. Install lower backbone caddy.
sm08570
a. Push caddy rearward to engage caddy latches.
2 b. Install two anchor pins.
c. Secure right front spark plug cable anchor to caddy.

1 38. See Figure 9-111. Install induction module connectors.

a. Install TMAP sensor connector (3). Engage yellow lock.
b. Install TCA connector (2). Install new anchored cable
strap in hole at front right side of induction module.
3
c. Install fuel injector connectors (1, 4). Grey connector to
front injector and black connector to rear injector.

39. Connect ACR connectors.

2 40. Connect knock sensor connectors.

41. Route the horn branch to the left side of the engine and
1. Harness caddy cover under the horn bracket. Route the branch under coolant
2. Pockets lines.
3. Retainer
42. Connect ET sensor connector.
Figure 9-116. Brake Line Retainer
43. Connect horn spade terminals. Capture conduit in J-clamp.
Secure to horn bracket with two cable straps.

9-88 94000383
44. Install air cleaner assembly. See AIR CLEANER
ASSEMBLY (Page 5-5).
45. Depending upon model, continue procedure at MAIN
WIRING HARNESS, Installation: Road King Models (Part
2) (Page 9-89), MAIN WIRING HARNESS, Installation:
Fork-Mounted Fairing Models (Part 2) (Page 9-89) or MAIN
WIRING HARNESS, Installation: Frame-Mounted Fairing
Models (Part 2) (Page 9-90).

sm08628

2 4

1. Lower front main harness to frame 3. Lower front harness only to frame
2. Conduit clips (secure harness and brake line) 4. Main, regulator and jiffy stand sensor harnesses
to frame
Figure 9-117. Lower Front Harness Cable Strap Locations
INSTALLATION: ROAD KING MODELS NOTE
(PART 2) Continue procedure at MAIN WIRING HARNESS, Installation:
All Models (Part 3) (Page 9-90).
1. Route front right section of main harness forward along
right side of steering head and into headlamp nacelle. INSTALLATION: FORK-MOUNTED FAIRING
2. See Figure 9-106. Secure caddy with retainer (5). MODELS (PART 2)
3. Mate connectors (1, 2). 1. Route main harness forward along each side of steering
4. See Figure 9-105. Route front left section of main harness head and into inner fairing area.
forward along left side of steering head and into headlamp 2. Secure steering head caddies with retainer. Push in
nacelle. retainer screw until fully seated.
5. Secure caddy with retainer (5). 3. Right side: Secure brake lines to caddy. Mate front wheel
6. Mate connectors (1-4). speed sensor connector. Secure to caddy, if equipped.
7. Mate nacelle switch connectors (3). 4. See Figure 9-109. Mate connectors (1-9). Secure to
anchors if present.
8. Install headlamp assembly. See HEADLAMP (Page 9-16).
5. Route dash panel and ignition switch connectors back
between handlebar and upper fork bracket.

94000383 9-89
6. Connect ignition switch connector. See Ignition Switch and
Fork Lock (Page 9-39).
7. Connect dash panel switch connectors. Install dash panel.
See DASH PANEL: FORK MOUNTED FAIRING MODELS
(Page 3-117).
8. Mate ground wire leading to upper fork bracket.
9. Install outer fairing. See OUTER FAIRING AND
WINDSHIELD: FORK MOUNTED FAIRING MODELS
(Page 3-115).
NOTE
Continue procedure at MAIN WIRING HARNESS, Installation:
All Models (Part 3) (Page 9-90).

INSTALLATION: FRAME-MOUNTED FAIRING

MODELS (PART 2)
1. Remove the retainer securing the left branch from the new
nacelle caddy.
2. Route main harness forward along each side of steering
head and into inner fairing area. The branch with the
nacelle caddy attached goes on the right side.
3. See Figure 9-110. Route both harness branches up
between brake lines and steering head. Secure the left
branch to the nacelle caddy.
4. Route accessory switch (6, 10) and ignition switch (9)
connectors back between handlebar and upper fork
bracket.
5. Mate connectors (1-4, 6-10).
6. Install fairing mounting bracket. See INNER FAIRING:
FRAME MOUNTED FAIRING MODELS (Page 3-131).
7. Install instrument nacelle and instrument bezel. See
INSTRUMENT NACELLE: FRAME MOUNTED FAIRING
MODELS (Page 3-126).
8. Install inner fairing. See INNER FAIRING: FRAME
MOUNTED FAIRING MODELS (Page 3-131).
9. Install outer fairing. See OUTER FAIRING AND
WINDSHIELD: FRAME MOUNTED FAIRING MODELS
(Page 3-127).
NOTE
Continue procedure at MAIN WIRING HARNESS, Installation:
All Models (Part 3) (Page 9-90).

INSTALLATION: ALL MODELS (PART 3)

1. Install side covers.
2. Install saddlebags. See SADDLEBAGS (Page 3-98).
3. Install fuel tank. See FUEL TANK (Page 5-6).
4. Install battery, top caddy and seat. See Battery
Maintenance (Page 2-51).

9-90 94000383
FAIRING HARNESS 9.38
HARNESS SERVICE: FORK-MOUNTED 3. See Figure 9-118. Disconnect connectors (1-5). Remove
FAIRING from retaining devices, if present.
4. Disconnect connectors (7, 9-15, 17). Remove from
FASTENER TORQUE VALUE retaining devices, if present.
Dash panel screws 25–30 in-lbs 2.8–3.4 N·m 5. Release six anchored cable straps (18) securing fairing
Fairing double studs 120–180 in-lbs 13.6–20.3 N·m harness.
6. FLHTK: Disconnect heated grips power connector (9).
Removal
7. Remove two fasteners (6) securing electrical caddy.
1. Remove main fuse. See System Fuses and Relays
(Page 9-6). 8. Remove fairing harness and electrical caddy as an
assembly.
2. Remove lamp brackets and outer fairing. See OUTER
FAIRING AND WINDSHIELD: FORK MOUNTED FAIRING
MODELS (Page 3-115).

sm07528a

3
2
1

18

6
17
7
15 13 11
10
14 12
9
8
16

1. Voltmeter connector 10. Left handlebar switches connector

2. Instrument cluster connector 11. Run/stop switch connector
3. Fuel gauge connector 12. Right handlebar switches connector
4. Left speaker connector 13. Main-to-fairing harness connector, right
5. Front fender tip lamp connector 14. TGS connector anchor
6. Fastener (2) 15. Right speaker connector
7. Main-to-fairing harness connector, left 16. Right front lighting
8. Left front lighting 17. Power outlet connector
9. Auxiliary power connector (heated handgrip 18. Anchored cable straps
power: FLHTK)
Figure 9-118. Inner Fairing Harness
3. Secure harnesses and connectors to caddy with new cable
Repair straps.
1. Remove cable straps securing harness to caddy.
Installation
2. Repair connectors and harnesses as necessary.
1. Remove screws securing dash panel.

94000383 9-91
2. Remove double studs securing inner fairing to fork 12. Install outer fairing and lamp brackets. See OUTER
brackets. FAIRING AND WINDSHIELD: FORK MOUNTED FAIRING
MODELS (Page 3-115).
3. Lift inner fairing straight up and hold.
13. Install main fuse. See System Fuses and Relays
4. While holding inner fairing up, push electrical caddy into (Page 9-6).
place. Mate tabs on caddy with slots in lower fairing
brackets. HARNESS SERVICE: FRAME MOUNTED
FAIRING
5. See Figure 9-118. Secure caddy with fasteners (6).

6. Secure fairing harness with anchored cable straps (18).

Removal
1. Remove main fuse. See System Fuses and Relays
7. Mate connectors (1-5). Secure to retaining devices, if (Page 9-6).
present. 2. Remove outer fairing. See OUTER FAIRING AND
WINDSHIELD: FRAME MOUNTED FAIRING MODELS
8. Mate connectors (7, 9-15, 17). Secure to retaining devices, (Page 3-127).
if present.
3. Remove headlamp. See HEADLAMP (Page 9-16).
9. FLHTK: Mate heated grips power connector (9). 4. See Figure 9-119. Release left (7) and right (9) main
harness connector anchors from radio support bracket.
10. Install double studs securing inner fairing to fork brackets. Separate connectors.
Tighten to 120–180 in-lbs (13.6–20.3 N·m). 5. Disconnect speaker connectors (6, 10).
6. Disconnect gauge connectors (3, 5).
11. Install screws securing dash panel. Tighten to 25–30 in-lbs
(2.8–3.4 N·m). 7. Release branch harness anchors (1) from radio support
bracket.
8. Cut harness anchor (2) cable straps.
9. Remove fairing harness assembly.

9-92 94000383
 sm08389

12
4
11 5
1

2 3

6
10
7

9 8

1. Turn signal branch harness anchor (2) (location 7. Main-to-fairing harness connector, left
stamped 2 or 4)
2. Harness anchor (2) 8. Headlamp harness anchor
3. Voltmeter connector 9. Main-to-fairing harness connector, right
4. Radio support bracket 10. Right speaker connector
5. Fuel gauge connector 11. Voltmeter jumper anchor (location stamped 1)
6. Left speaker connector 12. Fuel gauge jumper anchor (location stamped 3)
Figure 9-119. Inner Fairing Harness: FLTR models

Installation
1. See Figure 9-119. Secure fairing harness branch anchors
(2) to radio support bracket.
2. Mate gauge connectors (3, 5).
3. Mate speaker connectors (6, 10).
4. Mate main harness connectors (7, 9). Secure connector
to the radio mounting bracket.
5. Secure harness to harness anchors (2) with new cable
straps.
6. Install headlamp. See HEADLAMP (Page 9-16).
7. Install outer fairing. See OUTER FAIRING AND
WINDSHIELD: FRAME MOUNTED FAIRING MODELS
(Page 3-127).
8. Install main fuse. See System Fuses and Relays
(Page 9-6).

94000383 9-93
HANDLEBAR SWITCH PACKS 9.39
REMOVAL sm08222

NOTE
• The handlebar switches are modular and serviced as
assemblies only. this includes the clutch interlock switch
and front brake lamp switch.
• Several switch configurations are used on Touring models.
The service procedures are the same for all.
• Switch assemblies are different between cable clutch and
hydraulic clutch models. Install the correct switch module
assembly. Installation of the incorrect switch will allow the
engine to start in gear with the clutch engaged.
• To replace the switch pack harnesses on internally wired
handlebar, see HANDLEBAR, Remove Harnesses, FLTR
Models (Page 3-91). Figure 9-120. Pry off Trigger Finger Switch Cap

sm05016
Handlebar Controls 3
1. See Figure 9-121. Remove screws (3) and clamp (4).
Remove hand control assembly. 2 4
2. Left switch module:
a. See Figure 9-120. With a small screwdriver, carefully
pry between trigger finger switch cap and switch
plunger.
b. Slide trigger finger switch cap outboard to remove.

NOTE
See Figure 9-124. The switch housing screws (5) are captive.

3. Loosen switch housing screws (5). Remove switch

housings.
NOTE
See Figure 9-122. The latches on connectors are fragile. Use 1
care when disconnecting.

4. Remove connectors: 1. Ear

2. Recess
a. Using a pick, carefully press latch down.
3. Screw (2)
b. Use a prying motion on latch while pulling on connector 4. Clamp
to remove. Figure 9-121. Hand Control Assembly (typical)

5. See Figure 9-124. Release switch latch (2) and rotate sm08043
switch (1) down.
1
6. Remove module assembly from handlebar. Release wires
from switch pack.

1. Connector latch
2. Wire retainer
Figure 9-122. Switch Pack Connector (typical)

9-94 94000383
INSTALL d. Verify that hand grip has slight inboard-outboard free
play.
FASTENER TORQUE VALUE
e. Verify that hand grip rotates and returns freely.
Brake master cylinder, front, 60–80 in-lbs 6.8–9 N·m
clamp screws
8. Tighten brake control clamp screws (3) to 60–80 in-lbs
Clutch lever bracket clamp 60–80 in-lbs 6.8–9 N·m (6.8–9 N·m). Again verify hand grip rotation and slight end
screws play.
Handlebar switch housing 35–45 in-lbs 4–5 N·m
screws
WARNING

Right Handlebar Controls Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
1. Install throttle hand grip: death or serious injury. (00316a)

a. Verify that TGS is installed and fully engaged in the 9. Test switches for proper operation.
slots in handlebar.

b. Position hand grip with cosmetic features properly sm08042a

positioned. Install hand grip on handlebar and fully
engage on TGS splines until it bottoms. 4
1
c. Heated hand grips: Mate connector. See
HANDLEBAR, HEATED HAND GRIPS (Page 3-93).

2. See Figure 9-124. Mate electrical connectors (3). Route

harness through fingers (4) of wire retainer and into
channel in switch module.
2
3. Place switch module on handlebar. Rotate switch (1) up
and snap latch (2) into place.

NOTE
See Figure 9-123. Avoid pinching wires by alignment feature 3
(4) while assembling switch housings. Tuck wires close to the
wire retainer (2) as shown in Figure 9-122.
2
1. Trigger switch cap
4. Verify that wire harness is in the recess at bottom of 2. Housings
handlebar. 3. Switch assembly
4. Alignment feature
5. See Figure 9-124. Install switch housings. Tighten screws Figure 9-123. Switch Pack (typical): Left Side Shown
(5) until snug.

6. See Figure 9-121. Install brake control assembly. Position

for rider comfort.

a. Engage ear (1) in recess (2).

b. Rotate into position.

c. Install clamp (4) and screws (3).

7. Tighten switch housing:

a. Push hand grip inboard to verify that hand grip is

fully seated.

b. Move the switch housing assembly inboard (away

from grip) to remove all end play. Then move the
switch housing outboard 0.040 –0.08 in (1–2 mm)
to introduce end play.

c. While holding switch housing in place, tighten switch

housing screws to 35–45 in-lbs (4–5 N·m).

94000383 9-95
 7. Position control for rider comfort. Tighten to 60–80 in-lbs
sm07608
3 (6.8–9 N·m).

8. Tighten switch housing screws to 35–45 in-lbs (4–5 N·m).

9. See Figure 9-123. Slide trigger finger switch cap (1) until
4 it clicks into place.
2
WARNING
Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)
1
10. Test switches for proper operation.

6 WARNING
The left hand control switch pack controls the clutch
5
interlock. A motorcycle with the wrong switch pack
1. Switch installed can start in gear causing loss of control, which
2. Latch could result in death or serious injury. Verify clutch
3. Connectors interlock function whenever switch pack is replaced.
4. Fingers (00632b)
5. Screws
6. Front housing 11. Verify clutch interlock operation. Perform the following
Figure 9-124. Switch Pack (typical) steps in order. Do not skip any steps. If any test fails, stop
and diagnose the condition before proceeding.
Left Handlebar Controls
NOTE a. Remove spark plug cables from spark plugs.
Never install a switch from a different model. Although they
b. Straddle vehicle. Press and hold the rear brake
are similar and will physically install, certain features are
pedal.
different and will cause the clutch interlock to not operate
properly. c. Turn ignition switch ON. Turn the run/stop switch to
RUN.
1. Install new hand grip, if removed. See HANDLEBAR, Left
Hand Grip (Page 3-92). d. Shift into neutral and release the clutch lever. Briefly
push the start switch. The starter should operate.
2. See Figure 9-124. Mate electrical connectors (3). Route
harness through fingers (4) and into channel in switch e. Shift into the highest gear. Pull in the clutch lever
pack. and briefly press the start switch. The starter should
operate.
3. Place module on handlebar. Rotate switch (1) up and snap f. With the clutch lever released and transmission in
latch (2) into place. gear, briefly press the start switch. The starter should
not operate.
NOTE
See Figure 9-123. Avoid pinching wires by alignment feature g. Turn off the ignition and run/stop switches.
(4) while assembling switch housings. Tuck wires close to the
wire retainer (2) as shown in Figure 9-122. h. Install spark plug cables.

SWITCH PACK HARNESS

4. Verify that wire harness is in the recess at bottom of
handlebar.
Remove
5. Install switch housings. Tighten screws (5) until snug.
1. Fork-mounted fairing models: Remove outer fairing and
dash panel. See OUTER FAIRING AND WINDSHIELD:
6. See Figure 9-121. Install clutch control assembly. Position FORK MOUNTED FAIRING MODELS (Page 3-115) and
for rider comfort. DASH PANEL: FORK MOUNTED FAIRING MODELS
(Page 3-117) respectively.
a. Engage ear (1) in recess (2).
2. Frame-mounted fairing models: These models have
b. Rotate into position. internally wired handlebar. See HANDLEBAR, Remove
Harnesses, FLTR Models (Page 3-91).
c. Install clamp (4) and screws (3).

9-96 94000383
3. Road King models: Remove handlebar clamp shroud. sm07967
See HEADLAMP NACELLE: ROAD KING MODELS 3
(Page 3-144).
4. Remove switch module. See HANDLEBAR SWITCH 1
PACKS, Removal (Page 9-94). 5
5. Release harness from handlebar:
a. Fork-mounted fairing models: Cut cable strap
securing harness to handlebar.
b. Road King models: Remove two retainers from 2
handlebar. Remove retainers from harness.

6. Disconnect switch pack harness from main harness: 4

a. Fork-mounted fairing models: See Figure 9-125.
Disconnect from fairing harness caddy.
b. Road King models: See Figure 9-126 or Figure 9-127.
Disconnect from steering head caddies.

7. Pull harness forward to remove.

sm07998
1. Right handlebar switch module
2. Front WSS (ABS models)
3. Nacelle switch connector
4. Brake line retainer
5. Caddy retainer
Figure 9-127. Right Side Connectors: Road King

Install
1. Frame-mounted fairing models: These models have
1 2 internally wired handlebar. See HANDLEBAR, Install
Harnesses, FLTR Models (Page 3-91).

1. Right switch pack connectors 2. Route harness rearward between handlebar and upper
2. Left switch pack connector fork bracket. Continue to the switch module.
Figure 9-125. Handlebar Switch Pack Connectors: Fairing 3. Connect harness to switch module. Install switch module
Models and housings. See HANDLEBAR SWITCH PACKS, Install
(Page 9-95).
sm07537a
4. Connect switch module harness to main harness:
1 5
a. Fork-mounted fairing models: See Figure 9-125. Mate
2 to connectors on fairing harness caddy.
b. Road King models: See Figure 9-126 and Figure
9-127. Mate to connectors on steering head caddies.
3
5. Secure harness to handlebar:
a. Fork-mounted fairing models: Install new cable strap
4 securing harness to handlebar.
b. Road King models: Install two retainers to holes in
handlebar.

1. Left handlebar switch module 6. Fork-mounted fairing models: Install outer fairing and
2. TGS dash panel. See OUTER FAIRING AND WINDSHIELD:
3. Right auxiliary/fog/turn signal lamps FORK MOUNTED FAIRING MODELS (Page 3-115) and
4. Left auxiliary/fog/turn signal lamps DASH PANEL: FORK MOUNTED FAIRING MODELS
5. Caddy retainer (Page 3-117) respectively.
Figure 9-126. Left Side Connectors: Road King Models 7. Road King models: Install handlebar clamp shroud. See
HEADLAMP NACELLE: ROAD KING MODELS
(Page 3-144).

94000383 9-97
HANDLEBAR SWITCH CAPS 3. Install switch cap:
a. Rocker switch caps: Hook new cap on one end and
1. Remove handlebar switch housing. See HANDLEBAR rotate into place. An audible snap will be heard when
SWITCH PACKS, Removal (Page 9-94). securely installed.
2. Remove switch cap: b. Toggle and joystick caps: Push straight on with finger.
a. Rocker switch caps: See Figure 9-128. Entering from
the end, carefully pry between the switch cap and switch 4. Install switch housing. See HANDLEBAR SWITCH PACKS,
plunger. Remove switch cap. Install (Page 9-95).

b. Toggle and joystick caps: Grasp with pliers and pull

straight off. Removal will destroy cap.

sm08017a

1 2

1. Remove cap 2. Install cap

Figure 9-128. Replace Switch Caps

9-98 94000383
SECURITY SYSTEM MAINTENANCE 9.40
FOB BATTERY
Battery Replacement
Battery Replacement Schedule 1. Disarm system. Remove siren.

Replace the fob battery every year. 2. See Figure 9-130. With a small screwdriver, push the
catches (1) in through the two slots (2) in the end of the
siren. Release the battery cover (3).
Battery Replacement
1. Open the fob case. NOTE
• For protection against corrosion, battery terminals and
a. See Figure 9-129. Place a thin blade in the thumbnail battery clip are covered with a special grease. Do not wipe
slot (1). away this substance. Apply all available existing grease to
b. Twist the blade to separate cases. terminals on new battery.
• Use only a 9 V nickel metal hydride battery in the siren.
NOTE
Use a CR2032 or equivalent battery. 3. Replace 9 volt battery (4) by removing old battery from
polarized battery clip.
2. Install a new battery with the positive side up.
4. Recharge and install or install a new 9 volt nickel metal
a. Push the latch (3) away from the battery. hydride battery.
b. Lift the battery from the side opposite the latch. 5. Install cover (3).
c. Verify that the metal tabs will firmly contact battery. a. Carefully replace the rubber seal (5) on the cover.
Bend up slightly if necessary.
b. Align battery cover with case placing round corners on
d. Install the battery against the latch with the positive side cover away from connector [142A] (6).
up. Drop into place.
c. Snap cover into place.
3. Close the case.
6. Install siren and check operation. Two chirps after an
a. Align case halves. arming command indicate a working siren.
b. Snap case halves together. sm06145a

4
sm08665
1 2

CR2032
5 6
3

1. Catch (2)
1 2. Slot (2)
3
3. Cover
4. 9 Volt battery
1. Thumbnail slot
5. Rubber seal
2. Battery (CR2032)
6. Connector [142A]
3. Latch
Figure 9-130. Siren Battery Compartment
Figure 9-129. Replace Fob Battery
SMART SIREN (IF EQUIPPED) SECURITY SYSTEM ANTENNA

Battery Replacement Schedule Removal

1. Remove seat.
The siren internal 9 V battery is rechargeable and does not
require regular replacement. Battery life under normal 2. See Figure 9-131. Release security system antenna (6)
conditions is approximately 3-6 years. from top caddy (1).

NOTE 3. Disconnect security system antenna harness.

If the motorcycle battery is less than 12.5 V, the internal siren
battery may not charge.

94000383 9-99
Installation
1. See Figure 9-131. Connect security system antenna (6)
to harness.
2. Engage groove on security system antenna on tongue at
front of top caddy.
3. Install seat. After installing seat, pull up on the seat to be
sure it is secure.
4. Test all security system functions.

sm07592
1

6 2

4 3

1. Top caddy
2. Screw (2)
3. ECM
4. Connector, grey
5. Connector, black
6. HFSM antenna
7. Purge valve solenoid
Figure 9-131. Top Caddy

9-100 94000383
PERSONAL IDENTIFICATION NUMBER (PIN) 9.41
GENERAL Modifying an Existing PIN

The PIN consists of five digits. Each digit can be any number If a PIN was previously entered, the odometer will display the
from 1 through 9. There can be no zeros (0) in the PIN. Use equivalent digit. Each additional press of the left turn switch
the PIN to disarm the security system in case the fob becomes will increment the digit.
unavailable. Examples:
CHANGING THE PIN • To advance from 5 to 6, press and release the left turn
switch 1 time.
The rider can change the PIN at any time. Refer to Table 9-9. • To advance from 8 to 2, press and release the left turn
switch 3 times (9-1-2).
Table 9-9. Changing the PIN: HFSM
STEP ACTION CONFIRMATION NOTES
Select a five-digit (1 through 9) PIN and
record in the owner's manual and on the
1 wallet card.
With fobs present, cycle ignition switch
2 IGNITION-OFF-IGNITION-OFF-IGNITION.
3 Press left turn signal button twice. Turn signals flash 3 times.
Current PIN will appear in odometer. The
4 Press right turn signal button once. first digit will flash.
Enter first digit (a) of new PIN by pressing
left turn signal button until desired digit is
5 displayed in odometer.
The new digit replaces the current in the
6 Press right turn signal button once. odometer. The second digit flashes.
Enter second digit (b) of new PIN by
pressing left turn signal button until de-
7 sired digit is displayed in odometer.
The new digit replaces the current in the
8 Press right turn signal button once. odometer. The third digit flashes.
Enter third digit (c) of new PIN by pressing
left turn signal button until desired digit is
9 displayed in odometer.
The new digit replaces the dash in the
10 Press right turn signal button once. odometer. The fourth digit flashes.
Enter fourth digit (d) of new PIN by press-
ing left turn signal button until desired digit
11 is displayed in odometer.
The new digit replaces the current in the
12 Press right turn signal button once. odometer. The fifth digit flashes.
Enter fifth digit (e) of new PIN by pressing
left turn signal button until desired digit is
13 displayed in odometer.
The new digit replaces the current in the
14 Press right turn signal button once. odometer. The first digit flashes.
Turning ignition switch to OFF
15 Turn the ignition switch to OFF. stores PIN.

94000383 9-101
SECURITY SYSTEM ACTUATION 9.42
SIDECAR CONFIGURATION
sm08666

WARNING
1
Do not add sidecar to this motorcycle. Operating
motorcycle with sidecar can cause loss of vehicle control,
which could result in death or serious injury. (00590d)
ACTIVATION

Activation consists of assigning two fobs to the system and

entering an initial PIN.

NOTE
If the fob is lost or inoperable, the PIN allows the owner to 2
disarm the system. See Personal Identification Number (PIN),
Changing the PIN (Page 9-101). 1. Fob serial number
2. Fob cover
1. Configure the security system by assigning both fobs to Figure 9-132. Fob Serial Number
the vehicle.
2. Configure the security system by entering a PIN picked
by the owner.

Record the PIN in the owner's manual. Instruct the customer

to carry a copy (use the wallet card found in the owner's
manual). See Personal Identification Number (PIN)
(Page 9-101).

Once the system has been activated, it "arms" within 5 seconds

of switching the IGN switch to OFF and no motorcycle motion.

FOB ASSIGNMENT

PART NUMBER TOOL NAME

HD-48650 DIGITAL TECHNICIAN II

Use DIGITAL TECHNICIAN II (PART NUMBER: HD-48650)

to assign both fobs to the vehicle.

NOTE
• Choose the correct fob type. Choosing incorrectly at the
beginning of the process will result in a failure to assign the
fob. This can be mistakenly diagnosed as a bad fob or SCM.
• When assigning a fob, keep the fob within 3 ft (1 m) of the
vehicle seat.

See Figure 9-132. Follow the menu prompts to scan the fob
serial number with the bar code reader. Alternatively, enter the
number using the keyboard. Use DIGITAL TECHNICIAN II
(PART NUMBER: HD-48650) to assign fob and enter initial
PIN.

NOTE
Each fob has a unique serial number. Attach fob label to a
blank NOTES page in the owner's manual for reference.

9-102 94000383
SECURITY SIREN 9.43
REMOVAL 5. Install left side saddlebag. See SADDLEBAGS
(Page 3-98).
1. Remove left side saddlebag. See SADDLEBAGS
sm07594
(Page 3-98). 2
1
2. Remove left side cover.
3. With security fob present, turn ignition switch ON.
4. See Figure 9-133. Remove main fuse (3).
5. Disconnect security siren connector (1).
6. Remove security siren (2).
INSTALLATION
3
1. See Figure 9-133. Install security siren (2).
2. Connect security siren connector [142] (1).
3. Install main fuse (3) into holder. 1. Security siren connector
4. Install left side cover. 2. Security siren
3. Main fuse
Figure 9-133. Security Siren

94000383 9-103
NOTES
SUBJECT PAGE NO.
A.1 CONNECTORS .................................................................................................................... A-1
A.2 WIRING DIAGRAMS ............................................................................................................ A-7

APPENDIX A WIRING
NOTES
CONNECTORS A.1
CONNECTOR LOCATIONS Connector Number
On wiring diagrams and in service instructions, connectors are
Function/Location identified by a number in brackets.
All vehicle connectors are identified by their function and
location. Refer to Table A-1. Repair Instructions
The repair instructions in Appendix B of the electrical diagnostic
Place and Color manual (EDM) are by connector type. Refer to Table A-1.
The place (number of wire cavities of a connector housing)
and color of the connector can also aid identification.
Table A-1. Connector Locations
TERMINAL
DESCRIPTION TYPE PROBE COL- LOCATION
NO. OR
16-way Molex MX 150 Sealed Inner fairing - right radio support
[1] Fairing harness Gray
(BK) bracket
12-way Molex MX 150 Sealed Inner fairing - left radio support
[2] Fairing harness Gray
(GY) bracket
[4] AUX devices 4-way Molex MX150 (GY) Gray Under left side cover
2-way Delphi 800 Metri-Pack
[5] Main fuse Red Under left side cover
Sealed (BK)
6-way Molex MX150 Sealed
[7] Rear fender lights harness Gray Top of rear fender (under seat)
(BK)
6-way Molex MX150 Sealed
[12] Tour-Pak lights Gray Under seat in front of Tour-Pak
(BK)
2-way Tyco 070 Multilock Un-
[12-2] Right side marker light Gray Inside Tour-Pak
sealed (BK)
2-way Tyco 070 Multilock Un-
[12-3] Left side marker light Gray Inside Tour-Pak
sealed (BK)
4-way Molex MX150 Sealed
[13] Fuel tank harness Gray Behind fuel tank (under seat)
(GY)
2-way Tyco 070 Multilock Un- Circuit board under tail lamp as-
[18] Right rear turn signal Gray
sealed (BK) sembly
2-way Tyco 070 Multilock Un- Circuit board under tail lamp as-
[19] Left rear turn signal sealed (BK) Gray sembly
8-way Molex MX150 Sealed
[20] Console harness (BK) Gray Under seat
Inner fairing - under radio right side
(with fairing) (except FLT)
Instrument nacelle (back of speedo-
meter) (FLT models)
Inside headlamp nacelle (without
RHCM main harness 4-way JAE MX19 Sealed (BK) Yellow fairing)
[22-1] RHCM 4-way JST JWPF Sealed (W) Light blue Inside RHCM housing
Inner fairing - under radio right side
(with fairing) (except FLT)
Instrument nacelle (back of speedo-
meter) (FLT models)
Inside headlamp nacelle (without
RHCM main harness 2-way JAE MX19 Sealed (BK) Yellow fairing)
[22-2] RHCM 2-way JST JWPF Sealed (W) Light blue Inside RHCM housing

94000383 A-1
 Table A-1. Connector Locations
TERMINAL
DESCRIPTION TYPE PROBE COL- LOCATION
NO. OR
Inner fairing - under radio left side
(with fairing) (except FLT)
Instrument nacelle (back of speedo-
meter) (FLT models)
Inside headlamp nacelle (without
LHCM main harness 4-way JAE MX19 Sealed (BK) Yellow fairing)
[24] LHCM 4-way JST JWPF Sealed (W) Light blue Inside LHCM housing
48-way Molex CMC Sealed Inner fairing - back of radio (right
[27] Radio (BK) Breakout Box side)
[29] Position lamp (if equipped) 2-way EPC (BK) Gray Inside headlamp nacelle
Inside headlamp nacelle (without
4-way Tyco 070 Multilock Un- fairing)
sealed (BK) (without fairing) Inside left front turn signal/Aux lamp
Left front turn signal/auxiliary 4-way JAE MX19 Sealed (BK) Gray support (with fairing) (except FLT)
[31L] lamp (with fairing) Yellow Inner fairing - lower right side (FLT)
Inside headlamp nacelle (without
6-way Tyco 070 Multilock Un- fairing)
sealed (BK) (without fairing) Inside right front turn signal/Aux lamp
Right front turn signal/auxiliary 4-way JAE MX19 Sealed (BK) Gray support (with fairing) (except FLT)
[31R] lamp (with fairing) Yellow Inner fairing - lower right side (FLT)
Inner fairing - below upper for bracket
(left side) (with fairing)
Front fender tip lamp jumper 2-way Tyco 070 Multilock Un- Inside headlamp nacelle (without
[32] harness (if equipped) sealed (BK) Gray fairing)
2-way Delphi GT 150 3.5mm Bottom of ignition switch (with fairing)
[33] Ignition switch sealed (GY) Gray Under console (without fairing)
[34-1] Right front speaker 2-Way Molex MX150 (BK) Gray Inner fairing (right speaker enclosure)
Tyco Insulated Spade terminals
[34-2] Right front speaker (BK) Gray Inner fairing (back of right speaker)
[35-1] Left front speaker 2-Way Molex MX150 (BK) Gray Inner fairing (left speaker enclosure)
Tyco Insulated Spade terminals
[35-2] Left front speaker (BK) Gray Inner fairing (back of left speaker)
[36+] Tyco Insulated Spade terminals Inside left speaker POD (back of left
[36-] Left rear speaker (BK) Gray speaker)
[37+] Tyco Insulated Spade terminals Inside right speaker POD (back of
[37-] Left rear speaker (BK) Gray right speaker)
4-way Delphi 150 Metri-Pack
[38] Headlamp (BK) Gray Inner fairing back of headlamp
[38HI] Headlamp high beam 2-way Tyco (GY) Gray Inside headlamp nacelle
[38LO] Headlamp low beam 2-way Tyco (BK) Gray Inside headlamp nacelle
Back of speedometer under console
(without fairing) (except FLT)
Instrument nacelle (back of IM) (FLT
Speedometer (without fairing) 12-way Delphi Micro 64 Sealed models)
[39] IM (with fairing) (GY) Breakout Box Inner fairing back of IM (with fairing)
[41+] Tyco Insulated Spade terminals Inside right saddlebag (back of
[41-] Right saddlebag speaker (BK) Gray speaker)
[42+] Tyco Insulated Spade terminals Inside left saddlebag (back of
[42-] Left saddlebag speaker (BK) Gray speaker)
Rear fender tip lamp (if Circuit board under tail lamp as-
[45] equipped) 2-way Tyco 070 Unsealed Gray sembly
[47] Stator 3-way Dekko (BK) Green Bottom of voltage regulator (left side)
[50] CB antenna cable 1-way AMP TCN Inner fairing - back of CB module

A-2 94000383
 Table A-1. Connector Locations
TERMINAL
DESCRIPTION TYPE PROBE COL- LOCATION
NO. OR
[51] Radio antenna cable 1-way AMP TCN Inner fairing - back of radio (left side)
[52] Radio antenna cable to mast 1-way AMP TCN Inside of Tour-Pak
[53] Rider headset 6-way Molex MX150 (BK) Gray Under seat
24-way fargo fuse block un-
[64] Fuse block sealed (BK) Gray Under left side cover
3-way Delphi GT 150 Sealed Top of transmission case (under
[65] VSS (BK) Gray starter)
4-way Tyco Mate-N-lok Un-
[67] Accessory switch sealed (BK) Gray Inside headlamp nacelle
2-way Delphi 280 Metri-Pack
[73] Auxiliary/fog lamps Sealed (BK) Purple Inside auxiliary/fog lamps
[76] Passenger headset 7-way DIN (BK) Below rear left speaker box
Bottom of voltage regulator (right
[77] Voltage regulator 2-way Dekko (BK) Green side)
[78-1] ECM 18-way Tyco (BK) Breakout Box Under seat
[78-2] ECM 18-way Tyco (GY) Breakout Box Under seat
[78-3] ECM 18-way Tyco (BN) Breakout Box Under seat
2-way Deutsch DTM Sealed Rear of lower front frame crossmem-
[79] CKP sensor Brown
(BK) ber
[80] TMAP sensor 4-way MCON 1.2 Sealed Light blue Top of induction module
[83] Ignition coil 3-way Delphi GT 150 3.5mm Gray Bottom front of battery tray
[84] Front fuel injector 2-way Molex BPT Sealed (BK) Purple Below fuel tank (left side)
[85] Rear fuel injector 2-way Molex BPT Sealed (BK) Purple Below fuel tank (left side)
[90] ET sensor 2-way MCON 1.2 Sealed Light blue Back of front cylinder (left side)
[91] DLC 4-way Deutsch DT Sealed (GY) Black Under left side cover
[91-2] DLC 6-way Deutsch DT sealed (GY) Black Under left side cover
4-way Tyco 070 Multilock Un- Circuit board under tail lamp as-
[93] Tail lamp Gray
sealed (BK) sembly
Rear fender lights harness in 6-way Tyco 070 Multilock Un- Circuit board under tail lamp as-
[94] Gray
circuit board sealed (BK) sembly
2-way Delphi 150 Metri-Pack
[95] Purge solenoid Gray Under seat
Sealed (R)
2-way Delphi 150 Metri-Pack
[97] Right cooling fan Gray Inside right lower fairing
Sealed (BK)
6-way Molex MX150 Sealed
[105L] OE dash switch pack Gray Behind switch cover (left side)
(BK)
6-way Molex MX150 Sealed
[105R] P&A dash switch pack Gray Behind switch cover (right side)
(BK)
2-way Molex MX64 Unsealed
[107] AAT sensor Light blue Steering head, left side
(BK)
Auxiliary lamps switch (without 4-way Tyco Mate-N-Lok Un-
[109] Gray Inside headlamp nacelle
fairing) sealed (BK)
4-way Delphi GT 150 3.5mm
[111] Voltmeter Gray Inner fairing (back of voltmeter)
Sealed (BK)
Inner fairing (marked with yellow spot
[111-2] Voltmeter jumper 4-way JAEMX19 Sealed (BK) Yellow
tape)

94000383 A-3
 Table A-1. Connector Locations
TERMINAL
DESCRIPTION TYPE PROBE COL- LOCATION
NO. OR
4-way Tyco 040 Multilock un- Inner fairing (back of fuel gauge)
sealed (BK) (without fairing) (with fairing)
[117] Fuel gauge Gray
4-way Delphi GT 150 3.5mm Bottom fuel tank left side (without
Sealed (BK) (with fairing) fairing)
Inner fairing (marked with yellow spot
[117-2] Fuel gauge jumper 4-way JAEMX19 Sealed (BK) Yellow
tape)
Push-on Right Angle Molded
[120] Oil pressure switch Black Front right crankcase
terminal (BK)
[121-1] Mid-chassis, lower right side between
Rear brake switch Push-on Molded terminals (BK) Red
[121-2] frame and exhaust pipe)
[122-1]
Horn Flag terminals (BK) Red Between cylinders (left side)
[122-2]
[128] Starter solenoid Delphi 56 Spade terminal (W) Red Top of starter
[131-1] Push-on Right Angle Molded
Neutral switch Top of transmission (right side)
[131-2] terminals (BK)
2-way Tyco 070 Multilock Un-
[132] Power outlet Gray Inner fairing
sealed (BK)
[132C] Power outlet 2-way Delphi Unsealed (GY) Red Inner fairing
3-way Molex MX 150 Sealed Rear of lower front frame crossmem-
[133] JSS Gray
(BK) ber
4-way Molex MX 150 Sealed
[137] HO2S rear Gray Under right side cover
(BK)
4-way Molex MX 150 Sealed
[138] HO2S front Gray Under right side cover
(GY)
3-way Delphi GT 150 3.5mm
[139] Oil pressure sender Gray Front right crankcase
Sealed
Fuel pump and fuel level 4-way Delphi GT 280 Sealed Under console on top of fuel tank
[141] Gray
sender (BK) canopy
3-way Delphi GT 150 Sealed
[142] Security siren Gray Under left side cover
(BK)
Front fender tip lamp (if 2-way Tyco 070 Multilock Un-
[143] Gray Under front fender tip lamp bracket
equipped) sealed (BK)
23-way Tyco AMPSEAL Sealed
[149-1] Audio amplifier 1 Black Under fairing above radio
(BK)
23-way Tyco AMPSEAL Sealed
[149-2] Audio amplifier 2 Black Inside left saddlebag
(BK)
6-way Molex MX150 (BK) Inner fairing - above radio (FLHX/S,
(without Tour-Pak) FLT)
[162] Rear audio Gray
16-way Molex MX150 (BK) Under seat just in front of Tour-Pak
(with Tour-Pak) (FLHT)
26-way Bosch BTC Sealed
[166] ABS module Breakout Box Under right side cover
(BK)
2-way Delphi 150 Metri-Pack Just below upper fork bracket right
Sealed (BK) (with fairing) Gray side (with fairing)
[167] Front WSS
2-way Deutsch DTM Sealed Brown Inside headlamp nacelle (without
(BK) (without fairing) fairing)
2-way Delphi 150 Metri-Pack
[168] Rear WSS Gray Under right side cover
Sealed (BK)
12-way Molex MX150 Sealed
[184] CB module Gray Inner fairing - left side of radio
(BK)

A-4 94000383
 Table A-1. Connector Locations
TERMINAL
DESCRIPTION TYPE PROBE COL- LOCATION
NO. OR
Inner fairing - under radio right side
Heated handgrip to main har- 2-way Tyco 040 multilock Un- (with fairing) (except FLT)
[189] Gray
ness sealed (BK) Instrument nacelle (back of IM) (FLT
models)
2-way Tyco Superseal 1.5
[203F] ACR (front) Gray Bracket attached to the throttle body
Sealed
2-way Tyco Superseal 1.5
[203R] ACR (rear) Gray Bracket attached to the throttle body
Sealed
Inner fairing - right side below radio
(with fairing) (except FLT)
Instrument nacelle (back of IM) (FLT
[204] TGS harness 6-way JST JWPF Sealed Light blue
models)
Inside headlamp nacelle - fork stem
nut lock plate (without fairing)
[205] Chassis cooling fan switch 4-way Mate-N-Lock Gray Inside headlamp nacelle
[206] Heated handgrip interconnect 2-way Tyco 040 Unsealed Gray Inside outer fairing, right side
2-way Molex MX64 Unsealed
[209] Security antenna Light blue Under seat
(BK)
Right side of engine (induction mod-
[211] TCA 6-way Delphi GT 150 Sealed Gray
ule)
2-way Delphi 150 Metri-Pack
[215] Left cooling fan Gray Inside left lower fairing
Sealed (BK)
[225] Rider headset 7-way DIN (BK) Under Console
12-way Delphi Micro 64 Sealed
[226] Rear lighting jumper harness Breakout Box Rear fender tip fascia module
(GY)
2-way Molex MX150 Sealed
[232R] Right cooling fan jumper Gray Under voltage regulator
(BK)
4-way Molex MX150 Sealed
[232L] Left cooling fan jumper Gray Under voltage regulator
(BK)
[235] Cooling pump 3-way MCON 1.2 Sealed Light blue
2-way Delphi GT 150 3.5mm
[236] ECT sensor Gray Inside left lower fairing
Sealed ( BK)
48-way Molex CMC Sealed
[242] BCM Breakout Box Under left side cover
(BK)
Inner fairing next to left speaker en-
[243] P&A CAN 4-way JAEMX19 Sealed (BK) Yellow
closure
2-way Tyco 070 Multilock Un-
[258] Power outlet Gray Inside Tour-Pak
sealed (BK)
1-way Delphi 800 Metri-Pack
[259] BCM power Red Under left side cover
Sealed (BK)
12-way Delphi Micro 64 Sealed
[262] Rear lighting jumper harness Breakout Box Rear fender tip fascia module
(GY)
12-way Molex MX150 Sealed
[280] P&A audio Gray Inner fairing - above radio
(GY)
[281] Battery tender 2-way overmold (BK) Under left side cover
[287] Tour-Pak lights 5-way Delphi 150 Metri-Pack Gray Inside Tour-Pak
12-way Deutsch DT Sealed
[288] Left saddlebag Black Inside left saddlebag
(BK)
[296] Speaker interconnect 4-way Molex MX150 (BK) Gray Under seat just in front of Tour-Pak
[297] Speaker interconnect 4-way Molex MX150 (BK) Gray Under seat just in front of Tour-Pak
[298] Right saddlebag 2-way Molex MX150 (BK) Gray Inside right saddlebag

94000383 A-5
 Table A-1. Connector Locations
TERMINAL
DESCRIPTION TYPE PROBE COL- LOCATION
NO. OR
2-way Tyco 070 Multilock Un-
[299] P&A accessory power Gray Inner fairing
sealed (BK)
[315] Front knock sensor 2-way KOSTAL MLK 1.2 Light blue Under fuel tank
[316] Rear knock sensor 2-way KOSTAL MLK 1.2 Light blue Under fuel tank
[317] Oil cooling fan 2-way Delphi Metr Pack 150 Gray
[318] Chassis cooling fan 2-way Delphi Metr Pack 150 Gray Under seat
[319] Terminating resister 2-Way Delphi GT 150 Gray Right side cover
[325] P&A accessory 3-way Molex MX150 Gray Right side cover
[GND1]
[GND2] Harness grounds Ring terminals Under seat
[GND2A]
1-way Push On Molded termin-
[GND3] Fork bracket ground Steering head, left side
al (BK)

A-6 94000383
WIRING DIAGRAMS A.2
WIRING DIAGRAM INFORMATION ed03175
5
Wire Color Codes
3 4
Wire traces on wiring diagrams are labeled with alpha codes. 6
Refer to Table A-2.

For Solid Color Wires: See Figure A-1. The alpha code 1 2 7
identifies wire color.

GN/Y
W
For Striped Wires: The code is written with a slash (/) between 8
the solid color code and the stripe code. For example, a trace [21A] 1 2

labeled GN/Y is a green wire with a yellow stripe. [21B] 1 2

9

GN/Y
Wiring Diagram Symbols
See Figure A-1. On wiring diagrams and in service/repair 1 2 10
instructions, connectors are identified by a number in brackets
[ ]. The letter inside the brackets identifies whether the housing
is a socket or pin housing. 13 11
A=Pin: The letter A and the pin symbol after a connector
number identifies the pin side of the terminal connectors. 12
B=Socket: The letter B and the socket symbol after a connector
number identifies the socket side of the terminal connectors. 1. Connector number
Other symbols found on the wiring diagrams include the 2. Terminal code (A=pin, B=socket)
following: 3. Solid wire color
4. Striped wire color
Diode: The diode allows current flow in one direction only in 5. Socket symbol
a circuit. 6. Pin symbol
7. Diode
Wire break: The wire breaks are used to show option variances 8. Wire break
or page breaks. 9. No connection
No Connection: Two wires crossing over each other in a wiring 10. Circuit to/from
diagram that are shown with no splice indicating they are not 11. Splice
connected together. 12. Ground
13. Twisted pair
Circuit to/from: This symbol indicates a more complete circuit Figure A-1. Connector/Wiring Diagram Symbols
diagram on another page. The symbol is also identifying the
direction of current flow. ed03380

Splice: Splices are where two or more wires are connected

together along a wiring diagram. The indication of a splice only
indicates that wires are spliced to that circuit. It is not the true 6 5 4 3 2 1

location of the splice in the wiring harness. 8 1 2

12 11 10 9 8 7

Ground: Grounds can be classified as either clean or dirty 9 10 3

18 17 16 15
grounds. Clean grounds are identified by a (BK/GN) wire and OMRON
G8VA-1A4T
OMRON
G8VA-1A4T
14 13

are normally used for sensors or modules. -R01 -R01 4

12VDC
7 JAPAN 12VDC
6 JAPAN
20 19

NOTE 2755D5 2755D5 5

24 23 22 21

Clean grounds usually do not have electric motors, coils or

anything that may cause electrical interference on the ground
circuit.

Dirty grounds are identified by a (BK) wire and are used for 1. System power
components that are not as sensitive to electrical interference. 2. Battery
3. Spare
Twisted pair: This symbol indicates the two wires are twisted 4. Spare
together in the harness. This minimizes the circuit's 5. Spare
electromagnetic interference from external sources. If repairs 6. Cooling relay
are necessary to these wires they should remain as twisted 7. P&A relay
wires. 8. Radio
9. P&A
10. Cooling
Figure A-2. Fuse Block [64B]

94000383 A-7
 Table A-2. Wire Color Codes Table A-2. Wire Color Codes
ALPHA CODE WIRE COLOR ALPHA CODE WIRE COLOR
BE Blue PK Pink
BK Black R Red
BN Brown TN Tan
GN Green V Violet
GY Gray W White
LBE Light Blue Y Yellow
LGN Light Green
2017 TOURING WIRING DIAGRAMS
O Orange

WIRING DIAGRAM LIST

FIGURE NUMBER
Battery Power Distribution: FLH with Fairing Figure A-3.
Battery Power Distribution: FLT Figure A-4.
Battery Power Distribution without Fairing Figure A-5.
Ignition and ACC FLH: 2017 Touring Figure A-6.
Ignition and ACC FLT: 2017 Touring Figure A-7.
Sensor Grounds FLH: 2017 Touring Figure A-8.
Sensor Grounds FLT: 2017 Touring Figure A-9.
Ground Circuit FLH: 2017 Touring Figure A-10.
Ground Circuit FLT: 2017 Touring Figure A-11.
Front Lighting and Hand Controls: 2017 Touring Figure A-12.
Fairing Harness FLH: 2017 Touring Figure A-13.
Main Harness FLH (1 of 3): 2017 Touring (with Fairing) Figure A-14.
Main Harness FLH (2 of 3): 2017 Touring (with Fairing) Figure A-15.
Main Harness FLH (3 of 3): 2017 Touring (with Fairing) Figure A-16.
Fairing Harness FLT: 2017 Touring Figure A-17.
Main Harness FLT (1 of 3): 2017 Touring (with Fairing) Figure A-18.
Main Harness FLT (2 of 3): 2017 Touring (with Fairing) Figure A-19.
Main Harness FLT (3 of 3): 2017 Touring (with Fairing) Figure A-20.
Main Harness (1 of 3): 2017 Touring (without Fairing) Figure A-21.
Main Harness (2 of 3): 2017 Touring (without Fairing) Figure A-22.
Main Harness (3 of 3): 2017 Touring (without Fairing) Figure A-23.
Rear Lighting: 2017 Touring Figure A-24.
OE Radio: 2017 Touring (Except FLHX/S, FLT) Figure A-25.
OE Radio: 2017 Touring (No Tour-Pak) Figure A-26.
Speaker and P&A Amplifier Layout: 2017 Touring Figure A-27.
P&A Radio with 1 Amp: 2017 Touring Figure A-28.
P&A Radio with 2 Amps (1 of 2): 2017 Touring Figure A-29.
P&A Radio with 2 Amps (2 of 2): 2017 Touring Figure A-30.
P&A Radio with 4 Amps (1 of 4), Front Amp: 2017 Touring Figure A-31.
P&A Radio with 4 Amps (2 of 4), Left Saddlebag Amp: 2017 Touring Figure A-32.
P&A Radio with 4 Amps (3 of 4), Right Saddlebag Amp: 2017 Touring Figure A-33.
P&A Radio with 4 Amps (4 of 4), Tour-Pak Amp: 2017 Touring Figure A-34.

A-8 94000383
 em01977

Security Siren
Voltmeter LHCM RHCM ECM (If Equipped)
[111B] D [24A] 1 [22A-1] 1 [78B-2] 18 [142B] 1
R/O (GY)

R/O

R/O

R/O

R/O
[281B]

R 1 Battery
Tender
[1A] [1B]

R/O 4 4 R/O

Fuse Block
[64B]
Battery
R/O

R/O

[27B] R/O 2 1 R

[39B] 5 [117B] D Radio

M3 R/PK R/PK 6 5 R
IM Fuel Radio
M4

R
Gauge R/PK
P&A
R/BE 12 11 R

R/BE
Cooling
BN 10 9 R

P&A Relay
24 5 87

R/BE 17 3 30
18 1 85
23 2 86

Cooling Relay
22 5 87

BN 15 3 30
R/GN 16 1 85
Voltage 21 2 86
Regulator
[77B] P
R

R/GN
R

[166B] 1 17 [259B] 1 L3 [242B]

ECU [259A] 1 L3 [242A] Red Band
(ABS Only)
Battery Power

System Power

[5B] A B
BK

BK

BCM
Battery Starter Main
Fuse

Figure A-3. Battery Power Distribution: FLH with Fairing

94000383 A-9
 em01978

Security Siren
Voltmeter ECM (If Equipped)
[111B] D [78B-2] 18 [142B] 1
(GY)

R/O

R/O

R/O
[281B]

R 1 Battery
Tender
[1A] [1B]

R/O 4 4 R/O

Fuse Block
[64B]
Battery
R/O

R/O 2 1 R
[27B]
[117B] D Radio
M3 R/PK R/PK 6 5 R
Fuel Radio
M4 R/PK
Gauge

R
P&A
R/BE 12 11 R

R/BE
Cooling
BN 10 9 R

P&A Relay
24 5 87

R/BE 17 3 30
18 1 85
RHCM IM 23 2 86
[22A-1] 1 [39B] 1
Cooling Relay
R/O

R/O

Voltage 22 5 87
Regulator
BN 15 3 30
[77B] P R/GN 16 1 85
21 2 86
R

R/O

R/O

R R R
R/O

[24A] 1
R

[166B] 1 17 LHCM
R/GN

Red Band
R

ECU
(ABS Only) [259B] 1 L3 [242B]
R

[259A] 1 L3 [242A]
[5B] A B
BK
Battery Power

System Power

BK

Battery Starter Main

Fuse
BCM

Figure A-4. Battery Power Distribution: FLT

A-10 94000383
 em01979

Security
Siren
Speedometer LHCM RHCM ECM (If Equipped)
[39B] 5 [24A] 1 [22A-1] 1 [78B-2] 18 [142B] 1
R/O (GY)

R/O

R/O

R/O

R/O
[281B]

R 1 Battery
Tender
[20B] [20A]

R/O 6 6 R/O

Fuse Block
[64B]
Battery
R/O 2 1 R

R
P&A
R/BE 12 11 R
R/O

R/O

R/O

R/O

R/O

R/BE
Cooling
BN 10 9 R
Indicators
P&A Relay
24 5 87

R/BE 17 3 30
18 1 85
23 2 86

Cooling Relay
22 5 87

BN 15 3 30
R/GN 16 1 85
21 2 86
Voltage
Regulator
[77B] P
R
R

[166B] 1 17
R/GN

Red Band
R

ABS ECU
(If Equipped) [259B] 1 L3 [242B]
R

R
[259A] 1 L3 [242A]
[5B] A B
BK
Battery Power

System Power

BK

Battery Starter Main

Fuse
BCM

Figure A-5. Battery Power Distribution without Fairing

94000383 A-11
NOTES
 et00863
P&A Accessory Front Power Heated hand OE Dash P&A Dash P&A P&A Accessory P&A
Power Outlet Grips Switch Pack Switch Pack Accessory Audio Switch Accessory
[299A] 1 [132A] 1 [189B] 1 [105LB] 5 [105RB] 5 [325B] 1 [280A] 9 [67A] 1 [325B] 1

V/BE

V/BE

V/BE

V/BE

V/BE

V/BE

V/BE

V/BE

V/BE
[2A] [2B]

V/BE 2 2 V/BE

Fuel Auxiliary Lamps Rear Front

With W/O Fuel Fuel Ignition
Gauge Switch Fairing Fairing

V/BE
ECM Injector Injector Coil
[117B] 1 [109A] 1 [162A] 14
[78B-2] 16 [85B] A [84B] A [83B] B
(GY)

R/Y

R/Y

R/Y

R/GN

R/GN

R/GN

R/GN
R/Y

R/Y
Fuse Block
[64B]
W/O With Fairing, DLC 7.5A
System Power

R/Y
Fairing Except FLHX [91A] 5
R/GN 4 3 V/GN

R/Y
P&A Relay
Except FLHX V/BE 24 5 87
R/Y R/Y
17 3 30
R/Y R/Y R/Y 18 1 85
23 2 86
R/Y R/Y
FLHX
Purge ACR HO2S
Solenoid Front Front
[1A] [1B] [95B] A [203FB] 1 [138A] 1

V/GN

V/GN

V/GN
BE 10 10 BE

BE/BK 13 13 BE/BK
BE/BK

BE/BK
BE

BE

BE

BE
1 [32A] 4 1 [31LA] 4 1 [31RA] D [38A]
Front Fender Left Front Right Front Head
Tip Lamp Turn Signal/ Turn Signal/ Lamp

V/GN

V/GN
Jumper Auxiliary Auxiliary
Harness Lamps Lamps
[203RB] 1 [137A] 1

ACR HO2S
With Fairing, Rear Rear
Except FLHX
[12A] [12B]

BE/BK
BE 3 3 BE

R/GN
R/BN
R/BN

W/O
W/O

R/Y
BE

R
V/BE 1 1 V/BE
[13B] 1 3 [139B] [242B] E3 F4 J3 L3 L4 M2 1 [259B]
[13A] 1 Oil Pressure [242A] E3 F4 J3 L3 L4 M2 1 [259A] Red Band
Switch

Oil Pressure Input

Fuel Pump Power

Running/Position light Power

System Power
AUX Lamp Power
Accessory Power

Battery Power
V/BE

V/BE

V/BE

BE

R
[5B] A B

BK
2 [258A] 1 [12-2A] 1 [12-3A] C [287A]
R/Y
BE

BK
Rear Power Right Side Left Side Tour-Pak
[7A] 3 1 Outlet Marker Light Marker Light Lights

R
See Rear Lighting (If Equipped) [141B] B

Fuel Pump And

Fuel Level Sender Battery Starter 50A
Main Fuse
BCM

Figure A-6. Ignition and ACC FLH: 2017 Touring

94000383 A-13
Ignition and ACC FLH: 2017 Touring Ignition and ACC FLH: 2017 Touring

94000383 A-14
 et00864
P&A Accessory Front Power OE Dash P&A Dash Heated Hand P&A P&A
Power Outlet Switch Pack Switch Pack Grips Audio Accessory
[299A] 1 [132A] 1 [105LB] 5 [105RB] 5 [189B] 1 [280A] 9 [325B] 1

V/BE

V/BE

V/BE

V/BE

V/BK

V/BE

V/BE
[2A] [2B]

V/BE 2 2 V/BE V/BE V/BE

Rear Front
Fuel Fuel Ignition
ECM Injector Injector Coil
[78B-2] 16 [85B] A [84B] A [83B] B
(GY)

R/GN

R/GN

R/GN

R/GN
Fuse Block
[64B]
DLC 7.5A
System Power
[91A] 5
R/GN 4 3 V/GN

R/Y
P&A Relay
V/BE 24 5 87

17 3 30
R/Y 18 1 85
23 2 86

Purge ACR HO2S

Solenoid Front Front
[1A] [1B] [95B] A [203FB] 1 [138A] 1

V/GN

V/GN

V/GN
BE 10 10 BE

BE/BK 13 13 BE/BK

R/Y 16 16 R/Y
BE/BK

BE/BK
BE

BE

R/Y
4 1 [31LA] 4 1 [31RA]
Left Front Right Front D [38B]
Turn Signal/ Turn Signal/

V/GN

V/GN
Auxiliary Auxiliary Head
Lamps Lamps Lamp
[203RB] 1 [137A] 1

ACR HO2S
Rear Rear

BE/BK
R/GN
R/BN
W/O

R/Y
BE
R/BN

R
[242B] E3 F4 J3 L3 L4 M2 1 [259B]
[13B] 1
[242A] E3 F4 J3 L3 L4 M2 1 [259A] Red Band
[13A] 1

Oil Pressure Input

Fuel Pump Power

Running/Position light Power

System Power
AUX Lamp Power
Accessory Power

System Power
W/O

R
[5B] A B

BK
[139B]
R/Y

3
BE

BK
Oil Pressure
[7A] 3 1 Sender

R
See Rear Lighting [141B] B

Fuel Pump And

Fuel Level Sender Battery Starter 50A
Main Fuse
BCM

Figure A-7. Ignition and ACC FLT: 2017 Touring

94000383 A-15
Ignition and ACC FLT: 2017 Touring Ignition and ACC FLT: 2017 Touring

94000383 A-16
 et00865

[162A]

[22A-1] [1A] [1B] Except

FLHX BK/GN BK/GN 16

RHCM 2 BK/GN BK/GN 5 5 BK/GN BK/GN [162A] Rear Audio

FLHX BK/GN BK/GN 4

[24A]
[13A] [13B] [141B]
LHCM 2 BK/GN
BK/GN 3 3 BK/GN C
Fuel pump
and Sender

With Fairing
[33B]
[111B]
BK/GN 1
Ignition
Voltmeter B BK/GN Switch

BK/GN
[117B]
Fuel B BK/GN
Gauge

[166B]

[20B] BK/GN BK/GN 26

ABS ECU
(If Equipped)
IM 7 BK/GN
[133B]

BK/GN 3 JSS

[78B-1] (BK)
[242B]
ECM 10 BK/GN
BK/GN G4 BCM
[78B-2] (GY)

ECM 10 BK/GN
BK/GN

BK
[78B-3] (BN)

BK
ECM 10 BK/GN

BK

BK
[39B] [20B] [20A] [117B]
W/O Fairing [65B]

BK
Fuel

/G
Speedometer 7 BK/GN BK/GN 2 2 BK/GN BK/GN 4
Gauge

N
C Battery
VSS BK/GN BK/GN

GND 1 Transmission
BK/GN

[141B] [24A]
Fuel
Pump
C BK BK BK/GN 2 LHCM
BK/GN

[33B] [22A-1]

Ignition 1 BK/GN BK/GN 2

Switch RHCM

Figure A-8. Sensor Grounds FLH: 2017 Touring

94000383 A-17
Sensor Grounds FLH: 2017 Touring Sensor Grounds FLH: 2017 Touring

94000383 A-18
 et00866

[1A] [1B] [162A]

BK/GN 5 5 BK/GN BK/GN 16 Rear Audio

[13A] [13B] [141B]

BK/GN 3 3 BK/GN C Fuel Pump

and Sender

[33B]

BK/GN 1
Ignition
[111B] Switch

Voltmeter B BK/GN

[117B]
Fuel B BK/GN
Gauge

[166B]

BK/GN 26
ABS ECU
(If Equipped)
[133B]

BK/GN 3 JSS

[78B-1] (BK)
[242B]
ECM 10 BK/GN
BK/GN G4 BCM
[78B-2] (GY)

ECM 10 BK/GN

BK
[78B-3] (BN)

BK
ECM 10 BK/GN

BK

BK
[39B]
[65B]

BK
/G
IM 7 BK/GN

N
C Battery
VSS BK/GN BK/GN

GND 1 Transmission
[24A]

BK/GN 2 LHCM

[22A-1]

BK/GN 2 RHCM

Figure A-9. Sensor Grounds FLT: 2017 Touring

94000383 A-19
Sensor Grounds FLT: 2017 Touring Sensor Grounds FLT: 2017 Touring

94000383 A-20
 et00867
BK
[20B] [20A]
W/O

BK

BK

BK

BK

BK
Fairing
[GND3A] [GND3B]
BK 8 8 BK W/O
2 [29B] 1 [31LA] 1 [31RA] 1 [38LB] 1 [38HB] [141B] Fairing
BK 1 1 BK Front Position Left Front Right Front Headlamp Headlamp BK Fuel Pump and D BK
Lamp Low Beam High Beam Fuel Level Sender [13B] [13A]
Turn/Auxiliary Turn/Auxiliary
Lamps Lamps With
BK 4 4 BK Fairing
[2A] [2B] With
Fairing

BK
BK

BK
BK BK 3 3 BK
[109A] [235B]
Cooling Pump
FLHR/C Auxiliary Lamps

BK

BK

BK

BK

BK

BK

BK
3 BK BK 3 (If Equipped)
Switch With Fairing
2 [189B] 2 [132A] 2 [32A] 3 [31LA] 3 [31RA] A [38A] 2 [299A]
GND3-2 GND3-1
[325A]
Heated Hand Front Power Front Fender Left Front Right Front Head P&A Accessory
Grips to Main Outlet Tip Lamp Turn/Auxiliary Turn/Auxiliary Lamp Power
Harness Jumper Lamps Lamps BK 2 P&A Accessory
Harness
[131B-2] [4A]
With Fairing,
[12A] [12B] Except FLHX Neutral
Switch
1 BK BK 4 AUX Device
BK 6 6 BK [27B]
Tour-Pak [166B] [91A]

BK

BK

BK

BK
B1
Lights
1 [258A] 2 [12-2A] 2 [12-3A] B [287A] Radio L3 ECU
(ABS Only)
9 BK BK 2 DLC
L4

BK
Rear Power Right Side Left Side Tour-Pak Lights
Outlet Marker Light Marker Light (If Equipped)
[7A] 6
[122B-2]
[184A]
Except FLHX FLHX FLHX Horn 1 BK
[7B] 6 [7B] 6 [7B] 6 [7B] 6
CB
FLHX (Canada Only) (HDI Only) (DOM Only) 10
Module
BK

BK

BK

BK
[105RB] [281B]
P&A Dash Battery
4 BK BK 2
Switch Pack
BK
BK

BK
BK

BK
BK
[280A] Tender
[226B] 1 7 [226B] 1 7 [226B] 1 7 P&A Except
Audio
10 FLHR/C [105LB] [142B]
[226A] 1 7 [226A] 1 7 [226A] 1 7
Security
Facia/Converter Facia/Converter Facia/Converter OE Dash 4 BK BK 3 Siren
Module Module Module Switch Pack (If Equipped)
[262A] 4 5 [262A] 4 5 11 [262A] 5 6 11

[262B] 4 5 [262B] 4 5 11 [262B] 5 6 11 [121B-2]

Fuse Block
Rear Brake
BK
BK

BK
BK
BK

BK
BK
BK
[64B] BK 1
Cooling Relay Switch
87 5 22

30 3 15 Fuse Block
BK

BK

85 1 16
[64B]
BK
BK
BK

BK
BK
BK
86 2 21 BK P&A Relay
[94B] 6 [94B] 6
5 87

3 30
Voltage
1 85
[18B] 6 [94A] Regulator BK 23 2 86
Right Rear N [77B]
BK 2 2 [18A]
Turn Lamp

BK
Circuit

BK
[19B]

BK
Board
Left Rear [19A]
BK 2 2
Turn Lamp
4 4 BK BK

BK
BK 1 1

BK

BK
BK
Fender

BK
Tip/License BK 3 3 Battery
Lamp Tail Lamp
[45B] [45A] [93A] [93B]
GND 2 GND 1 Transmission

Figure A-10. Ground Circuit FLH: 2017 Touring

94000383 A-21
Ground Circuit FLH: 2017 Touring Ground Circuit FLH: 2017 Touring

94000383 A-22
 et00868

[141B]
Fuel Pump and D BK
[GND3A] [GND3B] Fuel Level Sender

BK 1 1 BK

BK
4 [13B]
[2A] [2B] 4 [13A]

BK

BK
BK

BK
BK 3 3 BK

[189B]

BK

BK

BK

BK

BK
Heated Hand
BK 3 Grips to Main
2 [132A] 3 [31LA] 3 [31RA] A [38A] 2 [299A] Harness
GND3-2 GND3-1
[325B]
Front Power Left Front Right Front Head P&A Accessory
Outlet Turn/Auxiliary Turn/Auxiliary Lamp Power
Lamps Lamps BK 2 P&A Accessory

[131B-2] [4A]
Neutral
Switch
1 BK BK 4 AUX Device
[27B]

B1 [166B] [91A]
Radio L3 ECU
(ABS Only)
9 BK BK 2 DLC
L4

BK
[7A] 6
Canada Only HDI Only DOM Only [122B-2]
[184A]
Horn 1 BK
[7B] 6 [7B] 6 [7B] 6
CB 10
Module
BK

BK

BK
[105RB] [281B]
P&A Dash Battery
4 BK BK 2
Switch Pack
BK
BK

BK
BK

BK
BK
[280A] Tender
[226B] 1 7 [226B] 1 7 [226B] 1 7 P&A
Audio
10 [105LB] [142B]
[226A] 1 7 [226A] 1 7 [226A] 1 7
Security
Facia/Converter Facia/Converter Facia/Converter OE Dash 4 BK BK 3 Siren
Module Module Module Switch Pack (If Equipped)
[262A] 4 5 [262A] 4 5 11 [262A] 5 6 11

[262B] [262B] [262B] Fuse Block [121B-2]

4 5 4 5 11 5 6 11
[64B]
Cooling Relay Rear Brake
BK
BK

BK
BK
BK

BK
BK
BK
BK 1
87 5 22 Switch
30 3 15
85 1 16 Fuse Block
86 2 21 BK
[64B]
BK
BK
BK

BK
BK
BK
P&A Relay
BK

5 87
6 [94B] 3 30
Voltage
[94A] 1 85
[18B] 6 Regulator BK 23 2 86
Right Rear N [77B]
BK 2 2 [18A]
Turn Lamp

BK
Circuit

BK
[19B]

BK
Board
Left Rear [19A]
BK 2 2
Turn Lamp
4 4 BK BK

BK
BK 1 1

BK

BK
BK
Fender

BK
Tip/License BK 3 3 Battery
Lamp Tail Lamp
[45B] [45A] [93A] [93B]
GND 2 GND 1 Transmission

Figure A-11. Ground Circuit FLT: 2017 Touring

94000383 A-23
Ground Circuit FLT: 2017 Touring Ground Circuit FLT: 2017 Touring

94000383 A-24
 et00752
FLHR/C
Right
FLHX Auxiliary RHCM
(HDI) [38HA] [38HB] Lamp

Headlamp 1 1 BK BK A
High Beam 2 2 BE/W
BE/Y B See Fairing [22D-2] [22C-2]
BE/W C Harness [73RB]

BK
BE D W/GY 1 1 Engine Stop Switch
[31RB]
[38LA] [38LB] Heated
[38A] R/O 1 1 Battery Fuse
GY/BK 4 BK/GN 2 2 Ground
Hand Grips
Headlamp 1 1 BK BK BK 3 (If Equipped)
Low Beam Right Turn 2
W/R 3 3 CAN High TGS
2 2 BE/Y BN BN
And DOM BE BE 1 W/BK 4 4 CAN Low
Running Lamp See Main Harness
Without Fairing
[29A] [29B] (1 of 3) [22D-1] [22C-1]

5V Sensor Ground 2
5V Sensor Ground 1
5V Sensor Power 2
5V Sensor Power 1
[31LB]

BK
BK
1 1 BK
Position Lamp

P&A Power
2 2 BE GY/BK 4
(If Equipped)

Ground
BK BK 3
Left Turn

TGS 2
TGS 1
V V 2
And DOM 1
BE BE
Running Lamp
Front Brake

W
W

W
BK
BK

BK
R
R
GY/BK
Switch
FLHX
(DOM)
[38HA] [38HB] [73LB]
BK [204B]
Headlamp 1 1 BK BK A
BE/Y B See Fairing Left BK
High Beam 2 2 BE/W Auxiliary
6
BE/W C Harness W 5 See Main
Lamp R 4 Harness
BK 3 (2 of 3)
[38LA] [38LB] [38A]
W 2
R 1

Headlamp 1 1 BK
[22B-2]
Low Beam 2 2 BE/Y FLHT

Right W/GY 1
Auxiliary
Lamp R/O 1
FLHR/C FLHTCU, FLHTK, FLT BK/GN 2
W/R 3
[38HA] W/BK 4 See Fairing
[73RB] Harness

BK
BK

W
Headlamp 1 If Equipped or
[31RB] [22B-1] Main Harness
High Beam 2 Headlamp [206B] 1 2

[206A] 1 2
[38A] GY/BK 4
BK BK 3 [24B]

BK/W
BK/W
[38LA] Right Turn
BN BN 2
A And DOM BE BE 1
1
See Main Harness Running Lamp W/BK 4
Headlamp Without Fairing Low
W/R 3
Low Beam
B See Fairing
2 (1 of 3) High BK/GN 2
C Harness R/O 1
Position Clutch
D [143B] [143A] [32B] Switch
[29A] See Fairing R 1
Fender Tip Lamp O/W O/W
Harness
1 1 1 BK 2 See Fairing

BK/W
BK/W
Position Lamp 1 (If Equipped) BK 2 2 BK 2

BK
Harness

R
(If Equipped) 2 [189A]

P&A Power
Ground
P&A Power
Ground
[31LB] Heated
Hand Grips

BK
BK
GY/BK 4 (If Equipped)
FLHX, FLT BK BK 3
Left Turn
V V 2 W/BK 4 4 Can Low
BK BK 3 And DOM 1
BE BE
Right Directional Running Lamp W/R 3 3 Can High
V/BN V/BN 2
And DOM

GY/BK
BE BE 1 BK/GN 2 2 Ground
Running Lamp
R/O 1 1 Battery Fuse
[31RB] See Fairing
Harness [73LB]
[24D] [24C]
BK
BK BK 3
Left Directional Left
V/BN V/BN 2 Auxiliary
And DOM BE BE 1
Running Lamp Lamp LHCM

[31LB]

Figure A-12. Front Lighting and Hand Controls: 2017 Touring

94000383 A-25
Front Lighting and Hand Controls: 2017 Touring Front Lighting and Hand Controls: 2017 Touring

94000383 A-26
 et00675
Voltmeter
Right Front

HD-Link Output
Speaker

Battery Fuse
See Front Lighting and

Ground
Hand Controls
See Main Harness 1 of 3 Front Power P&A Accessory A B D [111A]
[22A-1] 1 2 3 4 1 [22A-2] 1 2 3 4 [31RA] 1 2 3 4 5 7 8 9 10 11 12 13 [1A] [34A-2] Outlet Power A B D [111B]
1 2 [34B-2] 1 2 [132C] 1 2 [299A]

W/GY

W/GY
W/R

W/R
W/BK

W/BK

W/Y
BE/W

V/W
R/O
BK/GN

R/O
BK/GN

BK/GN
R/O
BE/O

BE/O
BE/BK

BE/Y

BE/PK
BE/BK
BE

BK

BE

V/BE

V/BE
PK/BK

BK

BK
PK
1 2 [34A-1] 1 2 [132B]
1 2 [34B-1] 1 2 [132A]

PK/BK

V/BE
PK

BK
[38B]

A BK
See Front B BE/Y
Lighting and
Hand Controls C BE/W

D BE
[39B] [39A]

V/W 1 1 HD-Link Output

W/R 2 2 CAN High

TN/GN 4 4 Parking Brake

R/O 5 5 Battery Fuse

IM

BK/GN 7 7 Ground

W/BK 8 8 CAN Low

W/Y 9 9 Fuel Level

PK/GY
PK/O
2 1 [35B-1]
2 1 [35A-1]
BK/GN

BK/GN
PK/GY
TN/GN
BE/PK

BE/BK

PK/BK
W/BK

PK/O
V/BE
W/R

V/W
R/O

R/O
BE

BK

BK

PK

PK/BK
PK
[24A] 1 2 3 4 [31LA] 1 2 3 4 [2A] 2 3 7 8 9 10 11 12 A B D [117B]

V/BE

BE
BK
BK
See Main Harness 1 of 3 2 1 [35B-2] A B D [117A]

HD-Link Output
Ground
Battery Fuse
[35A-2] 1 2 [189B] 1 2 [32A]
See Front Lighting and
Hand Controls See Front Fender Tip
Lighting and Lamp
Hand Controls (If Equipped)

Left Front Fuel Gauge

Speaker

Figure A-13. Fairing Harness FLH: 2017 Touring

94000383 A-27
Fairing Harness FLH: 2017 Touring Fairing Harness FLH: 2017 Touring

94000383 A-28
 et00819 CB Rider Headset CAV CIR DESCRIPTION

CB, Audio (+)

CB, Audio (-)
Front WSS (If Equipped) 1 BK MICROPHONE, COMMON (-) ET
Module

Mic Out (+)

Mic Out (-)
2 BK HEADSET, COMMON (-)
(If Equipped) Sensor

CAN (+)
3 PK/BE HEADSET, RT FRONT (+)

CAN (-)
Ground
Horn

Power
4 R MICROPHONE, FRONT (+)

Front WSS High

Engine Temperature
Front WSS Low
5 PK/GN HEADSET, LT FRONT (+)

5V Sensor Ground
6 BK JUMPER

Horn Power
7 N/C
TAB SHIELD MIRCRPHONE, SHIELD
Rear Audio

BK/GN
R/O

Y/O
Y/V

Ground
BK
W

R
Y
[162A] [162A]

TAB
P&A Audio 2 5 6 3 4 1 1 2 3 4 1 2 3 4 5 6 7 8 9 10 14 15 16
[225B]

Shield
R/W
[280A]

LBE/W

BK/GN
R/Y
LBE/GY
LBE/O

LBE/O
LBE/GY

BK/PK

BK
LBE/BK

LBE/V

LBE/BK

LBE/PK
LBE

LBE
1 2 3 4 5 6 7 8 9 10 11
1 2 3 4 5 6 7 8 9 10 11 12 [184B] [122A-2] 1 1 [122A-1]

BK

PK/BE
R

Shield
R/W

PK/GN
PK/GN

LBE/W
PK/BE

BK/PK

V/BE
[90B]

BK

BK
R

LBE/BN
LBE/V

BK
[184A] 1 2

R
1 2 3 4 5 6 7 8 9 10 11 12 [122B-2] [122B-1]

BK
1 1
[167A] A B 1 2 [90A]

W/BN
W/PK
W

R/BE
BK/Y
BK

BK

BK
R

Shield

R/V
BK
[167B] A B [53B]

BK/W
1 2 3 4 5 6

GN
Radio FLHX Except FLHX
[53A] 1 2 3 4 5 6

O/BE
O/BK
CAN High A1 A1 W/R

Shield
R/W
LBE/W

BK/GN
R/Y
LBE/O
LBE/GY

BK/PK

BK

LBE/BK

LBE/PK
LBE/V

LBE
Shield
PK/GN
BK/PK
PK/BE

BK
R
CAN Low A2 A2 W/BK
AUX CAN Low A3 A3 W/BN
AUX CAN High A4 A4 W/PK
Ground B1 B1 BK
Rear Switch Input B2 B2 LBE/PK
Microphone Front (+) C1 C1 R
Microphone Common (-) C2 C2 BK
Microphone Sum Out (+) C3 C3 R
Microphone Rear (+) D1 D1 R/W
Microphone Shield D2 D2 BK/W
Microphone Sum Out (-) D3 D3 BK
GN
Headset Left Rear (+) E1 E1 LBE/W
BK/W
Headset Right Rear (+) E2 E2 LBE/V W/Y
Headset Common (-) E3 E3 BK/PK W/V
Headset Left Front (+) F1 F1 PK/GN W/R See Main
W/BK Harness FLH
Headset Right Front (+) F2 F2 PK/BE
BK/GN
External AMP Power Control F4 F4 LBE/BN With Fairing
R/GN
Page (2 of 3)
Speaker Left Rear (-) H1 H1 LBE/GY BN/Y
Audio In 1 Right (+) H2 H2 R GY/BE
GN/BE
Audio In 1 Shield/Mono (-) H3 H3 BK
R/O
Speaker Left Rear (+) J1 J1 LBE/O BK
Audio In 1 Left/Mono (+) J2 J2 W BK
Audio In 3 Left/Mono (+) J3 J3 W
Speaker Right Rear (+) K1 K1 LBE
Speaker Right Rear (-) K2 K2 LBE/BK
BE
Audio In 3 Right (+) K3 K3 R
V/BE
Audio In 3 Shield/Mono (-) K4 K4 BK/Y R/Y
Speaker Left Front (-) L1 L1 PK/GY R/V
Speaker Left Front (+) L2 L2 PK/O
LBE/GN
Ground L3 L3 BK
BE/GY
Ground L4 L4 BK R/PK
See Main
Speaker Right Front (+) M1 M1 PK Harness FLH
LBE/W
Speaker Right Front (-) M2 M2 PK/BK
W/BE
With Fairing
Radio Fuse M3 M3 R/PK Page (3 of 3)
LBE/Y
Radio Fuse M4 M4 R/PK W/GY
BE/W
BE/Y
[27A] [27B] BE/O
BE/PK
BE/BK
R
R/BE
BK

LBE/GN

BK/GN
PK/GY

BE/GY
PK/BK

BE/PK
BE/BK

BK/GN

LBE/W

BK/GN

GN/BE
GY/BE
LBE/Y
O/BN
O/PK
W/GY
BK/W

W/BK

BE/W
PK/O

BE/O
BN/Y
V/BE

V/BE

BE/Y

W/BK

W/BE
O/BN
O/BE

O/PK
O/BK

R/GN
V/BE
W/R
W/V

W/Y
[GND3B]
R/O

W/R
1
BK
PK

BK

BE

BK

BK
R

R
[GND3A] 1
[2B] 2 3 9 10 11 12 [105LB] 1 2 3 4 5 [107B] 1 2 [1B] 1 2 3 4 5 7 8 9 10 11 12 13 [166B] 1 9 10 14 15 17 18 23 24 26 [168B] A B
[105RB] 2 3 4 5 [33B] 1 2 [83B] A B C
[168A]
BK

See Fairing [105LA] [107A] See Fairing [166A] A B

1 2 3 4 5 1 2 1 9 10 14 15 17 18 23 24 26 [105RA] 2 3 4 5 [33A] 1 2 [83A] A B C
Auxiliary Lamp Switch
Chassis Cooling Fan
OE Switch Output 2

5V Sensor Ground

Harness FLH Harness FLH

P&A Relay Power

Ait Temperature

CAN High
CAN Low
Ground
Ground

Battery Power (Motor)

Rear WSS -
Front WSS +
Battery Power (Solenoids)

Rear WSS +
Front WSS -
Ground (ECU)

P&A Switch Output 2

P&A Switch Output 1
Ground
P&A Relay

Rear Ignition Coil

System Power
Front Ignition Coil
OFF
BK
R

800
BK

IGN
Rear WSS High
Rear WSS Low

ACC
BK
BK

200
AAT Sensor Ignition Ignition
ABS ECU
GND 3-1 GND 3-2 OE Dash (If Equipped) Rear WSS P&A Dash Switch Coil
Switch Pack (If Equipped) Switch Pack

Figure A-14. Main Harness FLH (1 of 3): 2017 Touring (with Fairing)

94000383 A-29
Main Harness FLH (1 of 3): 2017 Touring (with Fairing) Main Harness FLH (1 of 3): 2017 Touring (with Fairing)

94000383 A-30
 See Main Harness FLH With Fairing (1 of 3)

94000383
et00820

[203FA]
[203FB]

[78A-1]
[78B-1]
BK
BK
GN

R/O
W/V
W/Y

W/R

BN/Y
R/GN
W/BK
BK/W

ECM
GY/BE
GN/BE
BK/GN
1
1

V/GN System Power

Rear Ignition Coil GY/BE
2
2
ACR

ACR Enable
Front

Front Ignition Coil GN/BE LGN/R

Front HO2S Ground BK/O
VSS LGN/Y
Front Fuel Injector GN/Y
Rear Fuel Injector GY/Y
[84B]
[84A]

MAP Input GY
JSS LGN/GY
A
A

R/GN System Power

Chassis Cooloing Fan BN/Y

(BK)
B
B

GN/Y Front Injector

Front

Ground BK/GN
CAN Low W/BK
Fuel Injector

CAN High W/R

Rear HO2S Ground BK/PK
CKP Sensor High R
[211B]
[211A]

Front HO2S GN/BN

CKP Sensor Low

1 2 3 4 5 6 7 8 9 10 13 14 15 16 17 18
1 2 3 4 5 6 7 8 9 10 13 14 15 16 17 18
BK GY/O ETC Low
BK/W 5V Sensor Ground 1
GN/V TPS 1
R/W 5V Sensor Power 1
TCA

[78A-2]
[78B-2]
GY/V TPS 2
A B C D E F
A B C D E F

GN/O ETC High

Chassis Cooling Fan Control V/BK
Front Knock Sensor HI BN/W
Coolant Pump Control BN/BK
ACR Enable LGN/R
[80B]
[80A]

Purge Solenoid LGN/BK

IAT GN/GY
5V Sensor Ground 1 BK/W GY MAP Input
ET GN R/GY 5V Sensor Power 2
5V Sensor Power 1 R/W GN/GY IAT
TMAP
Sensor

1 2 3 4
1 2 3 4

BK/GY 5V Sensor Ground 2

Ground BK/GN
Front Knock Sensor LO LGN/W

(GY)
Rear Knock Sensor HI BN/V
[85B]
[85A]

Rear Knock Sensor LO LGN/V

TPS 2 GY/V
A
A

System Power R/GN R/GN System Power

Rear HO2S GY/BN
B
B

Rear Injector
Rear

GY/Y
Battery Fuse

1 2 3 4 5 6 7 8 9 10 11 12 13 15 16 17 18
1 2 3 4 5 6 7 8 9 10 11 12 13 15 16 17 18
R/O
Fuel Injector

[78A-3]
[78B-3]
[203RB]
[203RA]

Cooling Fan Left GN/BK

1
1

TPS 1 GN/V V/GN System Power

AAT W/V
2
2
ACR

ACR Enable
Rear

LGN/R
(Twin-Cooled) Cooling Fan Right GY/BK
(Air-Cooled) Cooling Fan Control GY/BK
ETC High GN/O
[95B]
[95A]

ETC Low GY/O

Ground BK/GN
A
A

V/GN System Power

Oil Pressure Sensor W/O

(BN)
B
B

TGS 1 GN/W LGN/BK Purge Solenoid

Purge
Solenoid

TGS 2 GY/W
Coolant Temperature GY/GN
5V Sensor Ground 2 BK/GY
[315B]
[315A]

5V Sensore Power 2
1 2 3 5 5 8 9 10 12 13 14 15 17 18
1 2 3 5 5 8 9 10 12 13 14 15 17 18

R/GY
1
1

LGN/W Front Knock Sensor LO

2
2

BN/W Front Knock Sensor HI

Front
Knock
Sensor

[215B]
[215A]
[232LB]
[232LA]

Left GN/BK GN/BK

Cooling Fan
1 2
1 2

(If Equipped)
B A
B A
[316B]
[316A]

BN/BE BN/BE
GY/GN GY/GN
1
1

3 4
3 4

A B
A B

BK/W BK/W LGN/V Rear Knock Sensor LO

2
2

Rear Knock Sensor HI

Rear

BN/V
Knock
Sensor

BK
ECT
[236A]
[236B]

BK
(If Equipped)
GND 2

BK
[235B]
[235A]

BK/GN
Figure A-15. Main Harness FLH (2 of 3): 2017 Touring (with Fairing)
1
1

BN/BE Cooling Relay Power

GND 1

BK/GN
2
2

BN/BK Cooling Pump Control

3
3

BK Ground
BK
(If Equipped)
Cooling Pump

[65A]
[65B]
[13A]
[13B]
[141B]

5V Sensor Power R/W

VSS Input LGN/Y
R/BN R/BN W/Y
VSS
A B C
A B C

Ground BK/GN
W/Y W/Y R/BN
BK/GN BK/GN BK/GN
1 2 3 4
1 2 3 4
A B C D

BK BK BK
Fuel Pump and

[131A-2]
[131B-2]
Fuel Level Sender

1
1

BK
[232RA]
[232RB]
[97A]

1
1

Switch
Neutral

GY/BK GY/BK
1
1

W
2
2
B A

BN/BE BN/BE
(If Equipped)
Right Cooling Fan

R/W R 5V Sensor Power 1

GN/W W TGS 1
[131A-1]
[131B-1]

BK/W BK 5V Sensor Ground 1

R/GY R 5V Sensor Power 2
TGS

1
1

Starter Solenoid Power R/BK GY/W W TGS 2

1 2 3 4 5 6
1 2 3 4 5 6

BK 5V Sensor Ground 2
Starter

BK/GY
[128A]
[128B]
[204A]
[204B]

A
A

Chassis Cooling Fan Control V/BK

1
1

R Security Antenna High

B
B

Cooling Relay Power BN/BE

2
2

BK Security Antenna Low

Chassis
Security
Antenna

Cooling Fan
(If Equipped)
[318A]
[318B]
[209B]
[209A]

A
A

Cooling Relay Power BN/BE

Fan
B
B

Oil Cooling Fan Control GY/BK

R
R

BK
BK
BK
BK
BK
BK/PK

W
R/BK
BN/BE

R/BN
BK/O

V/GN
R/O
BK/GN
LGN/GY
GY/BN

R/GN
GN/BN
BK/W

W/BK
W/R
R/W

W/O

Oil Cooling
(If Equipped)

See Main Harness FLH With Fairing (3 of 3)

[317B]
[317A]

A-31
Main Harness FLH (2 of 3): 2017 Touring (with Fairing) Main Harness FLH (2 of 3): 2017 Touring (with Fairing)

94000383 A-32
 et00821 HO2S Front HO2S Rear Stator Security
CKP Siren
Sensor

Heater Ground

Heater Ground
JSS (If Equipped)

BK 5V Sensor

BK 5V Sensor
(If Equipped)

O2

GY Front O2

Security Siren
W Rear O2

GY Rear O2

CKP Sensor High

System

System
Ground

Ground

CKP Sensor Low

Sensor

Sensor
Power

Power
AUX P&A

Front

5V Sensor Power 1
See Rear See Rear Devices Accessory

Ground
DLC

Power
Lighting Lighting
[91A] 1 2 3 5 6 [4A] 1 2 3 4 1 2 [325B]

W
[47B]

V
[12B] [7A]

JSS Signal
1 2 3 1 2 3 4 5 6 1 2 3 4 5 6
[142A]

Ground

W/R

W/BN
W/BK
[47A] 1 2 3

LBE/W
R/Y

LBE/GN

V/BE
BK

BK

BK
LBE/Y
[138B] 1 2 3 4 [137B] 1 2 3 4 1 2 3

BE/BN

BE/R

R/Y
BE/BN

BE/R
V/BE

BE/V

BE/V
BE

BK

BE

BK
[138A] 1 2 3 4 [137A] 1 2 3 4 Voltage [142B] 1 2 3

BK
Regulator

W/GN
R/O

BK
BK
W
BK/W
BK/W
GN/BN

V/GN

GY/BN
V/GN

R
BK/O

BK/PK
[77A] N P
[133A] 1 2 3 [79A] 1 2 [281B]
BN/BE [77B] N P
[133B] 1 2 3 [79B] 1 2
BK/W

BK

R
GN/BN R 1 Battery

R/W
LGN/GY
BK/GN

BK
R
BK/O BK 2 Tender
GY/BN
BK/PK
BK
R/W
LGN/GY Fuse Block
BK/GN
5A Battery [64B]
R
See Main BK R/O 2 1 R
Harness FLH R/O 7.5A
With Fairing R/GN System Power
(2 of 3) R/BK R/GN 4 3 V/GN
R/BN
W
20A Radio
R/PK 6 5 R
BK

R
R 20A P&A
R/BE R/BE 12 11 R
5A Spare

R/BE
BK
V/GN 8 7 BK
W/BK 7.5A Spare
W/R BK 14 13 BK
W/O
BK
20A Spare
BK 20 19
BE
V/BE
10A Cooling
R/Y BN 10 9 R
R/V P&A Relay
V/BE 24 5 87
LBE/GN
BE/GY R/BE 17 3 30
R/PK
See Main R/Y 18 1 85
BK 23 2 86
Harness FLH LBE/W
With Fairing W/BE
(1 of 3) Cooling Relay
LBE/Y
BN/BE 22 5 87
W/GY
BE/W BN 15 3 30
BE/Y R/GN 16 1 85
BE/O BK 21 2 86
BE/PK
BE/BK
R
R/BE

Red Band

BE/GN

BK/GN
BE/GY

BE/BN
BE/PK

BE/BK
W/GN
W/GY
W/BN

W/BE

W/BK

BE/W
R/GN
R/BN

BE/O

BE/R

R/BK
BE/V

BE/Y
W/R

R/V

R/Y
BK
BK

BE
W
R

R
[259B] [242B]
BE/GN

1 A2 A3 A4 B2 B3 C3 C4 D2 D3 E2 E4 F3 F4 G4 H2 J2 J3 J4 K2 K3 K4 L2 L3 L4 M2 M3 M4
W/BK

BK/W
W/R

W/O
R/W
BK

[259A] 1 A2 A3 A4 B2 B3 C3 C4 D2 D3 E2 E4 F3 F4 G4 H2 J2 J3 J4 K2 K3 K4 L2 L3 L4 M2 M3 M4 [242A]

BK
BK

R
BK
Battery Power

Security Antenna (+)

Start Enable
Security RF Antenna
Security Antenna (-)
AUX Lamp Switch
Ignition/Accessory Switch Input
Run/Stop Switch input
CAN High
Neutral Switch input
CAN Low
Horn Power

Running/Position Light Power

Brake Switch Input
Fuel Pump Power
Ground
Security Siren

Brake Light Power

Starter Solenoid Power

System Power
AUX Lamp Power
Accessory Power
High Beam Power
Low Beam Power
Front Right Turn Signal

Front Left Turn Signal

Rear Right Turn Signal

Rear Left Turn Signal

[319B] A B [121B-1] 1 1 [121B-2] [139B] 1 2 3 [5B] A B

BK

R
[319A] A B [121A-1] 1 1 [121A-2] [139A] 1 2 3
5V Sensor GND 1
5V Sensor Power 1
Oil Pressure

BK
120
Battery Starter
50A
Main Fuse
Rear
Terminating Brake
Resister Switch Oil Transmission
Pressure
BCM

Figure A-16. Main Harness FLH (3 of 3): 2017 Touring (with Fairing)

94000383 A-33
Main Harness FLH (3 of 3): 2017 Touring (with Fairing) Main Harness FLH (3 of 3): 2017 Touring (with Fairing)

94000383 A-34
 et00650
Voltmeter
Right Front

HD-Link Output
Speaker

Battery Fuse
Ground
See Front Front Power
Lighting and See Main Harness FLT Outlet
Hand Controls (1 of 3) P&A Accessory A B D [111A]

P&A Power
1 2 3 4 [31RA] 2 3 4 5 7 8 9 10 11 12 13 16 [1B] [34A-2] Power A B D [111B]

Ground
[34B-2] 1 2 [299A]

W/R
W/BK

V/W
BE/W
1 2

R/O
BK/GN

V/W
BE/O

BE/O

R/Y

BK/GN
R/O
BE/BK

BE/Y

BE/PK
BE/BK
BE

BK

BE

V/BE
BK
PK/BK
1 2 [132D]

PK
1 2 [132C]
1 2 [34A-1]

V/BE
BK
1 2 [34B-1]

PK/BK
PK

BK/GN
1 2 [132B]

V/W

R/O
1 2 [132A]
1 2 4 [111A-2]

V/BE
BK
1 2 4 [111B-2]

V/W
BK/GN
R/O
[38B]

A BK
See Front B BE/Y
Lighting and
Hand Controls C BE/W

D R/Y

BK/GN
V/W

R/O
1 2 4 [117B-2]
1 2 4 [117A-2]

V/W
BK/GN
R/O
PK/GY
PK/O
2 1 [35B-1]
2 1 [35A-1]

BK/GN
PK/GY
BE/PK

BE/BK

PK/BK
W/BK

W/BK

W/BK

PK/O
V/BE

V/W

R/O
W/R

W/R

W/R
BE

BK

BK

PK

PK/BK
PK
[31LA] 1 2 3 4 [243A] 4 3 2 1 [2A] 2 3 4 5 9 10 11 12 A B D [117B]
See Front [243B] 4 3 2 1 See Main Harness FLT 2 1 [35B-2] A B D [117A]
Lighting and (1 of 3)

HD-Link Output
Ground
Battery Fuse
[35A-2]
W/R

W/R
W/BK

W/BK

Hand Controls

P&A
CAN Left Front Fuel Gauge
Speaker

Figure A-17. Fairing Harness FLT: 2017 Touring

94000383 A-35
Fairing Harness FLT: 2017 Touring Fairing Harness FLT: 2017 Touring

94000383 A-36
 et00840 CB Rider Headset CAV CIR DESCRIPTION
See Front Lighting and

CB, Audio (+)

CB, Audio (-)
Front WSS (If Equipped) 1 BK MICROPHONE, COMMON (-) ET
Module

Mic Out (+)

Hand Controls

Mic Out (-)

2 BK HEADSET, COMMON (-)
(If Equipped) Sensor

CAN (+)
3 PK/BE HEADSET, RT FRONT (+)

CAN (-)
Ground
Horn

Power
4 R MICROPHONE, FRONT (+)

Front WSS High

Engine Temperature
Front WSS Low
5 PK/GN HEADSET, LT FRONT (+)

5V Sensor Ground
6
[24A] 1 2 3 4 [22A-1] 4 3 2 1 1 [22A-2] BK JUMPER

Horn Power
7 N/C
TAB SHIELD MIRCRPHONE, SHIELD
Rear Audio

BK/GN

W/GY
W/R

W/R
W/BK

W/BK
R/O
BK/GN

BK/GN
R/O
R/O

Y/O
Y/V

Ground
BK
W

R
Y
[162A] [162A]

TAB
P&A Audio 2 5 6 3 4 1 1 2 3 4 1 2 3 4 5 6 7 8 9 10 14 15 16
[225B]

Shield
R/W
[280A]

LBE/W

BK/GN
R/Y
LBE/GY
LBE/O

LBE/O
LBE/GY

BK/PK

BK
LBE/BK

LBE/V

LBE/BK

LBE/PK
LBE

LBE
1 2 3 4 5 6 7 8 9 10 11
1 2 3 4 5 6 7 8 9 10 11 12 [184B] [122A-2] 1 1 [122A-1]

BK

PK/BE
R

Shield
R/W

PK/GN
PK/GN

LBE/W
PK/BE

BK/PK

V/BE
[90B]

BK

BK
R

LBE/BN
LBE/V

BK
[184A] 1 2

R
1 2 3 4 5 6 7 8 9 10 11 12 [122B-2] [122B-1]

BK
1 1
[167A] A B 1 2 [90A]

W/BN
W/PK
W

R/BE
BK/Y
BK

BK

BK
R

Shield

R/V
BK
[167B] A B [53B]

BK/W
1 2 3 4 5 6

GN
Radio Except FLTRU FLTRU
[53A] 1 2 3 4 5 6 IM

O/BE
O/BK
CAN High A1 A1 W/R

Shield
R/W
LBE/W

BK/GN
R/Y
LBE/O
LBE/GY

BK/PK

BK

LBE/BK

LBE/PK
LBE/V

LBE
Shield
PK/GN
BK/PK
PK/BE

BK
R

HD Link Output
CAN Low A2 A2 W/BK

Fuel Level
AUX CAN Low A3 A3 W/BN

CAN High

CAN Low
Ground
Battery
AUX CAN High A4 A4 W/PK
Ground B1 B1 BK
Rear Switch Input B2 B2 LBE/PK [39A] 1 2 5 7 8 9
Microphone Front (+) C1 C1 R
[39B] 1 2 5 7 8 9
Microphone Common (-) C2 C2 BK

W/R
V/W

W/BK
W/Y
R/O
BK/GN
Microphone Sum Out (+) C3 C3 R
Microphone Rear (+) D1 D1 R/W
Microphone Shield D2 D2 BK/W
Microphone Sum Out (-) D3 D3 BK
GN
Headset Left Rear (+) E1 E1 LBE/W
BK/W
Headset Right Rear (+) E2 E2 LBE/V W/Y
Headset Common (-) E3 E3 BK/PK W/V
Headset Left Front (+) F1 F1 PK/GN W/R See Main
W/BK Harness FLT
Headset Right Front (+) F2 F2 PK/BE
BK/GN
External AMP Power Control F4 F4 LBE/BN With Fairing
R/GN
Page (2 of 3)
Speaker Left Rear (-) H1 H1 LBE/GY BN/Y
Audio In 1 Right (+) H2 H2 R GY/BE
GN/BE
Audio In 1 Shield/Mono (-) H3 H3 BK
R/O
Speaker Left Rear (+) J1 J1 LBE/O BK
Audio In 1 Left/Mono (+) J2 J2 W BK
Audio In 3 Left/Mono (+) J3 J3 W
Speaker Right Rear (+) K1 K1 LBE
Speaker Right Rear (-) K2 K2 LBE/BK
BE
Audio In 3 Right (+) K3 K3 R
V/BE
Audio In 3 Shield/Mono (-) K4 K4 BK/Y R/Y
Speaker Left Front (-) L1 L1 PK/GY R/V
Speaker Left Front (+) L2 L2 PK/O
LBE/GN
Ground L3 L3 BK
BE/GY
Ground L4 L4 BK R/PK
See Main
Speaker Right Front (+) M1 M1 PK Harness FLT
LBE/W
Speaker Right Front (-) M2 M2 PK/BK
W/BE
With Fairing
Radio Fuse M3 M3 R/PK Page (3 of 3)
LBE/Y
Radio Fuse M4 M4 R/PK W/GY
BE/W
BE/Y
[27A] [27B] BE/O
BE/PK
BE/BK
R
R/BE
BK

LBE/GN

BK/GN
PK/GY

BE/GY
PK/BK

BE/PK
BE/BK

BK/GN

LBE/W

BK/GN

GN/BE
GY/BE
LBE/Y
O/BN
O/PK
W/BK

BK/W

W/BK

BE/W
PK/O

BE/O
BN/Y
V/BE

V/BE

V/BE

BE/Y

W/BK

W/BE
O/BN
O/BE

O/PK
O/BK

R/GN
V/BE
W/R

W/R
W/V

V/W
[GND3B]
R/O

R/Y

W/R
1
BK
BK

PK

BK

BE

BK

BK
R

R
[GND3A] 1
[2B] 2 3 4 5 9 10 11 12 [105LB] 1 2 3 4 5 [189B] 1 2 [107B] 1 2 [1B] 2 3 4 5 7 8 9 10 11 12 13 16 [166B] 1 9 10 14 15 17 18 23 24 26 [168B] A B
[105RB] 2 3 4 5 [33B] 1 2 [83B] A B C
[168A]
BK

See Fairing [105LA] [107A] See Fairing [166A] A B

1 2 3 4 5 Heated 1 2 1 9 10 14 15 17 18 23 24 26 [105RA] 2 3 4 5 [33A] 1 2 [83A] A B C
Auxiliary Lamp Switch
Chassis Cooling Fan
OE Switch Output 2

5V Sensor Ground

Harness FLT Harness FLT

P&A Relay Power

Ait Temperature

Grips

CAN High
CAN Low
Ground
Ground

Battery Power (Motor)

Rear WSS -
Front WSS +
Battery Power (Solenoids)

Rear WSS +
Front WSS -
Ground (ECU)

P&A Switch Output 2

P&A Switch Output 1
Ground
P&A Relay

Rear Ignition Coil

System Power
Front Ignition Coil
OFF
BK
R
(FLTRX)

800
BK

IGN
Rear WSS High
Rear WSS Low

ACC
BK
BK

200
AAT Sensor Ignition Ignition
ABS ECU
GND 3-1 GND 3-2 OE Dash (If Equipped) Rear WSS P&A Dash Switch Coil
Switch Pack (If Equipped) Switch Pack

Figure A-18. Main Harness FLT (1 of 3): 2017 Touring (with Fairing)

94000383 A-37
Main Harness FLT (1 of 3): 2017 Touring (with Fairing) Main Harness FLT (1 of 3): 2017 Touring (with Fairing)

94000383 A-38
 See Main Harness FLT With Fairing (1 of 3)

94000383
et00874

[203FA]
[203FB]

[78A-1]
[78B-1]
BK
BK
GN

R/O
W/V
W/Y

W/R

BN/Y
R/GN
W/BK
BK/W

ECM
GY/BE
GN/BE
BK/GN
1
1

V/GN System Power

Rear Ignition Coil GY/BE
2
2
ACR

ACR Enable
Front

Front Ignition Coil GN/BE LGN/R

Front HO2S Ground BK/O
VSS LGN/Y
Front Fuel Injector GN/Y
Rear Fuel Injector GY/Y
[84B]
[84A]

MAP Input GY
JSS LGN/GY
A
A

R/GN System Power

Chassis Cooloing Fan BN/Y

(BK)
B
B

GN/Y Front Injector

Front

Ground BK/GN
CAN Low W/BK
Fuel Injector

CAN High W/R

Rear HO2S Ground BK/PK
CKP Sensor High R
[211B]
[211A]

Front HO2S GN/BN

CKP Sensor Low

1 2 3 4 5 6 7 8 9 10 13 14 15 16 17 18
1 2 3 4 5 6 7 8 9 10 13 14 15 16 17 18
BK GY/O ETC Low
BK/W 5V Sensor Ground 1
GN/V TPS 1
R/W 5V Sensor Power 1
TCA

[78A-2]
[78B-2]
GY/V TPS 2
A B C D E F
A B C D E F

GN/O ETC High

Chassis Cooling Fan Control V/BK
Front Knock Sensor HI BN/W
Coolant Pump Control BN/BK
ACR Enable LGN/R
[80B]
[80A]

Purge Solenoid LGN/BK

IAT GN/GY
5V Sensor Ground 1 BK/W GY MAP Input
ET GN R/GY 5V Sensor Power 2
5V Sensor Power 1 R/W GN/GY IAT
TMAP
Sensor

1 2 3 4
1 2 3 4

BK/GY 5V Sensor Ground 2

Ground BK/GN
Front Knock Sensor LO LGN/W

(GY)
Rear Knock Sensor HI BN/V
[85B]
[85A]

Rear Knock Sensor LO LGN/V

TPS 2 GY/V
A
A

System Power R/GN R/GN System Power

Rear HO2S GY/BN
B
B

Rear Injector
Rear

GY/Y
Battery Fuse

1 2 3 4 5 6 7 8 9 10 11 12 13 15 16 17 18
1 2 3 4 5 6 7 8 9 10 11 12 13 15 16 17 18
R/O
Fuel Injector

[78A-3]
[78B-3]
[203RB]
[203RA]

Cooling Fan Left GN/BK

1
1

TPS 1 GN/V V/GN System Power

AAT W/V
2
2
ACR

ACR Enable
Rear

LGN/R
(Twin-Cooled) Cooling Fan Right GY/BK
(Air-Cooled) Cooling Fan Control GY/BK
ETC High GN/O
[95B]
[95A]

ETC Low GY/O

Ground BK/GN
A
A

V/GN System Power

Oil Pressure Sensor W/O

(BN)
B
B

TGS 1 GN/W LGN/BK Purge Solenoid

Purge
Solenoid

TGS 2 GY/W
Coolant Temperature GY/GN
5V Sensor Ground 2 BK/GY
[315B]
[315A]

5V Sensore Power 2
1 2 3 5 5 8 9 10 12 13 14 15 17 18
1 2 3 5 5 8 9 10 12 13 14 15 17 18

R/GY
1
1

LGN/W Front Knock Sensor LO

2
2

BN/W Front Knock Sensor HI

Front
Knock
Sensor

[215B]
[215A]
[232LB]
[232LA]

Left GN/BK GN/BK

Cooling Fan
1 2
1 2

(If Equipped)
B A
B A
[316B]
[316A]

BN/BE BN/BE
GY/GN GY/GN
1
1

3 4
3 4

A B
A B

BK/W BK/W LGN/V Rear Knock Sensor LO

2
2

Rear Knock Sensor HI

Rear

BN/V
Knock
Sensor

BK
ECT
[236A]
[236B]

BK
(If Equipped)
GND 2

BK
[235B]
[235A]

BK/GN
Figure A-19. Main Harness FLT (2 of 3): 2017 Touring (with Fairing)
1
1

BN/BE Cooling Relay Power

GND 1

BK/GN
2
2

BN/BK Cooling Pump Control

3
3

BK Ground
BK
(If Equipped)
Cooling Pump

[65A]
[65B]
[13A]
[13B]
[141B]

5V Sensor Power R/W

VSS Input LGN/Y
R/BN R/BN W/Y
VSS
A B C
A B C

Ground BK/GN
W/Y W/Y R/BN
BK/GN BK/GN BK/GN
1 2 3 4
1 2 3 4
A B C D

BK BK BK
Fuel Pump and

[131A-2]
[131B-2]
Fuel Level Sender

1
1

BK
[232RA]
[232RB]
[97A]

1
1

Switch
Neutral

GY/BK GY/BK
1
1

W
2
2
B A

BN/BE BN/BE
(If Equipped)
Right Cooling Fan

R/W R 5V Sensor Power 1

GN/W W TGS 1
[131A-1]
[131B-1]

BK/W BK 5V Sensor Ground 1

R/GY R 5V Sensor Power 2
TGS

1
1

Starter Solenoid Power R/BK GY/W W TGS 2

1 2 3 4 5 6
1 2 3 4 5 6

BK 5V Sensor Ground 2
Starter

BK/GY
[128A]
[128B]
[204A]
[204B]

A
A

Chassis Cooling Fan Control V/BK

1
1

R Security Antenna High

B
B

Cooling Relay Power BN/BE

2
2

BK Security Antenna Low

Chassis
Security
Antenna

Cooling Fan
(If Equipped)
[318A]
[318B]
[209B]
[209A]

A
A

Cooling Relay Power BN/BE

Fan
B
B

Oil Cooling Fan Control GY/BK

R
R

BK
BK
BK
BK
BK
BK/PK

W
R/BK
BN/BE

R/BN
BK/O

V/GN
R/O
BK/GN
LGN/GY
GY/BN

R/GN
GN/BN
BK/W

W/BK
W/R
R/W

W/O

Oil Cooling
(If Equipped)
[317B]
[317A]

See Main Harness FLT With Fairing (3 of 3)

A-39
Main Harness FLT (2 of 3): 2017 Touring (with Fairing) Main Harness FLT (2 of 3): 2017 Touring (with Fairing)

94000383 A-40
 et00875 HO2S Front HO2S Rear Stator Security
CKP Siren
Sensor

Heater Ground

Heater Ground
JSS (If Equipped)

BK 5V Sensor

BK 5V Sensor
(If Equipped)

O2

GY Front O2

Security Siren
W Rear O2

GY Rear O2

CKP Sensor High

System

System
Ground

Ground

CKP Sensor Low

Sensor

Sensor
Power

Power
AUX P&A

Front

5V Sensor Power 1
See Rear See Rear Devices Accessory

Ground
DLC

Power
Lighting Lighting
[91A] 1 2 3 5 6 [4A] 1 2 3 4 1 2 [325B]

W
[47B]

V
[12B] [7A]

JSS Signal
1 2 3 1 2 3 4 5 6 1 2 3 4 5 6
[142A]

Ground

W/R

W/BN
W/BK
[47A] 1 2 3

LBE/W
R/Y

LBE/GN

V/BE
BK

BK

BK
LBE/Y
[138B] 1 2 3 4 [137B] 1 2 3 4 1 2 3

BE/BN

BE/R

R/Y
BE/BN

BE/R
V/BE

BE/V

BE/V
BE

BK

BE

BK
[138A] 1 2 3 4 [137A] 1 2 3 4 Voltage [142B] 1 2 3

BK
Regulator

W/GN
R/O

BK
BK
W
BK/W
BK/W
GN/BN

V/GN

GY/BN
V/GN

R
BK/O

BK/PK
[77A] N P
[133A] 1 2 3 [79A] 1 2 [281B]
BN/BE [77B] N P
[133B] 1 2 3 [79B] 1 2
BK/W

BK

R
GN/BN R 1 Battery

R/W
LGN/GY
BK/GN

BK
R
BK/O BK 2 Tender
GY/BN
BK/PK
BK
R/W
LGN/GY Fuse Block
BK/GN
5A Battery [64B]
R
See Main BK R/O 2 1 R
Harness FLT R/O 7.5A
With Fairing R/GN System Power
(2 of 3) R/BK R/GN 4 3 V/GN
R/BN
W
20A Radio
R/PK 6 5 R
BK

R
R 20A P&A
R/BE R/BE 12 11 R
5A Spare

R/BE
BK
V/GN 8 7 BK
W/BK 7.5A Spare
W/R BK 14 13 BK
W/O
BK
20A Spare
BK 20 19
BE
V/BE
10A Cooling
R/Y BN 10 9 R
R/V P&A Relay
V/BE 24 5 87
LBE/GN
BE/GY R/BE 17 3 30
R/PK
See Main R/Y 18 1 85
BK 23 2 86
Harness FLT LBE/W
With Fairing W/BE
(1 of 3) Cooling Relay
LBE/Y
BN/BE 22 5 87
W/GY
BE/W BN 15 3 30
BE/Y R/GN 16 1 85
BE/O BK 21 2 86
BE/PK
BE/BK
R
R/BE

Red Band

BE/GN

BK/GN
BE/GY

BE/BN
BE/PK

BE/BK
W/GN
W/GY
W/BN

W/BE

W/BK

BE/W
R/GN
R/BN

BE/O

BE/R

R/BK
BE/V

BE/Y
W/R

R/V

R/Y
BK
BK

BE
W
R

R
[259B] [242B]
BE/GN

1 A2 A3 A4 B2 B3 C3 C4 D2 D3 E2 E4 F3 F4 G4 H2 J2 J3 J4 K2 K3 K4 L2 L3 L4 M2 M3 M4
W/BK

BK/W
W/R

W/O
R/W
BK

[259A] 1 A2 A3 A4 B2 B3 C3 C4 D2 D3 E2 E4 F3 F4 G4 H2 J2 J3 J4 K2 K3 K4 L2 L3 L4 M2 M3 M4 [242A]

BK
BK

R
BK
Battery Power

Security Antenna (+)

Start Enable
Security RF Antenna
Security Antenna (-)
AUX Lamp Switch
Ignition/Accessory Switch Input
Run/Stop Switch input
CAN High
Neutral Switch input
CAN Low
Horn Power

Running/Position Light Power

Brake Switch Input
Fuel Pump Power
Ground
Security Siren

Brake Light Power

Starter Solenoid Power

System Power
AUX Lamp Power
Accessory Power
High Beam Power
Low Beam Power
Front Right Turn Signal

Front Left Turn Signal

Rear Right Turn Signal

Rear Left Turn Signal

[319B] A B [121B-1] 1 1 [121B-2] [139B] 1 2 3 [5B] A B

BK

R
[319A] A B [121A-1] 1 1 [121A-2] [139A] 1 2 3
5V Sensor GND 1
5V Sensor Power 1
Oil Pressure

BK
120
Battery Starter
50A
Main Fuse
Rear
Terminating Brake
Resister Switch Oil Transmission
Pressure
BCM

Figure A-20. Main Harness FLT (3 of 3): 2017 Touring (with Fairing)

94000383 A-41
Main Harness FLT (3 of 3): 2017 Touring (with Fairing) Main Harness FLT (3 of 3): 2017 Touring (with Fairing)

94000383 A-42
 et00831 See Front Lighting and Front WSS ET ACR
Hand Controls (If Equipped) Sensor Front Front Fuel TCA

Engine Temperature
Injector

5V Sensor Ground 1
5V Sensor Ground
Front WSS High

5V Sensor Power 1
Front WSS Low
Horn

System Power

System Power
Front Injector
[31RA] [31LA] [24A] [38LB] [38HB] [29B]

ACR Enable
1 2 3 4 1 2 3 4 1 2 3 4 1 2 1 2 2 1

Horn Power

ETC High
ETC Low
W/R

BE/W
W/BK
R/O
BK/GN
BE/O

BE/Y
BE/BK

BE/PK

BE/BK

BK

BK

BK
BE
BK

BE

BK

BE

Ground

TPS 1

TPS 2
BK
R
A B [90B] [122A-1] 1 1 [122A-2] 1 2 [203FA] A B [84A] A B C D E F [211A]
1 2 [167A] A B [90A] [122B-1] 1 1 [122B-2] 1 2 [203FB] A B [84B] A B C D E F [211B]
[22A-1] 1 2 [167B]

R/GN
V/GN

GN/Y
LGN/R

R/W
BK/W

BK/W

GN/O
GY/O

GN/V
GN

GY/V
R/V

BK
O/BE

O/BK
1 R/O
See
2 BK/GN BE/Y
Front
V/BE
Lighting 3 W/R
and BE/W
Hand 4 W/BK
BE
Controls
R/Y
[22A-2] R
BK See Main
1 W/GY W/GY Harness
W/BE W/O Fairing
BE/GY (3 of 3)
BK 1 1 BK W
R/V
BE/O
BK

BK

[GND3A] [GND3B]
BE/BK
BE/PK
R/BN

GND 3-1 GND 3-2 GN

LGN/R
GY/V
Accessory Power 1 1 R/Y O/BE
Auxiliary O/BK
Lamp Ground 3 3 BK
BK/W
Switch BE/GY BK
AUX Lamp Switch Input 4 4
V/GN
W/BK
[109B] [109A] R/W
R/GN
Chassis
GY/W
Cooling P&A Relay Power 1 1 V/BE See Main
GY/O
Fan Chassis Cooling Fan Switch 4 4 BN/Y Harness
BK/GN
Switch W/O Fairing
BK/GN
(2 of 3)
[205B] [205A] LGN/Y
BN/Y
R/O
[33A] [33B] Indicators LGN/BK
GN/Y
IGN
BK/GY
2 2 W/BE
Ignition 200 ACC GN/O
W/O
BE/W

W
R/O

R/O

R/O

R/O

R/O
BE/O
BE/PK

Switch 800
OFF
GN/V
1 1 BK/GN R/GY
GN/W
GY/BE
GN/BE
[39A] [39B] R/W
Speedometer

LGN/BK
BK/GN

GN/BE
GY/BE

BK/GY
GN/W

GY/W
BK/W
R/GN

V/GN

R/GY
Oil Pressure Indicator 1 1 W/O

R/W
W/Y
R/Y

BK
R
CAN High 2 2 W/R
High Beam Indicator 4 4 BE/W [20B] [20A] [117B] 1 2 4 [83B] A B C [95B] A B [209B] 1 2 [204A] 1 2 3 4 5 6

BK/GN
LGN/Y
Battery Fuse 5 5 R/O

R/W
[117A] [83A] A B C [95A] A B [209A] [204B]

BK
1 2 4 1 2 1 2 3 4 5 6

W
Neutral indicator 6 6 W W/R 1 1 W/R

Security Antenna High

Security Antenna Low

Rear Ignition Coil
System Power
Front Ignition Coil

System Power
Purge Solenoid
Ground 7 7 BK/GN BK/GN 2 2 BK/GN

BK/GN

BK

BK
[65B] A B C [131B-1] [131B-2]

W
R

R
W/Y 1 1
R/Y

CAN Low 8 8 W/BK W/BK 3 3 W/BK

Fuel Level 9 9 W/Y W/Y 4 4 W/Y [65A] A B C [131A-1] 1 1 [131A-2]

5V Sensor Power 1
TGS 1
5V Sensor Ground 1
5V Sensor Power 2
TGS 2
5V Sensor Ground 2

5V Sensor Power
VSS Input
Ground
Left Turn Indicator 10 10 BE/PK W/BE 5 5 W/BE
Accessory Power
Fuel Level
Ground

Right Turn Indicator 12 12 BE/O R/O 6 6 R/O

R/BN 7 7 R/BN
BK 8 8 BK
Fuel Level A A W/Y Neutral
Fuel Pump Power B B R/BN Ignition Purge Security Switch
Coil Solenoid Antenna
Ground C C BK
Ground D D BK TGS VSS
Fuel Gauge
Fuel Pump and
Fuel Level Sender [141A] [141B]

Figure A-21. Main Harness (1 of 3): 2017 Touring (without Fairing)

94000383 A-43
Main Harness (1 of 3): 2017 Touring (without Fairing) Main Harness (1 of 3): 2017 Touring (without Fairing)

94000383 A-44
94000383
et00832

(1 of 3)
Harness
See Main
W/O Fairing
BK
GN

R/O

R/W
W/R

BN/Y
O/BK
O/BE
GY/V

R/GY
GN/V
GN/Y
V/GN

GY/O
R/GN

GN/O
W/BK
BK/W

GY/W

GN/W
LGN/Y

GY/BE
BK/GY
LGN/R

GN/BE
BK/GN
BK/GN

LGN/BK

[78A-1]
[78B-1]

ECM
4
4

BK/GY 5V Sensor Ground 2

1
Rear Ignition Coil GY/BE
3
3

GN/GY IAT

2
2
Front Ignition Coil GN/BE

3
3
2
2

Front HO2S Ground BK/O R/GY 5V Sensor Power 2

TMAP
Sensor

4
4
VSS LGN/Y
1
1

GY MAP Input

5
5
Front Fuel Injector GN/Y

6
6
Rear Fuel Injector GY/Y
MAP Input GY
[80B]
[80A]

7 8
7 8
JSS LGN/GY

(BK)
Chassis Cooling Fan Switch BN/Y
Ground BK/GN
CAN Low W/BK
CAN High W/R
Rear HO2S Ground BK/PK
A
A

R/GN System Power

CKP Sensor High R
B
B

GY/Y Rear Injector

Injector

Front HO2S GN/BN

Rear Fuel

CKP Sensor Low

9 10 13 14 15 16 17 18
9 10 13 14 15 16 17 18
BK
[85B]
[85A]

V/GN System Power

1 2
1 2

LGN/R ACR Enable

ACR
Rear

[78A-2]
[78B-2]
1
1
Chassis Cooling Fan Control V/BK

2
2
Front Knock Sensor HI BN/W

4
4
ACR Enable LGN/R
[203RB]
[203RA]

5
5
Purge Solenoid LGN/BK

6
6
IAT GN/GY
5V Sensor Ground 1 BK/W

7 8
7 8
ET GN
5V Sensor Power 1 R/W

(GY)
Ground BK/GN BK
Front Knock Sensor LO LGN/W
Rear Knock Sensor HI BN/V BK/GN
GND 1

Rear Knock Sensor LO LGN/V

BK/GN
TPS 2 GY/V
System Power R/GN
Rear HO2S GY/BN
BK
Battery Fuse R/O

9 10 11 12 13 15 16 17 18
9 10 11 12 13 15 16 17 18
GND 2

BK

[78A-3]
TPS 1
[78B-3] GN/V
Cooling Fan Control GY/BK
B
B

O/BN BK Rear WSS Low

2 5 8
2 5 8

ETC High GN/O

A
A

O/PK R Rear WSS High

ETC Low GY/O
Rear WSS
(If Equipped)

Ground BK/GN
Oil Pressure Sensor W/O

(BN)
TGS 1 GN/W
[168B]
[168A]

TGS 2 GY/W
5V Sensor Ground 2 BK/GY
5V Sensore Power 2
9 10 12 13 14 17 18
9 10 12 13 14 17 18

R/GY
1
1

R Batter Power (Motor)

BK Ground (Motor)
W/BK CAN Low
O/BN Rear WSS Low
1
1

Starter Solenoid Power R/BK O/BE Front WSS High

R Battery Power (Solenoids)
Starter
Solenoid

W/R CAN Hign

O/PK Rear WSS High
[128A]
[128B]

Figure A-22. Main Harness (2 of 3): 2017 Touring (without Fairing)

O/BK Front WSS Low

ABS ECU (If Equipped)

BK/GN Ground (ECU)

9 10 14 15 17 18 23 24 26
9 10 14 15 17 18 23 24 26

A
A

Chassis Cooling Fan Control V/BK

[166B]
[166A]

B
B

Cooling Relay Power BN/BE

System
(If Equipped)
1
1

V/GN V Power
Rear O2
2
2

Chassis Cooling Fan

BK/PK W Heater Ground

[318A]
[318B]

Rear O2
3
3

GY/BN GY
Sensor
HO2S Rear

5V Sensor
4
4

BK/W BK Ground
A
A

Cooling Relay Power BN/BE

B
B

Oil Cooling Fan Control GY/BK

[137A]
[137B]

(If Equipped)
Oil Cooling Fan

System
1
1

V/GN V Power
Front O2
2
2

[317B]
[317A]

BK/O W
Heater Ground
Front O2
3
3

GN/BN GY
Sensor
5V Sensor
HO2S Front

4
4

BK/W BK
Ground
5V Sensor
1
1

Power R R/W
2
2

JSS Signal W LGN/GY

JSS
[138A]
[138B]

3
3

Ground BK BK/GN
1
1

[133A]
[133B]

LGN/W Front Knock Sensor LO

2
2

BN/W Front Knock Sensor HI

Sensor

2
2
Front Knock

CKP Sensor High BK

BK
CKP

CKP Sensor Low

1
1

R
Sensor
[315B]
[315A]

BK
BK
BK

R/BK
BN/BE

R/O
BK/GN
V/GN

R/GN

BK/W
W/BK

R/W
W/R

W/O
1
1

LGN/V Rear Knock Sensor LO

[79A]
[79B]
2
2

BN/V Rear Knock Sensor HI

Sensor
Rear Knock

(3 of 3)
Harness
[316B]
[316A]

See Main
W/O Fairing

A-45
Main Harness (2 of 3): 2017 Touring (without Fairing) Main Harness (2 of 3): 2017 Touring (without Fairing)

94000383 A-46
 et00833
Stator
Security
Siren
(If Equipped)
See Rear Lighting P&A Battery

Security Siren
[7A] DLC Accessory Tender Fuse Block
1 2 3 4 5 6
[47B] 1 2 3 1 2 3 5 6 [91A] 1 2 [325B] 1 2 [281B] [61D]

Ground

Power
R/Y
BE/BN

BE/R
BE/V
BE

BK
[47A]

W/R

W/BN
W/BK
R/Y
1 2 3 5A Battery

V/BE
BK

BK

BK
R
[142A] 3 2 1
Voltage R/O 2 1 R
Regulator
[142B] 3 2 1
[77A] N P
7.5A
System Power

W/GN
R/O
BK
[77B] N P R/GN 4 3 V/GN

BK

R
15A
Cooling
BE/Y
BN 10 9 R
V/BE
20A P&A
BE/W
R/BE 12 11 R
BE
R/Y
R
5A Spare
See Main BK 8 7 BK
Harness W/GY
W/O Fairing W/BE 7.5A Spare
(1 of 3) BE/GY BK 14 13 BK
W
R/V
20A Spare
BE/O
BK 20 19
BE/BK
BE/PK
P&A Relay

R/BE
R/BN
V/BE 24 5 87

R R/BE R/BE 17 3 30
R/Y 18 1 85
BK 23 2 86
BN/BE
BK
R
Cooling Relay
BN/BE 22 5 87
BK
V/GN BN 15 3 30
W/BK R/GN 16 1 85
See Main W/R BK 21 2 86
Harness R/GN
W/O Fairing BK/GN
(2 of 3) R/BK
R/O
BK
W/O
R/W
BK/W

BK
Red Band

R
BK

BK
[5B] A B

BK

BK

R
Transmission Battery Starter
40A
BE/GN

BE/GN

BK/GN
BE/GY

BE/BN
BE/PK

BE/BK
W/GN
W/GY
W/BN

W/BE

W/BK

BE/W

W/BK
R/GN
BK/W

R/BN

BE/O

BE/R

R/BK
BE/V

BE/Y
Main Fuse
W/R

W/R
W/O
R/W

R/V

R/Y
BK

BK
BK

BE
W
R

R
[121B-2] 1 1 [121B-1] [139B] 1 2 3 [242B] A2 A3 A4 B2 B3 C3 C4 D2 D3 E2 E4 F3 F4 G4 H2 J2 J3 J4 K2 K3 K4 L2 L3 L4 M2 M3 M4 1 [259B] A B [319B]
[121A-2] 1 1 [121A-1] [139A] 1 2 3 [242A] A2 A3 A4 B2 B3 C3 C4 D2 D3 E2 E4 F3 F4 G4 H2 J2 J3 J4 K2 K3 K4 L2 L3 L4 M2 M3 M4 1 [259A] A B [319A]
5V Sensor GND 1
5V Sensor Power 1
Oil Pressure

Security Antenna High

Start Enable
Security RF Antenna
Security Antenna Low
Aux Lamp Switch Input
Ignition Switch Input
Engine Stop Switch Input
CAN High
Neutral Switch Input
CAN Low
Horn Power
Brake Switch Input
Fuel Pump Power
Ground
Security Siren
Right Front Turn Signal
Running Light Power
Left Front Turn Signal
Right Rear Turn Signal
Brake Light Power
Left Rear Turn Signal
Starter Solenoid Power
System Power
Front Running/Fog Light Power
Accessory Power
High Beam Power
Low Beam Power

Battery Power
120
Rear Brake
Switch
Terminating
Oil Resister
Pressure

BCM

Figure A-23. Main Harness (3 of 3): 2017 Touring (without Fairing)

94000383 A-47
Main Harness (3 of 3): 2017 Touring (without Fairing) Main Harness (3 of 3): 2017 Touring (without Fairing)

94000383 A-48
 et00671

CB Antenna 1 BK
Except FLHX, FLT FLHX, FLT (Canada Only) FLHX, FLT (HDI Only) FLHX, FLT (DOM Only) Ground
See Main Harness See Main Harness See Main Harness See Main Harness
(3 of 3) (3 of 3) (3 of 3) (3 of 3) [104A]
[7B] 6 5 4 3 2 1 [7B] 6 5 4 3 2 1 [7B] 6 5 4 3 2 1 [7B] 6 5 4 3 2 1 BK

BE/R

BE/BN
R/Y

BE/R

BE/BN
R/Y

BE/R

BE/BN
R/Y

BE/R

BE/BN
R/Y
BE/V

BE/V

BE/V

BE/V
BK

BE

BK

BE

BK

BE

BK

BE
CB Antenna

BK
Cable

CB Loading
Coil

Right Side
Marker Lights

BE/BN

BE/BN

BE/BN
BE/R

BE/R

BE/R
BE/V

BE/V

BE/V
R/Y

R/Y

R/Y
BK

BE
BK

BK

BE
BK

BK

BE
BK
[226B] 1 3 4 5 6 7 12 [226B] 1 3 4 5 6 7 12 [226B] 1 3 4 5 6 7 12

[226A] [226A] [226A]

BE
BK
1 3 4 5 6 7 12 1 3 4 5 6 7 12 1 3 4 5 6 7 12
See Main Tour-Pak
Harness FLH 1 2 [12-2A] Lights
Facia/Converter Facia/Converter Facia/Converter With Fairing
Module Module Module 1 2 [12-2B] (If Equipped)
(3 of 3)

V/BE
BK
[12A]
1 2 3 4 5 7 10 1 2 3 4 5 7 8 9 10 11 1 2 5 6 7 8 9 11
[262A] [262A] [262A]
1 2 3 4 5 7 10 1 2 3 4 5 7 8 9 10 11 1 2 5 6 7 8 9 11 6 BK BE/R E E
[262B] [262B] [262B]
5 BE/V BE/V D D

GN/W

R/W
W/BK

Y/W

W
GN
BE/BN

BE/R

R/Y

V/BN
BE/V
BE

BK
BK

BK

BK

BK
BK
BK
BE
BE
BK
R

V
4 BE/R BE C C
3 BE BK B B
2 BE/BN BE/BN A A
1 V/BE

[287B] [287A]
2 V/BE

GN/W
W/BK

V/BN
R/W
GND

Y/W

GN
BK

BK
1 BK

BK
BK
BK
BE
BE
BK
W
R

Y
BE/BN

BE/BN

[283B]

V
BE/R

BE/R
BE/V

BE/V
R/Y

R/Y
BK

BE

BK

BE

V/BE
[258B]

BK
1 BK
[94B] 6 5 4 3 2 1 [94B] 6 5 4 3 2 1
Power Outlet 1 2 [12-3B]
1 2 [12-3A]
FLHR/C, FLHX, FLT Only

BK
BE
BK
6 5 4 3 2 1 [94A] [52-2B]
Right Rear [18B]
Turn Rear Lighting
Lamp V/BN 1 1
BK 2 2 [18A] AM/FM
Left Side Antenna
[19B] Circuit Base
Board Marker Lights
Left Rear
BK
Turn V/BN 1 1
R/Y
Lamp BK 2 2 [19A] O/W
BE/W
4 4 BK Tail Lighting
BK 1 1 3 3 R/Y
2 2 2 2 O/W
BK 3 3 1 1 BE/W
Running Light (DOM)
Fender Tip/License
Plate Lamp [45B] [45A] [93A] [93B] Running Light (HDI) AM/FM
[52C] Antenna
Base
1

AM/FM
Antenna
Cable

Figure A-24. Rear Lighting: 2017 Touring

94000383 A-49
Rear Lighting: 2017 Touring Rear Lighting: 2017 Touring

94000383 A-50
 et00870 CB Rider Headset CAV CIR DESCRIPTION

CB, Audio (+)

Module [37B] [37A]

CB, Audio (-)

1 BK MICROPHONE, COMMON (-)

Mic Out (+)

Mic Out (-)
2 BK HEADSET, COMMON (-)

CAN High
CAN Low
3 PK/BE HEADSET, RT FRONT (+)

Ground
4 MICROPHONE, FRONT (+) 1 Left Rear

Power
R LBE/O
5 PK/GN HEADSET, LT FRONT (+)
6 BK JUMPER LBE/GY 2 SPKR
7 N/C
TAB SHIELD MICROPHONE, SHIELD

TAB
BK/GN
[225B] 2 5 6 3 4 1

R/O

Y/O
Y/V
BK
W

R
Y
P&A Audio
[280A] 1 2 3 4 5 6 7 8 9 10 11 12 [162A] [162B]
1 2 3 4 5 6 7 8 9 10 11 12 [184B]

PK/GN

PK/BE

BK/W
R/W

BK

BK
PK/GN

LBE/W
[76B]

PK/BE

BK/PK

V/BE
BK

BK
R

LBE/BN
LBE/V

R
1 2 3 4 5 6 7 8 9 10 11 12 [184A] LBE/O 1 1 LBE/O
LBE/GY 2 2 LBE/GY

W/BN
W/PK
W

W
Passenger

R/BE
BK/Y
BK

BK

BK
R

R
LBE/W 3 3 PK/GN PK/GN 5

BK/W
[53B] 1 2 3 4 5 6
Headset
BK/PK 4 4 BK BK 2 CAV CIR DESCRIPTION
Radio [53A] 1 2 3 4 5 6 LBE/V 5 5 PK/BE PK/BE 3 1 BK MICROPHONE, COMMON (-)
2 BK HEADSET, COMMON (-)

CAN High A1 A1 W/R R/W 6 6 R R 4 3 PK/BE REAR RT HEADSET (+)

BK/W
PK/GN
BK/PK
PK/BE

BK
R
4 R REAR MICROPHONE (+)
BK 7 7 BK BK 1 5 PK/GN REAR LT HEADSET (+)
CAN Low A2 A2 W/BK
BK/W 8 8 BK/W BK/W TAB 6
AUX CAN Low A3 A3 W/BN LBE 9 9 LBE
7
TAB SHIELD MICROPHONE, SHIELD
AUX CAN High A4 A4 W/PK LBE/BK 10 10 LBE/BK
Ground B1 B1 BK R/Y 14 14 W/R
Rear Switch Input B2 B2 LBE/PK LBE/PK 15 15 W/BN
Front Microphone (+) C1 C1 R BK/GN 16 16 W
Microphone Common (-) C2 C2 BK [36B] [36A]
Microphone Sum Out (+) C3 C3 R
LBE 1 Right Rear
Rear Microphone (+) D1 D1 R/W
Microphone Shield D2 D2 BK/W
LBE/BK 2 SPKR
Microphone Sum Out (-) D3 D3 BK
Left Rear Headset (+) E1 E1 LBE/W
Right Rear Headset (+) E2 E2 LBE/V W/R Accessory Power
Speaker POD
Headset Common (-) E3 E3 BK/PK W Ground
Switch

BK/GN
W/BN Rear Switch Input 1
Left Front Headset (+) F1 F1 PK/GN
Right Front Headset (+) F2 F2 PK/BE
External AMP Power Control F4 F4 LBE/BN
Left Rear Speaker (-) H1 H1 LBE/GY
Audio In 1 Right (+) H2 H2 R
Audio In 1 Shield/Mono (-) H3 H3 BK GND 1
Left Rear Speaker (+) J1 J1 LBE/O
Audio In 1 Left/Mono (+) J2 J2 W
Audio In 3 Left/Mono (+) J3 J3 W
Right Rear Speaker (+) K1 K1 LBE
Right Rear Speaker (-) K2 K2 LBE/BK
Audio In 3 Right (+) K3 K3 R
Audio In 3 Shield/Mono (-) K4 K4 BK/Y
Left Front Speaker (-) L1 L1 PK/GY
Left Front Speaker (+) L2 L2 PK/O
Fuse Block
Ground L3 L3 BK
Ground L4 L4 BK 20A Radio
Right Front Speaker (+) M1 M1 PK R/PK 6 5 R
Right Front Speaker (-) M2 M2 PK/BK 20A P&A
Radio Fuse M3 M3 R/PK R/BE 12 11 R

Radio Fuse M4 M4 R/PK P&A Relay

V/BE 24 5 87

[27A] [27B] R/BE 17 3 30

R/Y 18 1 85
BK 23 2 86
W/BK
W/R
BK
PK/GY
PK/BK
PK/O

[64B]
PK

BK
To Main Harness
[2B] 9 10 11 12 1 [GND3-B]

R/Y
[2A] 9 10 11 12 GND 2 1 [GND3-A] Red Band
[242B] M2
PK/O
PK/GY
PK/BK
PK

R
BK
[242A] M2
A B [5B]

Accessory Power

R
BK
BK

BK
BK

BK
BK
[34A-1] [34B-1] [35B-1] [35A-1]

BK
Right Front 1 PK 1 1 PK PK/GY 2 2 PK/BK 2 Left Front
SPKR 2 PK/BK 2 2 PK/BK PK/O 1 1 PK 1 SPKR Starter 50A
GND 3-2 GND 3-1 GND 1 Main Fuse
Battery
[34A-2] [34B-2] [35B-2] [35A-2] BCM

Figure A-25. OE Radio: 2017 Touring (Except FLHX/S, FLT)

94000383 A-51
OE Radio: 2017 Touring (Except FLHX/S, FLT) OE Radio: 2017 Touring (Except FLHX/S, FLT)

94000383 A-52
 et00869 CB Module
(if Equipped)

CB, Audio (+)

CB, Audio (-)
Mic Out (+)
Mic Out (-)

CAN High
CAN Low
Ground
Power
P&A Audio

BK/GN
[280A]

R/O

Y/O
Y/V
BK
1 2 3 4 5 6 7 8 9 10 11

R
Y
R/W

PK/GN

LBE/W
PK/BE

BK/PK

V/BE
BK

BK
R

LBE/BN
LBE/V
1 2 3 4 5 6 7 8 9 10 11 12 [184B] [162A]

1 2 3 4 5 6 7 8 9 10 11 12 [184A]
LBE/O 1
Radio

W/BN
W/PK
2

W
LBE/GY

R/BE
BK/Y
BK

BK

BK
R

BK/W
LBE 3
CAN High A1 A1 W/R
LBE/BK 4
CAN Low A2 A2 W/BK
AUX CAN Low A3 A3 W/BN
AUX CAN High A4 A4 W/PK
Ground B1 B1 BK

Front Microphone (+) C1 C1 R

Microphone Common (-) C2 C2 BK
Microphone Sum Out (+) C3 C3 R
Rear Microphone (+) D1 D1 R/W
Microphone Shield D2 D2 BK/W
Microphone Sum Out (-) D3 D3 BK
Left Rear Headset (+) E1 E1 LBE/W
Right Rear Headset (+) E2 E2 LBE/V
Headset Common (-) E3 E3 BK/PK
Left Front Headset (+) F1 F1 PK/GN
Right Front Headset (+) F2 F2 PK/BE
External AMP Power Control F4 F4 LBE/BN
Left Rear Speaker (-) H1 H1 LBE/GY
Audio In 1 Right (+) H2 H2 R
Audio In 1 Shield/Mono (-) H3 H3 BK
Left Rear Speaker (+) J1 J1 LBE/O
Audio In 1 Left/Mono (+) J2 J2 W
Audio In 3 Left/Mono (+) J3 J3 W
Right Rear Speaker (+) K1 K1 LBE
Right Rear Speaker (-) K2 K2 LBE/BK
Audio In 3 Right (+) K3 K3 R
Audio In 3 Shield/Mono (-) K4 K4 BK/Y
Left Front Speaker (-) L1 L1 PK/GY
Left Front Speaker (+) L2 L2 PK/O
Ground L3 L3 BK Fuse Block
Ground L4 L4 BK
20A Radio
Right Front Speaker (+) M1 M1 PK
R/PK 6 5 R
Right Front Speaker (-) M2 M2 PK/BK
20A P&A
Radio Fuse M3 M3 R/PK
R/BE 12 11 R
Radio Fuse M4 M4 R/PK
P&A Relay
V/BE 24 5 87
[27A] [27B]
R/BE 17 3 30
R/Y 18 1 85
BK 23 2 86
PK/GY
PK/BK
PK/O
PK

[64B]

BK
W/BK
W/R

[2B] 9 10 11 12 1 [GND3-B]

R/Y
[2A] 9 10 11 12 1 [GND3-A] Red Band
To Main Harness
[242B] M2
PK/O
PK/GY
PK/BK
PK

R
BK
[242A] M2
A B [5B]

Accessory Power

R
BK
BK

BK
BK

BK
BK
[34A-1] [34B-1] [35B-1] [35A-1]

BK
Right Front 1 PK 1 1 PK PK/GY 2 2 PK/BK 2 Left Front
SPKR 2 PK/BK 2 2 PK/BK PK/O 1 1 PK 1 SPKR Starter 50A
GND 3-2 GND 3-1 GND 1 Main Fuse
Battery
[34A-2] [34B-2] [35B-2] [35A-2] BCM

Figure A-26. OE Radio: 2017 Touring (No Tour-Pak)

94000383 A-53
OE Radio: 2017 Touring (No Tour-Pak) OE Radio: 2017 Touring (No Tour-Pak)

94000383 A-54
 et00830
[35] [35T] Radio [34T] [34] Amp #1 (Behind Front fairing)

Fairing

Fairing

[35WL] [35TL] [34WL] [34TL]

Lowers
Lowers

Pod Pod

[37] [36]
Tour-Pak
[37T] [36T] Amp #4
(Under Tour-Pak)

[41T] [42T]

[41W] [42W]

Saddlebag Saddlebag Saddlebag Saddlebag

Amp #2
(Inside left Saddlebag)

Amp #3
(Inside Right Saddlebag)

Figure A-27. Speaker and P&A Amplifier Layout: 2017 Touring

94000383 A-55
Speaker and P&A Amplifier Layout: 2017 Touring Speaker and P&A Amplifier Layout: 2017 Touring

94000383 A-56
 et00871 To RHCM
[35A-2] [35B-2] [34B-2] [34A-2] To Main Harness

W/R

W/BK
R/O

BK/GN
Left Front 1 PK 1 1 BN/O BN/GN 2 2 PK/BK 2 Right Front

LBE/GY

LBE/BK

BK/GN
LBE/O
SPKR 2 PK/BK 2 2 BN/GY BN/PK 1 1 PK 1 SPKR

LBE
[35A-1] [35B-3] [34B-3] [34A-1] 1 2 9 10 16 [162A]
1 2 9 10 16 [162C]

LBE/O
LBE/GY

BK
LBE/BK
LBE
BK/GN

W/BK
W/R
R/O
Amplifier #1
LR OUT + 1 1 LBE/O 1 2 3 4 [22B-1] 3 PK/BK 3 3 LBE
LR OUT - 2 2 LBE/GY 1 2 3 4 [22A-3] 4 PK 4 4 LBE/BK
RR OUT + 3 3 LBE 1 PK/GY 1 1 LBE/O

W/R

W/BK
R/O

BK/GN
RR OUT - 4 4 LBE/BK 2 PK/O 2 2 LBE/GY
LF OUT - 5 5 BN/GY

LBE/GY

LBE/BK
LBE/O
LF OUT + 6 6 BN/O [297D] [297A] [297B]

LBE

BK
RF OUT + 7 7 BN/PK
RF OUT - 8 8 BN/GN
1 2 9 10 16 [162D]
Power 9 9 R
Ground 10 10 BK
1 2 9 10 16 [162B]

W
LBE/O
LBE/GY

LBE/BK
CAN High 11 11 W/R

LBE
Power 16 16 R

LBE/GY

LBE/BK
LBE/O
Ground 17 17 BK

LBE
CAN Low 18 18 W/BK
To Rear Speaker
SW ACCY 19 19 V/BE [296A] 1 2 3 4 Pod
L IN (-) 20 20 PK/GY
Not Used
L IN (+) 21 21 PK/O
R IN (+) 22 22 PK
R IN (-) 23 23 PK/BK
3 LBE

PK/GY
PK/BK

PK/O
4 LBE/BK
[149A-1] [149B-1]
PK
1 LBE/O
1 2 [34A-3] 1 2 [35A-3] 2 LBE/GY
LBE 3
1 2 [34B-1] 1 2 [35B-1] 4
LBE/BK

LBE/GY

LBE/BK
[297D]

LBE/O
PK/O
PK/GY
1
PK/BK
PK

LBE/O
R

LBE
LBE/GY 2
[43]
B
[42B] A B [41B] A B
40A [297C] [42A] [41A]
Inline
Fuse
PK/GY
PK/BK
PK/O

BK/GN

W/BK
A
PK

V/BE

W/R
R/O
BK
9 10 11 12 [2B]
R

1 2 [132B] 1 2 3 4 [22B-3] Left Right

9 10 11 12 [2A] Saddle SPKR Saddle SPKR
1 2 [132A] 1 2 3 4 [22A-1]
PK/O
PK/GY
PK/BK
PK

W/R

W/BK
R/O

BK/GN
V/BE

Radio BK 3 LBE
CAN High A1 A1 W/R 4 LBE/BK
CAN Low A2 A2 W/BK 1 LBE/O
Left Front Speaker (-) L1 L1 PK/GY 2 LBE/GY

BK
Left Front Speaker (+) L2 L2 PK/O

LBE/GY

LBE/BK
Ground L3 L3 BK 1 [GND3B] [297D]

LBE/O

LBE
Ground L4 L4 BK 1 [GND3A]
Right Front Speaker (+) M1 M1 PK

BK
Right Front Speaker (-) M2 M2 PK/BK [35LB] 1 2 [34LB] 1 2
Radio Fuse M3 M3 R/PK [35LA] [34LA]
Radio Fuse M4 M4 R/PK BK
BK

BK

BK
R

[27A] [27B]

BK/GN
R/PK

W/BK
V/BE

W/R
R/O
BK

Lower Fairing Lower Fairing

LT SPKR RT SPKR
GND 3 Radio Battery To Fairing Harness GND 3-2 GND 3-1 To Main Harness
Fuse

Figure A-28. P&A Radio with 1 Amp: 2017 Touring

94000383 A-57
P&A Radio with 1 Amp: 2017 Touring P&A Radio with 1 Amp: 2017 Touring

94000383 A-58
 et00731 To RHCM
[35A-2] [35B-2] [34B-2] [34A-2]

W/R

W/BK
R/O

BK/GN
Left Front 1 PK 1 1 BN/O BN/GN 2 2 PK/BK 2 Right Front
SPKR 2 PK/BK 2 2 BN/GY BN/PK 1 1 PK 1 SPKR

[35A-1] [35B-3] [34B-3] [34A-1]

BK/GN

W/BK
W/R
R/O
Amplifier #1
LR OUT + 1 1 LBE/O 1 2 3 4 [22B-1]
LR OUT - 2 2 LBE/GY 1 2 3 4 [22A-3]
RR OUT + 3 3 LBE

W/R

W/BK
R/O

BK/GN
RR OUT - 4 4 LBE/BK
LF OUT - 5 5 BN/GY
LF OUT + 6 6 BN/O
RF OUT + 7 7 BN/PK
RF OUT - 8 8 BN/GN
Power 9 9 R
Ground 10 10 BK
CAN High 11 11 W/R
Power 16 16 R
Ground 17 17 BK
CAN Low 18 18 W/BK
SW ACCY 19 19 V/BE
L IN (-) 20 20 PK/GY
L IN (+) 21 21 PK/O
R IN (+) 22 22 PK
R IN (-) 23 23 PK/BK

PK/GY
PK/BK

PK/O
[149A-1] [149B-1]

PK
1 2 [34A-3] 1 2 [35A-3]
LBE 3 3 LBE
1 2 [34B-1] 1 2 [35B-1] 4 4
LBE/BK LBE/BK

PK/O
PK/GY
1 1

PK/BK
PK
LBE/O LBE/O
R

LBE/GY 2 2 LBE/GY
[43]
B

40A [297C] [297D]

Inline
Fuse

PK/GY
PK/BK
PK/O

BK/GN

W/BK
A

PK

V/BE

W/R
R/O
BK
9 10 11 12 [2B]
R

LBE/GY

LBE/BK
1 2 [132B] 1 2 3 4 [22B-3]

LBE/O
[2A]

LBE
9 10 11 12
1 2 [132A] 1 2 3 4 [22A-1]
PK/O
PK/GY
PK/BK
PK

W/R

W/BK
R/O

BK/GN
V/BE

BK
[35LB] 1 2 [34LB] 1 2

Radio [35LA] [34LA]

CAN High A1 A1 W/R
CAN Low A2 A2 W/BK
Left Front Speaker (-) L1 L1 PK/GY

BK
Left Front Speaker (+) L2 L2 PK/O
Ground L3 L3 BK 1 [GND3B] Lower Fairing Lower Fairing
Ground L4 L4 BK 1 [GND3A] LT SPKR RT SPKR
Right Front Speaker (+) M1 M1 PK

BK
Right Front Speaker (-) M2 M2 PK/BK
Radio Fuse M3 M3 R/PK
Radio Fuse M4 M4 R/PK

BK
BK

BK

BK
R

[27A] [27B]

BK/GN
R/PK

W/BK
V/BE

W/R
R/O
BK

GND 3 Radio Battery To Fairing Harness GND 3-2 GND 3-1 To Main Harness
Fuse

Figure A-29. P&A Radio with 2 Amps (1 of 2): 2017 Touring

94000383 A-59
P&A Radio with 2 Amps (1 of 2): 2017 Touring P&A Radio with 2 Amps (1 of 2): 2017 Touring

94000383 A-60
 et00872
To Main Harness

[37B] [37A] [42B] [42A]

LBE/GY

LBE/BK
LBE/O

LBE
LBE/O 1 Left Rear LBE/GY B Left
Speaker POD Saddlebag
1 2 9 10 [162A] LBE/GY 2 LBE/O A
Speaker
1 2 9 10 [162C]

LBE/GY
LBE/O

LBE/BK
LBE
LBE/O 1 1 PK/O
LBE/GY 2 2 PK/GY
LBE 3 3 PK
LBE/BK 4 4 PK/BK

Amplifier #2
[296A] [296B]
LBE/O 1 1 LR OUT +

1 1 BN/O LBE/GY 2 2 LR OUT -

LBE/O
LBE/GY 2 2 BN/GY LBE 3 3 RR OUT +

BN/PK LBE/BK 4 4 RR OUT -

LBE 3 3
BN/GY 5 5 LF OUT -
LBE/BK 4 4 BN/GN
BN/O 6 6 LF OUT +
LBE/GY

LBE/BK

BN/PK 7 7 RF OUT +
LBE/O

[297B] [297A]
LBE

BN/GN 8 8 RF OUT -
R 9 9 Power
1 2 9 10 [162D] BK BK 10 10 Ground
1 2 9 10 [162B] W/R 11 11 CAN High
PK/W PK/W 12 12 Config 1
LBE/GY
LBE/O

To Main
LBE/BK
LBE

R 16 16 Power
DLC Harness BK BK 17 17 Ground
6 5 3 2 1 [91A-2] 6 5 3 2 1 [91B] W/BK 18 18 CAN Low
R/Y 19 19 SW ACCY

W/BN

W/R

W/BN

W/R
W/BK

W/BK
R/Y

R/Y
BK

BK
PK/GY 20 20 L IN (-)
PK/O 21 21 L IN (+)
R

PK 22 22 R IN (+)
[43-2] PK/BK 23 23 R IN (-)
R

40A [149B-2] [149A-2]

Inline
Fuse
A
Battery [288B] [288A]

W/R 1 1 W/R
R

W/BK 2 2 W/BK
R 3 3 R
R 4 4 R
R/Y 5 5 R/Y
BN/PK 6 6 BN/PK
BN/O 7 7 BN/O
PK/GY 8 8 PK/GY
PK/BK 9 9 PK/BK
BN/GN 10 10 BN/GN
BN/GY 11 11 BN/GY
PK/O 12 12 PK/O
PK 13 13 PK
BK 14 14 BK
BK 15 15 BK
LBE 16 16 LBE
BK

LBE/BK 17 17 LBE/BK

1 [GND3B]
[36B] [36A] [41B] [41A]
1 [GND3A]
LBE 1 Right Rear LBE/BK 2 2 LBE/BK LBE/BK B Right
BK

Speaker POD Saddlebag

BK

BK

LBE/BK 2 LBE 1 1 LBE LBE A

Speaker

[289A] [289B]

GND 3-2 GND 3-1

Figure A-30. P&A Radio with 2 Amps (2 of 2): 2017 Touring

94000383 A-61
P&A Radio with 2 Amps (2 of 2): 2017 Touring P&A Radio with 2 Amps (2 of 2): 2017 Touring

94000383 A-62
 et00795 To RHCM
[35A-2] [35B-2] [34B-2] [34A-2]

W/R

W/BK
R/O

BK/GN
Left Front 1 PK 1 1 BN/O BN/GN 2 2 PK/BK 2 Right Front
SPKR 2 PK/BK 2 2 BN/GY BN/PK 1 1 PK 1 SPKR

[35A-1] [35B-3] [34B-3] [34A-1]

BK/GN

W/BK
W/R
R/O
Amplifier #1
LR OUT + 1 1 LBE/O 1 2 3 4 [22B-1]
LR OUT - 2 2 LBE/GY 1 2 3 4 [22A-3]
RR OUT + 3 3 LBE

W/R

W/BK
R/O

BK/GN
RR OUT - 4 4 LBE/BK
LF OUT - 5 5 BN/GY
LF OUT + 6 6 BN/O
RF OUT + 7 7 BN/PK
RF OUT - 8 8 BN/GN
Power 9 9 R
Ground 10 10 BK
CAN High 11 11 W/R
Power 16 16 R
Ground 17 17 BK
CAN Low 18 18 W/BK
SW ACCY 19 19 V/BE
L IN (-) 20 20 PK/GY
L IN (+) 21 21 PK/O
R IN (+) 22 22 PK
R IN (-) 23 23 PK/BK

PK/GY
PK/BK

PK/O
[149A-1] [149B-1]

PK
R

[43] 1 2 [34A-3] 1 2 [35A-3]

B LBE 3 3 LBE
1 2 [34B-1] 1 2 [35B-1] 4 4
LBE/BK LBE/BK
40A
Inline

PK/O
PK/GY
1 1

PK/BK
PK
LBE/O LBE/O
Fuse LBE/GY 2 2 LBE/GY
A
[313A] [313B]
R

PK/GY
PK/BK
PK/O

BK/GN

W/BK
PK

V/BE

W/R
R/O
BK
9 10 11 12 [2B]

LBE/GY

LBE/BK
Radio 1 2 [299B] 1 2 3 4 [22B-3]

LBE/O
[2A]

LBE
9 10 11 12
Right Rear Speaker (-) K2 K2 LBE/BK 1 2 [299A] 1 2 3 4 [22A-1]
Right Rear Speaker (+) K1 K1 LBE
PK/O
PK/GY
PK/BK
PK

W/R

W/BK
R/O

BK/GN
V/BE

BK
Left Rear Speaker (-) H1 H1 LBE/GY
[35TB] A B [34TB] A B

Left Rear Speaker (+) J1 J1 LBE/O [35TA] A B [34TA] A B

CAN High A1 A1 W/R
CAN Low A2 A2 W/BK
Left Front Speaker (-) L1 L1 PK/GY
Left Front Speaker (+) L2 L2 PK/O
Ground L3 L3 BK
Ground L4 L4 BK
Right Front Speaker (+) M1 M1 PK
Right Front Speaker (-) M2 M2 PK/BK
Radio Fuse M3 M3 R/PK
Radio Fuse M4 M4 R/PK Left Front Right Front
Tweeter/Mid Tweeter/Mid
BK

LBE/GY

LBE/BK

[27A] [27B]
LBE/O

BK/GN
LBE
R/PK

W/BK
V/BE

W/R
R/O
BK

See left
GND 3 Radio Battery Saddlebag Amp To Fairing Harness GND To Main Harness
Fuse

Figure A-31. P&A Radio with 4 Amps (1 of 4), Front Amp: 2017 Touring

94000383 A-63
P&A Radio with 4 Amps (1 of 4), Front Amp: 2017 Touring P&A Radio with 4 Amps (1 of 4), Front Amp: 2017 Touring

94000383 A-64
 et00796
PK/O 1 [42WB] [42WA]
PK/GY 2 See
Tour-Pak LBE/GY B Left
PK 3
Amp Saddlebag
See Front Amp PK/BK 4 LBE/O A
Woofer

[296A-4]

LBE/GY

LBE/BK
LBE/O

LBE
BN/O A A Left
Saddlebag
1 2 9 10 [162A] BN/GY B B
PK/O 1 Tweeter/Mid
1 2 9 10 [162C] PK/GY 2 See Right
Saddlebag Amp [42TB] [42TA]
PK 3
LBE/GY
LBE/O

LBE/BK
LBE
PK/BK 4 Amplifier #2
LBE/O 1 1 LR OUT +
[296A-3] LBE/GY 2 2 LR OUT -
LBE 3 3 RR OUT +
LBE/BK 4 4 RR OUT -
LBE/O 1 1 PK/O PK/O 1 1 PK/O BN/GY 5 5 LF OUT -
LBE/GY 2 2 PK/GY PK/GY 2 2 PK/GY BN/O 6 6 LF OUT +

LBE PK PK PK BN/PK 7 7 RF OUT +

3 3 3 3
BN/GN 8 8 RF OUT -
LBE/BK 4 4 PK/BK PK/BK 4 4 PK/BK
R 9 9 Power
BK BK 10 10 Ground
[296A] [296B] [296A-2] [296B-2]
W/R 11 11 CAN High
PK/W PK/W 12 12 Config 1
R 16 16 Power
BK BK 17 17 Ground
See Right To Main W/BK 18 18 CAN Low
Saddlebag Amp Harness R/Y 19 19 SW ACCY
R

6 5 3 2 1 [91A-2] 6 5 3 2 1 [91B] PK/GY 20 20 L IN (-)

[43-2] R
PK/O 21 21 L IN (+)
B

W/BN

W/R

W/BN

W/R
W/BK

W/BK
R/Y

R/Y
BK

BK
PK 22 22 R IN (+)
40A PK/BK 23 23 R IN (-)
Inline
Fuse
Battery [288B] [288A] [149B-2] [149A-2]
A

W/R 1 1 W/R
R

W/BK 2 2 W/BK
R 3 3 R
R 4 4 R
R/Y 5 5 R/Y
BN/PK 6 6 BN/PK

PK/GY 8 8 PK/GY
PK/BK 9 9 PK/BK
BN/GN 10 10 BN/GN

PK/O 12 12 PK/O
PK 13 13 PK
BK 14 14 BK
BK 15 15 BK
LBE 16 16 LBE
BK

LBE/BK 17 17 LBE/BK

1 [GND3B]
1 [GND3A] [41WB] [41WA]

Right
BK

LBE/BK A
BK

BK

Saddlebag
LBE/BK 4 4 LBE/BK LBE B
Woofer
LBE 3 3 LBE
BN/GN 2 2 BN/GN
BN/PK 1 1 BN/PK
GND 3-2 GND 3-1
BN/PK A A Right
[289A] [289B] BN/GN B B Saddlebag
Tweeter/Mid
[41TB] [41TA]

Figure A-32. P&A Radio with 4 Amps (2 of 4), Left Saddlebag Amp: 2017 Touring

94000383 A-65
P&A Radio with 4 Amps (2 of 4), Left Saddlebag Amp: 2017 Touring P&A Radio with 4 Amps (2 of 4), Left Saddlebag Amp: 2017 Touring

94000383 A-66
 et00797

[35TLA] [35TLB]

Left Lower A A LBE/O

Tweeter/Mid B B LBE/GY

[35WLA] [35WLB]

Left Lower A BN/O

[289B-2] [289A-2]
Woofer B BN/GY

BN/O 1 1 BN/O
BN/GY 2 2 BN/GY
BN/PK 3 3 BN/PK
BN/GN 4 4 BN/GN
[34TLA] [34TLB]

Right Lower A A LBE

Tweeter/Mid B B LBE/BK
Amplifier #3
LBE/O 1 1 LR OUT +
[34WLA] [34WLB] LBE/GY 2 2 LR OUT -
LBE 3 3 RR OUT +
LBE/BK 4 4 RR OUT -
Right Lower A BN/PK
BN/GY 5 5 LF OUT -
Woofer B BN/GN
BN/O 6 6 LF OUT +
BN/PK 7 7 RF OUT +
BN/GN 8 8 RF OUT -
R 9 9 Power
BK BK 10 10 Ground
W/R 11 11 CAN High
PK/W PK/W 13 13 Config 2
R 16 16 Power
BK BK 17 17 Ground
W/BK 18 18 CAN Low
R/Y 19 19 SW ACCY
PK/GY 20 20 L IN (-)
See See PK/O 21 21 L IN (+)
Tour-Pak Left Saddlebag
R

PK 22 22 R IN (+)
Amp Amp
[43-3] 6 5 3 2 1 [91A-3] 6 5 3 2 1 [91B-2] PK/BK 23 23 R IN (-)
R

B
W/BN

W/R

W/BN

W/R
W/BK

W/BK
R/Y

R/Y
BK

BK
40A [149B-3] [149A-3]
Inline
Fuse
A
Battery [289B-1] [289A-1]

W/R 1 1 W/R
R

W/BK 2 2 W/BK
R 3 3 R
R 4 4 R
R/Y 5 5 R/Y
LBE/O 7 7 LBE/O
PK/GY 8 8 PK/GY
PK/BK 9 9 PK/BK
1 PK/O LBE/GY 11 11 LBE/GY
See 2 PK/GY PK/O 12 12 PK/O
Left Saddlebag
Amp 3 PK PK 13 13 PK
4 PK/BK BK 14 14 BK
BK 15 15 BK
[296B-3] LBE 16 16 LBE
LBE/BK 17 17 LBE/BK
BK

GND

Figure A-33. P&A Radio with 4 Amps (3 of 4), Right Saddlebag Amp: 2017 Touring

94000383 A-67
P&A Radio with 4 Amps (3 of 4), Right Saddlebag Amp: 2017 Touring P&A Radio with 4 Amps (3 of 4), Right Saddlebag Amp: 2017 Touring

94000383 A-68
 et00798

[37TA] [37TB]
Left A A LBE/O
Speaker POD
Tweeter/Mid B B LBE/GY

1 PK/O
[37A] [37B] See Left 2 PK/GY
Saddlebag
Amp 3 PK
Left 1 LBE/O
Speaker POD 4 PK/BK
2 LBE/GY
Woofer
Amplifier #4
[296B-4]
LBE/O 1 1 LR OUT +

LBE/O 1 1 LBE/O LBE/O 1 1 BN/O LBE/GY 2 2 LR OUT -

LBE/GY 2 2 LBE/GY LBE/GY 2 2 BN/GY LBE 3 3 RR OUT +

LBE LBE LBE BN/PK LBE/BK 4 4 RR OUT -

9 9 3 3
BN/GY 5 5 LF OUT -
LBE/BK 10 10 LBE/BK LBE/BK 4 4 BN/GN
BN/O 6 6 LF OUT +
BN/PK 7 7 RF OUT +
[162B] [162D] [297B] [297A]
BN/GN 8 8 RF OUT -
R 9 9 Power
BK BK 10 10 Ground
W/R 11 11 CAN High
See Right PK/W PK/W 12 12 Config 1
Saddlebag
DLC PK/W 13 13 Config 2
Amp
BK R 16 16 Power
6 5 3 2 1 [91A-4] 6 5 3 2 1 [91B-3] BK 17 17 Ground
W/BK 18 18 CAN Low

W/BN

W/R

W/BN

W/R
W/BK

W/BK
R/Y

R/Y
BK

BK
R/Y 19 19 SW ACCY
PK/GY 20 20 L IN (-)

R
PK/O 21 21 L IN (+)
[43-4] PK 22 22 R IN (+)

R
B
PK/BK 23 23 R IN (-)
40A
Inline [149B-4] [149A-4]
Fuse
A
Battery
[36A] [36B] R

Right 1 LBE
Speaker POD 2 LBE/BK
Woofer

[36TA] [36TB]

Right A A LBE
Speaker POD B B LBE/BK
Tweeter/Mid

BK
GND

Figure A-34. P&A Radio with 4 Amps (4 of 4), Tour-Pak Amp: 2017 Touring

94000383 A-69
P&A Radio with 4 Amps (4 of 4), Tour-Pak Amp: 2017 Touring P&A Radio with 4 Amps (4 of 4), Tour-Pak Amp: 2017 Touring

94000383 A-70
SUBJECT PAGE NO.
B.1 METRIC CONVERSION ...................................................................................................... B-1
B.2 FLUID CONVERSION .......................................................................................................... B-2
B.3 TORQUE CONVERSION ..................................................................................................... B-3
B.4 GLOSSARY .......................................................................................................................... B-4

APPENDIX B REFERENCE
NOTES
METRIC CONVERSION B.1
CONVERSION TABLE
Table B-1. Metric Conversions
MILLIMETERS to INCHES INCHES to MILLIMETERS
(MM x 0.03937 = IN) (IN x 25.40 = MM)
mm in mm in mm in mm in in mm in mm in mm in mm
.1 .0039 25 .9842 58 2.283 91 3.582 .001 .025 .6 15.240 1-15/16 49.21 3-5/16 84.14
.2 .0078 26 1.024 59 2.323 92 3.622 .002 .051 5/8 15.875 2 50.80 3-3/8 85.72
.3 .0118 27 1.063 60 2.362 93 3.661 .003 .076 11/16 17.462 2-1/16 52.39 3.4 86.36
.4 .0157 28 1.102 61 2.401 94 3.701 .004 .102 .7 17.780 2.1 53.34 3-7/16 87.31
.5 .0197 29 1.142 62 2.441 95 3.740 .005 .127 3/4 19.050 2-1/8 53.97 3-1/2 88.90
.6 .0236 30 1.181 63 2.480 96 3.779 .006 .152 .8 20.320 2-3/16 55.56 3-9/16 90.49
.7 .0275 31 1.220 64 2.519 97 3.819 .007 .178 13/16 20.638 2.2 55.88 3.6 91.44
.8 .0315 32 1.260 65 2.559 98 3.858 .008 .203 7/8 22.225 2-1/4 57.15 3-5/8 92.07
.9 .0354 33 1.299 66 2.598 99 3.897 .009 .229 .9 22.860 2.3 58.42 3-11/16 93.66
1 .0394 34 1.338 67 2.638 100 3.937 .010 .254 15/16 23.812 2-5/16 58.74 3.7 93.98
2 .0787 35 1.378 68 2.677 101 3.976 1/64 .397 1 25.40 2-3/8 60.32 3-3/4 95.25
3 .1181 36 1.417 69 2.716 102 4.016 .020 .508 1-1/16 26.99 2.4 60.96 3.8 96.52
4 .1575 37 1.456 70 2.756 103 4.055 .030 .762 1.1 27.94 2-7/16 61.91 3-13/16 96.84
5 .1968 38 1.496 71 2.795 104 4.094 1/32 .794 1-1/8 28.57 2-1/2 63.50 3-7/8 98.42
6 .2362 39 1.535 72 2.834 105 4.134 .040 1.016 1-3/16 30.16 2-9/16 65.09 3.9 99.06
7 .2756 40 1.575 73 2.874 106 4.173 .050 1.270 1.2 30.48 2.6 66.04 3-15/16 100.01
8 .3149 41 1.614 74 2.913 107 4.212 .060 1.524 1-1/4 31.75 2-5/8 66.67 4 101.6
9 .3543 42 1.653 75 2.953 108 4.252 1/16 1.588 1.3 33.02 2-11/16 68.26 4-1/16 102.19
10 .3937 43 1.693 76 2.992 109 4.291 .070 1.778 1-5/16 33.34 2.7 68.58 4.1 104.14
11 .4331 44 1.732 77 3.031 110 4.331 .080 2.032 1-3/8 34.92 2-3/4 69.85 4-1/8 104.77
12 .4724 45 1.772 78 3.071 111 4.370 .090 2.286 1.4 35.56 2.8 71.12 4-3/16 106.36
13 .5118 46 1.811 79 3.110 112 4.409 .1 2.540 1-7/16 36.51 2-13/16 71.44 4.2 106.68
14 .5512 47 1.850 80 3.149 113 4.449 1/8 3.175 1-1/2 38.10 2-7/8 73.02 4-1/4 107.95
15 .5905 48 1.890 81 3.189 114 4.488 3/16 4.762 1-9/16 39.69 2.9 73.66 4.3 109.22
16 .6299 49 1.929 82 3.228 115 4.527 .2 5.080 1.6 40.64 2-15/16 74.61 4-5/16 109.54
17 .6693 50 1.968 83 3.268 116 4.567 1/4 6.350 1-5/8 41.27 3 76.20 4-3/8 111.12
18 .7086 51 2.008 84 3.307 117 4.606 .3 7.620 1-11/16 42.86 3-1/16 77.79 4.4 111.76
19 .7480 52 2.047 85 3.346 118 4.645 5/16 7.938 1.7 43.18 3.1 78.74 4-7/16 112.71
20 .7874 53 2.086 86 3.386 119 4.685 3/8 9.525 1-3/4 44.45 3-1/8 79.37 4-1/2 114.30
21 .8268 54 2.126 87 3.425 120 4.724 .4 10.160 1.8 45.72 3-3/16 80.96 4-9/16 115.89
22 .8661 55 2.165 88 3.464 121 4.764 7/16 11.112 1-13/16 46.04 3.2 81.28 4.6 116.84
23 .9055 56 2.205 89 3.504 122 4.803 1/2 12.700 1-7/8 47.62 3-1/4 82.55 4-5/8 117.47
24 .9449 57 2.244 90 3.543 123 4.842 9/16 14.288 1.9 48.26 3.3 83.82 4-11/16 119.06

94000383 B-1
FLUID CONVERSION B.2
UNITED STATES SYSTEM

Unless otherwise specified, all fluid volume measurements in

this manual are expressed in United States (U.S.)
units-of-measure. See below:

• 1 pint (U.S.) = 16 fluid ounces (U.S.)

• 1 quart (U.S.) = 2 pints (U.S.) = 32 fl. oz. (U.S.)
• 1 gallon (U.S.) = 4 quarts (U.S.) = 128 fl. oz. (U.S.)
METRIC SYSTEM

Fluid volume measurements in this manual include the metric

system equivalents. In the metric system, 1 liter (L) = 1,000
milliliters (mL). To convert between U.S. units-of-measure and
metric units-of-measure, refer to the following:

• fluid ounces (U.S.) x 29.574 = milliliters

• pints (U.S.) x 0.473 = liters
• quarts (U.S.) x 0.946 = liters
• gallons (U.S.) x 3.785 = liters
• milliliters x 0.0338 = fluid ounces (U.S.)
• liters x 2.114 = pints (U.S.)
• liters x 1.057 = quarts (U.S.)
• liters x 0.264 = gallons (U.S.)
BRITISH IMPERIAL SYSTEM

Fluid volume measurements in this manual do not include the

British Imperial (Imp.) system equivalents. The following
conversions exist in the British Imperial system:

• 1 pint (Imp.) = 20 fluid ounces (Imp.)

• 1 quart (Imp.) = 2 pints (Imp.)
• 1 gallon (Imp.) = 4 quarts (Imp.)

Although the same unit-of-measure terminology as the U.S.

system is used in the British Imperial (Imp.) system, the actual
volume of each British Imperial unit-of-measure differs from its
U.S. counterpart. The U.S. fluid ounce is larger than the British
Imperial fluid ounce. However, the U.S. pint, quart, and gallon
are smaller than the British Imperial pint, quart, and gallon,
respectively. To convert between U.S. units and British Imperial
units, refer to the following:

• fluid ounces (U.S.) x 1.042 = fluid ounces (Imp.)

• pints (U.S.) x 0.833 = pints (Imp.)
• quarts (U.S.) x 0.833 = quarts (Imp.)
• gallons (U.S.) x 0.833 = gallons (Imp.)
• fluid ounces (Imp.) x 0.960 = fluid ounces (U.S.)
• pints (Imp.) x 1.201 = pints (U.S.)
• quarts (Imp.) x 1.201 = quarts (U.S.)
• gallons (Imp.) x 1.201 = gallons (U.S.)

B-2 94000383
TORQUE CONVERSION B.3
UNITED STATES SYSTEM

The U.S. units of torque, foot pounds and inch pounds, are
used in this manual. To convert units, use the following
equations:

• foot pounds (ft-lbs) X 12.00000 = inch pounds (in-lbs)

• inch pounds (in-lbs) X 0.08333 = foot pounds (ft-lbs)
METRIC SYSTEM

All metric torque specifications are written in Newton-meters

(Nm). To convert metric to United States units and United
States to metric, use the following equations:

• Newton meters (Nm) X 0.737563 = foot pounds (ft-lbs)

• Newton meters (Nm) X 8.85085 = inch pounds (in-lbs)
• foot pounds (ft-lbs) X 1.35582 = Newton meters (Nm)
• inch pounds (in-lbs) X 0.112985 = Newton meters (Nm)

94000383 B-3
GLOSSARY B.4
ACRONYMS AND ABBREVIATIONS
Table B-2. Acronyms and Abbreviations
ACRONYM OR ABBREVIATION DESCRIPTION
A Amperes
AAT Ambient air temperature
ABS Anti-lock braking system
AC Alternating current
ACC Accessory position on ignition switch
ACR Automatic compression release
AGM Absorbed glass mat (battery)
Ah Ampere-hour
AIS Active intake solenoid
AWG American wire gauge
B+ Battery voltage
bar Bar
BAS Bank angle sensor
BCM Body control module
BOB Breakout box
BTDC Before top dead center
°C Celsius (Centigrade)
CA California
CAL Calibration
CAN Controller area network
CB Tx CB send transmission
CB Rx CB receive transmission
cc Cubic centimeters
CCA Cold cranking amps
CCW Counterclockwise
CKP Crankshaft position
cm Centimeters
cm3 Cubic centimeters
CW Clockwise
DC Direct current
DLC Data link connector
DOM Domestic
DOT Department of Transportation
DTC Diagnostic trouble code
DVOM Digital volt ohm meter
ECM Electronic control module
ECT Engine coolant temperature
ECU Electronic control unit
EEPROM Electrically erasable programmable read only memory
EFI Electronic fuel injection
EHCU Electro hydraulic control unit
ET Engine temperature
ETC Electronic throttle control

B-4 94000383
 Table B-2. Acronyms and Abbreviations
ACRONYM OR ABBREVIATION DESCRIPTION
EVAP Evaporative emissions control system
°F Fahrenheit
fl oz Fluid ounce
FPS Fuel pressure sensor
ft Feet
ft-lbs Foot pounds
FTP Flash to pass
g Gram
gal Gallon
GAWR Gross axle weight rating
GND Ground (electrical)
GPS Global positioning system
GVWR Gross vehicle weight rating
HCU Hydraulic control unit
HDI Harley-Davidson International
HD-Link Networking system
H-DSSS Harley-Davidson smart security system
HFM Hands-free mode
HFSM Hands-free security module
Hg Mercury
H02S Heated oxygen sensor
hp Horsepower
hr Hour
IAC Idle air control
IAT Intake air temperature
IC Instrument cluster
ID Inside diameter
IGN Ignition light/key switch position
IM Instrument module
in inch
in3 Cubic inch
INJ PW Injector pulse width
INTCM Intercom
in-lbs Inch pounds
JSS Jiffy stand sensor
kg Kilogram
km Kilometer
km/h Kilometers per hour
kPa Kilopascal
kW Kilowatt
KS Knock sensor
L Liter
lb Pounds
LCD Liquid crystal display
LED Light emitting diode

94000383 B-5
 Table B-2. Acronyms and Abbreviations
ACRONYM OR ABBREVIATION DESCRIPTION
LH Left hand
LHCM Left hand control module
LP License plate
LT Left
mA Milliampere
MAP Manifold absolute pressure
max Maximum
mi Mile
min Minimum
mL Milliliter
mm Millimeter
mph Miles per hour
ms Millisecond
Nm Newton-meter
NIM Navigation interface module
NiMH Nickel metal hydride
N/A Not applicable
O2 Oxygen
OD Outside diameter
OEM Original equipment manufacturer
oz Ounce
P&A Parts and Accessories
Part No. Part number
PIN Personal identification number
PND Personal navigation device
psi Pounds per square inch
PWM signal Pulse width modulated signal
qt Quart
RAD Radio
RCM Reverse control module
RDS Radio data system
RES Reserve mark on fuel supply valve
RH Right hand
RHCM Right hand control module
rpm Revolutions per minute
RT Right
s Seconds
SCFH Cubic feet per hour at standard conditions
SDARS Satellite digital audio radio service
SPDO Speedometer
SPKR Speaker
STT Stop/tail/turn
TA Traffic announcement
TCA Throttle control actuator
TDC Top dead center

B-6 94000383
 Table B-2. Acronyms and Abbreviations
ACRONYM OR ABBREVIATION DESCRIPTION
TGS Twist grip sensor
TPMS Tire pressure monitoring system
TPS Throttle position sensor
TSM Turn signal module
TSSM Turn signal/security module
TT Telltale
USB Universal serial bus
V Volt
VAC Volts of alternating current
VDC Volts of direct current
VIN Vehicle identification number
VR Voice recognition
VSS Vehicle speed sensor
W Watt
WA Weather alert
WSS Wheel speed sensor

94000383 B-7
NOTES
TOOLS
PART NUMBER TOOL NAME NOTES
93979-10 SCREAMIN' EAGLE MAGNETIC LIFTER 4.27 CAM COMPARTMENT AND COMPONENTS,
HOLDERS Remove
B-45525 VALVE GUIDE HONE 4.24 CYLINDER HEAD, Inspect
B-49312 CYLINDER HEAD HOLDING FIXTURE 4.24 CYLINDER HEAD, Disassemble
4.24 CYLINDER HEAD, Assemble
BB200A BASIC VACUUM BRAKE BLEEDER 2.12 HYDRAULIC CLUTCH FLUID, Replace Clutch
Fluid
2.13 BRAKES, Replace Brake Fluid
3.16 Brake Lines, Front Brake Line: Non-ABS
3.16 Brake Lines, Rear Brake Line: Non-ABS
3.16 Brake Lines, Brake Line: Front Master Cylinder
to ABS Module
3.16 Brake Lines, Brake Line: ABS Module to Front
Caliper
3.16 Brake Lines, Brake Line: Rear Master Cylinder
to ABS Module
3.16 Brake Lines, Brake Line: ABS Module to Rear
Caliper
3.17 ABS Module, ABS Module
3.18 BLEED BRAKES, Fill and Bleed
3.26 BLEED CLUTCH CONTROL SYSTEM, Drain
and Fill
FABL5 LONG SHANK BALL END SOCKET 9.14 Turn Signal Lamps, Rear Turn Signal Lamp
FRX181 FLARE NUT SOCKET 2.22 Headlamp Alignment, Adjust Auxiliary/Fog
Lamps
9.10 AUXILIARY/FOG LAMPS AND BRACKETS,
Auxiliary/Fog Lamp Housing
HD-23688 BATTERY TESTER 2.8 Coolant, Freeze Point Test

TOOLS
HD-25070 ROBINAIR HEAT GUN 3.33 TOUR-PAK SERVICE, Tour-Pak Seal
3.45 WINDSHIELD: ROAD KING MODELS,
Windshield Window
4.29 Crankcase, Sprocket Shaft Bearing Inner Race
HD-26568 BATTERY TESTER 2.8 Coolant, Freeze Point Test
HD-29545-6A COOLANT FLUORESCENT LEAK DETECTION 6.4 TESTING AND DIAGNOSTICS, Leak Detection
DYE Dye Test
HD-33223-1 CYLINDER COMPRESSION GAUGE 4.8 Troubleshooting, Compression Test
HD-34736-B VALVE SPRING COMPRESSOR 4.24 CYLINDER HEAD, Disassemble
4.24 CYLINDER HEAD, Assemble
HD-34751 CLEANING BRUSH 4.24 CYLINDER HEAD, Inspect
4.24 CYLINDER HEAD, Assemble
HD-34902-B BIG-TWIN MAINSHAFT PRIMARY BEARING 4.29 Crankcase, Sprocket Shaft Bearing Inner Race
RACE REMOVER AND INSTALLER
HD-34902-C BEARING RACE REMOVER AND INSTALLER 7.5 PRIMARY CHAINCASE HOUSING, Mainshaft
KIT Bearing Inner Race
HD-35316-D MAIN DRIVE GEAR REMOVER AND INSTALLER 8.8 MAIN DRIVE GEAR AND BEARING, Remove
SET 8.8 MAIN DRIVE GEAR AND BEARING, Install
HD-35381-A BELT TENSION GAUGE 2.15 DRIVE BELT AND SPROCKETS, Check Drive
Belt Deflection
HD-35457 BLACK LIGHT LEAK DETECTOR 6.4 TESTING AND DIAGNOSTICS, Leak Detection
Dye Test
HD-35667-A CYLINDER LEAKDOWN TESTER 4.8 Troubleshooting, Cylinder Leakdown Test
HD-41137 HOSE CLAMP PLIERS 6.5 COOLING SYSTEM REPAIR, Crimp Clamps
6.5 COOLING SYSTEM REPAIR, Radiator
HD-41177 FORK TUBE HOLDER 3.19 FRONT FORK, Disassemble
3.19 FRONT FORK, Assemble
HD-41182 FUEL PRESSURE GAUGE 5.3 Fuel Pressure Test, Test
HD-41417 PROPANE ENRICHMENT KIT 5.4 Intake Leak Test, Leak Tester

94000383 I
TOOLS
PART NUMBER TOOL NAME NOTES
HD-42311 OIL FILTER WRENCH 2.5 ENGINE OIL AND FILTER, Change Oil and Oil
Filter
HD-42326-B CRANKSHAFT GUIDE 4.29 Crankcase, Assemble
HD-42720-2 CRANKCASE BEARING REMOVER/INSTALLER 4.29 Crankcase, Repair Right Crankcase Half
BASE
HD-42720-5 CRANKCASE BEARING REMOVER/INSTALLER 4.29 Crankcase, Repair Left Crankcase Half
BASE
HD-44060-10A COLLET 3.10 SEALED WHEEL BEARINGS, Remove
HD-44060-11A COLLET 3.10 SEALED WHEEL BEARINGS, Remove
HD-44060D WHEEL BEARING INSTALLER/REMOVER 3.10 SEALED WHEEL BEARINGS, Remove
3.10 SEALED WHEEL BEARINGS, Install
HD-44061 FUEL PRESSURE GAUGE ADAPTER 5.3 Fuel Pressure Test, Test
HD-44067A OIL FILTER WRENCH 2.5 ENGINE OIL AND FILTER, Change Oil and Oil
Filter
HD-44358 FLYWHEEL SUPPORT FIXTURE 4.29 Crankcase, Sprocket Shaft Bearing Inner Race
HD-45305 FORK SEAL DRIVER 3.19 FRONT FORK, Assemble
HD-45327 REAR SWINGARM BEARING INSTALLER 3.22 REAR FORK, Assemble
HD-45335 COOLANT SYSTEM PRESSURE TESTER 6.4 TESTING AND DIAGNOSTICS, Pressure Cap
Test
6.4 TESTING AND DIAGNOSTICS, System
Pressure Test
HD-45968 FAT JACK 2.2 General, Secure the Motorcycle for Service
4.17 REMOVE ENGINE, Remove
HD-46282A FINAL DRIVE SPROCKET LOCKING TOOL 7.8 TRANSMISSION SPROCKET, Remove
7.8 TRANSMISSION SPROCKET, Install
HD-47856 MAIN DRIVE GEAR SEAL INSTALLER KIT 8.8 MAIN DRIVE GEAR AND BEARING, Install
HD-47910 MAINSHAFT LOCKNUT WRENCH 7.8 TRANSMISSION SPROCKET, Remove
7.8 TRANSMISSION SPROCKET, Install
HD-47925 AXLE NUT TORQUE ADAPTER 2.15 DRIVE BELT AND SPROCKETS, Adjust Belt
Deflection
3.5 REAR WHEEL, Remove
HD-47932 MAIN DRIVE GEAR BEARING AND SEAL 8.8 MAIN DRIVE GEAR AND BEARING, Replace
INSTALLATION TOOL Needle Bearings
HD-47933 MAIN DRIVE GEAR SEAL INSTALLER 8.8 MAIN DRIVE GEAR AND BEARING, Replace
Mainshaft Seal
HD-47941 CRANKSHAFT/CAMSHAFT SPROCKET 4.27 CAM COMPARTMENT AND COMPONENTS,
LOCKING TOOL Remove
4.27 CAM COMPARTMENT AND COMPONENTS,
Install
HD-48219 PRIMARY DRIVE LOCKING TOOL 7.4 DRIVE COMPONENTS, Remove
7.4 DRIVE COMPONENTS, Install
HD-48646 CAM RING REMOVER/INSTALLER 5.7 FUEL TANK TOP PLATE, Removal
5.7 FUEL TANK TOP PLATE, Installation
HD-48650 DIGITAL TECHNICIAN II 3.17 ABS Module, ABS Module
3.18 BLEED BRAKES, Fill and Bleed
9.4 ELECTRONIC CONTROL MODULE (ECM),
ECM
9.5 BODY CONTROL MODULE (BCM), Installation
9.34 Boom! Box Infotainment System, Radio:
Fork-Mounted Fairing
9.34 Boom! Box Infotainment System, Radio:
Frame Mounted Fairing
9.42 SECURITY SYSTEM ACTUATION, Fob
Assignment
HD-48921 REAR WHEEL COMPENSATOR SPROCKET 3.6 REAR WHEEL COMPENSATOR, Disassemble
BEARING REMOVER/INSTALLER 3.6 REAR WHEEL COMPENSATOR, Assemble

II 94000383
TOOLS
PART NUMBER TOOL NAME NOTES
HD-48985 SPOKE TORQUE WRENCH 2.9 TIRES AND WHEELS, Wheel Spokes
3.9 WHEEL RUNOUT, True Laced Wheels
HD-50017 OXYGEN SENSOR WRENCH 5.15 HEATED OXYGEN SENSORS (HO2),
Remove
5.15 HEATED OXYGEN SENSORS (HO2), Install
HD-51198 IGNITION SWITCH ALIGNMENT TOOL 9.15 Ignition Switch and Fork Lock, Fairing Models
HD-51337 SHIFTER SHAFT SEAL INSTALLATION TOOL 8.9 TRANSMISSION CASE, Assemble
HD-51656 DIN CONNECTOR TOOL 9.34 Boom! Box Infotainment System, Rear
Speaker Enclosures
9.34 Boom! Box Infotainment System, Rider
Headset Connector
HD-51727 STEERING HEAD BEARING INSTALLER 3.20 STEERING HEAD BEARINGS, Assemble
HD-52004 24 INCH HOSE CLAMP TOOL 2.8 Coolant, Drain and Fill Cooling System
4.9 OIL COOLER AND DOWNTUBE, Remove
4.10 OIL COOLANT LINES, Remove
6.5 COOLING SYSTEM REPAIR, Remove Upper
Coolant Lines
6.5 COOLING SYSTEM REPAIR, Coolant
Downtubes
6.5 COOLING SYSTEM REPAIR, Horizontal
Coolant Tube
6.5 COOLING SYSTEM REPAIR, Coolant Pump
HD-52252 CRANKSHAFT LOCKING TOOL 4.8 Troubleshooting, Cylinder Leakdown Test
HD-59000B FORK OIL LEVEL GAUGE 3.19 FRONT FORK, Assemble
HD-94660-2 PILOT 7.8 TRANSMISSION SPROCKET, Remove
7.8 TRANSMISSION SPROCKET, Install
HD-94681-80 SPOKE WRENCH 2.9 TIRES AND WHEELS, Wheel Spokes
3.9 WHEEL RUNOUT, Laced Wheel Rim Offset
3.9 WHEEL RUNOUT, True Laced Wheels
HD-95637-46B WEDGE ATTACHMENT 4.29 Crankcase, Sprocket Shaft Bearing Inner Race
HD-96333-51F PISTON RING COMPRESSOR 4.25 CYLINDERS, Install
HD-96921-52D OIL PRESSURE TEST GAUGE KIT 4.7 Oil Pressure, Oil Pressure Check
HD-97225-55C SPROCKET SHAFT BEARING INSTALLER 4.29 Crankcase, Assemble
4.29 Crankcase, Sprocket Shaft Bearing Inner Race
HD-99500-80 WHEEL TRUING STAND 3.9 WHEEL RUNOUT, Inspect
3.9 WHEEL RUNOUT, Laced Wheel Rim Offset
3.9 WHEEL RUNOUT, True Laced Wheels
MCR102A MATCO VACUUM VENTURI COOLING SYSTEM 2.8 Coolant, Drain and Fill Cooling System
REFILLER
MPT10128 COOLING SYSTEM ADAPTER 2.8 Coolant, Drain and Fill Cooling System
TA360 TORQUE ANGLE GAUGE 7.8 TRANSMISSION SPROCKET, Install

94000383 III
NOTES
Torque Values
FASTENER TORQUE VALUE NOTES
ABS module locknuts 53–88 in-lbs 6–10 N·m 3.17 ABS Module, ABS Module
ACR 16–19.5 ft-lbs 23–26.4 N·m 9.21 Automatic Compression Release
(ACR), Install
Apply three equally spaced dots of LOC-
TITE 246 MEDIUM STRENGTH/HIGH
TEMPERATURE THREADLOCKER (blue)
around lower third of threads
Accessory switch module screws 12–17 in-lbs 1.4–1.9 N·m 9.16 ACCESSORY SWITCHES, Fork-
Mounted Fairing Models
Air cleaner cover screw 36–60 in-lbs 4.1–6.8 N·m 2.6 AIR CLEANER ELEMENT, Install
Apply LOCTITE 243 (blue) to the threads
of screw.
Air duct nut, lower fairing 65–75 in-lbs 7.3–8.4 N·m 6.5 COOLING SYSTEM REPAIR, COOL-
ING FAN
Air duct screws, lower fairing 65–75 in-lbs 7.3–8.4 N·m 6.5 COOLING SYSTEM REPAIR, COOL-
ING FAN
Air filter element screws 40–60 in-lbs 4.5–6.8 N·m 2.6 AIR CLEANER ELEMENT, Install
Auxiliary/fog lamp bracket acorn nuts: 120–180 in-lbs 13.6–20.3 N·m 9.10 AUXILIARY/FOG LAMPS AND
Fairing models BRACKETS, Turn Signal/Auxiliary/Fog
Lamp Bracket
Auxiliary/fog lamp bracket acorn nuts: 72–108 in-lbs 8.1–12.2 N·m 9.10 AUXILIARY/FOG LAMPS AND
Road King models BRACKETS, Turn Signal/Auxiliary/Fog
Lamp Bracket
Auxiliary/fog lamp door screw 6–10 in-lbs 0.7–1.1 N·m 9.10 AUXILIARY/FOG LAMPS AND

TORQUE-VALUES
BRACKETS, Replace Auxiliary/Fog Lamp
Bulb
Auxiliary/fog lamp flange nut: Models with 20–24 ft-lbs 27.1–32.5 N·m 2.22 Headlamp Alignment, Adjust Auxili-
bullet style turn signal lamps ary/Fog Lamps
Auxiliary/fog lamp flange nut: Models with 15–18 ft-lbs 20.3–24.4 N·m 2.22 Headlamp Alignment, Adjust Auxili-
flat lens turn signal lamps ary/Fog Lamps
Auxiliary/fog lamp stud locknut 20–24 ft-lbs 27.1–32.5 N·m 9.10 AUXILIARY/FOG LAMPS AND
BRACKETS, Auxiliary/Fog Lamp Housing
Banjo bleeder bolt to front caliper 17–19 ft-lbs 23.1–25.8 N·m 3.13 FRONT BRAKE CALIPER, Install
Banjo bolt to ABS module, 10 mm 17–19 ft-lbs 23.1–25.8 N·m 3.16 Brake Lines, Brake Line: ABS Module
to Front Caliper
Banjo bolt to ABS module, 12 mm 28–30 ft-lbs 38–40.6 N·m 3.16 Brake Lines, Brake Line: Front Master
Cylinder to ABS Module
Banjo bolt to front master cylinder 17–19 ft-lbs 23.1–25.8 N·m 3.12 FRONT BRAKE MASTER CYLIN-
DER, Install
Banjo bolt to rear caliper 17–19 ft-lbs 23.1–25.8 N·m 3.15 REAR BRAKE CALIPER, Install
Banjo bolt to rear master cylinder 17–19 ft-lbs 23.1–25.8 N·m 3.14 REAR BRAKE MASTER CYLINDER,
Install
Battery ground cable to transmission 66–114 in-lbs 7.5–12.9 N·m 8.9 TRANSMISSION CASE, Install
Battery terminal bolt 60–70 in-lbs 6.8–7.9 N·m 2.21 Battery Maintenance, Battery
Battery tray screws 132–156 in-lbs 14.9–17.6 N·m 3.16 Brake Lines, Brake Line: Front Master
Cylinder to ABS Module
Brake bleeder screw, front 72–108 in-lbs 8.1–12.2 N·m 2.13 BRAKES, Replace Brake Fluid
Brake bleeder screw, rear 75–102 in-lbs 8.5–11.5 N·m 2.13 BRAKES, Replace Brake Fluid
Brake caliper pad pin 75–102 in-lbs 8.5–11.5 N·m 2.14 BRAKE PADS AND DISCS, Replace
Brake Pads
Always use new part
Brake caliper, front, mounting screws 28–38 ft-lbs 37.9–51.5 N·m 2.14 BRAKE PADS AND DISCS, Replace
Brake Pads
metric
Brake caliper, rear, mounting screws 43–48 ft-lbs 58.3–65.1 N·m 2.14 BRAKE PADS AND DISCS, Replace
Brake Pads
metric

94000383 V
Torque Values
FASTENER TORQUE VALUE NOTES
Brake disc, front, screws (metric) 16–24 ft-lbs 21.7–32.5 N·m 3.4 FRONT WHEEL, Assemble
Always use new screws
Brake disc, rear, screws 30–45 ft-lbs 41–61 N·m 3.5 REAR WHEEL, Assemble
Always use new part
Brake line bracket to lower fork bracket 12–18 in-lbs 1.4–2 N·m 3.20 STEERING HEAD BEARINGS, As-
screws semble
Brake line, rear, P-clamp screw 80–100 in-lbs 9–11.3 N·m 3.16 Brake Lines, Rear Brake Line: Non-
ABS
Brake master cylinder reservoir cover 12–15 in-lbs 1.4–1.7 N·m 2.14 BRAKE PADS AND DISCS, Replace
screws Brake Pads
Brake master cylinder, front, clamp screws 60–80 in-lbs 6.8–9 N·m 3.12 FRONT BRAKE MASTER CYLIN-
DER, Install
Brake master cylinder, front, reservoir 12–15 in-lbs 1.4–1.7 N·m 2.13 BRAKES, Replace Brake Fluid
cover screws
Brake master cylinder, rear, mounting 126–150 in-lbs 14.2–17 N·m 3.14 REAR BRAKE MASTER CYLINDER,
screws Install
Brake master cylinder, rear, reservoir 12–15 in-lbs 1.4–1.7 N·m 2.13 BRAKES, Replace Brake Fluid
cover screws
Brake pedal shaft locknut 15–20 ft-lbs 20.3–27.1 N·m 3.14 REAR BRAKE MASTER CYLINDER,
Install
Breather bolts 22–24 ft-lbs 29.8–32.5 N·m 5.5 AIR CLEANER ASSEMBLY, Install
metric
Breather screw 90–120 in-lbs 10.2–13.6 N·m 4.21 BREATHERS, Install
CB antenna base set screw 14–16 in-lbs 1.6–1.8 N·m 9.13 TOUR-PAK LIGHTS, Wrap-Around
Lamp (if equipped)
CB antenna stud nut 14–16 in-lbs 1.6–1.8 N·m 9.13 TOUR-PAK LIGHTS, Tour-Pak Lights
Harness
CB module bracket to speaker enclosure 25–35 in-lbs 2.8–4 N·m 9.34 Boom! Box Infotainment System, CB
screw Module: Fork Mounted Fairing
CB module to speaker enclosure screw 25–35 in-lbs 2.8–4 N·m 9.34 Boom! Box Infotainment System, CB
Module: Fork Mounted Fairing
CKP mount screw 90–120 in-lbs 10.2–13.6 N·m 9.17 CRANKSHAFT POSITION SENSOR
(CKP), Installation
Cam chain tensioner fasteners 90–120 in-lbs 10.2–13.6 N·m 4.27 CAM COMPARTMENT AND COM-
PONENTS, Install
Cam cover screws 90–120 in-lbs 10.2–13.6 N·m 4.27 CAM COMPARTMENT AND COM-
PONENTS, Complete
Cam needle bearing installation maximum 25 ft-lbs 33.9 N·m 4.27 CAM COMPARTMENT AND COM-
torque PONENTS, Camshaft Needle Bearings
Cam sprocket screw, final torque 34 ft-lbs 46.1 N·m 4.27 CAM COMPARTMENT AND COM-
PONENTS, Install
Apply LOCTITE 262 HIGH STRENGTH
THREADLOCKER AND SEALANT (red)
Cam sprocket screw, first torque 15 ft-lbs 20.3 N·m 4.27 CAM COMPARTMENT AND COM-
PONENTS, Install
Cam support plate screws 90–120 in-lbs 10.2–13.6 N·m 4.27 CAM COMPARTMENT AND COM-
PONENTS, Install
Charcoal canister screws 15–20 in-lbs 1.7–2.3 N·m 5.18 EVAPORATIVE EMISSIONS CON-
TROL SYSTEM, Charcoal Canister
metric
Clutch actuator bleeder screw 56–75 in-lbs 6.3–8.5 N·m 2.12 HYDRAULIC CLUTCH FLUID, Re-
place Clutch Fluid
Clutch actuator screws 100–120 in-lbs 11.2–13.6 N·m 8.6 SECONDARY CLUTCH ACTUATOR,
Install
Clutch fluid line flare nut 133–186 in-lbs 15–21 N·m 3.25 CLUTCH FLUID LINE, Install
Clutch hub mainshaft nut 70–80 ft-lbs 94.9–108.5 N·m 7.4 DRIVE COMPONENTS, Install

VI 94000383
Torque Values
FASTENER TORQUE VALUE NOTES
Clutch inspection cover screws 84–108 in-lbs 9.5–12.2 N·m 2.10 Primary Chaincase Lubricant, Change
Primary Chaincase Lubricant
Torque sequence
Clutch lever bracket clamp screws 60–80 in-lbs 6.8–9 N·m 3.27 HANDLEBAR, Install
Clutch master cylinder banjo bolt 14–22.8 ft-lbs 19–31 N·m 3.23 CLUTCH MASTER CYLINDER AND
RESERVOIR, Install
Clutch master cylinder clamp screws 60–80 in-lbs 6.8–9 N·m 3.23 CLUTCH MASTER CYLINDER AND
RESERVOIR, Install
Tighten top screw first.
Clutch reservoir cover screws 12–15 in-lbs 1.4–1.7 N·m 2.12 HYDRAULIC CLUTCH FLUID, Re-
place Clutch Fluid
Clutch stopper plate bolts 70–100 in-lbs 7.9–11.3 N·m 7.6 CLUTCH: ASSIST AND SLIP, Clutch
Pack Only
Compensating sprocket bolt, final torque 175 ft-lbs 237.3 N·m 7.4 DRIVE COMPONENTS, Install
Compensating sprocket bolt, first torque 100 ft-lbs 135.6 N·m 7.4 DRIVE COMPONENTS, Install
Loosen then final tighten
Console fastener, front 20–30 in-lbs 2.3–3.4 N·m 5.6 FUEL TANK, Console
Console fastener, rear 36–60 in-lbs 4.1–6.8 N·m 5.6 FUEL TANK, Console
Coolant bottle nut 65–75 in-lbs 7.3–8.4 N·m 6.5 COOLING SYSTEM REPAIR, Coolant
Bottle
Coolant downtube lower screws 20–22 ft-lbs 27.1–29.8 N·m 4.9 OIL COOLER AND DOWNTUBE, In-
stall
Coolant downtube upper screws 90–110 in-lbs 10.2–12.4 N·m 4.9 OIL COOLER AND DOWNTUBE, In-
stall
Coolant line manifold screws 90–120 in-lbs 10.2–13.6 N·m 6.5 COOLING SYSTEM REPAIR, Install
Upper Coolant Lines
Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (BLUE)
Crankcase oil check valve or plug with O- 120–168 in-lbs 13.6–19 N·m 4.29 Crankcase, Plugs and Oil Fittings
ring
Crankcase screws, first torque 120 in-lbs 13.6 N·m 4.29 Crankcase, Assemble
final tighten
Crankcase screws, last torque 15–19 ft-lbs 20.3–25.8 N·m 4.29 Crankcase, Assemble
Crankcase tapered plugs 120–144 in-lbs 13.6–16.3 N·m 4.29 Crankcase, Plugs and Oil Fittings
Crankshaft sprocket screw, final torque 24 ft-lbs 32.5 N·m 4.27 CAM COMPARTMENT AND COM-
PONENTS, Install
Crankshaft sprocket screw, first torque 15 ft-lbs 20.3 N·m 4.27 CAM COMPARTMENT AND COM-
PONENTS, Install
Apply LOCTITE 262 HIGH STRENGTH
THREADLOCKER AND SEALANT (red)
Cylinder head bolt first torque 20–30 ft-lbs 27.1–40.7 N·m 4.24 CYLINDER HEAD, Install
Apply ENGINE OIL to cylinder head bolt
washers and threaded portion of the cylin-
der head bolts. See procedure for torque
sequence.
Cylinder head bolt second torque 9–11 ft-lbs 12.2–14.9 N·m 4.24 CYLINDER HEAD, Install
Cylinder head bolt third torque 25–27 ft-lbs 33.9–36.6 N·m 4.24 CYLINDER HEAD, Install
Cylinder stud 120–240 in-lbs 13.6–27.1 N·m 4.29 Crankcase, Cylinder Studs
Cylinder temperature sensor 120–180 in-lbs 13.6–20.3 N·m 4.24 CYLINDER HEAD, Assemble
Dash panel screws 25–30 in-lbs 2.8–3.4 N·m 3.37 DASH PANEL: FORK MOUNTED
FAIRING MODELS, Dash Panel
Debris deflector screw 65–85 in-lbs 7.3–9.6 N·m 3.22 REAR FORK, Install
Engine guard lower screws 15–20 ft-lbs 20.3–27.1 N·m 3.35 FAIRING LOWERS AND ENGINE
GUARD, Engine Guard
Engine guard upper screw 22–28 ft-lbs 29.8–37.9 N·m 3.35 FAIRING LOWERS AND ENGINE
GUARD, Engine Guard

94000383 VII
Torque Values
FASTENER TORQUE VALUE NOTES
Engine mount end cap screws, front 42–48 ft-lbs 56.9–65 N·m 3.16 Brake Lines, Rear Brake Line: Non-
ABS
Engine mount flange nut 50–60 ft-lbs 67.8–81.3 N·m 3.53 FRONT ENGINE MOUNT, Installation
Engine oil drain plug 14–21 ft-lbs 19–28.5 N·m 2.5 ENGINE OIL AND FILTER, Change
Oil and Oil Filter
Engine stabilizer bracket screws 50–60 ft-lbs 67.8–81.3 N·m 3.53 FRONT ENGINE MOUNT, Stabilizer
Link
Engine stabilizer link screws 30–35 ft-lbs 40.7–47.5 N·m 3.53 FRONT ENGINE MOUNT, Installation
Engine temperature sensor 132–188 in-lbs 14.9–21.2 N·m 9.19 ENGINE TEMPERATURE SENSOR
(ET), Install
Exhaust crossover pipe clamp 38–43 ft-lbs 51.5–58.3 N·m 5.17 EXHAUST SYSTEM, Install Exhaust
System
Always use a new clamp
Exhaust crossover pipe hanger bracket 100–120 in-lbs 11.3–13.6 N·m 4.31 OIL PAN, Complete
Exhaust crossover pipe hanger to transmis- 14–18 ft-lbs 19–24.4 N·m 5.17 EXHAUST SYSTEM, Install Exhaust
sion bracket fastener System
Exhaust flange adapter nuts, final torque 100–120 in-lbs 11.3–13.6 N·m 5.17 EXHAUST SYSTEM, Install Exhaust
System
Exhaust flange adapter nuts, first torque 9–18 in-lbs 1–2 N·m 5.17 EXHAUST SYSTEM, Install Exhaust
System
Exhaust shield clamps 20–40 in-lbs 2.3–4.5 N·m 5.17 EXHAUST SYSTEM, Install Exhaust
System
Exhaust side bracket flange locknut 15–20 ft-lbs 20.3–27.1 N·m 5.17 EXHAUST SYSTEM, Install Exhaust
System
Fairing air deflector screws: Frame- 8–15 in-lbs 0.9–1.7 N·m 3.43 STORAGE COMPARTMENTS:
mounted fairing FRAME MOUNTED FAIRING MODELS,
Storage Compartment, Door and Hinge
Fairing air deflector screws: fork mounted 15–25 in-lbs 1.7–2.8 N·m 3.44 Air Deflectors, Fairing Air Deflectors
fairing
Fairing air duct latch screws 9–13 in-lbs 1–1.5 N·m 3.42 INNER FAIRING: FRAME MOUNTED
FAIRING MODELS, Fairing Air Duct
Fairing air duct to inner fairing: Frame- 8–15 in-lbs 0.9–1.7 N·m 3.42 INNER FAIRING: FRAME MOUNTED
mounted fairing FAIRING MODELS, Fairing Air Duct
Fairing air duct to inner fairing: frame 8–15 in-lbs 0.9–1.7 N·m 3.42 INNER FAIRING: FRAME MOUNTED
mounted fairing FAIRING MODELS, Inner Fairing Shell
Replacement
Fairing double studs 120–180 in-lbs 13.6–20.3 N·m 3.38 INNER FAIRING: FORK MOUNTED
FAIRING MODELS, Rotate Inner Fairing
Fairing lower inner panel screws 65–75 in-lbs 7.3–8.5 N·m 3.35 FAIRING LOWERS AND ENGINE
GUARD, Fairing Lower: Air-Cooled
Fairing mount to steering head locknuts: 20–30 ft-lbs 27.1–40.7 N·m 3.42 INNER FAIRING: FRAME MOUNTED
Frame-mounted fairing FAIRING MODELS, Installation
Fairing speaker enclosure to fairing screws 48–60 in-lbs 5.4–6.8 N·m 3.38 INNER FAIRING: FORK MOUNTED
FAIRING MODELS, Replace Inner Fairing
Shell
Fairing speaker enclosure to fairing sup- 48–60 in-lbs 5.4–6.8 N·m 9.34 Boom! Box Infotainment System,
port screws Front Fairing Speakers: Fork Mounted
Fairing
Fairing speaker enclosure to radio support 48–60 in-lbs 5.4–6.8 N·m 9.34 Boom! Box Infotainment System,
bracket screws: FLTR Front Fairing Speaker and Enclosure:
Frame-Mounted Fairing
Fairing speaker grille screws 9–13 in-lbs 1–1.5 N·m 3.38 INNER FAIRING: FORK MOUNTED
FAIRING MODELS, Replace Inner Fairing
Shell

VIII 94000383
Torque Values
FASTENER TORQUE VALUE NOTES
Fairing speaker screw 9–13 in-lbs 1–1.5 N·m 9.34 Boom! Box Infotainment System,
Front Fairing Speakers: Fork Mounted
Fairing
Fairing support bracket-to-engine guard 40–50 in-lbs 4.5–5.7 N·m 3.42 INNER FAIRING: FRAME MOUNTED
screws FAIRING MODELS, Installation
Fairing support bracket-to-inner fairing 48–60 in-lbs 5.4–6.8 N·m 3.42 INNER FAIRING: FRAME MOUNTED
screws: Frame-mounted fairing FAIRING MODELS, Installation
Fairing vent to inner fairing: fork mounted 20–30 in-lbs 2.3–3.4 N·m 3.38 INNER FAIRING: FORK MOUNTED
fairing FAIRING MODELS, Fairing Vent
Fender tip lamp, front 20–25 in-lbs 2.3–2.8 N·m 9.12 FENDER TIP LAMPS, Front Fender
Tip Lamp
Fender tip lamp, rear, harness P-clamp 45–85 in-lbs 5.1–9.6 N·m 9.12 FENDER TIP LAMPS, Rear Fender
locknut Tip Lamp
Fender tip lamp, rear, screws 12–18 in-lbs 1.4–2 N·m 9.12 FENDER TIP LAMPS, Rear Fender
Tip Lamp
Fender trim strips, front 10–15 in-lbs 1.1–1.7 N·m 9.12 FENDER TIP LAMPS, Front Fender
Tip Lamp
Fender, front, fender tip lamp nuts 20–25 in-lbs 2.3–2.8 N·m 3.47 Front Fender, Removal
Fender, front, fender tip screws 20–25 in-lbs 2.3–2.8 N·m 3.47 Front Fender, Removal
Fender, front, mounting screws 16–20 ft-lbs 21.7–27.1 N·m 3.47 Front Fender, Removal
Fender, front, trim skirt screws/nuts 10–15 in-lbs 1.1–1.7 N·m 3.47 Front Fender, Removal
Fender, front, trim strip T-bolt nut 10–15 in-lbs 1.1–1.7 N·m 3.47 Front Fender, Removal
Fender, rear, lights harness stud plate 60–96 in-lbs 6.8–10.9 N·m 9.11 Rear Lighting, Rear Fender Lights
flange nuts Harness: all except FLHX, FLHXS, FLTRX,
FLTRXS
Fender, rear, mounting boss 15–20 ft-lbs 20.3–27.1 N·m 3.48 REAR FENDER, Fender Repair
Fender, rear, mounting screws 15–20 ft-lbs 20.3–27.1 N·m 3.48 REAR FENDER, Installation
Fender, rear, stud plate 60–96 in-lbs 6.8–10.8 N·m 3.48 REAR FENDER, Fender Repair
Fender, rear, support to fender nut 45–85 in-lbs 5.1–9.6 N·m 3.49 REAR FASCIA, Installation
Footboard bracket screws, rider 36–42 ft-lbs 48.8–56.9 N·m 3.51 FOOTBOARDS AND FOOTRESTS,
Rider Footboards
Footboard feeler screws 96–108 in-lbs 10.8–12.2 N·m 3.51 FOOTBOARDS AND FOOTRESTS,
Rider Footboards
Footboard pivot bolt nut, rider 60–80 in-lbs 6.8–9 N·m 3.51 FOOTBOARDS AND FOOTRESTS,
Rider Footboards
Footboard/footrest lower fastener, passen- 48–72 in-lbs 5.4–8.1 N·m 3.51 FOOTBOARDS AND FOOTRESTS,
ger Passenger Footboard
Footboard/footrest lower fastener, passen- 48–72 in-lbs 5.4–8.1 N·m 3.51 FOOTBOARDS AND FOOTRESTS,
ger: FLHX, FLHXS, FLTRX, FLTRXS Passenger Footrest: FLHX, FLHXS,
FLTRX, FLTRXS
Footboard/footrest upper fastener, passen- 36–42 ft-lbs 48.8–56.9 N·m 3.51 FOOTBOARDS AND FOOTRESTS,
ger Passenger Footboard
Footboard/footrest upper fastener, passen- 36–42 ft-lbs 48.8–56.9 N·m 3.51 FOOTBOARDS AND FOOTRESTS,
ger: FLHX, FLHXS, FLTRX, FLTRXS Passenger Footrest: FLHX, FLHXS,
FLTRX, FLTRXS
Footrest pad screw (FLHX, FLHXS, 15–20 ft-lbs 20.3–27.1 N·m 3.51 FOOTBOARDS AND FOOTRESTS,
FLTRX, FLTRXS) Passenger Footrest: Low Models
Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue).
Footrest pad screw: FLHX, FLHXS, 15–20 ft-lbs 20.3–27.1 N·m 3.51 FOOTBOARDS AND FOOTRESTS,
FLTRX, FLTRXS Passenger Footrest: FLHX, FLHXS,
FLTRX, FLTRXS
Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue).
Fork bracket to fork pinch screws 14–18 ft-lbs 19–24.4 N·m 3.19 FRONT FORK, Install
Alternately tighten each screw twice.

94000383 IX
Torque Values
FASTENER TORQUE VALUE NOTES
Fork bracket to steer stem pinch screw 22–26 ft-lbs 29.8–35.2 N·m 3.20 STEERING HEAD BEARINGS, Upper
Fork Bracket
Fork damper tube screw (metric) 30–37 ft-lbs 40–50 N·m 3.19 FRONT FORK, Assemble
Fork lock screws: Road King 36–60 in-lbs 4.1–6.8 N·m 9.15 Ignition Switch and Fork Lock, Road
King Models
Fork slider cover screws 24–48 in-lbs 2.7–5.4 N·m 3.19 FRONT FORK, Install
Apply LOCTITE 246 MEDIUM STRENGTH
THREADLOCKER (blue) to the threads of
screws
Fork tube plug 22–59 ft-lbs 30–80 N·m 3.19 FRONT FORK, Assemble
Front axle nut 70–75 ft-lbs 94.9–101.7 N·m 3.4 FRONT WHEEL, Install
metric
Front axle pinch screw 18–22 ft-lbs 24.4–29.8 N·m 3.4 FRONT WHEEL, Install
metric
Fuel door lock 30–40 in-lbs 3.4–4.5 N·m 5.6 FUEL TANK, Fuel Door
Fuel door screws 30–35 in-lbs 3.4–4 N·m 5.6 FUEL TANK, Fuel Door
Fuel rail screws 31–49 in-lbs 3.5–5.5 N·m 5.14 Fuel Injectors, Install
Fuel supply line quick-connect fitting 22–26 ft-lbs 29.8–35.3 N·m 5.6 FUEL TANK, Fuel Supply Check
Valve/Tube
metric
Fuel tank front screws 15–20 ft-lbs 20.3–27.1 N·m 5.6 FUEL TANK, Installation
Fuel tank rear bracket screws 15–20 ft-lbs 20.3–27.1 N·m 5.6 FUEL TANK, Installation
Gauges, 2 inch diameter gauge screws 8–15 in-lbs 0.9–1.7 N·m 3.38 INNER FAIRING: FORK MOUNTED
FAIRING MODELS, Replace Inner Fairing
Shell
Gauges, instrument cluster screws 10–20 in-lbs 1.1–2.3 N·m 3.38 INNER FAIRING: FORK MOUNTED
FAIRING MODELS, Replace Inner Fairing
Shell
Gauges, instrument cluster screws: frame 12–17 in-lbs 1.4–1.9 N·m 9.31 GAUGES AND INSTRUMENTS:
mounted fairing models FAIRING MODELS, Speedometer/Tacho-
meter Instrument Cluster: Frame Mounted
Fairing
Glove box screws, lower fairing 12–16 in-lbs 1.4–1.8 N·m 6.5 COOLING SYSTEM REPAIR, COOL-
ING FAN
HO2 sensor 14 ft-lbs 19 N·m 5.15 HEATED OXYGEN SENSORS
(HO2), Install
metric
Handlebar clamp shroud screws 10–20 in-lbs 1.1–2.3 N·m 3.46 HEADLAMP NACELLE: ROAD KING
MODELS, Installation
Handlebar lower clamp bolt 30–40 ft-lbs 40.7–54.2 N·m 3.27 HANDLEBAR, Handlebar Clamps
and Rubber Mounts
Handlebar switch housing screws 35–45 in-lbs 4–5 N·m 9.39 HANDLEBAR SWITCH PACKS, In-
stall
Handlebar upper clamp screws 16–20 ft-lbs 21.7–27.1 N·m 3.27 HANDLEBAR, Adjust
Harness ground stud flange nuts 50–90 in-lbs 5.7–10.2 N·m 9.7 IGNITION COIL AND SPARK PLUG
CABLES, Install
Headlamp bezel: FLTR 8–15 in-lbs 0.9–1.7 N·m 9.9 HEADLAMP, Headlamp: FLTR Models
Headlamp door screw 9–18 in-lbs 1–2 N·m 3.36 OUTER FAIRING AND WIND-
SHIELD: FORK MOUNTED FAIRING
MODELS, Outer Fairing and Windshield
Headlamp mount to fairing 22–32 in-lbs 2.5–3.6 N·m 3.36 OUTER FAIRING AND WIND-
SHIELD: FORK MOUNTED FAIRING
MODELS, Outer Fairing and Windshield
Headlamp mount to nacelle screws 9–18 in-lbs 1–2 N·m 3.46 HEADLAMP NACELLE: ROAD KING
MODELS, Installation

X 94000383
Torque Values
FASTENER TORQUE VALUE NOTES
Headlamp nacelle acorn nuts: FLHR/C 96–132 in-lbs 10.8–14.9 N·m 3.46 HEADLAMP NACELLE: ROAD KING
MODELS, Installation
Headlamp nacelle chrome strip flange nut 15–20 in-lbs 1.7–2.3 N·m 3.46 HEADLAMP NACELLE: ROAD KING
MODELS, Installation
Headlamp retaining ring screws: All except 23–26 in-lbs 2.6–2.9 N·m 9.9 HEADLAMP, Headlamp: All But FLTR
FLTR Models
Headlamp screws: FLTR models 48–60 in-lbs 5.4–6.8 N·m 9.9 HEADLAMP, Headlamp: FLTR Models
Headset DIN connector 7–9 in-lbs 0.8–1 N·m 9.34 Boom! Box Infotainment System,
Rear Speaker Enclosures
Horn bracket acorn nut 80–120 in-lbs 9–13.6 N·m 9.29 HORN, Installation
Horn bracket to cylinder head screws 35–40 ft-lbs 47.5–54.2 N·m 9.29 HORN, Installation
Horn cover to bracket 35–55 in-lbs 3.9–6.2 N·m 9.29 HORN, Installation
Horn rubber mount 120–180 in-lbs 13.6–20.3 N·m 9.29 HORN, Installation
Apply LOCTITE 271 HIGH STRENGTH
THREADLOCKER (red)
Horn stud flange nut 80–100 in-lbs 9–11.3 N·m 9.29 HORN, Installation
Hydraulic line multi-clamp screw 10–15 in-lbs 1.1–1.7 N·m 3.16 Brake Lines, Rear Brake Line: Non-
ABS
Ignition coil screws 32–40 in-lbs 3.6–4.5 N·m 5.18 EVAPORATIVE EMISSIONS CON-
TROL SYSTEM, Charcoal Canister
Ignition switch housing nut 13–15 ft-lbs 17.5–20.9 N·m 3.37 DASH PANEL: FORK MOUNTED
FAIRING MODELS, Dash Panel
Ignition switch housing nut: Fairing models 13–15 ft-lbs 17.5–20.9 N·m 9.15 Ignition Switch and Fork Lock, Fairing
Models
Ignition switch housing screws: Fairing 85–115 in-lbs 9.6–13 N·m 9.15 Ignition Switch and Fork Lock, Fairing
models Models
Ignition switch screws: Road King 25–35 in-lbs 2.8–3.9 N·m 9.15 Ignition Switch and Fork Lock, Road
King Models
Induction module bracket 66–84 in-lbs 7.5–9.5 N·m 5.12 INDUCTION MODULE, Assemble
Induction module flange adapter screws 96–156 in-lbs 10.9–17.6 N·m 5.12 INDUCTION MODULE, Install
metric
Inner fairing to mount screws: frame- 96–144 in-lbs 10.9–16.3 N·m 3.42 INNER FAIRING: FRAME MOUNTED
mounted fairing FAIRING MODELS, Radio Support
Bracket
Inner fairing-to-mount screws: Frame- 96–144 in-lbs 10.9–16.3 N·m 3.42 INNER FAIRING: FRAME MOUNTED
mounted fairing FAIRING MODELS, Installation
Instrument bezel screws 10–15 in-lbs 1.1–1.7 N·m 3.39 INSTRUMENT BEZEL: FRAME
MOUNTED FAIRING MODELS, Instru-
ment Bezel
Instrument nacelle to fork bracket screws 96–115 in-lbs 10.8–13 N·m 3.40 INSTRUMENT NACELLE: FRAME
MOUNTED FAIRING MODELS, Instru-
ment Nacelle
Jiffy stand bracket fasteners 36–42 ft-lbs 48.8–57 N·m 3.52 Jiffy Stand, Jiffy Stand Bracket
Jiffy stand interlock sensor fastener 96–120 in-lbs 10.8–13.6 N·m 3.52 Jiffy Stand, Jiffy Stand Interlock
Sensor
Use LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue)
if reusing screw
Jiffy stand leg stop hex screw 15–20 ft-lbs 20.3–27.1 N·m 3.52 Jiffy Stand, Install Leg
Knock sensor screw 13–17 ft-lbs 17.6–23 N·m 4.24 CYLINDER HEAD, Assemble
Left electrical caddy fastener 72–96 in-lbs 8.1–10.8 N·m 3.50 Rear Frame, Rear Frame
Left electrical caddy fasteners 72–96 in-lbs 8.1–10.9 N·m 9.6 ELECTRICAL CADDIES, Left Side
Caddy
License plate bracket screws 60–90 in-lbs 6.8–10.2 N·m 9.14 Turn Signal Lamps, Rear Turn Signal
Lamps Bracket
Lifter anti-rotation device screw 90–120 in-lbs 10.2–13.6 N·m 4.23 Pushrods, Lifters and Covers, Install
Lifter cover screws 132–156 in-lbs 14.9–17.6 N·m 4.23 Pushrods, Lifters and Covers, Install

94000383 XI
Torque Values
FASTENER TORQUE VALUE NOTES
Lower fairing cap flange nut 30–35 in-lbs 3.4–3.9 N·m 3.35 FAIRING LOWERS AND ENGINE
GUARD, Fairing Lower: Air-Cooled
Lower fairing glove box screws 12–16.8 in-lbs 1.4–1.9 N·m 3.35 FAIRING LOWERS AND ENGINE
GUARD, Fairing Lower: Air-Cooled
Lower fairing glove box tray screws 12–18 in-lbs 1.4–2 N·m 3.35 FAIRING LOWERS AND ENGINE
GUARD, Fairing Lower: Air-Cooled
Lower fairing vent knob screw 12–18 in-lbs 1.4–2 N·m 3.35 FAIRING LOWERS AND ENGINE
GUARD, Fairing Lower: Air-Cooled
Lower fairing, lower clamp 90–100 in-lbs 10.2–11.3 N·m 3.35 FAIRING LOWERS AND ENGINE
GUARD, Fairing Lower: Air-Cooled
Lower fairing, upper clamp nuts 30–35 in-lbs 3.4–3.9 N·m 3.35 FAIRING LOWERS AND ENGINE
GUARD, Fairing Lower: Air-Cooled
Lower rocker cover screws 90–120 in-lbs 10.2–13.6 N·m 4.19 UPPER ROCKER COVERS, Install
Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue)
to screws.
Mass damper screw 90–120 in-lbs 10.2–13.6 N·m 7.3 PRIMARY CHAINCASE COVER, In-
stall
Media compartment screw, lower 8–12 in-lbs 0.9–1.3 N·m 3.38 INNER FAIRING: FORK MOUNTED
FAIRING MODELS, Replace Inner Fairing
Shell
Media compartment screw, upper 25–35 in-lbs 2.8–4 N·m 3.38 INNER FAIRING: FORK MOUNTED
FAIRING MODELS, Upper Support
Bracket
Mid-frame air deflector screws 25–35 in-lbs 2.8–4 N·m 3.44 Air Deflectors, Mid-Frame Air Deflect-
ors
Mirror flange nut: FLHX/S 20–30 in-lbs 2.3–3.4 N·m 3.28 Mirrors, FLHX, FLHXS
metric
Mirror stem acorn nut 60–96 in-lbs 6.8–10.8 N·m 3.28 Mirrors, All Models Except FLHX,
FLHXS
metric
Muffler clamp 38–43 ft-lbs 51.5–58.3 N·m 5.17 EXHAUST SYSTEM, Mufflers
Muffler to saddlebag support screws 14–18 ft-lbs 19–24.4 N·m 2.15 DRIVE BELT AND SPROCKETS,
Adjust Belt Deflection
Nacelle switch hex nut 9–15 in-lbs 1–1.7 N·m 9.16 ACCESSORY SWITCHES, Nacelle
Switches
Neutral switch 120–180 in-lbs 13.6–20.3 N·m 9.26 NEUTRAL SWITCH, Installation
Oil cooler screws 96–120 in-lbs 10.8–13.6 N·m 4.9 OIL COOLER AND DOWNTUBE, In-
stall
Oil line manifold screws 90–120 in-lbs 10.2–13.6 N·m 4.10 OIL COOLANT LINES, Install
Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (BLUE)
Oil pan fasteners 132–156 in-lbs 14.9–17.6 N·m 4.31 OIL PAN, Install
Torque sequence; LOCTITE 243 MEDIUM
STRENGTH THREADLOCKER AND
SEALANT (blue) with used fasteners
Oil pan tapered plug 30–36 ft-lbs 40.7–48.8 N·m 4.31 OIL PAN, Install
Apply LOCTITE 565 THREAD SEALANT
Oil pressure sender 13–17 ft-lbs 17.6–23 N·m 9.27 Oil Pressure Switch, Install
Oil pump screws, final torque 90–120 in-lbs 10.2–13.6 N·m 4.27 CAM COMPARTMENT AND COM-
PONENTS, Install
Oil pump screws, first torque 12–60 in-lbs 1.4–6.8 N·m 4.27 CAM COMPARTMENT AND COM-
PONENTS, Install
Oil return tube/cover screw 100–120 in-lbs 11.3–13.6 N·m 8.9 TRANSMISSION CASE, Assemble

XII 94000383
Torque Values
FASTENER TORQUE VALUE NOTES
Outer fairing lower screws (also air deflect- 8–15 in-lbs 0.9–1.7 N·m 3.41 OUTER FAIRING AND WIND-
or): frame mounted fairing SHIELD: FRAME MOUNTED FAIRING
MODELS, Outer Fairing
Outer fairing screws: fork mounted fairing 20–30 in-lbs 2.3–3.4 N·m 3.36 OUTER FAIRING AND WIND-
SHIELD: FORK MOUNTED FAIRING
MODELS, Outer Fairing and Windshield
Outer fairing upper screws (near speak- 20–30 in-lbs 2.3–3.4 N·m 3.41 OUTER FAIRING AND WIND-
ers): frame mounted fairing SHIELD: FRAME MOUNTED FAIRING
MODELS, Outer Fairing
Outer transmission cover screws 100–120 in-lbs 11.2–13.6 N·m 3.26 BLEED CLUTCH CONTROL SYS-
TEM, Bleed Hydraulic Clutch System
Passenger audio switch screws 25–30 in-lbs 2.8–3.4 N·m 9.34 Boom! Box Infotainment System,
Rear Speaker Enclosures
Passenger backrest flange nuts 108–132 in-lbs 12.2–14.9 N·m 3.34 TOUR-PAK BACKREST, Passenger
Backrest
Passenger backrest flap screws 21–24 in-lbs 2.4–2.7 N·m 3.34 TOUR-PAK BACKREST, Passenger
Backrest Flap
Piston jet screws 25–35 in-lbs 2.8–3.9 N·m 4.29 Crankcase, Repair Right Crankcase
Half
Power outlet, front 13–17 in-lbs 1.5–1.9 N·m 3.38 INNER FAIRING: FORK MOUNTED
FAIRING MODELS, Replace Inner Fairing
Shell
Primary chain tensioner fasteners 21–24 ft-lbs 28.5–32.6 N·m 7.4 DRIVE COMPONENTS, Install
Primary chaincase drain plug 14–21 ft-lbs 19–28.5 N·m 2.10 Primary Chaincase Lubricant, Change
Primary Chaincase Lubricant
Primary chaincase sealing screws 26–28 ft-lbs 35.3–38 N·m 7.5 PRIMARY CHAINCASE HOUSING,
Install
Primary cover fasteners 12–13 ft-lbs 16.3–17.6 N·m 7.3 PRIMARY CHAINCASE COVER, In-
stall
See sequence in the procedure
Radio (or storage box) to fairing support 60–84 in-lbs 6.8–9.5 N·m 9.34 Boom! Box Infotainment System,
bracket screws Radio: Fork-Mounted Fairing
Radio antenna inner set screw 14–16 in-lbs 1.6–1.8 N·m 9.13 TOUR-PAK LIGHTS, Wrap-Around
Lamp (if equipped)
Radio antenna stud nut 16–19 in-lbs 1.8–2.1 N·m 9.13 TOUR-PAK LIGHTS, Wrap-Around
Lamp (if equipped)
Radio support bracket to inner fairing 48–60 in-lbs 5.4–6.8 N·m 3.42 INNER FAIRING: FRAME MOUNTED
screws: FLTR FAIRING MODELS, Inner Fairing Shell
Replacement
Radio to fairing support bracket screws 60–84 in-lbs 6.8–9.5 N·m 9.34 Boom! Box Infotainment System,
Radio: Frame Mounted Fairing
Rear axle cone nut, final torque 95–105 ft-lbs 128.8–142.4 N·m 2.15 DRIVE BELT AND SPROCKETS,
Adjust Belt Deflection
Rear axle cone nut, first torque 15–20 ft-lbs 20–27 N·m 2.15 DRIVE BELT AND SPROCKETS,
Adjust Belt Deflection
For belt adjustment only
Rear fascia flange nuts 30–45 in-lbs 3.4–5.1 N·m 3.49 REAR FASCIA, Installation
Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue).
Rear fascia lamp screws 18–22 in-lbs 2–2.5 N·m 3.49 REAR FASCIA, Installation
Rear fork bracket screws 55–65 ft-lbs 74.6–88.1 N·m 3.22 REAR FORK, Install
Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue).
Rear fork pivot shaft screws 55–65 ft-lbs 74.6–88.1 N·m 3.22 REAR FORK, Install
Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue).
Rear frame to main frame fastener 40–45 ft-lbs 54.2–61 N·m 3.50 Rear Frame, Rear Frame

94000383 XIII
Torque Values
FASTENER TORQUE VALUE NOTES
Rear speaker enclosure to Tour-Pak 20–25 in-lbs 2.3–2.8 N·m 9.34 Boom! Box Infotainment System,
screws Rear Speaker Enclosures
Right caddy to battery tray screw 36–40 in-lbs 4.1–4.5 N·m 9.6 ELECTRICAL CADDIES, Right Side
Caddy
Rocker shaft screw 23–27 ft-lbs 31.2–36.6 N·m 4.22 Rocker Arms, Install
Saddlebag face plate/hinge screw 40–45 in-lbs 4.5–5.1 N·m 3.31 SADDLEBAG SERVICE, Repair
Saddlebag
Saddlebag guard to frame screw, lower 32–36 ft-lbs 43.4–48.8 N·m 3.31 SADDLEBAG SERVICE, Saddlebag
Support
Saddlebag guard to frame screw, upper 32–36 ft-lbs 43.4–48.8 N·m 3.31 SADDLEBAG SERVICE, Saddlebag
Support
Saddlebag hinge to latch assembly screw 30–35 in-lbs 3.4–3.9 N·m 3.31 SADDLEBAG SERVICE, Repair
Saddlebag
Saddlebag hinge to saddlebag screw 40–45 in-lbs 4.5–5.1 N·m 3.31 SADDLEBAG SERVICE, Repair
Saddlebag
Saddlebag latch assembly screws 40–45 in-lbs 4.5–5.1 N·m 3.31 SADDLEBAG SERVICE, Repair
Saddlebag
Saddlebag latch handle screw 40–45 in-lbs 4.5–5.1 N·m 3.31 SADDLEBAG SERVICE, Repair
Saddlebag
Saddlebag lock lever nut 25–35 in-lbs 2.8–3.9 N·m 3.31 SADDLEBAG SERVICE, Repair
Saddlebag
Saddlebag lock screw 20–30 in-lbs 2.3–3.4 N·m 3.31 SADDLEBAG SERVICE, Repair
Saddlebag
Saddlebag strike screw 15–20 in-lbs 1.7–2.3 N·m 3.31 SADDLEBAG SERVICE, Repair
Saddlebag
Saddlebag support casting to frame screw 15–20 ft-lbs 20.3–27.1 N·m 3.31 SADDLEBAG SERVICE, Saddlebag
Support
Saddlebag support to lower fender support 15–20 ft-lbs 20.3–27.1 N·m 3.49 REAR FASCIA, Stud Plate
screw
Saddlebag support tube screw 70–100 in-lbs 7.9–11.3 N·m 3.31 SADDLEBAG SERVICE, Saddlebag
Support
Saddlebag support tube to support casting 30–37 ft-lbs 40.7–50.2 N·m 3.31 SADDLEBAG SERVICE, Saddlebag
fastener, large Support
Saddlebag support tube to support casting 15–20 ft-lbs 20.3–27.1 N·m 3.31 SADDLEBAG SERVICE, Saddlebag
fastener, small Support
Saddlebag tether screw 40–45 in-lbs 4.5–5.1 N·m 3.31 SADDLEBAG SERVICE, Repair
Saddlebag
Seat bumper fastener: FLHX, FLHXS and 32–36 ft-lbs 43.4–48.8 N·m 3.29 SEAT, Seat Bumper
FLTRX, FLTRXS
Seat mounting screw 48–72 in-lbs 5.4–8.1 N·m 3.29 SEAT, SEAT
Seat strap bracket screw 120–144 in-lbs 13.6–16.3 N·m 3.31 SADDLEBAG SERVICE, Saddlebag
Support
Seat strap screw 48–72 in-lbs 5.4–8.1 N·m 3.29 SEAT, SEAT
Shift drum detent screw 120–150 in-lbs 13.6–17 N·m 8.7 Transmission, Assemble
Shift drum lock plate screws 57–63 in-lbs 6.4–7.1 N·m 8.7 Transmission, Assemble
Shift lever pinch screw, heel and toe levers 18–22 ft-lbs 24.4–29.8 N·m 7.3 PRIMARY CHAINCASE COVER, In-
stall
Shifter pawl centering screw 18–23 ft-lbs 24.4–31.2 N·m 8.9 TRANSMISSION CASE, Assemble
Shifter peg screw 96–144 in-lbs 10.9–16.3 N·m 8.4 SHIFTER LINKAGE, Heel-Toe Shift
Levers
Shifter rod jamnut 80–120 in-lbs 9–13.6 N·m 8.4 SHIFTER LINKAGE, Shifter Rod
Shifter rod lever pinch screw, front lever 132–156 in-lbs 14.9–17.6 N·m 8.4 SHIFTER LINKAGE, Shifter Rod
Lever, Front
Shifter rod lever pinch screw, transmission 18–22 ft-lbs 24.4–29.8 N·m 8.9 TRANSMISSION CASE, Complete
lever

XIV 94000383
Torque Values
FASTENER TORQUE VALUE NOTES
Shifter rod to front lever nut 70–90 in-lbs 7.9–10.2 N·m 8.4 SHIFTER LINKAGE, Shifter Rod
Lever, Front
Shifter rod to shift lever 70–90 in-lbs 7.9–10.2 N·m 8.4 SHIFTER LINKAGE, Shifter Rod
Shifter rod to shift lever nut 70–90 in-lbs 7.9–10.2 N·m 8.4 SHIFTER LINKAGE, Shifter Rod
Shock absorber mounting bolt 63–70 ft-lbs 85.4–95 N·m 3.21 Rear Suspension, Install Shock Ab-
sorber
Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue).
Solenoid terminal post nut 70–104 in-lbs 7.9–11.8 N·m 9.8 STARTER, Install
Spark plug 89–133 in-lbs 10–15 N·m 2.18 Spark Plugs, Install
Speedometer bracket acorn nuts: FLHP 72–108 in-lbs 8.1–12.2 N·m 3.46 HEADLAMP NACELLE: ROAD KING
MODELS, Installation
Spoke nipple 55 in-lbs 6.2 N·m 2.9 TIRES AND WHEELS, Wheel Spokes
Starter mounting screws 22–24 ft-lbs 29.8–32.5 N·m 9.8 STARTER, Install
Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue).
Stator mounting screws 55–75 in-lbs 6.2–8.5 N·m 9.23 ALTERNATOR, Install
Always use new screws
Stop lamp switch, rear 12–15 ft-lbs 16.3–20.3 N·m 3.16 Brake Lines, Rear Brake Line: Non-
ABS
Use LOCTITE 565 THREAD SEALANT
Storage compartment door hinge screws 8–15 in-lbs 0.9–1.7 N·m 3.43 STORAGE COMPARTMENTS:
FRAME MOUNTED FAIRING MODELS,
Storage Compartment, Door and Hinge
Storage compartment door screws 8–15 in-lbs 0.9–1.7 N·m 3.43 STORAGE COMPARTMENTS:
FRAME MOUNTED FAIRING MODELS,
Storage Compartment, Door and Hinge
Storage compartment screws 48–60 in-lbs 5.4–6.8 N·m 3.42 INNER FAIRING: FRAME MOUNTED
FAIRING MODELS, Inner Fairing Shell
Replacement
Suspension air valve nut 40–50 in-lbs 4.5–5.6 N·m 3.31 SADDLEBAG SERVICE, Saddlebag
Support
Tail lamp base screw 40–48 in-lbs 4.5–5.4 N·m 9.11 Rear Lighting, Tail Lamp Base
Tail lamp screws 20–24 in-lbs 2.3–2.7 N·m 9.11 Rear Lighting, Replace Tail Lamp
Bulb
Temperature manifold absolute pressure 23–39 in-lbs 2.5–4.5 N·m 5.13 TEMPERATURE MANIFOLD ABSO-
sensor (TMAP) screw LUTE PRESSURE SENSOR (TMAP), In-
stall
Temperature sensor, radiator 17.7–19.2 ft-lbs 24–26 N·m 9.20 ENGINE COOLANT TEMPERATURE
SENSOR (ECT), Coolant Temperature
Sensor
Throttle body to manifold screws 35–53 in-lbs 4–6 N·m 5.12 INDUCTION MODULE, Assemble
Timer cover screws 25–35 in-lbs 2.8–4 N·m 4.27 CAM COMPARTMENT AND COM-
PONENTS, Complete
Top caddy screws 72–96 in-lbs 8.1–10.9 N·m 2.21 Battery Maintenance, Battery
Top duct door mechanism 6–8 in-lbs 0.7–0.9 N·m 3.41 OUTER FAIRING AND WIND-
SHIELD: FRAME MOUNTED FAIRING
MODELS, Top Air Duct
Tour-Pak adapter mounting screws (APC 60–72 in-lbs 6.8–8.1 N·m 3.32 TOUR-PAK, Removal and Installation
models)
Tour-Pak catch screws 25–35 in-lbs 2.8–3.9 N·m 3.33 TOUR-PAK SERVICE, Latch Handle
and Catch
Tour-Pak fasteners 60–72 in-lbs 6.8–8.1 N·m 3.29 SEAT, SEAT
Tour-Pak ground plate screws 20–25 in-lbs 2.3–2.8 N·m 9.13 TOUR-PAK LIGHTS, Tour-Pak Lights
Harness
Tour-Pak hinge screw 25–35 in-lbs 2.8–3.9 N·m 3.33 TOUR-PAK SERVICE, Hinges

94000383 XV
Torque Values
FASTENER TORQUE VALUE NOTES
Tour-Pak latch handle 25–35 in-lbs 2.8–3.9 N·m 3.33 TOUR-PAK SERVICE, Latch Handle
and Catch
Tour-Pak lockset screws 25–35 in-lbs 2.8–3.9 N·m 3.33 TOUR-PAK SERVICE, Tour-Pak Lock
Tour-Pak luggage rack fastener 40–48 in-lbs 4.5–5.4 N·m 3.33 TOUR-PAK SERVICE, Luggage Rack
Tour-Pak mounting nuts 60–72 in-lbs 6.8–8.1 N·m 3.32 TOUR-PAK, Removal and Installation
Tour-Pak side marker lamp screws 20–25 in-lbs 2.3–2.8 N·m 3.33 TOUR-PAK SERVICE, Ground Plate
Tour-Pak support cover screws 8–18 in-lbs 0.9–2 N·m 3.32 TOUR-PAK, Tour-Pak Support
Tour-Pak support screws 15–20 ft-lbs 20.3–27.1 N·m 3.32 TOUR-PAK, Tour-Pak Support
Tour-Pak tether anchor screws 16–22 in-lbs 1.8–2.5 N·m 3.33 TOUR-PAK SERVICE, Tour-Pak
Liner
Tour-Pak tether reel screws 16–22 in-lbs 1.8–2.5 N·m 3.33 TOUR-PAK SERVICE, Tether
Tour-Pak wrap-around lamp screws 20–25 in-lbs 2.3–2.8 N·m 9.13 TOUR-PAK LIGHTS, Wrap-Around
Lamp (if equipped)
Transmission bearing housing screws 22–25 ft-lbs 29.8–33.9 N·m 8.7 Transmission, Install
Transmission drain plug 14–21 ft-lbs 19–28.5 N·m 2.11 Transmission Lubricant, Change
Transmission Lubricant
Transmission filler plug/dipstick 25–75 in-lbs 2.8–8.5 N·m 2.11 Transmission Lubricant, Check
Transmission Lubricant
Transmission inner side cover screws 132–156 in-lbs 14.9–17.6 N·m 8.5 TRANSMISSION SIDE COVERS, In-
stall
Transmission mainshaft/countershaft 85–95 ft-lbs 115.3–128.8 N·m 8.7 Transmission, Assemble
locknuts
Transmission mounting bolts, final torque 34–39 ft-lbs 46.1–52.9 N·m 8.9 TRANSMISSION CASE, Install
Transmission mounting bolts, initial torque 15 ft-lbs 20.3 N·m 8.9 TRANSMISSION CASE, Install
Transmission outer side cover screws 100–120 in-lbs 11.2–13.6 N·m 8.5 TRANSMISSION SIDE COVERS, In-
stall
Transmission sprocket lockplate screws 90–120 in-lbs 10.2–13.6 N·m 7.8 TRANSMISSION SPROCKET, Install
Lock patch, use 3-5 times
Transmission sprocket nut, final torque 35–40 ° 35–40 ° 7.8 TRANSMISSION SPROCKET, Install
Do not loosen to align lockplate screws.
Transmission sprocket nut, first torque 100 ft-lbs 135.6 N·m 7.8 TRANSMISSION SPROCKET, Install
Apply LOCTITE 271 HIGH STRENGTH
THREADLOCKER (red) to last few
threads. Loosen one full turn after first
torque.
Transmission sprocket nut, second torque 35 ft-lbs 47.5 N·m 7.8 TRANSMISSION SPROCKET, Install
plus 35-40 degrees
Transmission top cover 132–156 in-lbs 14.9–17.6 N·m 8.7 Transmission, Install
Turn signal lamp mounting screw, front: 48–60 in-lbs 5.4–6.8 N·m 3.41 OUTER FAIRING AND WIND-
frame mounted fairing SHIELD: FRAME MOUNTED FAIRING
MODELS, Outer Fairing
Turn signal lamp to auxiliary/fog lamp 96–120 in-lbs 10.9–13.5 N·m 2.22 Headlamp Alignment, Adjust Auxili-
bracket screw: Bullet style turn signal ary/Fog Lamps
lamps
Turn signal lamp to auxiliary/fog lamp 36–60 in-lbs 4.1–6.8 N·m 2.22 Headlamp Alignment, Adjust Auxili-
bracket screws: Flat lens turn signal lamps ary/Fog Lamps
Turn signal lamp to fairing screws: FLTRU, 60–120 in-lbs 6.8–13.6 N·m 9.14 Turn Signal Lamps, Front Turn Signal
FLTRX, FLTRXS Lamp
Turn signal lamp to rear turn signal lamps 30–50 in-lbs 3.4–5.6 N·m 9.14 Turn Signal Lamps, Rear Turn Signal
bracket screws Lamp
Turn signal lamp, front, mounting bracket 30–60 in-lbs 4.1–6.8 N·m 9.14 Turn Signal Lamps, Front Turn Signal
screws: Flat lens style Lamp
Turn signal lamps bracket, rear, screws 84–144 in-lbs 9.5–16.3 N·m 9.14 Turn Signal Lamps, Rear Turn Signal
Lamps Bracket
Use LOCTITE 271 HIGH STRENGTH
THREADLOCKER (red)

XVI 94000383
Torque Values
FASTENER TORQUE VALUE NOTES
Turn signal, front, lamp to bracket screw: 96–120 in-lbs 10.9–13.5 N·m 9.14 Turn Signal Lamps, Front Turn Signal
Bullet Style, auxiliary/fog lamp equipped Lamp
Turn signal, front, lamp to bracket screw: 15–20 ft-lbs 20.3–27.1 N·m 9.14 Turn Signal Lamps, Front Turn Signal
Bullet Style, without auxiliary/fog lamps Lamp
Upper rocker cover screws 120–140 in-lbs 13.6–15.8 N·m 4.19 UPPER ROCKER COVERS, Install
Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue)
to screws.
Upper steering stem pinch screw 22–26 ft-lbs 29.8–35.2 N·m 2.19 STEERING HEAD BEARINGS,
Check and Adjust Swing-Back
Upper steering stem, final torque: Fork 63 in-lbs 7.1 N·m 2.19 STEERING HEAD BEARINGS, In-
mounted fairing models spect and Lubricate
Upper steering stem, final torque: Frame 192 in-lbs 21.7 N·m 2.19 STEERING HEAD BEARINGS, In-
mounted fairing models spect and Lubricate
Upper steering stem, final torque: Road 108 in-lbs 12.2 N·m 2.19 STEERING HEAD BEARINGS, In-
King models spect and Lubricate
Upper steering stem, final torque: Trike 108 in-lbs 12.2 N·m 2.19 STEERING HEAD BEARINGS, In-
models spect and Lubricate
Upper steering stem, first torque 35 ft-lbs 47.5 N·m 2.19 STEERING HEAD BEARINGS, In-
spect and Lubricate
Upper support bracket to inner fairing 10–20 in-lbs 1.1–2.2 N·m 3.38 INNER FAIRING: FORK MOUNTED
screws FAIRING MODELS, Replace Inner Fairing
Shell
Upper support bracket to radio (storage 25–35 in-lbs 2.8–4 N·m 3.38 INNER FAIRING: FORK MOUNTED
box) screws FAIRING MODELS, Upper Support
Bracket
Upper support bracket to speaker enclos- 48–60 in-lbs 5.4–6.8 N·m 3.38 INNER FAIRING: FORK MOUNTED
ure screws FAIRING MODELS, Upper Support
Bracket
VSS fastener 100–120 in-lbs 11.3–13.6 N·m 9.24 Vehicle Speed Sensor (VSS), VSS
Valve stem nut 12–15 in-lbs 1.4–1.7 N·m 3.11 Tires, Install
Voltage regulator screws 96–120 in-lbs 10.8–13.6 N·m 4.9 OIL COOLER AND DOWNTUBE, In-
stall
Windshield screws: Fork-mounted fairing 25–30 in-lbs 2.8–3.4 N·m 3.36 OUTER FAIRING AND WIND-
models SHIELD: FORK MOUNTED FAIRING
MODELS, Outer Fairing and Windshield
Windshield screws: Frame mounted fairing 8–12 in-lbs 0.9–1.4 N·m 3.41 OUTER FAIRING AND WIND-
models SHIELD: FRAME MOUNTED FAIRING
MODELS, WINDSHIELD
Windshield screws: Frame-mounted fairing 8–12 in-lbs 0.9–1.4 N·m 3.41 OUTER FAIRING AND WIND-
models SHIELD: FRAME MOUNTED FAIRING
MODELS, Outer Fairing
Windshield window screws: Road King 20–25 in-lbs 2.3–2.8 N·m 3.45 WINDSHIELD: ROAD KING MOD-
models ELS, Windshield Window

94000383 XVII
NOTES
Index
A Console.......................................................................5-7, 5-7
ABS Module......................................................................3-60
ABS Operation..................................................................3-60
Accessory Switches.......................................9-42, 9-42, 9-43
Acronyms and Abbreviations.............................................B-4
Air Deflectors.......................................................3-140, 3-140
Alternator..........................................................................9-52
Ambient Air Temperature Sensor.....................................9-63
Anniversary Badging.......................................................3-163
Antenna Cables.......................................................9-77, 9-77
Audio System....................................................................9-68
Auxiliary Lamp......................................9-18, 9-18, 9-19, 9-20
Auxiliary/Fog Lamp........................................9-18, 9-18, 9-19
Auxiliary/Fog Lamps.........................................................2-57
B D
BCM.............................................................................9-8, 9-8
Badges............................................................................3-163
Battery.......................2-51, 2-52, 2-53, 2-53, 2-54, 2-54, 9-11
Battery Maintenance......................................2-53, 2-54, 2-54
Battery Positive Cable......................................................9-15
Battery Tray......................................................................9-11
Belt Deflection...................................................................2-39
Black Light Leak Detector (HD-35457)...............................6-5
Body Control Module (BCM).......................................9-8, 9-8
Boom! Box Infotainment System..........9-68, 9-68, 9-69, 9-70,
9-71, 9-72, 9-74, 9-76, 9-76
Bottom End Repair...........................................................4-21
Bottom End Service.................................................4-26, 4-27
Brake Caliper (Front)........................................................3-43
Brake Caliper (Rear)...............................................3-47, 3-47
Brake Caliper, Front.................................................3-43, 3-43
Brake Caliper, Rear.................................................3-47, 3-47
Brake Line....................................3-49, 3-51, 3-54, 3-56, 3-58
Brake Lines.......................................................................2-33
Brake Lines (ABS)............................................................2-33
Brake Lines (Non-ABS)....................................................2-33
Brake Master Cylinder (Front)..........................................3-41
Brake Master Cylinder (Rear)...........................................3-46
Brake Master Cylinder, Front............................................3-41
Brake Master Cylinder, Rear............................................3-46
Brakes...............................................................................2-32
Bulb Replacement.................................9-16, 9-21, 9-31, 9-31
C Fairing Cap.....................................................................3-117
CKP Sensor.............................................................9-44, 9-44
Capacities..................................................................3-10, 5-2
Changing Engine Oil.........................................................2-15
Changing Transmission Lubricant....................................2-28
Changing the Pin............................................................9-101
Check................................................................................3-64
Checking Engine Oil.........................................................2-15
Checking Fasteners..........................................................2-10
Cleaning..............................................................................2-5
Clutch.............................................................7-12, 7-12, 7-14
Clutch Fluid System..........................................................3-85
Clutch Master Cylinder................3-79, 3-79, 3-80, 3-80, 3-80
Clutch Master Cylinder/Reservoir............................3-79, 3-79
Compression Test.............................................................4-14
Connectors.........................................................................A-1
Conversions........................................................B-1, B-2, B-3
Coolant...........................................................2-19, 2-20, 3-10
Coolant System Pressure Tester (HD-45335)............6-4, 6-4,
6 - 5
Coolant Temperature Sensor............................................9-47
Cooling System....................2-20, 6-2, 6-4, 6-4, 6-4, 6-5, 6-6,
6 - 9 , 9 - 4 7
Cooling System Troubleshooting........................................6-4
Crank Position Sensor (CKP)..................................9-44, 9-44
Crankcase......................................................4-58, 4-63, 4-64
Crankshaft runout, measuring..........................................4-66
Crimp Clamps.....................................................................6-6
Cylinder Head...................................................................4-38
Cylinder Heads.................................................................4-38
Dash Panel Switches.....................................9-42, 9-42, 9-43
Dash Panel: Fork Mounted.............................................3-117
Disposal and Recycling......................................................2-5
Drive Belt.....................................2-37, 2-38, 2-39, 7-20, 7-20
Drive Belt Deflection Specifications..................................2-38
Drive Belt and Sprockets..................................................2-37
E
ECM....................................................................................9-7
Electrical Caddies...........9-9, 9-9, 9-9, 9-10, 9-11, 9-82, 9-82,
9 - 9 1
INDEX
Engine..............................................................4-3, 4-14, 4-21
Engine Guard..................................................................3-114
Engine Mounts.......................................................3-76, 3-161
Engine Mounts (Front)....................................................3-161
Engine Oil.................................2-8, 2-9, 2-15, 2-15, 3-10, 5-2
Engine Oil and Filter.........................................................2-15
Engine Stabilizer.............................................................3-162
Evaporative Emissions Control....5-29, 5-30, 5-30, 5-30, 5-30,
5 - 3 1
Evaporative Emissions Control: CA Models.....................5-31
Evaporative Emissions Tube..............................................5-7
Exhaust System.............................................5-26, 5-26, 5-27
F
Fairing Harness.......................................................9-91, 9-92
Fairing and Windshield.............................3-115, 3-127, 3-128
Fairing, Inner.3-117, 3-118, 3-118, 3-119, 3-121, 3-122, 3-123
Fairing, Inner: Fork Mounted.3-117, 3-118, 3-118, 3-119, 3-121,
3 - 1 2 2 , 3 - 1 2 3
Fairing, Inner: Frame Mounted.3-131, 3-132, 3-133, 3-134, 3-135
Fairing, Inner: Frame Mounted Models...............3-131, 3-132
Fairing, Lower.................................................................3-112
Fascia, Rear........................3-152, 3-152, 3-152, 3-152, 9-24
Fender (Front).....................................................3-146, 3-147
Fender (Rear)...........................................3-149, 3-150, 3-150
Fender Tip Lamps...................................................9-26, 9-26
Fender, Front.......................................................3-146, 3-147
Fender, Rear............................................3-149, 3-150, 3-150
Fluid Conversions...............................................................B-2
Fluids and Lubricants........................................................2-10
XIX
Index
Flywheel/Connecting Rod.......................................4-66, 4-66
Fob..................................................................................9-102
Fob Assignment..............................................................9-102
Footboards......................................................................3-155
Footboards and Footrests.............3-155, 3-156, 3-156, 3-157
Foreword.................................................................................I
Fork...................................................................................3-64
Fork Bracket, Upper..........................................................3-71
Fork (Front).......................................................................3-67
Fork (Rear)..............................................................3-76, 3-76
Fork, Front.............................................3-64, 3-66, 3-67, 3-68
Fork, Rear................................................................3-76, 3-76
Frame, Rear....................................................................3-153
Front Brake Caliper...........................................................3-43
Front Brake Master Cylinder.............................................3-41
Front Engine Mounts......................................................3-161
Front Fender........................................................3-146, 3-147
Front Fork................................................................3-64, 3-67
Front Forks.......................................................................3-67
Front Headset Receptacle................................................9-76
Front Wheel Speed Sensor and Connector......................9-55
Fuel.............................................................2-8, 2-8, 3-10, 5-2
Fuel Door............................................................................5-7
Fuel Filter.................................................................5-11, 5-11
Fuel Level Sender...................................................5-13, 5-13
Fuel Pressure Regulator.........................................5-12, 5-12
Fuel Pump......................................................5-24, 5-24, 5-24
Fuel Pump and Fuel Level Sender Wire Harness............5-25
Fuel Supply Check Valve/Tube...........................................5-8
Fuel Tank......................................5-6, 5-6, 5-7, 5-7, 5-9, 5-10
Fuel Vapor Vent Tube.......................................................5-30
Fuel and Oil...............................................................2-8, 3-10
Fuse Block..........................................................................9-6
Fuse Blocks........................................................................9-6
Fuses and Relays.................................................9-6, 9-6, 9-6
G Metric System.....................................................................B-2
Gasoline..............................................................................2-8
Gauges and Instruments.........................................9-63, 9-64
Gauges/Instrument...........................................................9-54
Glossary.............................................................................B-4
H
HFSM Antenna.................................................................9-99
Hand Grip, Left.................................................................3-92
Handlebar....................................3-87, 3-87, 3-90, 3-91, 3-91
Handlebar Switch Assemblies..............9-94, 9-95, 9-96, 9-98
Handlebars.......3-87, 3-87, 3-90, 3-91, 3-91, 3-92, 3-92, 3-92
Headlamp.......................................................2-56, 9-16, 9-16
Headlamp: Single Headlamp Models...............................9-16
Headset Connector, Rider................................................9-76
Headset Receptacle (Front).............................................9-76
Heated Hand Grips...........................................................3-93
High Oil Consumption.......................................................4-15
Horn.........................................................................9-60, 9-60
How To Use This Section...............................4-21, 4-21, 4-21
Hydraulic Clutch Fluid.......................................................2-30
XX
I
Ignition Coil..............................................................9-13, 9-13
Ignition/Light Key Switch and Fork Lock.................9-39, 9-40
Inner Fairing....................................................................3-131
Inner Fairing, frame mounted fairing...................3-131, 3-132
Instrument Nacelle..........................................................3-126
Intake Leak Test..........................................................5-4, 5-4
J
Jiffy Stand.....................................3-159, 3-159, 3-159, 3-160
L
Laced Wheel Rim Offset...................................................3-30
Left Hand Grip..................................................................3-92
Left Side Caddy..................................................................9-9
Lower Fairing and Engine Guard....................................3-114
Lubricants, Greases, Sealants (Table).............................2-10
M
Main Drive Gear and Bearing...........................................8-20
Main Fuse...........................................................................9-6
Main Fuse Holder...............................................................9-6
Main Harness...........9-82, 9-82, 9-82, 9-83, 9-84, 9-85, 9-89,
9 - 8 9 , 9 - 9 0 , 9 - 9 0
Main Wiring Harness......................................9-82, 9-82, 9-83
Maintenance......2-8, 2-10, 2-15, 2-15, 2-19, 2-28, 2-33, 2-38,
2-43, 9-16, 9-21, 9-31, 9-31
Maintenance Schedule.....................................................2-10
Maintenance Specifications..............................................2-10
Maxi-Fuse...........................................................................9-6
Medallions.......................................................................3-163
Mid-Frame Air Deflectors................................................3-140
Mirrors, Fairing Mounted...................................................3-95
Mirrors, Handlebar Mounted.............................................3-95
Mufflers.............................................................................5-26
N
Nacelle Switches..............................................................9-43
Neutral Switch.........................................................9-57, 9-57
O
Octane Rating.....................................................................2-8
Oil.......................................................................................2-8
Oil Level............................................................................2-15
Oil Pressure.............................................................4-13, 4-13
Oil Pressure Indicator Lamp.............................................4-13
Oil Pressure Switch..........................................................9-58
Oil Pressure Switch/Sender....................................9-58, 9-58
Oil Pump...........................................................................4-10
Oxygen Sensor........................................................5-22, 5-22
Index
P Spark Plug Cables............................................................9-14
Passenger Audio Controls................................................9-76
Passenger Backrest............................................3-109, 3-109
Personal Identification Number (PIN)..................9-101, 9-101
Piston................................................................................4-48
Power Outlet, Front.................................................9-62, 9-62
Primary Chaincase........................2-26, 3-10, 5-2, 7-10, 7-11
Primary Chaincase Housing......................................7-9, 7-11
Purge Solenoid.................................................................5-30
Purge Tube (Long)............................................................5-30
Purge Tube (Short)...........................................................5-30
Push Rods, Lifters and Covers......................4-35, 4-37, 4-37
Pushrods, Lifters and Covers.........................4-35, 4-37, 4-37
Q
Quick Reference Chart.....................................................2-10
Quick Reference Data......................................................2-10
R Tank Emblems................................................................3-163
Radio................................................................................9-68
Radio Antenna Cable..............................................9-77, 9-77
Radio: Fork Mounted Fairing............................................9-68
Radio: Frame Mounted Fairing.........................................9-71
Rear Belt and Sprockets...................................................2-37
Rear Brake Caliper..................................................3-47, 3-47
Rear Brake Master Cylinder.............................................3-46
Rear Facia...........................................................3-152, 3-152
Rear Fascia...................................3-152, 3-152, 3-152, 3-152
Rear Fascia Lamps.............................................3-152, 3-152
Rear Fender.............................................3-149, 3-150, 3-150
Rear Fork.................................................................3-76, 3-76
Rear Frame.....................................................................3-153
Rear Shock Absorbers............................................3-74, 3-74
Rear Wheel Compensator................................................2-42
Reference.........................................................................2-10
Repair and Replacement Procedures................................2-4
Right Side Caddy..............................................................9-10
Rotor/Stator......................................................................9-52
S
Saddlebag...........................................3-98, 3-98, 3-99, 3-101
Saddlebags..............................................................3-98, 3-98
Safe Operating Maintenance..............................................2-3
Sealed Wheel Bearings....................................................3-33
Seat................................................................3-96, 3-97, 3-97
Security Siren......................................................9-103, 9-103
Serialized Badges...........................................................3-163
Service Aids......................................................................2-10
Service Wear Limits............................................................8-2
Servicing a New Motorcycle...............................................2-3
Shift Linkage.........................................................8-5, 8-5, 8-6
Shock Absorber................................................................2-49
Shock Absorbers..............................................................3-74
Shock Absorbers, Rear..................................3-74, 3-74, 3-74
Shop Practices........................................................II, 2-3, 2-5
Side Caddy, Left.................................................................9-9
Sidecar Configuration.....................................................9-102
Smoking Engine................................................................4-15
Spark Plugs....................................................2-44, 2-44, 2-44
Speaker Grille, Front...............................................9-70, 9-72
Speakers........................................................9-70, 9-72, 9-74
Specifications...............2-8, 2-8, 2-10, 2-23, 2-38, 3-10, 3-30,
4 - 3 , 5 - 2 , 7 - 2 , 8 - 2 , 9 - 5
Spokes..............................................................................2-24
Starter......................................................................9-15, 9-15
Steering Head Bearings.................................2-46, 2-48, 3-71
Stop Lamp Switches................................................9-59, 9-59
Stoplight Switches...................................................9-59, 9-59
Storage...........................................................2-59, 2-59, 2-59
System Fuses and Relays..................................................9-6
T
TGS.........................................................................5-14, 5-14
TSM/TSSM/HFSM.......................................................9-8, 9-8
Tail Lamp...............................................9-21, 9-21, 9-22, 9-24
Tail Lamp Assembly................................................9-21, 9-21
Tail Lamp Bulb Replacement............................................9-21
Tire Replacement.............................................................2-24
Tires........2-23, 2-24, 3-10, 3-36, 3-36, 3-36, 3-37, 3-38, 3-38
Tires and Wheels...........................................2-23, 2-24, 2-24
Tool Safety..........................................................................2-6
Top Caddy...........................................................................9-9
Top End Repair.................................................................4-21
Top End Service......................................................4-24, 4-24
Top Plate....................................................................5-9, 5-10
Torque Conversion.............................................................B-3
Tour-Pak.................3-103, 3-104, 3-105, 3-107, 3-107, 3-109
Tour-Pak Backrest....................................3-109, 3-109, 3-109
Tour-Pak Lights/Backrest/Speaker Box..........................3-109
Tour-Pak Service.3-105, 3-105, 3-105, 3-106, 3-106, 9-28, 9-28,
9 - 2 9
Tour-Pak Speaker Enclosure............................................9-74
Trademarks......................................................................III, III
Transmission.................2-28, 2-28, 3-10, 5-2, 8-3, 8-15, 8-22
Transmission Case.........................................8-25, 8-26, 8-26
Transmission Sprocket.....................................................7-18
Troubleshooting........2-33, 2-60, 2-60, 2-61, 2-62, 2-62, 2-62,
2-63, 4-14, 4-14, 4-15, 6-4
True Laced Wheels...........................................................3-31
Truing Laced Wheels...............................................3-30, 3-31
Turn Signal Lamps..............9-19, 9-31, 9-31, 9-31, 9-34, 9-36
Turn Signals............................................................9-31, 9-31
Twin-Cooling.....................................................2-20, 6-9, 6-10
Twist Grip Sensor....................................................5-14, 5-14
Typical Symptoms.............................................................4-21
U
Upper Fork Bracket...........................................................3-71
V
V.I.N..................................................................................3-13
VIN....................................................................................3-13
VIN codes.........................................................................3-13
Vapor Valve.......................................................................5-29
Vehicle Identification Number...........................................3-13
XXI
Index
Vehicle Identification Number (VIN)..................................3-13
Vent Tube............................................................................5-7

Weight Limits....................................................................3-10
Wheel Bearings................................................................3-33
Wheel Compensator, Rear...............................................2-42
Wheel Lacing...........................................................3-24, 3-26
Wheel Lacing: 16 In. Rear Rim.........................................3-26
Wheel Speed Sensor (Front)............................................9-55
Wheel Speed Sensor (Rear)............................................9-56
Wheel Speed Sensor, Front.............................................9-55
Wheel Speed Sensor, Rear..............................................9-56
Wheel lacing: 16 In. rear wheel........................................3-26
Wheels.........................................2-24, 2-24, 3-30, 3-31, 3-38
Windshield......................................................................3-127
Winter Lubrication...............................................................2-9
Wiring.................................................................................A-7
Wiring Diagram Symbols....................................................A-7
Wiring Harness.................................................................9-85

XXII
INSIDE BACK COVER GOES HERE
OUTSIDE BACK COVER GOES HERE