2010 Harley Davidson Touring Service Repair Manual Instant Download

1
21o Harley-Davidson Touring Models Service Manual
CcJ20O9 H-D. ALL RIGHTS RESERVEEF
99483-10 Printed in the U.S.A.
VISIT THE HARLEY-DAVjDSON WEB SITE http//www.har1
ey-davidson.com
CMI - SM - 07/09
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• MAINTENANCE
• FASTENER TORQUE VALUES
• Fastener Torque Values in this Chapter.
• GENERAL

1.7 AIR CLEANER AND EXHAUSI SYSTEM
Removal... I0StñIlIt\tIOn..... ,. Exhau!t System
Leak Check..... 1.8 TIRES AND WHEELS G
reertl,.... i S Tire RpIacement,..
Inpection..., . .
. 1-17 ..1-17 1-17
......... ... ..
.1-1
-g 1.
Servicing a New Motorcycle........ . Safe
Operating Maintenance.... .. ... Shop
Practices.. . R0PdiL NOtes. . ........ ...
.. Salety . ..
1-19 1-19 120 .1-20 1-20 1-20 .1-21 1-21 . 1-21
. ...... . 1-3 .g .g ..1-3 .g ..1-4 ...........
.1-4 .1-4 .............1-4 ,1 -4 .1-4 1-4
.
.,,,
When To Replace Tires. Wheel Bearings Wheel
Spokes.... . Identify Wheel Spoke Groups.. Wheel
Spoke Adjusimenl...............
.
. .
Removing Parts.................... ..
Cleaning... . DisassemDly and Assembly..........
Checking Torques on Fasteners.... Magnetic Parls
Trays..................... Repair and Replacement
Procedures.. Hardware and ThreadeJ
Parfs...... Threadlocking Agents.................
Wiring, Hoses ancl Lines...............
1.9 PI1IMARY CHAINCASE LUBRICANT
General............... ... Primari ChaiPCase
Lubricant....... .....
y .gg ... ............1 -23
Ch ck Lubricani Level....................
.......................1-23 Ch znging Chaincase
Lubricant...... . 1 23
Instruments and Gauges............
.....,,............... ........ . 1-4
Bearings...... Bushings..... Gaskets....... Lip-Ty
pe Seals........... O-Rings (Pre-Formed
Packings.... Gears.......... Shafts.......... . .
.... Part Replacemenl.......... . Exhaust System
Leakage............... Cleaning......... ..
. ... ............. 1-4 . ... .. .......
...1-4 . 1-4 ..1-4 I -4 .1-5 .1-5 .1-5 .........1-
5 .1-5
1.101RANSMISSION LUBRICANT Transmi ssion
Lubricat!on.. Genera .............................
.............. . Ch'ck Lubricant
Level.................... Changing Transmission
Fluid 1.11 C'LUTCH Adjustm2Flt... . . 1.12
ERIVE BELT AND SPROCKETS
1 -25 1-25 1-25 1 -25
TABLE OF CONTENTS
1-27
Part Protection........................ .......
....... ...............1 -5
Cleaning Process....... Rush or Corrosion
Remova/............
..........1-5 . -5
General . .......
..1-Z9 .....1-29
. .,..,... ... .. ...
Bearings...... Tool Safety.......... Air
Tools....... Wrenches....
. ...........................1-5 ..,....,1-5 1-5
.1-5
Cleanintj.............. .,.,.,. Insp !t3
kets..... Drive Belt. ... . . . . ... ... ..
.. .
1 2 .. . ..... .1-29 .1 -30 .1-31 .,..,.1-31
.
Pliers/CuiterS/Pry Bars...................
Hammers..... . ...... Punches/Chisels .........
.................. CFeWdriVerS..
................. ... .. Ratchets and
Handles....................
.....1-5 .,.,1-5 . . ..1-6 ..... ..... ..
6 . . .. ............1-6
Checkintj Drive BeI1 Deflection...............,..
... Setting EJeIt Deflection.....................
... ..
Adjfislment... . . QSSi FDbl'y'.
... ..,,..,,.., .. ... .. ... ..,,,,, , ,,. ...
... ... I -33
1.13 CABLE AND CHASSIS LUBRITATION
Sockets......... .................................
............................. 1-6 Slorage
Units....,.............. .. . .,. .. ... ..
1 -6

• General................ .
• Steering Head Bearings........................
  Jilly Stand........... . . ...
• Miscellaneous LuDrication......................
• Hinges, Latches. Etc.......... ..........
• BRAKES
• Fluid Inspection..
• BLEEDING BRAKES

..1-34 .,...1-34 ......1-34 ..1-34 ....,1-34

• FUEL AND OIL
• Fuel.
• Gasoline Blends... Engine Lub sea(ten
• Winter Lubrication...
• BULB REQUIREMENTS
• General...

..,.
.1 -7 1-7 1 -7 , 1 -8
1-35
......
.1-9

• MAINTENANCE SCHEDULE
• General.
• ENGINE OIL AND FILTER
• Checking Oil Level....
• Oil Level Cold Gheck.... Oil Level Hot Check..
• Changing Oil anri Oil Filter..

General............... ................... .
.,,,.,,, .,, Procedui e........... . . 1.16
BRAKE PADS AND DISCS Inspection............ Brak
Pacls.. . . .. Brake? DiSc Thickness.............
........
......1-36 .,,,... ..1-36
1-11
.1-38 .1-38 . .,...1-38
, 1-15 .1-15 .1 -15 1-15
Brnk.? Disc Lateral Runout.............
.....,.... ... .......1 -38
Brake Pa 1 Replacement................. . Rear
Brake Caliper......................... Front
Brake Calipers............. ......... .,.
......1 38 .,...,..,....1-38 .1 -40
4
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SAQ L OF CO T N 1.17 SPARK PLUGS
Overheating...................... .. ......
..,...1-62
Valve Train Noise...........................
.......... . -
,,,.,,1-42 ,..,,,.,,. 1-42
,..,,,
.,.........,.1-62
Inspection..........................
Excessive Vibration....
Spark Plug Cable Inspection......................,
.,,
Check Engine Light Illuminates During
Operation.....1-62 Luhricntion System....
.......................... .,.,....... . g -62
1.18 FRONT FORK OIL Replacing Fork Oil...
... .. ,. ,,,. ,...............1-44
Oil Does Not Return To Oil Reservoir...........,..
..........1-62 Engine Uses Too Much Oil Or Smokes
Excessively ..1-62 Engine Leaks Oil From Cases.
Push Rods, Hoses.

• SUSPENSION ADJUSTMENTS
• General
• STEERING HEAD BEARINGS

Etc . .
.. -6 ..1 -63
Low Oil Pressure...............
1-45
High Oi1 Pressure.................. .. .. ...
.............. Electrical System...............
......... ....,.....1-63
Alternator Does Not Charge....................
......,.1 -63
. ,. ,,,. ,,,. ,,,.. ..1-47 ...,. ... ...1 -47
Lubrication...................................
.,,.. .. .. Checking................... ....
Alternator Charge Rate Is Below
Normal..................1-63 Speedometer Operates
Erratically.............. ............1-63
Transrrission..................................,.
... ...........................1 63
Adjustment, ....................................,
,,..,,...........................1-48

• HEADLAMP ALIGNMENT
• Headlamp Aligi\rnent.......................... ..
  . ... ..,.,., 1 49
• Hcacllamp Adjustment Single Headlamp
  Models..........., -49 Headlamp Adjustment Dual
  Headlamp Models......... ..... 1-50 Auxiliary
  Lamp Alignment...................... .. .. .. ...
  ........ 1-50
• CRITICAL FASTENERS

1-63 ,1-63 .1-63 ..1-63 ..1-63 .1-63 1.68 1-64 1-6
4
Shifts Hard.............................. Jumps
Out Of Gear...... ........... .. ... ... ....
Clutch Slips........................ ..
................... Clutch Drngs Or Does Not
Release............ Clutch Chatters...............
....... .. ........... ... Handling...............
..........................................
.. Irregularities Brakes.........................
........... ... .................... Brake Does
Not Hold Normally............. CHASSIS
Ins pe ction.....................................
.. ...... 1 -52 Checking Torques on
Fasteners................,,,.,,,..,,..,,,
1-52 1.23 BATTERY MAINTENANCE General.............
.... .. . . .,.,.., 1-53 Cleaning and
Inspection........................... .. .. ...
... ... .1-54 Battery.............................
..... ... .. ..............1 54

• FASTENER TORQUE VALUES
• Fastener Torque Values in this Chapter..
• SPECIFICATIONS
• Specifications
• Chassis Specifications Tire Specifications

Z-1
Disconnection and Removal.................. ..
... .. .. .1-54
.1 -54 .1-55 1-S5 1-55 . 1 -S5 .... 1-55 .1-56
Installation and Connection.. Voltmeter
Test...............................
....................... Voltmeter Test. Charging
Battery............. Safety Precautions...........
..... Using a Battery Charger.....................
. Storage............... 1.24 ENGINE MOUNTS
2-6 .2-6 .2 -7

• VEHICLE IDENTIFICATION NUMBER (V.I.N.)
• Vehicle Identification Number Touring
  Models.......
• FRONT WHEEL
• Removai...,........................ . .. ...
  ....

..2-9
Inspection..................... ..............
... ... ... .. 1-58 Geiieral......................
............. . . .,..,1-58
z-
Stabilizer Link, ,,, ,,,...,...,..................
...................... . , 1-58
Cleaning and Inspection...........................
... .. . .........2-12 I f1S(DIIBtiOP
............................. .. ..,,. ,,,.
,,,..,,..................2-1 g
.. -5g . 1 -58

• Front Engine Mount......... .,, .
• Rear Frame Fasteners............... .
• STORAGE
• General.............................
• Placing in Storage. .... .....................
  Removal from S!0raqe....
• TROUBLESHOOTING
• General ...................
• ErJgiiJC ,,,,, .,,,..............................
  .. ..

2.5 REAR WHEEL Removal.. CIeaing and
Inspection................ .. Installation........
. .
........... 2-14 . .........................2-15
...........2-15
. 1-59 .1-59 1-59
... ..

• REAR WHEEL COMPENSATOR
• Isolator Replacement........................
• Removal . Installntion
• Sprocket Bear ing RepJacemenl..................
• Removal ..
• !rJstaIIntion.
• WHEEL LACING FRONT RIM
• When I Lacing Angle Flange Hub..

2.18 2-18 .... .2-18 .2-18 .2 -1B .2-18
. 1 -6 1 . 1 -6 T
. ...
Starter Motor Does Not Operate or Does Not T Inn
Enqine
Over .................. .. . ....................
..............1 -61 Engine Turns Over But Does
Not Start . ...... ., 1 -61 ldf)S H8fÖ
..................................................
..............1 -fi1 Starts But Runs IrregUlar Iy
or Misses ................ . ..1 61 A Spark Plug
Fouls Repeatedly................................1
62 Pre-Ignition or Detonation (Knocks or Pangs).
.. ......1 -62
2-20
IV TABLE OF CONTENTS
6
TABLE OF COI1TENTS

• Wheel Lacing Straight Flange Hub. Single Hole
  Circle .2-21 Wheel Lacing. Straight Flange Hub,
  Dual Hole Circle.... .2-22
• WHEEL LACING 16 INCH REAR RIM
• Wheel LaCing 16 In. Rear 7/heeI..........
  .........., ...,,...,,.., .2-25
• CHECKING AND TRUING WHEELS

RE!movaI..........................................
............... IntaIla ion... 2.15 REAR BRAKE
CALIPER Removal. Installation
..2-48 ..2-49
.2-5 1 .2-5 1
2.16 I'RONT FORK Changing Fork Oil................
................ ............................2-52
General....................... Checking Wheel
Runout........ Lateral Runout....... .......
........... ........... ....
?-28 2-2B ..... '-28
Draining......... .. Filling.....................
. . . .......................
..2 52 .2-52
Radial Runout.............. ......................
.............. .,-28
Setting Rim Offset..... Truing Wheels.............
..... .. Radial Truing
.,.,..,.... .........................,2-28 ...
.............................2-30 ?-30
RemovJI.................... .. . .
. Disassmbly................... .. ...
... Cleanin g and inspection......................
.......... . Assembly............... 1nsiallal io
n.................... ..
... .. ... ..2-53 ..2-53 .........2-55 ..2-56 ..2
-56
Lateral Truing....................................
............... ... ...,,2-31 2.10 SEALED WHEEL
BEARINGS Inspection

• EiTEERlNG HEAD BEARINGS
• Removal.............. .. ........................
  ..........
• InsQecti3n......................................
  ..
• Install at ion................. ... .. .,..,...
  .
• FtEAR AIR SUSPENSION
• Check fr Air Leaks........................

2-82 2-33
Removal 1nstat 1ation 2.11 TIRES General..........
.....................
.........2-58 ..2-59 ......2-60
..... ....................-35
Removal...........................................
.................... .. . ..2-35
..2-61
Cleaning Inspection and ReJair............. ..
. . ..2-35 Installation...........................
...........................................,.2-36
Col ipression Fitting............................
......................2-61 Air /aIve
Assembly..........................,...............
..... .2-61 Air"ubes.... .......2-61 2.19 REAR
SHOCK ABSORBERS Removal . . . 2-63
Tube Type Tires ... ... ... ... . .. .. ..
Tubeless Tires....................................
.......... Checking Tire Runo t...............
.............
..2-36 ....2-36 ..g-37
Lateral Runout..............................
.. Radial Runout..............................
.. Wheel Balancing........................... ...
..
.. . .. .. ...2-37 .. .. .. .. .. ...2-37 .. ..
.. . .. .......2-38
Cleaning and Inspeclion.........................
..........................2-63
Disassembly and Assembly....................... .
.. Installati in............. .. .. ...
..2-63 ..2-63
Weights............. ... ... .. ... .
............ ,.. ,,,.. ,,,, ,,,. .,2-38
2.20 REAR FORK Removal................. .,.,...
..,2-64
2.12 FRONT BRAKE MASTER CYLINDER
General................ ... Removal and
DsassemDIy............... .. . ...
., -39 ..2-39
Disassembly and Assembly...................,..,..
......... ..........2-65 Beam ing
Removal......... ..................
............... ..........2-65 Beam ing
Installation............... .....................
..............2-65
Removal.................................. .
.,..., .. .. ..2-39
Oisassembly.......................................
.
.2- .2-41 , ,-41 ...2-41 ..g-41 ..-41 ..2-'t1
2-42
Cleaning and Inspection...............
... Assembly and Installation...............
.., .. ..
Pivo Shatt/Mount disassembly........ ,.,. InstaI
IatiJn.........
.. .... .2-66 ..2-66
Assembly............... .. Installation..........
..... ...
2.21 CLUTCH CABLE R2 LOVE I .. .. .........
.......... .. .. ... ..... .. -' ' ' -' '-' ' '
' InstaIIatirn..
Front Brake Line Non-ABS Ei Removal.............
....... InstaIIation.,.,..,.. ..
pped ..... .... ...,. . .. . . .. .......
2- ..2-67
2.22 H.4NDLEBARS Adjustmc nt.. R C IT\Oyk I ..
.. . ............... .

• FRONT BRAKE CALIPER
• Removal. Installation.
• REAR BRAKE MASTER CYLINDER

..2-70
. ... .. .. -' ' ' ' ' ' ' ' '

. . 2-71 ..2-72 2-72 ..2-72 .......2 72 .. ..
......2 72
Installation................................
....,...................
Left Hanr.lgrip............... ...... .....
... Rem ovaI.......... .. Installation...........
,..,.,.
General . Removal IFId DISA\SSemIiy
Removal............................ ... .., .,.
..
..2-45 .,.., -45 .. . .. ......2-45 ..2-46 g-
47 .2-48 ...2-48 ..2-4B
Heated FTandgrips............... .. ..
Flemove Left Handgrip.................... - .
..
Insta I Left Handgr ip...................... .
.,. ,,,,. ,,,.. .. .... .2-73 Rem we Right
Handgrip.................. -.....................
..2-73
Disassembly..... ............... .. ..... .,.
. Cleaning and Inspection..... Asserr D)y and
\nsta\\at\on............................ AssemDly.
........... . .. Instal1ation.,..
lnstall Right Handgrip.... -
RuDDer IVlounts ........ .......................,,
. ,,,... .....................2 74
RemJvaI................. .. Insta.Iation.........
..
..2-74 ..2-74
Rear Brake Line! Non-ABS Equippccl
....................... ,....2-48
TABLE OF CONTENTS V
7
TABLE OF CONTENTS Installing Tether Bracket on
Tour-Pak..... ... .. ... ....2-88
2.23 MIRRORS AII Models Except FLH X..........
..............,,,. ,,,..,,..........
.2-76 Removal........................ ..
......,,..,,..,,.. ... .... .........2-76 Installa
tion...........................
..,,...........................2-76
Lugga9 Rack. ... ... ................... ... ..
.. ....,.,..... .2-B8 2.29 TOUR-PAK LIGHTS e
FLH X . .. . ..... .,...... .. . ..,.,.
2-76 Removal ......... .......................,,.
.............,,,. ,,,. ,,,.......2-76 f1SUIIÜtiOU.
. .. .. .......... .. .. ............. - ---
--- --''..2- 7
Gide M rker Lights (if equipped)....
......tt..t t 2 9 RemovaL...................
..... . ..........,.,.,... ............2-89
installation.. . .. ..,..,.. . .2- g Tour-Pak
Lights Harness..................................
................2-89 Removal......................
.... ........ .. .. ....,.,.....
.2-89 Installation................................
................,........ .2-89
2.24 SEAT Seat ! Mopels withouI
ToUr-Pak.. Removal... Installation...............
.. Seat Morlels with Tour- Pak...................
....
.. ,,..,,,. ,,,...2 -77 ..2-77 .2-77 ,.
,,..,,..2-77 ..,,,.,,,..,,.2-77 ..2-78
Wrap-AFOU0d Lights (if equipped)..................
...................2-90
BUID Replacement......................... Removal
.................................
.............2-90 ...,,..,,...,.... ....2-90
.. ... ..,,.,,,
Removal.................... ..
InstaIIa1ion.............................
........,..,.,..............2-91
Installation.............. .. .. .. ...
2.30 TOUR-PAK BACKREST Passengcr
Backrest................ .,,,,.,,, . ,.....2-92
Removal ............... ..................,,,
,,,,.,,.......................2-92
Seat Road King Models....... .,................
...2-78 R _at_--OVa . ,,, ,,,..,,................
,..,,,. ,,..,........................., -7
- 2 - ,,,.,,,., ,...2-78
I ft SUII Ation .......................... ... ..
......... ... -- Seat Retention Nut Replacement.
..... ......... 2.25 SADDLEBAGS R Ü fi OV0 I,
........................................ I l1Sta
II at I Il
Rubber Isolators...............................
...,..,,,. ,,,..,,......... ...2-92
Removal............ - Installation..............
................,..,,. ,,,..,,..,,...............
.2-92
Z-80 2-80
........ - -

• Passen9er Backresl Flap........................
  ......................2-93
• R efTjOVal ..,,,. ,,,. ,,..,,,.., .. ... ...
  ............................. ... 2 -
  Installation........ ....,.. ........2-93
• TOUR-PAK SPEAKER BOX
• Speaker Box .. ... ... ... .. .. .. ..
  ....................................2-94
• R eFDOVB I .. ... .. ... ... ..
  ........................................... - 4
• Installation......................................
  ...........................2-94
• LOWER FAIRING AND ENGINE GUARD

2.26 SADDLEBAG SERVICE S addlebng
Hardware.................. . Removal............
Installation...................................
. ...,.,.
..2-81 ..2-81 ..2-82
S acldleUag Guard/Support Rail ,... ...
........... ..................2-82
Removal...........................................
.........................2-82 IsStBIIntion.......
..................................................
........2 -82 2.27 TOUR-PAK
Lower Fairing.....................................
........ Removal..................................
............. Disassembly.........................
................
2-95 2-95 2-95 2-96 2-96 2-96 2-96 2-96 ........2-
96 ..z-gs
Removal/Installation.............................
Removal............................... Installatio
n..............................
2-84 . .2-84 .................... ... .2-84
Assembly......... . Installation........ Serrated
Washer Replacement................ ..
Removal...........................................
.... Installation.. Engine Guard.... Removal.....
Adjustment....... ..... .... .....................
..................................2-85
........
. ..2-85 2 -85 . .2-85
Luggage Ruck/TOUr-Pak SUpport............... R
emOval .................................. Assembly
and Installation................... 2.28
TOUR-PAK SERVICE Lockset
InsIaIIation,. .,.................................
2-96 2.33 UPPER FAIRING AND WINDSHIELD FORK
MOUNTED FAIRING MODELS Outer Fair ing and
Windshield........................................
...2-98
2-86 . . . . 2-86 Z-86 2-86 2-86
Removal Installation Hinges Removal
. . ..
Installation................................
.......................... .....2-86
Latches.Lock set Catch................. .. .. ..
.. .. .. .. ......2-87 Removal.... ...........2-8
7 InstnIIat ion...................................
. .. .. .. .. ... ......2-B7 C at
ches............................. ..,2-B7
Removal... .... .... .............................
............................2-87 Installation.....
..................................................
..........2-87
Removal............................ .......
.. Installa1ion...... ..
..2-98 .......................2-98
2.34 FAIRING CAP FORK MOUNTED FAIRING
MODELS Fairing Cap................................
..... .. .. .. ... ... .........2-99
Tether.... ..... .................................
..............2-87 Removal .......................
............ .. ... ... ... .. ...
......2-87 Installation...........................
......................................2-87 Tether
Brackets....... ... ......................
........................ ...2-88 Removing Tether
Bracket from Tour-Pak...................2-88
Removing Tether Bracket mom Tour- Pak
Lid.............2-88 Installing Tether Bracket on
Tour-Pak Lid............... ..2-8B
Removal...... .. . ..............................
............2-99 Installation.....................
............. .. .. .. ... ... .......2-99 2.35
INNER FAIRING FORK MOUNTED FAIRING
MODELS Removal 2-100
VI TABLE OF CONTENTS
8
TABLE OF CO71TENTS

• 2.44 I'RONT FENDER
• Re moval
• 1nstallat ion
• I1EAR FENDER
• Rcmov ml........... Fender Repair
• Mounting Hardware....... Lights and Harnesses
• Instal laion
• F\EAR FASCIA
• RemovJl. Installation Stud PI1tc.....
• Removal....
• Ins allation..
• Rear Fascia Lamp.
• Removal Installation..................... ..
• FIEAR FRAME
• Rear Fi ame.
• Removal Installation TlirJad Repair,
• FOOTBOARDS AND FOOYRE TS

lns!aIanon 2.36 AIR DEFLECTORS Air
Deflectors...........................
2-102
.2 -122 2.122
..2-104 ..2- 104 ..2-104
.. . .,,, ,,, ,,,
Removal ........ ,...,,,. ,,,..,,. ,,,, ,,,,
,,,,. ,,,, ,,,. . Installation..... .
Mid-Frame Air DefIectJrs..... ...................
., . .,...2 104
2 -1 24 .2-I 24 .2-1 24 2-124
Removal.,.,...,. .2-104
Installation.............. ............... .
......................... ....2-104 2.37 UPPER
FAIRING AND WINDSHIELD FRAME MOUNTED FAIRING
MODELS
Windshield....................................,
, , ,. Removal.....,...,...,. Installati
on.. Outer Fairing............................
..2-105 ..2-105 ..2-105 ......... .....2-105
2-126 2-126 2-126 2-126 .2-1 26 .2-126 .2-126 L126
..2-105 ..2-106
Removal.....................................
............. .... I stalIation..................
.................................... 2.38
INSTRUMENT BEZEL FRAME MOUNTED FAIRING
MODELS Bezcl...
..2-108
RE'mOVaI.................................. .....
................. ..... .. . 2- 1 08
.2-127 .2-1 27 2-128 ?-128
Installation...............................
....... 2.39 INSTRUMENT NACELLE FRAME MOUNTED
FAIRING MODELS
2-109
Instrument Nacelle................... Removal ...
... .. . .. . ... ,. ,.,. Installation.
....
... ... 2-110 ,2-110 2-111
Rider Fc othoards.............................
... .. .. ... ... ...... 2-129 Removal
...............................................
................. 2-129
Inst. IIatioi...................................
......... Diszisseirhly..........................
...............
.. 2-129 . ..2-129
2.40 INNER FAIRING FRAME MOUNTED FAIRING MODELS
Ass rnDI y. . .. .. .. . .. .. ... .. .. ..
.. ... .. .2-129 Passenger Footboard ..........
.............. .. .......... .......2-130 Removal
......................................... .2-130 D
ist ssembly....... ........................ .. ..
.. .. . .. .2-130 Assmbly.......... .... .. .
. ............ ................. ... .....2-130
InsttIIation......... .................. . .
.. .. . . .. 2-130 Passengi Foatrest! FLHX.
FLT R x .. ........ . ... .. ........2-130 R bit
IO'V0I............................................
... ..2 -130 Disassembly.........................
...................................2-13D Ass!mbly
.................................. .. . ...
.... . ........?- 131 Instzillatiun...............
...................... ........ ..............2-13
1 2.49 JIFFY STAND /eNeFEII. . .. ..
................................... ..
................. -1 /2
Removal.... Disassembly................... Install
ation............. .., , . .
..2-112 . . ........................
...2-113 ..2-114
..2 -114 ..2-114
OI ter Fairing.................. ......... .. .
. . .. Inner Pairing...................
............. ,,,. ,,,. ,,,, ,,, 2.41 GLOVE BOX
DOOR AND HINGE FRAME MOUNTED FAIRING MODELS
G love Box Door and Hinge............ ...... .
.. . .. ......2-116 Removal............
..................................................
...2-116 fnStt/fa f/Orl..........................
........................ ..... .... ... -
16 2.42 WINDSHIELD ROAD KING MODELS
..2-132 ..2-132 ..2-133 2 133 ....2-133 2
133 2-133 . 2 -133
Leg Ren ioval... ............................ Leg
Inst. Ilation.......................
.......... Jiffy Stand Bracket....................
................. . Removal Installation..........
........ .... .... ......... Jilly Stan ñ Inner
lock Sensor......................... Removal InStn
IIat ior 2.50 FFtONT ENGINE MOUNT R c
rnovert IlñSl H11ñ 11Ctlâ.
Windshield .,.,.. Removal., ,..................
.......... Installation........................
............. .... .... Windshield
Window................ ............ Removal
................................. Installation....
.......... ...... . .. ..
..2 117 2-1 7 ..2 117 ..2-117 . .2-117 .2 118
..
2.43 HEADLAMP NACELLE ROAD KING MODELS
.2-135 .2-135
Removal. Installation
.2 -12U .2 -1 21
TABLE OF CONTENTS VII
9
TABLE OF CONTENTS
Engine Removed From Chassis.......................
. 3.14 STRIPPING MOTORCYCLE FOR SERVICE
ENGINE
..3-27

• FASTENER TORQUE VALUES
• Fastener Torque Values in this Chapter............
  ..................3-1
• SPECIFICATIONS
• Specilicaiions ...................................
  3-3

Procedure.....................................
....................................3-28
Cam Compartment Service Only.,... ...
... ....3-28 Top End Service......................
..... ......................... .3-28 3.15
ASSEMBLING MOTORCYCLE AFTER SERVICE Procedure.....
..................................................
..................3-29
3.3 SERVICE WEAR LIMITS 3.3 SERVICE WEAR LIMITS 3.3 SERVICE WEAR LIMITS 3.3 SERVICE WEAR LIMITS 3.3 SERVICE WEAR LIMITS 3.3 SERVICE WEAR LIMITS
General... General... General... General... General... General... 3-5
3.4 ENGINE OIL FLOW 3.4 ENGINE OIL FLOW 3.4 ENGINE OIL FLOW 3.4 ENGINE OIL FLOW 3.4 ENGINE OIL FLOW 3.4 ENGINE OIL FLOW
Oil Feed. .. .. .. .. . . . . . . . . Oil Feed. .. .. .. .. . . . . . . . . Oil Feed. .. .. .. .. . . . . . . . . Oil Feed. .. .. .. .. . . . . . . . . Oil Feed. .. .. .. .. . . . . . . . . Oil Feed. .. .. .. .. . . . . . . . . .. .. .. .. .3-7
Top End. . . .. .. .. .. ... 3-7 3-7
BollornEnd OiI Relurn Z-9 3-11 Z-9 3-11

• After Top End Service.............................
  ..... ..3-29
• After Cam Compartment Service.................
  ... ......3-29
• REMOVING ENGINE FROM CHASSIS
• Procedure.........................................
  ................................3-30
• INSTALLING ENGINE IN CHASSIS
• Procedure.. .. .. .. .. .. .. .. .. .. .. .. ...
  .. ...... .. 3-31
• TOP END OVERHAUL DISASSEMBLY
• General...........................................
  ..................................3-32

Oil Cooler Operation.............................
............................3-12 3.5 OIL PUMP
OPERAT1ON
ÙCìne fIl.........................................
.......... .................. Operalio n . 3.6
BREATHER OPERATION
.. 3- 3 3-4 3
Rocker Covers.... ..3-32 Rocker Arm Support
Plate.............................................
...3-32 Push Rods, LifterS and Covers.............
............................3-34 Cylinder
Head..............................................
.....................3-35 Cylinder................
..................................................
..........3-36 P i StO n .........................
................................................
...3-3b 3.19 TOP END OVERFIAUL
ASSEMBLY General..................................
...........................................3-38
3.7 OIL PRESSURE Oil Pressure lndicator
Lamp Checking OiI Pressure 3.8 TROUBLESHOOTING
.3-16 .3-16
Diagnosing Valve Train Noise......................
....................3-17 F
Piston................................. 3 38
Cylinder..........................................
..................................3-39 Gylinder
Head..............................................
.....................3-41 Push Rods. Lifters and
Covers.........................................3-4
4 Rocker Arm Support Plate........................
........................3-45
ylind eS' enkdwnTest 3-! Diagnosing Smoking
Engine or High Oil Consumption..I3-18 Check
Prior To Cylinder Head Removal....... ..
........3-18 Check After Cylinder Head
Removal........... .... ... ....3-18 3.9 OIL
COOLER
Breaiher Assembly............ 3.20 BOTTOM END
OVERHAUL DISASSEMBLY
..3-46
Removal... Installation. ... .. ... ... ... ...
.......... ................ 3.10 OIL COOLER
ADAPTER Rem oval Disc ssc mb1 y. . AssemD1
y 1nsÎal iatio n. . . .. . . .
..3-19 ........3-19
General......... ............................ ...
... ... ... ... .... .. ......3-48 Cam Support
Plate and Cover...................................
.......3-48 Prepare Engine......................
........,....,..........,3-48 Cam Chain and
Sprockets.................... ... .. ....
....3-48 Cam Support Plate.......................
.............................3-49
Crankcase................................ 3-50 3.2
1 BOTTOM END OVERHAUL ASSEMBLY General...
....................................
..................................3-52 Crankcase..
..................................................
....................3-52 Carn Support Plate and
Cover......................... ... ...
......3-54 3.22 BREATHER ASSEMBLY Removal
Overview...... ..3-59 Disassembly.................
.................................................
.3-59 Cleaning and Inspection........
................................. ..3-59
220 3-20 3-Z0 3-20
3.11 HOW TO USE THIS SECTION General........
................................
..................... Top End Overhaul............
............. ... ... ...... .. Bottom Encl
Overhaul............... .......... ..
...3-22 ..3-22 ..3-22
SuDassembly Service and Repair....................
............ ..3-23 3.12 TOP END SERVICE
Engine in Chassis...............................
., .. Engine Removed from Chassis................
.... ............. 3.13 BOTTOM END SERVICE Engine
in Chassis......................................
...3-24 .3-25
Asse rnbly..................................... .
.. ... ... ... ... .... ... 3-59 Installation
Overview.......................... ...............
...3-59
3-26
VIII TABLE OF CONTENTS
10
TABLE OF CONTENTS
3.23 ROCKER ARM SUPPORT PLATE Removal
Overview.............. .. ...., .. ... .. Disas
sembly........ . ........... ..
..3-88 3-88 3-88 ..3-gg .,3-g8 ....3-88 ..3-90
Oil Pressure Relief Valve............ ...........
. ......
........... ....,... .... .. .
Removal............ ..
s-so ..3-60
lntaIIa ion................... Inlt.pection......
.......... ..
Cleaning and Inspection... ....................
....................... .'3-60
Cam Needle Bearings.................. ..,....
.. .. Removal......... . ... ..
Inspection... Rocker Shaft Fit
........ ..?-60 ....... .....3-60
Installation......... . ... Cleaning and
Inspection..... . ...... .. ..
Rocker Arm Shaft to Bushing,.,............ ......
..3-61
............. 3-9i ..3-g1 .. .3-91 .,.,..,.......
.3-gJ
Replace Rocker Arm Brushings.. Assembly...........
......... Installation Overview.......
........ ...3-61 ..3-62 ..3-62
.........
Oil Pressure Valve............ ..
Ca Support Plate......................
. Installation Overview...........................
... ... 3.29 L)IL PUMP Removz I Overview.
Cleanin and Inspection Installat on
Overview.......... 3.30 C'RANKCASE
3.24 PUSH RODS, LIFTERS AND COVERS
Removal Overview....................... Disassembl
y......... . .................
.3-63 .3-63 3-63 ..3-64 . ..3-64
392 3-92 3-92
Cleaning and Inspection.............. ... ......
Lifter Inspection..... .. Assembly...............
. Installation Overview.
..,.,......... ................. .
.......... . .. .. ............ . 3-64
Removal Overview........................ .. .....
....... . . .. ... .3-93
3.25 CYLINDER HEAD Removal Overview.....
Disassembly.............. Cleaning...............
.. .
Right Crankcase Half.......................
............ .. . ..3-93 Man Beai ing
Removal.................................. .......
..3-93 Mal.n Bearing Installation.................
.............. ...........3-93 Pist n Jets
Removal...........................................
... ...3-94 Pist.3n Jets Installation.............
...................... .. ..3-94
..3-6s ...........3-65 .3-66
Inspection...,.,.. Cylinder Head..... Valve
Guides.. . Valves.................
. ,., ........ ............................3-67
..3-67 ..3-67 ..3-67
Left Crankcase Half..............................
............................3-94
Manu Bearing Remova1...................... . ..
... .. Main Bearing Installation..................
.... . . Sprocket Shaft Bearing Inner
Race................... ....... Ren
oval.......................................
.............. .... Inst\Ilation.................
........................... .. ... Cyl\nder
Studs......................... ..
....3-94 ..3-96 ...3-97 ..3-97 ..3-98 .3-99
. .. ................................
Valve Springs............... Tapered
Keepers.......... Valve Seats.................. Va
lve Guide Replacement... Removal . . . .
Installation........
..3-67 ...3-68 ...368 ..3-68 3-68 .3-69
................... .. . .
Rerrioval........ .. Instrillation.. .. .. ...
..........................................
.......3-99 ..3-99
Pipe Pluj and Oil Fittings.....................
.. .. ... ... ... ....3-100
Valve and Seal Refacing .3-72
Assembly............. .3-74
Installation Overview .3-75
3.26 CYLINDER
Removal Overview..................... .,.,..376
Cleaning .... ........... .....................,..,,,. ,,,, ,,,..,, . . .. .... .3-76
Inspection.................... . ... ..,.3-76
Rerr oval... ....... IIS,-tl ätiOlü. ... ..
.. .. .......................... . Cleaning and
Inspection.................
..3-100 ..Ü-1 CO ..3-100
Installatie.n Overview..........................
.., .. ,..,,..,,,. ,,,. ,,,.3-100 3.31 FI YWHEEL
AND CONNECTIN, RODS Removal Overview....... .....
.................3-101
Inspection.....................................
,,..,,.., .. .. .. .. .......3- 101 Instaliation
Overview............... ... ..3-101 3.32 OIIL PAN
Deglazing Cylinder... ............................
..........................3-78 Boring and Honing
Cylinder..........................
,,,..,.............3-79
InstaIIaIion Overview.............. .... ...
.....,.. 3.27 PISTON Removal Overview.............
.... . Disassembly...............................
. Piston Rings........................... .
............. .... Cleaning.......................
......... Inspection... .. ................... ..
.. .,.
..3-/9
Removal...........................................
.............................3-102 lnstallatic
n....... ............................... ..
...,.......,.,..,3-102
..3-81 ,,, ,,,.,3-g1 ..3-81 .....3-81 ..3-82
FUEL SYSTEM

• FAtTENER TORQUE VALUES
• Fastener torque Values in this Chapter............
  ..................4- 1
• SPIECIFICATIONS FUEL SYSTEM

,di, e fTj D 'y'....... , , .. , , , . , , , .
, , , . , , , .. , , .............................
............... - Checking Piston Ring
Gap.................................... 3-83
Installing Piston Rings... Installation
Overview............. .............,,..,,
....3-84 ......3-85
Specifications...
.4-3
4.3 ELECTRONIC FUEL INJECTION (EFI) Troubleshootin
g........................... . ..4-4
3.28 CAM SUPPORT PLATE AND COVER
Removal Overview................... ..........
.. CôfTjShaftS,. .. .. ... .. .. .. .
........ Removal................... .. .. ..
. .. ... ......... 3-86 .3-ÛÔ ..3-86 .
. .........3-86
Assembly........................... .. . .. ..
TABLE OF CON1ENTS IX
11
TABLE OF CONTENTS 4.4 AIR CLEANER ASSEMBLY
.,..,..,.. ,.,..4-23 .,..., ..,.....4-23
Removal ...... ...................... Inslallation
. .. . .. .. 4.16 FUEL INJECTORS
R e - O\/ , , , , , , ............ , , . , , ,
................... .. .. ' . ' ' ' ' ' - - -
- - - ' ' '
Installation............. 4.5 FUEL TANK
,.,.. .. ..,.,4-5
General................................ Removal...
.........................
................,.................4-25 ..,,..
... ..,,,..,,...,4-25
. ,..,..........,................4-7
Removal........... . ..........
Purge and Disconnect Fuel Line....................
.............4-7
4.17 FUEL PUMP General ............. . ...
...........
Remove Tant....................... . ..
....,.. .. ....,..,..4-7
û t BtiOt'j,,,,..................... . ...
.'''.'''-.' -- -- '--''''' 4- Evapcrative
Emissions Tube. Non-CA Models.......... ........4
8
.,..,,...,. ....
,,,.,,,..4-27 ,..4-27
Removal......
Removal.... .4-8
Installation................... ..... .. ..... ....... . 4-8
ll Supply Check Valve/Tube.......................,..,.,.. .. ..4-8 Removal......... ...... . .. - ..4-8 Installation..................... .,.,..................4-9 ll Supply Check Valve/Tube.......................,..,.,.. .. ..4-8 Removal......... ...... . .. - ..4-8 Installation..................... .,.,..................4-9 ll Supply Check Valve/Tube.......................,..,.,.. .. ..4-8 Removal......... ...... . .. - ..4-8 Installation..................... .,.,..................4-9
/- ta jQtOn ...............,,..,,,.,,..........
.................. .. ' ..'' .''.4- 27
Fuel Pump and Fuel Level Sender Wire
Harness.......,,,..4-28
Fu
Removal ............. . .. .. Installation......
. . ..,,.,,,.,, .. .. ... ............4-28 4-28
4.18 FUEL PRESSURE TEST (/al'9f?fdl.,.,.......
..................................................
.......---..4-2 Testing . ,....,..,..4-29
4.6 FUEL TANK TOP PLATE
, ,.,.. , .,..,..
.. .410 .....4-11
Removal .. Installation .. .
4.19 EXHAUST SYSTEM Mufflcrs..
4.7 FUEL FILTER QQ'pMOV3l.......,..........
...........................................4-
.,.,.,.... .. ... ......4-31
Installation . 4-12 4.8 FUEL PRESSURE
REGULATOR
Removal.................. .. ... ... .. ..4-31
InSU110IOFj,,.,,,..,,..,,..,,..,,.. .. .. .. ...
... .. ..............4 1
System Removal..................................
.. .. ... ...............4-31 Ç\S1epM
lp1StgläÎiOFj....................................
......................,4-//
Removal....................................
,......,. Installation................. ....
...............,.. 4.9 FUEL LEVEL
SENDER Removal... Installation. 4.10 TWIST GRIP
SENSOR Removal.......................... . . . ..
.. ..
.. .. .. .......4-13 ..4- 13
4.20 ACTIVE EXHAUST (HDI) Exhaust Valve
Actuator..........................................
...........4-34 Removal...........................
.........................................4-34 Irls
tallation.........................................
........................4-34 Exhausi Valve
Actuator CaDIe....................................
......4-34
4-14 4-1 4
Removal.......... . 4-34 Installation............
......................... .. ... .... ...
.........4-34
..,.4-15
Active Exhaust Valve .. .. .. ... ... ... ... ...
.. .. ... .......4-34 General.....................
.............. ... .. ... ... ... ...
......4-34 4.21 INTAKE LEAK TEST e9efBI ... ..
.. .. . .. .. .. .. .. .. .. ... . 4-35
Installation.....................................
... ... .. .. .. ... ........4-16
Twist Grip Sensor Jumper Harness..................
................4-17 Removal......................
............ ... .. .. .. .. .. ....
..4-17 Installation...............................
.. . .. .. .. .. .. ......4- 17 4.11 THROTTLE
CONTROL ACTUATOR
Leak Tester......,......,.,.,.,.........
..........................4-35
Parts List...................... .......
..4-35 ......4-35 4-35 4-35
TCA) GClüTûI..................... .... . ... .
.. .. .. .. ... .. .. .. 4-18 4.12 ENGINE
TEMPERATURE SENSOR (ET)
Tester Assembly............................. Teste
r Adjustment.......................... Procedure..
.............. ..
.. .. . .
4.22 EVAPORATIVE EMISSIONS CONTROL (CA MODELS)
Removal 4-19
Installation 4-19
4.13 INDUCTION MODULE
Removal.................................... ......4-20
Installation.............. ... ....4-21
General Vapor Valve. Fuel Vapor Vent
Tube....... Removal Installation...... .........
. Canister-to-SoIeno!d Tube Removal lnstal lation.
.....
.4-37 .4-37 .4-38 .4-38 4-38 4-38 .438 .4-38 .4-3
B .4-38 .4-38 4-09 .4-39 .4-39
.......
4.14TEMPERATURE MANIFOLD ABSOLUTE PRESSURE SENSOR
(TMAP)
General Removal
4-22 ..4-22
Solenoid-to-Induction Module Tube..... Removal
Installation.
lnSÍRlIdtlOTl.. .................................
...............................4-22
4.15 OXYGEN SENSORS (02) GCOCfäI .
Purge SolenoirJ ........ Removal.. Installation..
.......
4-22
X TABLE OF CONTENTS
12
TABLE OF CO7JTENTS
6.2 SPECIFICATIONS TRANSMIStION Specifizations.
..................................................
.......... .....6-2 Service Wear
Limits............................................
................6 2 6.3 TI1ANSMISSION
Charcoal Canister................................
.............................4-39
. t-39 .4-39
Removal.................................
........................ Installation....... . DRI
VE

• FASTENER TORQUE VALUES
• Fastener Torque Values in this Chapter.......
  .......................5-1
• SPECIFICATIONS DRIVE

Power I-low... ...................................
...6-3 Neutral.... .
..6-3 6-3 6-3 ...... ..............6 3 6-3
1st Gear.................................. 2n!
Gear....................................
3rd Gear.. . . . . 4th Gear......................
............ Sth Gear.............................
..... . 6th Gear 6.4 StJIFTER LINKAGE
Specificalions......... .... 5.3 PRIMARY
CHAINCASE COVER General...........................
.... ....... ...........
5-2
.. . .. .. .. .. .. 6-3 6-3
..5-3
Removal...........................................
..................................5-3 lnstallation
.............. ..5-3 5.4 DRIVE COMPONENTS
Shifter God ....... .. .
6- 5
6.5 CA.UTCH RELEASE COVER Removal and
Disassembly..................... 6-6 C1eanintj
and Inspection....................................
... .............6-6 Assemb y and
Inslallation..... ......... ....
.............................6-7
Removal...........................................
..................................ñ-5 Installation
5-6 5.5 PRIMARY CHAINCASE HOUSING
6.6 TR ANSMISSION ASSEMBLY ReMOVE
I....... .........................................
.........................6 -8 Disassembly.........
........... ............. ......... 6-9 Shifer
Cam/Shifter Forks.....................
......................6-9 Malr1Sh
aft....... .......................................
..............b 11 CoU ntershaft...... ...
..........6-13
Removal................................... . ..
.. .. .. . ... .. ...5 10 InSpeCtlOn.
..................................................
......................5-10 Mainshaft Bearing and
Lip SaI......... . 5-10
Removal.......................... .....
...................................S-10
installation.... Mainshaft Bearing Inner
Race................. Removal.....................
.............. ...............
..5-10 ..5-11 . ..5-11 .. .. ...5-11
Rep acing Side Door Bearings.................... .
.6-14 Cleaniig and Inspection....................
.... .. .. ... . .. ....6-15 ASST Mbl
y.................................................
.........................6-15 Installing Side
Door Bearings........ .................
..........6-1 S Mâu/,e\sh" 6!
6 Shifter Carn/Shifter Forks... ...... t. I.
.. t... I.It t....6- 16 InstaIIat\n.. .
,.6-18
Installation................................ . ..
.. . .
...... .. ..
.. .. ... .. ..5- 12 . . .. .......ñ-12
Shifter Shalt Bushings. ... .. . . .
Installation.....................................
. 5.6 CLUTCH
Removal and Installation..........................
........................5-14
Clutch Pack Only........ 5-14 Par1iaI
Disassembly............................ .. .. .
. ....5- 14 Cleaning And Inspection..............
........................... ..5- 14
6.7 MA.IN DRIVE GEAR AND BEARIING Removal
................. . ..6-20 Cleaning and
Inspection........................................
...........6-21 Neeclle Bearing
Replacement.........................
.........6-22 Mainshali Seal Replacement..........
.............. .. .. . ......6-23 Installatic
n.................................................
.......................6-24 lnsta ling Main Drive
Gear Bearing................. .
......6-24 Installing Main Drive
Gear.................... ...............
...6-24 Installing Main Drive Gear Large
Seal.......................6-25 6.8 TR/tNSMlSSlON
CASE Removal..... 6 27 INStal1DtIO n .. .. .. ..
................ ..............................
........ 6 -27
Assembly. ........ .. .........
.............................. ... Clutch Pack
and Bearing..
..515 ..5-16
Complete Disassembly.... ............. .
.....................5-16
Assembly................................ .. .
.... .. . ........ 5.7 TRANSMISSION
SPROCKET Remova1................................
......5-17
..5-19
.............5-19 .5-19
Cleaning and Inspection.........................
Installation.............. . 5.8 DRIVE BELT
Removal and Adjustment.......................
........................5-21
Disassembly.... Shiftc r Arm Assembly ........
.. .. Cleaning and Inspection.....................
... Assembly ......... . .
..6-28 .. ... ... . ......6-2B ......... .... ..
..... ..6-28 6-29
..5-21 .5-21 5-21
Adjustment........................ .... .....
.... ......... Removal............................
. Inslallation TRANSMISSION
Coun ershaft Needle Bearing Replacemnt.....
........6-29 Shifter Pawl Lever Assembly. 6-29
6.1 FASTENER TORQUE VALUES Fastener Torque Values
in this ChatJtr.................
... .6-1
TABLE OF CONTENTS XI
13
TABLE OF CONTENTS
7.10 STARTER General..............................
. Wiring Diagrams Pdlnt Touch-Up..................
......... Removal Field Coil Assembly.............
.............. Disassembly... Inspection.. Assembl
y.............. Drive Assembly... Disassembly.....
.. 1nspection......... Assern Oly I n st a 1 law
to n
ELECTRICAL
.7-18 .7-18 718 7- 18 7- 18 .7-18 .7-18 7.19 7-20
7-ZO 7-20 720 7-21
7.1 FASTENER TORQUE VALUES Fastener Torqre
Values in this Chapter................ ........
...7-1
7.2 SPECIFICATIONS ELECTRICAL Specifications....
.7-5
7.3 VOLTAGE REGULATOR Removal InstalIation
76 .7-6
.,,,. ,,,. ..
7.4 ELECTRONIC CONTROL MODULE (ECM)
7.11 STARTER SOLENOID Solenoid Assembly...........
................. ,....,.,.,..,.. Disassembly
.............................. ..,.,.,.....
ASsembly.................. ......... Solenoid
Plunger. DisassemDly..........................
....,.,.,.,..... Assembly....................
...... .........
. RozovaL stalalion
. . 7-7 7-7 7-7
ECM
. . .
..7-22 ..7-22 ..7-22 ..7-22 ..7-22 ..7-22
7.5TURN SIGNAL AND SECURITY MODULE (TSM/TSSM/HFSM)
General .... Removal .. Installation HFSM
Antenna nemnvnl \nstallation.
7-8
Solenoid Contacts............. ............... ..
.. Disassembly...............................,.
Assembly.................
. .. .,.. ,.7-22 .,.. .... ...7-22 ..7-23
7-8 78 .7-8 7-9

• HEADLAMP ALL EXCEPT ROAD GLIDE
• Headlamp! Single Headlamp Models.................
  ..............7-25 Removal........................
  ............................................7-25
• BUIb Replacement.................................
  ....................7-2S
• Installation. .. . . . . . ............
  ................................7-25
• HEADLAMP ROAD GLIDE
• Headlamp AdjuSter Assembly........................
  ..................7-26 Removal....................
  ................................................7-
  26
• Repair............................................
  ............................7-26
• Installation.................................. ..
  ... ... .. ... ........7-26
• Headlamp Bulb Replacement Dual Headlamp
  Models.....7-26 Removal.........................
  ..... ...................................7-26
• BulD Replacement.............................. ..
  ... .... ........7-26
• 1nsialiat io n . .. . . ,7-27
• AUXILIARY LAMPS AND BRACKETS
• Aux\!Jary Lamp Bi Jb Replacement....... 7-28

7.6 IGNITION COIL Removal. l staIln!iul. 7.7
SYSTEM FUSES AND RELAYS Main Frose...... Removal..
.. Installation.. . . .
7-10 7-10
..7-11 ......7-11 . ,.7-11
.. .. .. 7-11 ..7-11 ..7-11 .. ..
.....7-11 ..7-11 ..7-11 . . .7-12 ..7-12 7-12
Main Fr se Holder............................. ..
.. .. .. Removal... Installation.. System Fuses
and Relays............................
.. Removal... Installation.. Fuse
Blockr Rcrnovul..... .,.,.,. Instalation 7.8
ELECTRICAL CADDIES Top Caddy.
R e INOVB .. ......................
.........................................7-28 Inst
allation...............................
................................7-28 Auxiliary
Lamp Housing..........................
..........................7-28 Removal......
....................... .. . ... .. ... ..
........7-28 Installation.........................
........ ......................... ...7 29
7-13 7-13 7-i3 7-13 7-13 7-13 .7 -15 , 7-15 7-1C
Installation.. Left SiCl0 Cacldy. ,,,,, ,,,, ,,,,
Removal Installation.. Battery Tray FtemovaI
.. InstaIIation.
Auxiliary Lamp Bracket.... .............
.........,..,. Removal........................
..........................................
..7-30 .7-30
Installation................................
..............................7-31
Adjustment................. ... ...
............... .. ..7-3J 7.15 TAIL LAMP
7.9 SECURITY SIREN Ren ovnL . nsa Eton
Tail Lamp Bulb Replacement................... Rer\
JovaI.................. ..........................
.......... Install0tion...........................
....... Carc it Board/Chrome Base....... ........
... Removal....................
7-32 ..7-32 ......7 -32 .7-32 7-32
7.17 ,7-17
XII TABLE OF CONTENTS
14
TABLE OF CONTENTS ..7-57
In Stall aItiOn ..... ... . ........ y_3/
InstaII\tion. Left S!do Switch...
Rear Fender Lights Harness (all except FLHX. FLTR
X ...7-33
..... .....
7-S7 7-57
Removal.............. I nStallatlOM............
. Rear Fender Lights Harness (FLHX. FLTRX) ..
..7-33 ....... . ..7-34 .. 7-35
R ! ht Siae Switches..
7.21 CRANKSHAFT POSITION SEiNSOR
(CKP) General,....
Refruval... Installation... 7.16 FENDER TIP
LAMPS Front Fender Tip Lamp.. Removal............
Installaiion......
.
. . .735 /.gg
76Q
Removal 1ns tallatio n..
.7-60
A60
7-37 .7-57 7-37 -37 7-37 .7-38 gjg .7-39 7-40
7.22 J\UTOMATIC COMPRESSIORNELEASE (ACRI
Front Fender Tlp Lamp Jumper Harness. Removal.,.
Installation......... Rear Fender Tlp
Lamp Removal..........
Genera Removal. lnsallalion.. . 7.23
/'tLTERNATOR Re m0v I Cleaning) and Inspection
Installai on.
..7-61 7-61 .7 -61
lnslallalion 7.17 TURN SIGNAL LAMPS Turn Signal
Bulb Replacement Bu!Iei Style........ Turn
Signal Bulb Replacement! Fla Lens Style. Front
Turn Signal Lamp... ....... Removal Flat Lens
Style... Installation Flat Lens
St/le...................... . Removal! Bullet
Style. Fork Mounted........... Installation
Bullet Style. Fork kJounted....... Removal!
Bullet Style. Fairing hloun