2017 Harley Davidson Touring Service Repair Manual Instant Download

1
2ö17 Harley-Davidson TouringModeis Service Manual
_at_2016 H-D ALL RIGHTS RESERVED 94000383 Printed in
the U.S.A.
?ISIT THE HARLEY-DAVIDSON WEgïglTE http//www.har
ey-davidson.com
CMI-6M-08/16
2
TABLE OF CONTENTS

• FUEL AND OIL
• Fuel..............................................
  ......................................J-8
• Gasoline Blends...................................
  ...............................2-8
• Engine Lubrication................................
  ..............................2-8
• Low Temperature Lubrication.......................
  ......................2-9
• MAINTENANCE SCHEDULE
• General...........................................
  ..................................2-10
• ENGINE OIL AND FILTER
• Check Engine Oil Level............................
  ........................2-15

SAFETY
1.1 SAFETY Safety.................................
.................................................1
-1 Safety Messages................................
..........................1-1 Customer
Safety............................................
...............1-1 Personal Protection............
...........................................1-1 Too
l Safety.........................................
...........................1-1 Product
Safety............................................
..................1-1 Hazardous
Materials.........................................
............1-1 Electrical Systems................
.........................................1-2 MAINT
ENANCE
ck ' ............. .2 15
ee
o. Leve! otC

• Change Oil and Oil Filtertttttt.I....I.tttt....I..
  .ttttt..I..I.tttttt.1...2-15
• AIR CLEANER ELEMENT
• Remove............................................
  ...............................7-17
• Clean and Inspect.................................
  ............................2-17
• Install...........................................
  .....................................2-17
• EXHAUST SYSTEM
• Leak Check........................................
  ...............................2-18
• COOLANT
• Cooling System....................................
  .............................2-19
• 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
• TIRES AND WHEELS
• General...........................................
  ..................................2-23
• Tires.............................................
  .....................................2-23
• Replace Tire.....................................
  ................................2-24
• Inspection........................................
  ...........................J-24

• FASTENER TORQUE VALUES
• Fastener Torque Values in this Chapter............
  ..................2-1
• 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

3
TABLE OF CONTENTS

• Brake Disc.......................................
  ............................2-34
• Replace Brake Pads................................
  .........................2-34
• Prepare...........................................
  ............................2-34
• Remove............................................
  ...........................2-34
• Install...........................................
  ................................2-35
• Complete..........................................
  ...........................2-36
• DRIVE BELT AND SPROCKETS
• General...........................................
  ..................................2-37
• Cleaning..........................................
  ..................................2-37
• lnspect...........................................
  ...................................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
• REAR SPROCKET ISOLATOR
• lnspect...........................................
  ...................................2-42

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
t SSeS
SpaBPlR o RlJe eatedIM' 260
Pre-Ignition or Detonation (Knocks
orPings)..............2-61 Overheating...........
..................................................
...2-61 Valve Train Noise......................
.................................2-61 Excessive
Vibration.........................................
............2-61
E g ht Illuminates During Operations.. 2-61
Lub ha on em!g
2
e es Re MnTh Ot Rr eokes Excessively... t2-61
ng ne
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 Speedomete
r Operates Erratically............................
..2-62 Transmission...............................
.....................................2-62 Shifts
Hard..............................................
....................2-62 Jumps Out Of
Gear..............................................
.......2-62 Clutch Slips.........................
........................................2-62 Clutc
h Drags Or Does Not Release.......................
.....2-62 Clutch Chatters........................
...................................2-62 Handling..
..................................................
........................2-62 Irregularities.......
..................................................
.......2-62 BRAKES................................
...........................................2-63 Br
ake Does Not Hold Normally........................
...........2-63 CHASSIS

• FASTENER TORQUE VALUES
• Fastener Torque Values in this Chapter............
  ..................3-1
• SPECIFICATIONS
• Specifications....................................
  ................................3-10
• Chassis Specifications............................
  ....................3-10
• Tire Specifications...............................
  ........................3-11
• VEHICLE IDENTIFICATION NUMBER (VIN)
• Vehicle Identification Number (VIN)...............
  ...................3-13 General...................
  ..................................................
  ..3-13
• Location..........................................
  ............................3-13
• Abbreviated VIN..................................
  ........................3-13
• FRONT WHEEL
• Remove............................................
  ................................3-15
• Install...........................................
  .....................................3-15
• Disassemble.......................................
  ..............................3-16
• Clean and lnspect.................................
  ............................3-16
• Assemble..........................................
  ................................3-16

TABLE OF CONTENTS VI
4
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5
TABLE OF CONTENTS

• REAR WHEEL
• Prepare...........................................
  ..................................3-18
• Remove............................................
  ................................3-18
• Install...........................................
  .....................................3-19
• Complete..........................................
  ................................3-20
• Disassemble.......................................
  ..............................3-20
• Clean and lnspect.................................
  ............................3-21
• Assemble..........................................
  ................................3-21
• REAR WHEEL COMPENSATOR
• Prepare...........................................
  ..................................3-22
• Remove............................................
  ................................3-22
• Install...........................................
  .....................................3-22
• Complete..........................................
  ................................3-22
• Disassemble.......................................
  ..............................3-22
• Clean and lnspect.................................
  ............................3-23
• Assemble..........................................
  ................................3-23
• WHEEL LACING FRONT RIM
• Lace Wheel Angle Flange Hub......................
  ..................3-24
• WHEEL LACING 16 INCH REAR RIM

• FRONT BRAKE CALIPER
• Remove............................................
  ................................3-43
• Install...........................................
  .....................................3-43
• REAR BRAKE MASTER CYLINDER
• General...........................................
  ..................................3-44
• Prepare...........................................
  ..................................3-44
• Remove............................................
  ................................3-44
• lnstall...........................................
  .....................................3-44
• Complete..........................................
  ................................3-45
• Disassemble.......................................
  ..............................3-45
• Clean and lnspect.................................
  ............................3-46
• Assemble..........................................
  ................................3-46
• REAR BRAKE CALIPER
• Remove............................................
  ................................3-47
• Install...........................................
  .....................................3-47
• BRAKE LINES
• Front Brake Line Non-ABS.........................
  .....................3-48 Prepare.................
  ..................................................
  ....3-48
• Remove............................................
  ...........................3-48
• Install...........................................
  ................................3-48

TABLE OF CONTENTS VII
6
TABLE OF CONTENTS

• Bleed Hydraulic Clutch System.....................
  ...................3-85
• 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
• MIRRORS
• AII Models Except FLHX, FLHXS.....................
  ................3-95 Removal......................
  ................................................3-
  95

Fork Oil Seals....................................
.........................3-64 Check Oil
Leak..............................................
..............3-64 Prepare........................
..................................................
...3-64 Remove....................................
........................................3-64 Insta
ll................................................
................................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
3.22 REAR FORK Remove.............................
...............................................3-7
6 Install.........................................
.......................................3-76 Disass
emble.............................................
........................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
• HYDRAULIC CLUTCH HAND LEVER
• Remove............................................
  ................................3-81
• Install...........................................
  .....................................3-81
• CLUTCH FLUID LINE
• Prepare...........................................
  ..................................3-82
• Remove............................................
  ................................3-82
• Install...........................................
  .....................................3-82
• Complete..........................................
  ................................3-83
• BLEED CLUTCH CONTROL SYSTEM
• Drain and Fill....................................
  .................................3-85
• Drain.............................................
  ..............................3-85
• Fill..............................................
  ..................................3-85

TABLE OF
VIII
7
TABLE OF CONTENTS

• DASH PANEL FORK MOUNTED FAIRING MODELS
• Dash Panel........................................
  .............................3-117
• Removal...........................................
  .........................3-117
• Installation......................................
  ...........................3-117
• INNER FAIRING FORK MOUNTED FAIRING MODELS
• RotRate!I!nentettrSFPa,irainge..................
  ..................................................
  .........................................33-"11118
  8
• Remove and Install Inner Fairing
  Assembly....t.1......1...3-118
  Removal...........................................
  .........................3-118
• Installation......................................
  ...........................3-119 Replace Inner
  Fairing Shell.....................................
  .......3-119 Removal..............................
  ......................................3-119
• Installation......................................
  ...........................3-120
• Fairing Vent.....................................
  ................................3-121
• Cleaning..........................................
  ..........................3-121
• Removal...........................................
  .........................3-121
• Installation......................................
  ...........................3-121
• Vent Repair.......................................
  ........................3-122
• Upper Support Bracket.............................
  ......................3-122
• Removal...........................................
  .........................3-122
• Installation......................................
  ...........................3-123
• Media Compartment................................
  .......................3-123

• Installation......................................
  ...........................3-104
  Disassembly/Assembly..............................
  ...............3-104
• TOUR-PAK SERVICE
• Tour-Pak Liner...................................
  .............................3-105
• Removal...........................................
  .........................3-105
• Installation......................................
  ...........................3-105
• Tour-Pak Seal.....................................
  ............................3-105
• Inspection........................................
  ..........................3-105
• Replacement.......................................
  ......................3-105
• Tour-Pak Lock.....................................
  ............................3-105
• Removal...........................................
  .........................3-105
• Installation......................................
  ...........................3-105
• Hinges............................................
  .................................3-105
• Removal...........................................
  .........................3-105
• Installation......................................
  ...........................3-106
• Latch Handle and Catch............................
  .....................3-106
• Removal...........................................
  .........................3-106
• Installation......................................
  ...........................3-106
• Tether............................................
  ..................................3-106
• Removal...........................................
  .........................3-106

8
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
• 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 DoorlHinge.................3-138
  Storage Compartment Media Cable...................
  ......3-139
• AIR DEFLECTORS
• Fairing Air Deflectors............................
  ..........................3-140
• Removal Fork-mounted fairing models..............
  ......3-140

• Removal...........................................
  .........................3-152
• Installation......................................
  ...........................3-152
• Rear Fascia Lamp..................................
  ........................3-152
• REAR FRAME
• Rear Frame.......................................
  ..............................3-153
• Removal...........................................
  .........................3-153
• Installation......................................
  ...........................3-154
• Thread Repair....................................
  .......................3-154
• 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

4.1 FASTENER TORQUE VALUES Fastener Torque Values
in this Chapter..............................4-1
TABLE OF
9
TABLE OF CONTENTS

• SPECIFICATIONS
• Specifications....................................
  ..................................4-3
• SERVICE WEAR LIMITS
• Specifications....................................
  ..................................4-5
• ENGINE OIL FLOW
• Oil Flow..........................................
  .....................................4-7 Internal
  Oil Distribution All.............................
  ...............4-8
• External Oil Distribution Air Cooled
  Only.....................4-9
• OIL PUMP OPERATION
• General...........................................
  ..................................4-10
• Operation.........................................
  .................................4-10
• BREATHER OPERATION
• Crankcase Ventilation............................
  ...........................4-12
• OIL PRESSURE
• Oil Pressure Indicator Lamp.......................
  ......................4-13
• Oil Pressure Check................................
  ...........................4-13
• TROUBLESHOOTING
• Compression Test.................................
  ............................4-14

• TOP END SERVICE
• Engine in Chassis.................................
  ............................4-24
• Engine Removed from Chassis.......................
  .................4-24
• CAM COMPARTMENT SERVICE
• Replace Camshaft..................................
  ..........................4-26
• BOTTOM END SERVICE
• Engine Removed from Chassis.......................
  .................4-27
• REMOVE ENGINE
• Remove............................................
  ................................4-28
• INSTALL ENGINE
• Install...........................................
  .....................................4-29
• UPPER ROCKER COVERS
• Prepare...........................................
  ..................................4-30
• Remove............................................
  ................................4-30
• Install...........................................
  .....................................4-30
• Complete..........................................
  ................................4-30
• LOWER ROCKER COVERS
• Prepare...........................................
  ..................................4-32
• Remove............................................
  ................................4-32

L Di "ld e akde
e nain N ise 415
Diagnosing Smoking Engineor'H gh'OilConsumptiont
ttt.4-15

• Check Before Cylinder Head Removal...............
  .......4-15
• Check After Cylinder Head Removal................
  .........4-15
• 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
• OIL COOLANT LINES
• Prepare...........................................
  ..................................4-19
• Remove............................................
  ................................4-19
• Install...........................................
  .....................................4-19
• Complete..........................................
  ................................4-20
• HOW TO USE THIS SECTION
• Top End Repair....................................
  .............................4-21
• Bottom End Repair.................................
  ..........................4-21

10
TABLE OF CONTENTS Assemble Valve and 3eat
Repair... 4.25 CYLINDERS Prepare...
Remove... Clean and Inspect... Deglaze Cylinder..
Install Complete. 4.26 PlSTt3NS Prepare...
Remove... Install...... Complete. DisassemLIe.
Cle Cng
4-44 4-42
Install.. Plugs and Oil Fitting!s....
................. Remove...................... Ins
tall..
..4-64 ..4-64 ..4-64 ..4-64
4.30 FLYWHEE.L AND CONNECTING RODS Sy
.,4-43 .4-43 .4-43 .4-43 .4-44 ...4-45
"4"66 ..4-66 ..4-66 ..4-66 ..4-66 ..4-66 ..4-67
a/ rvt/w "" No Oil Pressure. Vibration... ....
.. .............. . ....... Inspection...
............. ......... . Measuring Crankshaift
Runout........ Crankshaft Installed....... .
....... Crankshaft Removed. .... ........ 4.31
OIL PAN Prepare Remove.. Install.. Complete. FUEL
SYSTEM
.4-46 4-46 4-46 4-47 4-48 4-48 4-48 4-49 4-49
..4-69 ..4-69 ..4-69 ..4-69
Check Piston Ring Gap.. Assemble. 4 27 CAM
COMPARTMENT AND COMPONENTS Prepare... Remove.. Cam
Comtonent Inspection. Camshaft. Cam S spport
Plate...... Cam Di ive Components. Install Complet
e. Camshaft NeE!dIe Bearings.. Remove.. Install

• FASTENED. TORQUE VALUES
• Fastener Torque Values in this Chapter............
  ..................5-1
• SPECIFICATIONS FUEL SYSTEM

.4-51 .4-51 4-52 .4-52 .4-52 .4-52 .4-52 ..4-54 .4
-54 .454 ..4-54

• Specifications.....
• FUEL PRESSURE TEST
• Prepare. Test Complete.....
• INTAKE LEAK TEST
• Leak Tester....... Parts List.. Tester Assembly
• Tester Adjustment......
• Procedure......
• AIR CLEANER ASSEMBLY
• Remove.
• Install.
• FUEL TANK
• Removal...

.5-2
.. ..5-3 ..5-3 . ..5-3
4.28 OU. PUMP
Prepare... ..4-56
Remove.. ..4-56
Disassemble and Inspect.. .456
Assemble. ..4-57
InstaII....... ..4-57
Complete. .4-57
4.29 CRANKCASE
Prepare... .... ... ..... ..458
Disassemble. ..4-58
Cleaning and Inspection.... ..4-58
Assemble. .... ........ ..4-59
Complete. ..4-60
Repair Right (Crankcase Half.............................. ..4-60
.5-4 .5-4 .....5-4 .5-4 .5-4
..5-6
Purge and Disconnect Fuel Supply
Line.......................5-6
..5-6 ..5-6
Remove Tank.... .......... ............. Installat
ion. ............. .......... Coi ieettal Install
ation......... Fuel Door.. Replace Door....
.......... Replace Lock...............
Remove Plain Bearing . ......... ..... Install
lvlain Bearing..... Remove Piston Jets.....
Install fiston Jets.... Repair Let Crankcase
Half............................... Remove Plain
Bearing. ....... .... ............. Install Main
Bearing..... Sprocket Shaft Bearing Inner
Race............ . ........ .. Remove. . .... ...
Install.. Cylinder Studs................... Remove
.,..
..4-60 ..4-61 ..4-61 ..4-62 ..4-62 ..4-62 ..4-62 .
.4-63 ..4-63 ..4-64 ..4-64 ..4-64
5 7 ..5-7 ..5-7 .....5-7 ..5-7 -5-7
Ven IModels \Vithout EVAP System........ ..
Re
Installation..... t.. . ........
............. Fuel Supply Check
\/aIve/Tube........ Remove........................
Install...
..5-8 .........................5-8 ..5-8 ..5-8
TABLE OF
XII
11
TABLE OF CONTENTS

• FUEL TANK TOP PLATE
• Removal...........................................
  ...................................5-9
• Installation......................................
  ...................................5-10
• FUEL FILTER
• Removal...........................................
  .................................5-11
• Installation......................................
  ...................................5-11
• FUEL PRESSURE REGULATOR
• Removal...........................................
  .................................5-12
• Installation......................................
  ...................................5-12
• FUEL LEVEL SENDER
• Removal...........................................
  .................................5-13
• Installation......................................
  ...................................5-13
• TWIST GRIP SENSOR (TGS)
• Remove............................................
  ................................5-14
• lnstall...........................................
  .....................................5-14
• INDUCTION MODULE
• Prepare...........................................
  ..................................5-17
• Remove............................................
  ................................5-17
• Install...........................................
  .....................................5-18

5.18 EVAPORATIVE EMISSIONS CONTROL
SYSTEM General.............................,......
.........................................5-29 Vapo
r Valve..........................................
.............................5-29 Fuel Vapor Vent
Tube..............................................
.........5-30 Removal.............................
.........................................5-30 Inst
allation..........................................
.........................5-30 Canister-to-Solenoid
Tube............................................
....5-30 Removal..................................
....................................5-30 Installat
ion...............................................
....................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

• FASTENER TORQUE VALUES
• Fastener Torque Values in this Chapter............
  ..................6-1
• SPECIFICATIONS COOLING SYSTEM
• General...........................................
  ....................................6-2
• COOLING SYSTEM OPERATION
• Operation.........................................
  ...................................6-3
• TESTING AND DIAGNOSTICS
• TroiJbleshooting..................................
  ................................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
• 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

TABLE OF CONTENTS XIII
12
TABLE OF CONTENTS Installation....................
...............................................6-1
1 DRIVE

• TRANSMISSION SPROCKET
• Prepare...........................................
  ..................................7-18
• Remove............................................
  ................................7-18
• Clean and Inspect.................................
  ............................7-18
• Install...........................................
  .....................................7-18
• Complete..........................................
  ................................7-19
• DRIVE BELT
• Remove............................................
  ................................7-20
• Install...........................................
  .....................................7-20
• TRANSMISSION

• FASTENER TORQUE VALUES
• Fastener Torque Values in this Chapter............
  ..................7-1
• SPECIFICATIONS DRIVE
• Specifications....................................
  ..................................7-2
• PRIMARY CHAINCASE COVER
• Prepare...........................................
  ....................................7-3
• Remove............................................
  ..................................7-3
• Install...........................................
  .......................................7-3
• Complete..........................................
  ..................................7-4
• DRIVE COMPONENTS
• Prepare...........................................
  ....................................7-5
• Remove............................................
  ..................................7-5
• lnstaI...........................................
  .......................................7-6
• Complete..........................................
  ..................................7-8
• PRIMARY CHAINCASE HOUSING
• Prepare...........................................
  ....................................7-9
• Remove............................................
  ..................................7-9
• Inspect...........................................
  .....................................7-9
• Install...........................................
  .......................................7-9

• FASTENER TORQUE VALUES
• Fastener Torque Values in this Chapter............
  ..................8-1
• SPECIFICATIONS TRANSMISSION
• Specifications....................................
  ..................................8-2
• SERVICE WEAR LIMITS...............................
  .....................8-2
• TRANSMISSION OPERATION
• Power Flow.......................................
  ..................................8-3
• Neutral...........................................
  ...............................8-3
• First Gear.......................................
  ...............................8-3
• Second Gear......................................
  ...........................8-3
• Third Gear.......................................
  ..............................8-3
• Fourth Gear......................................
  .............................8-3
• Fifth Gear.......................................
  ...............................8-3
• Sixth Gear.......................................
  ..............................8-3
• SHIFTER LINKAGE
• Shifter Rod......................................
  ....................................8-5
• Replace...........................................
  ..............................8-5
• Adjust............................................
  ................................8-5
• Heel-Toe Shift Levers.............................
  ............................8-5

TABLE OF
XIV
13
TABLE OF CONTENTS

• 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...................
  ...............................................9-1
  0
• 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
• IGNITION COIL AND SPARK PLUG CABLES
• Removal...........................................
  .................................9-13
• Install...........................................
  .....................................9-13 SPARK
  PLUG CABLES.......................................
  .............9-13

• 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
• MAIN DRIVE GEAR AND BEARING
• Prepare...........................................
  ..................................8-19
• Remove............................................
  ................................8-19
• Clean and lnspect.................................
  ............................8-20
• Install..... .....................................
  .....................................8-20
• Complete..........................................
  ................................8-21 Replace
  Needle Bearings...................................
  ..............8-21
• Replace Mainshaft Seal............................
  ........................8-22
• TRANSMISSION CASE
• Prepare...........................................
  ..................................8-24
• Remove............................................
  ................................8-24

• FASTENER TORQUE VALUES
• Fastener Torque Values in this Chapter............
  ..................9-1
• SPECIFICATIONS ELECTRICAL
• Specifications....................................
  ..................................9-5
• 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
• ELECTRONIC CONTROL MODULE (ECM)
• ECM...............................................
  .....................................9-7
• Removal...........................................
  .............................9-7
• Installation......................................
  ...............................9-7
• BODY CONTROL MODULE (BCM)
• Removal............... ..........................
  ....................................9-8

TABLE OF
XV
14
TABLE OF CONTENTS

• lnstall Fork Lock.................................
  .........................9-41
• 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
• CRANKSHAFT POSITION SENSOR
• (CKP)
• Remove............................................
  ................................9-44
• Installation......................................
  ...................................9-44
• KNOCK SENSOR (KS)
• Prepare...........................................
  ..................................9-45
• Remove............................................
  ................................9-45
• Install...........................................
  .....................................9-45
• Complete..........................................
  ................................9-45
• ENGINE TEMPERATURE SENSOR (ET)

• 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
• 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
• TOUR-PAK LIGHTS
• Tour-Pak Side Lamps/Trim Strips...................
  ..................9-28 Removal....................
  ..................................................
  9-28
• Installation......................................
  .............................9-28

äï Fat Lams Style 9-32
Installation Flat Lens Style..........t.........
...............t..t9-32
Removal Bullet Style, Fork-Mounted...............
..........9-32 Installation Bullet Style,
Fork-Mounted......................9-33 Removal
Buffet Style, Fairing Mounted.....................
.9-33 Installation Bullet Style, Fairing
Mounted...................9-33 Lamp Repair
Bullet Style......................................
.....9-34 ReR
u vsi Aa'ba FLHX FLHXS FLTRX FLTRXS 934
Installation AII but FLHX, FLHXS, FLT ,
FLTRXSttt9-35
Removal FLHX, FL.HXS, FLTRX, FLTRXS..............
.,9-35
Installation FLHX, FLHXS, FLTRX,
FLTRXS.............9-36 Lamp Repair..............
.................................................9
-36 Rear Turn Signal Lamps Bracket................
......................9-36 Removal AII but FLHX,
FLHXS, FLTRX, FLTRXS.....9-36 Installation AII
but FLHX, FLHXS, FLTRX, FLTRXS...9-37 Removal
FLHX, FLHXS, FLTRX, FLTRXS................9-37 Ins
tallation FLHX, FLHXS, FLTRX, FLTRXS.............
9-38 9.15 IGNITION SWITCH AND FORK LOCK Fairing
Models............................................
......................9-39 Removal.,..............
..................................................
....9-39 t RoadSKln M dels"""""""""""""""""""""
"""""" 9 Remove Ignition/Light"KeySwitch........
......,tt.............9-40 Install Ignition/Light
Key Switch..................................9-40
Remove Fork Lock..................................
....................9-41
TABLE OF
XVI
15
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16
TABLE OF CONTENTS

• Removal...........................................
  ...........................9-55
• Installation......................................
  .............................9-55
• Rear Wheel Speed Sensor...........................
  ....................9-56 Removal..................
  ..................................................
  ..9-56
• Installation......................................
  .............................9-56
• NEUTRAL SWITCH
• Removal...........................................
  .................................9-57
• Installation......................................
  ...................................9-57
• OIL PRESSURE SWITCH
• Removal...........................................
  .................................9-58
• InstaII...........................................
  .....................................9-58
• 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
• HORN
• Removal...........................................
  ...................... ..........9-60
• Installation......................................
  ...................................9-60

• 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

Installations Fra MM ededF nrinMMdels
Pa2)2).......9- 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
17
TABLE OF CONTENTS
B.2 FLUID CONVERSION System......
Harness Servic.e Frame Mounted
Fairing....... Removal... Installation............
........... .... 9.39 HANDLEBAR SWITCH
PACKS Removal............ Handlebar
Controls........................ Install..........
............. Right Handlebar Controls............
..............
.........9-92 ........9-92 ..9-93
. ...................B-2 .B-2 .B-2
Metred S !es
British Imperial System...........................
B.3 TORQUE CONVERSION
...9-94 ..9-94 ..9-95 ..9-95 ..9-96 ..9-96 ..9-96
..9-97 ..9-98
United States System........ Metric
System........... B.4 GLOSSARY Acronyms and
Abbreviations... REFERENCE MATERIAL
.B-3 .B-3
.......
Left Handlebar Controls........ Switch Pack
Harness..................... Remove... Install...
. Handlebar Switch Caps..................
..B-4
TOOLS.............................................
..............I Torque Values.....................
.........................V Index..................
.......................................XIX
9.40 SECURITY SYSTEM MAINTENANCE
Fob Battery.......................................
......... Battery Retlacement Schedule....
Battery Replacement..............................
Smart Siren (If Equipped)...................... Ba
ttery Retlacement Schedule........ .. .. Battery
Replacement................. Security System
Antenna........... Removal.......... ...
................................ Installation.....
........
..9-99 ..9-99 ..9-99 ..9-99 ..9-99 ..9-99 ..9-99 .
.9-99 ..9-100
9.41 PERSONAL IDENTIFICATION NUMBER (PIN)
General. ......... .9-101
Changing the FIN............................ ...9-101
Modifying an Existing PIN........... .9-101
9.42 SECURITY SYSTEM ACTUATION
Sidecar Config uration. .9102
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 Jolor.............. ..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 Tab