2012 Harley Davidson Softail Service Repair Manual Instant Download

1
2012 Softai? Mode?s Service Manua?
?2011 H-D. ALL R?GHTS RESERVED 99482-12A Printed
in the U.S.A.
2
1.7 A?R CLEANER AND EXHAUST SYSTEM Removal........
..................................................
...................1-17 Cleaning and
lnspection........................................
....1-17 lnstallation.............................
............................................1-18
Exhaust System Leak Check.........................
....................1-19
MA?NTENANCE
1.1 FASTENER TORQUE VALUES Fastener Torque Values
in this Chapter...............................1-1
1.2 GENERAL Servicing a New Motorcycle............
....................................1-4 Safe
Operating Maintenance.............................
..................1-4 Shop Practices..............
..................................................
.....1-4 Repair Notes.............................
....................................1-4 Safety....
..................................................
......................1-4 Removing Parts
..................................................
.........1-4 Cleaning.............................
..........................................1-4 Disa
ssembly and Assembly .............................
...........1-5 Checking Torques on
Fasteners..................................1-5
Magnetic Parts Trays .............................
......................1-5 Repair and Replacement
Procedures ................................1-5 Har
dware and Threaded Parts..........................
...........1-5 Threadlocking Agents...............
....................................1-5 Wiring,
Hoses and Lines...................................
...........1-5 Instruments and Gauges
.............................................1-5
Bearings..........................................
.............................1-5 Bushings.........
..................................................
............1-5 Gaskets ..........................
.............................................1-5 L
ip-Type Seals.....................................
........................1-5 O-Rings
..................................................
.....................1-6 Gears....................
..................................................
.....1-6 Shafts ..................................
........................................1-6 Part
Replacement.......................................
.................1-6 Exhaust System
Leakage...........................................
.1-6 Cleaning.....................................
.........................................1-6 Part
Protection........................................
.....................1-6 Cleaning
Process...........................................
.............1-6 Rust or Corrosion
Removal.........................................1-
6 Bearings........................................
..............................1-6 Tool Safety
..................................................
........................1-6 Air
Tools.............................................
..........................1-6 Wrenches............
..................................................
......1-6 Pliers/Cutters/Pry Bars
...............................................1-6
Hammers..........................................
...........................1-7 Punches/Chisels....
..................................................
....1-7 Screwdrivers..............................
..................................1-7 Ratchets
and Handles.......................................
..........1-7 Sockets.............................
...........................................1-7 Sto
rage Units........................................
.......................1-7
1.8 T?RES AND WHEELS General......................
..................................................
.....1-20 Tires...................................
...............................................1-2
0 Tire Replacement...............................
..............................1-21 lnspection.....
..................................................
...........1-21 When To Replace
Tires.............................................
.1-21 Wheel Bearings..............................
...................................1-21 Wheel
Spokes............................................
.......................1-21 Identify Wheel Spoke
Groups....................................1-21 Whe
el Spoke Adjustment...............................
...........1-22
1.9 PR?MARY CHA?NCASE LUBR?CANT General...........
..................................................
................1-23 Changing Primary Chaincase
Lubricant...........................1-23
1.10 TRANSM?SS?ON LUBR?CANT Checking Transmission
Lubricant.....................................1-25
Changing Transmission Lubricant..................
..................1-25
1.11 CLUTCH Adjustment............................
............................................1-27
1.12 DR?VE BELT AND SPROCKETS General.............
..................................................
..............1-29 Cleaning.......................
..................................................
....1-29 lnspection...............................
..........................................1-29 Spr
ockets............................................
.......................1-29 Drive
Belt..............................................
......................1-29 Checking Belt
Deflection........................................
...........1-30 Adjusting Belt Deflection
..................................................
.1-31
1.13 THROTTLE CABLES Cable Inspection,
Lubrication and Adjustment .................1-33
Inspection and Lubrication........................
................1-33 Adjustment...................
...............................................1-3
3
1.14 CABLE AND CHASS?S LUBR?CAT?ON General........
..................................................
...................1-35 Cables and Hand
Levers............................................
......1-35 Jiffy Stand............................
.............................................1-35
Steering Head Bearings............................
........................1-35
1.3 FUEL AND O?L Fuel.............................
..................................................
.......1-8 Gasoline Blends........................
..........................................1-8 Engi
ne Lubrication....................................
..........................1-8 Winter
Lubrication.......................................
........................1-9
1.15 BRAKES Fluid Inspection......................
...........................................1-36 Re
ar Brake Pedal....................................
.........................1-36 Pedal
Height............................................
..................1-36 Pedal Lubrication..........
.............................................1-36
Pedal Pad.........................................
.........................1-36
1.4 BULB REQU?REMENTS General.....................
..................................................
......1-10
1.5 MA?NTENANCE SCHEDULE General..................
..................................................
.........1-11
1.16 BRAKE PADS AND D?SCS lnspection..............
..................................................
.........1-37 Brake Pads..........................
......................................1-37 Brake
Disc..............................................
...................1-37 Brake Pad
Replacement.......................................
............1-37 Rear Brake Caliper...............
.....................................1-37 Front
Brake Caliper.....................................
..............1-39
1.6 ENG?NE O?L AND F?LTER Checking and Adding
Oil...............................................
....1-15 Type of Oil..............................
...................................1-15 Checking
Oil Level ........................................
............1-15 Changing Oil and
Filter............................................
.........1-15
1.17 SPARK PLUGS Removal..........................
..................................................
.1-41
3
TABLE OF CONTENTS
Inspection........................................
..................................1-41 CIeaning...
..................................................
.......................1-41 InstaIIation..........
..................................................
.............1-41 Spark PIug CabIe
Inspection........................................
....1-42
Low OiI Pressure..................................
.....................1-60 High OiI
Pressure..........................................
............1-60 EIectricaI System................
..............................................1-60
AIternator Does Not Charge.......................
...............1-60 AIternator Charge Rate Is
BeIow NormaI..................1-60 Speedometer
Operates ErraticaIIy............................1-
60 Transmission...................................
.................................1-60 Shifts
Hard..............................................
...................1-60 Jumps Out Of
Gear..............................................
.....1-60 CIutch SIips............................
....................................1-60 CIutch
Drags Or Does Not ReIease.........................
.1-60 CIutch Chatters.............................
.............................1-60 HandIing........
..................................................
..................1-60 IrreguIarities.............
..................................................
1-60 Brakes.......................................
........................................1-60
Brake Does Not HoId NormaIIy......................
...........1-60
1.18 STEERING HEAD BEARINGS Adjustment FLSTC,
FLSTF/B, FLSTN, FLS....................1-43 Bearin
g Adjustment (FaII-away)..........................
......1-43 Adjustment FXST, FXS..................
..................................1-44 Bearing
Adjustment (FaII-away)............................
....1-44 Lubrication..............................
..........................................1-46
1.19 CRITICAL FASTENERS Inspection................
..................................................
.......1-48 Checking Torques on
Fasteners................................1-48
1.20 BATTERY MAINTENANCE GeneraI..................
..................................................
........1-49 CIeaning and Inspection............
.......................................1-50 VoItme
ter Test..........................................
.........................1-50 VoItmeter
Test..............................................
..............1-50 Charging Battery...............
................................................1-
50 Safety Precautions............................
........................1-50 Using a Battery
Charger...........................................
.1-50 Disconnection and RemovaI
.............................................1-51
Storage...........................................
...................................1-51
InstaIIation and Connection.......................
.......................1-52
CHASSIS
2.1 FASTENER TORQUE VALUES Fastener Torque VaIues
in this Chapter..............................2-1
2.2 SPECIFICATIONS Specifications.................
..................................................
...2-4 Chassis Specifications.....................
........................ 2-4 Tire
Specifications....................................
...................2-5
2.3 VEHICLE IDENTIFICATION NUMBER
(V.I.N.) VehicIe Identification
Number............................................
.2-8
1.21 HEADLAMP ALIGNMENT HeadIamp
AIignment.........................................
...............1-54 HeadIamp Adjustment..........
............................................1-54
2.4 FRONT WHEEL RemovaI...........................
.........................................
2-10 DisassembIy ................................
.....................................2-10 Disc
WheeI.............................................
...................2-10 Laced Whee1.
..................................................
...........2-10 CIeaning and Inspection..........
................ ..........................2-12 As
sembIy............................................
................................2-12 Disc
WheeI.............................................
.....................2-12 Laced
WheeI.............................................
.................2-13 InstaIIation................
..................................................
.......2-13
1.22 SUSPENSION ADJUSTMENTS Shock
Absorbers.........................................
.....................1-55 CaIcuIate Number of
Turns........................................1-55
Adjustment........................................
.........................1-55
1.23 STORAGE GeneraI..............................
...............................................1-5
6 PIacing in Storage..............................
...............................1-56 RemovaI from
Storage...........................................
...........1-56
1.24 TROUBLESHOOTING GeneraI......................
..................................................
.....1-58 Engine..................................
.............................................1-58
Starter Motor Does Not Operate or Does Not Turn
Engine Over ......o ............................
.......................................1-58 Engine
Turns Over But Does Not Start ...................
.1-58 Starts Hard................................
................................1-58 Starts But
Runs IrreguIarIy or Misses .......................
1-58 A Spark PIug FouIs RepeatedIy................
................1-59 Pre-Ignition or Detonation
(Knocks or Pings)............1-59
Overheating.......................................
........................1-59 VaIve Train
Noise.............................................
..........1-59 Excessive Vibration................
...................................1-59 Check
Engine Light IIIuminates During
Operation.....1-59 Lubrication System
..................................................
........1-59 OiI Does Not Return To OiI
Tank...............................1-59 Engine
Uses Too Much OiI Or Smokes ExcessiveIy..1-59
Engine Leaks OiI From Cases, Push Rods, Hoses,
Etc...............................................
..............................1-59
2.5 REAR WHEEL RemovaI ........................
...........................................2-14 Di
sassembIy.........................................
............................2-15 CIeaning and
Inspection........................................
...........2-15 AssembIy..........................
................................................2-
15 InstaIIation...................................
......................................2-16
2.6 WHEEL LACING WheeI Lacing AngIe FIange
Hub.....................................2-17
2.7 CHECKING AND TRUING WHEELS GeneraI............
..................................................
...............2-19 Checking WheeI
Runout............................................
.......2-19 Checking LateraI Runout...............
............................2-19 Checking RadiaI
Runout............................................
2-19 Laced WheeI Rim Offset.......................
............................2-20 Truing Laced
WheeIs............................................
............2-22 RadiaI Runout....................
........................................2-22
IV TABLE OF CONTENTS
4
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TABLE OF CONTENTS
2.16 FRONT FORK TELESCOPIC GeneraI...............
..................................................
.............2-57 RepIacing Fork
OiI...............................................
.......2-57 RemovaI. 2-58
DisassembIy. 2-58 CIeaning and
Inspection. 2-58 AssembIy...
. 2-62 InstaIIation...................
... .... 2-62
LateraI Runout....................................
.......................2-22
2.8 SEALED WHEEL BEARINGS Inspection..............
..................................................
.........................2-24 RemovaI.............
..................................................
2-24 InstaIIation............................
........................................ 2-26
2.9 TIRES GeneraI.................................
.......................................
2-28 RemovaI......................................
................................. 2-28 CIeaning,
Inspection and Repair.............................
.... 2-28 InstaIIation............................
.............................................2-29
Tube Type Tires...................................
......................2-29 TubeIess Tires Cast
WheeIs.....................................2-29 Tu
beIess Tires Laced WheeIs........................
..........2-30 Checking Tire Runout...............
.........................................2-31 Late
raI Runout........................................
....................2-31 RadiaI
Runout............................................
.................2-31 WheeI BaIancing.............
..................................................
.2-31 Static vs Dynamic...........................
............................2-31 Weights..........
..................................................
.......... 2-31
2.17 STEERING HEAD RemovaI........................
..................................................
..2-63 FLSTC, FLSTF/B, FLSTN, FLS
ModeIs....................2-63 FXST
ModeI.............................................
..................2-63 FXS ModeI..................
...............................................2-6
3 Inspection......................................
...................................2-64 AII
ModeIs............................................
......................2-64 DisassembIy............
..................................................
.......2-64 Removing Lower Bearings From Fork
Stem.............2-64 Steering Head Bearing Race
RemovaI.....................2-64
AssembIy..........................................
.................................2-65 InstaIIation
..................................................
......................2-65 FLSTC, FLSTF/B, FLSTN,
FLS ModeIs....................2-65 FXST
ModeIs............................................
.................2-65 FXS ModeIs..................
.............................................2-66
2.10 VEHICLE ALIGNMENT AxIe AIignment.............
..................................................
...2-33 Checking AxIe AIignment...................
.......................2-33 Adjusting AxIe
AIignment.........................................
..2-34
2.18 BELT GUARD AND DEBRIS DEFLECTOR RemovaI......
..................................................
....................2-67 BeIt Guard..............
..................................................
.2-67 Debris DefIector............................
.............................2-67 InstaIIation....
..................................................
...................2-67 BeIt Guard...............
..................................................
2-67 Debris DefIector.............................
............................2-67
2.11 FRONT BRAKE MASTER CYLINDER GeneraI..........
..................................................
.................2-35 RemovaI and
DisassembIy.......................................
........2-35 CIeaning and Inspection..............
.....................................2-37 AssembIy
and InstaIIation.................................
................2-37
2.12 FRONT BRAKE CALIPER RemovaI..................
..................................................
..2-39 DisassembIy ...............................
.......................................2-39 CIeani
ng, Inspection and Repair.........................
.............2-41 AssembIy........................
..................................................
.2-42 InstaIIation................................
..........................................2-43
2.19 REAR SHOCK ABSORBERS GeneraI.................
..................................................
...............2-68 RemovaI ......................
................................................2-
68 InstaIIation...................................
..................................2-68 Shock
DisposaI..........................................
........................2-69
2.13 REAR BRAKE MASTER CYLINDER GeneraI...........
..................................................
...............2-44 RemovaI.......................
..................................................
..2-44 DisassembIy................................
....................................2-44 CIeaning
and Inspection....................................
...............2-45 AssembIy......................
..................................................
..2-45 InstaIIation...............................
............................................ 2-46
2.20 REAR FORK RemovaI............................
........................................2-71 CIean
ing and Inspection ...............................
....................2-72 Pivot Bearing
RepIacement.......................................
.......2-72 InstaIIation..........................
..................................................
2-73
2.21 THROTTLE CONTROL RemovaI/DisassembIy.........
.............................................2-74
CIeaning and Inspection..........................
........................2-74 AssembIy/InstaIIation
..................................................
..........2-74
2.14 REAR BRAKE CALIPER RemovaI...................
..................................................
.......2-50 DisassembIy...........................
..........................................2-50 CIe
aning, Inspection and Repair......................
................2-52 AssembIy.....................
..................................................
...2-52 Rear Brake Line Routing...................
...............................2-53
InstaIIation......................................
....................................2-53
2.22 CLUTCH CONTROL RemovaI.......................
..............................................2-76
InstaIIation ...............................2-76
2.23 HANDLEBARS FLSTC, FLSTN, FLS,
FXST RemovaI......................................
.....................................2-78 InstaIIa
tion..............................................
.......................... .2-79
2.15 BLEEDING BRAKES GeneraI......................
..................................................
......2-55 Procedure..............................
............................................2-55
TABLE OF CONTENTS V
6
TABLE OF CONTENTS
2.24 HANDLEBARS FLSTF/ RemovaI...................
..................................................
.......2-80 InstaIIation..........................
...............................................2-8
1
2.35 FORK LOCK RemovaI............................
..............................................2-10
3 InstaIIation....................................
...................................2-103
2.25 HANDLEBARS FXS RemovaI......................
..................................................
....2-84 InstaIIation.............................
............................................2-84
2.36 SEAT AND STRAP RETENTION NUT RepIacement.....
..................................................
............2-104
2.37 SEAT FLS, FXS, FXST RepIacement.............
..................................................
....2-105 RemovaI.................................
.................................2-105 InstaIIatio
n.................................................
..............2-105
2.26 FRONT FENDER RemovaI.........................
..................................................
.2-86 InstaIIation................................
.........................................2-86
2.27 REAR FENDER FLSTC RemovaI...................
..................................................
.......2-87 InstaIIation..........................
...............................................2-8
7
2.38 SEAT FLSTN, FLSTF, FLSTFB, FLSTC RemovaI
and InstaIIation.................................
...............2-106
2.39 LUGGAGE RACK FLSTN RemovaI and
InstaIIation......................................
..........2-107
2.28 REAR FENDER FLSTF/B RemovaI.................
..................................................
.........2-89 InstaIIation........................
.................................................2
-89
2.40 SADDLEBAGS FLSTC RemovaI....................
..................................................
....2-108 InstaIIation............................
...........................................2-108
2.29 REAR FENDER FXST RemovaI....................
..................................................
......2-90 InstaIIation...........................
..............................................2-90
2.41 WINDSHIELD FLSTC RemovaI....................
..................................................
....2-110 InstaIIation............................
...........................................2-110
2.30 REAR FENDER FLS, FXS RemovaI................
..................................................
..........2-92 InstaIIation.......................
..................................................
2-92 License PIate Bracket AssembIy and
InstaIIation FXS, FLS (aII but Domestic and
CaIifornia modeIs)...........2-92 License PIate
Bracket AssembIy and InstaIIation FLS (Domestic
and CaIifornia modeIs)...........................
..2-93 Fender InstaIIation......................
...............................2-93
2.42 SAREE GUARD INDIA MODELS Left Side RemovaI
and InstaIIation.................................2
-111 RemovaI......................................
............................2-111 InstaIIation....
..................................................
.........2-111 Right Side RemovaI and
InstaIIation...............................2-111
RemovaI...........................................
.......................2-111 InstaIIation.........
..................................................
....2-111
2.31 REAR FENDER FLSTN RemovaI...................
..................................................
.......2-95 DisassembIy...........................
..........................................2-95 Ass
embIy.............................................
.............................2-96 InstaIIation....
..................................................
...................2-97
2.43 FRONT LICENSE PLATE BRACKET RemovaI and
InstaIIation......................................
..........2-112
ENGINE
2.32 REAR FENDER WIRE CONDUIT InstaIIation........
..................................................
...............2-98
3.1 FASTENER TORQUE VALUES Fastener Torque VaIues
in this Chapter..............................3-1
2.33 FOOTBOARDS AND FOOTRESTS Rider
Footboards........................................
......................2-99 RemovaI................
..................................................
..2-99 InstaIIation...............................
..................................2-99 Rider
Footrest..........................................
........................ 2-99 RemovaI.............
..................................................
.....2-99 InstaIIation............................
.....................................2-99 Passenge
r Footrest ......................................
...................2-99 RemovaI...................
.................................................2
-99 InstaIIation..................................
.............................2-100
3.2 SPECIFICATIONS Specifications.................
..................................................
...3-3
3.3 SERVICE WEAR LIMITS GeneraI...................
..................................................
..........3-5
3.4 ENGINE OIL FLOW OiI Feed....................
..................................................
........3-7 Top End.............................
..................................................
3-8 Bottom End..................................
.......................................3-9 Chain
Guide Bracket....................................
.....................3-11 OiI
Return............................................
..............................3-11
2.34 JIFFY STAND CIeaning.........................
.................................................
2-101 Sensor HOI ModeIs.......................
.................................
2-101 RemovaI.....................................
.....................................2-102 InstaII
ation.............................................
..........................2-102
3.5 OIL PUMP OPERATION GeneraI....................
..................................................
.......3-12 Operation.............................
.............................................3-12
VI TABLE OF CONTENTS
7
TABLE OF CONTENTS
3.6 BREATHER OPERATION GeneraI....................
..................................................
.......3-13
Inspection................o .......o .......o
.................................3-35 Rocker
Shaft Fit................................0
........................3-35 Rocker Arm Shaft to
Bushing....................................3-36 Re
pIace Rocker Arm Bushings.........................
........3-36 AssembIy.............................
.............................................3-37
3.7 OIL PRESSURE OiI Pressure Indicator
Lamp.............................................3
-14 Checking OiI Pressure.........................
.............................3-14
3.19 PUSH RODS, LIFTERS AND COVERS DisassembIy....
..................................................
................3-38 CIeaning and
Inspection........................................
............3-38 Lifter Inspection...............
..................................................
3-38 AssembIy.....................................
................................. 3-39
3.8 TROUBLESHOOTING Diagnosing VaIve Train
Noise...........................................3-
16 Compression Test...............................
..............................3-16 CyIinder
Leakdown Test.....................................
..............3-16 Diagnosing Smoking Engine or
High OiI Consumption.....3-17 Check Prior To
CyIinder Head Remova1....................3-17 Chec
k After CyIinder Head RemovaI.....................
....3-17
3.20 CYLINDER HEAD DisassembIy....................
..................................................
. 3-40 CIeaning...................................
..........................................3-41 Ins
pection...........................................
...............................3-41 CyIinder
Head..............................................
...............3-41 VaIve Guides.................
...........................................
3-42 VaIves.......................................
................................ 3-42 VaIve
Springs...........................................
................. 3-42 Tapered
Keepers...........................................
........... 3-42 VaIve Seats......................
.........................................
3-42 VaIve Guide RepIacement......................
......................... 3-42 RemovaI............
..................................................
..... 3-42 InstaIIation..........................
......................................
3-42 VaIve and Seat Refacing......................
.............................3-46 AssembIy........
..................................................
.......... ..3-48
3.9 HOW TO USE THIS SECTION Top End
Repair............................................
.....................3-18 Bottom End
Repair............................................
...............3-18 TypicaI Symptoms..............
...............................................3-1
8
3.10 TOP END SERVICE Engine in Chassis............
.................................................3
-19 Engine Removed from Chassis...................
.....................3-20
3.11 CAM COMPARTMENT SERVICE Engine in
Chassis...........................................
..................3-21 Engine Removed From
Chassis.......................................3-22
3.21 CYLINDER CIeaning............................
.................. ...............................
3-50 Inspection...................................
........ ...............................3-50 DegIa
zing CyIinder.................................
...........................3-52 Boring and Honing
CyIinder..........................................
......3-52
3.12 STRIPPING MOTORCYCLE FOR SERVICE Procedure...
..................................................
....................3-23
3.13 ASSEMBLING MOTORCYCLE AFTER
SERVICE Procedure.................................
.........................................3-24
3.22 PISTON DisassembIy...........................
..............................................3-54
Piston Rings....................................
.............................3-54 CIeaning........
..................................................
......................3-54 Inspection.............
..................................................
...........3-54 AssembIy..........................
.................................................3
-56 Checking Piston Ring Gap......................
...................3-56 InstaIIing Piston
Rings.............................................
...3-56
3.14 REMOVING ENGINE FROM CHASSIS Procedure.......
..................................................
.................3-25
3.15 INSTALLING ENGINE IN CHASSIS Procedure.......
..................................................
.................3-26
3.23 TOP END OVERHAUL ASSEMBLY GeneraI...........
..................................................
........3-58 Piston...............................
.........................................3-58 CyIi
nder..............................................
.................................3-59 CyIinder
Head..............................................
......................3-61 Push Rods, Lifters and
Covers .........................................3-
65 Rocker Arm Support PIate.......................
..........................3-66 Breather and
Rocker Cover......................................
.........3-67
3.16 TOP END OVERHAUL DISASSEMBLY GeneraI........
..................................................
................... 3-28 Rocker
Covers............................................
...................... 3-28 Rocker Arm Support
PIate.............................................
...3-28 Push Rods, Lifters and Covers.............
............................3-30 CyIinder
Head..............................................
......................3-31 CyIinder...............
..................................................
.............3-32 Piston..........................
..................................................
.....3-32
3.24 CAM COMPARTMENT AND COMPONENTS Cam Support
PIate and Cover RemovaI...........................
3-68 Prepare Engine..............................
............................3-68 Cam Chain and
Sprockets RemovaI..........................3-68
Cam Support PIate RemovaI.........................
.............3-69 Cam Support PIate CIeaning and
Inspection.....................3-70 OiI Pressure
VaIve.............................................
.........3-70 Cam Support PIate...................
.................................3-70
3.17 BREATHER ASSEMBLY DisassembIy................
..................................................
......3-34 CIeaning and Inspection................
................................3-34
AssembIy..........................................
...................................3-34
3.18 ROCKER ARM SUPPORT PLATE DisassembIy.........
..................................................
..............3-35 CIeaning and
Inspection........................................
............3-35
TABLE OF CONTENTS VII
8
TABLE OF CONTENTS
Camshafts.........................................
................................3-70 RemovaI......
..................................................
............3-70 InstaIIation.....................
............................................3-71 O
iI Pressure ReIief VaIve.........................
.........................3-72 RemovaI.............
..................................................
.....3-72 Inspection..............................
....................................3-72 InstaIIat
ion...............................................
..................3-73 Cam NeedIe
Bearings..........................................
.............3-73 RemovaI.........................
...........................................3-73 In
staIIation........................................
.........................3-74 Cam Support PIate
and Cover InstaIIation.......................3-76
Chain Tensioner Guides..........................
..................3-98 BaIance Shaft
Support...........................................
...3-98 BaIance Chain...........................
................................3-99
3.29 CRANKCASE ASSEMBLY CounterbaIancer AssembIy
InstaIIation..........................3-100
Crankcase.........................................
..............................3-103
3.30 OIL TANK RemovaI and DisassembIy...........
..................................3-106 OiI
Tank..............................................
......................3-106 OiI Line
Fittings/Retainers................................
.......3-108 InstaIIation.........................
..............................................3-10
9
3.25 OIL PUMP RemovaI.............................
...............................................3-8
0 CIeaning and Inspection.......................
............................3-80 InstaIIation.....
..................................................
..................3-81
FUEL SYSTEM 4.1 FASTENER TORQUE VALUES Fastener
Torque VaIues in this Chapter.....................
.........4-1
3.26 CRANKCASE DISASSEMBLY AND REPAIR Crankcase
DisassembIy.......................................
............3-82 CounterbaIancer
AssembIy..........................................
....3-82 CIeaning and Inspection................
...................................3-84 Right
Crankcase HaIf...................................
.....................3-85 Chain Guide
Screen............................................
......3-85 Main Bearing RemovaI.................
.............................3-85 Main Bearing
InstaIIation......................................
.....3-86 Piston Jets RemovaI
..................................................
3-86 Piston Jets InstaIIation...................
............................3-86 Left Crankcase
HaIf..............................................
............3-87 Main Bearing
RemovaI...........................................
...3-87 Main Bearing InstaIIation...............
............................3-88 Sprocket Shaft
Bearing Inner Race...............................
...3-88 RemovaI...................................
.................................3-88 InstaIIation
.................................................
................3-89 CyIinder
Studs.............................................
.....................3-91 RemovaI.................
..................................................
.3-91 InstaIIation................................
.................................3-91 Pipe PIugs
and OiI Fittings..................................
..............3-91 RemovaI/InstaIIation...........
.......................................3-91
4.2 SPECIFICATIONS FUEL SYSTEM Specifications....
..................................................
................4-3
4.3 AIR CLEANER ASSEMBLY RemovaI..................
..................................................
......... 4-4 InstaIIation......................
..................................................
.. A-4 BackpIate AssembIy HDI
ModeIs......................................4-5
4.4 FUEL SUPPLY LINE Purging FueI SuppIy
Line..............................................
......4-6 Disconnecting FueI SuppIy
Line.........................................4-6
4.5 FUEL PRESSURE TEST GeneraI....................
..................................................
.........4-7 Testing..............................
..................................................
4-7
4.6 FUEL TANK Generai.............................
.................................................A
-9 Removai........................................
.....................................A-9 CIeaning
and Inspection..................................
................A-10 InstaIIation.................
..................................................
......4-11
3.27 FLYWHEEL AND CONNECTING RODS GeneraI.........
..................................................
..................3-92 Symptoms...................
...............................................3-9
2 No OiI Pressure...............................
..........................3-92 Vibration..........
..................................................
........3-92 Inspection...........................
..............................................3-92
Measuring Crankshaft Run-Out....................
....................3-93 Crankshaft
InstaIIed.........................................
..........3-93 Crankshaft Removed...............
..................................3-93
4.7 CONSOLE FXS MODEL RemovaI....................
..................................................
......4-12 InstaIIation...........................
..............................................4-12
4.8 THROTTLE POSITION SENSOR (TPS) GeneraI
..................................................
...........................4-13 RemovaI...........
..................................................
...............4-13 InstaIIation..................
..................................................
.....4-13
3.28 COUNTERBALANCER ASSEMBLY REPAIR CIeaning,
Inspection, and Repair............................
......... 3-95 GeneraI............................
.......................................... 3-95
BaIance Shaft RemovaI...........................
..................3-95 Bearing
RemovaI...........................................
............3-96 BaIance Shaft
InstaIIation......................................
....3-96 BaIance Shaft Support Bearings
RemovaI................3-97 BaIance Shaft Support
Bearings InstaIIation.............3-97 Front and
Rear BaIance Sprockets...........................3
-98 HydrauIic Tensioners........................
.........................3-98
4.9 INTAKE AIR TEMPERATURE SENSOR
(IAT) GeneraI.....................................
........................................4-14 Remov
aI ..............................................
............................. 4-14 InstaIIation...
..................................................
....................4-14
4.10 ENGINE TEMPERATURE SENSOR (ET) GeneraI.......
..................................................
....................4-15 RemovaI..................
..................................................
........4-15
VIII TABLE OF CONTENTS
9
TABLE OF CONTENTS
4.191NTAKE LEAK TEST GeneraI......................
..................................................
...... 4-33 Leak Tester..........................
.................................................4
-33 Parts List....................................
................................. 4-33 Tester
AssembIy..........................................
............... 4-33 Tester Adjustment...........
...........................................4-33 Pr
ocedure...........................................
..............................4-33
InstaIIation......................................
...................................4-15
4.11 INDUCTION MODULE RemovaI.....................
..................................................
..... 4-16 InstaIIation...........................
..............................................4-17
4.12 IDLE AIR CONTROL (?AC) GeneraI...............
..................................................
............ 4-18 RemovaI.........................
..................................................
.4-18 InstaIIation ...............................
.........................................4-18
4.20 EVAPORATIVE EMISSIONS CONTROL
SYSTEM GeneraI....................................
......................................... 4-35
4.13 MANIFOLD ABSOLUTE PRESSURE SENSOR (MAP)
GeneraI...........................................
..................................
4-19 RemovaI......................................
......................................4-19 InstaII
ation.............................................
...........................4-19
CharcoaI Canister ...............................
4-36
RemovaI...........................................
......................... 4-36 InstaIIation.......
..................................................
........4-36
Purge SoIenoid....................................
............................. 4-36 RemovaI........
..................................................
..........4-36 InstaIIation.......................
..........................................4-36 Hos
e Routing/RepIacement.............................
.................4-36 FueI Tank Vent
Hose.......................................
4-36 Purge SoIenoid-to-Induction ModuIe
Tube................4-36 CharcoaI
Canister-to-Purge SoIenoid Tube...............
4-37 Vent Tube-to-CharcoaI Canister
Tube.......................4-37
4.14 OXYGEN SENSOR GeneraI........................
..................................................
....4-20 RemovaI .................................
...........................................4-20 Fr
ont 02 Sensor...................................
................4-20 Rear 02 Sensor..............
........................................4-20 Insta
IIation...........................................
..............................4-20 Front 02
Sensor............................................
.... 4-20 Rear 02 Sensor........................
... ........................4-20
DRIVE
5.1 FASTENER TORQUE VALUES Fastener Torque VaIues
in this Chapter...............................5-1
4.15 FUEL INJECTORS GeneraI ......................
..................................................
.....4-22 RemovaI ................................
...........................................4-22 In
staIIation........................................
.................................4-22
5.2 SPECIFICATIONS DRIVE Specifications..........
..................................................
...........5-2
4.16 FUEL PUMP AND FUEL GAUGE SENDING
UNIT GeneraI......................................
........................................4-24 Remov
aI................................................
............................4-24 Vapor
VaIve ............................................
....................4-25 DisassembIy and
AssembIy..........................................
.... 4-26 FueI FiIter.............................
......................................4-26 ReguIat
or ...............................................
....................4-26 InIet
sock..............................................
.....................4-27 FueI
Pump..............................................
...................4-27 InstaIIation..............
..................................................
.........4-28
5.3 PRIMARY CHAINCASE COVER GeneraI...............
..................................................
...............5-3 RemovaI........................
..................................................
.....5-3 InstaIIation.............................
..............................................5-3
5.4 DRIVE COMPONENTS RemovaI......................
..................................................
.......5-4 InstaIIation ..........................
................................................5-
6
5.5 PRIMARY CHAINCASE HOUSING RemovaI.............
..................................................
................5-9 Inspection....................
..................................................
.....5-9 Mainshaft Bearing and Lip
SeaI..........................................5-9
RemovaI...........................................
............................5-9 InstaIIation......
..................................................
...........5-9 Mainshaft Bearing Inner Race
..........................................5-10
RemovaI .........................................
.......................5-1 0 InstaIIation.........
..................................................
...5-10 InstaIIation..............................
...........................................5-11
4.17 EXHAUST SYSTEM FXST, FLSTC MuffIers.........
..................................................
..................4-29 RemovaI....................
................................................
4-29 AssembIy.....................................
..............................4-29 System.........
..................................................
...................4-29 RemovaI...................
.................................................
4-29 InstaIIation.................................
................................4-29
4.18 EXHAUST SYSTEM FLSTF, FLSTFB, FLSTN, FLS,
FXS MuffIers......................................
........................................4-31 Remov
aI................................................
.....................4-31 AssembIy................
..................................................
..4-31 System.....................................
..........................................4-31 Rem
ovaI..............................................
.......................4-31 InstaIIation..........
..................................................
......4-31
5.6 CLUTCH RemovaI and InstaIIation...............
...................................5-13 CIutch
Pack OnIy.........................................
.....................5-13 PartiaI
DisassembIy.......................................
............5-13 CIeaning And Inspection..........
.................................5-13
AssembIy..........................................
.........................5-14 CIutch Pack and
Bearing...........................................
.......5-15 CompIete DisassembIy.................
.............................5-15
AssembIy..........................................
............................5-16
TABLE OF CONTENTS IX
10
TABLE OF CONTENTS
5.7 TRANSMISSION SPROCKET RemovaI.................
..................................................
.........5-18 CIeaning and Inspection...........
........................................S-19 Insta
IIation...........................................
..............................5-19
InstaIIing Main Drive Gear.......................
..................6-26 InstaIIing Main Drive Gear
Large SeaI.......................6-26
6.8 TRANSMISSION CASE RemovaI.....................
..................................................
.....6-29 InstaIIation............................
.............................................6-29
DisassembIy.......................................
..............................6-30 Shifter Arm
AssembIy..........................................
......6-30 CIeaning and Inspection..............
.....................................6-30
AssembIy ........................................
..................................6-31 Countershaf
t NeedIe Bearing RepIacement..............6-31
Shifter PawI Lever AssembIy.....................
................6-31
5.8 DRIVE BELT RemovaI............................
................................................
5-21 Inspection..................................
........................................5-21 Insta
IIation...........................................
.............................. 5-21
TRANSMISSION
6.1 FASTENER TORQUE VALUES Fastener Torque VaIues
in this Chapter..............................6-1
ELECTRICAL
7.1 FASTENER TORQUE VALUES Fastener Torque VaIues
in this Chapter..............................7-1
6.2 SPECIFICATIONS TRANSMISSION Specifications...
..................................................
.................6-2 Service Wear
Limits............................................
................6-2
7.2 SPECIFICATIONS ELECTRICAL Specifications.....
..................................................
...............7-3
6.3 TRANSMISSION Power FIow.....................
..................................................
..6-3 NeutraI.....................................
....................................6-3 1st
Gear..............................................
.........................6-3 2nd
Gear..............................................
........................6-3 3rd
Gear..............................................
.........................6-3 4th
Gear..............................................
.........................6-3 5th
Gear..............................................
.........................6-3 6th
Gear..............................................
..........................6-3
7.3 ELECTRICAL PANEL GeneraI......................
..................................................
.......7-4 RemovaI................................
..............................................7-4
InstaIIation......................................
.....................................7-5
7.4 ELECTRONIC CONTROL MODULE (ECM) GeneraI.......
..................................................
......................7-6 RemovaI.................
..................................................
...........7-6 InstaIIation.......................
..................................................
..7-6
6.4 SHIFTER Adjustment ...........................
...............................................6-5
Shifter Rod....................................
......................................6-5 Shift
Lever RepIacement................................
....................6-5
7.5 BODY CONTROL MODULE (BCM) GeneraI.............
..................................................
................7-7 BCM Configuration...........
..................................................
7-7 RemovaI.......................................
.......................................7-7 InstaII
ation.............................................
..............................7-7
6.5 CLUTCH RELEASE COVER RemovaI and
DisassembIy.......................................
..........6-7 CIeaning and Inspection...........
..........................................6-7 Asse
mbIy and InstaIIation...........................
........................6-8
7.6 H-DSSS ACTUATION Sidecar Configuration......
..................................................
..7-9 Actuation...................................
..........................................7-9 Fob
Assignment......................................
............................7-9
6.6 TRANSMISSION ASSEMBLY RemovaI.................
..................................................
...........6-9 DisassembIy........................
.............................................6-10
Shifter Cam/Shifter Forks.......................
....................6-10 Mainshaft................
..................................................
.6-12 Countershaft................................
..............................6-15 Removing
Bearing Housing Bearings.......................6
-16 CIeaning and Inspection.....................
..............................6-17
AssembIy..........................................
................................6-17 InstaIIing
Bearing Housing Bearings........................
.6-17 Countershaft................................
..............................6-17 Mainshaft......
..................................................
...........6-18 Shifter Cam/Shifter
Forks..........................................6-1
8 InstaIIation....................................
.....................................6-20
7.7 PERSONAL IDENTIFICATION NUMBER
(PIN) GeneraI.....................................
........................................7-10 Chang
ing the Pin.....................................
.........................7-10 Modifying an
Existing Pin.....................................
.....7-10
7.8 HD-SSS MAINTENANCE Fob Battery..............
..................................................
.......7-12 Battery RepIacement
ScheduIe.................................7-12
Battery RepIacement.............................
....................7-12 Smart Siren (If
InstaIIed)........................................
...........7-12 Battery RepIacement
ScheduIe.................................7-12
Battery RepIacement.............................
....................7-12
6.7 MAIN DRIVE GEAR AND BEARING RemovaI...........
..................................................
...............6-22 CIeaning and
Inspection........................................
...........6-23 NeedIe Bearing
RepIacement...................................6-24
InstaIIation.....................................
....................................6-25 InstaIIin
g Main Drive Gear Bearing.........................
...6-25
7.9 SECURITY SIREN RemovaI........................
..................................................
..7-13 InstaIIation...............................
..........................................7-13
X TABLE OF CONTENTS
11
TABLE OF CONTENTS
7.10 VOLTAGE REGULATOR DisassembIy................
..................................................
...7-14 InstaIIation..............................
...........................................7-14
AuxiIiary Lamp Housing RemovaI....................
.........7-35 AuxiIiary Lamp Housing
InstaIIation..........................7-35 Adjustm
ent FLSTC/FLSTN ModeIs...........................
......7-36
7.19TURN SIGNALS AND RUNNING LIGHTS BuIb
RepIacement BuIIet StyIe.........................
...............7-38 BuIb RepIacement FIat Lens
StyIe..................................7-38 Lamp
RepIacement.......................................
....................7-38 AII ModeIs...............
..................................................
.7-38 Front Turn SignaIs AII But FLSTC,
FLSTN...............7-39 Front Turn SignaIs
FLSTC, FLSTN..........................7-40 Rear
Turn SignaIs AII But FLSTN, FXS..................
..7-40 Rear Turn SignaIs FLS, FXS................
....................7-40 Rear Turn SignaIs
FLSTN........................................7-42
7.11 FUSES RemovaI................................
............................................7-15 I
nstaIIation.......................................
..................................7-15
7.121GNITION AND LIGHT SWITCH GeneraI.............
..................................................
..............7-16 RemovaI and InstaIIation AII
But FXS..............................7-16 RemovaI
and InstaIIation FXS.............................
............7-17
7.13 BATTERY CABLES Routing Procedure.............
...............................................7-1
8
7.20 CRANK POSITION SENSOR (CKP) GeneraI
..................................................
...........................7-44 RemovaI...........
..................................................
...............7-44 InstaIIation..................
..................................................
.....7-44
7.14 STARTER GeneraI..............................
...............................................7-2
0 RemovaI.........................................
...................................7-20 Drive
AssembIy..........................................
.......................7-20 DisassembIy...........
..................................................
7-20 Inspection...................................
...............................7-21 AssembIy......
..................................................
...........7-21 SoIenoid..........................
..................................................
7-22 Cover and PIunger RemovaI....................
.................7-22 Short