2011 Harley-Davidson
Touring Models Service
Manual
CMI- SM- 06 / 10
©2010 H-D.
ALL RIGHTS RESERVED
99483-11
Printed in the U.S.A.
VISIT THE HARLEY-DAVIDSON WEB SITE
http://www.harley-davidson.com
ABOUT THIS MANUAL
GENERAL
This Service Manual has been prepared with two purposes in
mind. First, it will acquaint the user with the construction of the
Harley-Davidson product and assist in the performance of basic
maintenance and repair. Secondly, it will introduce to the pro-
fessional Harley-Davidson Technician the latest field-test ed
and factory-approved major repair methods. We si ncerely
believe that this Service Manual will make your association
with Harley-Davidson products more pleasant and profitable.
HOW TO USE YOUR SERVICE MANUAL
Refer to the table below for the content layout of this manual.
NO. CHAPTER
1 Maintenance
2 Chassis
--· --
3 En gine
- -------
4 Fuel System
-- - - -~--
5 Drive
·-
6 Transmission
-- -
7 Electrical
A Appendix A Connector Repair
'
----- -
B Appendix B Wiring
I -
c Appendix C ABS
f
D Appendix D Conversions
I -- -- --------
E Appendix E Glossary
- ·-
Use the TABLE OF CONTENTS (which follows this FORE-
WORD) and the INDEX (at the back of this manual} to quickly
locate subjects. Chapters and topics in this manual are
sequentially numbered for easy navigation.
For example, a cross-reference shown as 2.2 SPECIFICA-
TIONS refers to chapter 2 CHASSIS, heading 2.2 SPECIFIC-
ATIONS.
For quick and easy reference, all pages contain a chapter
number followed by a page number. For example, page 3-5
refers to page 5 in Chapter 3.
A number of acronyms and abbreviations are used in this
document. See the E.1 GLOSSARY for a list of acronyms,
abbreviations and definitions.
PREPARATION FOR SERVICE
A wARNING
Stop the engine when refueling or serv1cmg t he fuel
system. Do not smoke or allow open flame or sparks near
gasoline. Gasoline is extremely flammable and hi ghly
explosive, which could result in death or serious injury.
(00002a)
Good preparation is very important for efficient service work.
A clean work area at the start of each job will allow you to
perform the repair as easily and quickly as possible, and wi ll
reduce the incidence of misplaced tools and parts. A motorcycle
that is excessively dirty should be cleaned before work starts.
Cleaning will occasionally uncover sources of trouble. Tools,
instruments and any parts needed for the job should be
gathered before work is started. In terrupting a job to locate
tools or parts is a distraction and causes needless delay.
NOTES
To avoid unnecessary disassembly, carefully read all rel-
ative service inf ormation before repair work is started.
In figure legends, th e number which follows the name of
a part in dicates the quantity necessary for one complete
assembl y.
When servicing a vehicle equipped with the Harley-Dav-
idson Smart Security System (H-DSSS), you must first
disarm the security system. Either keep the fob in close
proximity to the ve hicle, or use Digital Technician II to
disable th e security system while the ve hicle is being ser-
viced andre-e nable the system after service is completed.
SERVICE BULLETINS
In addition to the information presented in t hi s manua l, Harl ey-
Davidson Motor Company wi ll periodically issu e service bul -
letins to Harley-Davidson dealers. Service bu ll etins cover
interim engineering changes and supp lementary info rm ati on.
Consult the service bulletins to keep your product knowledge
current and com pl ete.
USE GENUINE REPLACEMENT PARTS
A wARNING
Harl ey-Davidson parts and accessories are designed for
Harl ey-Davidson motorcycles. Using non-Harley-Davidson
parts or accessories can adversely affect performance,
stability or handling, which could result in death or serious
injury. (00001 b)
To achieve satisfactory and lasting repairs, carefully fo ll ow the
service manual instructions and use only gen ui ne Harley-
Davidson re pl acement parts. Behind the emblem bearing the
words GENUINE HARLEY-DAVIDSON stand more than 100
years of design, research, manufacturi ng, testing and inspecting
experience. This is your assura nce th at the pa rts you are using
will f it right, ope ra te properly and last longer.
WARNINGS AND CAUTIONS
Statements in this manual preceded by the following words
are of special significan ce.
A wARNING
WARNING indicates a potentially hazardous situation
whic h, if not avoided, could result in death or serious
injury. (00119a)
AcAUTION
CAUTI ON indi cates a potentially hazardous situation which,
if not avoi ded, may result in minor or moderate injury.
(00139a)
NOTICE
NOTICE indicates a potentially hazardous situation which,
if not avoided, may result in property damage . (00140b)
c
0::::
0
3:
w
0::::
0
LL
NOTE
Refers to important information, and is placed in italic type. It
is recommended that you take special notice of these items.
Proper service and repair is important for the safe, reliable
operation of all mechanical products. The service procedures
recommended and described in this manual are effective
methods for performing service operations.
A wARNING
Always wear proper eye protection when using hammers,
arbor or hydraulic presses, gear pullers, spring com-
pressors, slide hammers and similar tools. Flying parts
could result in death or serious injury. (00496b)
Some of these service operations require the use of tools
specially designed for the purpose. These special tools should
be used when and as recommended . It is important to note
that some warnings against the use of specific service methods,
which could damage the motorcycle or render it unsafe, a~e
stated in this manual. However, remember that these warnings
are not all-inclusive. Inadequate safety precautions could result
in death or serious injury.
Since Harley-Davidson could not possibly know, evaluate or
advise the service trade of all possible ways in which service
might be performed , or of the possible hazardous con-
sequences of each method, we have not undertaken any such
broad evaluation. Accordingly, anyone who uses a service
procedure or tool which is not recommended by Harley-Dav-
idson must first thoroughly satisfy himself that neither his nor
the operator's safety will be jeopardized as a result. Failure to
do so could result in death or serious injury.
PRODUCT REFERENCES
A wARNING
Read and follow warnings and directions on all products.
Failure to follow warnings and directions can result in
death or serious injury. (00470b)
When reference is made in this manual to a specific brand
name product, tool or instrument, an equivalent product, tool
or instrument may be substituted.
Kent-Moore Products
All tools mentioned in this manual with an "HD", "J" or "B"
preface must be ordered through SPX Kent-Moore. For ordering
II FOREWORD
information or product returns, warranty or otherwise, visit
www.spx.com.
Loctite Sealing and Thread locking Products
Some procedures in this manual call for the use of Loctite
products. If you have any questions regarding Loctite product
usage or retailer/wholesaler locations, please contact Loctite
Corp. at www.loctite.com.
PRODUCT REGISTERED MARKS
Apple, Alcantara S.p.A., Allen , Amp Multilock, Bluetooth,
Brembo, Delphi, Deutsch, Dunlop, Dynojet, Fluke, G.E.
Versilube, Garmin, Gunk, Hydroseal, Hylomar, iPhone, iPod,
Kevlar, Lexan, Loctite, Lubriplate, Keps, K&N , Magnaflux,
Marson Thread-Setter Tool Kit, MAXI fuse, Molex, Michelin,
MPZ, Mulitilock, nano , NGK, Novus, Packard , Pirelli , Permatex,
Philips, PJ1 , Pozidriv, Robinair, S1 00, Sems, Snap-on, Teflon ,
Threadlocker, Torca, Torco, TORX, Tufoil, Tyco, Ultratorch,
Velcro, X-Acto, XM Satellite Radio, and zOmo are among the
trademarks of their respective owners.
H-D MICHIGAN, INC. TRADEMARK
INFORMATION
Harley, Harley-Davidson, H-D, Bar & Shield, Cross Bones,
Digital Tech, Digital Technician , Digital Technician II , Dyna ,
Electra Glide , Evolution , Fat Bob , Fat Boy, Glaze , Gloss , H-D ,
H-Dnet.com, HD , Harley, Harley-Davidson, Heritage Softail,
Low Rider, Night Rod , Nightster, Night Train, Profile, Revolu-
tion , Road Glide, Road King , Road Tech , Rocker, Softail,
Sportster, Street Glide, Street Rod, Sun Ray, Sunwash, Tech
Link, Twin Cam 88, Twin Cam 88B, Twin Cam 96, Twin Cam
96B, Twin Cam 103, Twin Cam 103B, Twin Cam 110, Twin
Cam 11 OB , Tour-Pak, Screamin' Eagle, Softail, Super Glide,
SYN3, Ultra Classic, V-Rod, VRSC and Harley-Davidson
Genuine Motor Parts and Genuine Motor Accessories are
among the trademarks of H-D Michigan, Inc.
CONTENTS
All photographs, illustrations and procedures may not neces-
sarily depict the most current model or component, but are
based on the latest production information available at the time
of publication .
Since product improvement is our continual goal, Harley-Dav-
idson reserves the right to change specifications, equipment
or designs at any time without notice and without incurring
obligation.
MAINTENANCE
1.1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter .... ..... ........ 1-1
1.2 GENERAL
Servicing a New Motorcycle .... ....... .......... ... .. .. ... ........ ...... .1-3
Safe Operating Maintenance . ... ............ ... ... . .. ...... ........ .......1-3
Shop Practices . .. ....... ........ .. .. ... .... ....... .... ..... .. ... . .. ....... ... ..... 1-3
Repair Notes ... ... .......... .. ..... .... ..... .. ......... ... .................. 1-3
Safety ............ ....................................... ..... .......... 1-3
Removing Parts ................................... .... ...... .... ... . ... ...1-3
Cleaning ............ ...... ... ... ........... ... .. ...... ... .. ................ .. . 1-3
Di sassembly and Assembly .. ....... .......... . .. .................. 1-4
Checking Torques on Fasteners ...... .. ...... .. . .. .... .... .... ... 1-4
Magnetic Parts Trays ......................................... ... .... ...1-4
Repair and Replacement Procedures ........... ........ ...... ....... 1-4
Hardware an d Threaded Parts ..... ..... ..... . .. .. ... .. . .. ....... .1-4
Threadlocking Agen ts ...... .. ......... ...... ..... . .. ... ... ... .......... 1-4
Wiring, Hoses and Lines. .. ... ......... .. .................. 1-4
In struments and Gauges .... ...... .. ... .. ..... .. ...... ........ .... ... 1-4
Bearings ..................................... ... .......... .. ... .. ..... . .. ..... 1-4
Bushings ........... ...... ........ ...... ..... . ... ......... ... ..... .. ........ ... 1-4
Gaskets ..... . .................................... .... ............... 1-4
Lip-Type Seals ........ ........... ......... ....... ........ .......... ... .....1-4
0-Rings (Pre-Fo rm ed Packings) ... ....... ....... ..... .... ....... 1-4
Gears .......... ................................... ... .. . .. ... .. .. ... ............ 1-5
Shafts ................................................ ... .............. ......... 1-5
Part Replacement. .... ... ... ............... ....... ........ ... .. .......... 1-5
Exhaust System Leakage ... ..... .. .... .... .......... .... ... ......... 1-5
Cleaning ... ..... ..... ................. ........... ....... ............ .... ..... ...... .. .1-5
Part Protection ... ....... .. ....... ... ......... ......... . .. ..... .... . ... ..... 1-5
Cleaning Process .......................... ...... .. .. ... .. ... ... .. ....... 1-5
Rust or Corrosion Removal. .... ...... .... ... ..... ................ ..1-5
Bearings .................................................................. ....1-5
Tool Safety ............... ... ...... ..... ..... ............................ .. .. ...... .. 1-5
Air Tools ...... .......................... ......... .......... ........... ......... 1-5
Wrenches ......... . ... ...................... . .. .. .......... .. ... ............1-5
Pliers/Cutters/Pry Bars ........ .. ..... ... ..... .... .... .. ...... ......... 1-5
Hammers ..... ...... ....... ...... ... .. ...... . ... .............. .. .. .. ........ ..1-5
Punches/Chisels ........... ........ ..... . ... .... ..... ... .................. 1-6
Screwdrivers ..... ...... ... ............... ... ...... ........ ... ... ............1-6
Ratchets and Handles .................. ............... .............. .. 1-6
Sockets .. ..... ...... .. .. .... ..... ........... ...... .. ... .. ... .. ... ......... .. .. .1-6
Storage Units ......................................... .. .... ...... ......... 1-6
1.3 FUEL AND OI L
Fuel. ................................................................. .. ...... .... ... .. 1-7
Gasoline Blends .......... .... ... ... ... ... .. .... ... ..... .. ... ... .. ...... ....... ... 1-7
Engine Lubrication ..... ........ ................... ......... .... .... ............ 1-7
Winter Lubrication ... ........... .................. ........ ...... ..... .... ...... .1-8
1.4 BULB REQUIREMENTS
General ..... ...... ..... .......... ............ .. .. ... ........... .. ............ 1-9
1.5 MAINTENANCE SCHEDULE
General. ................ ......... .................... ..... . .. .... .... ... . ... ...... 1-11
1.6 ENGINE OIL AND FILTER
Checking Oil Level. ............................ ........ ..... ... ............ 1-15
Oil Level Cold Check ................ ... ... ........ ... .... ........ .. .. 1- 15
Oil Level Hot Check ..... ............. .... .......... . ... .. ..... ........ 1- 15
Changing Oil and Oil Filter ................................. .. .. . .. ...... 1- 15
1.7 AIR CLEANER AND EXHAUST SYSTEM
Removal ............... ... ...... . .. ................. ... .. ...... ... .................. 1- 17
Installation ........ .. ............................................ ... ..... ...... . ... .1-17
Exhaust System Leak Check ......................... .. .... ............. 1- 17
1.8 TIRES AND WHEELS
General ...... ... .. ... ... .......... .... .. .. ................. ................ ......... 1-19
Tires ........... .. ... ...... ................ .......... ...... ... ............... .......... 1-19
Tire Replacement ...................... ........ .. ...... .. ..... ........... .... .1-19
Inspection .. ...... ... ........................... .. ... . ... .. .. .. .......... ...1-19
When To Replace Tires ......... .. ....... .. .. .. ..................... 1-19
Wheel Bearings .... ......... . ... ...... ..... ... ... ........ ... . ... ... .... ...... ..1-20
Wheel Spokes ... .... ...... ................. ............ .. .. ..... ... . ... .... ..... 1-20
Identify Wheel Spoke Groups .................................... 1-20
Wheel Spoke Adjustment. .... . .. ..... ..... .. .... ........ ..........1-20
1.9 PRIMARY CHAINCASE LUBRICANT
General .... .. .. ... .... .. ... ... ... ..... ... .. .. ...... ... . ... . .. ............ .. .. ... ....1-22
Changing Primary Chaincase Lubricant.. .......... ..... .. ... .... .1-22
1.10 TRANSMISSION LUBRICANT
Transmission Lubrication .. ...... .. ... ................................... .. 1-24
General . ......... .... ........................ ... .. ... .. .. .... ...... ........ ..1-24
Check Lubricant Level. ...... ........... ..... ..... .. .. ...... ... ...... 1-24
Changing Transmission Fluid .... ....... .... ............. ........ 1-24
1.11 CLUTCH
(/)
Adjustment... ........ .. . .. .................. .. ............ .. ..................... 1-26 1-
Z
w
1-
1.12 DRIVE BELT AND SPROCKETS
General......... .. ..... ... ... .. ......... .. .. .......... ............ . ... 1-28 z
Cleaning ...... .. .. .. .................................. ... .... .... ............ ....... 1-28 0
Inspection ..... .... ........... .. ..................... .... ... ........ .. ............. 1-28 U
Sprockets .. .. .... .. .... ..... ..... ...... .. ........... .. ...................... 1-28 LL
Drive Belt. . ... ... .. .. . ... .. .... ...... .. .... ...... ......... ... ..... .......... 1-28 O
Checking Drive Belt Deflection ................................ .. ...... .1-29
Setti ng Belt Deflection .................. ... ................................. 1-30 W
Adjustment. ..... .. ....... ............. .. ... .... ..... ........ .. ... . .. ....... 1-30 ~
1
.
1
;s~e~:Y ~~ ·~·~~~~·~ · ~·~·~~~-~~~ . ... .. .. ...... 1-32 ~
ISOLATOR
Inspect ion ................................................... .. ........ .. ........ .1-33
1.14 CABLE AND CHASSIS LUBRICATION
General. ...... ........ ...... ... .. .. . .. . ... ............ ... .. ... ... ................... 1-34
Steering Head Bearings .................. .. .............. .. .. ......... ..... 1-34
Ji ffy Stand ... ..................... .... .... ... .. .. ........ .. ... ..... .. .... ... ...... . 1-34
Miscellaneous Lubrication ...... ........ ........ ...... .. ..... ....... .. .... 1-34
Hinges, Latches, Etc ..... ......... ...... .... .. .......... .. ... ..... .... 1-34
1.15 BRAKES
Fluid Inspection .................. .. .. .... .... .... .. ............. .. .. ............ 1-35
1.16 BRAKE PADS AND DISCS
Inspection ....................................... .. ................................1-36
Brake Pads ........... .. ................................ .. .............. ... 1-36
Brake Disc Thickness ................................ ... ............. 1-36
Brake Disc Lateral Runout ............... ........ ...... .... ... .... 1-36
Brake Pa d Replacement.. ................. .. ..... ..... ......... .... ....... 1-36
Rear Brake Caliper .......... ........ .... .. ........ ......... .. ..... .... 1-36
Front Brake Calipers ................... ........... .. .... .... .......... 1-38
Ill
TABLE OF CONTENTS
1.17 SPARK PLUGS
Inspection ............................. ... ........... ...... ... ... ........ ........ ..1-40
Spark Plug Cable lnspection .... ...... .... ....... .. .. .. .. ....... ........ 1-40
1.18 FRONT FORK OIL
Replacing Fork Oil .......................................... .. .. .............. 1-42
1.19 SUSPENSION ADJUSTMENTS
General ........................................... ... ................. .... .... .. ....1-43
1.20 STEERING HEAD BEARINGS
Lubrication ........................................................................ 1-45
Checking .. ... .. ......... ..... .. .. ............. .. ...... . .. .. ...... .. .............. ..1-45
Adjustment. ......... ...... .... ...... .... .... ...... ..... ................ .. .. ....... 1-46
1.21 HEADLAMP ALIGNMENT
Headlamp Alignment. .... ... .... ................................. .. ........ .1-47
Headlamp Adjustment: Single Headlamp Models ............ 1-47
Headlamp Adjustment: Dual Headlamp Models ............... 1-48
Auxiliary Lamp Alignment. .... .. .. ...... ...... ....... .... .. ............... 1-48
1.22 CRITICAL FASTENERS
Inspection .......... .... ... ... ..... .. .. .... . ... ...... .... .......................... 1-50
Checking Torques on Fasteners .. ...... ...... ... .. ............. 1-50
1.23 BATTERY MAINTENANCE
General. ....... ....... ....... ............. .......... ..... ...... .. ... ... ..... . ... . .. . 1-52
Cleaning and lnspection .. ................................ .. ..... ....... ...1-53
Battery ... ...... .. ...... ...... . .. . .. ...... .. ............. .. .. ..... ....... .. .... .... .. 1-53
Disconnection and Removal ......... ... .......... .. ...... ..... ... 1-53
Installation and Connection .......................... ... ........ .. 1-53
Voltmeter Test. . .. ...... .... ................... .... .... .. ...... ... ... ..... . ... . .. 1-54
Voltmeter Test ... ... .... .............................................. .. .. 1-54
Charging Battery ........................ .. ...................... .. ...... ....... 1-54
Safety Precautions ... .. .. ....... ..... .. .. ........... ... ...... .. .. .....1-54
Using a Battery Charger .......... . .. ............................... 1-54
Storage .... ............ ............ .... ............... ..... ......... . ... . ... .. ..... .1-55
1.24 ENGINE MOUNTS
Inspection ... ............... . .. .. .... ...... ... ... ......... ... ........ ......... ... .. 1-57
General. .......... ... ... ........... ... ...... ... .. ..... ........ ......... ... ...1-57
Stabilizer Link ... ............................... .. ........................ 1-57
Front Engine Mount .......................................... .. ....... 1-57
Rear Frame Fasteners ....... .. ................... .. ...... .. .... .. .. 1-57
1.25 STORAGE
General .. . ... ......... ........... .......... ........ ......... ... .... ... .............. 1-58
Placing in Storage ... ...... ......... . ... ...... ..... .. .......................... 1-58
Removal from Storage ................................ .. .. .................. 1-58
1.26 TROUBLESHOOTING
General .... ................ .. ... .......... ......... ... .... .......... ... ... ..... . .. .. 1-60
Engine ...... .. ............. .... .... .... .. .. . ... . ... . ... .......... .. ... . ... ...... ..... 1-60
Starter Motor Does Not Operate or Does Not Turn Engine
Over ......................................... ...... ...... ...... .. ....... . ... .. 1-60
Engine Turns Over But Does Not Start ................... .1-60
Starts Hard ................. .. .... .. ........................... .. .. .. ...... 1-60
Starts But Runs Irregularly or Misses .......... .. ........... 1-60
A Spark Plug Fouls Repeatedly ................................ 1-61
Pre-Ignition or Detonation (Knocks or Pings) ............ 1-61
IV TABLE OF CONTENTS
Overheating ......... ..... .. ... .. .. .. ..... .. .. .. ..... .... .................. 1-61
Valve Train Noise .............. .. .. ....... ........ ........ ..... ......... 1-61
Excessive Vibration ........... .. ..... .. .................... ........... 1-61
Check Engine Light Illuminates During Operation .. ... 1-61
Lubrication System ................... .. ...................................... 1-61
Oil Does Not Return To Oil Reservoir ........................ 1-61
Engine Uses Too Much Oil Or Smokes Excessively .. 1-61
Engine Leaks Oil From Cases, Push Rods, Hoses,
Etc ... ................... ... ........ ....... ..... ............ ....... .... ......... 1-61
Low Oil Pressure ...... ...... ...... ...... .. .. ...... ............ .. .. .... .1-62
High Oil Pressure ......................................................1-62
Electrical System ... ......... ..... ... . .. ... .. ... . ... ........ ...... .. ........... 1-62
Alternator Does Not Charge ...................................... 1-62
Alternator Charge Rate Is Below Normal .................. 1-62
Speedometer Operates Erratically ............................ 1-62
Transmission ..................................................... .. ... . ... ...... 1-62
Shifts Hard .... .... ........... ... .... .. ... .. .. ......... ....... ..... ... ...... 1-62
Jumps Out Of Gear ................................................... 1-62
Clutch Slips ................................................................ 1-62
Clutch Drags Or Does Not Release ........ .. ................ 1-62
Clutch Chatters .. ..... ....... ... .. ... ........ .... .... ......... ......... ..1-62
Handling ....... ........ .......... .......... ....... ...... .. .. .. .... ..... .. ... ........ 1-62
Irregularities ............ ........ . .. ...... .......... ................ .. ... .. .1-62
Brakes ................................ ..... ..... ... ..... ... . .. ... .... ... . ... .... .. .. .1-63
Brake Does Not Hold Normally ................................. 1-63
CHASSIS
2.1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter .............................. 2-1
2.2 SPECIFICATIONS
Specifications .......................................... ..... . ... .. .. .. ......... ... .2-6
Chassis Specifications ......... ..... ...... .......... ....... .. ......... 2-6
Tire Specifications ..................................... .. ................ 2-7
2.3 VEHICLE IDENTIFICATION NUMBER
(V.I.N .)
Vehicle Identification Number: Touring Models ...... ..... ........ 2-9
2.4 FRONT WHEEL
Removal. ............ .. ... .............. ......... ........ ...... . .. ... .. ....... .. .. .. 2-11
Cleaning and Inspection ...................................................2-12
Installation .................. ......... .......... ...... . ... ..... .... ... ... ... .. ... .. .2-12
2.5 REAR WHEEL
Removal. .... .......................... ........... .. .. .. ............. ........ ...... .2-14
Cleaning and Inspection ................................................ .. . 2-15
Installation ...... .. ... ..... .... ......... ... .. ... .... ... ........... . ... .... ....... ...2-15
2.6 REAR WHEEL COMPENSATOR
Isolator Replacement. .......... ...... .............. .... .... ................ .2-18
Removal ... ................. ........ .. ............ . .. ................ . .. ....2-18
Installation ................................ ..... . .. .... .. ............. .. .... 2-18
Sprocket Bearing Replacement. ........ ....... .. .......... ..... ....... 2-18
Removal ... . .. . ... . ... .......... .... .. . ... .......... ....... ... .......... . .. .2-18
Installation ...... .... ........ ........ ..... .......... ..... ........ ...... . ... .2-18
2.7 WHEEL LACING: FRONT RIM
Wheel Lacing: Angle Flange Hub . .. ..... ...... .... ....... ............ 2-20
TABLE OF CONTENTS
2.8 WHEEL LACING: 16 INCH REAR RIM 2.15 REAR BRAKE CA LI PER
Wheel Lacing: 16 ln. Rear Wheel ...... ....... ............. ... ...... 2-22 Removal ....... ... .... .. .. ... ..... .. ..... ... .... ... ..... .... ...... ........... ... ...2-48
Installation ............. ... .. ........ ... ................. ........ .... ........ .. ... . 2-48
2.9 CHECKING AND TRUING WHEELS
General ..... .. ............. .. ........ ... . .. .. ..... . ... ..... .......... .. .......... .. .2-25
2.16 BLEEDING BRAKES
Checking Wheel Run out. .... .. .... ....... . ... ... .. .... ....... .. ...... ..... 2-25 General ...... ..... ...... ........ ...... ... ... .......... ... ... ....... ... .. . .. . .. ..... .2-49
Checking Lateral Runout. ..................... .. ....... ... .. .. ..... 2-25 Procedure ...... .......................... ... ................ .. ..... ....... . ... ..2-49
Checking Radial Runout. .......... .... ...... ... ..... .. ............. 2-25
Laced Wheel Rim Offset. .............................. .. ..... ............. 2-25
2.17 FRONT FORK
Truing Laced Wheels ... ...... .. .. ........... ... ..........................2-27
Changing Fork Oil ........ ................... ............ ............. ... ..... .2-51
Radial Runout. ................................... ............... .. ..... . 2-27
Draining .. ... .... ....... ...... . .. .. ........................... .............. .2-51
Lateral Runout. ..... ........ .. ....... .... ............. . .......... ..... .2-28
Filling ... .. ..... .. .... .. .. .... .. ... ....... ......... ....... ... .. .... ... ... ......2-51
2.10 SEALED WHEEL BEARINGS
Removal. ... ......... ... . ... ............ ...... ....... ...... .... ..... ............ ....2-52
Disassembly ................. ........ .... ... .. ..... ........ .......... ........... .2-52
Inspection .... .... ....... .............................. .. ........... .. ... .. .. ... .2-29 Cleaning and lnspection ..... .. ... .... .... .. .. .... .... ........ ............. 2-54
Removal. .... .... .... .................... ... ... .. ...... .. .... ..... ..... ... . .. .... ... 2-29 Assembly ... ........ ............ . .. ........ .... ................... . .. ..... .. .......2-55
Installation ..................... .. .. .... ... .................. ..... .. ... .... ....... .2-30 Installation .. . .. .. .. ....................... . ... ...... ... .... ....... ... .... .... ... .2-55
2.11 TIRES 2.18 STEERING HEAD BEARINGS
General .. ....... ...... ....... .. ..... .... .. ..... .. .. .. .. .... .... ..................... 2-32 Remova l. . ... . ... ... ... .. ... ........ .. .. .......... .. .. ... ......... ..... ...... ...... .2-57
Removal. .. ... .... ........................ ...... .. . ... ...... ....... ... ........ ..... 2-32 Inspection ....... .. ...... .... .. .... ................ ........ ...... ....... .......... .2-58
Cleaning, Inspection and Repair ........... .... ..... ..... ............. 2-32 In stallation ... ... .. ........... ... ............................... ....... ..... ..... .. .2-59
Installation .......................................................... ... .. ...... .... 2-33
Tube Type Ti res ............................ .. . ... ....................... 2-33
2.19 REAR AIR SUSPENSION
Tubeless Tires ...... .. .. ........... ........................... .. ... . .. ... 2-33
Check for Air Leaks ... ....... ......... ... . ... .... ............. .. .. ... .......2-60
Checking Tire Runout ........ ... .. ... . .. . ... ..... .. .......... ... ..... . ... ..2-34
Compression Fitting ............................. .. ..... ..... ... ... .... 2-60
Lateral Runout. ................ ... ...... ......... ..... ... .. .. ...... .. ... .2-34
Air Valve Assembly .. .. ............. ................ ... ... ..... ....... .2-60
Radial Runout. .... ... ......... ... ... ....... . .. .......................... .2-34
Air Tubes ..... ..... ........... .............. ..... ... ................ ..... .. .2-60
Wheel Balancing ........ .. .... ...... ... .... ........ ... .... ... .......... ...... ..2-35
Weights .......... ..... ........................ .. ...... ... ........ .......... ..2-35 2.20 REAR SHOCK ABSORBERS
2.12 FRONT BRAKE MASTER CYLINDER
Removal. ...... ............... .... .. ..... ... ............ .. .. ........... ... ..... ... .2-62
Cleaning and Inspection ......................... .. . ... .... .... ... ........ .2-62
General .......... .... ..... ...................... .. ...... ... ..... ..... .... .. .... .. .. .2-36
Disassembly and Assembly ...... ........ ......... ... ....... .. .. .. ...... .2-62
Removal and Disassembly ....... ...... ... ... ....... ... .............. ... .2-36
In stallation ........ ..... ..... ....... ..... ... ... ...... .... .... .............. .. ...... 2-62
Removal ..... ............... .......... .. .. ......... .... ........ ... ... .. .. .. .2-36
Disassembly ... .. ..... .... . .. . ... ....... ... . .. ..... .. . ... ...... ... ... .... .2-36 2.21 REAR FORK
Cleaning and Inspection ....... ...... ..... ... .............. .. ............. . 2-38
Assembly and lnstallation .......................... .. .......... ... ..... ... 2-38
Assembly .. ... ... ... ............... .. ...... .. ........... .... ...... .... ... . .. 2-38
lnstallation ..... ..... ............ .... ... ........... .. .... ...... .......... ...2-38
Front Brake Line: Non-ABS Equipped .... ...... ... .... ....... ... ... 2-38
Removal .... .. .......... ......... . ... ........ ... .. ....................... ...2-38
Installation ........ ...... ..... ... .......................... ......... .... ... 2-39
Removal ....... .. . ... ...... ..... .. ..... .... .. .. .. ..... ............ ........ ......... .2-63
Disassembly and Assembly ................ ...... ... ........ .. .... .... ... 2-63
Bearing Removal ... .... ....................................... ....... .. 2-63
Bearing In stallation ... .......... ..... .... ... .. ... ........... .. ........ .2-64
Pivot Shaft/Mount Disassembly . .. .. ... ...... ... .... .. ... ... .... 2-64
Installation ..... ... ....... ...... ..... ...... ... ....... ....... .... .. .... .. .. ......... .2-65
2.13 FRONT BRAKE CALIPER
2.22 CLUTCH CABLE
Removal. .............. ...... ........... ............................ .. ... .. ....... .2-41
Installation .............. .... ......... .. ........ ........ ........ .... ... ............ .2-41
Removal .......... .............................. .... ..... ....... ... . .. ...... ... .. .. .2-66
Installation .. ... .. . .. ..................... ... ......................... .. .. ........ .2-66
2.14 REAR BRAKE MASTER CYLINDER
2.23 HANDLEBARS
General . ......... ..... ..................................... .. ... ....... .. ....... ...2-42
Removal and Disassembly ...... ...................................... ... 2-42
Removal ........ ....... .. ........................ .... ... ........ ... ........ .2-42
Disassembly .... .... .... ... ... .. .. ............ ............................2-43
Cleaning and Inspection........................ .. ..... .. ......... 2-44
Assembly and Installation ...................... .... ... ...... ...... ... . ... .2-45
Assembly ....... ... ..... ..... ... ...... .. ........ ... ... .... ..... .... ..2-45
lnstallation ..... .................... .. .. .... .......... ................... ...2-45
Rear Brake Line: Non-ABS Equipped ........ ...... ................ 2-45
Removal ... . ... ...... ..... .... . .. .. .. ........ ... .2-45
lnstallation ....... .. ......... . ... .. .. .... .. .... .... ... . .. ........ ...... .. .. .2-46
Adjustment. ..... .. ....... ......... . .. ... ............................. .. ...... .... .2-69
Removal. .......... ... .............. .... ..... .................. ....... ... ... .. .... .. 2-69
Installation ........ ........ ....... .......... ....... ... ... ........ .. ... ...... ...... ..2-70
Left Handgrip ............. ......... ... .... .... ... ..... ...... .. .................. .2-71
Removal .. ... ... .... ..... .. .... .. ..... .. .............. .. ... .. .. .. .... ..... ..2-71
Installation .................. ........ .. ... ... ....... ... .. .. ...... ..... ...... 2-71
Heated Handgrips ....... ..... .. .. ... ..... .. ... ......... ...... . ... ........... . .2-71
Remove Left Handgrip ....... . .. ...... ..... .. .. ... ... .. ....... .... .. 2-71
In stall Left Handgrip ......... ... .. ............... ...... ... ....... .. .. .. 2-72
Remove Right Handgrip ...... ... .. .. ... .. .. .. ........ .............. 2-72
In sta ll Right Handgrip ...... ....... ... ...... . ... ... ...... ...... ...... .2-72
Rubber Mounts ......... ................. ....... ... ... .. ........... ..... .. ..... .2-72
TABLE OF CONTENTS V
Removal ............................................. ...... ................. 2-72
In stallation . ... .... .... ...... ..... .... .... ....... ............. ........... ...2-73
2.24 MIRRORS
All Models Except FLHX ..... ... ........ ...... ....... ... ... ... ... .......... 2-74
Removal . .. ... ... . ... ....... .. . .. ..... ... ..... ............. .... ... ..........2-74
Installation ............ ... ......... ................ ........ . .. ............. .2-7 4
FLH X ... . .. .......................... .. ........ ...... ...... ... ... ... ........... ...... .2-74
Remova1 ................. .. ... .. .. ......... .... .... .... . .. ... .. . .. ......... . 2-74
Installation ..... .... ... ........ ..................... .. ... ... . .. ..... ........ 2-7 4
2.25 SEAT
Seat: Models without Tour-Pak ........... ... ... ... ......... ......... ... 2-75
Removal .. ................................................ .. ...... .. .... .... 2-75
Installation ............. .......... ............... ... .. ...... .... ... .. .. .. . .. 2-75
Seat: Models with Tour-Pak .... .......... .. .. .......... .. ...... ...... .... 2-75
Remova1 ....... ...... ...... .. ..... ... .. ..................................... 2-75
lnstallation ....... ..... .... .. ........ .... ... ... .. ...... ........ ..... ....... .2-76
Seat: Road King Models ....... ..... ...... .. .. .. .... ..... ... ... ....... ..... 2-76
Removal ............................. ..... ... ....... ... ...... ... ...... ......2-76
lnstallation ........ .............. .............. .. ..... . .. ..... ...... ....... .2-76
Seat Retention Nut Replacement... ...... ........ ........ ..... ....... 2-76
Seat Bumper ................ .... .. ..... .............. ... .. ..... ...... ..... .... ... 2-77
2.26 SADDLEBAGS
Removal. .. ... ..... .. ...... ... ... .. .. ....... ...................... ... .... ... ........ 2-78
lnstallation .......... ............................................ .... ... .......... .. 2-78
2.27 SADDLEBAG SERVICE
Saddlebag Hardware ..... .. .. ........................................... ... .2-79
Removal ....................................... .. . .. ... .. ................ ...2-79
lnsta llation .... .... ....... ... ...... ... . ... . .. ....... .......... ............. .2-80
Saddlebag Guard/Support Rail ..... ........ ... ... ..... ....... ... ...... . 2-80
Removal .... ....... ... ............... .. ......... .......... .. ... ....... .. .... 2-80
Installation .................... ......... .................... ................ 2-80
2.28 TOUR-PAK
Removal/lnstallation ..... ....... ...... .. ............. ... .... ...... .. ........ .2-82
Removal ..... .... .......... .. ....................... ....................... .2-82
Installation ......... .. ...... ...... ...... ... ... ........... ... .. ... .......... .2 -82
Adjustment. ........ ................. ........ ...... . ... ... ... ..................... .2-83
Luggage Ra ck/Tour-Pak Support ....... ................. ......... . ... 2-83
Removal .. .... ... ..... ... ................................ .. ....... ....... ...2-83
Assembly and Installation ...... .. .... ........ . .. ........ .. ......... 2-83
2.29 TOUR-PAK SERVICE
Lockset . .............................. .... .. ... ...... .. .. .... .. ....... .. . ... ...... . .2 -84
Removal ... .............. ............... ... ..................... .. .... .... .. 2-84
Installation .... ......... .. ......... ......... ............ ..... ...... ........ .2-84
Hinges ................... .. .. .. ... .. .. ..... ............ .. .......... .. .... ........... .2-84
Removal .. ...... .................... ......................... ...... ........ .2-84
lnstallation .... ...................... .. ........ .. ...... .... .. ...... ...... . .. 2-84
Latches/Lockset Catch ... .. .... ................... ... ......... ..... .. ... ... 2-85
Removal ...... .... ... ... ..... ........ ... ................................... .2-85
lnstallation ... ... ..... ... . .. ............ .. ... ................. ......... .....2-85
Catches .. .......... ... .... ... .. ................... ....... .. ..................... ... .2-85
Removal .. ..... .. ... ........ ............ ........... ..... .......... ........ ..2-85
lnstallation ... .. ....... ... .. . ... ............................................2-85
Tether ........... ....... ..... .. .. ..................... .. ..... .. .. ..... . .. ............. 2-85
Removal ... ....... .............................. ........................... .2-85
lnstallation .. .................... ... ....... ........ .. ...... .. ... ........... .2-85
VI TABLE OF CONTENTS
Tether Brackets .. .... ...... ... ... ... ..... .. ..... .. ..... ... ... ... .. .... ...... ... .2-86
Removing Tether Bracket from Tour-Pak ........ .. ........ 2-86
Removing Tether Bracket from Tour-Pak Lid .... ... . ... .. 2-86
Installing Tether Bracket on Tour-Pak Lid .................. 2-86
Installing Tether Bracket on Tour-Pak .... ...... ..... .... .... . 2-86
Luggage Rack ......... ..... ... .................................................. 2-86
2.30 TOUR-PAK LIGHTS
General .... ................................................ . ... . .. .... .. .... .. ..... .2-87
Side Marker Lights (if equipped)..... .... ...... ............. ....... .... 2-87
Removal ................................................... .. .... .. ........ .2-87
lnstallation .......... ........ ...... .. ...................... ..... ... .... ... ..2-87
Tour-Pak Lights Harness .............. ..... ......... ......... ....... ...... 2-87
Removal .............. ........ ..... ...... .. ................ ....... ..... .... .2-87
lnstallation ...... ...... ..... ... .... .. ..... .. ..... .. ........... ..... .. ....... 2-87
Wrap-Around Lights (if equipped) ................... ...... .. .......... 2-88
Bulb Replacement.. ..... .... .. ....... .... ......... ...... ..... ..... .... 2-88
Removal .... .......... ..... .............. ........ . .. ..... ..... ..... ........ .2-88
lnstallation .. . ... ... ... ..... ... . ... ... ...... .... ... ........ ....... ... .. . .. ..2-89
2.31 TOUR-PAK BACKREST
Passenger Backrest. ............. .... ........... .... ......... ................ 2-90
Removal ................... .. ... .. .. . ... ...... ..... ... ..... .. ..... .. .... ... . 2-90
lnstallation .. ... ... ...... .... ... ....... .......... .... ..... .... ... .. ....... .. 2-90
Rubber Isolators ...................... ................................ ......... 2-90
Remo val ....... ....... ........... ... ................... .... ... ....... ....... 2-90
lnstallation .. .......... ...... ............................. ..... ..... .. ...... 2-90
Passenger Backrest Flap .. .......... ........ ... .... .. ... .. .. ... .. ...... ... 2-91
Removal ... ... ...... ............ .. .. .... .... .. ..... ... ........ ... .. ..... ... .2-91
Installation ......................... . .. ...... ... . ... ......... .... .... ... .. ..2-91
2.32 TOUR-PAK SPEAKER BOX
Speaker Box ...... ........... ........... .. ... .. ..... .... ... .... ... ...... ........ . 2-92
Removal .................................................................... 2-92
Installation ...................... ....... .. ......... ... .. ... .... .......... .. . 2-92
2.33 LOWER FAIRING AND ENGINE GUARD
Lower Fairing ...... .......... ........ .............. ............ ...... ......... ...2-93
Removal .... ... .. ... ..... .. ..... .. .. ... ... ...... .... ... ... .. .... .. ..... ..... 2-93
Di sassembly ............................................................. .2-93
Assembly ...... ...... ........ .......................................... .. ...2-94
lnstallation .................... ........... ........ ... ..... ... .. ..... ...... ..2-94
Serrated Washer Replacement. ......................... .. ..... .. ..... 2-94
Removal .......... ...... ....................................................2-94
lnstallation . .. ................. .. .... .. .. ... .... . .. ............. .. ... .... ... 2-94
Engine Guard ............ ........................... ........ ........ ...... ....... 2-94
Removal .... .. ..... .... . .. .... ... ... .. .... .. .. ..... .. .... ............ ....... 2-94
Installation .. ...... ...... .. .... ........... ................................. .2-94
2.34 UPPER FAIRING AND WINDSHIELD:
FORK MOUNTED FAIRING MODELS
Outer Fairing and Windshield ...... .... ... ....... ... ....... ............. 2-96
Removal ............ .......... ....... .............. .. ....................... 2-96
lnstallation .. ......... .. .... ......... ..... ........ ... .............. ... ......2-96
2.35 FAIRING CAP: FORK MOUNTED
FAIRING MODELS
Fairing Cap ..... ..... .. .... ................................. .. ..... .. .... ........ .2-97
Removal ...................... ........................... . .. .... ............ 2-97
lnstallation ... ... .... ...... .. .. ........... ............ ... ..... .... .. ........ 2-97
2.36 INNER FAIRING: FORK MOUNTED
FAIRING MODELS
Removal. .. ............... ....... . ... .......... ............ ... ......... .......... .. .2-98
Installation ................... ....... .................. ................ .......... .2-1 00
2.37 AIR DEFLECTORS
Air Deflectors ..... .. ... .. ................ ...... ....... .... . .. ..... .. ... .. .... . 2-1 02
Removal ..... ...... .. ..... ...... ..... .. ... ....... ................ ........ .2-1 02
Installation .. ............... . ... ...... ... ......... .... ................ ... . 2-1 02
Mid-Frame Air Deflectors ......... .. .................. .......... .. . .. .... 2-102
Removal ...... .............................................. ......... .. .2-1 02
Installation . ... ...... ....... ........ .......... .......... ... .. ....... ..... 2-1 02
2.38 UPPER FAIRING AND W IN DSHIELD:
FRAME MOUNTED FAIRING MODELS
Windshield ... ........ .. ....... ... .................. .... .. ..... ...... . ... ....... .2 -103
Removal ....................... .... ..... ... ........ .... ... .. . .. ....... ....2-103
Installation ......... ......... ... ........ .. . .. ........ .. ........ ... ..... . .. 2-1 03
Outer Fairing ........... ....................................... ............... .. 2-1 03
Removal . ... ....... .. ... .. .. ... .... ....... .... .. .. ... ..... .... ... ...... ...2-103
Installation ....... .. .... ... .................... ........ ..... .. ........... 2-1 04
2.39 INSTRUMENT BEZEL: FRAME
MOUNTED FAIRING MODELS
Bezel. ............... ........ .. ......... .... .. ............... .. ........ ............2-106
Removal ..... ................... ..... .. ...... .. .. ......... ...... ..... ... .. 2-106
Installation ..... ..... ...... ... .. .... ........ .. . ... ... . .. .... .... ......... .2-1 07
2.40 INSTRUMENT NACELLE: FRAME
MOUNTED FAIRING MODELS
Instrument Nacelle ........ .. ................ ........... . .. ..... .. ........... 2-1 08
Remova1 .................. ....... ... .... .......... ... ..... ... .... .... .. .. .2-108
Installation ... ................ ...... .. .... ... ........................... .2 - 109
2.41 INNER FAIRING: FRAME MOUNTED
FAIRING MODELS
Removal .......... ........... ............ ..... ........... ... .. ..... ... .. ...... ... .2 -1 10
Disassembly .................... ... .. ......... .. . .. ............. ........ 2- 11 1
Installation .. ... . ... ......... .. . .. ....................... .. . ... ...... ... ...... ... .2- 112
Outer Fairing ..... ......... ... .. ... ... ... ... .... .........................2-112
Inner Fairing ....... . .. ... ............................ .. ...... .. .. .... ... 2-112
2.42 GLOVE BOX DOOR AND HINGE:
FRAME MOUNTED FAIRING MODELS
Glove Box Door an d Hinge ................... ...... .. ... . ... . ... ...... . 2-11 4
Removal ... . .. ....... .. ...... .. .......... .............. .. .. ...... ........ . 2-114
Installation .......... ... ........ .... . ... ... .. .... ........................2-114
2.43 WINDSHIELD: ROAD KING MODELS
Windshield ........ ... ...... ................ ................ ..... ........ ........ 2-11 5
Remov al ........... ... .. .... .. .. .... .. .. .... .. ......................... ... 2-115
Installation ......... ... . .. .. .................... .. ..................... . 2-11 5
Windshield Window ... .... .... ................... ... . ... ................... 2-11 5
Removal ........ .. ... .. .... ..... ... .. .. .. ... ......... ............ ..... ...2-11 5
lnstallation ....... .. .. ...... ....... .. .. ... .... ..... .. ........ .. .... ...... .2 -11 6
TABLE OF CONTENTS
2.44 HEADLAMP NACELLE: ROAD KING
MODELS
Removal. .. ........ ... ............. ........ ...... ....... ............. ..... ........ 2-118
Installation .. ... ........ ..................................... ...... ........ .. . ... 2-119
2.45 FRONT FENDER
Removal ..... ... .. .. ....... ............................ ....... ... . ... ..... ...... .2 -120
Installation ...... .. ................... .. .. ...... .. ............. ....... .... .... .. .2-120
2.46 REAR FENDER
Removal. .... .. .. .. ............................. .............. ....... .. ..........2-121
Fender Repair .... ... .... ..... ... .... .. ..... ........... ..... ....... ......... ... 2-122
Mounting Hardware .. ....... ...... ... ... ..... .. .. ... .. .. ..... ...... . 2-122
Lights and Harnesses ... .......... ..... .... ......... . .. .. .... ..... 2-122
Installation .. ...... .... ........ ....................................... .. .. ..... ...2-122
2. 47 REAR FASCIA
Removal. ........................... ... .. ... ......... .. .. ........... .. .. ........ .2-124
Insta ll ation .. ... ...... .. ....... ... ......... .......... .. ....... ... ...... ... ..... ...2-124
Stud Plate ............ ....... ... .. .. ... ......... .............. ..... .. ...... .. ... .2-124
Removal .... ..... .... ... ..... ... ......... ................. ............. ..2-124
In stallation .................. ... ............... ......... ...... ........ .. .. 2-124
Rear Fascia Lamp ........ ... .. . .. ........... ... .. .. .. ..... .... .... .. ... .... 2-124
Removal ....... .. ........ .. ...... ....... ...... ... ....... ....... .. ... ... .. . 2-124
Installation ........ ..... .. .. ....... ............ .. ..... .. ... ..... ......... .2-124
2.48 REAR FRAME
Rear Frame ... .................................... .... ...... .. .. ....... . .. .. .. .2-125
Removal ........ ..... ... ... .. .. .. .. ........ ... .. .. .... .. ........ ... ... ... .2-125
Installation ..... .. ............ .. .... .. .. ...... .. .... . ... ... ........ .......2-126
Thread Repair ......................... ..... .. .. ... ..................... 2-126
2.49 FOOTBOARDS AND FOOTRESTS
Rider Footboards ............ . .. .. .. ............. ... . ... ... ... .............. .2-127
Removal .. .... .... .. ... ........ ............................... ... ........ .2- 127
Installation ........ ... ....... .... .. ........ .. .................. .. ........ 2-127
Disassembly .. ... .... ........ ... ........ ............. ........ .. ..... .... 2-127
Assembly ..... . .. ........... ........ ...... ...... ............... ... ....... .2-127
Passenger Footboard .. ... . .. .............. .... ... ...... .. .... ............ 2-128
Removal ... ... ..... ....... . .. .. .. ... . .. ........ ..... .... .. ................2-128
Disassembly ... ...... .... . ... ........ ... .... . ... ........ ....... .... .... .2-128
Assembly ....... ... ............ .......... .. ......... .. .. ..... ... ... ... .. .. 2-128
Installation ....... ................................. .. .... ... .. . ... ....... .2-128
Passenger Footrest: FLHX, FLTRX ... ..... ... ..... ... .... .. ... .... 2-128
Removal ........... ... ................. ... ...... .................. ..... ...2-128
Disassembly ........ ............. . ... .... ....... ..... ... .. ... ..... .... .. 2-128
Assembly .......... ..... .. .... ......... ........ ..... .. . ... ........ ... .....2-129
In stallation ... .............. ... ........... ..................... .. .. .. ..... 2-129
2. 50 JIFFY STAND
General ... .................................. .. .. .. .... ... ................ ... ..... 2-130
Leg Removal. ... .. ............... ...... ........ . ... ................... .. .. .. .. . 2-130
Leg In stallation . .. .... ... ..... .. .. .......... . .. ........ ...... ... ........ .. .... .2-130
Jiffy Stand Bracket. ...... .. ........ .... .... .......... ... ............ ....... .2-131
Removal .. ... ...... ... ..... .. ....... ............ .. .......... ..... .. ... . ... 2-131
Installation .. ......... ......... .. .. ... .. ........ .. .... ........ ........... .2-131
Jiffy Stand Interlock Sensor .......... .. ...... ................ ... ..... .. 2-131
Removal .......... ...................... .. ... ....... ... . ... .. .. ..... ..... .2-131
Installation .................. ...... .... .. .... ..... ...... ... .. .. .. ........ . 2-132
TABLE OF CONTENTS VII
TABLE OF CONTENTS
2.51 FRONT ENGINE MOUNT 3.13 CAM COMPARTMENT SERVICE
Removal ........ ... .. .... ... ............ .... .. ..... ..... .. ...... ... ..... .. ... ... ..2-133 Engine in Chassis ............................ ... .............. ... ... .......... 3-26
lnstallation .......... ....... .................. .... .. .......................... .. ..2-133 Engine Removed From Chassis ....... .. ... ......... ....... .... ... .. .. 3-27
ENGINE 3.14 STRIPPING MOTORCYCLE FOR
SERVICE
3.1 FASTENER TORQUE VALUES Proced ure .. .. ...... ....................................... .... .......... .. .. .. ... 3-28
Fastener Torque Values in this Chapter ............ .. ................ 3-1 Cam Compartment Service Only ............ .. ........ ......... 3-28
3.2 SPECIFICATIONS
Specificati ons ......... .......................................... ... ... ............. 3-3
3.3 SERVICE WEAR LIMITS
General .......... ........................... .. ...... ...... ..... ... . ... ....... ... ...... 3-5
3.4 ENGINE OIL FLOW
Oil Feed .......... ... ....... ... ......... ... ... ...... . ... ... ... ........................3-7
Top End ... .. .... ....... ........ .. ...... ..... ... .... ... . .. ........... .. ................3-7
Bottom End .......... . .. ....... . ... ....... .. .. .. ................... ... ...... ........ 3-9
Oil Return .. ......... ... .... ..... .. .. ......... .. ......... ........ ............... .... 3-11
Oil Cooler Operation ....... .. . ... .. .......... ... ... .. ... .. .... ... . ... .... .. .. 3-12
3.5 OIL PUMP OPERATION
General ....... .......... .......... ..... .. ............. ........... ...... ............ 3-1 3
Operation ............. ......... ..... ... ...... .............. .. .. .... ................ 3-13
3.6 BREATHER OPERATION
General. ....... ................... .......... ........... ........ .... ... ... ........... 3-1 5
3.7 OIL PRESSURE
Oil Pressure Indicator Lamp .................... .. ...................... 3-16
Checking Oil Pressure ..... .. ... ... ....... .... .. ...... . .. ................... 3-16
3.8 TROUBLESHOOTING
Diagnosing Valve Train Noise .............................. .. .... .. ..... 3-18
Compression Test. .......................................... ... . ... ........... 3-18
Cylinder Leakdown Test ....... .... .... .... .. .............................. 3-19
Diagnosing Smoking Engine or High Oil Consumption ..... 3-19
Check Prior To Cylinder Head Removal .................... 3-19
Check After Cylinder Head Remova1 .......... .. ............ .3-19
3.9 OIL COOLER
Removal ...... .. ... ............... .... . .. ........ . .. .............. ... . .. ... ......... 3-20
Installation ... ... ... .... ... ........................................... .. ............ 3-20
3.10 OIL COOLER ADAPTER
Removal ..... ...... ... ............ .. ........... .. ...................................3-21
Disassembly ............. .... ......... . .. ........ .. ... ................ ......... .. 3-21
Assembly ... .... ...... .. .............. ........ ........ ..... ........ ........ ...... .. 3-21
In stallation .... .... ... ..... ... . ... .. ........................................... .. ... 3-21
3.11 HOW TO USE THIS SECTION
Top End Repair .. .................................... . .. .... ... ......... .. .. .. .. 3-23
Bottom End Repair .. ...... .. ........... .. .. ................ ... ...... .. ....... 3-23
Typical Symptoms .......... .. .. ............ .. .... ............ .. ..... ...... .... 3-23
3.12 TOP END SERVICE
Engine in Chassis ... ..................... ........ ..................... ... ..... 3-24
Engine Removed from Chassis .................... .................... 3-25
VIII TABLE OF CONTENTS
Top End Service ............................................. .... .... ... 3-28
3.15 ASSEMBLING MOTORCYCLE AFTER
SERVICE
Procedure .... ... ........ ...... .... ....... ............ .. .. .. ... . .. .. . .. ............ 3-29
After Top End Service ............................ .. .... .. .... ........ 3-29
After Cam Compartment Service .. .. .. .... .. .. ................ 3-29
3.16 REMOVING ENGINE FROM CHASSIS
Procedure .. .... ......... .... .. ......... ..... ..... .. ... ............................ 3-30
3.17 INSTALLING ENGINE IN CHASSIS
Procedure ............. ............ .... .. ... .. .... .................... ...... ... .. .. 3-31
3.18 TOP END OVERHAUL: DISASSEMBLY
General ............ ............ ..... ............ ...... .. ....... ............. .. .. .... 3-32
Ro cker Covers ........ ... ..... ... ... ... .. .... . ... . ... ............ ..... .......... 3-32
Rocker Arm Support Plate .............. .. ................................ 3-32
Push Rod s, Lifters and Covers .................................... .... . 3-34
Cylinder Head .................... ..... .. . .. .......... ...... .... .. .. .... .. .. ..... 3-35
Cylinder ..... .. ....... ..... ... .... .. .... ......... .. ... ... ... ........ .. .. .. ........... 3-36
Piston .............. ..................... ..... .. ........ .. ... ............. .. ..... ..... 3-36
3.19 BREATHER ASSEMBLY
Disass embly .......... ..... ... ...... .... .. ......... ......... ..... ... .. ... .... .... 3-38
Early Production .... .... ....... ..... ... .. . ... . .. ........................ 3-38
Late Production ..................... . .. .. .. .. .... ... ...... .. .... ........ 3-38
Cleaning and lnspection ............ .... ...... ................ . ... ... ...... 3-38
Assembly .......... ....................... .. ............... ... ... ..... .... .... ..... 3-38
Early Production ... ... ......... ........ ..... ..... ..... .... ........... ... 3-38
Late Production ......... ....... .......... ................ ..... ..... ... .. 3-38
3.20 ROCKER ARM SUPPORT PLATE
Disassembly .................. ........... ...... ....... . .. ........................3-40
Cleaning and lnspection .... ....... .. ............... .. ... .. ... ...... ... .... 3-40
Inspection .... ... ... .. ... ......... .. .... . ... ..... ... ..... ..... . ... . ... .. .... 3-40
Ro cker Shaft Fit. ........... ............................................. 3-40
Rocker Arm Shaft to Bushing ........................ ............ 3-41
Replace Rocker Arm Bushings .............. .. ...... .... .. ..... 3-41
Assembly ........ .......... .. .. ..... ....... ...... ... ... .. ... ......... .. .......... .. 3-42
3.21 PUSH RODS, LIFTERS AND COVERS
Disassembly .... ....... .. ... ................ .... ....... . ... .. .................... 3-43
Cleaning and Inspection .... ... .. . .. .. ..................................... 3-43
Lifter lnspection .... ........................ ... ...... .. ....... ...... ..... .. ..... 3-44
Assembly ........... ........... . .. .... .. . .. .. ... ... ... ..... .... ........ ....... .... . 3-44
3.22 CYLINDER HEAD
Disassembly .... .. ... ...... ... .................................. ... .... ........ . 3-45
Cleaning ............ .. ... . .. ... .. ............... .. ... .. .. ...........................3-46
Inspecti on ....... ........... .. ......... .. .. ....................... ..... ..... ..... .. 3-46
Cylinder Head .... ............. ... ... .. ..... ....................... ... .... 3-46
Valve Guides .... ..................................................... .. .. 3-47
Valves ............. .................... ..... ....... ... ....... .... ...... .... ... 3-47
Valve Springs .......................... ............. ... ... ... ... .... ...... 3-47
Ta pered Keepers ... ....... ... .......... ............... ....... .... ...... 3-47
Valve Seats ....................... ..... ... . ... ........ ..... ...... .... ...... 3-47
Valve Guide Replacement. .. .......................... .. .............. .. . 3-47
Removal ...... .. ... ... . ... .. .. ... ............ .. .. .... ... ........ .... .. .. .... 3-4 7
lnstallation ..................... .... .... ... .... ... ......... ... ...... .. ...... 3-48
Valve and Seat Refacing .... ... ..... ........ .... ...... ...... .. ........ .. .. 3-51
Assembly ............ ....... ...... .................. ...... .............. ........ ... 3-53
3. 23 CYLINDER
Cleaning ........ ... ......... .................... .. ...... .... .. . .. .. ... ...... . .. .. ... 3-56
Inspection .......... .. ... .. ... . ... .... .. ........ .. ... ............ .. .. .. ...... .. .... 3-56
Deglazing Cylinder ....... ...... .. ...... . ... . .. ........... .. ...... . .. ... ....... 3-58
Boring and Honing Cylinder .... ...... .......... ...... .. ... .. ...... . .. .... 3-58
3.24 PISTON
Disassembly ...... . ........ ........ ... ..... .... ... ...... .. .................. .... 3-60
Piston Rings .... ..... ...... ....................... . .. .... .. ... ....... .... 3-60
Cleaning ...................... .. .. .. .. ......... ...... ......................... ..... 3-60
Inspection .......... . .. ... .. .... ... ... .. ........ ....... ........ .... .. . .. .. . ... . ... 3-60
Assembly ...... ... .. ................................. .. ........... ... ...... ... .. 3-62
Checking Piston Ring Gap .. ..... ..... .... ... ... .. ... ........... .. 3-62
Insta ll ing Pist on Rin gs ........... ....................... ......... . ... 3-62
3.25 TOP EN D OVERHAUL: ASSEMBLY
General ....... . .. ... .... ..... ....... ... ........... ............ . .. ...... ............ 3-64
Piston .... ... ... .. .. ... ....... .... .... ..... .. ...... .. ...... ... ............ ...... ... ... 3-64
Cylinder ......................... ...... ............ ... .... .............. ......... ... . 3-65
Cylinder Head .. .... ..... .. .. .... ... ......... .......... ...... ...... .. ........ .... 3-67
Push Rods, Lifters and Covers ... ......... .. .... .. .. .... .... .... ....... 3-71
Rocker Arm Support Plate ..... ............. ...... ..... .... .......... .. ... 3-72
Breather and Ro cker Cover ... .... ............... ................. .... ... 3-73
3.26 CAM COMPARTMENT AND
COMPONENTS
Cam Support Plate and Cover Removal. ..................... ...3-75
Prepare Engine ....... .. ................................... ...... .... . .. 3-75
Cam Chain and Sprockets Removal. ...... .. .... .... ....... 3-75
Cam Support Plate Removal. ............. ..... .. ......... .. .... 3-76
Cam Support Plate Cleaning and lnspecti on ... ... ... .. ... .... .. 3-77
Oil Pressure Valve ...... .. ......... ....................... ........... .. 3-77
Cam Support Plate ..... ... ........................... ... ... .. ... .. .... 3-77
Camshafts ......................... ..... .... ... ....................... .. ......... .. 3-77
Remov al ........ ........ .. ... ... ........... .. ............... ...... ...... .... 3-77
Installation .... ...... ........ ......... ... ........ .. ....... .............. .... 3-78
Oil Pressure Reli ef Va lve .. .... ........................ .. .... .. .. .. ... ..... 3-79
Removal. . . ... ........ ... ....... .. ......... .... ... . ... .. 3-79
Inspection ... ..... . ... ...... ................ ... ................ ... .. .... .. .. 3-79
In stallation .. ......... .... .. .... .. . .. ........... ..... ..... ......... .. .. ... .. 3-79
Cam Needle Bearings ............... ..... ..................... .............. 3-80
Removal .......................... . ... .. .......... ......... ....... ....... .. . 3-80
In sta llation ...... ... ... ................. ... ... ... ...... ... ...... ..... ....... 3-81
Cam Support Plate and Cover Installation .... .. ... .............. 3-83
3. 27 OIL PUMP
Removal. ................ ...... ............... ........... .. . .. ... .... . .. ........ ... 3-87
Clean ing and Inspection ....................... ...... ..................... 3-87
Installation ... ....... ......... ... ..... ...... .......... . ......... ..... ..... .. ..... 3-88
TABLE OF CONTENTS
3.28 CRANKCASE DISASSEMBLY AND
REPAIR
Crankcase Disassembly .... .... . ... ................. .. ... ..... .. ......... . 3-89
Cleaning and In spection .. ..... ....... .. ................... .. .............. 3-89
Right Crankcase Half .. ... ............ .... ....... ..... .. ... ...... .. .. ... .. ... 3-90
Main Bearing Removal ....... ............. ............ .... .......... 3-90
Main Bearing In stallation ... .. ....... ... .. .. .. ...... .. ........ .. ... 3-90
Piston Jets Remova \. ............... ... ........ ......... ... ....... ... . 3-91
Piston Jets lnstallation ... ..... ... ... .. ........ ................ ....... 3-91
Left Crankcase Half .. ............ ........ .............. .. ..... .... .. .. ....... 3-91
Main Bear in g Removal. ................ .......... .. .. .. ..... ....... . 3-91
Main Bearing lnstallation ... ... .. .. .. .... ... .................. ...... 3-93
Sprocket Shaft Bearing Inner Race ..... .. ......... ..... .. ......... .. 3-93
Removal ............ ....... ...... ....... ........... ............ .. .. ....... .. 3-93
Installation ... .. ............ ............ ............... ...... .. ........ ..... 3-94
Cylinder Studs ............ ................. .. .... .... .. .. .................. . .. 3-96
Removal ......... .. ... ........ .... ... .. ............. ..................... .. . 3-96
lnstallation . .. ...... ..... ..... ..... .... ...... ..... . .. .... .. ........ .. .. .. . .. 3-96
Pi pe Plug and Oil Fittings .. . .. ... ..... .. ..... .. ..... ..... .... .......... ... 3-97
Remova l ..... .... ..... .. .. .. ...... .. ... ... .. ...... ..... ...... ... ... ... ...... 3-97
Installation .. .... .... .. .. .................................................. 3-97
3.29 FLYWHEEL AND CONNECTING RODS
Inspection .... ..... ... ... ... .. .................... .. ... ................... ... .. ... 3-98
Measuring Crankshaft Run out... ...... .... ... .................. .. ..... 3-98
Crankshaft Removed ..... .... ..................... ..... 3-98
3.30 CRANKCASE ASSEMBLY
Crankcase Assembly .... ..... ...... ... .... ... ........... ...... ........... 3-1 00
3.31 OIL PAN
Removal ............. ... .. .. ... ... .. .. .. .. ..... ... ... ... ..... .. ... ........ .... .... 3-1 02
Installation ....... .. ... ... ...... .. .. ... ... ... .... .... .. ... ... ... .......... .. ..... 3-1 02
FUEL SYSTEM
4.1 FASTENER TORQUE VALUES
Fastener Torque Va lu es in this Chapter ... ....... .... ....... .. ..... .4-1
4.2 SPECIFICATIONS: FUEL SYSTEM
Specifications ... ......... . ... .................................................... .4-3
4.3 ELECTRONIC FUEL INJECTION (EFI)
Troubleshooting.... ...... ..... .. ................................... ...... ..4-4
4.4 AIR CLEANER ASSEMBLY
Removal .. .. ............. .... ...... .. ............ .. ... . .. ...... .... ..4-5
In stallation ......... ... ..... .... ... ...... .. .. ..... .. ..... ..4-6
4.5 FUEL TANK
Removal. .. ... ... .... .. ........ ................................ .. .. .. ... ............4-8
Purge and Disconnect Fuel Line ........ .. ..... ... ......... .... .4-8
Remove Tank ..... .. .............. ..... .... . ............................. .4-8
Installation . .. ........ ........ ....... .... .... ....... ........................ ......... .4-8
Evaporative Emissions Tube: Non-CA Models ...... ... .. .. ..... .4-9
Removai ..... .... ....... .... .. ... ......... .... ... ... ................ .. ...... . A-9
In stallation .. .. ........ ...... ... ... ..... ...... ........ ............. .. ... ..... . 4-9
Fu el Supply Check Valve/Tube ........ .. .......... ...... ..... .... .... ....4-9
Removal ....... .. ..... ...... ................................. ... ........... .4-9
Insta ll ation .. ... ... .......... .. .. .... .. .. .. .. .. ...... ... ... ... .... .. ....... .4-1 0
TABLE OF CONTENTS IX
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Description
Get the complete service and repair manual for the 2011 Harley-Davidson FLHTK Electra Glide Ultra Limited. This manual is a comprehensive resource for fixing issues with your bike, providing step-by-step instructions, clear images, and exploded-view illustrations.
Whether you're a professional mechanic or a DIY enthusiast, regular maintenance is essential for your motorcycle's longevity. Over time, certain parts will wear out and require replacement. A reliable motorcycle repair manual is invaluable, offering manufacturer-recommended troubleshooting charts and replacement procedures to help you save on repairs and enhance your bike's reliability.
Notably, this is not a generic manual but the official repair manual used by professional technicians. It contains detailed troubleshooting and replacement procedures, eliminating the need to search through numerous pages for specific information. Additionally, it's easily accessible and searchable, making it more convenient than traditional bound manuals.
Furthermore, this manual is available in a printable format and is compatible with various electronic devices, including PC, Mac, Android, and Apple devices. It only requires Adobe Reader, and you can also opt to print a physical copy if preferred.
