Harley Davidson FLHR Road King 2010 Service Repair Manual

ABOUT THIS MANUAL FOREWORD FOREWORD 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 perf ormance of basic maintenance and repair. Secondly, it will introduce to the pro- fessional Harley-Davidson Technician the latest field-tested and factory-approved major repair methods. We sincerely believe that this Service Manual will make your association with Harfey-Davidson products more pleasant and profitable. HOWTO USE YOUR SERVICE MANUAL Refer to the table below for the content layout of this manual. CHAPTI!R Maintenance 2 Chassis 3 Engine 4 Fuel System 5 Drive 6 Transmission 7 Electrical A Appendix A Connector Repair B Appendix B Wiring c Appendix C ABS D Appendix D Conversions 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. Sections and topics in this manual are sequentially numbered for easy navigation. For example, a cross-reference shown as 2.1 SPECIFICA· TIONS refers to chapter 2 CHASSIS, heading 2.1 SPECIFIC- ATIONS. For quick and easy reference, all pages contain a section number followed by a page number. For example, page 3-5 refers to page 5 in section 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 wA RNI NG Stop the engine when refueling or servi cing the fuel system. Do not smoke or allow open flame or sparks near gasoline. Gasoline Is extremely flammable and highly explosive, which cou ld result In death or serious injury. (000028) Good preparation is very important for elfocient 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 will reduce the incidence of misplaced tools and parts. A motorcyde that is excessively dirty should be deaned before work starts. Cleaning will occasionally uncover sources of trouble. Tools, instruments and any parts needed for the job should be gathered bef ore work is started. Interrupting a job to locate tools or parts is a distraction and causes needless delay. NOTES To avoid unnecessary disassembly. carefully read all ref· alive service information before repair wor k is started. In figure legends, the number which follows the name of a part indicates the quantity necessary for one complete assembly. When servicing a vehicle equipped with the Harley-Dav- idson Smart Security System (H·DSSS), you must first disarm the security sy.stem. Either keep the fob in close proximity to the vehicle, or use Digital Technician II to disable the security sy.stem while the vehicle is being ser- viced andre-enable the system after service is completed. SERVICE BULLETINS In addition to the information presented in this Service Manual, Harley-Davidson Motor Company will periodically issue Service Bulletins to Harley-Davidson dealers. Service Bulletins cover interim engineering changes and supplementary inf ormation. Consult the Service Bulletins to keep your product knowledge current and complete. USE GENUI NE REPLACEMENT PARTS A wARN ING Do not use aftennarket parts and custom made front forks wh ich can adversely affect performance and handling. Removing or altering factory Installed parts can adversely affect performance and could result In deat h or seri ous Injury . (00001a) To ensure satisfactory and lasting repairs, carefully follow the Service Manual instructions and use only genuine Harley· Davidson replacement parts. Behind the emblem bearing the words GENUINE HARLEY-DAVIDSON stand more than 100 years of design, research, manufacturing, testing and inspecting experience. This is your assurance that the parts you are using will fit right, operate properly and last longer. WARNINGS AND CAUTIONS Statements in this service manual preceded by the following words are of special significance. A wARN ING WARNING indicates a potentiall y hazardous situation which, If not avoided, could result In death or seri ous injury. (00119a) A cAUTION CAUTION Ind icates a pot ent i ally hazardous situation which, II n ot avoided, may result in minor or moderate injury. (00139a) CAUTI ON CAUTION u sed without the safety alert symbol indicates a potentially hazardous si tuati on which, If not avoided, may result In property damage. (00140a)

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 service manual are effective methods for performing service operations. A wARNING Always wear proper eye protection when using hammers, arbor or hydraulic presses, gear pullers, s pring com· pressors, slide hammers and si milar tools. Flying parts could result In death or serlous 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, are stated in this service manual. However, please 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 naither 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 wARN ING Reed and follow warnings and di rections 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 "8" 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 andThreadlocking 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 Alcantara S.p.A., Allen, Amp Multiloci<, 81uetooth, 8rembo, Delphi, Deutsch, Dunlop, Dynojet, Fluke, G.E. Versilube, Gunk, Hydroseal, Hyfomar, Kevlar, Lexan, Loctite, Lubriplate, Keps, K&N, Magnaflux, Marson Thread-Setter Tool Kit, MAXI fuse, Molex, Michelin, MPZ, Mulltilock, NGK, Novus, Packard, Pirelli, Permatex, Philips, PJ1 , Pozidriv, Robinair, S100, Sems, Snap- on, Teflon, Threadlocker, Torca, Torco, TORX, Tufoil, Tyco, Ultratorch, Velcro, X·Acto, and XM Satellite Radio are among the trademarks of their respective ownars. H-D MICHIGAN, INC. TRADEMARK INFORMATION Harley, Harley-Davidson, H·D, Bar & Shield, Cross Bones. Digital Tech, Dig~al 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, Nlghtster, Night Train, Profile, Revolu- tion, Road Glide, Road King, Road Tech, Rocker, Softail, Sportster, Street Glide, Street Rod, Sun Ray, Sunwash, Tech Unk, Twin Cam 88, Twin Cam 888, Twin Cam 96, Twin Cam 968, Twin Cam 103 , Twin Cam 1038, Twin Cam 110, Twin Cam 1108, Tour·Pak, Screamin' Eagle, Softail, Super Glide, SYN3, Ultra Classic, V·Rod, VRSC and Harley-Davidson Genuine Motor Parts and Genuina 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 componant, 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 Sate Operating Maintenance .............................................• 1-3 Shop Practlces................................................................... 1-3 Repair Notes ............ .. ................................................. 1-3 Salety.......................................................................... 1·3 Removing Parts ......... .................................................. 1-3 Cleaning...................................................................... 1·3 Disassembly and Assembly ........................................ 1· 4 Checking Torques on Fasteners .................................. 1·4 Magnetic Parts Trays ................................................... 1-4 Repair and Replacement Procedures ................................ 1-4 Hardware and Tlveaded Parts .......................•.•.......... 1-4 Threadlodling Agents .................................................. 1-4 Winng. Hoses and Unes ....................................•..•..... 1-4 Instruments and Gauges ............................................. 1-4 Bearings...................................................................... 1·4 Bushings .....................................................................1·4 Gaskets.......................................................................1·4 Up-Type Seals............................................................. 1-4 O·Rings (Pre-Formed Packings).............•................... 1·4 Gears .. ........................................................................ 1·5 Shafts.......................................................................... 1·5 Part Replacement .. ..................................................... 1-5 Exhaust System Leakage ............................•............... 1·5 Cleanl ng ............................................................................. 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 Pl iers/Cuners/Pry Bars ................................................ 1·5 Hammers ..................................................................... l-5 Punches/Chisels .......................................................... 1·6 Screwdrivers .......... ...................................................... 1·6 Ratchets and Handles ................................................. 1·6 Sockets ........................................................................ 1·6 Storage Units ...............................................•............... 1 ~ 1.3 FUEl AND Oil Fuel...........••....•..............................................•................... 1·7 Gasoline Blends•................................................................ 1· 7 Engine Lubrication............................................•................. 1· 7 Wonter Lubfication.............................................•.•.............. 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 .............................•................. t · 15 1.7 AIR CLEANER AND EXHAUST SYSTEM Removal .....................•...••................................................ 1· 17 lnstallation.........................•.............................................. 1·17 Exhaust System Leak Check ............................................ 1·1 7 1.8 TIRES AND WHEELS General.............................•.......••.....................................• 1·19 Tires..........•.........••.........•••............................................... l-19 Tire Replaoement. .......•.•.......•.......................................... l·20 lnspec1ion .......•...........•.............................................. l·20 When To Replace Tires ............................................. 1·20 Wheel Bearings ................................................................ l ·20 Wheel Spokes .................................................................. l ·21 Identify Wheel Spoke Groups .................................... l -2 1 Wheel Spoke Adjustment .......................................... l-21 1.9 PRIMARY CHAINCASE LUBRICANT General ......................•......•••.............................................l-23 Primary Chaincase Lubficant•..........•............................... l-23 General ...............................••.•...................................l-23 Check Lubficant Level ....•.•....•................................... 1·23 Changi ng Chaincase Lubficant. ................................ l ·23 1.10 TRANSMISSION LUBRICANT Transmission Lubfication......... ......................................... l·25 General..............•....................................................... l·25 Check Lubricant Level ............................. .......... ........ 1-25 Changing Transmission Fluid.................................... 1·25 1.11 CLUTCH Adjustment..•.................................................................... l-27 1.12 DRIVE BELT AND SPROCKETS Genera.! ........•................•...•.............................................. 1·29 Cleaning.......................•••......•.......................................... l ·29 lnspec1ion ..........................•.•............................................ l·29 Sprockets.................................................................. l-29 Drive Belt.....................•............................................. 1·29 Checking Drive Belt Deflection ......................................... 1-30 Sening Belt Oefleclion.............•........................................ 1·31 Adjustment ................................................................ 1·31 Assembly ................................................................... l-33 1. 13 CABLE AND CHASSIS LUBRICATION General............................................................................. l-34 Steering Head Bearings ................................................... 1·34 Jiffy Stand ......................................................................... l-34 Miscenaneous Lubrication................................................ 1-34 Hi nges. Latches. Etc ................................................ 1·34 1.14 BRAKES Auld Inspection ................................................................1·35 1. 15 BLEEDING BRAKES General............................................................................. l-36 Procedure......................................................................... l -36 1.16 BRAKE PADS AND DISCS lnspec1ion .........................................................................l ·38 Brake Pads ................................................................ 1·38 Brake Disc Thickness................................................ 1·38 Brake Disc Lateral Runout ........................................ l-38 Brake Pad Replacement ................................................... 1-38 Rear Brake Cal iper .................................................... l-38 Front Brake Cal ipers.................................................. 1·40 Ill (/) 1- z w 1- z 0 0 LL. 0 w ..J m <( 1-

TABLE OF CONTENTS 1.17 SPARK PLUGS lnspeclion ......................................................................... 1·42 Spark Plug Cable lnspection ............................................ 1-42 1.18 FRONT FORK OIL Replacing Fork Oil............................................................ 1-44 1.19 SUSPENSION ADJUSTMENTS General ............................................................................. 1-45 1.20 STEERING HEAD BEARINGS Lubricati on ........................................................................ 1· 47 Checking ........................................................................... 1·47 Adjustment....................................................................... 1-48 1.21 HEADLAMP ALIGNMENT Headlamp Alignment. ....................................................... 1·49 Headlamp Adjustment: Single Headlamp Models............ 1·49 Headlamp Adjustment: Dual Headlamp Models............... 1·50 Auxiliary Lamp Alignment .. .............................................. 1·50 1.22 CRITICAL FASTENERS lnspection .......... ............................................................. .. 1·52 Checking Torques on Fasteners.............................. .. 1·52 1.23 BATTERY MAINTENANCE General............................................................................. 1·53 Cleaning and Inspection................................................... 1·54 Battery .............................................................................. 1·54 Disconnection and Removal...................................... 1·54 Installati on and Connecti on ....................................... 1·54 Voltmeter Test................................................................... 1·55 Voltmeter Test............................................................ 1·55 Charging Battery .............................................................. 1·55 Safety Precautions.................................................... 1·55 Using a Battery Charger ............................................ 1·55 Storage............................................................................. 1·56 1.24 ENGINE MOUNTS lnspection......................................................................... 1·58 General ...................................................................... 1·58 Stabilizer Link............................................................ 1·58 Front Engine Moun\. .................................................. 1·58 Rear Frame Fasteners.............................................. 1·58 1.25 STORAGE General ............................................................................. 1·59 Placing in Storage............................................................ 1·59 Removal from Storage...................................................... 1·59 1.26 TROUBLESHOOTING General............................................................................. 1·61 Engine.......... .. .................................................................. 1·61 Starter Motor Does Not Operate or Does Not Turn Engine Over ... ....................................................................... 1·6 1 Engine Turns Over But Does Not Start ..................... 1·61 Starts Hard................................................................ 1·61 Starts But Runs Irregularly or Misses ....................... 1·61 A Spark Plug Fouls Repeatedly................................ l-62 Pre-Ignition or Detonati on (Knocks or Pings) ............ 1·62 IV TABLE OF CONTENTS Overheating............................................................... 1·62 Valve Train Noise....................................................... 1·62 Excessive Vibration................................................... 1·62 Check Engine Light Illuminates During Operation..... 1-62 Lubrication System........................................................... 1·62 Oil Does Not Return To Oil Reservoir........................ 1·62 Engine Uses Too Much Oil Or Smokes Excessively... 1·62 Engine Leaks Oil From Cases, Push Rods, Hoses. Etc ............................................................................. 1·62 Low Oil Pressure....................................................... 1· 63 High Oil Pressure...................................................... 1-63 Electrical System.............................................................. 1-63 Alternator Does Not Charge...................................... 1·63 Alternator Charge Rate Is Below Normal... ............... 1·63 Speedometer Operates Erratically ............................ 1·63 Transmission..................................................................... 1·63 Shifts Hard................................................................ 1·63 Jumps Out Of Gear................................................... 1·63 Clutch Slips ............................................................... 1·63 Clutch Drags Or Does Not Release.......................... 1·63 Clutch Chatters.......................................................... 1·63 Handling......................... .. ................................................ 1·63 Irregularities........................................................ ...... 1·63 Brakes................................................................. ............. 1·64 Brake Does Not Hold Normally ........................ .. ....... 1·64 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 lnspection................................................... 2· 12 lnstallation ..... .. ................................................................. 2· 12 2.5 REAR WHEEL Removal ........................................................................... 2·14 Cleaning and lnspection................................................... 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. 7WHEEL LACING: FRONT RIM Wheel Lacing: Angle Flange Hub..................................... 2·20

TABLE OF CONTENTS Wheel lacing: Straight Flange Hub, Single Hole Circle....2·21 Removal....................................................................2·48 Wheel Lacing: Straight Flange Hub. Dual Hole Circle......2·22 lnstallation................................................................. 2-49 2. 8WHEEL LACING: 161NCH REAR RIM 2.15 REAR BRAKE CALIPER Wheel Lacing: 16 ln. Rear Wheel ..................................... 2-25 Removal ........................................................................... 2·51 2.9 CHECKING AND TRUING WHEELS lnstallation........................................................................2·51 General............................................................................. 2·28 2.16 FRONT FORK Cheoklng Wheel Runout. ..................................................2·28 Changing Fork Oil............................... ..............................2·52 Lateral Runout......... ..................................................2-28 Draining.....................................................................2· 52 Radial Runout...........................................................2-28 Filling........................................ .................................2-52 Setting Rim Offset............................................................2-28 Removal ...................................... .....................................2-53 Truing Wheels...................................................................2-30 Disassembly.....................................................................2·53 Radial Truing .............................................................2·30 Cleaning and Inspecti on ...................................................2-55 Lateral Truing ............................................................. 2-31 Assembly.......................................................................... 2·56 2.10 SEALED WHEEL BEARINGS lnstallation........................................................................ 2-56 lnspection......................................................................... 2·32 2.17 STEERING HEAD BEARINGS Removal........................................................................... 2·32 Removal .......................................................................... 2-58 Installation........................................................................2-33 lnspect ion......................................................................... 2·59 2. 11 TIRES lnstallation ........................................................................ 2·60 General ................................................................. ............ 2·35 2.18 REAR AIR SUSPENSION Removal ........................................................................... 2·35 Check for Air Leaks.......................................................... 2· 61 Cleaning, Inspection and Repair......................................2·35 Compression Flttlng......... .........................................2· 61 Installation.................................................... .. .................. 2-36 Air Valve Assembly ....................................................2· 61 Tube Type Tires.........................................................2-36 Air Tubes....................................................................2·61 Tubeless Tires...........................................................2-36 Checking Tire Runout.......................................................2- 37 2.19 REAR SHOCK ABSORBERS lateral Runout...........................................................2-37 Removal........................................................................... 2·63 Radial Runout. ..........................................................2-37 Wheel Balancing.............................................................. 2·38 Weights..................................................................... 2-38 Cleaning and lnspection...................................................2·63 Disassembly and Assembly..............................................2-63 Installation........................................................................ 2·63 2.12 FRONT BRAKE MASTER CYLINDER 2. 20 REAR FORK General.............................................................................2-39 Removal ........................................................................... 2·64 Removal and Disassembly ............................ .. .................2·39 Removal .................................................................... 2·39 Disassembly ....................................... .......................2-39 Cleaning and Inspection...................................... .. ...........2-41 Assembly and Installation...................................... .. .........2·41 Assembly ...................................................................2·41 Installation............... ..................................................2·41 Disassembly and Assembly..............................................2-65 Bearing Removal ....................................................... 2·65 Bearing Installation.................... ................................2·65 Pivot Shaft/Mount Disassembly .. ...............................2·66 lnstallation........................................................................ 2·66 2.21 CLUTCH CABLE Front Brake Line: Non-ABS Equipped ..............................2·41 Removal ....................................................................2·41 lnstallation .................................................................2·42 Removal ........................................................................... 2·67 lnstallation........................................................................ 2·67 2. 13 FRONT BRAKE CALIPER Removal ........................................................................... 2·44 Installation........................................................................ 2-44 2.22 HANDLEBARS Adjustment...................................................................... 2-70 Removal .......................................................................... 2-70 lnstallat ion ........................................................................2·71 2.14 REAR BRAKE MASTER CYLINDER Left Handgrip ....................................................................2·72 Removal........................................ .. ..........................2-72 General............................................................................. 2-45 lnstallation................................................................. 2· 72 Removal and Disassembly...............................................2·45 Removal .......................................... .. ........................2-45 Heated Handgrips............................................................2· 72 Remove Left Handgrip ..............................................2·72 Disassembly.............................................................. 2-46 Cleaning and lnspection...................................................2-47 Assembly and lnstallation.................................................2-48 Assembly ................................................................... 2-48 Install Left Handgrip..................................................2· 73 Remove Right Handgrip............................................2·73 Install Right Handgrip ................................................2· 73 Rubber Mounts .................................................................2·7 4 lnstallation.................................................................2-48 Removal .................................................................... 2·74 Rear Brake Line: Non-ABS Equipped...............................2·48 lnstallation.................................................................2-74 TABLE OF CONTENTS V

Harley Davidson FLHR Road King 2010 Service Repair Manual

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