2010 Harley-Davidson Softail FLSTSB Cross Bones Service & Repair Manual
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201 0 Harley-Davidson Softail
Models Service Manual
CMI - SM - 07/09
©2009 H-D.
ALL RIGHTS RESERVED
99482-10
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 t he performance 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 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~
·· '·:
. :% 1il
1 Maintenance
I
r
I
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 Conversions
D Appendix D 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 D.1 GLOSSARY for a list of acronyms,
abbreviations and definitions.
PREPARATION FOR SERVICE
A wARNING
Stop the engine when refueling or serv1cmg the fuel
system. Do not smoke or allow open flame or sparks near
gasoline. Gasoline is extre mel y flammable and highly
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 will
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. Interrupting 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 information before repair work 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 system. Either keep the fob in close
proximity to the vehicle, or use Digital Technician II to
disable the security system 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 information.
Consult the Service Bulletins to keep your product knowledge
current and complete.
USE GENUINE REPLACEMENT PARTS
A wARNING
Do not use aftermarket parts and custom made front forks
which can adversely affect performance and handling.
Removing or altering factory installed parts can adversely
affect performance and could result in death or serious
injury. (00001 a)
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 wARNING
WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury. (00119a)
AcAUTION
CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury. (00139a)
CAUTION
CAUTION used without the safety alert symbol indicates
a potentially hazardous situation which, if not avoided,
may result in property damage. (00140a)
Q
a:
~
w
a:
0
u.
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, 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, are
stated in this service manual. However, please remember that
these warnings are not all-inclusive. Inadequate safety precau-
tions 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 wa rni ngs and directions on all products.
Failure to follow warn ings and directions can result in
death or serious i nj ury. (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
Alcantara S.p.A., Allen, Amp Multilock, Bluetooth, Brembo,
Delphi, Deutsch, Dunlop, Dynojet, Fluke, G. E. Versilube, Gunk,
Hydroseal, Hylomar, Kevlar, Lexan, Loctite, Lubriplate, Keps,
K&N, Magnaflux, Marson Thread-Setter Tool Kit, MAXI fuse,
Molex, Michelin, MPZ, Mulitilock, NGK, Novus, Packard, Pirelli,
Permatex, Philips, PJ1 , Pozidriv, Robinair, S100, Sems, Snap-
on, Teflon, Threadlocker, Torca, Torco, TORX, Tufoil, Tyee,
Ultratorch, Velcro, X-Acto, and XM Satellite Radio 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 Gl ide, 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 1 03B, Twin Cam 11 0, Twin
Cam 110B, 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 ................. ... . ... . ... . ... ............... 1-4
Safe Operating Maintenance. ... .... .. ..... .. .. ............ .. ....... ... . .. 1-4
Shop Practices ................................................................... 1-4
Repair Notes............................................................... 1-4
Safety .......................................................................... 1-4
Removing Parts......... ........ ........ ............... ......... .......... 1-4
Cleaning ... .. .. . ... .. .. . .. . ... . ... .. .. . ... .. .... ... ... . .. ..... .. .. . ... ........ 1-4
Disassembly and Assembly........................................ 1-5
Checking Torques on Fasteners ... ..................... .. ........ 1-5
Magnetic Parts Trays ... .. ................... .. ...... ... . ... . .. .. ... . ... 1-5
Repair and Replacement Procedures....... .... ..................... 1-5
Hardware and Threaded Parts .. ...... ... ......................... 1-5
Threadlocking Agents ............................................... ... 1-5
Wiring, Hoses and Lines ............................................. 1-5
Instruments and Gauges..................................... .. ...... 1-5
Bearings ...................................................................... 1-5
Bushings ... .. ................................. ..... ........ .. ..... ... ...... .. 1-5
Gaskets ........................ .. ...... .. ...... .. ...... ........ .. .... .. .. ..... 1-5
Lip-Type Seals............................................................. 1-5
0-Rings (Pre-Formed Packings) ....... .. ...................... .. 1-5
Gears .......................................................................... 1-6
Shafts ... ......... ... .. .. . .. ..... ... . ... . ... . ... . ... .. ... ... . .. .. ... .. .. ........ 1-6
Part Replacement. ....................................................... 1-6
Exhaust System Leakage ............................................ 1-6
Cleaning ..... .. ........... ... .. ..... ... .. . .... ... ..... ... . ........ ... .... . ... ..... ... 1-6
Part Protection .............. ... ................................ .. . .. .... .. 1-6
Cleaning Process........................................................ 1-6
Rust or Corrosion Removal. .................................... ... . 1-6
Bearings .. . .... ... ..... .. . ... .. .. . .. ... .. . .. ... .. . ... .. ... .... .. ..... .. ....... 1-6
Tool Safety ............................................... .. ......................... 1-6
Air Tools .. ... .......... .. .. ........ ................ .... ... .. .. ..... ....... .. .. . 1-6
Wrenches ........................................................ .. .......... 1-6
Pliers/Cutters/Pry Bars ................................................ 1-6
Hammers .. ....... .. ... ........ ... .... . ... .. .... .. . ... . ... .. .. . ... .... . ... . ... 1-6
Punches/Chisels.......................................................... 1-7
Screwdrivers............................................................. .. . 1-7
Ratchets and Handles................. .. ............ ... .. .... .. .. . ... . 1-7
Sockets ..................................................... ... ................ 1-7
Storage Units ... . ... ................... .. ......................... ... .... .. . 1-7
1.3 FUEL AND OIL
Fuel. ................................................................................... 1-8
Gasoline Blends............. ... ................................................. 1-8
Engine Lubrication .. ............................................................ 1-8
Winter Lubrication ...... ........ ......... ........ ........ ....... .. ...... .. ...... 1-9
1.4 BULB REQUIREMENTS
Genera1 ............................................................................. 1-1 0
1.5 MAINTENANCE SCHEDULE
General. ............................................................................ 1-11
1.6 ENGINE OIL AND FILTER
Checking and Adding Oil. ................................................. 1-1 5
Type of Oil. .................... .... .. .. .... .. .. .. ...... .. .. .......... ...... 1-15
Checki ng Oi l Level. ......................... .. ......................... 1-1 5
Changing Oil and Filter....................... .. ....... .. ................... 1-15
1.7 AIR CLEANER AND EXHAUST SYSTEM
Removal. ... ....................................................................... 1-17
lnstallation .................................................... .. ................ .. 1-18
Exhaust System Leak Check ............ .. .. ... . ... ................ .. ... 1-19
1.8 TIRES AND WHEELS
Tires .. . ... . ... ........ ... .. .. ......................... .. . ... ......... ... . ... . ... . ... . 1-20
Tire Replacement... ........................................ .. ................ 1-21
lnspection .................................................................. 1-21
When To Replace Tires .................................... ........ . 1-21
Wheel Bearings .... .. ...... ... .... .... .... ................................... .. 1-21
Wheel Spokes............................................. .......... .. .... ... .. 1-21
Identify Wheel Spoke Groups...................... ... . ... ....... 1-22
Wheel Spoke Adjustment. ......................................... 1-22
1.9 PRIMARY CHAINCASE LUBRICANT
General. ............................................................................ 1-23
Changing Primary Chaincase Lubricant... ... ... ...... ............ 1-23
1.10 TRANSMISSION LUBRICANT
Changing Transmission Lubricant... .................................. 1-25
1.11 CLUTCH
Adjustment.. ......................................................... ... . ... ..... 1 -27
1.12 DRIVE BELT AND SPROCKETS
General. ................................................................. ........ ... 1-29 ~
Cleaning ................. . ... ......... ... ......................... .. ............... 1-29 z
Inspection ................... .. .......................... .. .............. ..... ... .. 1-29 W
Sprockets ........... .... ....................... .. ....... .. ...... .. ...... .. . 1-29 t-
Drive Belt. ... ................ ... . ... . ... .......... ... ............ . ... . ... .. . 1-29 z
Checking Belt Deflection .................................................. 1-30 0
Adjusting Belt Deflection .. ................................ .. .. ...... .. .... 1-31 0
1.13 THROTTLE CABLES
Cable Inspection, Lubrication and Adjustment... ........ .... .. 1-33
Inspection and Lubrication ... .......... ... . ... .................... 1-33
Adjustment.. .............................................................. 1-33
1.14 CABLE AND CHASSIS LUBRICATION
General. ............................................................................ 1-34
Cables and Hand Levers .. ................................................ 1-34
Jiffy Stand ... ... . ... . ... .. .. ........... ..... ... .......... ... . ... ................. .. 1-34
Steering Head Bearings ................................................... 1-34
1.15 BRAKES
Fluid Inspection ......................... ... .......... ... . ... . ... . .... ........ .. 1-35
Rear Brake Pedal. .................... .. ....... .. ............................. 1-35
Pedal Height. ...................................... .. ..................... 1-35
Pedal Lubrication ......................... ... ............ ... ......... ... 1-35
Pedal Pad .............................................................. .. .. 1-35
1.16 BLEEDING BRAKES
General.. ........................................................................... 1-37
Procedure ............. ... ....... .. .. . ... ................. ... . .. .......... .. ....... 1-37
1.17 BRAKE PADS AND DISCS
lnspection ......................................................................... 1-38
Brake Pads ... .... . ... . ... .. .. . ... .. .. ..................................... 1-38
Brake Disc................................................................. 1-38
Brake Pad Replacement.. .... . .... ... . ... .. . .... .. ............ .. .......... 1-38
Rear Brake Caliper ......................................... .... ....... 1-38
Front Brake Caliper... ... .... ............................. ............ 1-40
Ill
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TABLE OF CONTENTS
1.18 SPARK PLUGS
Inspection ................................................................... ......1-42
Spark Plug Cable Inspection ....................... ..................... 1-42
1.19 SUSPENSION ADJUSTMENTS
Shock Absorbers ..............................................................1-44
Adjustment... ......................... ..... .......... ..................... 1-44
1.20 STEERING HEAD BEARINGS: ALL BUT
FLSTSB
Adjustment: FLST, FLSTC, FLSTF/B, FLSTN .................. 1-45
Bearing Adjustment (Fall-away) ................. .. ............. 1-45
Adjustment: FXST, FXSTC, FXCWC ..... .. ......... ............ .... 1-45
Bearing Adjustment (Fall-away) ............................ .... 1-45
Lubrication ........................................... .. ........................... 1-47
1.21 STEERING HEAD BEARINGS: FLSTSB
General. ................... .. .................. .. ......................... .......... 1-48
Lubrication ............................. .. .................................. 1-48
Adjustment: FLSTSB ........................................................ 1-48
Bearing Adjustment (Fall-away) .. .... ...... .. .. ................ 1-48
1.22 ROCKER BEARINGS: FLSTSB
lnspection ........................... .......................... .... .. .............. 1-50
1.23 HEADLAMP ALIGNMENT
Headlamp Alignment... ..................................................... 1-52
Headlamp Adjustment. ......................... .... ........................ 1-52
1.24 CRITICAL FASTENERS
lnspection .. .............................................. .. ....................... 1-54
Checking Torques on Fasteners ................................ 1-54
1.25 BATTERY MAINTENANCE
General ..... ................................................... .. ................... 1-55
Cleaning and Inspection .............................. ..................... 1-56
Voltmeter Test..:................................................................ 1-56
Voltmeter Test... ......................................................... 1-56
Charging Battery..................................... .... ............. ........ 1-56
Safety Precautions ................ .... .. ..............................1-56
Using a Battery Charger .. .......... .. ..............................1-56
Disconnection and Removal. ................................... ........ .1-57
Storage .............................................................................1-58
Installation and Connection .............................................. 1-59
1.26 ENGINE MOUNTS
lnspection ................................................................. .... .... 1-61
1.27 STORAGE
General. ... .. ......................... .............................................. 1-62
Placing in Storage ............................................................ 1-62
Removal from Storage..... .. ..................... .. ..... .... .. ............. 1-62
1.28 TROUBLESHOOTING
General. .............................................. .... .. ........................ 1-64
Engine ................................................................... .......... . 1-64
Starter Motor Does Not Operate or Does Not Turn Engine
Over ............................... .... .. ................................. .... 1-64
Engine Turns Over But Does Not Start ..................... 1-64
Starts Hard ............................... .. ...................... .... ..... 1-64
IV TABLE OF CONTENTS
Starts But Runs Irregularly or Misses ................... .... 1-64
A Spark Plug Fouls Repeatedly................................ 1-65
Pre-Ignition or Detonation (Knocks or Pings) ............ 1-65
Overheating ............................................................... 1-65
Valve Train Noise .......................................................1-65
Excessive Vibration ...................................................1-65
Check Engine Light Illuminates During Operation ..... 1-65
Lubrication System .......................................... .. .... ......... .. 1-65
Oil Does Not Return To Oil Tank................................ 1-65
Engine Uses Too Much Oil Or Smokes Excessively ... 1-65
Engine Leaks Oil From Cases, Push Rods, Hoses,
Etc ............................................................................. 1-65
Low Oil Pressure....................................................... 1-66
High Oil Pressure ...................................................... 1-66
Electrical System .............................................................. 1-66
Alternator Does Not Charge ......................................1-66
Alternator Charge Rate Is Below Normal. ................. 1-66
Speedometer Operates Erratically............................ 1-66
Transmission ........................................................... .... .... .. 1-66
Shifts Hard ........ ........................................................ 1-66
Jumps Out Of Gear................................................... 1-66
Clutch Slips.......................................................... .. .. . 1-66
Clutch Drags Or Does Not Release .......................... 1-66
Clutch Chatters .......................................................... 1-66
Handling ........................................................................... 1-66
lrregularities .............................................................. 1-66
Brakes ................ .. ................ .... ........................................ 1-66
Brake Does Not Hold Normally. .. ..............................1-66
CHASSIS
2.1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter .. .. .......................... 2-1
2.2 SPECIFICATIONS
Specifications .....................................................................2-5
Chassis Specifications............................... .. ...............2-5
Tire Specifications.......................................................2-6
2.3 VEHICLE IDENTIFICATION NUMBER
(V.I .N.)
Vehicle Identification Number........................................... .. 2-8
2.4 FRONT WHEEL: ALL BUT FLSTSB
Removal. .. .......... .. ............................................................2-1 0
Disassembly ............................................... .. ...... .... .. ........ 2-1 0
Disc Wheel.. ..............................................................2-10
Laced Wheel. ............................................ .. .... .. ...... .. 2-10
Cleaning and Inspection ............................................. .... .. 2-12
Assembly ..........................................................................2-12
Disc Wheel. ............................................................... 2-12
Laced Wheel. ............................................................2-12
Installation ........................................................................2-13
2.5 FRONT WHEEL: FLSTSB
Removal .... .. ..... .. .. .. ..........................................................2-14
Disassembly............................... .. . .......... ........ .. ............ .. .2-14
Cleaning and Inspection ................................................... 2- 14
Assembly.......................................... .. .............................. 2-14
Installation .......... .. ............................................................2-15
2.6 REAR WHEEL
Removal. ..........................................................................2-16
Disassembly .....................................................................2-16
Cleaning and Inspection ...................................................2-17
Assembly ... ....................................................................... 2-17
Installation ........................................................................ 2-18
2.7 SEALED WHEEL BEARINGS
Inspection .......... ............................................................... 2-19
Remova1 ........................................................................... 2-19
Installation ............................................... .. ....................... 2-20
2.8 WHEEL LACING
Wheel Lacing: Angle Flange Hub..................................... 2-22
2.9 TRUING LACED WHEELS
General ......................................................... .. ..................2-24
Setting Rim Offset.. .................................................. .. ...... 2-24
Truing Wheels .... .. ...................... .. ..................................... 2-25
Radial Truing ...................................................... ....... 2-25
Lateral Truing .............................................................2-26
2.10 CHECKING CAST WHEEL RUNOUT
General.. ......................................................................... .. 2-28
Checking Wheel Runout... ................................................ 2-28
Lateral Runout. ..........................................................2-28
Radial Runout. ...................................... .................... 2-28
Radial Runout. ...... .. .......................................................... 2-28
2.11 VEHICLE ALIGNMENT
Inspection ........ .. ...................................................... ......... 2-30
2.12 FRONT BRAKE MASTER CYLINDER
General.. ........................................................................... 2-31
Removal and Disassembly...............................................2-31
Cleaning and Inspection ............................... .. ........ .. ........2-33
Assembly and Installation .................................................2-33
2.13 FRONT BRAKE CALIPER: All BUT
FLSTSB
Removal. ... .. .... ... .. ........................................... .. ...... ......... 2-35
Disassembly .....................................................................2-35
Cleaning, Inspection and Repair ...................................... 2-37
Assembly ..........................................................................2-38
Installation ........................................................................ 2-38
2.14 FRONT BRAKE CALIPER: FLSTSB
Removal .. ......................................................................... 2-40
Disassembly ........................................... .... ......................2-41
Cleaning and Inspection ........................... .. ...................... 2-42
Assembly ................................................................ .... ......2-43
lnstallation ...... .. .. .. ...................................... .. ...... .. ............ 2-44
2.15 REAR BRAKE MASTER CYLINDER
General. ............................................................................ 2-46
Remova1 ...........................................................................2-46
Installation ....................................................... .. ..... .. ........2-46
Disassembly .....................................................................2-48
Cleaning and Inspection ...................................................2-49
Assembly .......................................................................... 2-49
TABLE OF CONTENTS
2.16 REAR BRAKE CALIPER
Removal . ..........................................................................2-51
Disassembly ..................................................................... 2-51
Cleaning, Inspection and Repair...................................... 2-53
Assembly.......................................................................... 2-54
lnstallation ........ .. ........................................ .. ... .. ... ............ 2-54
2.17TIRES
General. ............................................................................ 2-56
Removal ........................................................................... 2-56
Cleaning, Inspection and Repair......................................2-57
Installation ................................................ .. ......................2-57
Tube Type Tires.........................................................2-57
Tubeless Tires ........................ .. .................................2-57
Checking Tire Runout.. .................... .. ............................... 2-58
Lateral Runout. ........................... ........ ....................... 2-58
Radial Runout. ................................... .. ..................... 2-58
Wheel Balancing ... .... ........ ... ..................... .... .. .... .. ........... 2-59
Weights .. ................................................................... 2-59
2.18 FRONT FORK: TELESCOPIC
General .............................................................................2-60
Replacing Fork Oil. ...........................................................2-60
Removal ......................................... .. ..... .. ......................... 2-61
Disassembly..................................................................... 2-61
Cleaning and lnspection ................................................... 2-61
Assembly.......................................................................... 2-65
lnstallation ............ .......................... .. ..... .... ........ ........ ....... 2-65
2.19 FRONT FORK: SPRINGER
General. .. ..... .... ............................... .. ... .... .... .... .. .. .............2-66
Front Shock Absorber .......................................................2-66
Removal ....................................................................2-66
Installation.................................................................2-66
Rigid Fork.........................................................................2-66
Removal.. .................................................................. 2-66
Installation................................................................. 2-67
Spring Fork ....................................................................... 2-67
Disassembly ............................. .. . .. .................. .......... 2-67
Assembly ........................................ .. .......... .. ............. 2-69
Fork Rockers .............................................................. .. .... 2-71
Removal ....................................................................2- 71
Installation .................................................................2-71
Fork Stem Bearings .......................................................... 2-72
Removal and lnstallation........................................... 2-72
2.20 STEERING HEAD
Removal .. ........ ................................... ..............................2-73
FLST, FLSTC, FLSTF/B, FLSTN Models .................. 2-73
FXST, FXSTC Models............................................... 2-73
FXCWC Models......................................................... 2-73
FLSTSB Models............................ .. .. ........................2-74
lnspection .........................................................................2-74
All Models .. ................................................................2-74
Disassembly ................................... .... .............................. 2-74
Removing Lower Bearings From Fork Stem .............2-74
Steering Head Bearing Race Removal ..................... 2-75
Assembly.......................................................................... 2-75
Installation ........................................................................2-76
FLST, FLSTC, FLSTF/8, FLSTN Models ..................2-76
FXST, FXSTC Models ...............................................2-76
TABLE OF CONTENTS V
TABLE OF CONTENTS
FXCWC Models.. ... .................................................... 2-76
FLSTSB Models.......................................... ... . ... . ... . .. 2-76
2.21 BELT GUARD AND DEBRIS
DEFLECTOR
Removal. ........................................... ... . ... ..... .. . ... ............. 2-77
Belt Guard .................................................. ... . ... . ... . ... 2-77
Debris Deflector............................................. ... . ... . ... 2-77
Installation ........................................... .. ..... ... ...................2-77
Belt Guard ................................... ... .... ... .................... 2-77
Debris Deflector........................................................ 2-77
2.22 REAR SHOCK ABSORBERS
General. ... ... . ... ..................................................................2-78
Removal .......................................................... .. .... . ... .......2-78
Installation ........................................ .. .............. ................ 2-78
Shock Disposal. .. .............................................................. 2-79
2.23 REAR FORK
Removal ................................................. .. ........................2-81
Cleaning and Inspection ...................................................2-82
Pivot Bearing Replacement.. ............................................2-82
lnstallation ....... ... ............. ... ..............................................2-83
2.24 THROTTLE CONTROL
Removai/Disassembly...... ... ............................................. 2-84
Cleaning and lnspection ...................................................2-84
Assembly/Installation ................................ . ... .................... 2-84
Cable Routing ........................ ... ........................................ 2-85
2.25 CLUTCH CONTROL
Removal ............................................ .. .. . ... .......................2-86
Installation ........ ... . .. .......................................................... 2-86
2.26 HANDLEBARS: ALL BUT
FLSTF/FLSTFB/FLSTSBIFXCWC
Removal ................................................... ... ..................... 2-88
lnstallation .......................................... .. ............................ 2-89
2.27 HANDLEBARS: FLSTF/8
Removal ........ .. ................................................ .. .... .. .. . ... . .. 2-90
lnstallation ..................................... .. . ... ...... ....................... 2-91
2.28 HANDLEBARS: FLSTSB
Removal ................................................................... . ... .... 2-93
Installation ........................................... ... ....... .. .... ........ .. ...2-93
2.29 HANDLEBARS: FXCWC
Removal ................................. ... .................................... ... 2-95
Installation ..................................................................... .. .2-96
2.30 FRONT FENDER: ALL BUT FLSTSB
Removal ................................. ... .... ................................... 2-99
lnstallation ......................................................... .... .. . ... . ... .2-99
2. 31 FRONT FENDER: FLSTSB
Removal ......................................................................... 2-100
Installation ...................................................................... 2-1 01
VI TABLE OF CONTENTS
2.32 REAR FENDER: FLSTIFLSTC
Removal .......................................................... ........ ....... 2-102
Installation .. ....................................................................2-1 02
2.33 REAR FENDER: FLSTF/B
Removal. ........................................................................ 2-1 04
Installation ...................................................................... 2-1 04
2.34 REAR FENDER: FXSTIFXSTCIFLSTSB
Removal ......................................................................... 2- 1 06
Installation ........................ .... .... ... ....... ... . ... ....... .. .. ... ....... 2-1 06
2.35 REAR FENDER: FXCWC
Removal. .............. .......................................................... 2-1 08
Installation ...................................................................... 2-1 08
2.36 REAR FENDER: FLSTN
Removal. ........................................................................2-11 0
Disassembly................. .. ................................................2-11 0
Assembly......................... .. .............................................2-112
Installation ...................................................................... 2-112
2.37 REAR FENDER WIRE CONDUIT
lnstallation .................... .... .... .......................................... 2-113
2.38 JIFFY STAND
Cleaning ......................................................................... 2-1 15
Sensor (HOI Models) ............................ .... ...................... 2-115
Removal. ........................................................................2-116
Installation ......................................................................2-116
2.39 FORK LOCK
Removal. .............................. .. ........................................ 2-117
Installation ......................................................................2-117
2.40 SEAT AND STRAP RETENTION NUT
Replacement... ...............................................................2-118
2.41 SEAT: FXST
Removal and Installation ................................................2-119
Seat Strap ................................................... .... .. ...... 2-119
Seat. ........................................................................2-119
2.42 SEAT: FXSTC
Removal and Installation ................................................ 2-120
Seat Strap............................................................... 2-120
Seat. .............................. .. .......... .. .... ....... ... . ... . .. ....... 2-120
2.43 SEAT: FXCWC
Removal and lnstallation ................................................2-121
Rider Seat... ............................................................ 2-121
Passenger Seat Support... ......................................2-121
2.44 SEAT:
FLSTNIFLSTF/FLSTFBIFLSTIFLSTC
Removal and Installation ...................................... .. ........ 2-122
2.45 SEAT: FLSTSB
Seat: FLSTSB .. .. ...... .. ..................................................... 2-123
Removal. .................................................................2-123
lnstallation ...............................................................2-123
Adjusting Seat Position ................. .. ...................... .. 2-123
2.46 LUGGAGE RACK: FLSTN
Removal and lnstallation ........ ...... .. .... ..................... .. ..... 2-125
2.47 SADDLEBAGS: FLSTC
Removal .................. .. . .. ..................... .. .. ......................... 2-126
Installation ... .. ...................... .... ............................... ........ 2-126
2.48 WINDSHIELD: FLSTC
Removal. ................................................. .. .. ................... 2-127
Installation ................. . .. ......... .. ....................................... 2-127
ENGINE
3.1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter .......... .................... 3-1
3.2 SPECIFICATIONS
Specifications ....................... ............... .. ............................. 3-3
3.3 SERVICE WEAR LIMITS
General ............................... ........ .... ...... .. .... ........................ 3-5
3.4 ENGINE OIL FLOW
Oil Feed .. ...... ... ..... .... .... .............. .. .. ..... ..... .... .... .... .... .. . .. .....3-7
Top End ................ .. ...... .. .................................................... 3-8
Bottom End ......................................................................... 3-9
Chain Guide Bracket... ...... .......... ...... .. ....... .. .......... ........ .. 3-11
Oil Return .. .. ...... .. ..................................... .. .. ....................3-12
3.5 OIL PUMP OPERATION
General.. ............................... .. .............. .. .......................... 3-13
Operation .................... ....................... ........ .......................3-13
3.6 BREATHER OPERATION
General. ............................ ........ .......................... .. ......... .. .3-15
3.7 OIL PRESSURE
Oil Pressure Indicator Lamp .... ........... .. ....... .. ...... .. ........... 3-16
Checking Oil Pressure ......................................................3-16
3.8 TROUBLESHOOTING
Diagnosing Valve Train Noise...........................................3-17
Compression Test... .......................................................... 3-17
Cylinder Leakdown Test .................................................... 3-17
Diagnosing Smoking Engine or High Oil Consumption .....3-18
Check Prior To Cylinder Head Removal. .................. . 3-18
Check After Cylinder Head Removal. ........................3-18
3.9 HOW TO USE THIS SECTION
Top End Repair.................................................................3-19
Bottom End Repair .. ......... .. ...... .. ................... .. ...... ..... ......3-19
Typical Symptoms .. ................ .... .... .......... .. ................. .. ....3-19
3.10 TOP END SERVICE
Engine in Chassis............................................................. 3-20
TABLE OF CONTENTS
Engine Removed from Chassis............................ .. .......... 3-21
3.11 BOTTOM END SERVICE
Engine in Chassis ................................. .. ..........................3-22
Engine Removed From Chassis .......................................3-23
3.12 STRIPPING MOTORCYCLE FOR
SERVICE
Procedure ......................................................................... 3-24
3.13 ASSEMBLING MOTORCYCLE AFTER
SERVICE
Procedure .. .. .....................................................................3-25
3.14 REMOVING ENGINE FROM CHASSIS
Procedure ............. .. ...................................................... .. .. 3-26
3.15 INSTALLING ENGINE IN CHASSIS
Procedure .........................................................................3-27
3.16TOP END OVERHAUL: DISASSEMBLY
General. ............................................................................ 3-29
Rocker Covers..................................................................3-29
Rocker Arm Support Plate .............. .......... .. .... .... .. ...... .. ....3-29
Push Rods, Lifters and Covers .... .............. .. ...... .. ............. 3-31
Cylinder Head ... ........... .. ......... ........................ .. ................ 3-32
Cylinder ............................................................................ 3-33
Piston ........................................ .. ......... .... .......... .. ... ..... ... . 3-33
3.17TOP END OVERHAUL: ASSEMBLY
General. ............................................................................ 3-35
Piston ... .. .......................................................................... 3- 35
Cylinder............... .. .. .... .. ..... .. .. . .. ... .... .... .. ........ . .. ... .. .. .. ...... 3-36
Cylinder Head ........................................................... ........3-38
Push Rods, Lifters and Covers...... .... .. ...... .. .. .. ... ..... .. ....... 3-41
Rocker Arm Support Plate ................................................3-42
Breather Assembly........................ ..... .... ..... .. ...................3-43
3.18 BOTTOM END OVERHAUL:
DISASSEMBLY
General. ............................................................................ 3-45
Cam Support Plate and Cover..........................................3-45
Prepare Engine .......................................... .. .............3-45
Cam Chain and Sprockets........................................3-45
Cam Support Plate .. .. ...... ...... .. ........... .. ...... .. .............3-46
Crankcase ................................... .. .... ... .... .... .... .. ......... .. ... 3-47
Counterbalancer Assembly..............................................3-48
3.19 BOTTOM END OVERHAUL: ASSEMBLY
General. ............................................................................ 3-51
Counterbalancer Assembly .... .. .... ...... ... .. ... ... ... ..... ... ........ 3-51
Crankcase ................................................... .. .......... .... ..... 3-54
Cam Support Plate and Cover ........................ .. ...... .. ........3-58
3.20 BREATHER ASSEMBLY
Removal Overview ............................................................3-62
Disassembly ...... .. .......... .. ..................... .. .. ........................ 3-62
Cleaning and Inspection ................... .. . .. ...... .. .. .... ... .. .. .... .. 3-62
Assembly.............................................. .. .. ........................3-62
Installation Overview ................... . .. ....... ...................... .. . .. 3-62
TABLE OF CONTENTS VII
TABLE OF CONTENTS
3.21 ROCKER ARM SUPPORT PLATE
Oil Pressure Relief Valve .. .............. .. ................................ 3-91
Removal Overview .... .... .... .. ..............................................3-63
Disassembly ................................................................. .. .. 3-63
Cleaning and Inspection ................................................... 3-63
lnspection .. ....................... ......................................... 3-63
Rocker Shaft Fit... ......................................................3-63
Rocker Arm Shaft to Bushing .................................... 3-64
Replace Rocker Arm Bushings .................................3-64
Assembly .......................................................................... 3-65
Installation Overview........................................................3-65
Removal .................................................................... 3-91
lnstallation ............................................................... .. 3-91
lnspection .................................................................. 3-91
Cam Needle Bearings........................................... .. ......... 3-91
Removal. ... ................................................................ 3-91
Installation ................................................................. 3-93
Cleaning and Inspection ................. .. ................................3-94
Oil Pressure Valve ..................................................... 3-94
Cam Support Plate ............. .. .....................................3-94
Installation Overview..................... .- .. . .. ................. .. .... .. .... 3-94
3.22 PUSH RODS, LIFTERS AND COVERS
3.27 OIL PUMP
Removal Overview.... ...... .. ................ ................................ 3-66
Disassembly............................................... ................ ... . .. 3-66
Cleaning and Inspection ...................................................3-66
Lifter Inspection ................................................................3-67
Removal Overview............................................................3-95
Cleaning and lnspection ...................................................3-95
Installation Overview........................................................ 3-95
Assembly..........................................................................3-67
3.28 CRANKCASE
Installation Overview .............................................. .. ........3-67
Removal Overview .................................. .. ... .............. .......3-96
3.23 CYLINDER HEAD
Right Crankcase Half ........................................................ 3-96
Removal Overview ............................................................3-68
Disassembly ......... .. .................................. ........................3-68
Cleaning .......................................... .... ...... .......................3-69
Inspection ..................... .. .................................................. 3-70
Cylinder Head ............................................................3-70
Valve Guides .............................................................3-70
Valves ....................................................... .. ........ .. ... .. 3-70
Valve Springs............................... ............................. 3-70
Tapered Keepers ....................................................... 3-71
Valve Seats ............................................................... 3-71
Valve Guide Replacement.. .............................................. 3-71
Removal ..................................... .. ..... ... ........ ............. 3-71
lnstallation .......................... .......................................3-72
Valve and Seat Refacing .................................................. 3-75
Assembly .............................................. ........ .................... 3· 77
Installation Overview ........................................................ 3· 78
Chain Guide Screen ..................................................3-96
Crankshaft (Roller) Bearing Removal. .......................3-96
Crankshaft (Roller) Bearing Installation .....................3-97
Piston Jets Removal. ................................................. 3-97
Piston Jets Installation ............................................... 3-97
Left Crankcase Half.......................................................... 3-98
Main Bearing Removal. ......................................... .... 3-98
Main Bearing Installation ...........................................3-99
Sprocket Shaft Bearing Inner Race ................................3-100
Removal. ...................................... .. ......................... 3-1 00
lnstallation ............................. .. ...... .. ........ .. ...... .. ...... 3·1 01
Cylinder Studs .. ...... .. . .... .. ...... .. ......... .. ...... ... ... .. .............. 3-1 02
Remova l. ................................................................. 3-1 02
Installation ...............................................................3-1 02
Pipe Plugs and Oil Fittings ....... .... .. ................................ 3-1 02
Removal/Installation .............................................. .. 3-102
Cleaning and Inspection ...................... ........................... 3-1 03
3.24 CYLINDER
Installation Overview ...................................................... 3-1 03
Removal Overview....... .. ................................................... 3-79 3.29 FLYWHEEL AND CONNECTING RODS
Cleaning ...........................................................................3-79
Inspection ............................................................. .. .......... 3-79
Deglazing Cyli nder.......................................................... . 3-81
Boring and Honing Cylinder.............................................3-82
Removal Overview..........................................................3-104
Inspection ................... .... ...... .. ........................................ 3-1 04
Installation Overview..................... .. ........................... .. .. 3-104
Installation Overview........................................................ 3-82
3.30 COUNTERBALANCER ASSEMBLY
3.25 PISTON
Removal Overview..........................................................3-105
Removal Overview ............................ ................................ 3-84
Disassembly................................................................... .. 3-84
Piston Rings .......... .......... ..........................................3-84
Cleaning ........................................................ .. ........ ......... 3-84
Inspection .................. .. ........................ .... .. .... .... .... ........... 3-85
Assembly .. ........................................................................3-86
Checking Piston Ring Gap........................................3-86
Installing Piston Rings ............................................... 3-87
Installation Overview ....................................... .. ...............3-88
Cleaning, Inspection, and Repair...................................3-105
General. ................................................................... 3-1 05
Balance Shaft Removal ...........................................3-1 05
Balance Shaft Installation ........................................ 3-1 06
Balance Shaft Support Bearings Removal. ....... .... .. 3-1 06
Balance Shaft Support Bearings Installation .. .... .. ... 3-1 06
Front and Rear Balance Sprockets .........................3-107
Hydraulic Tensioners............................................... 3-1 07
Chain Tensioner Guides ..........................................3-108
Chain Guide Bracket.. .............................................3-108
3.26 CAM SUPPORT PLATE AND COVER
Balance Chain ......................... .. ..............................3-108
Installation Overview ...................................................... 3-1 08
Removal Overview .......................... .......................... ........3-89
Camshafts ....................................................... .. ............. .. 3-89 3.31 OIL TANK: ALL BUT FXCWC
Removal .................. .. ........................ .. ........... .... ....... 3-89
Assembly............... .. ..................................................3-89
Removal and Disassembly............................................. 3-1 09
Oil Tank .................................................................... 3-1 09
VIII TABLE OF CONTENTS
Oil Line Fittings/Retainers ............... ... .. ... .. .......... .. .. 3-111
lnstallation ... .. ....... ........ ... ................................ .. ............. 3-112
3.32 OIL TANK: FXCWC
Removal and Disassembly.......................... .... ... ..... ..... .. 3-113
Oil Tank. .. ........ .. ..................... .. .... .. .. .. ...................... 3-113
Oil Line Fittings/Retainers ......................... .. ........... . 3-115
Installation ................................. .. ........ .. .. .... ................... 3-116
FUEL SYSTEM
4.1 FASTENER TORQUE VALUES
Fastener Torque Values in this Chapter .. ......... .. ........... .. .... 4-1
4.2 SPECIFICATIONS: FUEL SYSTEM
Specifications ..... .. .... ..... .... .... .... .............. .. .. ....... .. ....... .. .... .4-3
4.3 ELECTRONIC FUEL INJECTION (EFI)
Troubleshooting ................................ .. ............................. .. .4-4
4.4 IDLE SPEED
Generai .............................................................................. A -5
4.5 AIR CLEANER ASSEMBLY
Removai ...................... .. ........................ ..... ........ ..... .......... A- 6
lnstallation .... ............... .... ..... ... .... ... .............. .. .......... ..... .. ..A -6
Backplate Assembly: HOI Models ..... .. .. ... .... .. ........... .. ....... .4-7
4.6 FUEL TANK
General. ........ ...... .... .......................... . .... .... ..... ... ... ....... .. .. ...4-8
Removal. .. .. ....................................................... .. .............. .4-8
Cleaning and Inspection .............. .. .................... .. .......... .. .4-12
Installation ...... ,........................ .. ...... .... .. .. ......... .. ........ ..... .4-12
All But FXCWC .......... ............ .. ..... .. ...... .. ...... .. .. ... ..... A-12
FXCWC .................................................................... A-12
4.7THROTTLE POSITION SENSOR (TPS)
General .... .. .......................................................................4-1 4
Removai .... .. .... ... .... .... ... ..................... .. ...... ..................... A-14
Installation ............................................ .. .......................... 4-14
4.8 INTAKE AIR TEMPERATURE SENSOR
(I AT)
General .. .... .. ..... .. ................. .. ...... ........ .. .... .. .. .. .. .............. .4-15
Removal . ........ .. ........ .. ..... .. .............. .. .. ....... .. ... .. .............. . 4-15
Installation .. ............. .. ................................. .. ................... .4-15
4.9 ENGINE TEMPERATURE SENSOR (ET)
General .......... .. ................. .. .............................................. 4-16
Removal . ........ .. ................. .. ...... .. .... .. .. .. ..... ...................... 4-16
Installation .................. .. .. ............. .... ................... .. ............ 4-16
4.10 INDUCTION MODULE
Removal . ............................................. .. .... .. ...... .... .......... . 4-18
Installation ............................................ .. ............. .. ...... .... .4-19
4.11 IDLE AIR CONTROL (lAC)
General ................................................................... ......... .4-20
Remova1 .................... .. .... .. ........ .. .. ... ..... .... ... .. .. ................4-20
TABLE OF CONTENTS
lnstallation ... .. .. .. ............... .... .. ..................... .. .................. A-20
4.12 MANIFOLD ABSOLUTE PRESSURE
SENSOR (MAP)
Generai. ..... .. ..... .. .... .. .... .. .... ......... .... ..... ........................... A-21
Removal ............................................. .. ........ .. .................. 4-21
lnstallation ................. .... .. ........ ................ .......... .... .... ..... .A-21
4.13 OXYGEN SENSOR
General. ..... .. ..... .. ............. ....... ... ..... .. .. ..................... .. ....... 4-22
Removai .......................................................................... A-22
Installation ................................................ .. .......... .. .. .. ...... 4-22
4.14 FUEL INJECTORS
General. ...................... .. ................. .. ....... .. ...... .. .. .. .. .......... 4-24
Removal ... ......... .. ........ .. .. ................................ .. .......... .. ... 4-24
lnstallation ............. .. .............................. .. ........................ A-24
4.15 FUEL PUMP AND FUEL GAUGE
SENDING UNIT
Generai .............. ..... .... .. ................................................... A-26
Removal .......................... ........... ...... .. ................... ..... ..... .4-26
Disassembly/Assembly..... ... .. ...... .. .... .. . .. .............. .. .......... 4-28
Fuel Filter .. ....................................................... .. ...... .4-28
Regulator......... .. .. ...................................................... 4-28
Inlet sock .. ........ .... ........... .. .................. .. .................... 4-29
Fuel Pump ..................... .. . .. . .. ... .. .. . .. ............. .. .......... A-30
Installation ........................... .. .. ........................... .. .. .. ....... .4-30
4.16 FUEL PRESSURE TEST
General ........ .. ...... ... .. .. ......... .. .. .. .. .. .... .. .. ..... .... .. .. .. .... .. ...... 4-32
Testing .............................................................................. 4-32
4.17 EXHAUST SYSTEM: ALL BUT
FLSTF/FLSTFB/FLSTNIFLSTSB
Mufflers .. .................. ........ ... ............................... .. .. .... ...... .4-35
Removal . ................. .. .. .. .... .. ... .. ....... .. .............. .. ........ 4-35
Assembly ............ ... .... .. ................. .. .. ........ .. ... ... .. ...... A -35
System . .... .. . .. . .. ... .... .... ... ........ .... ................ ........ .. ...... .... .. 4-35
Removal ... .................... ................................ .. ........... 4-35
Installation .... .. ... ....................... .. .. . .. .......................... 4-35
4.18 EXHAUST SYSTEM:
FLSTF/FLSTFB/FLSTNIFLSTSB
Mufflers ......... .. .................... ................................. .... ........ .4-37
Removai .. ........................ .... ... ...................... .... ... .... . A -37
Assembly .... .. ............... . .. . .. ...... .. ....... .... ................ .. ...4-37
Syste m ... .. ....................................................................... A-37
Removal .. .... ............ .. . .. .............. .. .......... .... ............... 4-37
lnstallation ............................... .. ....................... .. ...... .4-37
4.19 INTAKE LEAK TEST
General. ................. .. .................. .. .... .. .................... ..... ... .. 4-39
Leak Tester................... .. .......................... .. ............. .. ..... ..4-39
Parts List.. ...................... .. .. ............... ... .. .................. .4-39
Tester Assembly .. ................................... .. ...... .. .. ...... .4-39
Tester Adjustment. ........................................ .. .. .........4-39
Procedure .. ...... . .. .......... .. ..... .. ....... .. . .. .... ....... .. ............. .... .4 -39
TABLE OF CONTENTS IX
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This professional technical manual contains service, maintenance, and troubleshooting information for your Harley Davidson Softail FLSTSB Cross Bones 2010, covering all models, engines, trim, and transmission types. It is a top-quality workshop repair service manual that is complete and intact without any missing or corrupt parts or pages. This manual is guaranteed to be fully functional and is useful for both professional mechanics and DIY enthusiasts.
The original workshop manual contains hundreds of pages of diagrams and detailed information for specific vehicle or equipment repair. It includes pictures and easy-to-follow directions on what tools are needed and how the repair is performed. The manual covers general information, maintenance, chassis, fuel system, cooling system, engine, clutch, engine lubrication system, engine removal/installation, drive, transmission, wheels/tires, final drive, brakes, suspension, steering, frame, electrical system, and wiring diagrams, plus a lot more info.
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In this manual, detailed substeps expand on repair procedure information, and notes, cautions, and warnings throughout each chapter pinpoint critical information. Numbered instructions guide you through every repair procedure step by step, and detailed illustrations, drawings, and photos guide you through every procedure. Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
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