2006-2009 Harley-Davidson FXSTB Softail Night Train OEM Service & Repair Manual
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IMAINTENANCE
11
21
ICHASSIS
3.
2006
I ENGINE
SOFTAIL
4.
I FUEL SYSTEM
SERVICE
5.
MANUAL
I ELECTRIC STARTER
The information in this Service Manual applies
to all 2006 Softail® models .
I DRIVE
61
7.
I TRANSMISSION
8.
I ELECTRICAL
9.
I FUEL INJECTION
•
IAPPENDIX
•
I INDEX
FOREWORD
GENERAL
This Service Manual has been prepared with two purposes in
mind. First, it will acquaint the user with the construction of
the Harfey-Davidson product and assist in the performance of
basic maintenance and repair. Secondly, it will introduce to
the professional Harley-Davidson Technician the latest field-
tested and factory-approved major repair methods. We sin-
cerely believethatthis Service Manual will make your associ-
ation with Harley-Davidson products more pleasant and
profitable.
HOWTO USE
YOUR SERVICE MANUAL
Information is arranged as fo llows:
• Section 1-Maintenance
• Section 2-Ghassis
• Section 3- Engine
• Section 4-Fuel System
• Section 5- Electric Starte r
• Section 6-Drive
• Section 7- Transmission
• Section B-Electrical
• Section 9- Fuel Injection
• Appendix A-Tools
• Appendix B-Wiring
• Appendix C-Metric Conversions
• Appendix D- Japanese MainshafVCountershaft
• Appendix E-G lossary
Use the TABLE OF CONTENTS following this FOREWORD or
the INDEX at the back of the book to find the desired SUbject.
Note that each manual section contains sequentially num -
bared topics.The numbering system allows quick cross refer-
ences throughout the document.
For example, the sixth topic (BRAK ES) in section one (MAIN-
TENANCE) could be referred to as:
1.6 BRAKES
This cross reference directs the reader to section 1 (MA INTE-
NANCE) and topic 6 (BRAKES)
PREPARATION FOR SERVICE
AWARNING
Stop the eng ine when refueling or servicing the fuel sys-
tem. Do not smoke or allow open lIame or sparks near
gasoline. Gasoline is extremely 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 per-
form the repair as easily and quickly as possible, and will
reduce the incidence of misplaced tools and parts . A motorcy-
cle that is excessively dirty should be cleaned before work
starts. Cleani ng 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. See
APPENDIX A-TOOLS for equipment required for special ser-
vice work.
NOTE
• To avoid unnecessary disassembly. carefully read all rel-
ative service information before repair work is started.
• In ligure legends. the number which follows the name of
a part indicates the quantity necessary for one complete
essemoty:
SERVICE BULLETINS
In addition to the informa tion presented in this Service
Manual. Harfey-Davidson Motor Company will periodically
issue Service Bulletins to Harley dealers. Service Bulletins
coverinterim engineering changes and supplementary infor-
mation.
USE GENUINE
REPLACEMENT PARTS
AWARNING
When replacement parts are requ ired , use only genuine
Harley-Davidson parts or parts with equivalent character-
istics (which Include type , strength and material). Failure
to do so may result In product malfunction . This could
result in death or serious injUry.
To ensure satisfactory and lasting repairs, carefully follow the
Service Manual instructions and use only genuine Harley-
Davidson replacement parts. This is your assurance that the
parts you are using will fit right. operate properly and last
longer.
i.
WARNINGS AND CAUTIONS
Statements in this service manual preceded by the following
words are of special significa nce.
ADANGER
DANGER indicates an imminently hazardous s ituation
which , if not avoided, will result in death or serious
injury.
AWARNING
WARNING indicates a pote ntially hazardous situation
which , il not avoided, cou ld result in death or serious
injury. (00119a)
ACAUTION
CAUTION indicates a potentially hazardous s ituation
which , if not avoided, may result in minor or moderate
injury. (00139a)
CAUTION
CAUTION used without the salety ale rt symbol indicates
a potentially hazardous si tuat ion which , if not avoided,
may result in property damage (00140a)
AWARNING
• Proper service and repair is important for the safe ,
reliable operation 01 all mechanical products. The
se rvice procedures recommended and desc ribed in
this Service Manual are effective methods lor per-
forming service operations. Some of these service
ope rations requ ir e the use 01 tools spec ially
designed lor the purpose .These special too ls should
be used when and as recommended. It is important
to note that some warn ings aga inst the use 01 spe-
cific service methods, which cou ld damage the
motorcycl e or render it unsafe, are stated in this Ser-
vice Manual. However, please remember that these
warnings are not all- inclusive . Inadequate salety pre-
caution s could result in death or serious injury.
• Since Harley-Davidson could not possibl y know,
evaluate or advise the service trade 01all possible
ways in which service m ight be performed , or of the
possible hazardous consequences of each method ,
we have not undertaken any such broad eva luation .
Accordingly, anyone who uses a se rvice procedure
or tool which is not recommended by Harley-David-
son must lirstthoroughly sati sly himsellthat neither
his nor the operator's salety will be jeopardized as a
result. This could result in death or serious in jury.
• Wear eye protect ion when using hammers, arbor or
hydraulic presses, gear pullers, sp ring compressors ,
s lide hammers and similar tools . Be especially cau-
tio us when using pulling , pressing or compressin g
equipment. The forces involved can cause p arts to
fly outward with considerable lo ree, pos s ibly result-
ing in death or ser ious injury.
ii.
PRODUCT REFERENCES
AWARNING
Follow the directions listed on all products. Carelully
read all labels, warnings and cautions before use. Inade-
quate salety precautions could result in death or serious
injury.
When reference is made in this Service 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 "HO". "J" or "S"
preface must be ordered through:
Kent-Moore
SPX Corporation
28635 Mound Road
Warren, Michigan USA 48092·3499
Telephone: 1-800-345-2233
Midtron ics Electronic Systems Analyzer
For replacement parts and service informat ion, contact:
Midt ronics , Inc.
7000 Monroe Street
Willowbrook, Illinois USA 60527
Telephone: 1·800·776·1995
Sealing and Threadlocking Products
LOCTITE PRODUCTS
Some procedures in this Service 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 1-800-LOCTITE or www.loctite.com.
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-
Davidson reserves the right to change specifications, equip-
ment or designs at any time without notice and without incur-
ring obligation.
TABLE OF CONTENTS
Page No. Page No.
SECTION 1-MAINTENANCE
1.1 GeneraL .
Servicing a New Motorcycle .
Safe Operating Maintenance .
Shop Practices .
Repair Notes .
Safety .
Removing Parts .
Cleaning .
Disassembly and Assembly ..
Repair and Replacement Procedures .
Hardware and Threaded Parts .
Wiring. Hoses and Lines .
Instruments and Gauges .
Bearing s .
Bushings ..
Gaskets .
Lip Type Seals __ .
O-Rings (Preformed Packings) __ ..
Gears .
Shafts ..
Part Replacement __ __ ..
Cleaning __ __ .
Part Protection __ __ __ .. __ ..
Cleaning Process _ .
Rust or Corrosion Removal .
Tool Safety __ __ __ __ __ .
Air Tools __ __ __ __ .. __
W renches __ _ .
PliersiCultersiPrybars .
Hammers .
Punches/Chisels .
Screwdrive rs .
Ratchets and Handles .
Sockets ..
Storag e Units __ __ .
1.2 Fuel and Oil .
Fuel. __ ..
Gasoline Blends .
Engine Oil .
Winter Lubrication .
1.3 Maintenance Schedule .
First Scheduled Maintenance .
1.4 Engine Oil and Filter .
Checking and Adding Oil .
Type of Oil __ ..
Checking Oil Level ..
Recommended Oil Grades (table) .
Changing Oil and Filter .
1.5 Battery Maintenance ..
General __ __ .
Battery Electrolyte Antidote s (table) __ .
Disconnection and Removal .
Installation and Connection __
Inspection .", .
Storage .
1-1
1-1
1-1
1-1
1-1
1-1
1-1
1-2
1-2
1-2
1-2
1-2
1-2
1-2
1-2
1-3
1-3
1-3
1-3
1-3
1-3
1-3
1-3
1-3
1-3
1-3
1-3
1-3
1-4
1-4
1-4
1·4
1-4
1-4
1-4
1-5
1-5
1-5
1-5
1-5
1-6
1-6
1-11
1-11
1-11
1·1 1
1·11
1-12
1-13
1-13
1- 13
1-14
1-14
1-15
1-15
1.6 Brakes .
Fluid Inspection .
Rear Brake Pedal .
Pedal Height .
Pedal Lubrication .
Pedal Pad .
1.7 Bleed ing Brakes ..
Gener al .
Procedure __ .
1.8 Brake Pads and Discs ..
Inspection ..
Brake Pads .
Brake Disc Thickness .
Brake Disc Lateral Runout and \Xarpage ..
Brake Pad Replacement .
Rear Brake Caliper ..
Front Brake Caliper: All But FLSTSC/FXSTS .
1.9 Tires and Wheels .
Tires .
Tire Pressures (table) .
Tire Replacement.. ..
Wheel Bearings .
Wheel Spokes .
1.10 Primary Chain ..
Inspection .
1.11 Primary Chaincase Lubricant .
Changin g Lubricant .
1.12Clutch ..
Adjustment .
1.13 Transmission Lubricant ..
Changing Lubricant __ __ . __ ..
1.14 Rear Belt Deflection ..
Inspection __ __ __ .
1.15 Rear Belt and Sprockets ..
General .
Cleaning __ .. __ __ .
Inspection ..
Sprockets __ __ __ .
Rear Belt .
Drive Belt Wear Analysis (table) ..
1.16 Suspension Adjustments ..
Rear Shock Preload .
1.17 Steering Head Bearings: All But
FLSTSC/FXSTS .
Adjustment __ __ __ ..
Bearing Adjustment (Fall-away) ..
Lubricat ion .
1-16
1-16
1-17
1-17
,.,7
1-17
1-18
1-18
1-18
1-19
1-19
1-19
1-19
1-19
1-20
1-20
1-22
1-23
1-23
1-23
1-24
1-24
1-24
1-25
1-25
1-26
1-26
1-28
1-28
1-30
1-30
1-31
1-31
1-32
1-32
1-32
1-32
1-32
1-32
1-33
1-34
1-34
1-35
1·35
1-35
1-35
iii
Page No. Page No.
1.18 Steering Head Bearings:
FLSTSC/FXSTS .
General .
Lubrication .
Adjustment .
FLSTSC Models... . .
FXSTS Models .
1.19 Rocker Bearings: FLSTSCI
FXSTS .
Inspection .
1.20 Front Fork Oil .
Replacing Fork Oil .
1.21 Spark Plugs ..
Inspection .
1.22 Air Cleaner Filter .
Removal .
Installation .
1.23 Cable and Chassis Lubrication
General .
Cables and Hand Levers .. ..
Jiffy Stand ..
1.24 Throttle Cables .
Cable Inspection, Lubrication and Adjustment
Inspection and Lubrication .
Adjustme nt.. ... .. .
1.25 Enrichener: Carbureted .
Enrichener Operation.
1.26 Idle Speed and Ignition Timing:
Carbureted .
Idle Speed Inspection .. ..
Ignition Timing .., , .
1-36
1-36
1-36
1-36
1-37
1-37
1-39
1-39
1-41
1-41
1-43
1-43
1-44
1-44
1-45
1-46
1-46
1-46
1-46
1-47
1-47
1-47
1-48
1-49
1-49
1-50
1-50
1-50
1.32 Troubleshooting 1-59
General... 1-59
Engine ........ 1-59
Starter Motor Does Not Operate or Does Not Turn Engine
Over ..................................... 1-59
Engine Turns Over But Does Not Start.. 1-59
Starts Hard 1-59
Starts But Runs Irregularly or Misses 1-59
A Spark Plug Fouls Repeatedly.. 1-60
Pre-Ignition or Detonation (Knocks or Pings) 1-60
Overheat ing 1-60
Valve Train Noise 1-60
Excessive Vibratio n ..... 1~60
Check Engine Light Illuminates During Operation 1-60
Lubrication System 1-60
Oil Does Not Return To Oil Tank .......................... 1-60
Engine Uses Too Much Oil Or Smokes Excessively 1-60
Engine Leaks Oil From Cases, Push Rods, Hoses 1-60
Low Oil Pressure _.... ..... 1-61
High Oil Pressure 1-61
Electrical System 1-61
Alternator Does Not Charge 1-61
Alternator Charge Rate Is Below Normal ............. 1-61
Speedome ter Operates Erratically .... 1-61
Carburetor 1-61
Floods .............. 1-61
Transmission 1~61
Shilts Hard.. ......... 1-61
Jumps Out a t Gear 1-61
Clutch Slips ................... 1-61
Clutch Drags Or Does Not Release.............. 1-61
Clutch Chatters .. 1-61
Handling .:. 1-62
Irregularities .... 1-62
Brakes 1-62
Brake Does Not Hold Normally...... 1-62
SECTION 2-CHASSIS
1.27 Fuel Supply Valve Filter:
Carbureted .
Inspection .
Fuel System Lines and Fittings .
1.28 Engine Mounts .
Inspection .
1.29 Headlamp Alignment .
Inspection .
Adjustment .. .
FLSTSC/FXSTS Models ..
FLSTC/FLSTF/FLSTN/FXSTB/FXST/FLST Models
FXSTD Models .
1.30 Critical Fasteners .
Inspection . .
Critical Fasteners (table) .
1.31 Storage .
General .
Removal From Storage ..
iv
1-51
1-51
1-52
1-53
1-53
1-54
1-54
1-55
1-55
1-55
1-55
1-56
1-56
1-56
1-57
1-57
1-58
2.1 Specifications .
2.2 Torque Values .
Tires.... . .
Tire Fitment, Tubeless Cast Wheels (table) .
Tire Fitment, Laced Wheels (table) .
Tire Pressure, All Models (table) .
2.3 Vehicle Identification Number
(V.I.N.) .
General .
2.4 Front Wheel: All But FLSTSCI
FXSTS/FXSTD .
Removal .
Disassembly .
Disc Wheel ..
Laced Wheel ................ .. .
Cleaning and Inspection .
Assembly .
Disc Wheel .......... .. ..
Laced Wheel ..
Installation .
2-1
2-2
2-5
2-5
2-5
2-6
2-7
2-7
2-9
2-9
2-9
2-9
2-9
2-11
2-11
2-11
2-11
2-11
Page No. Page No_
2.5 Front Wheel: FXSTD .
Removal .
Disassembly ,." ,.. """" ,
Cleaning and Inspection .
Assembl y ,..
Installation , ,' " .
2.6 Front Wheel: FLSTSC .
Removal ',..,.,.."" " .." " "" ,.." ,.", .. """ ,
Disassembly , ", ,.. """ ..
Cleaning and Inspection .
Assembly , ,.., ..
Installation "., ..
2.7 Front Wheel: FXSTS .
Removal ." ". " "" " .., " , "" """ ',
Disassembly , , ..
Cleaning and Inspection .
Assembly , , .
Installation , ..
2.8 Rear Wheel .
Removal .
Disassembly , ..
Cleaning and Inspection ..
Assembly , .
Installation , " ..
2.9 Sealed Wheel Bearings .
Inspection ,." ,.." , " ,.,.., ,..", ." ", ..'" ,
Removal ", ..
Installation " ,.., ,..,.." , ,..
2.10 Wheel Lacing : 16 In. Rim .
General .
Procedure "" .
2.11 Wheel Lacing: 21 In. Rim .
Procedure " , ',.,.., , .
2.12 Truing Laced Wheel .
Gene ral ,.." ., , , , " .., ..
Lateral Truing , ,
Wheel Offset Dimensions (table) .
Radial Truing , ,., " .
2-12
2-12
2-12
2-12
2-13
2-13
2-14
2-14
2-14
2-14
2-14
2-16
2-17
2-17
2-17
2-17
2-17
2-19
2-20
2-20
2-20
2-22
2-22
2-22
2-23
2-23
2·23
2-24
2-25
2-25
2-26
2-28
2-28
2-31
2-31
2-31
2-32
2·34
2.16 Front Brake Master Cylinder ..
General .
Removal/Disassembly .
Cleaning and Inspection ..
Assembly/Installation ,.
2.17 Rear Brake Master Cylinderl
Reservoir ..
Hernoval.. , " , .
Installation , " .", "" "."" .
Disassembly ..
Cleaning and Inspection ..
Assembly , , ..
2.18 Front Brake Caliper: All But
FLSTSC/FXSTS .
Removal ", " ..
Disassembly , " ..
Cleaning, Inspection and Repair ~ ..
Assembly " , ',.,,'., .
Installation .
2.19 Front Brake Caliper: FLSTSC ..
Front Brake Caliper ..
Removal .
Installation ,..""", " "
Brake Reaction Link , ", .
Removal , ,.,." " .."", .,."", .., " " ",, '.., .
Installation ., "., .." ,, .
2.20 Front Brake Caliper: FXSTS .
Removal .
Installation ", ,..,' , " .."., ..
Disassemb ly "." , " ..
Cleaning and Inspection ..
Assembly " ., "" "", ,.., , " ", .
2.21 Rear Brake Caliper: All But
FXST/FXSTB/FXSTS .
Removal .
Disassembly , , ,, .
Cleaning , Inspection and Repair .
Assembly ,." " ", '
Installation , , , ..
2-41
2-41
2-41
2-42
2-44
2-46
2-46
2-46
2-49
2-50
2-50
2-52
2-52
2-52
2-55
2-56
2-57
2-58
2-58
2-58
2-58
2-60
2-60
2-60
2-61
2-61
2-62
2-63
2-64
2-65
2-66
2-66
2-66
2-69
2-69
2-70
2.13 Disc Rim Runout.. .
General .
Lateral Runout " , .
Radial Runout ,.." '.,.." ,..,.., ,.." , , " , "" ,,.,..
2.14 Tires .
General .. ,..,.., ,.
Removal , ,.., ,..
Cleaning and Inspection ..
Installation ,.." ,.." ,., , ,." ,'."" " ,..,
Checking Tire Hunout .. ..
Radial Runout "., ,'..,.." ,." " "",'.
Lateral Runout " " .., ..
Wheel Balancing ., " ." ", .
Wheel Weights (Table) ..
2.15 Vehicle Alignment... .
Inspection .
2-35
2-35
2-35
2-35
2-36
2-36
2-36
2-36
2-37
2·38
2-38
2-38
2-39
2-39
2-40
2-40
2.22 Rear Brake Caliper: FXST/FXSTBI
FXSTS 2-71
Removal .................................. " " ..,................... 2-71
Disassembl y " " ,.." ,.," ", ..,. 2-71
Cleaning, Inspection and Repair ............................... 2-74
Assembly 2-75
Installation , ' ".". "" , ",.. 2-76
2.23 Front Forks : All But FLSTSCI
FXSTS _.. ............................... 2-77
General ,.." .." """" ............... 2-77
Removal "".", ",., , "" 2-77
Disassembly , ,........................... 2-77
Cleaning and Inspection 2-77
Assembly " , , ",. 2-81
Installation , ,.......... 2-81
v
Page No. Page No.
2.24 Springer Fork: FLSTSC/FXSTS
Gene ral .
Handlebar and Risers .. . . .
Removal .
Installation .
Front Shock Absorber ..
Removal .
Installation ..
Rigid Fork.. ............. . ..
Removal ................. . .
Installation ..
Spring Fork .
Disassemb ly ..
Assem bly .............. .. .
Fork Rockers .
Removal ..
Installation .. .. ..
Fork Stem Bearings ..
Removal/Installation .
2.25 Steer ing Head .
Removal ,., ,.
FLSTC. FLSTF, FLSTN, FLST Models
FXSTD, FXST, FXSTB Models .
FLSTSC, FXSTS Models .. ..
Cleaning and Inspection .
All Models .
Disassembly .
Removing Lower Bearings From Fork Stem
Steering Head Bearing Race Removal .
Assembly .
Installation .
FLSTC, FLSTF, FLSTN, FLST Models .
FXSTD, FXST, FXSTB Models ..
FLSTSC, FXSTS Models ..
2.26 Rear Fork .
Removal ................ . .
Cleaning and Inspection ..
Installation ..
2.27 Rear Shock Absorbers .
General ..... . .
Removal .
Installation .
2.28 Throttle ControL .
Remova l/Disassemb ly .
Cleaning and Inspection .
Assembly/Installation .. .. .
Cable Routing ..
All Models Except FXSTS/FLSTSC/FXSTD ..
FXSTS/FLSTSC Models ..
FXSTD Models .
2.29 Handlebars .
Removal.. . .
All But FXSTD/FXSTS/FLSTSC .
FXSTD .
Instal lation . .
All But FXSTD/FXSTS/FLSTSC ..
FXSTD ..
All Models ..
2.30 Clutch Hand ControL .
Removal....... . .
Installation .
vi
2-82
2-82
2-82
2-82
2-82
2-84
2-84
2-84
2-85
2-85
2-85
2-86
2-86
2-88
2-90
2-90
2-90
2-91
2-91
2-92
2-92
2-92
2-92
2-93
2-93
2-93
2-93
2-93
2-94
2-94
2-95
2-95
2-95
2-95
2-96
2-96
2-96
2-97
2-98
2-98
2-98
2-98
2-99
2-99
2-99
2-99
2-100
2-100
2-100
2-100
2-101
2-101
2-101
2-102
2-103
2-103
2- 103
2-104
2-105
2-105
2-105
2.31 Front Fender: All But FLSTSCI
FXSTS.. 2-106
FXST, FXSTB Models.................................. 2-106
Remova l ...... .. 2- 106
Installation 2-106
FLSTC, FLSTN, FLST Models ... 2-106
Removal ........ .. 2-106
Installatio n.. 2- 106
FLSTF Models .. .. 2-107
Removal. ...... 2-107
Installation 2-107
FXSTD Models 2-107
Removal .. .. .. 2- 107
Installation 2-107
2.32 Front Fender: FLSTSC 2-108
Removal 2- 108
Front Fender .................... 2-108
Front Fender Bearing Heplacernent 2-108
Installation .. 2-109
2.33 Front Fender: FXSTS 2-110
Removal .................. 2-110
Installation 2-111
2.34 Rear Fender: FLSTC/FLSTFI
FLST 2-112
Removal................... 2-112
FLSTC 2-112
FLSTF/FLST 2-112
Installation .. 2-113
2.35 Rear Fender: FXST/FXSTSI
FXSTB 2-114
Removal ............... 2-114
Installation 2-115
2.36 Rear Fender: FXSTD 2-116
Removal ..................... 2-116
Disassembly ............. .. 2-116
Assem bly.. 2-117
Installation .... .. 2-117
2.37 Rear Fender: FLSTSC 2-118
Removal ...... 2-118
Disassemb ly.. ....... .. .. 2-118
Assembly ....... . 2-119
Installation 2-119
2.38 Rear Fender : FLSTN 2-120
Removal ......... 2-120
Disassembly... 2-120
Assembly.. ........ .. . 2- 122
Installation 2- 122
2.39 Rear Fender Wire Conduit:
All But FXSTD 2-123
Installation 2-123
Page No. Page No.
2.47 Seat: FLSTSC/FLSTN /FLST.. 2-133
Removal/Installation 2-133
2.48 Luggage Rack: FLSTN 2-134
RemovaVlnstaliation 2-134
2.43 Seat/Strap Retention NuL 2-129
Replacement 2-129
2.42 Fork Lock 2-128
Removal 2-128
Installation 2-128
3-13
3- 13
3-14
3-14
3·14
3-12
3-12
3-12
3-16
3-16
3-17
3-15
3-15
3-15
3·15
3-18
3-18
3·19
3-20
3-20
3-20
3-20
3-21
3-21
3-21
3-21
3-22
3-22
3.6 Breather Operation .
General .
3.8 How To Use This Section ..
Top End Repair .
Bottom End Repair ..
Typical Symptoms... .. ..
3.9 Top End Service ..
Engine In Chassis .
Engine Removed From Chassis ..
3.10 Bottom End Service :. ..
Engine In Chassis: Cam Compartment Service .
Engine Removed: Flywheel Compartment Service
or Complete Engine Overhaul. .
3.5 Oil Pump Operation ..
General .
Operation .
3.7 Oil Pressure .
Oil Pressure Indicator Lamp .
Checking Oil Pressure .
3.11 Troubleshooting ..
Diagnosing Valve Train Noise .
Compression Test .
Compress ion Test Results (table) .
Cylinder Leakage Test ..
Diagnosing Smoking Engine or High Oil Consumption
Check Prior To Cylinder Head Removal ..
Check Aller Cylinder Head Removal ..
3.12 Stripping Motorcycle For
Service .
Procedure .
2-125
2-125
2-125
2-125
2-125
2-125
2-125
2-126
2-126
2-127
2-127
2.44 Seat: FXST/FXSTB /FXSTS 2-130
RemovaVlnstallation 2-130
Seat Strap ............................................................. 2-130
Seat ...................................................................... 2-130
2.41 Jiffy Stand .
Cleaning .
Removal .
Installation .
2.45 Seat: FLSTF/FLSTC 2-131
RemovaVlnstallation 2-131
Seat ...................................................................... 2-131
Sissy Bar: FLSTC Models 2-131
2.46 Seat: FXSTD 2-132
Removal/Installation 2-132
2.40 Belt Guard/Debris Deflector .
Removal _ .._ _ __ .
Belt Guard .
Debris Deflector .
Installation .
Bell Guard .
Debris Deflector ..
2.49 Saddlebags: FLSTC 2-135
Removal 2-135
Installation ...... 2-135
3.13 Assembling Motorcycle After
Service ..
Procedure .
3-23
3-23
2.50 Windshield: FLSTC 2-136
Removal 2-136
Installation 2-136
3.14 Removing Engine From Chassis 3-24
Procedure 3-24
3.15 Installing Engine In Chassis..... 3-25
Procedure 3-25
SECTION 3-ENGINE
3.1 Specifications ..
3.2 Engine Torque Values (table) .
3.3 Service Wear Limits ..
General .
3.4 Engine Oil Flow ..
Oil Feed .
Top End .
Bottom End ..
Chain Guide Bracket ..
Oil Return .
3-1
3-3
3-4
3-4
3-6
3-6
3·7
3-7
3-1 1
3-11
3.16 Top End Overhaul : Disassembly
General .
Breather Assembly ..
Rocker Arm Support Plate ..
Push Rods, Lifters and Covers ..
Cylinder Head .
Cylinder .
Piston ..
3.17 Top End Overhaul : Assembly ..
General ..
Piston .
Cylinder .
Cylinder Head ..
Push rods, Lille rs and Covers .
Rocker Arm Support Plate ..
Breather Assembly .
3-27
3-27
3-27
3·28
3-29
3-30
3-31
3-33
3-34
3-34
3-34
3-35
3-38
3-41
3-42
3-43
vii
Page No. Page No.
3.19 Bottom End Overhaul : Assembly 3-52
General 3-52
Counterbalancer Assembly ....................................... 3-52
Balance Sprocket Spacers (table) 3-53
Crankcase 3·55
Cover and Cam Support Plate 3-59
Rear Cam Sprocket Spacers (table) 3-61
3.27 Cover and Cam Support Plate ... 3-103
3.28 Oil Pump 3-118
Removal Overview................................................... 3-118
Cleaning and Inspection 3- 118
Installation and Overview ......................................... 3-119
3.18 Bottom End Overhaul :
Disassembly .
General .
Cover and Cam Support Plate .
Crankcase .
Counterbalancer Assembly .
3.20 Breather Assembly ..
Removal Overview _ __ .._ _ .
Disassembly .
Cleaning and Inspection .
Assembly .
Installation Overview .
3.21 Rocker Arm Support Plate ..
Removal Overview _ _ .
Disassembly ..
Cleaning and Inspection ..
Assembly .
Installation Overview .
3.22 Push Rods, Lifters and Covers
Removal Overview .
Disassemb ly .
Cleaning and Inspection .
Lifter Inspection .
Assembly ..
Installation Overview _ .
3.23 Cylinder Head ..
Removal Overview __ .
Disassemb ly .
Cleaning .
Inspection .
Cylinder Head ..
Valve Guides .
Valve Stem To Guide Clearance Service Wear
Limits (table) .
Valves .
Valve Springs .
Tapered Keepers .
Valve Seats .
Valve Guide Replacement ..
Removal ..
Installation ..
Valve Stem To Guide Cleara nce (table) ..
Valve and Seat Relacing .
Assembly .
Installation Overview _ , .
vIII
3-45
3-45
3-45
3-48
3-49
3-65
3-65
3-65
3-65
3-65
3-65
3-66
3-66
3-66
3-66
3-69
3-69
3-70
3-70
3-70
3-70
3-71
3-72
3-72
3-73
3-73
3-73
3-75
3-75
3-75
3-76
3-76
3-76
3·76
3-76
3·76
3-77
3-77
3-78
3-8 1
3·82
3-85
3-87
3.24 Cylinder .
Removal Overview .
Cleaning ..
Inspection .
Deglazing Cylinder .
Bonng and Honing Cylinder .
Installation Overview .
Oversize PistonS/Cylinder Bores (table) ..
3.25 Piston ..
Removal Overview .
Disassembly ..
Piston Rings .
Cleaning .
Inspection .
Assembly .
Piston Rings .
Installation Overview .
3.26 Upper Conneclingflod .
Removal Overview .
Disassembly/Assembly ..
Removing Upper Connecting Rod Bushing ..
Installing Upper Connecting Rod Bushing ..
Reaming Upper Connecting Rod Bushing ..
Honing Upper Connecting Rod Bushing ..
Install ation Overview .
Removal Overvi ew .
Disassembly/Assembly .
Crankshaft Bushing .
Removal .
Installation ..
Reaming Crankshaft Bushing .
Camshafts and Camshaft Bearings .
Removal .
Installation .
Cam Chain Tensioners .
Removal .
Installation ..
Oil Pressure Relief Valve .
Removal .
Cleaning ..
Installation .
Cam Needle Bearings ..
Removal .
Installation ..
Installation Overview .
3·88
3-88
3-88
3-89
3-90
3-92
3-92
3-92
3-93
3-93
3-93
3-93
3-93
3-94
3-96
3-96
3-97
3-98
3-98
3-98
3-98
3-99
3-100
3-101
3-101
3-103
3-104
3-104
3-104
3- 104
3-105
3-106
3-106
3- 109
3-113
3-113
3-113
3-114
3-114
3-114
3-114
3-115
3- 115
3-116
3-117
Page No. Page No .
3.29 Crankcase .
Removal Overview .
Right Crankcase Half .
Chain Guide Screen ..
Cra nkshaft Bearing .
Piston Jets .
Left C rankcase Half ..
Cra nkshaft (Roller) Bearing .
Sprocket Shaft Bearing Inner Race .
Balance Shaft Support Bearings .
Cylinder St uds .
Removal .
Installation .
Pipe Plug and Oil Fitt ings .
RemovaVlnsta l1 ation .
Cleaning and Inspection .
Installation Overview .
3.30 Counterbalancer Assembly .
Removal Overview _ _ .
Cleaning. Inspection and Repair .
General ..
Balance Shaft Support Bearings ..
Front and Rear Balance Sprockets .
Hydraulic Tensioners .
Chain Tensioner Gu ides .
Chain Guide Bracket .
Balance Chain .
Installation Ove rview ", .
3.31 Flywheel/Connecting Rod .
Remova l Overview .
Inspection .
Installation OV8IView .
3.32 Oil Tank .
RemovaV Disassembly .
Oil Tank .
Oil Line Fittings/Retainers ..
Installation .
SECTION 4-FUEL SYSTEM
4.1 Specifications .
Torq ue Values (table) .
4.2 Fuel System Troubleshooting .
Carburetor .
Overflow Troubleshooting (table) .
Poor Idling (table) .
Poor Fuel Eco nomy (Iable) ..
Poor Acceleration (table) ..
Hard Starting (table) ..
Poo r Performance On Road (table) ..
Poor High Speed Performance (table) .
Vacuum Piston Asse mbly ..
Piston Does Not Raise Properly (table) .
Piston Does Not Close Properly (table) ..
4.3 Enrichener: Carbureted .
General .
Ope ration ..,.."" , ", ,.
Cool Engine .
Warm Climate or Hoi Engine ..
3-120
3-120
3-120
3-120
3-120
3- 12 1
3- 122
3-122
3-124
3-127
3-128
3- 128
3- 128
3-128
3-128
3-129
3 -129
3-130
3-130
3-130
3-130
3 -130
3-131
3-131
3-1 31
3- 131
3-131
3- 131
3-132
3-132
3-132
3-132
3-133
3 -133
3-133
3-135
3-136
4-1
4-1
4-2
4-2
4-2
4-2
4-2
4·3
4-3
4-3
4-4
4-4
4·4
4-4
4-5
4-5
4-5
4-5
4-5
4.4 Carburetor .
Removal , ,.." ., .
Installation .
Disassembly .
Vac uum Piston Chamber ..
Carburetor Body .
Acceierator Pump .
Cleaning and Insp ect ion .
Vacuum Piston Components .
Carburetor Body Components ..
Float Replacement .
Acce lerator Pump .
Assembly ..
Vacuum Piston Chamber .
Carburetor Body .
Accelerator Pump , "" " ""." .
4.5 Carburetor Adjustments .
Operation Check-Vacuum Piston ~ .
Opening Malfunction ..
Closing Malfunction .
Float Bowl ..
Float Bowl Inlet (Needle) Valve Replacement ..
Float Level ..
4.6 Fuel Supply Valve: Carbureted ..
General ..
Operation .
Removal, Inspection and Installation ..
Troubleshooting .
Trouble shooting Fuel Suppl y Valve (table) ..
Vacuum Test , .
4.7 Fuel Tank: Carbureted .
General .
Removal , " ,..
All But FXSTD Models ..
FXSTD Models .
Cleaning and Inspection .
Installatio n .
All But FXSTD Models ..
FXSTD Models ..
Vapor Valve .
4.8 Air Cleaner: Carbureted .
Removal .
Installation .
Backplate Assembly-Califomia Model s ..
4.9 Exhaust System: FXST/FLST/
FLSTC/FXSTB /FXSTS .
Removal .
Installation .
Disassembly .
Assembl y .
4.10 Exhaust System: FXSTD/FLSTF
Removal .
Mufflers Only .
Exhaust System .
Installation .
Mufflers Only .
Exhaust System ..
4-6
4-6
4-8
4-8
4-8
4-8
4-8
4-9
4-9
4-9
4-9
4-9
4- 10
4-10
4 -10
4-10
4-11
4-11
4-11
4-11
4-11
4-1 1
4-12
4-15
4-15
4-15
4·15
4-15
4-15
4-16
4-17
4-17
4-17
4-17
4-18
4- 18
4-21
4-21
4-21
4-22
4-23
4-23
4-23
4-24
4-25
4·25
4 -25
4-25
4-25
4-27
4-27
4- 27
4-27
4-27
4-27
4-27
Ix
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2006-2009 Harley-Davidson FXSTB Softail Night Train Service & Repair Manual
The 2006-2009 Harley-Davidson FXSTB Softail Night Train Service & Repair Manual is the official factory guide for maintaining and repairing the iconic FXSTB model. This manual was used by dealership technicians and covers all key systems found on the 1584cc Twin Cam 96B-powered Softail Night Train. Whether you're performing basic maintenance or digging into a full engine teardown, this manual provides the detailed technical instructions you need to get the job done right.
Step-by-step procedures are paired with exploded-view diagrams, torque specs, diagnostic tips, and factory tolerances — making it a must-have for pro mechanics and home wrenchers alike. Coverage is model-specific to the FXSTB, eliminating the clutter of unrelated models.
Content Overview:
- Routine Maintenance & Lubrication
- Chassis Setup & Adjustment
- Engine Specifications & Rebuild Procedures
- Fuel Injection & Fuel Tank System
- Electric Starter & Charging System
- Drive Components, Clutch & Belt
- Transmission: Assembly, Gears, Shift Forks
- Electrical System: Fuses, Battery, Headlamps, Sensors
- Instrument Panel & Gauges
- Lighting, Turn Signals, Brake Lights
- Handlebar Switches, Horn, ECM
- Wiring Harness & Detailed Color Diagrams
- Appendix: Tools, Connector Types, Deutsch/Delphi/Packard
- Glossary, Conversion Tables, Index
If you're restoring, customizing, or just maintaining your FXSTB Night Train, this is the go-to resource for dealer-grade procedures and OEM data.
Printable: Yes
Language: English
Compatibility: Works on all devices (Windows, Mac, iOS, Android)
Requirements: PDF reader (e.g. Adobe Reader)
